Generic Trigger X 50ccm Owner's Manual

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Contents

Contents ···················································································································································-1-

Preface ·····················································································································································-4-

Documents to be prepared ················································································································-5-

Inspection/adjustment······················································································································-19-

1 Brake····················································································································································-32-

1.1 Maintenance instruction·············································································································-32-

1.2 Fault diagnosis··························································································································· -32-

1.3 Front hydraulic brake·················································································································-33-

1.4 Rear hydraulic brake··················································································································-35-

2 Body cover···········································································································································-38-

3 Front wheel/ front suspension···············································································································-42-

3.1 Preparation data ·························································································································-42-

3.2 Fault diagnosis··························································································································· -42-

3.3 Front wheel································································································································-43-

3.4 Steering handle ··························································································································-45-

3.5 Front fork···································································································································-45-

4 Rear wheel/rear suspension ··················································································································-50-

4.1 Preparation data ·························································································································-50-

4.2 Fault diagnosis··························································································································· -50-

4.3 Rear wheel·································································································································-51-

4.4 Rear shock absorber/rear rocker·································································································-52-

4.5 Driving chain ·····························································································································-53-

5 Battery/charging system ·······················································································································-56-

5.1 Preparation data ·························································································································-56-

5.2 Fault diagnosis··························································································································· -57-

5.3 Battery······································································································································· -58-

5.4 Charging system ························································································································-59-

5.5 Voltage and current regulator ·····································································································-60-

5.6 Charge coil of the alternator·······································································································-60-

5.7 Illuminating coil of alternator·····································································································-61-

5.8 Disassembly of alternator···········································································································-61-

6 Ignition system ·····································································································································-64-

6.1 Preparation data ·························································································································-64-

6.2 Fault diagnosis··························································································································· -65-

6.3 Ignition system inspection·································································································

·········-66-

6.4 CDI group··································································································································-68-

6.5 Ignition coil ·······························································································································-68-

6.6 Trigger ·······································································································································-69-

7 Startup system ······································································································································-71-

7.1 Preparation data ·························································································································-71-

7.2 Fault diagnosis··························································································································· -72-

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7.3 Start electric machinery··············································································································-72-

7.4 Start relay···································································································································-74-

8 Bulbs/ switch/instrument ······················································································································-75-

8.1 Preparation data ·························································································································-75-

8.2 Fault diagnosis··························································································································· -75-

8.3 Replace the head light bulb········································································································-75-

8.4 Replace bulb of the front turning light ·······················································································-76-

8.5 Replace the bulb of the taillight / license light / rear turning light ··············································-76-

8.6 Instrument··································································································································-77-

8.7 Main switch ·······························································································································-77-

8.8 Horn ··········································································································································-77-

8.9 Handle switch ····························································································································-77-

Table of torque value of engine fastener ··································································································-79-

9 Lubrication system ·······························································································································-81-

9.1 Preparation data ·························································································································-81-

9.2 Fault diagnosis··························································································································· -81-

9.3 Oil pump····································································································································-81-

10 Carburetor ··········································································································································-84-

10.1 Preparation data ·······················································································································-84-

10.2 Fault diagnosis·························································································································-84-

10.3 Disassembly of carburetor········································································································-85-

10.4 Carburetor cover ······················································································································-86-

10.5 Float chamber ··························································································································-87-

10.6 Installation of carburetor··········································································································-87-

11 Cylinder cover/air cylinder/piston·······································································································-90-

11.1 Preparation data ·······················································································································-90-

11.2 Fault diagnosis·························································································································-91-

11.3 Disassembly of air cylinder······································································································-91-

11.4 Disassembly and installation of the piston················································································-92-

11.5 Installation of the air cylinder···································································································-95-

11.6 Disassembly of cylinder cover ·································································································-95-

11.7 Installation of the cylinder cover ························································································

······-96-

12 Crankcase/clutch/actuating lever ········································································································-98-

12.1 Preparation data ·······················································································································-98-

12.2 Fault diagnosis·························································································································-99-

12.3 Crankcase ································································································································-99-

12.4 Clutch·····································································································································-100-

12.5 Actuating lever························································································································-103-

13 Crankshaft-connecting rod set and shift chamber···············································································-105-

13.1 Preparation data ······················································································································-105-

13.2 Crankshaft and connecting rod set···························································································-105-

13.3 Shift chamber··························································································································-107-

13.4 Shift shaft set··························································································································-108-

13. 5 Main shaft and sub shaft ········································································································-109-

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14 Cooling system··································································································································-112-

14.1 Preparation data ······················································································································ -112-

14.2 Fault diagnosis························································································································-112-

14.3 Water pump/water tank ···········································································································-112-

15 Exhaust emission and control system·································································································-118-

15.1 Warranty of Exhaust emission and control system ··································································-118-

15.2 Regular maintenance guideline ·······························································································-119-

15.3 Mechanical function of the exhaust control system·································································-120-

15.4 Catalyst converter system ·······································································································-121-

15.5 Countermeasure of idle speed emission exceeding specified value（two-stroke)····················-122-

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Preface

This Manual explains the maintenance of Generic Trigger 50ccm

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：

For the universal parts of both types of motorcycle, this manual does not seperate the explanation.

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.

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Documents to be prepared

General safety Maintenance regulation
Specififcation sheet Troubleshooting

General safety

Carbon monoxide

The engine should be started in ventilated area other than closed area.

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.

- 5 -

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 the 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 operation should not be bended or distorted; otherwise it

will cause operational difficulties or demage ahead of time.

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.

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.

error

error

error

cover

- 6 -

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

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

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Specififcation Sheet Trigger X 50ccm

Model Trigger 50ccm Engine Type 40-2 2-stroke engine

Full length mm 2060 Fuel type

Unleaded gasoline of 95

Octane above

Full width mm 890

Number of

cylinders

1

Full height mm 1230

Inside measure

* stroke

40.25*39mm

Wheelbase mm 1370 Total flow rate 49.6mm

Front

axle

53 Start mode Start by electricity/foot

Rear

axle

58 Cooling mode Water-cooling

Vehicle weight kg

Tota l 111 Lubrication Separated lubrication

Front

（internal）

Front

（external）

3.00-21 3.00-21

Engine oil

capacity

0.8L

Rear（internal） Rear（external）

Tyre specification

4.10-18 4.10-18

Air cleaner Sponge

Engine

Petrol capacity 10（+/-）0.2 L

Clutch type

Wet multidisc brake

Maximum

speed

45km/h

Climbing

capability

Maximum climbing angle

no less than 15 degree

Transmission Manual

Idling speed -

rpm

1400±100rpm/min

Gearing

Driving mode Chain drive

Maximum

torque

2.60Nm/3000rpm

Battery

capacity/type

12V 3AH

Maximum

horsepower

1.39KW/5500 rpm

Generator type 1E40MB-2

Compression

ratio

7.0：1

Spark plug BR8ES/F10KC

Performance

Cylinder

pressure

1.1-1.3Mpa/1400rpm

Spark plug gap 0.5-0.7mm

Front liquid

braking disc

unit（mm）

φ230mm

Electrical installation

Ignition mode CDI

Brake

Rear liquid

braking disc

unit（mm）

φ220mm

- 8 -

Specififcation Sheet Trigger SM 50ccm

Model Trigger 50ccm Engine Type

40-2 2-stroke engine

Full length mm

2035 Fuel type

Unleaded gasoline of 95

Octane orabove

Full width mm

890 Number of cylinders 1

Full height mm

1230 Inside measure * stroke 40.25*39mm

Wheelbase mm

1390 Total flow rate 49.6mm

Front

axle

55 Start mode Start by electricity/foot

Rear

axle

60 Cooling mode Water-cooling

Vehicle weight kg

Tota l

115 Lubrication Separated lubrication

Front（external）

100/80-17

Engine oil capacity 0.8L

Rear（external）

Tyre specification

130/80-17

Air cleaner Sponge

Engine

Petrol capacity

10（+/-）0.2 L

Clutch type

Wet multidisc brake

Maximum speed 45km/h

Climbing capability

Maximum climbing angle

no less than 15 degree

Transmission Manual

Idling speed - rpm 1400±100rpm/min

Gearing

Driving mode Chain drive

Maximum torque 2.60Nm/3000rpm

Battery

capacity/type

12V 3AH Maximum horsepower 1.39KW/5500 rpm

Generator type 1E40MB-2 Compression ratio

7.0：1

Spark plug BR8ES/F10KC

Performance

Cylinder pressure 1.1-1.3Mpa/1400rpm

Spark plug gap 0.5-0.7mm

Front liquid braking disc

unit（mm）

φ280mm

Electrical installation

Ignition mode CDI

Brake

Rear liquid braking disc

unit（mm）

φ220mm

TRIGGER X 50ccm

- 9 -

- 10 -

TRIGGER SM 50ccm

- 11 -

Troubleshooting

Difficult to start or unable to start

Troubleshooting Tune-up inspection Failure cause

Enough oil to

carburator

No gasoline
to

carburator

Loosen the oil drain
bolt of carburator to
check whether there
is oil within the
carburator

Spark plug
has flashover

Weak spark or no
spark of spark
plug

Dismantle the spark
plug and put it into
spark plug cover to
connect engine and
check whether the
spark plug has
flashover

