Zhejiang Qianjiang Motorcycle RKV 200 Service manual

RKV 200 Motorcycle
Service Manual
1
ZHEJIANG QIANJIANG MOTORCYCLE CO.LTD.
Content
Content.........................................................................................................錯誤! 尚未定義書籤。
Preface................................................................................................. 錯誤! 尚未定義書籤。
Service Data ............................................................................................................................. 6
Inspection/Adjustment ........................................................................................................... 47
Inspection and maintenance of electrical system ............................................................................ 61
Ⅰ Battery/Charging System ........................................................................................................... 63
1.1 Service Data ..................................................................................................................... 63
1.2 Fault Diagnosis ................................................................................................................ 64
1.3 Battery .............................................................................................................................. 65
1.4 Charging system ............................................................................................................... 66
1.5 Voltage-current regulator.................................................................................................. 66
1.6 Magneto charging coil...................................................................................................... 67
1.7 Magneto Removal ............................................................................................................ 68
Ⅱ Ignition System .......................................................................................................................... 71
2.1 Service Data ..................................................................................................................... 71
2.2 Fault diagnosis ................................................................................................................. 72
2.3 Ignition system inspection................................................................................................ 73
2.4 CDI Assembly .................................................................................................................. 74
2.5 Ignition coil ...................................................................................................................... 75
2.6 Trigger .............................................................................................................................. 76
Ⅲ Starting System .......................................................................................................................... 78
3.1 Service Data ..................................................................................................................... 78
3.2 Fault Diagnosis ................................................................................................................ 79
3.3 Starter Motor .................................................................................................................... 79
3.4 Starter Relay ..................................................................................................................... 81
Bulbs/Switches/Instruments............................................................................................................ 83
4.1 Serivce Data ..................................................................................................................... 83
4.2 Fault Diagnosis ................................................................................................................ 84
4.3 Headlamp bulb replacement ............................................................................................. 84
4.4 Front turn signal lamp bulb replacement.......................................................................... 85
4.5 Tail lamp bulb replacement .............................................................................................. 85
4.6 Instrument ........................................................................................................................ 86
4.7 Main switch ...................................................................................................................... 86
4.8 Electric horn ..................................................................................................................... 87
4.9 Handle switch................................................................................................................... 87
Chassis Inspection and Maintenance .............................................................................................. 88
Ⅴ Braking System .......................................................................................................................... 91
5.1 Maintenance Instructions ................................................................................................. 91
5.2 Fault Diagnosis ................................................................................................................ 92
2
5.3 Front Hydraulic Brake...................................................................................................... 92
5.4 Rear Hydraulic Brake....................................................................................................... 94
Ⅵ Motorcycle Exterior ................................................................................錯誤! 尚未定義書籤。
7.1 Service data ................................................................................... 錯誤! 尚未定義書籤。
7.2 Fault Diagnosis ............................................................................. 錯誤! 尚未定義書籤。
7.3 Front Wheel................................................................................... 錯誤! 尚未定義書籤。
7.4Steering Handlebar ......................................................................... 錯誤! 尚未定義書籤。
7.5 Front Fork ..................................................................................... 錯誤! 尚未定義書籤。
Ⅷ Rear Wheel/Rear Suspension ..................................................................錯誤! 尚未定義書籤。
8.1 Service Data .................................................................................. 錯誤! 尚未定義書籤。
8.2 Fault Diagnosis ............................................................................. 錯誤! 尚未定義書籤。
8.3 Rear Wheel.................................................................................... 錯誤! 尚未定義書籤。
8.4 Rear Shock Absorber/Rear Swingarm........................................... 錯誤! 尚未定義書籤。
8.5 Chain Drive Assembly .................................................................. 錯誤! 尚未定義書籤。
Ⅸ Fuel Tank/Seat Cushion ..........................................................................錯誤! 尚未定義書籤。
9.1 Service Data .................................................................................. 錯誤! 尚未定義書籤。
9.2 Fault Diagnosis ............................................................................. 錯誤! 尚未定義書籤。
9.3 Fuel Tank/Seat Cushion ................................................................ 錯誤! 尚未定義書籤。
Engine Inspection and Maintenance ............................................................錯誤! 尚未定義書籤。
Ⅹ Lubricating System .................................................................................錯誤! 尚未定義書籤。
10.1 Service Data ................................................................................ 錯誤! 尚未定義書籤。
10.2 Fault Diagnosis ........................................................................... 錯誤! 尚未定義書籤。
10.3 Engine Oil Pump ......................................................................... 錯誤! 尚未定義書籤。
Ⅸ Carburetor ...............................................................................................錯誤! 尚未定義書籤。
11.1 Service Data ................................................................................ 錯誤! 尚未定義書籤。
11.2 Fault Diagnosis............................................................................ 錯誤! 尚未定義書籤。
11.3 Removal of Carburetor ................................................................ 錯誤! 尚未定義書籤。
ⅫCylinder Head/Valve ................................................................................錯誤! 尚未定義書籤。
12.1 Service Data ................................................................................ 錯誤! 尚未定義書籤。
12.2 Fault Diagnosis ........................................................................... 錯誤! 尚未定義書籤。
12.3 Cylinder Head ............................................................................. 錯誤! 尚未定義書籤。
12.4 Inspection .................................................................................... 錯誤! 尚未定義書籤。
12.5 Valve Guide Replacement ........................................................... 錯誤! 尚未定義書籤。
12.6 Vavle Race Fixing and Adjustment ............................................. 錯誤! 尚未定義書籤。
12.7 Installation ................................................................................... 錯誤! 尚未定義書籤。
ⅩⅢ Cylinder Block and Piston ..................................................................錯誤! 尚未定義書籤。
ⅩⅢ Cylinder Block and Piston ..................................................................錯誤! 尚未定義書籤。
13.1 Service Data ................................................................................ 錯誤! 尚未定義書籤。
13.2 Fault Diagnosis ........................................................................... 錯誤! 尚未定義書籤。
13.3 Cylinder Block ............................................................................ 錯誤! 尚未定義書籤。
13.4 Piston........................................................................................... 錯誤! 尚未定義書籤。
13.5 Cylinder Installation .................................................................... 錯誤! 尚未定義書籤。
ⅩⅣ Crankcase ............................................................................................錯誤! 尚未定義書籤。
14.1 Service Data ................................................................................ 錯誤! 尚未定義書籤。
3
14.2 Fault Diagnosis ........................................................................... 錯誤! 尚未定義書籤。
14.3 Crankcase .................................................................................... 錯誤! 尚未定義書籤。
14.4 Gearshift Mechanism .................................................................. 錯誤! 尚未定義書籤。
14.5 Crankshaft Connecting Rod Assembly ....................................... 錯誤! 尚未定義書籤。
14.6 Gearbox Assembly ...................................................................... 錯誤! 尚未定義書籤。
Exhaust System Inspection and Maintenance ..................................... 錯誤! 尚未定義書籤。
ⅩⅦ Emission Control System....................................................................錯誤! 尚未定義書籤。
