SERVICE MANUAL
Contents
1. It is not necessary to fill the oil reservoir to the full capacity Brake oil for replenishing should be the same as original E The specification of brake oil is indicated on the reservoir cover Place diaphragm Connect a transparent hose to exhaust valve Grip brake lever fast and open exhaust valve 1 2 turn to let out air and lock exhaust valve Repeat this operation till no bubbles are exhausted from brake oil passage brake lever releasing Do not release brake lever before exhaust valve is closed At the completion of adjustment replenish brake oil till oil is over the lower limit line lower limit line of the oil reservoir Mount diaphragm set and oil reservoir cover Tighten oil reservoir cover bolt Main Brake Oil Tank Dismounting and Mounting Dismounting head cover front part head cover rear part Remove screws of front part and rear part of head cover Remove front part and rear part of head cover 21 Exhaust brake oil from front brake system Pull out brake switch plug from main cable re Remove bracket bolts from handlebar Remove main cylinder Remove brake oil pipe from main cylinder Prevent brake oil from splashing to bracket bolts rubber plastic or painted surfaces Cover the above mentioned parts with a cloth Remove brake light switch and brake lever Remove retaining ring from main cylinder Use special retaining ring remover when removing retain2. indicator nearly touched brake disc the brake blocks must be replaced with new ones G wear amp tear indicator U brake disc brake blocks VII BRAKE SYSTEM INSPECTION ADJUSTMENT AND REPLACEMENT 1 Front brake disk brake Remove the bolts linking brake caliper and front shock absorber Remove brake caliper front shock absorber brake caliper Do not pull brake lever when brake caliper is removed so as to prevent jamming of brake block If brake block is jammed pry it with screwdriver and push piston back into caliper Brake Block Replacement Brake block must be replaced when it is worn to the limit of use t is not necessary to remove brake oil pipe when replacing brake block brake block pins Brake block must be replaced as a set brake caliper Y Remove the brake block pins Take out the old brake blocks and mount a set of new brake blocks Effect mounting in an order reversed to that of dismounting Brake Disc Inspection Inspect brake disc thickness Limit of use 3 0mm Inspect brake disc angularity Limit of use 0 3mm 2 Rear Brake Inspect rear brake lever free travel Free travel 10 20mm Turn adjusting nut to effect adjustment when free travel exceeds limit adjusting nut VIII FRONT AND REAR SHOCK ABSORBER INSPECTION 1 Front Shock Absorber Tighten front brake lever press front shock absorber up and dow
3. mQ oO 12 1 2 13 15 18 20 29 29 25 26 21 28 SUMMARY This 2 stroke scooter BT49QT 21B1 is with low weight enough power low oil consumption and good operating performance This manual is for maintenance men to repair and maintain BT49QT 21B1 and it is also useful when maintain other models This manual holds the latest technical information We reserve the right to amend the data instructions and specifications without advice The technical specifications of BT49QT 21B1 Size and weight Lengthxwidthxheight 1940x720x1150 Unloading weight 100 Wheel space 1300 254 kg 225KPa Fuel tank capacity 4 5 E 0 5L 205K iSo Engine 1390MA A Lubricate method Pressure spray 39mmx41 4mm Gasoline brand 90 or above Cylinder capacity Clutch type Automatic acentric Max torque 3 00 3 88 6500 Starting method Electric kick starting DINE POW 3 15 8500 Ienition method CDI kw r min Idling speed r min 1900 3 100 Cooling system Forced air cooled Electric system I2V 6AH Turning signal light 10W 12V Headlight 35 35W 12V Position light SW 12V Taillight brake light 5 21 W 12V 10 CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE I ITEMS OF MAINTENANCE When the motorcycle is used parts loose and mechanical wear inevitably occur to varied extents Neglecting of timely maintenance not only reduces its mechanical function economic performance stability and durability but also threatens the safety of
