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Race 50 - Generic Motor Danmark

1. brush and armature can not be damaged Take care in case the mounting shaft of the armature should damage the oil seal lip Put a new O ring on front cover Install with the boss on motor casing engaging with the recess on front cover Screw the housing bolts Attention When the housing and front cover is assembled together the armature is easy to pull up with a magnet attracting the front cover and can be put together with slight press down by hand 3 3 5 Installation Mount the wire of the startup electrical machinery and 94 confirm the soldering cup is installed Check the O ring for damage If abnormal situation is found replace it with a new one Apply engine oil to the O ring and then fit it on the starting motor Install the wire clamp of the rear brake 95 3 4 Start relay 3 4 1 Actuation inspection Disassemble the body guard Push the main switch to ON and press the startup electrical machinery with a click Sound means normal No sound Inspect voltage of the start relay Inspect the earth line of the start relay Inspect actuation of the start relay 3 4 2 Inspect voltage of the start relay Erect the main stand and measure the voltage between the earth line of the frame and the negative polar of the green yellow line of the starting relay connector Push the main switch to ON to pick up the brake rod The battery voltage should conform to regulations If there is no voltage on the
2. 7 Long term disuse without regular maintenance 201 8 Odometer damaged without immediate repair or factitious reconstruction disuse and replacement 9 Please go to the check point for regular exhaust inspection every 3 months The new motorcycle produced by the Company has passed EC 97 24 9 standards implemented by the European Union after noise inspection 17 2 Regular maintenance guideline To prevent further environment pollution the State requires all automotive vehicles by manufacturers should meet standards of air pollution emission Our Company does its utmost to purify air and reduce air pollution besides ensuring that production conforms to standards Each of the motorcycles has passed strict inspection before delivered out of the company and meets standards of air pollution emission But since customers differ in use of our products we ve established the following regular inspection table for exhaust emission to ensure normal emission Please inspect adjust or service the motorcycle at schedule time For special problems of use please inquire the dealers or service centers of Qianjiang Related emission regulations are as follows Emission regulation co HC NOx Emission standard lt 1 0g km lt 1 2g km If there is any change to the emission standard take the up to date state regulation as final If the motorcycle is banned due to nonperformance of periodic inspection
3. Notch face After installed the piston ring can rotate freely in the slot of the piston ring Scrape the adhesive gasket off the crankcase 169 Attention No foreign objects should fall into the crankcase Install the piston piston ring and retaining ring Attention Install the notch face of the pistion skirt towards air intake duct 13 5 Installation of piston Install the guide pin Paint the engine oil on each piston ring and piston Install the piston in the right place Attention The piston ring should not be broken 170 Drive disk Clutch Driven Wheel 171 Note The grease can not attach on the surface of the V belt during operation it must be removed if it is attached to reduce the slip between the V belt and belt wheel to the minimum Foot start mechanism 172 Note The grease can not attach on the surface of the V belt during operation it must be removed if it is attached to reduce the slip between the V belt and belt wheel to the minimum 1 Snap ring 2 Start claw 3 Idle gear 4 Idle gear shaft 5 Start shaft component 6 Foot start shaft spring 173 XIV Drive disk Clutch Driven Wheel Foot start mechanism Preparation data 14 1 Clutch Driven Wheel 14 5 Fault diagnosis 14 2 Disassemble the clutch and the driven wheel 14 6 Left crankcase cover 14 3 Installation
4. 1 The vehicle identification number VIN is inscribed at O on the frame See Figure 1 1 Identification number of manufacture and the 11 digit shows the code of the manufacture plant The anti refit name plate is stuck inside the helmet bucket the frame name plate is riveted to on the frame Figure 1 1 2 The engine series number is inscribed on the crankcase housing See Figure 1 2 Figure 1 2 Important Notices 1 Please use genuine parts of Qianjiang Motorcycle Use of the parts that fail the design specifications of Qianjiang Motorcycle may cause damage to engine 2 During servicing use metric tools only Do not interchange a metric bolt nut or screw and an English system fastener 3 During reassembly replace with new washers O rings cotter pins and locking pieces 4 When tightening bolts or nuts tighten the ones with larger diameters or comparatively located at inside first and then tighten all bolts or nuts diagonally to specified torques step by step unless described otherwise 5 Clean the removed parts with washing fluid Before assembly lubricate all sliding planes 6 After assembly check all parts for proper installation and correct operation 7 Before measurement remove dirt and oil during assembly add recommended lubricants to oil sites 8 When engine and driveline require a long term storage after dismounted please apply lubricant to surfaces of parts to prevent rust and
5. 14 5 Clutch driven wheel 14 5 1 Disassembly Fix the outer part of clutch with the fixing tool and dismantle the fixing nut Take down the outer part of clutch clutch driven wheel 14 5 2 Decomposing the clutch Dismantle the check ring and decompose the clutch Attention When decomposing there should be no grease adhesive to the friction plate of clutch 178 179 Check the abrasion of the outer part of clutch Measure the internal diameter of the outer part of clutch Allowable limit 118 5mm Friction plate Check the abrasion of the friction plate of clutch Measure the thickness of the friction plate Allowable limit 1 5mm Clutch spring compressor 14 6 Disassemble the clutch and the driven wheel When dismantling the clutch pressing spring use the clutch spring compressor in the operation Attention The spring compressor must be used in dismantling to prevent damaging the spring Fix the spring compressor and dismantle the fixing nut of clutch 180 Loosen the compressor and decompose the clutch and driven wheel 181 Take down the protective jacket of the spring The left half weldment of the driven wheel Guide pin Oil seal Dismantle the guide pin Take down the left half weldment of the driven wheel Dismantle the oil seal from the left half part of the driven wheel Free length Right half of the driven wheel Left half
6. 15 2 Fault diagnosis The motor can not move when the engine is started The drive gear is broken The drive gear is burnt out The gear oil is leaked The gear oil is too much The oil seal is damaged 15 3 Gear Case 15 3 1 Disassembly Dismount oil drain nut drain out oil from the gearbox Loosen the bolt and take down the gear case cover 189 Ss Gear case cover 190 Take down the gasket and the guide pin TS N A Take off the clutch main shaft output shaft gear ee pe Aa Outpubaxle gear Take off the middle shaft middle shaft gear ae dnputaxte A LN 4 nn Clutch main shaft 15 3 2 Output gearbox cover inspection Clutch main shaft gear bearing wear damage inspection Gearbox cover bearings exchange The clutch main shaft must be pressed during the clutch main shaft bearings exchange Take off from the gearbox cover Attention The bearing which is pushed out can not be used and should be replaced The disassembly of bearings and oil seal should use special tools Dismantle the oil seal on the gear case and push out the bearing Attention The bearing which is pushed out can not be used and should be replaced The disassembly of bearings and oil seal should use special tools 15 4 Installation The order of assembly is opposite to that of disassembly 191 Attention The assembly of bearings and oil seal should use special tools
7. Changing mobile oil Attention Change the mobile oil when the engine is warm for that it is easy to be effuse Kill the engine Dismantle the mobile oil drain bolt under the crankcase and discharge the mobile oil When the mobile oil is completely discharged reinstall the mobile oil drain bolt and joint washer after cleaning Add mobile oil to specified volume Check mobile oil leakage start engine at idle speed for several minutes 48 Reinspect mobile oil level 49 Inspection adjustmentof accelerator s pull wire Check the smoothness of accelerator pull wire Examination of the free replacement of accelerator stayguy Free displacement 5 10mm The main adjusting position is on the carburator side Loosen the fixing nut and adjust by turning adjusting nut Air cleaner Replacement of the filtrator Mounting bolt M6x20 Remove body fender Remove fixing bolt 3 of air cleaner cover Remove pipe clip 4 Remove the air filter Dismantle the clamping screw of the cover of air filter Take down the upper cover of the filter Dismantle the filter element from the filter Check to see if the filter element is polluted or damaged If it is polluted or damaged please replace with new one Dismantle the clamp component Remove the filter Check whether the filtrator is polluted or damaged If it is polluted or damaged please replace with new one Changing time If the motorcycle i
8. Connecting the positive pole of charger and the positive pole of battery Connecting the negative pole of charger and the negative pole of battery Warning Keep the battery away from ignition sources Shut off the charger first once charge is started or finished so as to prevent explosion hazard caused by flashes at the interconnecting part Charge operation must follow the marked time on the battery Attention Fast charging cannot be used except in contingency situations Do not measure the voltage until 30 minutes after the charge Charging current Standard 0 4A Fast 4 0A Charging time Standard 10 15h Fast 30m Charge completed open circuit voltage 12 8V or above 1 4 Charging system 1 4 1Short circuit test Remove the ground wire off the battery connect the voltmeter between the battery negative pole and ground wire with the switch at OFF and inspect whether there is short circuit Attention Connect the positive pole of avometer with the negative pole of battery If there is any disorder please inspect whether the main switch and main wire are in short circuit condition 1 4 2 Inspect the charging state Test with an avometer when the battery is fully charged Mount the fully charged battery after the engine warms up Connect a voltage meter between the battery terminals Connect an amperemeter at the position where two terminals 72 Avometer are disassembled to the main fuse
9. Too dense gas mixture Bad operation of enrichment valve Bad operation of needle valve Too high oil level Oilflow in carburetor Air channel blocked Filth in air filter 11 3 Disassembly of carburetor 11 3 1 Disassembly Startup difficulty flameout after startup unsteady idle speed Fuel system blockage Too dense or sparse gas mixture Secondary air inlet of suction system Bad idle adjustment Bad adjustment of oil volume Idle system or electric enrichment valve blocked Too sparse gas mixture Oil nozzle blocked Needle valve blocked Too low oil level Fuel system blocked Bad act of piston Secondary air inlet of suction system Intermittent flashover in acceleration Too sparse gas mixture Throttle cable _ Turn the fuel control switch to OFF Take away fuel delivery hose Release throttle cable MAA Electric enriching Wvalve conector Take away plug on the fuel hose end drain out fuel from Engine floater chamber into another case connector Take away the connector from the electric enriching valve ZA Carburetor Loosen the screws connecting the engine connector and air connector filter in carburetor take out the carburetor from them de 7 150 151 11 3 2 Decomposition of carburetor Loosen the electric starting valve bolt and take off the electric starting valve components Electric enriching u Electric enriching valve component
10. Y N Check cooling fan and its cowl for damage forced air cooling engine Y Check and Use an ignition timing troublesho light to detect if engine ignition timing is correct N Y 1 Check CDI Check for clutch slip igniter for malfunction 2 Check magneto flywheel and trigger coil for looseness Y N Clutch slips Refer to handlin of clutch slip 25 Spark plug insulator skirt renders black in addition exhaust muffler gives off black fume or blasts accelerating ability is poor or idle speed is instable and engine is liable to shutdown when it is runnin under medium low spee comparatively normal when it is running under high sneed Combustible mixture too rich 1 Check air cleaner for clogging 2 Check carburetor starting device i e starting richer system for proper operation Check carburetor float for insufficient height Spark plug renders chocolate brown Mixture combustible normal Check exhaust port of block and muffler for caused by cylinder exhaust clogging excessive deposit Remove spark plug observe color of spark plug insulator skirt and determine mixture ratio of combustible mixture according to various abnormal situations insulator skirt Spark plug renders white intermittent insulator skirt in addition engine stop carburetor backfire or power ratio of mixture Check lubrication system carbon Lubrication system
11. rotation of the crank shaft bearing If there is strange noises or loosening replace the crankshaft set Crankcase bearing 198 Attention The dismantled oil seal can not be used again The dismantling of the oil seal should use special tools 16 4 Installation The order of assembling crankcase is opposite to that of the disassembly Attention The installation of oil seal should use special tools in order to prevent the damage against the oil seal 199 Exhaust emission system inspection and maintenance Muffler Torque value for bolt 5 in Fig 5 9 Nem Torque value for bolt 5 in Fig 22 29 N m Torque value for bolt 5 1 Silencer assembly 2 Silencer body 3 Silencer decoration cover 4 Silencer front section 5 Bolt M616 6 Bolt M835 7 Bolt M8x20 8 Exhaust pipe gasket component 9 Nut M6 10 Silencer damping sleeve 11 200 Connecting flange sealing gasket 12 Screw M6x10 13 Screw M6x25 14 Spring washer 6 15 Washer 6 XVII Exhaust emission and control system Warranty of Exhaust emission and control system 17 1 Regular maintenance guideline ensurance of emission standard 17 2 Mechanical function of the exhaust control system 17 3 Catalyst converter system 17 4 Countermeasures to idle speed emission exceedi
12. 7 2 1 It s hard to rotate the direction handle Malfunction of the direction handle bearing 119 The direction handle bearing is damaged The air pressure of tire is ultra low Air leakage of tire 7 2 2 The direction is not stable The direction handle bearing is damaged The tire compression is not sufficient The front fork and the front wheel axle are crooked The tire of the front wheel is deformed with crooked tire 7 2 3 Front wheel yawing The rim is distorted The front wheel bearing is loosened The tyre is not good 7 2 4 The wheels rotate with difficulties The wheel axle bearing or the gear seats are in failure 7 2 5 Strange noise in front shock absorber Friction noise in shock absorber guard Loosening of bolts in shock absorber 7 3 Front wheel 7 3 1 Disassembly Attention Must prop the motorcycle firmly before head Loose the mounting bolt 1 of components of the braking cylinder Remove components 2 of the braking cylinder Place an appropriate supporting stand under the engine in order to raise the front wheel up Loose the mounting bolt 1 which fixing the axle of the front wheel in order to remove the front wheel and its axle Remove components of the gear seat 120 Remove the braking disk Remove axle sheath oil seal axle 6201 2RS axle insulating sheath axle 6201 2RS Note see P87 for figure RACE 50 for dismantling and mounting front wheel 121
13. Bearing the pressure caused by burning of combustible mixture gas and pass the pressure to the connecting rod driving the rotation of the crankshaft Shaping a combustion chamber with the cylinder cover and others Timingly press the fresh mixed gas from the crankcase into the cylinder and timely exhaust waste gas out of the cylinder after combustion Preparation standard Unit mm Item Standard value up limi Air internal diameter 39 995 40 015 40 05 cylinder bend 0 05 lindricit nn 0 006 0 05 flatness 0 03 0 05 162 13 2 Fault diagnosis Low compression pressure White fume in vent pipe The piston is worn out burnt out or broken The air and cylinder piston is worn out or damaged The piston and air cylinder is worn out or damaged The gasket is damaged there is air leakage between the crankcase and the gas Compression pressure is too high Piston noises Carbon deposit in the combustion chamber is in overabundance The air cylinder piston and piston ring is worn out The piston pin hole and piston pin are worn out 13 3 Cylinder body 163 roundness 0 05 Top ri 0 015 0 05 0 09 clearance between the piston ring and oe ring groove Second 0 015 0 05 0 09 ring Top ring 0 1 0 25 0 5 Piston Joint face clearance Second Piston 0 1 0 25 0 5 ring ring Piston outer diameter 39 97 39 99 39 9 Clearance of cylinder and p