15.1 Emission Control System Guarantee........................................... 錯誤! 尚未定義書籤。
15.2 Periodical Maintenance Instructions ........................................... 錯誤! 尚未定義書籤。
15.3 Mechanical Functions of Emission Control System ................... 錯誤! 尚未定義書籤。
15.4 Solutions to the problem of idle exhaust exceeding specified value (four-stroke)錯 誤 !
尚未定義書籤。
Complete 150-19A Schematic Circuit Diagram…………………………………………- 170-
4
Preface
The service manual contains descriptions of maintenance essentials on QJ
200-2A motorcycle.
Service data include attentions that shall be paid on all the maintenance
operations in the service manual. Please read the manual carefully before
operation.
Check and adjustment contains statements on the main points of
inspection and adjustment, safety of the vehicle, maintenance means of
each component’s performance. This shall be implemented from the time
of periodical inspection.
The parts after Part 1 demonstrate breakdown, assembly and main points
of
inspection of electrics, finished motorcycle, engine and other
components.
System diagrams, breakdown drawings, maintenance, fault diagnosis and
explanation are presented before each part when compiled.
Notes:
If patterns or structures of the motorcycles change, or differences exist
between pictures, drawings, instructions or others and physical products,
please take the later as the standard. The product is subject to change
without further notice.
ZHEJIANG QIANJIANG MOTORCYCLE CO.LTD
5
Service Data
General Safety
Maintenance Regulation
Specification Sheet
Fault Diagnosis
General Safety
Carbon monoxide (CO)
When it is necessary to start the engine, please make sure the workplace is well ventilated. You
shall never run the engine in an enclosed place.
Attention
Gas exhausted from the motorcycle contains toxic carbon monoxide, which may lead to loss of consciousness
and even death.
It is necessary to run the engine in an open area. If the engine is run in an enclosed site, ventilation
system shall be used.
Gasoline
Work in well-ventilated site. Fire and smoking are strictly forbidden in working sites or gasoline
storage places.
Battery
Battery shall be away from spark, open fire and smoking places since it may emit explosive gases.
Keep it in well-ventilated condition while charging.
Battery contains sulphuric acid (electrolyte), which will cause burns when contacting with skin or
eyes. Please put on protection clothing and helmet while handling battery.
——if electrolyte splashes on the skin, flush immediately with water.
——If electrolyte splashes into eyes, flush immediately with water for at least 15mintues and
get a medical examine.
Electrolyte is poisonous. If swallow it by mistake, please immediately drink plenty of water, milk
and milk of magnesia (a kind of laxative antacid) or vegetable oil and get a medical examine.
Keep it out of reach of Children.
6
Maintenance Regulations
While repairing and servicing, try to use tools of metric system as possible as you can. Incorrect
tools may damage the motorcycle.
Before take down or open protecting plate for maintenance work,
please clean the dirt on external surface of the component or the
assembly to prevent the dirt from falling into the engine, chassis or
braking system.
After disassembly and before measuring friction, please clean the
components and purge with air compressor.
Plastic parts may deteriorate due to aging, which are apt to be
damaged by solvent or oil. Check before re-installation and replace
if necessary.
While removing a component with many assemblies, do from outside
to inside. Loosen firstly smaller assemblies; for the complicated
assemblies, such as gearbox, keep them in a proper assembling order
for the sake of easy assembly later.
Pay special attention to the key fitting position before disassembly.
The components that are not used any more shall be replaced on time
before disassembly.
7
Length of bolts and screws are different for assemblies and protecting
plates. They shall be installed at correct positions. If confused, just
put the bolt inside the hole and see if it matches.
Fill lubricating grease into the groove during oil seal installation.
Check if the oil seal is smooth and if it is possible to be damaged
when installed.
Installation of rubber hose (fuel, vacuum, or coolant): insert its
end into bottom of connector so that there is enough room for
the hose clamp to grip the connector. Install the rubber or plastic
dustproof boot back to its originally designed position.
Disassembly of ball bearing: use a tool to push against one or
two (inner and external) bearing races. If the force works only
on one bearing race (whatever inner or external), the bearing
may be damaged when disassembled and it must be replaced.
8
Slack cable implies potential safety hazard on electrics.
Check the next cable when the cable is clamped to ensure
electric safety;
Cable clamp shall not be bent towards solder joint;
Tie the cable at appointed position;
Don’t lay the cable at the end of frame or at the closed angle;
Don’t lay the cable at the tip of a bolt or screw;
Wiring of cable shall be away from heat source or places
where cable may be clipped while moving;
Prevent the cable from being pulled too tightly or slacking
too much when the cable is wired along the handlebar pipe.
The cable shall not be affected by any adjacent components
at any turning place;
The cable shall be wired smoothly and shall not be knotted or
twisted;
Check if sheath of connector is damaged and if connector is
over stretched before butt connection;
If cable runs around the closed angle or the corner, please
protect it with tape or hose;
Tie the cable with adhersive tape reliably after repair;
Controlling cable shall not be bent or twisted. Broken
Controlling cable may result in non-flexible control.
9
Identification of motorcycle
1 . Frame number
① labeled as :
LBBPEM2A********* (Just for reference.
Labeling method may differ due to various
conditions),as shown in Figure 1-1.
2.Frame nameplate is riveted at Position ②, as
shown in Figure 1-1.
Frame
nameplate
adopts
non-European
KEEWAY09 Version. Contents needed to be
filled in the blank on the nameplate are
described as follows:
Model:RKV 200S
Displacement:200ML
Production date:such as 09/2010
Figure 1-1
3. Serial number of engine ① is marked on
the housing of crankcase, as shown in Figure
1-3.