4. 45 N m Mount left brake lever and fasten bolts Torque 9N m Mount front brake main cylinder Apply grease to throttle cable Mount throttle cable seat and connect throttle cable Mount throttle grip Mount covering parts of front head cover and rear head cover Confirm easy rotation of throttle grip When mounting handlebar rubber apply a thin film of adhesive to contacting face and then mount grip in a turning manner Vl REAR WHEEL SERVICE Dismounting Remove 2 connecting nuts and 2 mounting bolts of exhaust muffler Remove exhaust muffler Remove rear axle nut Rear Wheel Oscillation Inspection Measure oscillation value on a correcting bench by means of micrometers Limit of use Longitudinal gt 2 0 mm Traverse gt 2 0 mm 26 Mounting Mount rear wheel and fasten rear axle nut Torque 1203 m Mount exhaust muffler Fasten exhaust muffler connecting nuts and bolts Torque Exhaust muffler connecting nut 12N m Exhaust muffler mounting bolt 35N m Vl REAR BRAKE SERVICE Remove exhaust muffler Remove rear wheel Inspect rear brake drum Measure rear brake drum bore Limit of use 111mm effect replacement if the limit is exceeded Rear Brake Block Replacement Remove rear brake block and return spring as a whole and replace them with new ones e See that no grease is with brake block friction surface Rear Brake Disassembling Remove rear brake adj
5. the motorcycle and the rider Correct and timely maintenance of the motorcycle 18 necessary Items of maintenance refer to the parts and positions for maintenance Different items of maintenance are affected in different intervals and in different manners Running in Maintenance This is the maintenance at the end of the first 1000km and is an all round inspection of motorcycle A newly bought motorcycle or a motorcycle fresh from an overhaul might be severely overheated as a result of severe friction between the moving parts which might be imperfect in finishing or fitting Neglecting in use might lead to damage of the friction surfaces and might threaten the performance and the service life of the motorcycle Please observe the following points Restrict the speed in speed range specified in the instruction manual Restrict the load to 2 3 of the maximum load and ride in fairly good road conditions Restrict the length of riding time to avoid long time running of the engine Replace engine oil at short intervals so that metal chips caused in the running in period can be discharged It is recommended to replace engine oil for 3 times during the running in period 2 Routine Maintenance Routine maintenance is the basis of all kinds of maintenances It refers to the daily maintenance including cleaning inspecting and common troubleshooting 3 Periodic Maintenance This maintenance is to restore normal performance of the motorcycle
6. with new oils IV THROTTLE ACTUATION INSPECTION Inspect throttle grip for easy and smooth mo vement Inspect throttle free travel Free travel 2 6mm The main adjusting position 1s beside the carburetor Remove rear luggage box cover Adjust by loosening the fastening nut and turning the adjusting nut Fine adjustment is effected on the side of the throttle grip Effected adjustment is by removing the dust cover loosening the tightening nut and turning the adjusting nut free travel 2 6mm V AIR FILTER INSPECTION AND CLEANING After a certain mileage dust and impurities will gather in air filter case and strainer which will clog strainer pores and reduce inlet of air and thus lead to excessive concentration of mixed gas and reduce the performance of engine That s why the strainer must be cleaned every 2000 3000km and in dusty or rainy conditions strainer must be cleaned or replaced earlier Remove 5 tightening screws of air filter Remove strainer cover Take out the foam strainer Immerse foam strainer in gasoline and wash it to remove dust and impurities by gripping and pressing Press gasoline out of the foam Soak the cleaned foam with engine oil press out or throw out engine oil to leave it moist with oil cleaning gripping gasoline soaking gripping Mount VI BRAKE BLOCKS INSPECTION Grip the brake lever and check the wear amp tear indicator on the brake blocks If the