14. SCANDINAVIAN MACHINERY IMPORT ApS Holtvej 8 10 Horuphav 6470 Sydals Telefon 45 73 15 11 00 Fax 45 73 15 11 01 E mail info scanmi dk www scanmi dk CVR 27 73 31 07 November 2010 User s operation and maintenance manual for double wheel motorcycle RACE 50 Zhejiang Qianjiang Motorcycle Co Ltd Contents Contents 2 Preface 4 Documents to be prepared ccccccsesscessseeeseeeeseecescecseceeesseeessaeessaeceneeseceessseeceseecssaeeeeaeeeesseceseaesseseeseseeeeeeesaeenes 5 Inspection adj ustiient 222222 a N RL NEN INNERE NEN elle ONE 6 Inspection and Service of Electrical System 63 I Battery Charging system 67 UD Preparation data fees elle sanierte 53 1 2 Fault dia Mi di 53 Batres del e e E epee TER 71 1 4 Charging syto n hs 72 1 5 Voltage and A ae A RE 73 1 6 Charge coll of the alternator ninia 74 1 7 Disassembly of alternator ccccccesccssscceeseeeeseeceeecescecsenecesseecnseceseeceseecsaecsceeseseeeeseecssaeceeeseeeeseesseeeseneene 74 II Ignition system 61 2 1 Preparation data iia dis 61 2 2 ETE aaeei aA R e aa aie aa aee a aeir aoi a i Eaei ae aTe 79 2 3 Tenition system OS DECO ici e A ae sin 83 A ON 84 DILO Oli n 86 Poi om Haka da e del e en de e ee treet re terre Sr tha ee eee eas 86 IH Startup system 90 3 1 Preparation data sisino ane aa aeeiidea detest ah Es Bann bi AREE Ra E 91 3 2 Fault Gia onosiS ia tr site sine Ed a e A e aio 93 3 3 Starbelectric Machi A el a nine ees 93 SA
15. MQ SEE ss BA 73 1 5 2 Inspect the voltage and current regulator Check plug of voltage and current regulator for poor contact and measure impedance values between terminals on voltage and current regulator body Attention The metal area of the avometer prod mustn t be touched by fingers during inspection eInspect with an avometer Different avometers will give different resistance values and the inspection result is incorrect If the resistance value between terminals is abnormal the voltage regulator should be replaced 1 6 Charge coil of the alternator Attention Inspection of the charge coil of alternator may be conducted on the engine Inspection Disassemble the 6P joint of alternator Measure the resistance value between the white coil of alternator and the motorcycle frame with an avometer Standard value 1 5 20 20 C If the measured value exceeds the standard value replace the alternator coil 1 7 Disassembly of alternator Attention Inspection to lighting coil of magneto can be performed on engine 1 7 1 Inspection Remove 3P joint of magneto 74 L Green B 19 21 Black E Fixing spanner y In D ns Use a multimeter to measure the impedance value between green red wire on magneto and body ground Standard value 2 0 2 50 20 C When the measured val
16. Start the engine and measure the clamping voltage and current when the rotation speed gradually increases Clamping voltage rotation speed 14 15V 2500rpm If the clamping voltage exceeds the specified value range inspect the voltage regulator Inspect the clamping voltage of the lighting system Attention Set the avometer at the alternating voltage position Clamping voltage 13 1 0 5V 2500rpm Ifthe clamping voltage exceeds the specified value range inspect the voltage and current regulator 1 5 Voltage and current regulator 1 5 1 Inspect the main wire circuit Disassemble the 4P plug of the voltage and current regulator Inspect the conduction between main wire terminals with the following methods Item wire color Judging method between the battery red and there being battery body ground voltage between the ground wire black and body ground there being wire f there bei between the charge coil white decada Green re Red Black and body ground alternator coil After checking that the main d B E wiring end between illuminating there being line green red and body ground resistance in L resistor plug plug of automatic alternator coil side starter remove lighting switchboard and check in OFF 7 position is completely normal Unit
17. on 2 4 stroke engine 1 Check if volume of engine oil in crankcase is sufficient 2 Check if viscosity of engine oil in crankcase is too low or engine oil is too dirty 3 Check oil filter for clogging 4 Check oil pump for proper operation 5 Check lubricant ducts for clogging 26 lack of engine etc occurs during acceleration Combustible _ mixture too thin 1 Check fuel cock for BD operation Check carburetor float for height excess 3 Check all orifices and tunnels on carburetor for clogging Trouble diagnosis program for engine power lack Engine power lacks Erect main jiffy stand to enable wheels to be lifted off ground and then rotate them by hand Wheels rotate Wheels rotate freely dully Check tire 1 Check brake for retard pressure 2 Check wheel bearing for excessive wear or damage 3 Check for missing or comparatively short intermediate spacer of wheel hub Air pressure Air pressure too low normal Check tire valve core for air Remove spark plug block its threaded leak and check for pierced hole by finger and then depress start or cracked tire button or rapidly depress starting lever Fingers feel that gas dashes out Fingers do not feel that gas dashes out making pow pow sounds Compression pressure of Compression pressure of cylinder normal cylinder insufficient Start engine increase throttle opening slowly and observe for speed change of engine 1 Check all jo
18. 14 7 Drive disk 14 4 Foot start mechanism 14 8 14 1 Preparation data Matters needing attention in operation In the operation there should be no grease on the surface of the triangle belt Otherwise remove it to reduce the skidding between the triangle belt and belt wheel to the lowest Function the drive disk clutch and the driven wheel compose the steeples speeder The torque between the dive disk and the driven wheel is transmitted through the triangle belt Preparation reference Unit mm Item Standard value Allowable limit the right half of the internal diameter of the drive wheel 25 989 26 052 26 06 the external diameter of sliding sleeve 25 96 25 974 25 94 width of the triangle belt 17 16 thickness of the friction plate of clutch 1 8 1 5 the internal diameter of outer sleeve of clutch 118 118 3 118 5 the free length of clutch pressing spring 68 70 68 the external diameter of right half shaft sleeve of the driven wheel 32 95 32 975 32 94 the external diameter of right half sliding sleeve of the driven wheel 33 33 025 33 06 the external diameter of the rolling ball 14 92 15 08 14 4 14 2 Fault diagnosis The motor can not move after the engine is started The horsepower is not sufficient 174 There is shaking in the movement The triangle belt is wom out The triangle belt is wom out The friction plate spring of clutch is broken out The
19. 7 3 2 Inspection 7 3 2 1 Inspect bending of the wheel spindle Put the wheel axle on a V shape seat and use dial indicator to measure its excentricity Allowable limit if the value exceeds 2 0mm replace the rim 7 3 2 2 Inspect yawing of rim Put the wheel ring on an accurate bracket and examine its swinging degree Rotate the wheel by hand and read the swing degree Allowable limit Clearance Vertical orientation if the value exceeds 2 0mm replace the rim Transverse direction if the value exceeds 2 0mm replace the rim 7 3 2 3 Inspect the front wheel bearing Axial direction Remove front wheel axle braking disk Radial direction Remove front wheel left axle sheath then remove the oil seal Remove the axle Examine the rolling condition of the bearing If it doesn t roll or the bearing is damaged or loosened it should be replaced by new product 7 3 3 Replace the bearing After Dismantling the front wheel axle front wheel as well as the intermediate axle sleeve and the left axle sleeve 122 of the front wheel dismantle the oil seal and bearing by using the oil seal puller and bearing puller respectively Note the dismantled bearings should be replaced with new ones During the installation smear grease lubricant on the bearings Then drive in the bearings by bearing installation tools Attention The bearing must be punched in horizontally 7 3 4 Installation Mounting
20. Stare Tel ASS AA AA AA eo ASUS BU oh UII ee 96 IV Bulbs switch instrument 73 4 1 Preparation atars 208 cet OO 99 4 2 Fault diagnosis iii das 99 4 3 Replace the head lieht bul ii A A tia 99 4 4 Replace bulb of the front turning light oooonoccnonocionccnoncncnnnncononononccnoncnnononcnnnncnon no non nn cnn nn cnn ncnnrncnnnrnnannos 100 4 5 Disassembly replace the bulb of the taillight and rear right turning light nn 100 NAAA daxeegeres ete e a esd sales Ben Ri deen sees Gee ca e E r E eieies 101 ATM SWI CCI 25 A Ste coat boku deh A A a a 101 AS ss 102 4 9 Handle witch sad ts ette nee lo ela ei erraten 102 Inspection and Service of Chassis 103 V Brake 80 3 k Maintenance Am Struct OM 6 2 A A A aia 107 5 2 Fault dia onosis 2 222 420 hese eat E cde a Ea a EE RE E E EEE ani 108 5 3 Front hydraulic brake cuco bli 108 5 4 Rear drumbrake oo di 110 VI Body cover 86 VII Front wheel front suspension 90 Ao AA O 119 TZ Fault AOS ai 119 TESEO wheel oe ela el ele ia ll el el rl 120 TAP Steerng bar A A A CO Re es 123 EA A A A I AS as ss IN LOR tS 124 VIII Rear wheel rear suspension 97 8 1 Preparation ld A ince eel einen eh ed 128 8 2 Fault ALAMOS A ASAS aa el AR AS da 128 8 3 Real White 129 8 4Rear shock absorber eeccceesseesscesseeeeseecsseceeseceeseecsseecsseecseseeesseeessaecesaeeseceeseseeeeseeessaeenneeseeeenseeeseeessaeenes 130 IX Fuel tank seat mat 136 9 1 Preparation data iii bi 136
21. align with v mark resistance is felt arm has exceeded v mark on on brake hub cap when grasping rotates brake hub cap brake handle dully 1 Check surface of brake shoe plate for oil stains 2 Check if contact area percent of brake shoe plate and brake hub is less than 70 Movable art on rake cam 1 Check arc surface on brake cam for excessive wear 2 Check brake shoe plate for excessive rusted or wear locked by 3 Check bore of brake hub for excessive wear control cable moves dully in its jacket when pulled foreign material 32 Trouble diagnosis program for charge failure of battery Battery can not be charged Disconnect bundle conductor of magneto from connector of complete vehicle cable and then use an ohm meter to measure if resistance between output conductor ends of charge coil conforms to standard value Resistance is less Resistance conforms Resistance is than standard value to standard value infinite Charge coil Connect bundle conductor of magneto with Charge coil or its shorted connector of complete vehicle cable and output conductor disconnect rectifier or rectification regulator from opened connector of complete vehicle cable Use an ohm meter to measure resistance between output conductor ends of charge coil in connector to see if it corresponds to self resistance of charge coil Circuit from magneto to rectifier Set a multimeter to 0V 20V DC Voltage or rectification reg
22. at dealers or service centers of Qianjiang we do no shoulder any responsibilities Please make necessary inspection at any time in order to maintain optimized vehicle conditions 202 Note Increase cleaning times of air filter if the motorcycle is used on sandstone roadways or in severely polluted environment so that service life of the engine may be extended When the vehicle is driven at high speed or in frequent use with considerable service kilometers its maintenance degree should be increased Ensure the emission standards and pay attention to the following matters 1 Please use 92 or 95 unleaded gasoline only 2 Please use machine oil of specified Standard only 3 Please maintain the motorcycle according to stipulations in the regular maintenance table 4 As to exhaust control system random adjustment or replacement including use of spark plug idle adjustment ignition timing carburetor adjustment is strictly forbidden 5 Matters needing attention The disorder of ignition charge and fuel system will have great impact on the catalyst device therefore if you feel disorder of the engine please go to designated dealers or service centers of our Company for inspection adjustment or service Please use 92 or 95 unleaded gasoline only or else the catalyst device four stroke system will be damaged Two stroke system 6 The exhaust control system of the product conforms to state regulations so make
23. current Poor wiring contact of battery Poor contact of discharge system Poor contact or short circuit in lighting system Bad act of charging system Poor contact short line or short circuit of wire terminal Bad act of voltage and current regulator Bad act of alternator 69 Bad act of voltage and current regulator 70 1 3 Battery 1 3 1 Disassembly of the battery Open the battery cell lid Dismantle the clamping bar components of battery cell Disassemble the negative wire and then the positive wire Take out the battery Warning In the disassembly of positive pole the tools mustn t contact the frame because the short circuit spark will ignite gasoline and damage the battery Installation is conducted in the reverse order of disassembly Attention In order to prevent short circuit connect positive pole first before the negative pole Please do not disconnect battery when you perform overall lineup otherwise internal damage of complete vehicle components may result Inspect the charging state open circuit voltage Open the battery cell lid Dismantle the clamping bar components of battery cell Remove the joint wire of storage cell Measure the voltage between battery terminals Fully charged 13 1V Undercharged 12 3V The battery does not work for an hour Attention Inspection of charging state must be performed with a voltage meter 71 1 3 2 Charge Connecting method
24. diagnosis 4 2 Main switch 4 7 Replace the head light bulb 4 3 Horn 4 8 Replace bulb of the front turning light 4 4 Handle switch 4 9 Replace the bulb of the taillight 4 5 4 1 Preparation data Matters needing attention in operation The conduction of switches may be measured after disassembled from the motorcycle 4 2 Fault diagnosis Main switch is pushed to ON but the light doesn t work Bad act of the bulb Bad act of the switch Poor contact of the connector or broken line 4 3 Replace the head light bulb 4 3 1 Disassembly Dismantle the front cover Disassemble the fixing bolts so that the head light could be disassembled Cut off the switch connecter of the head lamp Remove the head lamp Disassemble the air guide sleeve Disassemble the glass sheet on the head light Fix the head light and turn the socket clockwise so that the bulb can be removed 4 3 2 Installation Install the bulb back to the original position in the reverse order of disassembly 99 4 4 Replace bulb of the front turning light 4 4 1 Disassembly Remove front shield of handle pipe Disconnect connecting wire of front turn signal lamp Unscrew the setscrew on the turning light Remove the bulb socket from the light 4 4 2 Installation Install the bulb back to the original position in the reverse order of d
25. engine gives off strong blue white smoke Check if engine oil level in crankcase exceeds the upper scale line marked If crankcase is overfilled with engine Start engine and then screw off oil oil drain redundant engine oil until dipstick with engine running under high engine oil level does not exceed the speed to check if engine oil filler port upper scale line smokes 1 Check cylinder piston and piston ring for excessive wear 2 Check for the piston ring having insufficient elastic force or locked in ring groove 3 Check if gaps on piston rings stagger each other Trouble diagnosis program for shift difficulty of transmission Transmission shift is difficult Start engine and check it for too high idle speed Y N Readjust Check for harmonious operations during shift Y N Check for halfway release of Improve method of clutch operation N Y 2 Check clutch springs for even elastic force 3 Check gullets on driving and driven hubs of clutch for saw teeth caused by wear 4 Check clutch driven disc for Check shift shaft for deformation and shift arm for 1 Check if free stroke of clutch grip deformation or excessive wear is within 10mm 20mm Y N Replace 1 Check inside of cam slot on shift camshaft for excessive wear or damage 2 Check shift fork hole for excessive wear warpage f 5 Check clutch operating device parts for excessive wear 3 Check shift fork for deformation 4 Check declutch shift shaft for d
26. half and right half parts of the drive wheel Paint grease on the guide pin install in the guide slot Install the protective jacket of the spring Wipe and clean the leakage grease 185 Guide slot Install the clutch pressing spring and clutch on the driven wheel Use clutch spring to compress and compose After compression install the locking nut Attention the spring should be compressed properly Otherwise the spring will be damaged 14 7 Installation The order of assembling the driven disk clutch and driven wheel is opposite to that of disassembly 14 8 Foot start mechanism Disassembly Check Dismount left crankcase cover Loosen screw take out plate Take off start claw component Take off start shaft component Inspect the wear condition of the start shaft Inspect the wear condition of the start shaft sleeve idle wheel shaft force position Inspect the wear condition of the idle wheel Measure the clamping force of the snip ring General standard value 8 12No Note 1 Snap ring 2 Start claw 3 Idle gear 4 Idle gear shaft 5 Start shaft component 6 Foot start shaft spring 187 Decelerator 188 XV Decelerator Preparation data 15 1 Fault diagnosis 15 2 Gear case 15 3 Installation 15 4 15 1 Preparation data Function convey the torque and determine the torque and rev of the final output