Figure 1-3
Important Notes
1.Please use spare parts manufactured by Zhejiang Qianjiang Motorcycle Co., Ltd. Components
that cannot comply with designed specifications of Zhejiang Qianjiang Motorcycle Co., Ltd. may
result in damage on the engine.
2.Only metric tools can be used for maintenance work. Metric bolts, nuts and screws cannot be
exchanged with inch fasteners.
3.While re-assembling, new washers, O rings, cotter pins and locking plates shall be used.
4.While tightening bolt or nut, please first fasten the ones with great-diameter or internal bolts;
and then tighten gradually to specified torque in diagonal order. Those with special requirements
are not included.
5.Clean removed components with cleaning liquid. Lubricate all the sliding surfaces before
assembly.
10
6.After assembly, check if all the components are correctly installed and can work properly.
7. Remove dirt and oil before measurement; apply recommended lubricant at lubricating positions
at assembly.
8. When the engine and transmission system are disassembled/assembled and needed to be stored
for a long time, please apply lubricant on the surface of the components to avoid rust and dust
deposition.
Special Tools
Special tools mean specially designed tools used at particular places for assembly or disassembly
of certain components on motorcycle. Appropriate special tools are essential for complete and
accurate adjusting and assembling work. Use of special tools can realize safe, reliable and quick
assembly/disassembly of components, working efficiency improvement and labour saving.
1.Tools for engine overhaul
Specially designed tools are required for smooth assembly and disassembly of some components
on the engine.
Special tools and product pictures for engine component assembly and disassembly are listed in
Table1-1 and Table 1-2.
Table 1-1
Name
Remarks
Special socket wrench
Clutch holder
Flywheel extractor
Feeler gauge
Bearing puller
Bearing installer
Oil seal remover
Puller handle
Piston pin puller
Piston ring pliers
Spark plug socket wrench
Clutch thickness measurement
Cylinder bore tester
Dial gauge
Dial gauge, V-block
Micrometer
Valve guide remover
Valve guide installer
Valve clearance adjuster
Valve spring remover
Valve guide reamer
Crankcase remover
Used for disassembly/assembly of flywheel bolt, Figure
1-3
Figure 1-4
Figure1-5
Figure1-6
Figure1-7
Figure1-8
Figure1-9
Figure1-10
Figure1-11
Figure1-12
Figure1-13
Figure1-14
Figure1-15
Measuring inner diameter of piston pin, Figure 1-16
Measuring valve stem deflection, Figure1-17
Measuring OD of valve stem, Figure1-18
Figure1-19
Figure1-20
Figure1-21
Figure1-22
Figure1-23
Figure1-24
Continued Table 1-2
11
Figure 1-3
Figure 1-4
Figure 1-5
Figure 1-6
Figure 1-7
Figure
Figure 1-8
1-9
Figure 1-10
① Handle
12
Figure 1-11
Figure 1-12
① Pliers
Piston
Figure 1-13
Figure 1-14
Figure 1-15
Figure 1-16
Figure 1-17
Figure 1-18
13
②
Figure 1-19
Figure 1-20
Figure 1-21
Figure 1-22
Figure 1-23
Figure 1-24
2.Toes for chassis overhaul
Common and special tools, as well as their pictures for chassis component assembly and
disassembly are listed in Table1-25 and 1-26.
Table1-25
Name
Torque wrench
Allen wrench
Socket wrench
Micrometer
Magnetic stand, V-block
Dial gauge
Venier caliper
Spring criclip pliers
Hammer screwdriver
Front fork oil seal installer
Front fork seal driver
Steering nut wrench
Remarks
Figure1-27
Figure1-28
Figure1-29
Figure1-30
Figure1-31
Figure1-32
Figure1-33
Figure1-34
Figure1-35
Figure1-36
Figure1-37
Figure1-38
(1) General tools used for chassis overhaul
Continued Table 1-26
14
Figure 1-27
Figure 1-28
Figure 1-29
Figure 1-30
Figure 1-31
Figure 1-32
Figure 1-33
Figure 1-34
Figure 1-35
Figure 1-36
(2)Special tools for chassis overhaul:front fork seal driver
15
Figure 1-37
(3)Steering nut wrench
Figure 1-38
3.Tools for electrical components
Special tools and their pictures for electrical component test are listed in Table1-39 and Table
1-40.
Table 1-39
Name
Remarks
Multimeter
Ignition tester
Figure1-41
Figure1-42
Continued Table 1-40
Figure 1-41
Figure 1-42
16
Specifications (QJ200-2A)
QJ200-2A
Engine type
QJ168FML -B
Overall Length(mm)
2080
Fuel
RQ-90
Overall Width(mm)
800
Number of
cylinders
1
Overall height(mm)
1060
Bore*stroke
68×55
Wheelbase(mm)
1350
Total
Displacement
200cc
Starting mode
Electric
Engine
Model
67
Rear
axle
73
Cooling mode
Air cooling and oil
cooling
Total
140
Front
tire
Lubricating
mode
Force-feed and splash
lubrication
100/80-17
Rear
tire
130/70-17
Air cleaner
Paper element
Wet multi-plate
friction type
Fuel tank
capacity
17±0.5L
Gearshift
pattern
Five-speed
gearshift
Carburetor
type
PD31
Transmission
Chain drive
Idle
speed-rpm
1400±100r/min
Battery
capacity/type
12V dry-charged
type
Max. torque
15N.m/7500rpm
Max. power
12.0kW/9000rpm
Weight (kg)
(Curb weight)
Tire
Drive Train
Clutch type
Electrical start
Electricals
Spark plug
Spark
plug
clearance
100W/8000rpm
Compression
ratio
NGK CR9E
Top speed
0.6-0.7mm
ECU-CDI
Brake
Ignition type
Performance
Front
axle
17
Diameter of
front brake
disc
Diameter of
rear brake
disc
9.5:1
100km/h
φ260mm
φ240mm
18
Fault Diagnosis
Engine will not start or is hard to start.
Diagnosis procedures
Engine will not start or is hard to start
Check ignition system
Remove the spark plug and check if electrodes of the plug are connected by carbon.
No
Yes
Perform spark-over test
Clean deposited carbon
Spark is weak between electrodes or no spark at all.