7. BT49QT 21B1 MODEL SERVICE MANUAL BT49QT 21B1 MODEL SPARE PARTS NAME 9 10 11 12 13 1415 16 17 18 1 front turning light taillight 13 main stand 2 headlight 8 rear reflector amp license plate light 14 starting pedal 3 rear view mirror 9 front brake disc 15 air filter 4 seat 10 front shock absorber 16 rear drum brake 5 rear shock absorber 11 front brake disk 17 rearturning light 6 rear carrier 12 side stand 18 side reflector CONTENTS SUMMARY CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE ITEMS OF MAINTENANCE PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS MAINTENANCE SPECIFICATIONS THROTTLE ACTUATION INSPECTION AIR FILTER INSPECTION AND CLEANING BRAKE BLOCKS INSPECTION BRAKE SYSTEM INSPECTION ADJUSTMENT AND REPLACEMENT FRONT AND REAR SHOCK ABSORBER INSPECTION FRONT WHEEL AND REAR WHEEL INSPECTION STEERING STEM INSPECTION CHAPTER TWO MAINTENANCE INFORMATION s IL FRAME NUMBER AND ENGINE NUMBER LOCATION PRECAUTIONS IN OPERATION SPECIFIED TORQUES CHAPTER THREE BODY TROUBLESHOOTING SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION SECTION TWO DETAILED DESCRIPTIONS OF BODY PARTS TROUBLES SSSs 5 57 FRONT WHEEL SERVICE FRONT BRAKE SERVICE DISK BRAKE FRONT SHOCK ABSORBER SERVICE FRONT FORK SERVICE HANDLEBAR SERVICE REAR WHEEL SERVICE REAR BRAKE SERVICE REAR SHOCK ABSORBER SERVICE N N tA N WW
8. The maintenance is classified into first grade periodic technical maintenance and second grade periodic technical maintenance also known as items of maintenance according to different mileages Generally speaking a first grade maintenance is effected after the initial 4000km and a second grade maintenance 15 effected every 8000km As the service time extends maintenance intervals should be shortened accordingly II PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS After a period of using one day one month or half a year for example or a certain mileage 1000km 4000km 8000km for example an all round maintenance operation should be effected including comprehensive inspection adjustment tightening lubrication cleaning or replacement The specific regulation made according to time intervals or mileages is known as maintenance interval The motorcycle maintenance schedule is as follows 2 1 Maintenance Schedule Maintenance Schedule Engine oil strainer Gasoline strainer a Steering rod bearing 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 New R 300km Clean every 3000km replace when necessary Z Screws I I bolts of parts Rear brake C cam Notes l 2 UJ I Inspect and when necessary clean lubricate supplement modify or replace A adjust C clean R replace T tighten Effect periodic mainte
9. ar Shock absorber nae Absorber Service Spring fatigue SECTION TWO DETAILED DESCRIPTION OF BODY PARTS MALFUNCTION Precautions in Operation Forced mounting or dismounting of body cover parts will cause damage to claws and slots of corresponding hoods When mounting body cover parts be sure to align the corresponding parts of hoods When mounting body cover parts avoid pressing wires cables or pipes I FRONT WHEEL SERVICE Front Wheel Dismounting Support the body bottom to lift front wheel Remove the connecting bolts linking brake calipers and front absorber remove brake calipers loosen axle nut remove the front axle nut front shock absorber transmission gearbox front axle bush and the small bush remove front axle front shock absorber Remove front wheel Remove brake disc mounting bolts Remove brake disc small front axle bush front axle bush 18 Axle Bending Inspection Place axle on a V seat and measure with a dial gauge The dial gauge indicates a 1 2 bending value Limit of use Replace if 0 2mm Wheel Rim Oscillation Inspection Measure oscillation value on a correcting bench Limit of use Replace if gt 2 0mm Traverse direction Replace if gt 2 0mm Front Wheel Bearing Inspection Remove front wheel bearing and dust cover Turn bearing inner race to inspect sliding Replace it with a new one in case of no sliding or damage or loose
10. cylinder piston Refer to Brake cylinder System Inspection Disk brake failure eeu i brake system Replacement Clogged narrow Front Brake liquid passage Service Viscous worn brake caliper Stuff brake lever Inability of brake caliper normal sliding brake caliper piston main cylinder piston block and brake disc Bent or deformed brake disc Inability of brake Resisted braking caliper normal sliding Wheel not adjusted straight 16 Chart continued Causes Hardened brake block surface or dusty block Uneven or slotted brake block Abnormal braking Refer to Rear Brake Service sound surface Serious wear of brake block lining Serious slots inside brake drum I Refer to Front Fork Steering stem rotation not easy Service Bent shock absorber Petia Front Shock Deviation of Shock absorber oil leakage Absorber Service motorcycle direction Bent front axle incorrect wheel inclining to roadside mounting Roundness error of wheel rim Refer to Front Wheel l Service Deformation of wheel rim Inadequate tire pressure Deformed wheel rim Loose front wheel bearing Refer to Front Wheel Service Front wheel oscillation Poor tire Poor axle locking Soft front shock Refer to Front Shock absorber Absorber Service 2 Deformed wheel rim Refer to Rear Wheel Rear wheel oscillation ee Poor wheel Service Soft rear shock Sprine fati Refer to Re