Compression
pressure

measurement

Compression
pressure too low,
no compression

p

ressure

Normal compression
pressure

No ignition
burst
phenomenon of
engine

With burst
phenomenon but
the engine failed
to start

Spark plug is
damp

Spark plug is
dry

Dismantle the spark plug
again to re-inspect

No gasoline in gasoline tank

Oil tube clog of gasoline tank carburator

Oil tube clog of float chamber

Conduit clog of evaporation control system of fuel tank

Gasoline filter clog

Auto oil ring is broken

Spark plug is broken

Spark plug is polluted

CDI group is broken

Trigger is broken

The lead of sparking coil is open circuit or short circuit

Sparking coil is open circuit or short circuit

Main switch is broken

Charge coil is broken

Start clutch is broken

Air cylinder piston and piston ring are

broken

Cylinder head leaks

Auto choke actuation is bad

Intaken air in intake manifold

Incorrect ignition time

Bad adjustment of adjustable bolt of

carburetor

Overhigh oil level of carburetor

Auto choke actuation is bad

Too big throttle opening

- 12 -

Improper gyration (impotent velocity)

Troubleshooting Tune-up inspection Failure cause

Winding number
of engine
increases

Engine revolution
unable to increase
completely

Start the engine
and slightly
accelerate

Correct ignition
time

Incorrect ignition

Adjust ignition
timing and use
ignition timing light

N

ormal compression

pressure

Compression pressure is too low

Bad timing
adjustment

No clog Clogged

With pollution
and discoloration

No pollution and no
discoloration

Dismantle the spark plug and re-inspect

Clog inspection of carburetor

Normal Abnormal

Without superheat

Overheating

No phenomenon

With phenomenon

Accelerated drive or

Engine overheat

Inspect the lubrication of
air c

y

linder head

Normal mobile
oil level

Too much
mobile oil

Check whether the
mobile oil in crankcase is
too much or polluted

Air cleaner clogged

Bad gasoline
Conduit clog of evaporation control

system of firing chamber

Exhaust pipe clogged

Auto choke is bad

Carburetor vacuum module is broken

Auto oil ring is broken

CDI group is broken

Trigger is broken

Air cylinder piston and piston ring are

broken

Cylinder head leaks

Cleaning contamination

Cleaning contamination

Discrepancy of spark-plug heat value

Too much mobile oil

Too little mobile oil

No change of mobile oil

Piston，cylinder wear

Piston，cylinder wear

Bad gasoline

Too much carbon laydown in combustion chamber

Too early ignition time

Too much carbon laydown in combustion chamber

Bad gasoline

Slipping of clutch

Tenuity of gas mixture

Too early ignition time

- 13 -

Improper gyration（especially at low speed）

Troubleshooting Tune-up inspection Failure cause

Normal Abnormal

Ignition time
adjustment

Favorable

adjustment

Maladjusted

Adjust the
adjustable screw of
carburetor oil level

No intake air With intake air

Dismantle the spark plug
and put it into spark plug
cover to connect engine
and check whether the
spark plug has flashover

Favorable
spark plug
flashover

Bad spark plug

flashover

Bad

Favorable

Intake air in

carburetor shim

CDI group is broken

Trigger is broken

Rare gas mixture（loosen the bolt）

Too thick gas mixture （locking

screw）

Bad heat spacer shim

Loosen fixing nut of carburetor

Broken shock insulator

Broken suction line

Bad or polluted spark plug

Bad CDI

Bad sparking coil
The lead of spark plug is open circuit

or short circuit
Main switch is broken

Damaged suction line

Ventilation hole clogged

- 14 -

Improper gyration（high speed）

Troubleshooting Tune-up inspection Failure cause

Normal

Abnormal

Ignition time
adjustment

Normal

Abnormal

No clog Clogged

Spring broken
and slack
elasticity

Favorable

Carburettor clogged

CDI group is broken

Trigger is broken

Too little gasoline in gasoline
tank
Gasoline filter of gasoline pipe
clogged

Conduit clog of evaporation
control system of fuel tank
Auto oil ring is broken

Purged

Bad spring

- 15 -

Improper charging (overdischarge or over charge of battery)

Troubleshooting Tune-up inspection Failure cause

No increase of

battery voltage

Battery voltage
rised to normal
value and restore its
original voltage
after killing engine

Measure the voltages
of the both ends of
battery, start the
engine

Normal Abnormal

Inspect whether the voltage regulator

plug

is slack

With voltage No voltage

Measuring alternator coil resistance value

Normal

Abnormal

Normal voltage

Voltage
higher than
normal value

Start engine, the red line of voltage regulator
socket connects to avometer and positive and
negative line connects the voltage of
motorcycle

Check the voltage regulator socket,
the red line connects universal meter
and positive and negative line connect
the volta

g

e of motorcycle

Improper charging

Normal

Slack and improper
connection

Inspect whether the connection of
voltage regulator wiring is correct

Voltage regulator unit test
impedance

Expired battery

Bad battery

Bad contact of plug

Open circuit of red line of wiring

Voltage regulator

Open circuit of white line of

wiring

Bad coil
Bad contact of joint
White line of alternator
disconnected
Bad battery

Improper contact of joint and

imperfect earth of wiring

Bad voltage regulator

- 16 -

Spark plug has no flashover

Troubleshooting Tune-up inspection Failure cause

Weak or no
flashover of
spark plug

Strong spark

Replace new spark plug
and examine it again

No slack Slack

Inspect spark plug and examine it
again

Normal Abnormal

Check the conduction among each
terminal of CDI group line trap, and
measure the resistance value

Normal Abnormal

Abnormal Normal

Inspection of
related position

Inspect whether the CDI
group plug is slack

Normal Abnor

Abnormal

Check sparking coil by CDI tester

Check CDI group by CDI tester

Bad former spark plug

Slack spark plug cover

Bad contact of plug

Main switch is broken

Charge coil is broken

Trigger is broken

Bad sparking coil

Main wiring disconnected

Bad contact of joint and socket

CDI group is broken

Bad sparking coil

- 17 -

Inspection/adjustment

Preparation of documents Cylinder pressure

Check list of constant maintenance Gear mobile oil

Engine mobile oil/oil strainer Changing gear oil

Gasoline filter Driving chain

Inspection/adjustment of accelerator's pull wire Clearance of front/rear brake

Air cleaner Front shoe block abrasion

Spark plug Head lighting

Battery Clutch

Carburator Front/rear suspension system

Ignition timing Bolt/nut/fixture

Rim/tyre Tyre specification

Steering post bearing and handle fixture

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.

- 18 -

Specification

Engine

Gyration speed at idle

speed

1400±100rpm/min

Spark plug gap 0.5-0.7mm Engine oil

capacity

0.8L

Spark plug specification BR8ES/F10KC

Compression pressure of

air cylinder

1.1-1.3Mpa/1400rpm

Firing time BTDC12 degree（+/-）1degree 1400±100rpm

Carriage

Free stroke of front brake

drawbar

20-30mm

Free stroke of rear brake

drawbar

20-30mm

Specification Tire pressure

Front wheel of

inside

3.00-21 2,25 Bar

Rear wheel of

outside

4.10-18 2,25 Bar

Front wheel 100/80-17 2,25 Bar

Tire pressure unit：Bar

Rear wheel

130/80-17 2,25 Bar

Front wheel

spindle

55-62 N·m

Torque

force

value

Rear-wheel spindle

nut

85-98 N·m

- 19 -

Check list of constant maintenance

Every

300 KM

Every

1000

KM

Every 3000

KM

Every 6000

KM

Every

12000 KM

Every

14500 KM

Mileage and time of

maintenance

Inspection items

New

motorcy

cle

One

month

3 months 6 months A year 15 months

Too ls

* 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

Handle inspection 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

Exhaust pipe 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

- 20 -

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 Generic 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.

Changing mobile oil

Attention

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

effuse.

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.

Engine oil capacity：0.8L

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

Reinspect mobile oil level.

Gasoline filter

Inspection of the deterioration and damage of fuel manifold.

If there is any deterioration, damage and fuel leak, it should be

fixing nut
adjusting nu

t

Oil drain bolt

Right cover

- 21 -

replaced with new product.

Warning!

Smoking or lighting fires are strictly forbidened.

Inspection/adjustmentof accelerator's pull wire

Check the smoothness of accelerator pull wire.

Check the clearance of accelerator pull wire.

Clearance：2 - 6mm

The main adjusting position is on the carburator side.

Loosen the fixing nut and adjust by turning adjusting nut.

Air cleaner

Replacement of filtrator.

Dismantle the cushion and frame cover.

Dismantle the fastening screw of air cleaner cover and take

down strainer cover.

Dismantle bolt and take down filtrator.

Dismantle the sponge from the filtrator.

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.

*Attention

•Please confirm whether the air cleaner is installed as installing

air cleaner cover.

Intake pipe

Intake pipe

Vent. Pipe

Vent. Pipe

- 22 -

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：0.5-0.7mm

*Attention

As installing spark plug, pleae install it

with hands and tighten by spark-plug

socket.

Battery

Dismantle battery

Open cushion.

Dismantle left guard strip and the top cover of air filter.

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 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.

Cylinder
head

spark plug gap

battery rac

k

Spark plug

- 23 -

Inspection of charging state (CCU)

Open cushion.

Unclose the top cover of air filter and disconnect the lead of

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.

*Attention

•If quick charge of battery is abnormal, the battery should

not be used.

•The voltage should be measured every 30 minutes after

charging.

Charging current：standard：0.4A
Quick：4.0A
Charging period: standard：10 - 15 hours
Quick：30 minutes

Completion of charge: CCU: above 12.8V

- 24 -

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 ：1400±100rpm/min

Readjust the idle adjustment bolt when the gyration at idle

speed is instable or there is dificulty of slight acceleration.