Strong blue or violet spark leaps between electrodes
Screw off spark plug cap, perform high-voltage wire spark
Use an ignition timing lamp to check ignition timing
over test
of engine
No
Strong blue spark leaps
Weak or no spark
Check spark plug and cap
Yes
1. Check CDI ignitor 2.
Loosen drain screw
Check magneto flywheel
of
or
check
trigger
coil
for
looseness.
carburetor
Check ignition
power supply.
Check if wires in
Check
the ignition system
CDI
are
fails.
shorted
or
No
if
ignitor
Check
broken.
Non-contact battery ignition system
compression
pressure in the cylinder
Check oil in
with a pressure gauge.
the fuel tank.
Non-contact magneto ignition system
Compression
Compression
pressure
1. Check electric quantity
1. Check if ignition
pressure
of
power supply coils are
the
battery; 2.Check if
in
cylinder
the
circuit
is
shorted or broken; 2.
shorted;
3
Check if trigger coil is
Yes
No
in
cylinder
is low.
low-voltage
overflow
pipe is clogged
Yes
Check
if
ignition coil
is shorted
or broken.
if
and
Refuel
is normal.
gasoline
broken
or
Check if trigger coil is
shorted or broken.
shorted or broken.
19
1.
Remove
spark
plug
and check.
Check
leakage
at
1. Check if breather on
external connection parts
the fuel tank cap is
of engine; 2.Check valve
clogged; 2. Check if
timing; 3. Check if valve
fuel
clearance is too small; 4.
switch are clogged; 3.
Check tightness between
Check if fuel switch
valve and valve seat;
works
5.Check if piston ring is
Check if oil intake of
stuck
inside
groove
or
filter
and
fuel
normally;
4.
the
ring
carburetor is clogged;
of
less
5. Check if carburetor
elasticity; 6. Check wear
float is too high.
and tear of piston ring
and cylinder.
Electrodes of spark plug are dry.
Electrodes of spark plug are wet.
Drop a little gasoline into the cylinder for a trial start.
Check overflow of carburetor
Yes
1.
Check
if
foreigh
there
is
substance
between
and
No
needle
valve
Check if air filter
is clogged.
valve
seat
of
carburetor float so that it
cannot
be
Check
if
closed;
the
Engine
can
Engine stalls when it
continue
to
run
runs a very short
when it is started.
time.
2.
conical
Carburetor
surface of needle valve of
carburetor float is worn
into a step form; 3. Check
Carburetor
is
starter
clogged
or
cranking
inside
float is too high.
if the float is broken; 4.
enrichment
system) fails.
Check if float is too low.
20
(i.e
Symptom: Engine Overheats
Diagnosis procedures
Engine Overheats
Check for improper operaton method
No
Yes
1. Check if gasoline grade being used is too
Check cooling system
low or the gasoline has been stored for a too
long time; 2. Check if engine runs at a high
speed for a very long time or overloaded
Oil cooling the engine
Air cooling the engine
Check if radiator plates are covered by too much mud, greasy oil or sand
Start the engine. When the temperature of the
engine is higher than the fully opened thermostat,
Yes
No
Clean
feel temperature of radiator and engine by hand.
Check if cooling fan or wind
scooper is damaged (forced
Basically temperature of
air cooled engine)
radiator
Temperature of radiator is lower
and
engine
is
than that of engine.
consistent.
Oil cooling system works
normally.
Yes
Check and solve
the problem.
No
Cycling of oil cooling system is bad.
Use an ignition timing lamp to
1. Check if radiator plates are
check ignition timing of engine.
seriously crushed or distorted;
2. Check if there is too much
No
Yes
mud,
greasy
oil
or
sand
sticking to the radiator;
3. Check if the radiator cover
1.
Check
CDI
Check if clutch slips.
works normally;
Check the engine oil capacity
ignitor. 2. Check
4.
magneto flywheel
works normally.
Check if the cooling fan
in the radiator.
or trigger coil for
looseness.
Yes
No
Insufficient engine oil
No engine oil inside.
inside.
Engine
oil
in
the
system is not enough.
21
Remove the spark plug and check
Clutch slips
Handle it as Item 1.7.
Skirt section of insulating part is black and when the
color of skirt section of insulating
1.
part and other abnormalities to judge
normally; 2 Check if thermostat
mixture ratio of combustible gas
works perfectly; 3. Check if oil pipe
mixture.
in the system is clogged.
Skirt section of insulating part is brown
Check
if
oil
pump
works
Skirt section of the insulating part of spark plug is
engine runs at middle or low speed,,exhaust muffler
white. While it is accelerated, the engine generates
gives off black smoke or explodes, acceleration
Mixture ratio of combustible gas mixture
an interval, there is explosion in the carburetor
capability is poor, idle speed is unstable and the engine
is normal.
and power of the engine is insufficient.
is apt to stall; but it runs normally at high speed.,
Combustible gas mixture concentration is too high.
Check if exhaust of cylinder
Check lubricating
Combustible
and exhaust muffler is clogged
system
concentration is too low.
gas
mixture
due to carbon deposition.
1. Check if air cleaner is clogged; 2.
Check
if
Carburetor
starter
(i.e.
1.
4-stroke
Check if the fuel
engine
cranking enrichment system) works
switch works normally; 2.
lubricating system
normally;
3.
Check
if
float
of
check
carburetor is too low.
if
float
of
carburetor is too high; 3.
Check if the gauge holes
1. Check if there is enough engine oil
and hole channels are
in
the
crankcase;
viscosity
of
engine
2.
Check
oil
in
if
the
crankcase is too low or the oil is
badly
contaminated;
3.Check
if
engine oil filter is clogged; 4. Check if
engine oil pump works normally; 5.
Check if lubricating pipe is clogged.
22
clogged.
Symptom: Engine lacks power
Diagnosis procedures
Engine lacks power
Lift it with main stand to have the wheels off the ground. Rotate wheels by hands.
Wheels rotate freely.
Wheels rotate inflexibly.
Check tire pressure
1. Check braking drag; 2. Check if
bearing of wheels are over worn or
injured; 3. Check if the middle spacers in
Air pressure too low
the hub are missed or a little shorter.