11. d bearing top removers Mounting Apply grease to bearing cup and bearing top at the bottom Mount in order bottom bearing cup bearing ball set bottom bearing top on the bottom of steering stem 24 Pass steering stem through head tube Apply grease to top bearing cup and bearing top Mount in order upper bearing cup bearing ball set and upper bearing top on the upper part of steering stem and fasten them Torque 15 N m Turn front fork right and left to effect close contact of bearing balls Loosen upper bearing top to torque O and fasten it Torque 2 5N m Fix upper bearing top and tighten steering stem setting nut Torque 70N m Turn front fork and confirm easy rotation without loosening Lock set nut Mount handlebar bolt bush and nut Mount handlebar Mount front body covering parts V HANDLEBAR SERVICE Dismounting Remove covering parts of front part and rear left grip part Remove left brake lever Remove left grip from handlebar Remove front brake main cylinder Remove throttle cable and throttle cable seat Remove throttle grip from handlebar Remove handlebar bolt bush and nut from handlebar Remove handlebar throttle cable 22 left brake lever assy throttle grip When removing left grip and throttle grip remove contamination and grease from contacting face Mounting Mount handlebar on steering stem guide tube fit bush setting bolt and nut Torque
12. d engine Remove rear shock absorber 28 Inspection Inspect rear shock absorber oil seal for oil leakage inspect buffer bar and spring for deformation and other parts for damage and loosening Mounting Mount rear shock absorber Torque upper mounting bolt 40N m bottom mounting bolt 25N m Mount air filter Mount motorcycle body covering parts 29
13. er on front fork and mount 2 bolts Torque upper bolt 40N m Mount front body covering parts Mount front fender mounting bracket Mount front fender Mount front wheel IV FRONT FORK SERVICE Dismounting Remove front body covering parts Remove bolt bush and nut Remove handlebar IPM m en Remove steering stem set nut y LES M li fi 1794 9 97 Remove upper bearing cup upper bearing top and bearing set 23 Remove front wheel and front shock absorber together with front fender and steering stem from head tube The removing of the bottom bearing cup bearing top and bearing set is the same as the removing of the upper series Do not damage steering stem when removing bearing cup and bearing top Clean opening parts of motorcycle body covering parts with cloth Inspection Inspect if there 1s slot or pit in bearing cup upper bearing top and bearing top If there 15 effect replacement Lui bottom bearing top Inspect for completeness of bearing balls bottom bearing cup and if there is effect replacement with new al ball set Ones Inspect for proper tightness of steering stem and if not effect adjustment and fasten it Inspect for correct position of bearing cup and bearing top and if not effect correct mounting Bearing Cup and Bearing Top Replacement Remove bearing cup and bearing top with special bearing cup an
14. f motorcycle frame Wire clamps must correctly keep wires in place Avoid welding stains of welded clamps when clamping wires Wire bunches must be fixed away from turning or moving parts Do not damage the covering of wire bunches In case of wire bunch defects remedy it with insulating bands Wire bunches must not be covered with mounted parts Do not twist or bend cables by force Deformed or damaged cables would result in poor rotation or damage SPECIFIED TORQUES Torques at important positions and standard torques of other positions are as follows SPECIFIED TORQUES Frame u Thread Torques Designations of tightening positions Number 22 specification N m 45 Engine suspension lug mounting nut Engine mountingnut 1 mo 45 Rear shock absorber lower mounting bolt 1 Front shock absorber upper lock bolt 2 Upper bearing top 00000000 Upper bearing top Exhaust muffler connector nut Exhaust muffler mounting bolt 13 Standard Torques Boks PS SeewM6 Flange bolt nut 8 Flange bolt nut MIO CHAPTER THREE BODY TROUBLESHOOTING SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION Body part common troubles and possible causes are as follows Causes Details reference Over tightening of handlebar adjusting nut Steering stem over worn Troubles Handlebar rotation not easy strenuous turning or unstable tightness Refer to Front Fo