Ignition timing

*Attention

The ignition timing requires no adjustment for CDI

ignition device.

Check the ignition system if the ignition timing is

incorrect.

Dismantle the left cover of engine.

Use the ignition timing light to inspect and confirm ignition

timing.

Cylinder pressure

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

Compression pressure：1.1-1.3Mpa/1400rpm
Check the following items if the compression pressure is too low:
—Damage of piston ring
—Ring wear
—Piston，cylinder wear
Check the combustion chamber and the carbon laydown on
the top of pistion if the compression pressure is too high.

Idle speed adjusting bol

t

left cover

fastening bolt

p

ressure gauge

measure the cylinder pressure

- 25 -

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.

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, 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.

Driving chain

Dismantle oil seal, check whether the fringe of oil seal is

broken.

Check whether the rear wheel bearing is broken and take

out the bearing.

Take out the bush and dismantle the rear driving chain and

the bolt of chain wheel.

Check whether the rear driving chain and chain wheel

exceeds the extreme dimension.

Driving chain
Chain wheel
stand

Right cover

Oil drain bolt

Right cover

Oil drain bolt

- 26 -

Clearance of front/rear brake

Front brake clearance

Measure the clearance of the front brake drawbar at the top

point of brake drawbar.

Clearance：20-30mm

Rear brake clearance

Measure the clearance of the rear brake drawbar at the top

point of brake drawbar.

Clearance：20-30mm

Abrasion of front brake shoe

Check the oil level via oil immersion lens when the brake is

down to bottom, if the liquid level of brake fluid is against

the arrow in the figure, please replace the brake shoe.

Head lighting

Adjustment

The optical axis adjustment of head lighting is done by

turning after unscrew the rotation adjustable bolt of head

lighting.

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.

oil pump

oil lens

installatio
n position
of
fastening
bolt

adjustable bolt

- 27 -

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 loosen.

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

Actuation inspection up and down

Rear shock absorption

bolt for fixing axle

- 28 -

Specified pressure unit：Kpa

Specification Tire pressure

Front
wheel

3.00-21 225

QJ50-23

Rear

wheel

4.10-18 225

Front
wheel

100/80-17 225

QJ50-23A

Rear

wheel

130/80-17 225

Tyre specification

Front wheel

of inside

3.00-21

Front wheel

of outside

3.00-21

Rear wheel

of inside

4.10-18

QJ50-23

Rear wheel

of outside

4.10-18

Front wheel 100/80-17

QJ50-23A

Rear wheel 130/80-17

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 spindle 55-62 N·m

Rear-wheel spindle nut 85-98 N·m

Steering post bearing and handle

fixture

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.

left and
righ
actuation
inspection

- 29 -

Front liquid brake

Rear liquid brake

brake shoe

Rear brake

assembly

- 30 -

1 Brake

Maintenance instruction ------------------------ 1.1

Fault diagnosis ----------------------------------- 1.2

Front hydraulic brake ----------------------------1.3

Rear hydraulic brake ---------------------------- 1.4

1.1 Maintenance instruction

Matters needing attention in operation

* Note

*Inspect the brake before riding the motorcycle.*

1.1.1 Specification

Item Standard value (mm) Allowable limit(mm)

thickness of front brake disc 4.0 -

thickness of front brake pad 4.5 3.0

thickness of rear brake disc 4.0 -

thickness of rear brake pad 7.0 3.0

QJ50-23 diameter of front hydraulic brake φ230mm Diameter of rear hydraulic brake φ220mm

QJ50-23A diameter of front hydraulic brake φ280mm Diameter of rear hydraulic brake φ220mm

1.1.2 torque value

Fixing bolt of brake disc 22-29 N·m
Mounting bolt of brake caliper 22-29 N·m

1.2 Fault diagnosis

Brake

Bad braking quality Slow brake or tight rod

1. Unfavorable brake adjustment 1. Unfavorable brake adjustment

•The braking components can not be spoiled by oil stain in installation or disassembly.

•Rinse with stipulated cleaning agent in order to avoid reduction of braking quality.

- 31 -

2. Brake pad worn out 2. Brake pad worn out

3. Improper installation of brake pad 3. Improper installation of brake pad

4. Brake pad polluted

Strange sound in braking

1. Brake pad worn out

2. Brake pad polluted

1.3 Front hydraulic brake

* Note

•The braking components can not be spoiled by oil stain

in installation or disassembly.

•Rinse with stipulated cleaning agent in order to avoid

reduction of braking quality.

Disassemble the front wheel spindle.

Unload the front wheel.

1.3.1 Disassembly

*Note

•Always replace the brake pad in pairs.

•If a brake pad is reused, mark a signal

on its side before disassembly so that it

can be installed to the original position.

Disassemble the brake cylinder set from the left shock

absorber and take out the brake pad from the brake cylinder

set.

Front brake syste

m

- 32 -

1.3.2 Inspection

Inspect whether the brake pad is worn out and replace it if

necessary.

Measure the brake pad and brake disc and put down the

maximal value.

Specification

QJ50-23

diameter of front hydraulic brake φ230mm

QJ50-23A

diameter of front hydraulic brake φ280mm

*Note

•It must be measured with a bore groove

vernier caliper or microcaliper.

Allowable limit: brake disc 3.0mm

If the thickness of brake disc is less than the allowable limit,

it should be replaced.

Measure the thickness of brake pad.

If the thickness of brake pad is less than the maintenance

value or it is polluted by grease, just replace it.

Allowable limit: brake pad 3.0mm

1.3.3 Installation

Install the front wheel.

Install the brake cylinder set.

Keep the brake pad free of grease.

* Note

Grease on the brake pad may reduce

brake ability and invalidate the brake.

Screw bolt and nut to the stipulated torque force value.

Torque value ：

Fixing bolt of brake disc 22-29 N·m

Mounting bolt of brake caliper 22-29 N·m

Keep the brake pad free of oil stain.

If the brake pad is polluted with oil, rinse it with brake

cleaning fluid.

measure thickness

brake pad

b

rake pad

- 33 -

* Note

Grease on the brake pad may reduce brake

ability and invalidate the brake.

1.4 Rear hydraulic brake

1.4.1 Disassembly

Disassemble the rear brake cylinder set.

Disassemble the rear wheel.

* Note

•Always replace the brake pad in pairs.

•If a brake pad is reused, mark a signal

on its side before disassembly so that it

can be installed to the original position.

Remove the following components from the rear wheel.
Rear hydraulic brake ：

1. Decorative board of rear brake

2. Rear brake system

3. Brake pads

1.4.2 Inspection

Inspect whether the brake disc and brake pad are worn out

and replace them if necessary.

Measure the brake pad and brake disc and put down the

maximal value.

* Note

•Clean the rust off the brake disc with

#_120 sandpaper.

•It must be measured with a bore groove

vernier caliper or microcaliper.

Measure the thickness of brake pad.

If the thickness of brake pad is less than the maintenance

value or it is polluted by grease, just replace it.

QJ50-23 and QJ50-23A can be applied to all

rear brakes.

Diameter of rear hydraulic brake φ220mm

Allowable limit: Brake pad 3.0 mm

Brake disc 3.0 mm

1.4.3 Installation

Install the rear wheel.

Install the rear brake cylinder back to the original position.

Install the decorative board of rear brake back to the

original position.

Brake pad

Rear brake

system

- 34 -

*Note

Grease on the brake pad may reduce brake ability and

invalidate the brake.

Screw the bolt and nut to the stipulated torque force value.

Torque value

mounting bolt of brake caliper： 22-29 N·m

Keep the brake pad and brake disc free of oil stain.

If the brake pad and brake disc are polluted with oil, rinse

them with brake cleaning fluid.

* Note

Grease on the brake pad may reduce brake

ability.

Brake pad

Rear brake

system

- 35 -

air guide sleeve

instrument suppor

t

right front upper boar

d

right front lower boar

d

right guard

right lower board

Connecting board

of left and right

guard

Rear mud

g

uard I

front mudguar

d

inner rear

mudguard

Rear mud

g

uard II

left guard strip

right guard strip

downward air sleeve

left front lower board

left front lower board

right frame

guard

left frame guard

cushion lock

left rear board

- 36 -

2 Body cover

Disassemble the motorcycle body according to the following order:

Rearview mirror → Air guide sleeve → Instrument support → Instrument → Front

mudguard →Front top guards

↓

Front bottom guards →cushion→left, right guard strip → Rear left and right

guard→ Connecting board of left and right guard

↓

→

Rear mudguard I→Rear mudguard II→Inner Rear mudguard → Left guard→Left and

right guard of the frame

* Note

Do not damage any body cover during installation or disassembly.

Do not damage the knuckle on body cover during installation or disassembly. Align the panel and cover plate

on the body cover with their own grooves.

Correctly install the knuckle of each part in assembly.

No spare parts could be damaged in installation of the cover.

- 37 -

Front wheel/ front suspension （QJ50-23）

- 38 -

Front wheel/ front suspension（QJ50-23A）

- 39 -

QJ50-23 Front wheel

QJ50-23A Front wheel

front rim

front wheel spindle

oil seal of front wheel

rolling bearing

odometer gear stand

middle shaft sleeve o

f

front wheel

mounting bolt of brake disc

left shaft sleeve
of front wheel

rolling bearing

oil seal of front wheel

front rim set

front brake disc

front rim

front wheel spindle

oil seal of front
wheel

vacuum tyre

rolling bearing

odometer gear stand

middle shaft sleeve of
front wheel

mounting bolt of brake disc

left shaft sleeve of front whee

front brake disc

oil seal of front
wheel

rolling bearing

- 40 -

3 Front wheel/ front suspension

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

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

Front wheel -------------------------3.3

Steering handle -------------------------3.4

Front fork -------------------------3.5

3.1 Preparation data

Matters needing attention in operation

Support the body bottom with a jack before disassembly so that the front wheel is suspended but couldn't

rotate.