27. joints outside engine for air leak 2 5 Check for the piston ring broken or locked in groove or aving insufficient elastic force 6 Check piston ring and cylinder for idle Readjust idle speed of carburetor Engine idle speed is enabled after adjustment Engine idle speed is poor Engine idle speed Engine idle speed too high unstable Pull carburetor throttle valve by hand to check if it has been completely closed Use an ignition timing light to detect if engine ignition timing is correct Check if cable 1 Check CDI wire of throttle igniter for control cable malfunction can be pulled 2 Check magneto to move flywheel and smartly in trigger coil for cable jacket looseness and if throttle valve spring is too soft Engine idle speed is still isabled after adjustment wear Air adjust Check idling jet fuel screw on way and air way on Adjust Check mixture carburetor or carburetor for clogging clearance ratio of adjusting screw between combustible on throttle electrodes mixture valve adjusted improperly N Y Check carburetor float for height Clean and excess dredge Adjust height 1 Check insulating body on carburetor for cracks 2 Check connecting and fixing nut on carburetor for looseness standard value 3 Check negative pressure pipe of fuel cock for breakage 4 Check leaf valve for air leak 28 Trouble diagnosis program for excessive fuel consumpt
28. 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 inspected if necessary it should be replaced before reinstallation Sleeve 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 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 orig
29. of the driven wheel Check the free length of the clutch spring 182 Allowable limit 68mm Rolling bearing gt gt Check the abrasion of the driven wheel Measure the external diameter of the right half shaft sleeve of the driven wheel Allowable limit 32 94mm Measure the internal diameter of the left half sliding sleeve of the driven wheel Allowable limit 33 06mm 14 6 1 Replacement of the right half bearing of driven wheel Stipulated grease Ball bearing Take down the needle bearing from the right half driven wheel Dismantle the elastic check ring and the outer rolling bearing Bearing opener Needle bearing Attention The dismantled nearing can not be used again 183 Paint grease on the outer rolling bearing and put it into the shaft sleeve Attention Compress the outer rolling bearing into the shaft sleeve with the marked side outward Then fill the 8 9g grease in the whole shaft cavity Assemble the elastic check ring Install the needle bearing Use the tools in the picture to compress the needle bearing 184 14 6 2 Combination of clutch and driven Grease wheel Clean the grease on the driven wheel surface Install the oil seal in the left half sliding sleeve of the driven wheel Paint grease on the O typed ring and install it on the left half sliding sleeve of the driven wheel Combine the left
30. real objects can be seen in table 1 31 and table 1 32 Table 1 31 Name Remarks universal meter Figure 1 33 ignition tester Figure 1 34 Successive table 1 32 Figure 1 33 Figure 1 34 Specififcation Sheet RACE 50 Model RACE 50 Engine Type QJIE40QMB 4 Full length mm 1820 Fuel type SS gt Number of Full width mm 695 Gylinders 1 Inside measure Full height mm 1140 Pa 40x39 2 Wheelbase mm 1280 Total flow rate 49 2 Start by electricity Front axle 37 Start mode Foot start mechanism Vehicle weight kg serving quality Rear axle 55 Engine Cooling mode Wind cooling Total 92 PE eee ubricate Outer Lubrication cover of 120 70 12 aa front wheel Tyre specification Sn awe 3 50x12 3XG uter Air cl cover of 130 70 12 Mae rear wheel Rear rim 3 50x12 Petrol capacity 5 0 2L Clutch type Dry centrifugal type Carburetor type IIF 45 Transmission Stepless shift Searing Idling speed 3 pal 1750 100rpm min Driving mode Belt drive Maximum 4 3 N m 5500rpm Battery 12V 4AH q capacity type dry charged type Perform ae Morgue 2 50kW 6000 rpm Capacity of alternator 90W 8000rpm Compression ratio Electrical Spark plug Ns e installation Maximum speed Spark plug 0 6 0 7mm Brake Danada front brake disk mm Ignition mode CDI Inner diameter of rear brake drum mm 20 RACE 50 22 Troubleshoo
31. should follow the reversed procedure of dismantling and pay attention to the following items lubricate front axle components of gear seat oil seal interface axle sheath axle 6201 2RS axle insulating sheath Recommended lubricant is grease of calcium radicle first Mount front wheel axle 8 front wheel components of gear seat 10 Bolts M12X1 25 7 Make certain that the joint position is matched well when mounting components of gear seat and odometer gear seat If those components are not jointed and locked tightly when mounting they will distort in the future Mount the braking cylinder to the front wheel hub Screw down the front wheel axle as the figure of right side Note see P87 for figure RACE 50 for dismantling and mounting front wheel Value of Torsion Blot for screwing down the front wheel axle 100 113 N m 7 4 Steering bar 7 4 1 Dissemble Remove components of back mirrors Remove bolts for fixing ornament lid of the upside and downside cover of the steering bar Remove the upside ornament lid and then remove meters 123 Remove components of the front cover Remove components of left right switch combination Remove components of fuel pump Remove the left holding bar and components of the fuel control bar Loose screw bolts of welded components of the steering bar Remove the welded components of the steering bar 7 4 2 Installation Note see P88 for figure for dism
32. the alternator 1 6 Disassembly of alternator 1 7 1 1 Preparation data Matters needing attention in operation Note 1 The battery can be charged and discharged over again If the battery is unused after discharge the service life will shorten and the performance will degrade Generally performance of the battery used for 2 or 3 years will degrade Such battery capacity declined may restore its voltage after charging but the voltage will drop off rapidly when loaded 2 Surcharge of battery generally surcharge can be observed from the battery proper If the battery is cut short inside no voltage can be tested at the terminal of the battery or the voltage is very low Invalidation of the regulator the battery will have too high voltage which may shorten its service life 3 Long rest of the battery will result in self discharge and the electric capacity will reduce therefore it must be charged every 3 months 4 Inspect the charging system in accordance with the order stipulated in the fault diagnosis table 5 If there is electric current passes through an electrical unit do not disassemble the connector otherwise overtension will occur which can damage the electronic parts inside the voltage regulator The main switch must be pushed to off before any operation 6 Maintenance free dry charged type battery does not need inspection replenish of electrolyte solution or distilled water 7 Inspect the entire pow
33. wheel from the crankshaft take off oil pump component 145 Oil pump assembling Shown in the following Fig Oil pump shanft Oil pump body Element spring Element Oil pump cover Gear 10 3 2 Installation Carry out the installation according to the reversed sequence of dismantle 10 3 3 Inspection Inspect worm wheel teeth surface whether there is damage Inspect key slot whether there is breakage Element outside diameter 146 Measure element outside diameter Allowable limit 2 61mmo Carburetor 147 Note Gasoline is very dangerous no smoke at work place Use cloth to block the intake manifold after dismounting carburetor to avoid other article entry 1 Screw 2 Float chamber 3 Needle valve component 4 Floater 5 Floater pin 6 Main jet 7 Idle speed injection nozzle 8 Main foam pipe 9 Idle speed adjusting screw 148 XI Carburetor Preparation data 11 1 Fault diagnosis 11 2 Disassembly of carburetor 11 3 Installation of carburetor 11 4 Adjustment of carburetor 11 5 11 1 Preparation data Matters needing attention in operation 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 impac
34. 2 2 Fault diagnosis Gas leakage between cylinder head and cylinder block or extra high combustion pressure Cylinder head gasket breakage Cylinder head bottom plane warp Combustion extra carbon deposit 12 3 Cylinder head 12 3 1 Dismantle Loosen shroud fixing bolt Dismount shroud Loosen fixing nut and spark plug dismount cylinder head 157 Bolt Shroud 158 12 4 Examination on cylinder head Inspect the cylinder head whether it is broken Inspect the planeness of the cylinder head bottom plane Allowable limit 0 04mmo ty Cylind r head 12 5 Cylinder head installation Implement mounting in a reverse order with dismounting 159 Air cylinder piston 160 3 Cylinder block 4 Cylinder gasket 5 Cylinder head 6 Nut 7 Spark plug 2 Piston pin ston 1 Pi 161 XIII Air cylinder piston Preparation data 13 1 Fault diagnosis 13 2 Cylinder body 13 3 13 1 Preparation data Matters needing attention in operation All parts should be cleaned before inspection and test and should be blow dry with high pressure air Function of the cylinder body 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
35. 3 2 Dismantling Disassemble the housing bolts front cover motor housing and others 3 3 3 Inspection Inspect other spare parts If uneven wear damage or burning is detected on the surface replace it with a new one The adhesive metal powder between commuator surfaces 93 must be cleaned away Inspect conduction of contact surfaces between other assemblies Confirm the armature shafts between each surface of the commutator cannot be connected Inspect conduction of the housing of startup Confirm the terminal and housing of the startup electric machinery cannot be connected Inspect conduction of the terminal and electric brush If there is disorder replace is with a new one Inspect conduction of the brush holder If there is conduction replace is with a new one Measure the length of the electric brush Allowable limit 3mm under the value replace it Inspect whether the needle shaft in the front cover is flexible in rotation and whether it is loosen when pressed in If there is disorder replace is with a new one Inspect whether the oil seal is worn out or damaged 3 3 4 Assembly Motor casing Oil seal in the front cover and coating of grease Mount the electric brush on the brush holder Spread grease on the active parts of the electric brush ends Press all brushes in bracket and then install front cover of electrode Attention eTake particular care that the contact surface of the electric
36. 7 14 Q 1 N 16 P 12 n 4 a 0 _ AA SN fe C Cr Ay LA bar a 4 GY I 4 ne af et t CR f SS A E and a 5 15 2 SE a 8 6 Ms 3 4 handle 6 10 118 left rear view mirror components 11 Right rear rearview mirror components 12 Left combination switch 13 left handle 14 Fixed handle screw M5 15 Nut MS 16 17 Right combination switch 17 Flat screw M5 x 20 VII Front wheel front suspension Preparation data 7 1 Fault diagnosis 7 2 Front wheel 7 3 Direction handle 7 4 Front fork 15 7 1 Preparation data Matters needing attention in operation Before the demolition of the front wheels the bottom of the body should be supported by jack and the front wheel floating ground should not be attention to the ground can not be invertible During the operating the brake shoes block friction chip components brake disc can not be attached to oil Reference for the entire motorcycle M iti ah standard value Allowable easuring position e nati limit rim front wheel spindle bending 0 2 front wheel run out of rim yerken dire enon u transverse direction Within 1 0 2 0 Torque value Tools The direction knob seal component fix bolt 40 60 N m Bearing puller Front axle lock nut 100 113 Nm Lock in nut wrench Front axle 100 113 N m 7 2 Fault diagnosis
37. 9 2 E MOSS ROOT Oo 136 9 3 Fueltank se t t a 8b ge dor na e do do e edo des du a seek do S 137 Inspection and maintenance of engine 139 X Lubrication system 107 10 1 Pr paration data c noninnin ada 143 10 2 Fault diagnosis ccccccssccessccssseeesneeeeeecsscecescecesseeesseeesseseseecssaecseceeesseeseseecssaecseaeesesseceaeecssaeessaeeesseeenseees 144 LOS OU pumas 22 228 Reise eles Meio een ees nee uns Rie eles OEE ee lees 144 XI Carburetor 111 11 1 Preparation data oooonnoccnonccnonccnonenononncnonncnononon nn non nn nor nc nnn rn nan nn non RR Ran RR an NRO nn RR RR RR Ran RR Ran nr naar rn nn rrnnnnncnnnrnnanno 149 11 2 F ult diagnosis 2 2 au Bine ee ee eee 150 11 3 Disassembly of carburetor u a eins eek tes Ae ia ee ae eae ae 150 11 4 Installation amp adjustment ec eeecsceseceseceseceseceseceseceseeeseceseceseceseceseeeseceseeaeesseeeeeeeeeeeeeeeeeeneeeteeeaees 155 XII Cylinder cover 116 12 1 Preparation ai a es avr evden esi ee i ein ed 157 12 2 Fault A io 157 1233 Gylindechead r amp 428242852 2042 aU HRS a die e eo 157 12 4 Examination on cylinder head viii dt 159 12 5 Gyl nderhead installation 22 222 228 Buena A el a ed a ee 159 XIII Air cylinder piston 120 13 1 Preparatisn dat a a dh cited RAO 13 2 Fa lt a iaa 13 3 Cylinder body onai aineenaan arannira a ieaiai a ne ie EE aie a EE n e ra niania APM A E A EE 13 3 Installation Ob piston a di XIV Drive disk Clutch Driven Wheel Foot start mec
38. Outer diameter of startup idler shaft Torque value Bolt in the clutch cover of the startup electrical machinery 12 Nm Fixing nut in the clutch of the startup electrical machinery 95 Nm Tools Fixing nut spanner Multiple use fixing spanner 91 92 3 2 Fault diagnosis Unable to startup Rotating force of start machinery too weak No revolution in the RE Rotary Engine Fuse blown Power shortage in battery Bad act of startup clutch Power shortage in battery Poor contact of connecting wire Reverse revolution of startup electrical machinery Bad acts of main switch Gear of the startup machinery jammed with foreign body Power shortage in battery Bad act of startup clutch Bad act of brake switch Bad act of start relay Poor contact of connecting wire Bad act of startup electrical machinery 3 3 Start electric machinery 3 3 1 Disassembly Attention The main switch must be switched to OFF before Commutator disassembly of the startup electrical machinery Dismantle the bonding strip of the battery and turn on the power supply to see whether the startup electrical machinery will run so as to confirm security First take down the wire clamp of the startup electrical machinery dismantle the fixed bolt of starting motor Separate the front end cover and the rear one Remove the starting motor Roll up the rubber waterproof jacket and disassemble the joint of startup electrical machinery 3
39. Score and touch positive and negative of battery instantly with a conductor to view status of sparks Sparks are generated No sparks are generated No electricity in N 1 Check for blown se 2 Check for opened or shorted circuit between battery and ignition switch 3 Check ignition switch for open circuit or short eircuit Replace head lamp bulb and check other illuminating lamp bulbs one by one for burn out Use test lamp method to check power input conductor of ighting switch for electric power output Short power supply conductor and output conductor of lighting switch with a conductor After illuminating shorted lamp Internal contact of lighting switch contacts poorly 37 Circuit between magneto or ignition switch and lighting switch opened or shorte After shorted illuminating lamp does Circuit between lighting switch and illuminating lamp opened or shorted Trouble diagnosis program for the malfunction that illuminating lamp bulb is liable to burn out Illuminating lamp is liable to burn out Turn on emnon switch depress horn button or toggle turn signa Electric horn is hoarse or does not make any sound and turn signal lamp light is dim 1 Check conductor joint connecting battery for poor contact 2 Check if electrolyte inside battery is insufficient 3 Check if density of electrolyte in battery is too low 4 Check for sulphated or shorted pole pla
40. Take out battery Measure the voltage between the battery terminals Fully charged 13 1V Undercharge 12 3V Attention The inspection of charging state should be made by voltage meter Charging Connecting method Connect the positive pole of charger to that of battery The negative pole of charge connects to that of battery Warning 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 53 Attention e If the storage cell is rapidly charged it can not be used generally except in emergency The voltage should be measured every 30 minutes after charging Charging current standard 0 4 A Quick 4 0A Charging period standard 10 15 hours Quick 30 minutes Completion of charge open circuit voltage above 12 8V 54 Carburator Idle adjustment Attention The idle adjustment should be made when the engine is warm It should be conducted after the warm up of engine Start engine and connect the turnmeter of engine Adjust the accelerator pull wire and bolt stopper to specifiy the winding number Winding number at idle speed 1750 100rpm min Readjust the idle adjustment bolt 2 when the gyration at idle speed is instable