15. ing ring Remove piston cover piston and spring Clean oil reservoir and piston with pure brake oil Do not effect cleaning with gasoline as it is corrosive to rubber parts Inspection Inspect for wear or ageing of main and auxiliary cups on pistons Inspect for scratches and other damages on main cylinder and piston Measure main cylinder bore Measure outside diameter of piston at the end of auxiliary cup Mounting Apply pure brake oil to piston main cup and auxiliary cup Mount spring piston retaining ring and piston cap Piston cup cannot be used inside out Apply grease to brake lever axis pin Mount brake lever and brake switch Mount main cylinder main cylinder bracket and lock them Mount brake oil pipe Connect brake light switch cable with switch Mount head cover front part and rear part Replenish brake oil and exhaust air in brake system 22 FRONT SHOCK ABSORBER SERVICE Dismounting Remove front body covering parts Remove front brake calliper Remove front wheel front fender Remove front fender mounting bolts and front fender mounting bracket Remove front fender Remove 2 pieces of bolts on the upper part of front shock absorber Remove shock absorber Inspection Inspect if there is oil leakage in front shock absorber if there is deformation of shock absorber arm and if there is damage or loosening of any part ENT B shock absorber Mounting Mount front shock absorb
16. n and inspect actuation Inspect front shock absorber to see if there is leakage of oil and if there is damage or loosening 2 Rear Shock Absorber Press rear shock absorber to inspect actuation Inspect rear shock absorber to see if there 1s oil leakage and if there is damage or loosening in machine parts Lift rear wheel press rear wheel right and left to inspect if engine suspension lug buffer bush is loose IX FRONT WHEEL AND REAR WHEEL INSPECTION Wheel Rim Inspection Inspect wheel rim remove rust stains and rubber chips Deformation and fissures are causes of air leakage Do not use wheel rims in the following cases Bruise of wheel rim face contacting tire bead ring exceeds 0 5mm in depth and 1 0mm in width Tire Inspection Inspect if there is fissure or iron nail in the tire In one of the following conditions tires must be replaced instead of repair Puncture of tire by a foreigner matter 6mm in diameter or tire fissure Layered tire Chunking of tread Damaged tire bead Broken tire bead or other tire bead damages Broken tire cord Damage due to forced dismounting Fissure extending to frame Abnormal inner lining Tire groove wear front wheel lt 0 8mm rear wheel lt 0 8mm Punctured or otherwise damaged tire flank Inspect tire pressure by means of a tire pressure gauge Tire pressure should be inspected when the motorcycle is in a cold state Specified pressure Unit kPa Fr
17. nance according to the instructions in the user s manual When the mileage exceeds the range specified in the schedule repeat the maintenance In dusty or rainy conditions inspection and replacement should be effected earlier In heavy load long distance or rainy conditions replacement should be effected earlier 2 Maintenance locations 2 Maintenance locations Spark plug Throttle grip Oil tank Front shock absorber damage contamination Cactuation play brake oil level damage loosening Rear tire Rearrim Frontrim Front tire wear damage tire pressure damage oscillation damage oscillation wear damage tire pressure Headlight Rear brake rod Rear shock absorber Air filter beam adjustment free travel damage loosening contamination Front brake disc Front brake caliper Rear brake gearcase damade wear wear of brake blocks wear of brake drum Cenaine oil auantitv MAINTENANCE SPECIFICATIONS The basic methods of motorcycle maintenance include inspection adjustment tightening lubrication cleaning supplementing and replacement which constitute the main elements of maintenance 1 Inspection Inspection refers to basic inspecting operations in accordance with items and requirements specified in the user s manual including inspection with instruments or with eyes for abnormalities in machine parts directly comparing related data and aligning with tools and gauges Adjustment Adjustmen