Keep the brake pad free of grease in operation.

Reference for the entire motorcycle

Measuring position Item

standard
value

(mm)

Allowable limit(mm)

front wheel spindle bending 0.2

vertical

direction

2.0

front wheel

run-out

of rim

transverse

direction

Within 1.0 2.0

Torque value Tools

Fixing bolt of steering lever 5-9 N·m Bearing puller

Front wheel spindle 55-62 N·m

3.2 Fault diagnosis

3.2.1 Actuation difficulty of steering lever

The Steering column nuts are over screwed.

The roller and bearing bracket of the steering column are severely worn out.

The steering column is badly distorted by collision.

The tyre pressure is too low.

- 41 -

3.2.2 Deviation of steering lever

The left and right shock absorbers are not balanced.

The front fork is bent.

The front tire is bent and the tyre deviates.

3.2.3 Front wheel yawing

The tyre is distorted.

The front wheel bearing is loosened.

The tyre is not good.

3.2.4 Front shock absorber too soft

Elasticity fatigue of spring

3.2.5 Strange noise in front shock
absorber

Friction noise in shock absorber guard

Loosening of bolts in rear shock absorber

3.3 Front wheel

3.3.1 Disassembly

Hold the body bottom up so that the front wheel can be

suspended.

Remove bolts and unload the front mudguard and odometer

wire.

Disassemble the front brake wire.

Disassemble the front wheel spindle.

Unload the front wheel.

*Remark：please refer to Page 41 for the disassembly

and assembly diagram of QJ50-23 and QJ50-23A.

3.3.2 Inspection

3.3.2.1 Inspect bending of the wheel
spindle

Place the wheel spindle on the V-shape holder and measure

with a micrometer screw caliper.

Allowable limit：replace it when the value exceeds

0.2mm.

3.3.2.2 Inspect yawing of rim

Allowable limit：

Vertical orientation：if the value exceeds 2.0mm, replace

the rim.

Transverse direction ： if the value exceeds 2.0mm,

replace the rim.

wheel spindle

- 42 -

3.3.2.3 Inspect the front wheel bearing

Disassemble the middle sleeve of front wheel and remove

the oil seal.

Inspect rolling condition of the inner race of swivel bearing

If it does not roll or is loosely contacted with the outer race

or it is damaged, please replace with a new one.

3.3.2.4 Inspect the spoke

Inspect the spoke，if it is bent, damaged, please change it .

If it is relaxed, please fasten it.

Screw up the spoke with the tightening torque on screw cap

of 0.3× 10 N·m.

3.3.3 Replace the bearing

Unload the front wheel spindle and the sleeve.

Spread grease on the bearing.

Punch in the left bearing.

Reload the sleeve.

Punch the bearing in.

* Note

•The bearing must be punched in

horizontally.

•The oil seal must be punched outward.

Middle sleeve of front wheel

oil seall

clearance

clearance

axial direction

radial direction

- 43 -

3.3.4 Installation

Spread grease on the oil seal at the brake disc.
Spread grease on the gearing mesh and the active parts of
speed indicator.
Install the brake disc after meshing between gears of speed
indicator and the bearing claws.

Note

•If the bearing claws do not mesh, the claws may be
distorted when screwing up the nuts.

•Rotate the wheel after mounting the wheel spindle to
confirm whether the driven shaft of speed indicator
rotates.

Mount the wheel spindle nuts and tighten them.

*Remark：please refer to Page 41 for the disassembly

and assembly diagram of QJ50-23 and QJ50-23A.

Torque force

Front wheel spindle 55-62 N·m

3.4 Steering handle

3.4.1 Disassembly

Disassemble the steering handle sleeve.
Disassemble the fixing bolts on brake rod and unload the
bracket.
Disassemble the bracket of rear brake rod.
Remove the throttle handle and bolts.
Remove the throttle handle and the
Throttle cable.

Remove the fixing bolts of handle and unload the handle.

3.4.2 Installation

Installation is conducted in the reverse order of

disassembly.

Fixing bolt
Torque value ：5-9 N·m

3.5 Front fork

3.5.1 Disassembly

Disassemble the front mudguard.

Disassemble the front wheel.

Disassemble the brake wire and speed indicator wire.

Disassemble the front shock absorber.

Disassemble the fixing nut.

Disassemble the steering handle.

fixing bol

t

upper handle

fixi

ng bolt of

steering
column

weld assembly
of steering
handle

upper connecting board

upper
connecting
board

l

ower

connecting
board

bearing

weld assembly
of instrumen

t

su

pp

ort

f

ront shock

absorbe

r

- 44 -

Tools：

Fixing spanner of steering lever

Fixing nut spanner

*Note：

•Clean the opening part of the body guard board with rags.

Specification of the front shock absorber

Length：862.5mm
Angle：64°
Compression stroke：200mm

3.5.3 Installation

Tools:

Fixing nut spanner

Rotate the front fork left and right to confirm there is no

loosening.
Steps：

Install the steering handle.

Install the front shock absorber.

Install the front wheel.

upper
connecting
board

l

ower

connecting
board

bearing

weld assembly
of instrumen

t

su

pp

ort

f

ront shock

absorbe

r

fixing bolt of
steering column

fixing bol

t

shock absorbe

r

guard

- 45 -

Rear wheel/rear suspension（QJ50-23）

- 46 -

Rear wheel/rear suspension（QJ50-23A）

- 47 -

Rear shock absorber/rear rocker

1. Mounting shaft of rear rocker 2. Cover of rear rocker 3.O-shape sealing washer 4. Distance
sleeve 5. Inner spindle sleeve 6. Weld assembly of rear rocker 7. Chain sleeve 8. Chain guard 9.
Wire clamp of hydraulic brake 10. Connecting rod set of rear shock absorber 11. Rocker set of
rear rocker 12. Chain tensioner sprocket 13. Decorative board of rear rocker 14. Weld
assembly of reinforcing plate 15. Rear shock absorber set 16. Fixing bolt and nut 17. Adjusting
bolt

- 48 -

4 Rear wheel/rear suspension

Preparation data -----------------4.1

Fault diagnosis -----------------4.2

Rear wheel -----------------4.3

Rear shock absorber/rear rocker ----------4.4

Driving chain -----------------4.5

4.1 Preparation data

Matters needing attention in operation

There cannot be any oil stain stuck to the surface of the brake disc or brake pad.

Preparation reference

Item Standard value （mm） Allowable limit （mm）

Vertical

direction

2.0

Run-out
of rear
wheel

Transverse

direction

2.0

Torque value

Nut of Rear-wheel spindle 85-98 N·m

Topping nut of the rear shock absorber 37-44 N·m

Bottom nut of the rear shock absorber 37-44 N·m

4.2 Fault diagnosis

4.2.1 Run-out of rear wheel

The rim is distorted.

The tyre is not good.

4.2.2 Shock absorber too soft

Elasticity fatigue of spring

- 49 -

4.3 Rear wheel

4.3.1 Disassembly

Loosen the nuts on rear-wheel spindle.

Remove the nuts on the rear-wheel spindle and the chain.

Unload the rear-wheel spindle.

Unload the rear-wheel.

4.3.2 Inspection

Inspect the run-out of rear wheel.

Allowable limit ：

Vertical direction ：2.0mm or above.
Transverse direction ：2.0mm or above.

When the run-out of rear wheel exceeds the allowable limit,

the bearing of final drive shaft will be loosened, resulting in

bending of bearing shafts. Replace the bearing after

inspection.

4.3.3 Installation

Install the rear wheel in the reverse order of disassembly

and screw the spindle nut.

Locknut of rear-wheel spindle
Torque value ：85-98 N·m

QJ50-23 rear wheel

rear-wheel
spindle

chain wheel

fixing bolt on chain wheel

bearing sleeve

left rear sleeve

rear wheel spindle

oil seal

rolling bearing

rear brake disc

fixing bolt of hydraulic brake

nut

rear wheel hub

p

ress plate of

rear wheel

- 50 -

QJ50-23A rear wheel

4.4 Rear shock absorber/rear rocker

4.4.1 Disassemble the rear shock absorber

Disassemble the body guard.

Disassemble the rear mudguard.

Disassemble the tool box.

Disassemble the air filter.

Remove the fixing bolts of rear-wheel shock absorber.

Unload the rear shock absorber.

4.4.2 Installation

Install the rear shock absorber.

Specification of the rear shock absorber

Length：418mm
Angle：42°
Compression stroke ：60mm

Outer diameter of spring ：62mm
Torque value ：
Upper fixing bolt ：37-44 N·m
Lower fixing bolt ：37-44 N·m

Install the air filter and tool box.

Install the rear mudguard.

Install the body guard.

fixing bolt on chain wheel

p

ress plate of

rear wheel

chain wheel

bearing sleeve

vacuum tyre

rear rim

rear brake disc

fixing bolt of hydraulic brake

rolling bearing

rolling bearing

oil seal of front wheel

p

ress plate of

rear wheel

rear wheel spindle

left rear sleeve

chain

fixing bolt

fixing nut

- 51 -

4.4.3 Disassemble the rear rocker

Disassemble the chain adjuster, rear-wheel spindle, rear

wheel and rear shock absorber.