41. able limit 12 04mm Measure the outer diameter of the piston pin Allowable limit 11 96mm Clearance of piston pin hole and piston pin Allowable limit 0 02mm 166 Measure the outer diameter of the piston Attention The measuring position and the piston pin form an angle of 90 degree some 11 5mm below the skirt of piston Allowable limit 39 9mm Inspect the abrasion and wear of the cylinder inner wall Attention 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 yr ml b Allowable limit 40 05mm Measure the clearance of the cylinder and piston and take the maximal value as final one Allowable limit 0 1mm 167 168 Measure the roundness of inner wall bore diameter difference between X and Y direction Allowable limit 0 05mm 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 Measure the bore diameter of connecting rod small end Allowable limit 14 06mm 13 4 2 Installation of piston Install the guide pin Paint the engine oil on each piston ring and piston Install the piston in the right place with the mark of piston ring upward Attention The piston should not be scratched and the piston ring should not be broken Upper Middle Lower
42. al or when there is no spark in the sparkplug Normal high voltage no spark bad act of spark plug or power leak in secondary coil bad act of ignition coil charge coil no high voltage The interior resistance is too low Test it with a designated tester The cranking speed is too low The tester is disturbed if the voltage measured for several times is above standard then the value is normal bad act of the charge coil no abnormality in Item no high voltage off and on high voltage bad act of the ignition coil bad act of the charge coil trigger high voltage too low The interior resistance is too low and tests it with a designated tester The cranking speed is too low The tester is disturbed if the voltage measured for several times is above standard then the value is normal bad act of the charge coil no abnormality in Item no high voltage off and on high voltage bad act of the ignition coil bad act of the trigger 81 82 2 3 Ignition system inspection Attention When there is no spark in the spark plug inspect whether the wire or part is loosen or in poor contact and confirm whether each voltage value is normal Since there are a great many of avometer brands with different interior resistance the values tested will differ accordingly Connect the avometer with a high voltage diverter or an electric meter with input resistance abov
43. amp 59 Clutch Start engine and increase the winding number slowly to inspect the actuation of clutch and check the clutch block if the motorcycle does not move or the engine misses Replace the new part if necessary Front rear suspension system Compress up Front and down Strain the front brake and compress the front shock absorber uf and down to check the actuation Check whether the front shock absorber is leak and each part is 60 Rear Compress the rear shock absorber up and down to check the actuation ope Check whether each part of the rear shock absorber is and down 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 61 Specified pressure Unit Kpa A a Tire Specification pressure Outer cover of 120 70 12 z P front wheel 145 170 Tyre specification Front rim 3 50x12 RACE 50 Outer cover of 130 70 12 rear wheel Rear rim 170 195 3 50x12 Outer cover of front wheel 120 70 12 Front rim 3 50x12 RACE 50 Outer cover of rear wheel 130 70 12 Rear rim 3 50
44. antling and mounting steering bar Mounting should follow the reversed procedure of dismantling Screw bolts of welded components of the steering bar Value of Torsion 40 60 N m 7 5 Front fork 7 5 1 Disassembly Disassemble the front wheel Remove the shielding plate for vehicle body Remove braking fluid tube wires of odometer Remove steering bar Remove in sequence the fastening bolts 4 anti sliding washer Remove the upside and downside steel bowl and steel balls 7 of the upside axle Remove the front fork Remove the upside and downside steel bowl 8 9 and steel balls 7 of the downside axle Loose screw bolts of front shock absorber and springs Remove both left and right components 1 2 of front shock absorber Tools Wrench for screw bolts of welded components of the steering bar Fixing nut spanner Specific dismounting tools for bearing steel bowl Attention Clean the opening part of the body guard board with rags Use specialized tools for dismantling the upside and downside steel bowl of axle 7 5 3 Installation Lubricate the downside axle steel bowl with grease and confirm the amounts of steel balls 21pcs 124 Don t rotate the steering bar when the steering bar is not completely mounted to avoid falling of steel balls Support the steering bar well lubricate the upside axle steel bowl with grease and confirm the amounts of steel balls 21pcs Lubricate the se
45. ar brake 1 Bolt 7 Brake shoe module 4 2 Rear brake rocker arm module 7 8 Brake shoe tension spring 5 3 Nut 9 Outer cover 130 70 12 2 4 Rear indicator 8 10 Rear rim 1 5 Rear brake return spring 9 11 Fixing nut of rear wheel 11 6 Rear brake camshaft 6 Attention Oil stain on the brake clutch will reduce its performance Note Detailed decomposition map can be seen on P79 112 Body cover Attention The cover of car body must not be damaged when taken apart The hook claws of the body cover must not be damaged when taken apart Correspond the embedded panel and spear plate of car body with respective slot In the composition hook in each part must be installed correctly Accessories should not be damaged in the installation of cover parts plates xr 9 elmets icence hooks 6 x 14 ard Il VI Body cover Disassemble the motorcycle body according to the following order Cushion covers components front big cover panel components front shielding back shielding front mudguards y Back shelf helmet box front cover boards linking plate I boards linking plate II left right protection components y Back licence brackets back mudguards battery lid foot panel lower lid inside mudguards helmet hooks foot guard board component Attention Do not damage any body cover during installation or disassemb
46. at ring of top seat with grease Rotate the steering bar left and right to make steel balls contacted closely Tools Wrench for screw bolts Confirm smoothly sliding of front fork without any loose Mounting procedure Mount components of front shock absorber Mount steering bar Mount the shielding plate of vehicle body Mount front wheel Note see P89 for figure for dismantling and mounting front fork 125 Rear wheel rear suspension Torsion for screw bolts 11 of rear wheel 100 113 Nm Torsion for screw bolts 3 37 44 Nm Torsion for screw bolts13 22 29 SY Nm Inner radius for braking hub abrasion limit 111mm 1 Rim 2 tyre130 70 12 3 screw M10x1 25x40 4 components of braking plate 5 tension spring of braking plate 6 camshaft of rear brake 7 crank components of rear brake 8 rear indicator 9 position return spring of rear brake 10 mounting bolts of rear crank 11 bolts 12 dust proof lid 13 screw M8x31 14 components of rear shock absorber 15 locking pin 126 Real wheel 1 rear ri plate Specification of outer tire 130 70 12 Speciation of rim 3 50x12 Wobbling limit Vertical 2 0mm Horizontal 2 0mm Torsion for screw bolts 11 of rear wheel 100 113N m spring of braking 9 position return spring of rear brake 10 screw of rear crank 11 bolts VIII Rear wheel rea
47. ater than 1mA Check charge coil of magneto for short circuit Cireuit between rectifier Y N rectification regulator or battery and ignition switch shorted Replace charge 1 Check if electrolyte inside battery is col insufficient 2 Check if density of electrolyte in battery is too low 3 Check for sulphated or shorted pole plate in battery 42 Inspection adjustment Preparation of documents Check list of constant maintenance Engine mobile oil oil filter direction column bearing and handle fixing Inspection adjustment of accelerator s pull wire Air cleaner Spark plug Battery Carburator Ignition timing Rim tyre Preparation requirement General Warning Cylinder pressure Gear mobile oil Changing gear oil Diving belt Front back brake free displacement The liquid volume examination of break fluid Head lamp Clutch Front rear suspension system Bolt nut fixture Tyre specification Before starting engine please confirm whether there is favorable ventilation and do not start engine in a closed location for that the exhaust gas contains carbon monoxide which may numb or kill people Under certain condition gasoline is prone to volatilize and explode so that the working place should be ventilated and kill the engine and should be free from smoking and lighting in the working area or oil storage Please do not disconnect battery when you perform overall lineup otherwise internal damage o
48. cnonccconcnconnncnonncnoncnnoncncononcnnnncnonnononnncannnonnnnnns 17 4 Catalyst converter system O ek Se Nase ci 17 5Countermeasure of idle speed emission exceeding specified value Two stroke ne Preface This Manual explains the maintenance of Qianjiang RACE 50 The documents to be prepared are the maintenance manual and all the operations are included in please read the manual prior to operation Inspection and Adjustment explains the gist of inspection and adjustment the maintenance of safety of vehicle and the performance of each part should come into force since regular inspection After Chapter I is the explanation of the gist of disassembly assembly and inspection of engine entire vehicle and electric fittings There are exploded view system diagram maintenance fault diagnosis and explanation before each chapter Notice There is no prior individual notification on the alteration of mode or structure of motorcycle and the actual product shall prevail if there is discrepancy between the photos pictures or explanation contained in this Manual and the actual product Zhejiang Qianjiang Motorcycle Co Ltd Documents to be prepared General safety Maintenance regulation Specififcation sheet Troubleshooting General safety Carbon monoxide If the engine must be activated make sure that the workplace is well ventilated The engine can not be running in a confined place Attention The e
49. d of start relay it not heard Remove connector of start relay from complete vehicle cable and then connect positive and negative of battery with two lead wires of start relay coil using two conductors After connection starting motor does not rotate yet and no engaging sound of start relay is heard Start relay coil opened or Ride on shorted motorcycle 1 Check start button contact for poor contact 2 Check rectifier diode for damage 3 Check neutral switch for improper operation 4 Check internal wiring of electric start control system for open circuit or short circuit horn does sound or only makes low sound and turn signal lamp Check Check contact for contact Repair replace button Trouble diagnosis program for rotation failure of starting motor Starting motor does not rotate Turn on ignition switch depress horn button or toggle turn signal lamp switch not conductor After shorted start ng motor can rotate normally After connection a motor rotates normally internal wiring of Start relay contact electric start control system burned through or damaged Sit on motorcycle Grasp brake grip to check if brake lamp will come on Y N Internal contact of brake lamp switch contacts poorly or its supporting circuit is opened button poor start of electric system Internal wirin start contro opened or shorted 35 Electric horn can make loud and clea
50. der smoothness please replace Please be inspected at the dealer in Qianjiang regularly in order to keep motorcycle under its optimized condition The said table is based on that the motorcycle runs 1000km per month I inspection A adjustment R replacement C clean L lubrication Remarks 1 for the project of exhaust emission according to the provisions of State Environmental Protection Administration of China the maintenance should be implemented according to the specifications of the Instruction Manual of the Company and should not be adjusted or repaired without permission otherwise the company will not take any responsibility 2 If the motorcycle is driven on the sandstone road or under the environment of severe contamination the times of purging air filtrator should be increased to prolong the service life 3 For the motorcycle which is frequently driven at high speed or the milage is large the frequency of maintenance should be increased Engine mobile oil filtrator Mobile oil level Attention The motorcycle of which the mobile oil is to be inspected should be done on the flat floor After running 2 3 minutes the engine should be stopped for 2 3 minutes for inspecting mobile oil level Inspect mobile oil level When the mobile oil level is below the lower limit please supplement it up to the upper limit position 1 Sump module 2 Sump cap module 3 Bolt M6x16 4 Oil sensor module 5 Clip 8
51. dictator Measure the inner canon of piston pin Figure 1 16 Figure 1 3 Figure 1 4 Figure 1 9 Figure 1 10 Handle Figure 1 11 Figure 1 12 opening pincer piston ai Figure 1 15 Figure 1 16 2 Tools used for the underpan overhaul The list of general tolls and specific tools for the dismounting of underpan components as well as the figure of real objects can be seen in table 1 17 and table 1 18 Figure 1 17 Name Remarks rest wrench Figure 1 19 inner hexagon wrench Figure 1 20 circular wrench Figure 1 21 micrometer Figure 1 22 magnetic stand V shape block Figure 1 23 dial indicator Figure 1 24 square caliper Figure 1 25 spring clip ring clipper Figure 1 26 whack type screw drive Figure 1 27 front fork oil seal dismounting tools Figure 1 28 front part seal element driving in tools Figure 1 29 steering nut wrench Figure 1 30 1 General tools for the underpan overhaul Successive table 1 18 Figure 1 19 Figure 1 20 sal A GG 08 u CD a ED nf Hr 1 Bush head 2 Shake handle 3 Ratchet type wrench 4 Connecting rod Figure 1 21 Figure 1 23 Figure 1 24 Figure 1 25 Figure 1 26 Figure 1 27 Figure 1 28 2 Specific tools for underpan overhaul front fork seal element driving in tools Figure 1 29 Figure 1 30 3 Tools used for electric apparatus components The list of specific tools for the testing of electric apparatus components as well as the figure of
52. driven wheel is worn out The clutch spring is deformed The clutch friction plate is damaged or worn out The ball bearing is worn out The clutch spring is broke The surface of the driving pulley is stained 14 3 Left crankcase cover Disassembly Dismantle the fixing bolt of the case cover and take down the gasket and the guide pin Attention When dismantling the fixing bolt loosen and dismantle it in cross way Take down the gasket and the guide pin 14 4 Drive disk 175 14 4 1 Disassembly Dismantle the fixing nut of the drive disk and take down the left half of the drive disk Take down the triangle belt from the drive disk Check whether the triangle belt is chapped and whether the rubber and cotton yarn fall off or are abnormally worn out Measure the width of the triangle belt Allowable limit 16mm Attention When replacing select the original parts Dismantle the right half components of the drive wheel Right half components of the drive wheel 176 14 4 2 Decompose the right half components of the drive wheel Check the abrasion of the ball bearing Measure the external diameter of the ball bearing Allowable limit 14 4mm 177 Measure the right half internal diameter of the driven wheel Right half components Allowable limit 26 06mm Measure the external diameter of the sliding sleeve Allowable limit 25 94mm E Sliding sleeve
53. ductor of turn Circuit between ignition switch and signal lamp opened or shorted flasher or flasher and turn signal lamp switch shorted or opened Trouble diagnosis program for the malfunction that electric horn does not sound Electric horn does not sound Turn on ignition switch and toggle turn signal lamp switch to check operation of turn signal lamp Turn signal lamp does not come on or Turn signal lamp can give only gives off dim light off bright light Battery level runs low or circuit Power supply from between battery and ignition battery is normal switch opened or shorted Pull off power supply conductor from power line terminal of electric horn and then score and touch power supply conductor and ground instantly to check status of sparks Sparks are generated No sparks are generated during scoring and touch during scoring and touch Power cord between ignition switch and Connect power supply conductor of electric horn and then make non power line terminal to terminal of button of electric horn contact with ground with a screwdriver electric horn opened After contact After contact electric electric horn sounds horn does not sound Internal contact of horn button Adjust volume and tone of electric contacts poorly or conductor horn After adjustment electric After adjustment electric horn horn does not sound yet sound is set right Electric horn has been Electric horn adjusted damaged
54. dust accumulation 13 Specific tools The so called specific tools refer to those specifically designed for assemble or dismantle of certain components of the motorcycle These tools are usually used in specific locations Appropriate specific tools are indispensable in the complete and accurate adjustment as well as in the assembly operations By taking advantage of specific tools the components can be safely reliably and quickly assemble or dismantle thus enhancing the work efficiency and saving lots of efforts 1 tools used for the engine overhaul When assembling or dismantling the engine specifically designed tools should be used for some certain components to guarantee a smooth dismounting The list of specific tools for the assembly and dismantling of engine components and the figure of real objects can be seen in table 1 1 and table 1 2 Successive table 1 2 Table 1 1 Name Remarks Specialized circular wrench Used for the assembly and dismantle of flywheel Clutch holder bolt figure 1 3 Flywheel extractor Figure 1 4 Spacer gauge Figure 1 5 Dismounting tools for bearing Figure 159 Assembling tools for bearing ee Is a f Figure 1 8 Oil seal dismounting tool Figure 1 9 Handle of dismounting tools Figure 1 10 Piston pin exhaustion apparatus Figure 1 11 Piston ring opening pincer Figure 1 12 Heating plug circular wrench Figure 1 13 Measure the thickness of clutch Figure 1 14 Cylinder diameter tester Figure 1 15 Dial