Air pressure normal
Check if valve core leaks
Remove spark plug and block the screwhole of spark plug with a
or tyre is broken.
finger. Press starter button or kick starter pedal.
Finger cannot feel strong air blasting out.
Finger can feel strong air blasting out
and meantime make a pitpat sound
Compression pressure in the cylinder is not enough.
Compression pressure in the cylinder is normal.
1. Check leakage at external
Start engine and accelerate gradually and
connection
observe variation of engine RPM.
2.Check valve timing; 3. Check if
parts
of
engine;
valve clearance is too small; 4.
Check tightness between valve
Engine RPM increases with acceleration.
Engine RPM does not increase with acceleration.
and valve seat; 5.Check if piston
ring is broken or stuck inside the
ring groove or of less elasticity; 6.
1.
Check
if
clutch
slips;
2.
Check
if
transmission belt is excessively worn; 3.
Use an ignition timing lamp to check
Check wear and tear of piston ring
ignition timing of engine
and cylinder.
Check if the centrifugal roller of driving wheel
Yes
is excessively worn; 4. Check if conical
surfaces of driving wheel and mobile friction
wheel is excessively worn or worn to groove;
5. Check if conical surface of driven wheel
and mobile driven wheel are excessively worn
or worn to groove; 6. Check if raceway on the
inner end face of friction wheel is excessively
No
1. Check if fuel supply system is smooth;
1.
2. Check if carburetor, air cleaner and
ignitor. 2. Check
exhaust muffler are clogged; 3. Check if
magneto flywheel
vacuum diaphragm of plunger valve on
or trigger coil for
carburetor is cracked or broken;.
looseness.
worn or pitted due to crush.
23
Check
CDI
Symptom: Poor idle speed of engine
Diagnosis procedures
Poor idle speed
Engine has no idle speed.
Higher idle speed
Unsteady idle speed
Pull throttle valve of carburetor by hand
Use an ignition timing lamp to
and see if it is completely closed.
check ignition timing of engine
Check compression pressure in cylinder
Yes
Insufficient compression
Yes
N0
compression pressure
pressure in cylinder
is
too big.
Engine still has no
Engine has idle speed
after adjustment.
idle
speed
after
if clearance of spark plug is
Re-adjust carburetor
idle speed.
idle
Check
of
1. Check leakage
at
external
connection parts
of engine; 2.Check
valve timing; 3.
Check if valve
clearance is too
small; 4. Check
tightness between
valve and valve
seat; 5.Check if
piston
ring
is
broken or stuck
inside the ring
groove or of less
elasticity; 6. Check
wear and tear of
piston ring and
cylinder.
Check
if
throttle control
cable can pull
flexibly in the
cable jacket
and if throttle
spring is too
soft
Check if jet
too small.
in cylinder is normal.
Yes
Air adjusting screw
of
carburetor
throttle
or
ignitor. 2. Check
if
magneto
flywheel
trigger
or
coil
looses.
No
Check if carburetor idle
Adjust
clearance
Check
mixture
jet, idle oil path and air
adjusting
screw is improperly
between electrodes.
ratio
of
path are clogged
combustible gas
adjusted.
No
mixture.
Yes
Check if float is too high.
float
1. Check CDI
adjustment
Yes
Adjust
No
Clean and dredge.
No
to
1.Check if carburetor insulator is cracked; 2. Check if
standard height.
connecting and fixation nut on carburetor looses; 3.
Check if negative pressure hose on fuel switch is
broken; 4. Check if leaf valve leaks air.
24
Symptom: Too much fuel consumption by the engine
Diagnosis procedures
Too much fuel consumption
Check operation method
Yes
No
Lift it by main stand, rotate wheels by hands
1. Check if motorcycle is driven
overspeed or not at economical
speed or driven at low gear; 2.
Wheels rotate inflexibly.
1.
Check
Check if gasoline grade being
Wheels rotate freely.
braking
used is correct.
Check tire pressure
drag; 2. Check if
bearing
of
wheels
are over worn or
Air pressure too low
injured; 3. Check if
middle
spacers
Air pressure normal
in
the hub are missed
Gas up as specified.
or a little shorter.
Check if fuel tank, fuel switch, delivery pipe
or carburetor leaks oil.
Yes
No
Exclude as practice.
Mixture ratio is normal.
Check mixture ratio of combustible gas mixture.
Concentration is too high.
Check if idle speed of engine is too high.
Yes
No
Check and adjust
Use an ignition timing lamp to
carburetor.
check ignition timing of engine
Yes
1. Check if air cleaner is
1. Check if carburetor
clogged; 2. Check if float
is clogged inside; 2.
of carburetor is too low;
Check if float is too
3. Check if main jet of
high.
carburetor is too big.
No
Check if transmission belt
Check ignition system.
of cluth slips.
25
Concentration is too low.
Symptom: Clutch slips
Diagnosis procedures
Clutch slips
Manually controlled wet multi-plate clutch slips
Automatic centrifugal shoe-type clutch slips
Check if braking shoe of shoe-type clutch is contaminated by oil
Check if clearance of clutch handle
bar is within 10mm~20mm.
No
No
Yes
Check if throttle control cable can
Re-adjust
pull flexibly in the cable jacket.
Check if braking shoe
Clean
is excessively worn.
dirt
No
No
Check if engine oil in the
replace
crankcase is less.
Yes
engine
oil.
oil.
Yes
Check if contact area between
Replace
braking shoe and friction disc
whole
is less than 70%.
clutch shoe.
No
No
Check if viscosity of engine oil in the
crankcase is too low or the oil is
badly contaminated
Yes
Replace
greasy
Yes
Clean, lubricate or
Refill
Yes
No
engine
Repair
between braking shoe
replace
and friction disc is worn
shoe.
1. Check if adjusting screw for clutch
push rod is properly adjusted; 2. Check if
down bolt for clutch spring is loose; 3.
Check if braking shoe of clutch is burnt or
excessively worn; 4. Check if elasticity of
clutch spring is enough; 5. Check if the
contact end face between driven hub,
pressure plate and braking shoe is over
worn. 6. Check if splines on clutch driven
and drive hubs are worn into zigzag form.