Remove nuts and rear rocker.

Disassemble the chain guard. Disassemble the rear rocker

set and the sleeve of middle shaft.

4.4.4 Inspect the rear rocker

Inspect the rear swing shaft by rotating it on flat surface
and t is bent，please replace it.

*Note

Never try to straighten the crooked shaft.

Clean the parts of rear swing shaft in solvent.

Inspect the components of the swing shaft sleeve and

middle shaft sleeve. If they are damaged, please replace.

4.5Driving chain

4.5.1．Disassembly

Place the motorcycle on flat ground and tightly fasten it.

Disassemble the shift lever rocker, left rear cover and

driving wheel.

Disassemble the rear wheel, chain guard and driving chain.

4.5.2．Inspection

Clean the driving chain by dipping it in kerosene and rinse

away dust as far as possible. Then take the chain out for air

dry.

Inspect the rotor  and side plate. If they are damaged or

worn out, replace the driving chain.

Lubricate the driving chain with lubricant available at

- 52 -

stores.
Inspect rigidity of the driving chain. If it is hard, please
rinse, lubricate or replace it.

Inspect the driving wheel, driven wheel and if 1/4 of
the gear teeth

○

,A are worn out, replace the chain

wheels. And if gear teeth are bent, replace chain
wheels too.

Inspect the wheel bearing. If the wheel hubcap has bearing
clearance or imbalance in wheel rotation, then replace the
bearing. Inspect whether the oil seal is worn out or
damaged and replace it if necessary.

4.5.3 Relax adjustment of the driving
chain

Place the motorcycle on flat ground and maintain its
upright position.

Inspect the relax degree of the driving chain

○

,a，the

value of which should be 30 - 40 mm.
If the value is not in line with the specification, please

make adjustment. Unscrew the axle nut .
Adjust the relax degree of the driving chain. The

adjusting steps are:
Unscrew the locknut and screw or unscrew the adjusting

device until the relax degree conforms to specification.
Screw it in，and the relax degree will increase；unscrew it,

and the relax degree will decrease.

Note：

Finally screw up the lock nut.

4.5.4．Installation

Installation is conducted in the reverse order of
disassembly.
Install the driving chain, housing, rear shock absorber (left),
rear wheel and wheel cap of driving chain.
Adjust the relax degree of the driving chain as well as
free stroke of the brake pedal；if the relax degree is too low,
the engine and other important parts will be overloaded；
maintain the relax degree within the specified value limit.

Coincide the circle number of each adjusting device so that
the axle shaft can be correctly installed.

- 53 -

- 54 -

5 Battery/charging system

Preparation data -------------5.1 Fault diagnosis -------------5.2
Battery ---------------5.3 Charging system -------------5.4
Voltage and current regulator -------5.5 Charge coil of the alternator ---5.6
Illuminating coil of alternator ---5.7 Disassembly of alternator -----5.8

5.1 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.

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

6. 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.

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

distilled water.

8. Inspect the entire power load.

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

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

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

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

- 55 -

Preparation reference

Item Specification

capacity/ type 12V-3AH/Dry charge type

Fully charged 13.1V

Battery

Voltage

（20）

Must be

charge

12.3V(not work for an hour)

Charging current Standard：0.4A，Fast：4A

Charging time Standard：10-15h，Fast：30m

Capacity 80W/5.000rpm

Alternator

Coil impedance value

（20）

Between white and black 3.3-3.5Ω

Typ e

single-phase semi wave SCR charge, SCR

semi wave short circuit mode

12.0-14.0V/5.000rpm

Illumination

limit

13.5V/5.000rpm

Voltage

regulator

Clamping

voltage

Charge limit 14-15.0V/5.000rpm

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

Testing instrument

Avometer

5.2 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

Bad act of voltage and current regulator

- 56 -

5.3 Battery

5.3.1 Disassembly of the battery

Unclose the pad.

Disassemble the left guard strip and then the air filter cover.

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.

* Note

In order to prevent short circuit, connect positive pole first

before the negative pole.
Inspect the charging state（open-circuit voltage）.

Unclose the pad.

Unclose the top cap of the air filter and disassemble the

connector wire of the battery.

Measure the voltage between battery terminals. Fully

charged：13.1V
Undercharged ：12.3V （The battery does not work for
an hour）

* Note

Inspection of charging state must be performed with a

voltage meter.

5.3.2 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.

电瓶的

安

装位置

mounting

p

osition

of the battery

- 57 -

*Note

•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

5.4 Charging system

5.4.1Short 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.

*Note

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.

5.4.2 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 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 （5.000rpm）

If the clamping voltage exceeds the specified value range,
inspect the voltage regulator.
Inspect the clamping voltage of the lighting system.

*Note

Set the avometer at the alternating voltage position.

Clamping voltage ：13.1（+/-）0.5V/5.000rpm

If the clamping voltage exceeds the specified value range,

inspect the voltage and current regulator.

- 58 -

5.5 Voltage and current regulator

5.5.1 Inspect the main wire circuit

Unload the body guard, pad and oil tank.

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

illuminating line

（ pink ）and body

ground（inspect the

resistor plug and plug of

the side auto-starter
when the lighting

switch is pushed to OFF

position)

there being resistance

in alternator coil

between the charge coil

（white）and body

ground

there being resistance

in alternator coil

5.5.2Inspectthe voltage and current
regulator

If the main wire terminal proves fine after inspection,
inspect whether the current regulator plug is in poor contact
and measure the resistance value between the terminals of
the voltage and current regulator.

*Note

•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.

5.6 Charge coil of the alternator

*Note

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

Inspection

Disassemble the 4P joint of alternator.

Measure the resistance value between the white coil of

alternator and the motorcycle frame with an avometer.

white

（A）

red

（L）

pink

（B）

black

（E）

avometer

Positive pole

Negative pole

Unit：KΩ

white（A） 13 6.5 8

red（L） 3 1 0.7

pink（B） 2 4 0

black（E） 2 5 1.2

- 59 -

Standard value ：0.6-1Ω（20）

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

5.7 Illuminating coil of alternator

*Note

Inspection of the illuminating coil of

alternator can be conducted on the engine.

Inspection

Disassemble the 4P joint of alternator.

Measure the resistance value between the white coil of

alternator and the body ground with an avometer.

Standard value ：0.6-1Ω（20）

If the measured value exceeds the standard value, replace

the alternator coil.

5.8 Disassembly of alternator

5.8.1 Disassembly

Disassemble the fixing bolts.

Unload the left cover.

Fix the flywheel with a multiple use fixing spanner.

Disassemble the flywheel fixing nut.

Remove the flywheel with a flywheel puller.

Disassemble the retaining key.

Disassemble the lead connector of the alternator.

Disassemble the alternator stator.

螺栓

bolt

固定
螺母

Fixing
nut

- 60 -

5.8.2 Installation

Install the alternator stator to the engine case.

Connect the lead connector of the alternator.

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.

*Note

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.

螺栓

固定
螺母

Fixing
nut

bolt

- 61 -

BATTERY

MAIN SW

FUSE
10A

W/G

SPARK PLUG

IGNITION COIL

B

B/W W/G

BL/W R/W

W

W/G

BL/W

B

MAGNETO

点火系统

Ignition system

- 62 -

6 Ignition system

Preparation data ---------------------- 6.1 Ignition coil -------------------- 6.5
Fault diagnosis ----------------------- 6.2 Trigger -------------------------- 6.6
Ignition system inspection --------- 6.3 Charge coil --------------------- 6.7
CDI group ---------------------------- 6.4

6.1 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 0.5-0.7mm

Primary coil 0.4Ω（+/-）10％

with plug cover 8-11KΩ

resistance

value of

ignition coil

（20）

Secondary

coil

without

plug cover 4.5-5.5KΩ

resistance value of the trigger（20） 100-200Ω

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

Trigger voltage 1.7V or above

Tools

Accessory of peak voltage meter
Avometer

- 63 -

6.2 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 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）.

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

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 -）

trigger

no high voltage ， off-and-on
high voltage



bad act of the ignition coil



bad act of the trigger

- 64 -

6.3 Ignition system inspection

*Note

•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.

6.3.1 Primary voltage of ignition coil

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

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.

Remove the middle cover.

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：95V or above.

*Note

The metal area of the avometer prod mustn't be touched

by fingers to prevent electroshock.

6.3.2 Charge coil

*Note

Install the spark plug on the air cylinder head and inspect

with normal compression pressure.

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.
Connecting method: positive pole connected with red /
white line, and negative pole connected with black line.

avometer

high voltage diverter

- 65 -

Minimum voltage：95V or above.

*Note

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 alternator connector.
Connect the charge coil（red / 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 charge coil can be

determined. Please refer to inspection of the charge coil

table.

6.3.3 Trigger

*Note

Install the spark plug on the air cylinder head and inspect

with normal compression pressure.

Remove the 4P joint of CDI group, and connect a peak
voltage diverter between the trigger of 4P 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.

*Note

The metal area of the avometer prod mustn't be touched

by fingers to prevent electroshock.

If the tested peak voltage at CDI terminal is abnormal,

disassemble 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 trigger can be determined.

Please refer to inspection of the charge coil table.

黑

红/白

black

red / white

Ω

蓝\白

黑

蓝/白

black

blue / white

blue / white

- 66 -

6.4 CDI group

6.4.1 System inspection

System inspection.