55. e 10MQ10CV 2 3 1 Primary voltage of ignition coil Multimeter LEN N Replace the spark plug with a good one and connect it with the engine Attention Correctly connect each circuit before the test Normal compression pressure of the air cylinder is achieved in the test when the spark plug is installed on the cylinder head Connect the wire of ignition coil and connect the primary coil terminal black white with the diverter at the Ground Press the startup electrical machinery or step on the actuating lever to measure the primary peak voltage of the ignition coil Minimum voltage 95 V or above Attention The metal area of the avometer prod mustn t be touched by fingers to prevent electroshock Remove the 4P and 2P joint of CDI group and connect a High Voltage diverter between the charge coil of the 2P joint red white terminal to the wire and the 4P joint black terminal Press the startup motor or step on the actuating lever to measure the peak voltage of the charge coil 83 Multimeter om Sil STI oo s Ignition coil 2 3 2 Trigger Attention Install the spark plug on the air cylinder head and inspect with normal compression pressure Remove the 6P joint of CDI group and connect a peak voltage diverter between the t
56. e piston ring locked in groove or having insufficient elastic force 3 Check piston ring and cylinder for wear 1 Check breather on fuel tank cap for clogging 2 Check fuel filter and fuel cock for clogging 3 Check fuel cock for proper operation 4 Check oil inlet on carburetor for clogging 5 Check carburetor float for height excess Spark plug electrode wet Check carburetor for flooding Spark plug electrode dry Drip a little gasoline into cylinder to perform experimental starting Check air cleaner for clogging 1 Check between needle valve and valve seat of carburetor float for ajar position caused by foreign materials 2 Check cone of float needle valve of carburetor for steps caused by wear 3 Check for broken Engine can continue to work Engine shuts down after start in a very short time after start carburetor float 4 Check carburetor float for insufficient height Carburetor startin device Inside of carburetor i e A starting logged or float richer system height excessive malfunctioning 24 Trouble diagnosis program for engine overheat Engine overheats Check for improper method of operation and usage N 1 Check gasoline for inferior Check cooling brand or extended storage system 2 Check if engine has ever run at high speed or worked under overload during running Ai i ir cooling engine Check radiating fins for sticking mud and sand or excessive oil stains
57. e rocker arm module 8 Rear indicator 9 Return spring of rear brake 10 Rear rocker arm bolt 11 Nut 12 Scraper seal 13 Tire valve cap V Brake Maintenance instruction 5 1 Fault diagnosis 5 2 Front liquid brake 5 3 Rear brake drum 5 4 5 1 Maintenance instruction Matters needing attention in operation Attention 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 Inspect the brake before riding the motorcycle 5 1 1 Specification Item Standard value mm Allowable limit mm thickness of front brake disc 4 0 3 0 Thickness of front friction lining 6 0 5 0 Diameter of front brake disc Bore ofrear brake drum thickness of rear brake pad 5 1 2 Torque value Fixing bolt of oil pump components 5 9 N m 107 Assemble bolt for the front brake cylinder components 22 29 N m Fixing bolt of rear brake rocker arm 5 9 Nm Fixing bolt of rear brake rocker arm 100 113 N m 5 2 Fault diagnosis Brake Bad braking quality Slow brake or handle tightening 1 Unfavorable brake adjustment 1 Unfavorable brake adjustment 2 Brake shoe and friction lining module worn 2 Brake shoe and friction lining module worn 3 Brake shoe and friction lining m
58. e the worm wheel has a little leap axially O ring in oil pump must not have edge cutting No oil leakage comes from the plugs in oil pump the sealing ring should be in good order Bolt 3 should be dismounted during the engine trial operation after assembling retighten it firmly till to the oil flowing out to be seen 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 Preparation reference Item Standard Permitted limit when changing the oil 0 1L machine oil capacit when dismantlin re 0 11L 143 10 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 10 3 Oil pump 10 3 1 Disassembly Loosen the fixed bolt and take off the chain cover Loosen the screws on the fan take off the fan Magnetic stator rotator bracket 144 Oil pump component Take off the magnetic motor stator rotator and bracket Take off worm
59. e tube screw bolt Cooling fan impeller screw bolt Fly wheel screw bolt Screw nail of stator of Magnetic motor Right crank box screw bolt Axle tightening plate screw bolt Cylinder Twin cap screw Motor screw bolt Crank box left lid cover screw bolt Crank box left cover screw bolt Driving hub screw bolt Idling hub screw bolt Idling hub clutch screw bolt Surpassing Clutch outer ring screw bolt idling wheel of Electric starting tightening plate screw bolt Gear box lid screw bolt Left crank box oil releasing screw bolt Left crank box positioning pin axle screw bolt 140 10 12 15 18 22 25 10 12 10 12 45 50 10 12 10 12 10 12 15 18 10 12 10 12 10 12 40 45 40 45 55 60 10 12 10 12 10 12 18 22 18 22 141 Lubrication system Note Worm and worm wheel should run flexibly without block and one side locking meanwhile the worm wheel has a little leap axially O ring in oil pump must not have edge cutting No oil leakage comes from the plugs in oil pump the sealing ring should be in good order l Es N a Se ts a 1 Crankcase 2 Carburetor 3 Oil tank 4 Oil pump 142 X Lubrication system Preparation data 10 1 Fault diagnosis 10 2 Oil pump 10 3 10 1 Preparation data Matters needing attention in operation Worm and worm wheel should run flexibly without block and one side locking meanwhil
60. e with the disassembly explanation Preparation reference Tools Accessory of peak voltage meter Item Standard value des Standard C5HSA NGK E Hard plug C6HSA NGK spark plug Soft plug C7HSA NGK Spark plug gap 0 6 0 7 mm Primary coil 0 60 10 Resistance With kol value of 1 a plus 5 11KO ioniti il har gt Secondary coil When N plug cover Bi Resistance value of the trigger 20 C 100 5000 Measured peak voltage of ignition coil at one go 95 400V Trigger voltage Above 1 7V Voltage of charge coil 95 400V 79 Avometer 80 2 2 Fault diagnosis No flashover in spark plug Abnormal circumstance Cause of badness confirm in order from 1 The interior resistance is too low and test it with a designated tester The cranking speed is too low ignition high voltage too low The tester is disturbed if the voltage measured for several coil 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 connecting error in tester bad act of the main switch poor contact of CDI joint short circuit or poor contact of CDI ground wire side no high voltage off and on bad act of charge coil peak voltage test voltage high voltage bad act of trigger peak voltage test bad act of connector for high voltage wire bad act of CDI group when item is abnorm
61. eformation or excessive wear 30 Trouble diagnosis for trip stop of transmission Trip stop of transmission Check for the spring of stationary wheel broken or having insufficient elastic Y N Repl Disassemble crankcase to check if approach depths of ace gears are satisfactory Approach depths of Approach depths of gears sufficient gears insufficient Check if approach end of cam claw on end face of meshing Check shift fork for excessive gear has been worn to a tap r or larger roundness and if groove wear or deformation e on corresponding gear end face has been worn to bell mouth X Y N Replace Check spline teeth on main gear shaft and countershaft and spline groove on sliding gear or excessive wear 1 Check shift fork hole and declutch shift shaft for excessive wear 2 Check for oversize fit clearance between shift fork pin and cam slot on shift camshaft 3 Check transmission for proper installation Trouble diagnosis program for clutch slip Clutch slips Automatic centrifugal dry type shoe clutch slips Check clutch shoe plate for oil stains Y Check clutch shoe Clear oil plate for excessive stains wear Y Check if contact area Replace clutch shoe as percent of clutch shoe a set plate and clutch friction disc is less than 70 N Y Repair or replace Check contact surface of clutch friction disc and shoe i clutch shoe plate for excessive wear 31 Y Replace shift fo
62. er all parts are properly mounted and operating after mounting Preparation reference Item Standard 9 screw nail M8x45 Limit for usage 4 protruding screw 10 Fuel tank capacity 5 0 2L Torsion for screwing down Screw bolts for rear luggage rack prop 5 9N m Screw bolts for fuel tank 5 9N m Screw bolts for helmet bucket 5 9N m 9 2 Troubleshooting Decrease of fuel quantity 136 Normal consuming of fuel Leakage of fuel 9 3 Fuel tank seat mat 9 3 1 Disassembly Open seat mat Remove the screw bolts of seat mat 4 pcs Remove oil pot shielding lid Remove oil pot Remove seat mat 7 and helmet bucket Remove rear luggage rack 8 Remove left right shielding plate Remove components of rear handrail and helmet bucket mounting seat Turn the fuel switch to OFF position disconnect fuel tube Remove the fuel tank from vehicle frame Note see P100 101 102 for detailed figure of dismantling and mounting 137 9 3 1 Installation Mounting should follow the reversed procedure dismantling Torsion for mounting Screw bolts for rear luggage rack prop 5 9N m Screw bolts for fuel tank 5 9N m Screw bolts for helmet bucket 5 9N m 138 Inspection and maintenance of engine Table of torque value of engine fastener Fastening area and fastener name Tightening torque N m 139 Lock bolt of Shroud Lock nut of cylinder cover Spark plug Air intak
63. er load 8 Emergency charging cannot be used except in contingency situations 9 In emergency charging of the battery it must be unloaded from the motorcycle before charging 10 Please do not use liquid type battery when exchanging batterys 11 A voltage meter must be used when inspecting the charging conditions 68 Preparation reference Torque value Rectifier bolt 5 0 Nm Fixing bolt of high tension coil 9 0 Nm Flywheel fixed nut 5 0 Nm Car body guard plate bolt 9 0 Nm 1 2 Fault diagnosis No power supply Over discharge of battery Battery wire not connected Fuse blown Bad act of power switch Low voltage Battery badly charged Poor contact Bad act of charging system Item Specification Capacity type 12V 4AH charge type Voltage Fully charged 13 1V Must be ch 20 C een 12 3V not work for an hour Battery Charging current Standard 0 4A Fast 4A Charging time Standard 10 15h Fast 30m Capacity 90W 8000rpm Impedance value of lighting Between green red and black 2 0 2 50 Magneto coil 20 Impedance value of charge coil f Between white and black 1 5 2Q 20 T Single phase half wave SCR charge SCR half wave Vol has short circuit method t z Lighting 14 0V 0 4V 5000rpm Bene Voltage limit limit 13 5V 5000rpm Charge limit 14 8V 0 4V 5000rpm Tools Multiple use fixing spanner Flywheel dissembler Testing instrument Avometer Discontinuous
64. f complete vehicle components may result 43 44 Specification Engine Gyration speed at idle speed 1750 100rpm min Spark plug gap 0 6 0 7mm Carriage Spark plug specification BR7ES NGK TORCH Certification of related components Free stroke of front brake drawbar 10 20mm Free stroke of rear brake drawbar 10 20mm Specification Tire pressure Outer cover of front 120 70 12 wheel 145 170kpa Tire pressure unit Kpa z RACE 50 Front rim 3 50x12 Outer cover of rear wheel 130 70 12 170 195kpa Rear rim 3 5012 Torque front wheel axle 100 113 Nm force clamping nut value rear wheel fixed nut 100 113 Nm Sort Name Certification number Outer cover of front wheel E11 75R 000210 Tire Outer cover ofrear wheel E11 75R 000216 Light fitting Head lamp E4 0012026 Tail lamp E11 000054 Front turn signal lamp E3 001024 45 Rear turn signal lamp E3 001024 Rear view mirror Rear view mirror E3 001002 Horn Horn E4 000066 Side reflector E11 020614 Reflector Rear reflector E11 020613 Muffler Muffler EURO2 CAT 46 Check list of constant maintenance Mileage and time of maintenance Air cleaner 15 months General purpose tool Gasoline filter General purpose tool Oil cleaner General purpose tool Changing engine mobile oil General purpose tool Tire press
65. for two circles at most Reset the idle adjustment screw and set the engine speed down to 1500 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 155 Cylinder cover Note In order to guarrante the sealing between cylinder head and cylinder block the cylinder head undertakes a very big bolt pretightening force Pretightening force value 50Nm 1 Spark plug 2 Cylinder head fixing bolt 3 Cylinder head 4 Cylinder gasket 5 Cylinder block 156 XII Cylinder cover Preparation data 12 1 Fault diagnosis 12 2 Cylinder head 12 3 Examination of the cylinder head 12 4 Installation of the cylinder head 12 5 12 1 Preparation data Matters needing attention in operation In order to guarrante the sealing between cylinder head and cylinder block the cylinder head undertakes a very big bolt pretightening force Pretightening force value 50Nm All parts should clean and blow cleanlily by high compressed air before inspecting and measuring The function of cylinder head The cylinder head which seals cylinder block consists of combustion chamber with piston bears high temperature high pressure gas and finishs intake and exhaust through valve mechanism 1
66. hanism 174 14 1Preparatio data ta A a ede Saa LADA die 14 3 Leftrcrankcase Gover tia iia 14 4 Dr ve disk ti A AA A A ee 14 5 Clutch driven WM lio A A AAA A AAA da 14 6 Disassemble the clutch and the driven wheel oooonoccnnococionocconncnononcnonncononononcnnononcnnnncnnnncnonnnnonnncannnnnnnnns 14 7 Installation cccccccecccsesecesseeeeseeeesceessceceeecenseecsscecsneessneeeeseeseseecssaecseaeeesseeesseecssaecesecsceesenseenseeesaeeneneenes 14 8 Foot start mechanism a seen tennis u gefickt ent Eeee XV Decelerator 137 15 1 Preparation data ccccccccccsscesscessceessneceeeeeseecsseeesseecesseeeeseecsseecsseecseceeseseseseeesseeeeseeeceeeeseseeesseeseeeeneaeenes AA Se Bestenlisten enter irn tests s lterirestgen 13 3 Geat Cases ass erlassen nes Lard ot nee iets 15 4 Installation ua aida XVI Crankcase 140 16 Prepara data A A ede a A 116 2 Fault diagnosi sasn ein E E Rain E OE E aA Enp RE E aE nt 16 3 Crankease EEE tr A A rece lat e ed E E A ET E 16 4 Installation A AS A aa E elder Sees Exhaust emission system inspection and maintenance 144 XVII Exhaust emission and control system 145 17 1 Warranty of Exhaust emission and control SYSteM oooocnnnoccnonccconcnconnnononnononcnnononoononcnnn non nnnnonnnconenonnnnnns 17 2 Regular maintenance Guideline ccc cescccsssccssecesceeeeeeeseeceseenseeceeecseceeseseeenseeceseeesceeseaeeseseeesseeensaeenes 17 3 Mechanical function of the exhaust control SYSteM ooooonnoc
67. ied Measure idle speed ee ar ee Disassemble and clean the Qualified Qualified carburetor for delivery SJ MJ SAJ MAJ and so on Qualified Change the carburetor Disassemble and repair the engine Qualified evalve leak 206 Remark 1 Measure with idle speed measuring procedure Remark 2 Adjust the engine speed within the stipulation with a set screw and measure idle speed CO HC 207 90T 21R ELECTRICITY PRINCIPLE DIAGRAM OIL INDICATOR LICHT 2 BEAR INDICATOR LIGHT 27 INSTRUMENT LIGHT 28x 2 UH SIGHAL INDICATOR LICHT 5 BRAKE SWITCH IGNITION SITE ELECTRIC CLOCE ee REESE RIGHT TUM LIGHT 10 HEAD LIGHT 55 559 SIDE LIGHT 5 a a iG ELA BYR T G D E 8 LEFT TORN LIGHT 10 TERFERETORE ACTONIZATION To LET aaa urn je iaa nio les ponerle leales ee a RE e 208
68. improperly between electric horn and button broken Trouble diagnosis program for the malfunction that brake lamp does not come on Brake lamp does not come on Remove brake lamp shade to check circuit board of brake lamp for burn out Replace circuit Short plugs on two terminals or lead wires of brake lamp board of brake lamp switch with a conductor After shorted brake lamp After shorted brake does not come on yet lamp comes on Score and touch power supply conductor Brake lamp switch is and ground of brake lamp switch with a adjusted improperly or its screwdriver or conductor to check status of internal contact contacts sparks poorly Sparks are generated No sparks are generated during scoring and touch during scoring and touch Conductor between brake lamp switch and brake Power supply conductor between zu switch and lamp shorted or opened brake lamp switch opened or shorte Trouble diagnosis program for undercharge of battery Battery is undercharged Check if brake lamp keeps illuminating Y N Adjust or replace brake Set ignition switch to OFF position remove negative cable from battery lamp switch connect negative meter pen of an ammeter to negative terminal of battery and positive meter pen to negative cable and then detect and measure leakage current Leakage current is less than Leakage current is greater than specified value specified value generally it is required that leakage current is not gre