26
set
of
Yes
Check if contact area
terribly.
the
or
clutch
Symptom: 4-stroke engine exhaust muffler gives off blue-white smoke
procedures
Diagnosis
4-stroke engine exhaust muffler gives off blue-white smoke
Check if engine oil level in the crankcase exceeds the upper limit line
Yes
No
Too much engine oil in the crankcase, bleed surplus oil
Start engine and run it at high speed; screw off
and decline oil level to upper limit line.
oil ruler and check if oil filler smokes.
No
Yes
Check if clearance between valve
1.Check if cylinder, piston or
and valve guide is too big.
piston ring is over worn; 2.
Check if elasticity of piston ring
Yes
No
is not enough or stuck in the ring
groove; 3. Check if openings of
Check if valve or valve guide is over worn.
Valve
oil
seal
is
damaged.
Symptom: Incomplete separation of clutch
Diagnosis procedures
27
piston ring are staggered with
each other.
Incomplete separation of clutch
Check if clearance of clutch handle bar is within 10mm~20mm.
No
Yes
i
Re-adjust
Check if adjusting screw for clutch push rod is properly adjusted
No
Yes
.
Check if elasticity of clutch spring is even.
Yes
Re-adjust
No
Check if splines on clutch active and drive hubs are worn into zigzag form
Replace the whole set of clutch
Yes
Repair or replace
No
spring.
1. Check if clutch driven plate is warping and distorted; 2. Check if
separation cam shaft, separaton push rod and other components of
clutch control mechanism are excessively worn.
Symptom: Difficult gearshift on transmission
Diagnosis procedures
28
Difficult gearshift on transmission
Start engine and check if idle is too high.
No
Yes
Readjust
Check if the operation is harmonious at gearshift.
Yes
No
Check if cluth is completely separated.
No
Yes
Check if gearshift box is distorted and shift lever is deformed or overworn.
Yes
Improve operation method.
1. Check if clearance of clutch handle bar is
within 10mm~20mm; 2. Check if elasticity of
No
clutch spring is even; 3. Check if splines on
Replace
1. Check if groove of gearshift
camshaft is over worn or injured; 2.
Check if shift fork hole is excessively
worn; 3. Check if shift fork is
deformed; 4. Check if fork shaft is
distorted or overworn.
29
clutch active and drive hubs are worn into
zigzag form; 4. Check if clutch driven plate is
warping
and
distorted;
5.
Check
if
components of clutch control mechanism are
excessively worn.
Symptom: Jumps of gear on the transmission
Diagnosis procedures
Jumps of gear on transmission
Check if spring of position wheel is broken or of insufficient elasticity.
Yes
Replace
No
Disassemble crankcase and check if meshing depth of each gear meets requirement.
Enough meshing depth
Insufficient meshing depth
Check if meshing end of cam pawl on end face of meshing
gear is worn or forms great roundness; and if corresponding
gear end groove is worn or like a horn mouth.
Yes
Check if shift fork is overworn.
No
No
1.Check if fork hole and fork shaft
Replace
gears.
Yes
Check if spline gear of main
shaft and counter shaft, or
spline groove of sliding
gear is overworn.
are overworn; 2. Check if matching
clearance between fork pin and cam
groove of shift gear shaft is big. 3.
Check if transmission is correctly
installed.
30
Replace fork.
Symptom: Drum-type brake fails
Diagnosis procedures
Drum-type brake fails.
Check if clearance of brake handle bar is within 10mm~20mm
or clearance of brake pedal within 20mm ~ 30mm range.
No
Yes
Re-adjust
Brake
rocker
arm
rotates
Separate cable of brake rocker arm from brake control cable. Move rocker arm by hands.
Rocker
Arrow on the indicating board
Arrow on the indicating board of cam doe
freely but there is resistance
arm turns
of cam aims at or exceeds“▽”
not align to the“▽” mark on hub cap.
feeling from brake handle.
inflexibly.
mark on hub cap.
制动凸轮上指示牌上的箭头未对准制动毂盖
上的“▽”标记
1.Check if there is oil adhered to
Brake
control
cable
Movable
parts
1. Check if crown face of brake cam
surface of brake shoe friction d
does not pull flexibly in
of
brake
cam
is over worn; 2. Check if brake shoe
2.Check if contact area betw
the jacket.
rusts or is stuck
friction disc is over worn; 3. Check if
braking shoe and friction disc
by
bore of brake hub is excessively
less than 70%
foreign
substances.
worn.
Symptom: Hydraulic disc brake fails
Diagnosis procedures
Hydraulic disc brake fails
Check brake liquid level in the liquid tank of main brake pump
Brake liquid level is lower than lower limit line of tank.
Refill brake liquid to
Brake liquid level is higher than lower limit line of tank.
If there is sponge-like feeling while operating brake handle.
the upper limit line of
tank,
meantime,
Yes
No
check if oil leaks at
brake caliper, brake
hose
and
connector.
hose
Check if brake shoe has been worn to the limit mark and brake disc is overworn.
Yes
No
Air
contained
in
the
hydraulic brake system.
Replace brake shoe
1. Check if piston surface of main brake pump and cylinder wall surface are
and brake disc.
over worn or injured; 2.Check if piston cup of main brake pump is damaged,
cracked or aged; 3. Check if sealing ring of brake caliper is damaged,
cracked or aged; 4.Check if piston surface of brake caliper and cylinder wall
31
surface are over worn or injured.
Symptom: Battery can not be charged
Diagnosis procedures
Battery can not be charged.
Disconnect connectors of magneto lead wire tied to the cables of the whole motorcycle.
Measure with an Ohmmer resistance between output wires from charging coil.
Resistance is less than standard.
Resistance meets the standard.
Resistance is infinitely great.
Connect connectors of magneto lead wire harness to the
Charging coil is shorted.
cables of the whole motorcycle; break off connectors of rectifier
or regulator to cables of the whole vehicle.
Charging
output
coil
wires
shorted.
Measure in the connectors with an Ohmmer resistance
between output wires from charging coil and check if the result
is in accord with the resistance of the charging coil itself.
Yes
No
Set multimeter on 0V~20V DC voltage, measure the
Wire from magneto to rectifier or wires
voltage between connector to the battery wire terminal
among rectification regulators are not well
(usually a red or red/white wire) and the ground.
connected or broken.
No voltage display
Wire
from
connector
Voltage displays
to
Check with an Ohmmeter if rectifier or
rectification regulator fails.
battery is broken.