18. ning of outer race 19 front axle bush dust cover Front Wheel Bearing Replacement Dismounting Remove front wheel bearing by means of a bearing remover take out spacer Mounting Apply grease to the bearing Drive in left bearings Mount spacer Drive in right bearings Bearings must be driven in parallel Dust cover must be driven in with the face out Apply grease to new dust cover lip Mount front axle bush Front Wheel Mounting Mount brake disc tighten brake disc mounting bolts Torque 27N m Spread front axle with a thin film of grease Mount front axle from left side Mount in order small bush left front shock absorber bush front wheel transmission gearbox right front shock absorber front axle nut and fasten it Torque 60N m Mount brake caliper as specified II FRONT BRAKE SERVICE DISK BRAKE Brake Oil Replacing Prevent dust or water from entering brake system Do not use brake oils of different specifications or impure brake oils Prevent brake oil from dripping onto rubber plastic or painted parts Brake Oil Exhausting Place main cylinder at a level place remove oil reservoir cover oil reservoir cover and diaphragm Connect a hose to oil exhaust valve loosen exhaust valve grip and release brake lever till oil is exhausted 20 Brake Oil Replenishing Lock exhaust valve Replenish oil reservoir with specified brake oil
19. ont wheel Tire Specifications Front wheel 110 70 12 Rear wheel 110 70 12 Inspect if front wheel nut is loose Inspect if rear wheel nut is loose If loose tighten them to specified torques Torques front wheel nut 60N m rear wheel nut 120N m X STEERING STEM INSPECTION Swing handlebar right and left to see if there 15 interference such as wire or other things Turn front wheel to see that handlebar 18 easy in operation In case of any difficulty operation inspect steering stem bearing assembly 11 rear axle nut CHAPTER TWO MAINTENANCE INFORMATION I FRAME NUMBER AND ENGINE NUMBER LOCATION PRECAUTIONS IN OPERATION Removed washers O rings elastic retaining rings and split pins must be replaced with new ones When mounting bolts nuts and screws proceed from trial tightening from larger diameters to smaller diameters and inner ones to outer ones in a diagonally order Tighten them to specific torques Parts and greases must be those made by our factory or recommended by our factory Special operations must be effected with special tools or specified universal tools Removed parts must be rubbed or cleaned before they are inspected or measured They must be coated on the sliding faces before mounting They must be greased at the specified positions with designated or equivalent greases Parts must be tightened and their performances inspected at their positions when m
20. ounted The battery s negative terminal must be disconnected before operation Make sure that tools such as wrenches are not in contact with the frame At the completion of operations reconfirm correct connections and fastenings The positive terminal must be connected first in case of a removed battery Connected terminals must be coated with lubricant The terminals must be completely covered with caps When a fuse is burnt inspect the cause and replace the fuse with a fuse of equivalent capacity At the completion of operation completely cover terminals with caps When removing connectors with locks they must be unlocked before operation When removing connectors the connectors proper must be held instead of pulling their wires Before connecting connectors confirm that they are free from breakage bending over length or loosening 12 Connectors must be inserted home When connecting connectors with locks confirm that their locks are fastened Confirm that the wires are not loose Confirm that connectors plastic sleeves completely cover the connectors without fail Before connecting the connectors confirm that their sleeves are free from breakage and their terminals are not oversized Connector plugs must be fully inserted Confirm that plastic sleeves completely cover the terminals Plastic sleeves should not be placed with the open side up Wire bunch bands should be fixed at the specified position o