Disassemble the CDI group and inspect the parts related

with the ignition system at the wire terminal.

6.4.2 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 red--Ground 100-200Ω

primary ignition coil

black/white—black 0.4Ω（+/-）10％

Secondary ignition coil black—spark plug cover

（spark plug not included）

4.5-5.5KΩ（+/-）10％

6.5 Ignition coil

6.5.1 Disassembly

Disassemble the body cover.

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.

*Note

The primary coil is installed in

accordance with the black/ white wire.

6.5.2 Inspect the primary coil

Measure the resistance between terminals of primary coil.

Standard value ：0.4Ω（+/-）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.

红/黑

蓝/白

黑

黑/白

black

Red/black

Black/white

blue/white

Ω

点火线图

Ignition line figure

- 67 -

6.5.3 Secondary coil

Measure the resistance value between the wire of spark plug

cover (with the spark plug) and the terminal.

Standard value ：8-11KΩ（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 ：4.5-5.5KΩ（+/-）10％（20）

6.6 Trigger

*Note

Inspection of the trigger can be conducted on

the engine.

Inspection

Disassemble the body guard.

Disassemble the lead connector of the trigger.

Measure the resistance value between the blue/white

terminal at the engine side and the body ground.

Standard value ：100-200Ω（20）

If the measured value exceeds the standard value, replace the

alternator.

点火线图

Ω

Ω

蓝\白

ignition line figure

磁电机接口

白

蓝/白

灰

黑

护套 DJ7041-1.5-21
端子 DJ624-1.8A
防水栓 MFD006-4

magnetor connector

black

brown

blue/white

white

sleeve

termina

waterproof bolt

- 68 -

启动示意图

BATTERY

RELAY

BRAKE SWITCHBRAKE SWITCH

STARTER SWITCH

STARTOR MOTOR

startup diagram

- 69 -

7 Startup system

Preparation data --------------------------7.1

Fault diagnosis ---------------------------7.2

Start electrical machinery ---------------7.3

Start relay ----------------------------------7.4

7.1 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 12.5mm 8.5mm

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

Tools

Fixing nut spanner

Multiple-use fixing spanner

- 70 -

7.2 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

7.3 Start electric machinery

7.3.1 Disassembly

*Note

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
Disassemble the fixing bolts on the startup electrical machinery
and unload the electrical machinery.
Roll up the rubber waterproof jacket and disassemble the joint of
startup electrical machinery.

7.3.2 Dismantling

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

7.3.3 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 must be

cleaned away.

电刷

electric brush

Commutator

- 71 -

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. .
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：8.5mm(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.

7.3.4 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 each electric brush into the holder and mount
the front cover.

*Note

•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.
Mount the new gasket ring to the front cover.
Install the motor housing by aligning its bolt holes
with those in the front cover.
Screw the housing bolts.

*Note

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.

7.3.5 Installation

Mount the wire of the startup electrical machinery

and confirm the soldering cup is installed.

Then install the startup electrical machinery.

Install the wire clamp of the rear brake.

电刷

electric brush

- 72 -

7.4 Start relay

7.4.1 Actuation inspection

Disassemble the body guard.

Push the main switch to "ON" and press the startup electrical

machinery with a "click ".

Inspect by sound.

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

7.4.2 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.

7.4.3 Inspect the earth line of the 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.

7.4.4 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 reads "0".

Ω

Ω

灰

start relay

brown

- 73 -

8 Bulbs/ switch/instrument

Preparation data -------------------------------8.1 Instrument-----------------8.6

Fault diagnosis --------------------------------8.2 Main switch --------------8.7

Replace the head light bulb -----------------8.3 Horn------------------------8.8

Replace bulb of the front turning light-----8.4 Handle switch ------------8.9

Replace the bulb of the taillight / licence light / rear turning light ----------8.5

8.1 Preparation data

Matters needing attention in operation

The conduction of switches may be measured after

disassembled from the motorcycle.

8.2 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

8.3 Replace the head light bulb

8.3.1 Disassembly

Disassemble the air guide sleeve.

Disassemble the bolts so that the head light could be
disassembled.
Disassemble the glass sheet on the head light.

Fix the head light and turn the socket clockwise so that the

bulb can be removed.

p

osition bulb

headlamp bulb

head light

left and right
turning light

head light

- 74 -

8.3.2 Installation

Install the bulb back to the original position in the reverse

order of disassembly.

8.4 Replace bulb of the front turning light

8.4.1Disassembly

Unscrew the setscrew on the turning light.

Remove the bulb socket from the light.

8.4.2Installation

Install the bulb back to the original position in the reverse order

of disassembly.

8.5 Replace the bulb of the taillight / licence light / rear turning light

8.5.1Disassembly

Disassemble the bolts so that the taillight cover can be
disassembled.

Remove the bulb from the socket.

8.5.2 Installation

Install the bulb back to the original position in the reverse order

of disassembly.

8.5.3 Replace the bulb of the rear turning

light

8.5.3.1Disassembly

Disassemble the bolts so that the turning light cover
can be disassembled.

Remove the bulb from the socket.

8.5.3.2 Installation

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

p

osition bulb

headlamp bulb

head light

fixing bolt

taillight

left and right

turning light

- 75 -

8.6 Instrument

Disassemble the rearview mirror；
Disassemble the faucet shield and unplug the waterproof
connector.
Disassemble the bolts.
Disassemble the instrument case so that the instrument
could be disassembled.

Install the speed indicator back to the original position in the

reverse order of disassembly.

8.7 Main switch

8.7.1 Inspection

Disassemble the setscrews.

Unload the fixing pad of the main switch.

Disassemble the setscrews and replace the main switch.

8.8 Horn

Inspection

Disassemble the horn wire.

If the horn rings when the horn wire is connected with the battery,

then it is the fine conditions.

8.9 Handle switch

Disassemble the rearview mirror and the handle cover.
Disassemble the handle switch connector.

Inspect the terminal of connector.

电源开关

instrument panel

p

ower switch

- 76 -

绿/白

白\红

绿/黑

棕

蓝

黑

橙

淡蓝

粉红

绿

/

黄

紫

white/red

green/white

orange

black

p

ink

Baby blue

blue

brown

green / black

violet

green/
yellow

- 77 -

Table of torque value of engine fastener

Fastening area and fastener name

Tightening torque （N·m）

Cylinder cover nut

Fixing nut in the power gear of the clutch

Stud bolt of air cylinder

Clutch locknut

Lock bolt of flywheel

Spark plug

Limiting screw of the feet starting lever

Shift positioned bolt

Mould assembling bolt

Bolt on the right and left crankcase cover

Loop bolt

Motor fixing bolt

Separating disk bolt of clutch

Fixing bolt of inlet valve

Setscrew of shift display

Setscrew of constant temperature set

Setscrew of electric wire clamp

Fixing bolt of water pump

18～22

50～60

18～22

50～60

35～40

10～15

40～50

10～16

10～12

10～12

10～12

10～12

10～16

10～12

4～7

4～7

4～7

10～12

- 78 -

piston

crankcase

carburetor

oil tank

oil pump

- 79 -

9 Lubrication system

Preparation data -----------9.1

Fault diagnosis -----------9.2

Oil pump -------------9.3

9.1 Preparation data

Matters needing attention in operation

The operation of engine in this chapter can be conducted on the motorcycle body.

When disassembling the oil pump, see to it that no foreign objects could enter into the engine.

After installation of oil pump, inspect whether machine oil leaks in each part.

Function of the lubrication system：supplying lubricating oil to the wear surface to reduce part wear by turning dry

friction between surfaces into liquid friction between lubricating oil particles；cooling high-load parts；absorbing

impact from the bearing and other parts and reducing noises；increasing air tightness between the piston ring and

cylinder wall；cleaning and carrying away impurities on part surfaces.

9.2 Fault diagnosis

Decrease of machine oil Engine burnt out

Natural loss of machine oil Absence of oil or oil pressure too low

Machine oil leak Oil path blocked

Wear and improper installation of the piston ring Machine oil not used

9.3 Oil pump

9.3.1 Disassembly

Pull out the inlet and outlet oil tube, unscrew the bolt
and disassemble the right cover.

inlet and outlet
oil tube

right cover

bolt

- 80 -

Take down the elastic collar and flat gasket.

Take down the drive gear set of the oil pump.

Unscrew the bolts and take down the oil pump cover.

Disassemble the tight wire of the oil pump and unload

the tight wire fixing set as well as the oil tube sleeve.

Unscrew the bolts and take down the oil pump.

9.3.2 Dismantling

Dismantle the oil pump as shown in the diagram.

elastic collar

flat gasket

drive gear set

oil pump cover

bolt

oil tube sleeve

oil pump

tight wire fixing set
of the oil pump

bolt

bolt

oil pump cover

p

iston spring

worm wheel

regulating plate

p

iston

torsion spring

camshaft

throttle handle set

oil pump body

worm gear

oil seal

- 81 -

9.3.3 Inspection

Inspect wear and tear of the worm wheel and worm gear.

Severe wear and replace.

Inspect wear and tear of the camshaft.

Severe wear and replace.

Measure the outer diameter of the piston.
Allowable limit ：2.45mm.

9.3.4 Assembly

Assembly of the oil pump is conducted in the reverse order of disassembly.

Note：

9.3.5 Installation

Install the oil pump body, oil tube sleeve and tight wire fixing

set of the oil pump.

Fix the tight wire of throttle.