32
or
its
are
Symptom: Battery cannot be fully charged
Diagnosis procedures
Battery cannot be fully charged.
Check if braking lamp is always on.
Yes
No
Adjust or replace braking
Set ignition switch to “OFF” position, disconnect negative wire from battery, and then put
lamp switch.
negative probe of ammeter onto the negative terminal and positive probe on the
negative wire to check current leakage.
Leaking current is smaller than specified.
Leaking current is bigger than specified(usually
It shall be no more than 1mA.)
Check if charging coil of magneto is shorted.
Wire
from
rectifier
or
rectification
regulator of battery to ignition switch is
Yes
No
Replace charging coil
shorted.
1. Check if electrolyte in the battery is
not enough.
2. Check if density of electrolyte in the
battery is too low.
3. Check if plates in the battery is
vulcanized or shorted.
33
Symptom: Starter motor does not run
Diagnosis procedures
Starter motor does not run.
Turn on ignition switch; press horn button or slide
turn signal lamp switch.
Electric horn does not sound or sound
Electric
horn sounds loudly.
weakly. Turn signal lamp is dim.
Turn signal lamp is bright.
Battery is low or the wire terminal
Grasp brake handle bar (autoscooter), or shift
connected with battery is poorly
transmission into neutral, or grasp clutch handle
contacted.
bar, push starter button.
Push starter button and the click from starter
Push starter button and a click from
relay cannot be heard.
starter relay can be heard.
Disassemble the connector of starter relay from cables of
Use a screwdriver or a piece of thick wire to
the whole vehicle; connect the two hatching wires from
connect battery terminal on the starter relay with
relay coil to negative and positive terminals of battery with
starter relay terminal.
two pieces of wires.
After
connection,
the
starter motor does not
After
connection,
starter motor works.
After
stater
short
motor
normally
run either and no click
sound can be heard from
starter relay.
34
circuit,
runs
After
short
circuit,
stater motor does not
run.
Coil in starter coil
Check wiring in electrical
Contact of stater
is
starter control system
relay is burnt or
broken
or
shorted.
Disassemble starter motor and
make the following inspections:
1.Check if the carbon brush is
over worn;
2. Check if carbon brush spring
is broken or weak.
3.
Check
if
armature
commutator is over worn.
4. Check if armature coil is
broken or shorted.
injured.
Striding Motorcycle
1.Check if contact inside clutch
switch is poorly contacted;
2. Check if starter button contact is
poorly contacted;
3. Check if rectifier diode is
damaged;
4. Check if neutral gear switch works
abnormally;
5. Check if wiring of electrical starter
system is broken or shorted.
Autoscooter
Grasp brake handle and check
if braking lamp is on.
Yes
No
Check if starter button contact
Inner contact of brake lamp switch is
is poorly contacted
poor contacted or matched wire is
broken.
Yes
Repair
or
No
Wiring of electrical starter system
is broken or shorted.
replace
starter button.
35
Symptom: Starter motor runs weakly
Diagnosis procedures
Starter motor runs weakly.
Turn on ignition switch; press horn button or slide
turn on signal lamp switch.
Electric horn does not sound or sound
Electric horn sounds
loudly.
weakly.
Turn signal lamp is bright.
Battery is low or the lead wire
Check if the lead wire connector from starter relay
connector connected with battery is
to starter motor is poorly contacted.
badly contacted.
No
Yes
Remove the starter motor lead wire and battery connecting
wire from starter relay, press starter button; when starter relay
gives a click sound, measure with an ohmmeter resistance
between battery terminal on the relay and starter motor
Check if starter button
contact
contacted.
terminal and check it for breakover.
Yes
No
Disassemble starter motor and make the
Starter relay contact is
burnt or injured.
following inspections:
1. Check if the carbon brush is over worn;
2. Check if carbon brush spring is broken or
weak.
3. Check if armature commutator is over worn,
burnt, or injured, or contaminated.
36
is
poorly
Symptom: All the lights are not on
Diagnosis procedures
All the lights are not on
AC power supplied lighting system
DC power supplied lighting system
Separate conductors of lead wire bundle of magneto from
the cables of the whole vehicle. Check if there is power
Press horn button or slide turn signal light.
output from lighting coil of magneto by lamp test method.
Test lamp is not lit
Lighting
magneto
coil
or
Test lamp is lit.
of
its
Start
engine
connectors
and
of
Electric horn sounds loudly
Electric horn does not sound
and turn signal light is lit.
and turn signal light is not lit.
separate
rectification
regulator from cables of the
output
wire
is
Normal
supply
power
from
quickly
positive
and
negative
terminal of battery to check spark.
battery
whole vehicle.
Use a piece of wire to touch
broken or shorted.
Lights are lit.
Lights are not lit
No spark at touch
Spark at touch
Short circuit inside
Battery is out
1.
Check if fuse is burnt;
rectifier
of power.
2. Check wiring between
battery and ignition switch
Disassemble headlamp assembly
for short circuit and break
and check if the bulb is burnt.
3. Check if ignition switch is
broken or shorted.
37
Yes
No
Replace headlamp bulb and
Check if there is power output from power
check other bulbs one by one.
input wire of light switch by lamp test
Yes
Use a piece of wire to short circuit power line and
output line of lighting switch.
No
Wiring from magneto or ignition
switch to lighting switch is broken
or shorted.
Lamp is lit after short circuit.
Inner contact of lighting switch
is poorly contacted.
Lamp is still not lit after short circuit.
Wiring from lighting switch to lamp
is broken or shorted.
38
Symptom: Light bulb is apt be burnt
Diagnosis procedures
Light bulb is apt to be burnt.
Turn on ignition switch; press horn button
or slide turn signal lamp switch.
Electric horn does not sound or sound
Electric horn sounds loudly.
hoarse. Turn signal lamp is dim.
Turn signal lamp is bright.
1. Check if the connector to the battery is poorly
Separate conductors of rectification regulator from
contacted;
cables of the whole vehicle. Measure and check with
2. Check if electrolyte in the battery is not enough.
an ammeter if wirings between lighting and charging
3. Check if density of electrolyte in the battery is
coil of magneto and regulator are broken.
too low; check if the base plate inside the battery
is vulcanized or broken.
Yes
No
Set multimeter on 0V~20V DC voltage, measure the
Connect well the
voltage between the wire from connector to battery
broken wire.
terminal (usually a red or red/white line) and the
ground.