69. inal 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 CL FAL iF Bh oe HG BY In both instances the bearings will be broken Loose cable is a hidden trouble to electrical safety After clamped check each cable to ensure electrical safety It is not allowed to leave any wire clip bending towards bonding points Bind each cable to its designated position It is not allowed to lay a cable to end or a sharp corner on frame It is not allowed to lay a cable to end of a bolt or screw When laying a cable keep it away from any heat source or any place where may bite it when it is moving When laying a cable along a handle avoid it being strained too tightly or loosely and it can not interfere with any adjacent part at any turning point All cables should be laid smoothly without twist or knot Before butt jointing a connector check if its sheath has been damaged and if it is overstretched If a cable is at a sharp corner or outer corner use tape or hose to protect it After a cable is repaired use tape to bind it securely Keep all control cables from bend or twist because dumb control will result in case any control cable is damaged O CORRECT X INCORRECT Motorcycle Identification
70. ing degree of the rear wheel exceeds the allowable limit the rear wheel bearing becomes flexible which leading to the swinging of the rear wheel Replace the rear wheel bearings with new ones after an examination 8 3 3 Installation Carry out the installation of the rear wheel according to a reversed sequence of dismantle and then tighten the nuts Rear wheel fixed nut Torque value 100 113 N m 129 Rear wheel 8 4 Rear shock absorber 130 8 4 Rear shock absorber 8 4 1 Disassembly Dismantle the cushion the left rear guard plate and the right rear guard plate Dismantle the rear handrail and the rear mudguard Remove the fixing bolts of rear shock absorber Unload the rear shock absorber 8 4 2 Installation Install the rear shock absorber Torque value Upper fixing bolt 37 44 N m Lower fixing bolt 22 29 N m The installation of rear shock absorber The installation of rear handrail and the rear mudguard The installation of cushion the left rear guard plate and the right rear guard plate 131 132 Fuel tank seat mat Caution must turn the fuel switch to the OFF position when dismantling the fuel tank Torsion for bolts 4 37 44 Nm Torsion for screw 10 5 9 N m 1 welded components for vehicle frame 2 screw axle for engine 3 bolts M12x1 25 4 screw bolts for hanging rack M10x41x1 25 5 bolts M10x1 25 6 welded components for welded components of p
71. ints outside engine for air leak 2 Check for the piston ring broken or locked in groove or having insufficient elastic force 3 Check piston ring and cylinder for wear Engine speed rises with increase of Engine speed can not rise with increase throttle opening of throttle opening 1 Check for clutch slip 2 Check drive belt for excessive wear 3 Check centrifugal rollers on head pulley for excessive wear 4 Check cones on drivirig wheels and moving friction wheels for excessive wear or grooves caused by wear 5 Check cones on driven wheels and moving driven wheels for excessive wear or grooves caused by wear raceway on inner end face of Use an ignition timing light to detect if engine ignition timing 1s correct 1 Check CDI igniter for malfunction 2 Check magneto flywheel and trigger coil for looseness 1 Check fuel supply system for unobstructed fuel supply 2 Check carburetor air cleaner and exhaust muffler for cloggin 3 Check vacuum diap in on 6 Check race moving friction wheel for excessive wear or pits caused by extrusion plunger valve of carburetor for map cracking or breakage 4 Check carburetor float for improper height 27 Trouble diagnosis program for poor engine idle speed Engine speed disabled Check compression pressure of cylinder Compression pressure Compression pressure of cylinder insufficient of cylinder normal Check for oversize idling jet 1 Check all
72. ion Engine fuel consumption is excessive Check for correct method of Operation and usage Y N Erect main jiffy stand and rotate 1 Check if motorcycle has ever run wheels by han under overload at non economical vehicle speed or in low gear 2 Check if brand of the gasoline used is correct Wheels rotate Wheels rotate dully freely 1 Check brake for Check tire retard pressure Check wheel bearing for excessive wear 3 Check for missing or comparatively short intermediate spacer of Air pressure Air pressure wheel hub too low normal Inflate until Check fuel tank fuel cock oil full as required delive pipe carburetor etc for oil lea Y N Troubleshoot as Check mixture ratio of appropriate combustible mixture Mixture ratio of combustible Combustible Combustible mixture normal mixture too rich mixture too thin Check engine for too high 1 Check air cleaner for 1 Check inside of idle speed clogging carburetor for cloggin 2 Check carburetor float for 2 Check carburetor float Y N insufficient height for height excess Check and adjust Use an ignition timing carburetor light to detect if engine timing is 3 Check for oversize main jet on carburetor ignition correct Y N Check for clutch Check ignition drive belt slip system 29 Trouble diagnosis program for the malfunction that exhaust muffler on a 2 stroke engine gives off strong blue white smoke Exhaust muffler on 2 stroke
73. ion data 2 1 CDI group 2 4 Fault diagnosis 22 Ignition coil 2 5 Ignition system inspection 2 3 Trigger 2 6 2 1 Preparation data Matters needing attention in operation 1 Inspect the ignition system in accordance with the order stipulated in the fault diagnosis table 2 The ignition system is an electronic auto advance device integrated in the CDI group therefore the ignition time needs no adjustment 3 Inspect the ignition system in accordance with the order stipulated in the fault diagnosis table 4 Take particular care in disassembly that the CDI group of ignition system should not fall off and drop down or should not stricken with might which is the main cause of fault 5 Bad socket contact is the main cause of the ignition system fault so inspect whether the joint of each part is in poor contact or not 6 Inspect whether the spark plug is utilized at a proper thermal value Improper spark plug may lead to unsmooth operation of engine or burn out of the spark plug 7 Inspection in the chapter is based on explanation of peak voltage and the judgment whether the resistance value of ignition coil is OK or not according to records after the inspection 8 Inspection of the main switch should be performed in accordance with the conduction table 9 The disassembly of the alternator and stator should be conducted in accordanc
74. isassembly 4 5 Disassembly replace the bulb of the taillight and rear right turning light 4 5 1 Disassembly Remove seat cushion Remove set screws of left and right rear fenders so that tail lamp shade can be taken off Disconnect wire connectors of tail lamp and left and right turn signal lamps Remove left and right rear fenders 1 tail lamp shade and rear license bracket Remove tail lamp 4 Remove tail lamp 4 and rear left and right turn signal lamps 4 5 2 Installation Install the taillight back to the original position in the reverse order of disassembly 4 5 3 Replace the bulb of the taillight 4 5 3 1 Disassembly Remove set screws of tail lamp shade Remove tail lamp shade together with tail lamp bulb Remove bulbs left and right turn signal lamp bulbs and tail lamp bulb from bulb holders 100 4 5 3 2 Installation Install the bulb back to the original position in the reverse take turns of disassembly Install the bulb back to the original position in the reverse take turns of disassembly 4 6 Instrument Remove set screws of front shield of handle pipe Remove set screws of instrument Disconnect odometer wire connector to remove the instrument Install the speed indicator back to the original position in the reverse order of disassembly 4 7 Main switch 4 7 1 Inspection Remove front cover twin lamp panel Remove foot protection plate Dismantle the wire joint of the main s
75. iston 0 005 0 015 0 1 Piston pin hole inner diameter 12 002 12 008 12 04 Outer diameter of piston pin 11 994 12 11 96 Clearance between piston pin hole and piston pin 0 002 0 014 0 02 Small end inner diameter of the connecting rod 14 016 14 034 14 06 The piston spring is worn down or damaged 13 3 1 Disassembly of air cylinder body Remove the air cylinder body after dismantle the air cylinder cover ia Testing gauge aie 13 3 2 Inspectionof air cylinder body Inspect the wear and tear of the cylinder inner wall Severe wear and replace it Inspect the cylinder face planeness of the cylinder block kT Ik Allowable limit 0 05 smil 32 164 13 4 Piston 13 4 1 Disassembly Disassemble the retaining ring for piston pin Attention When disassembling do not drop the retaining ring into the crankcase Withdraw the piston pin and unload the piston Inspect the piston piston pin and piston ring Unload the piston ring Attention Do not break or damage the piston ring Clean away the carbon deposit in the piston ring groove lt Testing gauge Unload the piston ring and install each piston ring at the bottom of the cylinder Attention Press the piston ring into the air cylinder with the piston crown 165 Measure the interface clearance of the piston ring Allowable limit 0 5mm ml 34M Measure the bore diameter of the piston pin hole Allow
76. it should be replaced Examine the carburettor body and the oil fired pipe If they are stained please clean them as per the instruction book Bolt a i Float chambre Needle valve Floater pin Floater A Main metering hole Idle speed injection nozzle an Idle adjusting screw 3 154 11 4 Installation amp adjustment Assembly and installatioj is conducted in the reverse order of disassembly Adjustment of carburetor Attention When the carburettor is ready for sell the idle adjusting bolts have already been adjusted so they generally require no adjustment When dismantling the carburettor the number of turning of the bolts should be recorded which is very helpful during the 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 1800rpm Screw the mixture adjustment bolt to the end with proper force 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
77. ly 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 114 Front wheel 115 Tire specifications outer tire 120 70 12 Wheels specifications 3 50 x 12 Rims facing poor limits vertical 2 0 mm horizontal 2 0 mm Front wheel axle degree limits 0 2 mm Outer tire of front wheel certification of E11 75R 1 Front whee 101 2RS 5 tires 120 70 12 left axis cover 10 gear wheel bracket component nuts ll valve cap 116 Front suspension Installed torque value in the map of bolt 11 5 9 N m Installed torque value in the map of bolt 14 40 60 N m The number of steel ball on the top 21 The number of steel ball on the bottom 21 1 Front righ e plate seal components wn bearings up steel bow x 12 12 cadres of brake fluid Clamps 2 13 cadres of brake fluid Clamps 1 14 bolts M10 x 1 25 x 30 15 bolts M6 x 16 Manipulation assembly Installation torque values of bolts 2 direction knob fixes the bolts in the map 2 40 60 N m Free trip of front shake handle before the brake handle free trip 10 20 mm Installation torque values of bolts 3 in the map 40 60 N m Free trip of throttle manipulation 2 5 mm 4 11 x 10 14 An i 7 4 9 AS 1
78. m diameter of front hydraulic brake 4 0mm Attention It must be measured with microcaliper Measure the thickness of brake pad If thicknesses of brake disc and friction lining module are less than the service values or they are contaminated by grease replace Allowable limit brake pad 5 0mm brake disc 3 0mm Note the brake clutch should be replaced in pairs 5 3 3 Installation Install the brake disk and front wheel 109 Install the brake hose assembly of the front brake and the brake cylinder components 2 Prevent brake clutch 3 and break disk from greasing Attention Presence of grease on friction lining will reduce braking performance resulting in brake failure Screw bolt and nut to the stipulated torque force value Torque value Fixing bolt of oil pump body module 5 9 Nm Mounting bolt of front brake cylinder module 22 29 Nm Do not allow oil stains to stick to friction lining If oil stains stick to friction lining clean with brake washing fluid Attention Oil stains sticking to friction lining will reduce braking performance 5 4 Rear drum brake 5 4 1 Disassembly Remove muffler Remove fixing nut of rear wheel 11 Remove rear wheel Remove brake shoe module 4 Attention Always replace the brake pad in pairs eIf a brake pad is reused mark a signal on its side before 110 disassembly so that it can be installed to the original position Remo
79. ng specified value 17 5 17 1 Warranty of Exhaust emission and control system 1 The exhaust emission and control system of this motorcycle conforms to European Union EC 97 24 5 I and the revised version of 2002 81 EC B stage Our Company gives warranty if the user fully follows regular service and specified maintenance of the system in effective service life 2 Warranty scope 1 Function warranty of exhaust emission and control system We guarantee that within riding of 15 thousand km regular or irregular exhaust inspection standards implemented by the government will be satisfied 3 If the following conditions occur this warranty clause is not applicable but maintenance and service at a reasonable price will be provided to customers by our dealers or service departments at province or city level 1 Regular maintenance is not performed in accordance with the specified time or service kilometers by our Company 2 Those who do not have regular inspection adjustment or service at our dealers or service centers or who fail to bring forward the maintenance records 3 Overload or improper use 4 Reconstruction of the vehicle disassembly of original binding parts or mounting other equipment at will 5 Used for racing or frequent riding on roads for non motorized vehicles 6 Damage caused by typhoon flood and other natural disasters or damage and fault caused by negligence traffic accidents collision with foreign objects
80. odule installed improperly 3 Brake shoe and friction lining module installed improperly 4 Brake shoe friction lining module and brake disc contaminated Strange sound in braking 1 Brake shoe and friction lining module worn 2 Brake shoe friction lining module and brake disc contaminated 5 3 Front hydraulic brake 5 3 1 Disassembly Attention Friction lining module replacement 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 modules from right grip and front shock absorber respectively Front brake 1 Hydraulic brake lever 21 2 Oil pump body module 3 3 Brake hose assembly 10 4 Brake cylinder module 15 5 Brake disc 13 108 Note Detailed decomposition map can be seen on P78 Attention 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 Unclamp the fixed bolt of the brake cylinder components Antle the following components from the front absorber Disassemble the front wheel spindle Unload the front wheel Remove the brake disk from the front wheel 5 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 RACE 50 diameter of front hydraulic brake 190m
81. oil black white black 0 60 10 Secondary ignition coil black spark plug cover spark 0 5 5 5KQ 2 5 Ignition coil u 2 5 1 Disassembly Disassemble the body guard _ Ignition line figure Disassemble the spark plug cover Disassemble the primary ignition coil Disassemble the ignition coil fixing bolts and unload the ignition coil Installation is conducted in the reverse order of disassembly Attention The primary coil is installed in accordance with the black white wire 2 5 2 Inspect the primary coil Measure the resistance between terminals of primary coil Standard value 0 60 10 20 C If the resistance value is within standard value range the primary coil is good The resistance value oo stands for broken line in the coil so replace with a new product p 2 5 3 Secondary coil Measure the resistance value between the wire of spark plug cover with the spark plug and the terminal Standard value 5 11KQ 20 C If the resistance value is within standard value range the Q primary coil is good l l The resistance value oo 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
82. olt of muffler Fixing bolt of muffler joint 104 Front liquid brake Diameter of front brake disc 190mm Thickness of front brake disc 4 0mm Service limit 3 0mm Thickness of friction lining 6 0mm Service limit 5 0mm Mounting torque value of the bolt 9 shown in the figure 5 9N m Mounting torque value of the nut 29 shown in the figure 37 44N m Free stroke of brake lever 10 20mm 1 Hydraulic brake assembly 2 Gasket 3 Oil pump body 4 Plunger module 5 Oil cup pad 6 Oil cup cover 7 Screw M4x10 8 Fixing cover of handle seat 9 Screw M6x23 10 Brake hose assembly 11 Coupling bolt 12 Oil pump body module 13 Front brake disc 14 Mounting bolt of front brake disc 15 Brake cylinder 16 Dust cover of bleeder valve 17 Spring leaf 18 Friction lining module 19 Return spring of handle 20 Bolt 21 Hydraulic brake lever 22 Bolt 23 NutM6 24 Brake cylinder 105 module 25 Front brake switch 26 Oil pump body gasket 27 Small pillar 28 Washer 29 Mounting nut of front brake disc M10x1 25 Rear brake drum Mounting torque value of A the nut 11 shown in the figure 100 113N m Bore of brake drum 110mm Wear limit 111mm Thickness of brake shoe C 6 0mm Service limit 5 0mm Free stroke of rear brake lever 10 20mm 1 Rear rim 2 Tire 130 70 12 3 Tire valve 4 Brake shoe module 5 Brake shoe tension spring 6 Rear brake camshaft 7 Rear brak