Install the oil pump cover.

Install the drive gear set of oil pump.

When in assembly，inspect and ensure there's no oil

leaking in each part of the oil pump.

The oil seal should be in good shape.
After assembly，the gear wheel and gear should be

flexible in rotation without clamping stagnation.

outer diameter

oil tube sleeve

oil pump body

tight wire fixing set
of the oil pump

tight wire fixing set
of the oil pump

oil tube sleeve

oil pump body

drive gear set

- 82 -

10 Carburetor

Preparation data-------------10.1 Float chamber -------------10.5
Fault diagnosis-------------10.2 Installation of carburetor -------10.6
Disassembly of carburetor-----------10.3
Carburetor cover -------10.4

10.1 Preparation data

Matters needing attention in operation

*Note

·Gasoline is extremely dangerous，so smoking or lighting is strictly forbidden in operational field.

·Pay special attention to flakes.

·No wire should be pulled and bent with rudeness. Distortion or damage will have impact on wire actuation.

·After the carburetor is disassembled， choke the intake manifold with clothing to prevent entry of foreign

objects.

·If the carburetor is not in use for more than one month, the gasoline inside the float chamber must be

discharged. Otherwise, the gasoline inside the float chamber will deteriorate and block the idle speed nozzle,

resulting in insecurity of idle speed.

Function of the carburetor：the carburetor is a critical component in the fuel delivery system of the

engine, the operating mode of which carries direct influence on the steady operation of the engine , its driving

force and economical indicator. The carburetor atomizes a given amount of gasoline into mini drops, which

then evenly mix with varying volumes of air to shape vaporous combustible mixture according to different

operating conditions of engines, and supplied to the engine in time, in order to ensure normal continuous

running of it.

Preparation reference

Unit：mm

Item Standard value

Throat diameter 17.5mm

Main nozzle B03

Main jet 95#

Idle jet 22.5#

Needle valve B05-Z

10.2 Fault diagnosis

Bad startup Startup difficulty，flameout after startup， unsteady idle speed

·No flashover in spark plug · Fuel system blockage

·Compression pressure too low · Bad ignition

- 83 -

·Carburetor short of fuel · Too dense or sparse gas mixture

-Gasoline filter blocked · Bad fuel

-Gasoline pipe blocked · Secondary air inlet of suction system

-Needle valve conglutination · Bad idle adjustment

-Bad adjustment of oil level · Bad adjustment of oil volume

Too much fuel in the engine Too sparse gas mixture

-Air filter blocked ·Oil nozzle blocked

-Overfuel and oilflow ·Needle valve blocked

·Secondary air inlet of fuel system ·Too low oil level

·Fuel deterioration ·Fuel system blocked

·Bad operation of electric enrichment valve ·Secondary air inlet of suction system

·Idle system or choke system blocked ·Bad act of piston

Too dense gas mixture Intermittent flashover in acceleration

·Bad operation of enrichment valve · Too sparse gas mixture

·Bad operation of needle valve

·Too high oil level

·Oilflow in carburetor

·Air channel blocked

·Filth in air filter

10.3 Disassembly of carburetor

10.3.1 Disassembly

Switch the fuel control switch to "OFF".

Pull out the oil inlet hose.

Pull out the throttle wire.

Pull out the enrichment valve wire.

Unscrew the bolts at the interface between the carburetor

and engine and at the interface between the carburetor and

air filter.

Unload the carburetor from the two interfaces.

10.3.2 Electric enrichment valve

Disassemble the carburetor and cool it down for 30

minutes.

Pull the enrichment valve wire, insert the nylon tube into

the extender oil pipe within and blow air into the pipe with

mouth. There should be air in the extender oil pipe,

otherwise, the pipe should be replaced.

throttle hose

throttle wire

enrichment
valve wire

engine interface

air filter interface

enrichment valve wire

extender oil pipe-hole

- 84 -

Do not pull the enrichment valve wire, insert the nylon tube

into the extender oil pipe and blow air into the pipe with

mouth. There should be no air in the extender oil pipe,

otherwise, the pipe should be replaced.

10.3.2.1 Disassembly

Unscrew the bolts and unload the enrichment valve set.

10.3.2.2 Inspection

Inspect the wear and tear of the enrichment valve and

needle valve.

If the wear is severe, replace the electric enrichment valve

set.

10.3.2.3 Installation

Install the enrichment valve by aligning its flange with the

carburetor and fasten the bolts.

10.4 Carburetor cover

10.4.1 Dismantling

Unscrew the two bolts on the cover and unload the cover,

shim, piston spring, compression cap, needle valve and

piston in turn.

10.4.2 Inspection

Inspect the wear and tear of the needle valve and piston.

If the wear is severe, replace them.

10.4.3 Assembly

Assembly is conducted in the reverse order of disassembly.

*Note

Do not damage the needle valve or piston in

assembly.

cover

gasket

p

iston spring

needle

needle

needle valve

enrichment valve

bolt

extender oil pipe-hole

enrichment valve wire

- 85 -

10.5 Float chamber

10.5.1 Dismantling

Dismantle the four fixing bolts and unload the
float chamber.
Dismantle the float pin and unload the float and
needle valve set.
Dismantle the main jet, main bubble tube and
idle jet.
Dismantle the idle adjustment bolts.

10.5.2 Inspection

Inspect whether the needle valve set is worn out
or damaged. If it's true, replace it with a new
product and replace the main jet at the same
time.
Inspect whether the idle jet, main jet and main
bubble tube is worn out, damaged or polluted.
If it's true, replace them.

Note：

Clean every part of the carburetor with gasoline
and blow them dry with high pressure air.

10.5.3 Assembly

Assembly is conducted in the reverse order of
disassembly.

10.6 Installation of carburetor

Assembly is conducted in the reverse order of
disassembly.

Note：

Assembly is conducted in the reverse order of disassembly.
Install the carburetor in the reverse order of disassembly.

10.6.1Adjustment of carburetor

Note：

The idle adjustment bolt was adjusted when delivered out
of the factory and needs no readjustment. When
dismantling, take down the turning circle number for the

benefit of installation.
Switch on and warm up the machine for about 3 minutes, so that the engine will operate in normal running
temperature.
Adjust the idle adjustment bolts and set engine speed to be 1400rpm.
Screw the mixture adjustment bolt to the end with proper force.

The idle adjustment bolt and nozzle shouldn't

be damaged. When screwing off the idle

adjustment bolts，memorize the circle number.

The idle speed must be adjusted after the

installation.

bolt

float chamber

needle valve set

float

main jet

float pin

main bubble tube

idle adjustment bolt

idle jet

- 86 -

At this point the engine will stall（if not，inspect whether air escapes at the interface of air filter , whether the

bolt is tightened and whether the intake of the air filter is blocked).

Withdraw the mixture adjustment bolt for 1 circle.

Restart and adjust the idle adjustment screw so that the rotation speed reaches 2000-2500rpm.
Slowly adjust the mixture adjustment bolts（anticlockwise), till the engine speed reaches its utmost（ mixture
bolt is withdrawn for two circles at most）.

Reset the idle adjustment screw and set the engine speed down to 1400±100rpm/min.
Pull the throttle for several times for acceleration and inspect whether the idle speed is steady.
Test the outlet and compare it with the specified standards.

- 87 -

constant temperature set

gasket

spark plug

temperature controller

nut

cylinder cover

- 88 -

11 Cylinder cover/air cylinder/piston

Preparation data ---------------11.1

Fault diagnosis ---------------11.2

Disassembly of air cylinder -------------11.3

Disassembly and installation of the piston -------11.4

Installation of air cylinder -------------11.5

Disassembly of cylinder cover -----------11.6

Installation of cylinder cover - ---------11.7

11.1 Preparation data

Matters needing attention in operation

·The operation of air cylinder/piston can be conducted on the frame.

·Blow it dry with compressed air after dismantling, before inspection and test or after cleaning.

·In order to ensure the encapsulation of cylinder cover and cylinder body，the cylinder cover bears considerable
bolt retightening force. Retightening force value：50Nm.

All parts should be cleaned before inspection and test and should be blow dry with high pressure air.

Function of the cylinder： the cylinder body provides space for the compression, burning and
expansion of air and plays a steering function to piston motion.

It also transmits part of the heat in the air cylinder to the surrounding cooling media.

Function of piston：

1．Bearing the pressure caused by burning of combustible mixture gas and pass the pressure to the connecting

rod, driving the rotation of the crankshaft.
2．Shaping a combustion chamber with the cylinder cover and others.
3．Acting as the sliding valve to lock and unlock the air channel, pressing the fresh air mixture in the crankcase

into the air cylinder and ejecting the exhaust gas out of the air cylinder after combustion.

Function of the cylinder cover ：the cylinder cover is designed to encapsulate the air cylinder,
constitute a combustion chamber with the piston and bear combustible gas with high pressure
and high temperature.

Preparation reference Unit: mm

- 89 -

Item Standard value

Allowable

limit

Bore diameter 40.27-40.28 40.3

Bent 0.05

Cylindricity 0.05

Air

cylinder

Roundness 0.05

Top ring 0.015-0.05 0.09

clearance between the piston

ring and piston ring groove

Second

ring

0.015-0.05 0.09

Top ring 0.1-0.25 0.5

Interface clearance

Second

ring

0.1-0.25 0.5

Outer diameter of piston 40.22-40.23 40.2

Clearance of piston and air cylinder 0.04-0.06 0.1

Piston and

piston

ring

Bore diameter of piston pin hole 12.002-12.008 12.04

Outer diameter of piston pin 11.994-12 11.96

Clearance of piston pin hole and piston pin 0.002-0.014 0.08

Bore diameter of connecting rod small end 14.995-15.006 15.06

11.2 Fault diagnosis

·If bad startup or unsmooth low speed occurs，inspect whether white fume is ejected out of the crankcase

breather. If the crankcase vent hole does have white fume ejected, the piston ring must be worn out, burnt out

or the piston must be broken.