21. rk Service Incorrect mounting of brake cable or Refer to Handlebar tachometer cable Service Front Fork Service Remarkable deformation of steering stem due to outside impact Heavy steering stem Over tightening of steering stem top turning ball bearing retainer Damaged or broken ball bearing Refer to Front Fork Service Refer to Front Reduced tire air Service Imbalance of right and left shock Sd pu absorbers Service Deflected steering Refer to Front Fork stem Bent front fork Service Refer to Front Bent front tire deflected tire 1 1 2 Normal wear of brake lining Hardened brake block or dusty block Excessive front brake and rear brake Refer to Brake System Inspection Adjustment and Replacement Rear Brake Service Drum brake failure Damaged brake cable Brake cam rotation not easy Worn brake block Worn or slotted brake drum bore Bent brake lever Refer to Brake Air in hydraulic device System Inspection Adjustment and Replacement Front Brake Service Feeble brake Disk brake failure Leakage in hydraulic lever device Clogged hydraulic passage 15 Chart continued Details reference Inadequate liquid block and brake disc brake disc caliper brake caliper piston Feeble brake Viscous or worn lever brake caliper piston Inability of brake caliper normal sliding Worn main cylinder piston seal ring main
22. t refers to inspection based adjustment and rectification of some specified machine parts including adjustment of machine part plays and rectification of misfittings and deformations so as to restore correct positions forms and plays Tightening Tightening refers tightening of bolts screws and nuts of machine parts with tools so as to avoid loosening of machine parts and to obtain specified tightening torques Cleaning Cleaning is needed where call for cleanliness and tidiness Cleaning operations include all the means and measures taken to remove dust contamination metal chips oily stains and carbon deposits that might lead to pipe clogging or reduction in motorcycle performance Cleaning measures are washing carbon deposit removing rubbing cleaning and clearing Lubrication In order to facilitate smooth and easy running of moving machine parts including swinging parts reciprocating parts sliding parts and vibrating parts to reduce scuffing abrasion deformation and to reduce friction it is necessary to coat or spray these parts with a lubricant Different lubricants and lubricating methods are required for different machine parts with different functions Application of lubricants to machine parts is known as lubrication Replenishing supplement and replacement These operations refer to addition of oil lubricants cooling water electrolyte fuel and replacement of damaged parts with new ones and replacement of denatured oils
23. usting nut remove rear brake cable from brake swing arm Remove brake block assembly Remove brake swing arm setting bolt and swing arm Remove brake cam Rear Brake Device Assembling Apply grease to setting pin brake cam and brake block friction surface Apply grease to moving part of brake cam 27 brake block 4 brake block set pin return spring return spring brake cam rear brake cable brake cam set bolt brake swing arm adjusting nut Do not apply grease to parts not specified Superfluous grease flows into brake friction linings of brake drum shall reduce braking effect Mount brake cam Mount brake swing arm on brake cam Notch on brake swing arm should be aligned with the cut off of brake cam Mount brake swing arm setting bolt and fasten it Torque 10N m Mount brake block assembled with spring Mount rear wheel Mount exhaust muffler Mount brake swing arm pin and rear brake cable adjusting nut Mount return spring of brake cable with MM PER the spring aligned with the recess hole of left crankcase cover Mount adjusting nut Adjust brake system Vil REAR SHOCK ABSORBER SERVICE Dismounting Remove motorcycle body covering parts Remove 3 mounting bolts of air filter Withdraw air filter Remove mounting bolt connecting rear shock absorber and motorcycle frame bolt connecting rear shock absorber an
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