83. or terminal on start ae conductive when start relay makes engaging sound Start relay contact Disassemble starting motor and perform burned through or the following checks 1 Check carbon brush for excessive wear 2 Check for the carbon brush spring broken or having insufficient elastic force 3 Check surface of armature commutator for sticking dirt or burn through and damage 4 Check armature commutator for damaged excessive wear 36 Trouble diagnosis program for the malfunction that none of illuminating lamps comes on None of illuminating AC power supply lighting system Disconnect bundle conductor of magneto from connector of complete vehicle cable and then use test lamp method to check if electric power is output from output conductor of lighting coil of magneto Electric horn makes loud and clear sound and turn signal lamp Test lamp Test lamp does not comes on comes on Lighting coil of Start engine and disconnect magneto or its rectification regulator from output conductor connector 0 complete opened or shorted vehicle cable Illuminating Illuminating lamp comes on lamp does not Internal short circuit of rectification regulator Disconnect head unit to check lamp bulb has burned out lamp if head been DC power supply lighting system Depress horn button or toggle turn signal lamp switch Electric horn does not make sound and turn signal lamp does not
84. or there is dificulty of slight acceleration Ignition timing Attention Warm up engine for 3 5 minutes Shut down engine and connect timing lamp to spark plug conductor Notice Please refer to instructions for timing lamp before any operation Remove fender 1 Start engine and idle it Check ignition timing If symbol F aligns with the mark symbol on right crankcase cover it indicates that the ignition timing is correct Raise engine speed and check if symbol F starts to move Idle speed 1750 100rpm min Cylinder pressure It should be made when the engine is warm Remove the guard plate of car body Dismantle spark plug Install cylinder pressure meter Full throttle press Start to run motor and measure the Measure the cylinder pressure cylinder s pressure Check the following items if the compression pressure is too low Cylinder head gasket is damaged Damage of piston ring Ring wear Piston cylinder valve wear Check the combustion chamber and the carbon laydown on the top of pistion if the compression pressure is too 55 high 56 Gear mobile oil Inspection Attention Fuel check let down the middle supporter to be perpendicular to motorcycle on the flat floor Dismantle the inspection bolt of gear oil after stopping engine 1 The oil level is below the lower limit of bolt hole is good Please supplement gear oil when the oil level is
85. ower 133 output hanging rack 7 seat mat assembly 8 fuel tank assembly 9 components of seat mat lock 10 screw M6x20 11 prop for rear luggage rack 12 screw M6x12 13 tight wire of seat mat 14 rivet3 2x7 Fuel tank Fuel capacity 5 0 2L Torsion for screw 2 5 9 Nm Length of the vacuum tube of the fuel tank 360mm caution must turn the fuel switch to the OFF position 134 1 tank components 2 screw M6x16 3 components of fuel tank switch 4 fuel tube 180mm 5 heat insulation spring 6 hoop 8 7 vacuum tube 360mm 8 hoop 7 9 fuel tube 2250mm 10 filter components 11 fuel position sensor 12 screw M5x16 13 gasket of fuel position sensor 14 seal rubber 15 gasket 5 16 filter core 17 sheath gasket Seat mat Torsion for screw 4 5 9 Nm Torsion for screw 7 5 9 Nm 135 1 components of seat mat 2 components of rotating leaf 3 0 shape ring 84 4x3 1 M6x14 5 helmet bucket 6 gasket8 7 screw M6x12 8 rear luggage rack plastic gasket 11 bottom lid of helmet bucket IX Fuel tank seat mat Preparation 9 1 Troubleshooting 9 2 Fuel tank seat mat 9 3 9 1 Preparation Matters needing attention in operation The place for dismantling should be far away from fire must turn the fuel switch to the OFF position when dismantling the fuel tank Torsion for screwing bolts must meet the determined value Check wheth
86. r sound and turn signal lamp can give off bright light Grasp brake grip sit on motorcycle or set transmission to neutral position or grasp clutch grip and then depress start button After start button is depressed engaging sound of start relay can be heard Short battery terminal on start relay and starting motor terminal with a screwdriver or thick After shorted starting motor does not rotate yet motor ollowing Disassemble startin and perform the checks 1 Check carbon brush for excessive wear 2 Check for the carbon brush spring broken or having insufficient elastic force 3 Check armature commutator excessive wear 4 Check armature coil for open circuit or short circuit for Trouble diagnosis program for weak rotation of starting motor Starting motor rotates weakly Turn on ignition switch depress horn button or toggle turn signal lamp switch Electric horn does not Electric horn can make loud and sound or only makes low clear sound and turn signal lamp sound and turn signal lamp can give off bright light light is dim Battery level is low or Check conductor joint between conductor joint connecting start relay and starting motor for battery contacts poorly poor contact Y Remove connecting conductors of starting motor and Check and battery from start relay depress start button and troubleshoot then use an ohm meter to measure if resistor between battery terminal and starting mot
87. r suspension Preparation data 8 1 Fault diagnosis 8 2 Rear wheel 8 3 Rear shock absorber rear rocker 8 4 8 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 Run out of rear wheel Transverse direction Vertical direction Standard value mm 12 dust proof washer 13 valve cap Allowable limit mm 2 0 Torque value Fixing nut of rear wheel Topping nut of the rear shock absorber Bottom nut of the rear shock absorber 8 2 Fault diagnosis 8 2 1 Run out of rear wheel The rim is distorted Tire malfunction The rear wheel is not fastened 100 113 N m 37 44 Nm 22 29 Nm 128 The tire pressure is not enough 8 2 2 Shock absorber too soft Elasticity fatigue of spring 8 3 Real wheel 8 3 1 Disassembly Remove muffle components 1 Remove rear inner mudguard Remove screw bolts of rear wheel axle Remove rear wheel components 2 8 3 2 Inspection 8 3 2 1 an examination on the swinging of wheel ring Rotate the wheel by hand and measure the eccentricity through the dial gauge Allowable limit Vertical direction Replace for that is above 2 0mm Transverse direction Replace for that is above 2 0mm When the swing
88. rigger of 6P joint blue white terminal o the wire and the 4P joint black terminal Press the startup electrical machinery or step on the actuating lever to measure the peak voltage of the trigger Connecting method positive pole connected with blue white line and negative pole connected with black line Minimum voltage 1 7V or above Attention The metal area of the avometer prod mustn t be touched by fingers to prevent electroshock ara If the peak voltage of the CDI terminal has an abnormal value White green y disassemble the right body guard and the alternator joint Connect the trigger blue white with the diverter If the tested voltage of CDI is abnormal whereas the tested voltage at the alternator is normal poor contact or broken line Blue White can be determined If both are abnormal bad act of the trigger can be determined Please refer to inspection of the troubleshooting table 2 4 CDI group 2 4 1 System inspection System inspection Disassemble the CDI group and inspect the parts related with the ignition system at the wire terminal 84 2 4 2 Inspection Disassemble the CDI group and inspect whether the joint is loosen or eroded Inspection item Testing terminal Standard value 20 Main switch red red white Conducted when main switch at lug not included 85 Trigger Blue white white green 100 5000 primary ignition c
89. rk Trouble diagnosis program for hydraulic disc brake failure Hydraulic disc brake fails Check brake fluid level in fluid reservoir of brake master cylinder Brake fluid level is below lower Brake fluid level is above lower limit line on fluid reservoir limit line on fluid reservoir Refill brake fluid If you have a sponge like to upper limit line feel when operating brake on fluid reservoir grip also check brake caliper brake hose and_ hose connector for oil leak Check if brake lining has been worn to limit mark and if brake disc is excessively worn Residual air exists in brake line Replace brake 1 Check surface of brake master cylinder piston and that of oil lining and brake cylinder wall for excessive wear or damage disc 2 Check brake master cylinder piston cup for damage map cracking and aging 3 Check brake caliper gasket for damage map cracking and aging 4 Check surface of brake caliper piston and that of oil cylinder wall for excessive wear or damage Trouble diagnosis program for drum brake failure Drum brake fails Check if free stroke of brake grip is within 10mm 20mm or if that of brake pedal is within 20mm 30mm N Y Readjust Separate brake rocker arm from cable wire of brake control cable and then pull brake rocker arm by hand to check Brake rocker arm Brake Arrow on indicator board of Arrow on indicator board of brake rotates smartly but a rocker brake cam aligns with or cam does not
90. rod Ttem Standard value Allowable limit clearance of connecting rod big end in right and left direction Dee 439 Radial clearance of the big end of 0 015 0 025 0 05 connecting rod Clutch spring compressors Box spanner Bearing driver 194 16 2 Fault diagnosis Strange noises in crankcase Parts shattered or broken in crankcase The bearings of crankshaft pin are loosened 16 3 Crankcase 16 3 1 Disassembly of crankcase Loosen bolt take off the start drive gear Take off the gear on the satellite wheel seat Dismount crankcase fixing bolts Dismount left right crankcase Attention Don t damage the gasket The crankshaft bearings are loosened Clutch depressed A 7 G ar 195 ut Sat llite wheel Sab rn Take down the gasket and the guide pin Take off the crankshaft from the crankcase Scrape off the gasket on the crankcase joint face Attention Don t damage the crankcase joint face Dismount oil sealing from the left crankcase 196 Dismount oil sealing from the right crankcase 16 3 2 Inspection Clearance measurement of connecting rod big end in right and left direction Allowable limit 0 6mm 197 Clearance measurement of connecting rod big end in X and Y direction Allowable limit 0 05mm Inspect whether there are strange noises or loosening in
91. s frequently driven on bad road or in rain it should be replaced early 50 Attention Please confirm whether the air cleaner is installed as installing air cleaner cover 51 Spark plug Dismantle spark plug Check the overburning pollution and carbon laydown of spark plug Spark plug gap If there is the said problem please purge it with cleaner of spark plug or steel brush Inspection of spark plug gap Clearance 0 6 0 7mm Attention As installing spark plug pleae install it with hands and tighten by spark plug socket Battery Dismantle battery Open the battery cell lid Dismantle the clamping bar components of battery cell Dismantle the negative lead of prior to the positive lead Take out battery Warning 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 52 extremely dangerous The installtion is in the reverse order of dismantling Warning In order to prevent short circuit please connect positive pole prior to the negative one Please do not disconnect battery when you perform overall lineup otherwise internal damage of complete vehicle components may result Inspection of charging state CCU Open the battery cell lid Dismantle the clamping bar components of battery cell Remove the negative pole wire first and then the positive pole wire
92. starting relay line inspect the wire and conduction of the brake switch 3 4 3 Inspect the earth line of the start relay Remove the connector of start relay Inspect conduction between the gray line at the lead connector terminal and the body ground When pressing the start button the gray line of the connector and the body ground are in good conduction If no conduction occurs inspect the wire and conduction performance of the start button 3 4 4 Actuation inspection Connect the starting relay with the battery and connect the terminal of startup electric machinery with the avometer Connect the fully charged battery between the black line and green yellow line of the relay At this point the relay should give out a Click sound and the avometer resistance 96 Y Start relay reads 0 97 Bulbs switch instrument 98 Certification number of head lamp E4 0012026 Certification number of front turn signal lamp E3 001024 Certification number of tail lamp E11 000054 Certification number of rear turn signal lamp E3 001024 Certification number of rear reflector E11 020613 1 Head lamp 2 Turn signal lamp FL 3 Turn signal lamp RL 4 Side reflector 5 Turn signal lamp RR 6 Meter 7 Tail lamp 8 Turn signal lamp FR 9 Rear reflector IV Bulbs switch instrument Preparation data 4 1 Instrument 4 6 Fault
93. sure to use parts from Qianjiang when replacing any part of the system And the replacement should be carried out by the designated dealers or service centers 17 3 Mechanical function of the exhaust control system Outline The countermeasure of exhaust gas is taking the four stroke single cylinder engine carburetor mode as the reference and adopts Air induction device to maintain fine exhaust level In addition the charcoal Canister Purge is employed in vaporized exhaust 203 x Improvement of engine Middle spark plug semicircular combustion chamber and improvement of compression ratio ignition time such improvement in exhaust system alone has achieved high intake and exhaust efficiency which enables increase of combustion efficiency X Air induction device Introduce the air into the vent pipe so that the CO and HC incomplete combustion could be turned into innocuous gas in the second reaction Difference Device Constituting part Objective and function Exhaust Canned oxygenation catalyst installed in xhaus Catalyst device Catalyst converter the center of the vent pipe enables the system oxygenation of CO HC and NOX Adjustable parameters and suggested set value Idle adjustment engine speed 1750 100rpm min CO concentration 0 5 1 0 204 17 4 Catalyst converter system 17 4 1 Structure _ di Catalyst placing 17 4 2 Description 1 The function of the conver
94. t 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 Main nozzle 47 5 Main jet 80 Idle jet 15 149 Needle valve B05 2 11 2 Fault diagnosis Bad startup Carburetor short of fuel Gasoline filter blocked Gasoline pipe blocked Needle valve conglutination Bad adjustment of oil level Too much fuel in the engine Overfuel and oilflow Secondary air inlet of fuel system Fuel deterioration Bad operation of electric enrichment valve Idle system or choke system blocked
95. te in battery No voltage display lamp switch Electric horn can make loud and clear sound and turn signal lamp can give off bright light Disconnect rectification regulator from connector of complete vehicle cable and then use an ohm meter to measure if circuits between lighting and charge coils of magneto and rectification regulator are opened Set a multimeter to OV 20V DC Voltage On range and then measure voltage between conductor end generally red wire or red white wire from connector to battery and negative Voltage display available Conductor from connector to Check rectification regulator for battery opened malfunction 38 Trouble diagnosis program for weak illuminating lamp light Illuminating lamp light is dim DC power supply AC power supply lighting system lighting system Disconnect bundle conductor of magneto Turn on ignition switch depress horn button or from connector of complete vehicle cable toggle turn signal lamp switch and then use an ohm meter to measure if Electric horn is hoarse and turn signal lamp light is dim resistance between output conductor ends of lighting coil of magneto is less than standard value Y Lighting coil Start engine and restrict its Electric horn shorted speed disconnect rectification can make loud Battery level runs low or joint regulator from connector of and clear sound between battery and ignition complete vehicle cable and then and t
96. ter catalyst is to convert HC CO and NOx after incomplete combustion into innocuous gas such as H20 CO2 and N2 then discharge them out 2 The converter catalyst contains rare metal like platinum and rhodium and only unleaded gasoline can be used Note that leaded gasoline will invalidate the catalyst Matters needing attention in overhaul of vehicles vent pipes loaded with catalyst converter 1 For Keep the vehicles loaded with catalyst converter away from inflammable materials the engine is too hot to be touched shortly after it is started or stalled 2 Keep the vehicles loaded with catalyst converter away from inflammable materials 3 The vent pipe contains CO that does harm to health therefore don t run the engine in enclosed space 4 The vehicle loaded with catalyst converter can not use leaded gasoline To guard against catalyst poisoning 5 do not start the engine by pushing the vehicle If startup must be done by pushing wait until the temperature of engine and catalyst converter drops 6 Do not shift up or stall when descending 205 7 Do not drive vehicle with bad ignition 8 Do not repair the engine ignition system by dismantling the spark plug and starting the engine to inspect whether the spark plug is sparkless If such operation is necessary it cannot be performed for a long time 17 5 Countermeasure of idle speed emission exceeding specified value Two stroke Qualified Conduct regular inspection Qualif