Low compression pressure ite fume in vent pipe

·The piston ring is worn out，burnt out or broken. ·The piston ring is worn out or damaged.

·The air cylinder piston is worn out or damaged. ·The air cylinder piston is worn out or damaged.

Compression pressure too high Piston noises

·The piston combustion chamber has carbon deposit. ·The air cylinder piston and piston ring is worn out.

·The piston pin hole and piston pin are worn out.

11.3 Disassembly of air cylinder

Disassemble the cylinder body.

Disassemble the gasket and scrape clean the adhesive

gasket at the cylinder junction.

Inspect the wear and tear of the cylinder inner wall.

Severe wear and replace it.

gasket

cylinder

- 90 -

11.4 Disassembly and installation

of the piston

Disassemble the retaining ring for piston pin.
Note：When disassembling，do not drop the retaining ring

into the crankcase.

Withdraw the piston pin and unload the piston.

Unload the piston ring.

Inspect the piston, piston pin and piston ring.
Note：

Do not break or damage the piston ring.

Clean away the carbon deposit in the

piston ring groove.

Install the piston ring.

Measure the clearance of the piston ring and piston ring

groove.

Allowable limit ：

Top r i ng：0.09mm.

Second ring ：0.09mm。

Unload the piston ring and install each piston ring at the

bottom of the cylinder.
Note：

Press the piston ring into the air cylinder with

the piston crown.

Measure the interface clearance of the piston

ring.

Allowable limit：0.5mm.

p

iston pin

p

iston

retaining ring for

piston pin

p

iston

Testing gauge

p

iston ring

insert

p

iston

p

iston ring

Testing gauge

- 91 -

Measure the bore diameter of the piston pin hole.

Allowable limit：12.04mm。

Measure the outer diameter of the piston pin.

Allowable limit：11.96mm。

Measure the outer diameter of the piston.
Note：

The measuring position and the piston pin form an

angle of 90 degree, some 15.5mm below the skirt of

piston.

Allowable limit：40.20mm。

Clearance of the piston pin hole and piston pin.

Allowable limit：0.08mm。

Inspect the abrasion and wear of the cylinder inner wall.

Note：

Measure the bore diameter of the cylinder at the

upper, middle and lower part when keeping an angle

of 90 degree from the piston pin.

Allowable limit：40.3mm。

Measure the clearance of the cylinder and piston and take the

maximal value as final one.

Allowable limit：0.1mm。

Testing
gauge of ai

r

cylinder

- 92 -

Measure the roundness of inner wall（bore diameter difference between X and Y direction ）.
Allowable limit：0.04mm。

Measure the cylindricity of inner wall（bore diameter difference at the upper , middle and lower part in X or Y
direction）.

Allowable limit：0.05mm。

Inspect the flatness of the cylinder surface.

Allowable limit：0.05mm。

Measure the bore diameter of connecting rod small end.

Allowable limit：15.06mm。

11.4.1 Installation of piston

Install the guide pin.

Evenly spread machine oil on each piston ring and
piston and correctly install the piston ring by
aligning it with the guide pin on the piston.

Note：

The piston should not be scratched and the

piston ring should not be broken.

The piston ring should be assembled with its

marked side upward.

upper

middle

lower

middle

rule

r

Testing gauge

cylinder

bore diameter of connecting rod small end

guide

p

iston

Top ring

second
ring

- 93 -

Scrape the adhesive gasket off the crankcase.
Note：

No foreign objects should fall into the crankcase.

Install the piston, piston ring and retaining ring.
Note：

Install according to the arrow mark on the piston top.

The retaining ring should not fall into the crankcase.

11.5 Installation of the air cylinder

Install the gasket on the crankcase.

Evenly spread machine oil on cylinder inner wall,
piston and piston ring.

Take care to install the piston ring in the cylinder.
Note：

The

piston ring should not be

damaged.

11.6 Disassembly of cylinder cover

11.6.1 Disassembly

Disassemble the spark plug and unscrew the temperature

controller.

Unscrew the four nuts and unload the cylinder cover.

arrow mark

gasket

cylinder

spark plug

temperature

controller

fixing bolt

- 94 -

Unload the gasket.

Unscrew the bolts and unload the constant temperature set

from the cylinder cover.

11.6.2 Inspection

Inspect whether the cylinder cover is broken.

Inspect the flatness of the bottom surface of the cylinder.

Allowable limit：0.05mm.

Remove the carbon deposit on the cylinder cover
with a bamboo scraper.

11.7 Installation of the cylinder cover

Installation is conducted in the reverse order of disassembly.

constant temperature set

gasket

spark plug

temperature controller

nut

cylinder cover

gasket

constant

temperature set

bolt

ruler

Testing gauge

cylinder cover

- 95 -

Crankshaft-connecting rod set right crankcase

bolt

balancing

shift chamber

left crankcase

Housing set

internal gear gasket

center

wearing plate

iron friction plate

fixing gasket

Locknut

clamp nut

flat gasket

dish gasket

bearing ball

inward release lever

outward release lever

p

ressure cove

r

p

ressure spring

Bolt and gasket

adjustment bolt

- 96 -

12 Crankcase/clutch/actuating lever

Preparation data ----------------12.1

Fault diagnosis -----------------12.2

Crankcase -----------------------12.3

Clutch ---------------------------12.4

Actuating lever -----------------12.5

12.1 Preparation data

Matters needing attention in operation

Since the crankcase is a thin-section casting, please avoid impact on it during operation in case there is any
distortion or rupture.
All parts should be cleaned before inspection and test and should be blow dry with high pressure air.
Before operation, discharge the lubricating oil in the crankcase.

Function of the crankcase：the bearing part of the engine. Its primary function is supporting the

crankshaft, clutch, gearbox, cylinder body as well as the cylinder cover and bearing bursting impact of
combustion and movement inertia force of crankshaft connecting rod system and constituting some closed
（oil, air seal) space. The crankcase has a hanging hole which links the engine and the frame with other parts
by connecting with the hanging hole.

Preparation reference Unit：mm

Item Standard value Allowable limit

clearance of connecting

rod big end in right and left

direction

0.1-0.35 0.55

axial clearance of

connecting rod big end in

vertical angle

0-0.008 0.05

Crankshaft

vibration 0.1

Thickness of wearing plate 2.9-3 2.6

Clutch

Length of pressure spring 29.4-30.6 29.0

Bore diameter of shift fork 7.825-7.845 7.91

Thickness of shift fork 3.95-4.05 3.9

Outer diameter of shift drum 41.8-42 41.75

Shift

mechanism

Locked groove width of shift

drum

6.05-6.15 6.3

Tools

Multiple use fixer Clutch spring compressors
Driver's perch Box spanner

Guide rod Bearing driver

- 97 -

12.2 Fault diagnosis

Low compression pressure Strange noises in crankcase

Air escape in crankcase Parts shattered or broken in crankcase

Overheat of engine Engine stalling

Slipping of clutch Clutch depressed

Lubricant starvation

Unable to put the shift Difficulty in gearshift

Gearshift fork broken or distorted Half disengagement

Fork pin broken Bad operation of shift return spring

Gear cam wear Locked groove wear of shift drum

Automatic off-gear

Joint cam is worn out and the edge turns round.

Weakening elasticity of return spring
The spline gear of the spline shaft and spline groove of the slide gear are worn out， resulting in considerable

axial force in gear movement.

The shift drum and shift fork are worn out.

12.3 Crankcase

12.3.1 Disassembly of left crankcase

cover

Unscrew the binding bolt and unload the left crankcase
cover（ called as left cover for short in the diagram）.

Unscrew the locknut and unload the magnetor set.

binding bolt

magnetor set

multiple use fixer

box spanner

left cover

- 98 -

Unload the release lever set.

Unload the electric starter set.

12.3.2 Disassembly of right crankcase

cover

Unscrew the binding bolts and unload the right crankcase
cover（ called as right cover for short in the diagram）.
Note：when unloading the right cover, disassemble the oil

pump set and water pump set together.

12.3.3 Installation of crankcase cover

Install in the reverse order of operation.

12.4 Clutch

12.4.1 Disassembly

Unload the right cover and then unload the gasket and guide pin.

Remove the adhesive gasket on the joint face of the right cover and crankcase.

guide pin

gasket

water pump set

oil pump set

binding bolts

right cover

electric starter set

release lever
set

- 99 -

Unscrew the four bolts，and unload the pressure spring,

clutch pressure plate.

Unload the adjustment bolt and clamp nut on the press

plate.

Remove the gasket lock by unscrewing the locknut with a

special tool.

Remove the outward release lever of the clutch.
Unload the wearing plate set（ centre, wearing plate set and
iron friction plate ）. See the dismantling diagram for

parts.

Unload the internal gear gasket.

Unload the housing set.

Unload the dish gasket and flat gasket.

Assembly of clutch is conducted in the reverse order of disassembly.

bolt

adjustment
bolt/ bolt

p

ressure spring

clutch pressure plate

multiple use fixer

box spanner

internal gear gasket

housing set