97. ting Trouble diagnosis program for engine start failure or difficulty Engine fails or is difficult to start Check ignition system Remove spark plug to check between its electrodes for carbon connection N Y Perform spark over test of Clear carbon deposit spark plug Sparks between electrodes weak or Strong blue or purple blue sparks can jump out none at all from between electrodes Screw off spark plug cap to perform Use an ignition timing light to detect if engine spark over test of ignition coil ignition timing 1s correct Strong blue sparks can Se weak or none at 1 Check CDI igniter for Loosen drain screw jump out all malfunction on carburetor to check 2 Check magneto flywheel if gasoline and trigger coi for flows out from looseness overflow pipe on Check spark plug and its cap for carburetor malfunction Check Check Check internal Check CDI supply of ignition coil wiring of igniter for ignition or short ignition system malfunction Use a cylinder power circuit or for short circuit pressure gauge to open circuit or open circuit check and measure compression Check inside of fuel tank for presence of No contact magneto ignition system 1 Check ignition power Y N coil for short circuit or open circuit 2 Check trigger coil for short circuit or open circuit Fill gasol ine 23 Remove spark plug for inspection 1 Check all joints outside engine for air leak 2 Check for th
98. to prevent damage Crankcase 192 193 Note The crankcase is a thin wall casting part avoid stamp during the work to prevent deformation and breakage All parts should clean and blow cleanlily by high compressed air before inspecting and measuring The oil in crankcase should be drained out before work XVI Crankcase Preparation data 16 1 Fault diagnosis 16 2 Crankcase 16 3 Installation 16 4 16 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 crankcase is 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 Crankshaft Tools Multiple use fixer Driver s perch Guide
99. too low Install the inspection bolt of gear oil Attention Confirm the airtightness of bolt and whether it is out of clutch and damage Changing gear oil Dismantle the inspection bolt of gear oil Dismantle the oil drain bolt 1 the gear oil will effuse Install the oil drain bolt Attention Confirm the airtightness of bolt and whether it is out of clutch and damage Supplement gear oil Check the oil leak of each position after operation Install the inspection bolt of gear oil Driving chain Dismantle the left crankcase lid 57 Check to see if the driving belt is broken or worn out Replace for new products when necessary or periodically Free displacement of the front rear brake Free displacement of the front brake Measure the free displacement of the front brake handle at the tip of the brake handle Free displacement 10 20mm Free displacement of the rear brake tip of the brake handle Free displacement 10 20mm 58 Examination on the liquid amount of the brake liquid When braking to its end check up the oil amount through the oil lens If the liquid level of the brake fluid is vertical to or is lower than the graphic arrow brake liquid should be injected in till the ceiling level Note During the examination the oil pump body should be parallel with the surface Head lamp Remove the front cover Cut off the switch connecter of the head lamp Remove the head l
100. ue exceeds the standard value replace the magneto coil 1 7 2 Disassembly Disassemble the body guard Remove right body fender Remove fixing bolts and screws and take off fan cover Remove 4 fixing bolts of cooling fan to take the latter off Fix the flywheel with a multiple use fixing spanner Disassemble the flywheel fixing bolt Remove the flywheel with a flywheel puller Disassemble the retaining key Disassemble the lead connector of the alternator Disassemble the alternator stator 75 1 7 3 Installation Flywheel Cooling fan Fan cover Install magneto stator on engine case Connect wire terminals of magneto Clean the tapered part of the crankshaft and flywheel Install the retaining key of flywheel in the key groove on the crankshaft and confirm Align the flywheel groove with the retaining key of the shaft Attention Confirm no bolts are on the inner face of the flywheel because of magnetism of the inner face Fix the flywheel with a multiple use fixing spanner and screw the fixing nut Torque value 9 0 N m Install the left body guard 76 Ignition system 77 AGNETO Ignition system 1 Battery 12 4AH 2 Ignition coil assembly 3 Rectifier 4 Power lock module 5 Igniter 6 Relay 7 Cushion lock module 8 Horn 78 IL Ignition system Preparat
101. ulator contacts range and then measure voltage between conductor end generally red wire or red white wire from connector to battery and negative poorly or opened No voltage Voltage display display available Use an ohm meter to check and measure rectifier or Conductor from connector to rectification regulator for battery opened malfunction 33 Trouble diagnosis program for undercharge of battery Battery is undercharged Check if brake lamp keeps illuminating Y N Adjust or replace brake Set ignition switch to OFF position remove negative cable from battery lamp switch connect negative meter pen of an ammeter to negative terminal of battery and positive meter pen to negative cable and then detect and measure leakage current Leakage current is less than Leakage current is greater than specified value specified value generally it is required that leakage current is not greater than 1mA Check charge coil of magneto for short circuit Circuit between rectifier Y N rectification regulator or battery and ignition switch shorted Replace charge 1 Check if electrolyte inside battery is col insufficient 2 Check if density of electrolyte in battery is too low 3 Check for sulphated or shorted pole plate in battery 34 Electric light is dim Battery level is low or conductor joint connecting battery contacts poorly After start button is depressed engaging soun
102. ure Pressure meter inflator Battery inspection Clearance inspection Gravimeter universal meter General purpose tool examination on the tightness of direction handle General purpose tool Shock absorber inspection Bolt inspection General purpose tool Torque spanner Oil leak inspection of gear case General purpose tool Spark plug inspection or lacement Replacement of gear case oil General purpose tool General purpose tool Lubrication of each part Lubrication filler Muffler General purpose tool Ignition timing Timing lamp Carburator Inspection of idle speed and exhaust gas Tachometer CO HC analyser Accelerator inspection Fuel line inspection General purpose tool General purpose tool Lamplight instruments electric installations Visual universal meter Main rack side rack General purpose tool Shock absorber General purpose tool Torque force of engine bolt 47 Torque spanner Pre inspection Ignition system maintenance and inspection of ignition malfunction of distinct continuity engine failed to start and superheat of afterburning 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 Piston air cylinder excessive wear of air cylinder and cylin
103. urn signal switch contacts poorly check brightness of illuminating lamp can give lamp light off bright light After disconnection illuminating After disconnection lamp light is still comparatively illuminating lamp dim light is set right Check charge coil and internal wiring of charging Flat voltage of system of magneto for short rectification circuit regulator too low Y Check and Disconnect head lamp unit and troubleshoot then check if head lamp bulb glass renders black or yellow green N Y Check if power of bulb used Replace head in lighting system is lamp bulb satisfactory N 1 Check internal contacts of Replace illuminating lighting switch and dimmer lamp bulb switch for poor contact 2 Check connectors and ground wires in system for poor contact 39 Trouble diagnosis program for the malfunction that turn signal lamp does not come on Tum signal lamp does not come on Part of turn signal lamps at None of turn signal lamps at None of turn signal one side does not come on one side comes on lamps comes on Remove turn signal lamp Remove turn signal lamp shade to check tum signal shade to check turn Depress horn button to check operation lamp bulb for burn out signal lamp bulb for of electric horn burn out Electric horn does not make any Electric horn Use a voltmeter Replace Disconnect connector can make loud to measure tum signal of turn signal lamp and clear sound sound or is hoarse
104. value 0 5 5 5KQ 10 20 C 2 6 Trigger Attention paa gt Inspection of the trigger can be conducted on the engine White green ISS 3 Inspection CAAA wa 86 Blue white Disassemble the body guard Disassemble the lead connector of the trigger 87 Measure the resistance value between the blue white terminal Interface of magnetor at the engine side and the body ground Standard value 100 500 20 C DJ7031 2 8 21 If the measured value exceeds the standard value replace the DJ621 2 8x 0 5 alternator 88 Startup system BRAKE SWTCH BRAKE SWTCH STARTER SWTCH STARTCR MOTOR Ad Tg Startup diagram 89 1 Battery 12V 4AH 2 Cushion lock module 3 Horn 4 Rectifier 5 Power lock module 6 Igniter 7 Relay 8 Release resistor 90 IH Startup system Preparation data 3 1 Fault diagnosis 3 2 Start electrical machinery 3 3 Start relay 3 4 3 1 Preparation data Matters needing attention in operation Disassembly of the start electrical machinery may be conducted on the engine Please refer to disassembly operation in disassembly Preparation reference Item Standard value Allowable limit Brush length of startup motor 6 2mm 3mm Liner of startup idler shaft 8 3mm
105. valve component Fixing flange Enriching valve Examine the electric starting valve and the attrition condition of the needle valve If the needle valve is seriously worn electric starting valve components should be replaced Oil needle Screw Top Cover Element spring Element Loosen the bolt and dismantle the upper cover Take out the spring and the plunger components he E Examine the attrition condition of Fuel needle pressing cap the plunger If the plunger is worn down it should be replaced Examine the attrition condition of the needle valve If the needle valve is worn down it should be replaced Loosen screws take off the float chamber Dismantle the float components floater pin and needle valve component 11 3 3 Examination Examine if the needle valve core needle valve and the float components are damaged or worn down If the needle valve core is damaged or worn down it should be replaced If the needle valve seat is worn down then the carburetor body should be replaced If the float tongue piece is worn down it should be replaced Examine the oil needle of the carburetor to see if it is damaged or worn down If so the oil needle as well as the main nozzle should be replaced Examine the idle metering hole the main metering hole and the main nozzle to see if they are damaged worn down or stained If so they should be replaced Examine the plunger to see if it is worn down If so
106. ve the following components from the rear wheel Rear brake 1 Bolt 7 Brake shoe module 4 2 Rear brake rocker arm module 7 8 Brake shoe tension spring 5 3 Nut 9 Outer cover 130 70 12 2 4 Rear indicator 8 10 Rear rim 1 5 Rear brake return spring 9 11 Fixing nut of rear wheel 11 6 Rear brake camshaft 6 12 Scraper seal 12 Note Detailed decomposition map can be seen on P79 5 4 2 Inspection Check brake drum and brake shoe for wear When needed replace Measure thickness of brake shoe and bore of brake drum and take down the maximum values Attention e Be sure to use a micrometer to measure e Measure bore of brake drum and thickness of brake shoe If the thickness of brake pad is less than the maintenance value or it is polluted by grease just replace it Note the brake clutch should be replaced in pairs Bore of rear brake drum 110mm Thickness of rear brake shoe 6 0mm Allowable limit Bore of brake drum 111mm Brake shoe 5 0mm 5 4 3 Installation Install brake shoe module Install rear wheel Reinstall muffler 111 Attention 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 Fixing nut of rear wheel 100 113N 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 Re
107. voltage between lamp bulb switch and then use power cord an ohm meter to contact on lamp detect if turn signal holder and lamp switch is Power suppl negative conductive at from batten p M Battery level runs malfunctionine side normal low Remove turn signal lamp Voltage display No voltage shade to check turn available display Output Internal contact signal lamp bulb for power cord of turn signal burn out at lamp switch malfunctioni contacts poorly ng side opened or lamp holder z eround voor Toggle turn signal lamp switch and Replace turn signal short two terminal lugs on flasher lamp Lamp holder ground poor or poor contact between turn signal lamp bulb and lamp holder ulo with a conductor or screwdriver meanwhile check rectification regulator for improper operation After shorted turn signal lamp After shorted turn signal does not come on yet lamp comes on Disconnect connector of turn signal lamp switch and then Flasher has short power input conductor of turn signal lamp switch and been damaged power supply conductors of left and right turn signal lamps respectively with a conductor After shorted turn After shorted turn signal signal lamp comes on lamp does not come on yet Internal contact of turn Use test lamp method to check power input conductor of turn signal lamp switch poor signal lamp switch for power output Test lamp Test lamp does comes on not come on Power supply con
108. witch The conduction checking of the joint terminal Wiring logic diagram ME L 4 7 2 Replacement of main switch Remove front cover twin lamp panel Remove foot protection plate Disassemble the setscrews unload the fixing pad of the main switch Disassemble the setscrews and replace the main switch 101 4 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 4 9 Handle switch Remove left and right rear view mirrors Remove set screws of left and right combination switches Loosen left and right combination switches Remove right grip module and left steering handle sheath Take off left and right combination switches 102 103 Inspection and Service of Chassis Table of Torques for Fasteners on Chassis Fastening location and name of fastener Tightening torque N m Fixing bolt of oil pump body module 5 9 Mounting bolt of front brake cylinder module 22 29 Fixing bolt of rear brake rocker arm 5 9 Fixing nut of rear wheel 100 113 Fixing bolt of welded module of steering handle 40 60 Lock nut of front wheel spindle 55 62 Front wheel spindle 55 62 Fixing nut of rear wheel 100 113 Top nut of rear shock absorber 37 44 Bottom nut of rear shock absorber 22 29 Fixing bolt of rear shelf support 5 9 Fixing bolt of fuel tank Fixing bolt of helmet bucket Fixing b
109. x12 Check whether the front wheel spindle is loosened Check whether the nuts of rear wheel are loosened If so please tighten to specified torque force value Torque force value front wheel axle clamping nut 100 113 N m rear wheel fixed nut 100 113 N m Direction column bearing and handle fixing Swing the handle to check and confirm whether the leads are interfered Turn the front wheel and swing the handle freely to confirm Check the steering post bearing if the handle is not smooth and loosened 62 63 Inspection and Service of Electrical System Table of Torques for Fasteners in Electrical System Fastening location and name of fastener Tightening torque N m 12 Starting motor clutch cover bolt Fixing nut of starting motor clutch cover Rectifier bolt 5 0 Fixing bolt of ignition coil 9 0 Fixing nut of flywheel 5 0 Body fender bolt 9 0 64 65 tem ing sys Charg 66 1 Battery 12V 4AH 2 Cushion lock module 3 Horn 4 Rectifier 5 Power lock module 6 Igniter 7 Relay 8 Release resistor 67 I Battery charging system Preparation data 1 1 Fault diagnosis 1 2 Battery 1 3 Charging system 1 4 Voltage and current regulator 1 5 Charge coil of
110. xhaust contains toxic gas carbon monoxide which can numb people and may result in death The engine should be started in an open area and the exhaust scavenging system should be applied if the engine has to be started in a closed area Gasoline The operation should be made in a ventilated area and smoking or lighting fires should be strictly forbidden in working space or the place stored gasoline Battery Battery could give off explosive gases so keep it away from incineration area or open flame or where smoking is permissible When charging keep it well ventilated Battery contains sulphuric acid electrolyte which could result in burn if contacting your skin or eye so wear protective clothing and faceshield If electrolyte spatters on your skin use fresh water to flush immediately If electrolyte spatters in your eye use fresh water to flush for more than 15 minutes and see a doctor immediately Electrolyte is toxic In case you drink some electrolyte inadvertently drink a large volume of fresh water milk and milk of magnesia a kind of laxative antiacid or vegetable oil and see a doctor immediately Keep it at a place where is beyond reach of children Maintenance regulation As maintaining this vehicle the instrument of metric system should be applied as possible for the reason that the application of incorrect instrument may demage this vehicle Before dismantling from or frame cover of vehicle to

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