No voltage displays.
Voltage displays.
Wiring from connector to
battery is broken.
39
Check if regulator malfunctions.
Symptom: Headlamp is dim.
Diagnosis procedures
Headlamp is dim
AC power supplied lighting system
DC power supplied lighting system
Separate conductors of lead wire bundle of magnet from
Turn on ignition switch; press horn button
cables of the whole vehicle. Measure and check with an
or slide turn signal lamp switch.
ohmmeter if resistance between lead wire section output
from magneto lighting coil is smaller than the standard.
Yes
No
Electric horn sounds hoarse.
Lighting coil is
Start engine and limit its RPM. Separate
shorted.
Turn signal lamp is dim.
conductors of rectification regulator from the
cables of the whole vehicle. Check brightness of
headlamp.
Battery is low or the connection
position between ignition switch
and battery is badly contacted.
Headlamp light recovers
Headlamp light is still
after separation.
dim after separation.
Electric
horn
sounds
loudly. Turn signal lamp
Stable
voltage
of
Check
if
charging coil
rectification regulator is
magneto and wirings in the
too low.
charging system are shorted.
Yes
is bright.
of
No
Check and solve the
Disassemble headlamp assembly and check if
problem.
the bulb glass black or yellowish-green.
40
No
Yes
Check if power of bulb in the lighting
system is up to the requirement.
Yes
No
1. Check if headlamp switch
Replace bulb.
and contact in the switch is
poorly contacted;
2. Check if connectors and
earthing
wire
are
poorly
contacted.
41
Replace the bulb.
Symptom: Turn signal lamp is off.
Diagnosis procedures
Turn signal lamp is not on.
Some of the turn signal lamps on one
side is not on.
All the turn signal lamps are not on.
All the turn signal lamps on
one side are not on.
Take down the turn signal lamp
Take down the turn signal lamp
Press horn button and
cover and check if the bulb is burnt.
cover and check if the bulb is burnt.
check
No
Yes
Measure
Replace
turn signal
voltage
Electric
between
power line contact of lamp
holder and the ground with a
lamp bulb.
No
Yes
Replace
Separate connectors of
turn signal
turn signal lamp, measure
and
lamp bulb.
check
with
Electric
horn
or
sounds loudly
an
horn
does not sound
sounds
hoarse.
ohmmeter if turn signal
voltmeter.
lamp switch is conductive
Power
on faulty side.
supply
from
Battery
battery is normal.
is
low.
No voltage displays
No voltage displays
No
Yes
Take down the turn signal
lamp cover and check if
Power
Grounding wire of lamp
Power line to
holder
the
is
of
poor
contact or bulb of turn
holder
signal lamp is badly
broken.
contacted
with
lamp
line
on
Inner contact
the troubled side
of turn signal
is
lamp is poor.
lamp
broken
or
the bulb is burnt.
is
grounding
wire
of lamp holder is
poorly contacted.
No
holder.
Yes
Slide turn signal lamp switch and short circuit it with a piece of
Replace turn signal lamp
wire or a screwdriver two lugs of scintillate.
bulb and check if regulator
works normally.
Turn signal lamp is still off after short circuit.
Turn signal lamp is still on after short circuit.
42
Separate connectors of turn signal lamp switch and use
Scintillator is damaged.
a piece of wire to short circuit respectively power input
line of the switch and power lines output to left and right
turn signal lamps.
Turn signal lamp is on after short circuit.
Turn signal lamp is still off after short circuit.
Inner contact of turn signal lamp is
Check if there is power output from power input line of
poorly contacted.
turn signal lamp switch by lamp test
Test lamp is on
power line of turn signal lamp
is broken or shorted.
Test lamp is off
Wire
from
ignition
switch
to
scintillator or from scinllator to turn
signal lamp switch is shorted or
broken.
43
Symptom: Electric horn mutes.
Diagnosis procedures
44
Electric horn mutes.
Turn on ignition switch; slide turn signal
lamp switch and check.
Turn signal lamp is not lit or dim.
Turn signal lamp shines brightly.
Battery is low or the wire from battery
Power supply from battery is normal.
to ignition switch is broken or shorted.
Pull out power line from power terminal of electric horn; touch
the power line quickly with ground wire to check spark.
Spark at touch
No spark at touch
Connect well the power line of horn; use a
Power line between ignition switch
screwdriver to connect non-power terminal
and electric horn is broken.
(terminal to button) of horn with ground wire.
Electric horn sounds after connection.
Electric horn does not sound after connection.
Inner contact of horn is poorly
Adjust volume and tune of horn.
contacted or the wire from
horn to button is broken.
Horn does not work after adjustment.
Horn is damaged.
45
Horn works normally after adjustment.
Horn is improperly adjusted
Symptom: Brake lamp does not work.
Diagnosis procedures
Brake lamp does not work.
Take down cover of brake lamp and check if bulb is burnt.
Yes
No
Replace bulb
Use a piece of wire to short circuit two terminals of
brake lamp switch or plugs of two hatching lines.
Lamp is not lit after short circuit.
Brake lamp is lit after short circuit.
Use a screwdriver or a piece of wire to touch
Brake lamp switch is not
quickly power line of brake lamp switch and
properly adjusted or its
grounding wire and check sparks.
inner contact is not well
contacted.
Spark at touch
No spark at touch
Wire from brake lamp
Power line from ignition
switch to brake lamp is
switch to brake lamp switch
broken or shorted.
is broken or shorted.
46
Inspection/Adjustment
Basic data
Compression pressure of cylinder
Periodic maintenance schedule chart
Engine oil/filter
Engine oil
Replacement of engine oil
Steering stem bearing and handlebar fixation
Throttle cable adjustment
Drive chain slackness
Front/rear brake clearance
Air cleaner
Headlamp
Spark plug
Clutch
Battery
Front/rear suspension
system
Carburetor
Bolt/nut/fasteners
Ignition timing
Tire specification
Wheel rim/tire
Basic Data
General Precautions
Warning!
•Before running the engine, please make sure if the workplace in is well ventilated. You shall
never run the engine in an enclosed site. Gas exhausted from the motorcycle contains carbon
monoxide, which may lead to loss of consciousness and even death.
• Under certain conditions, gasoline is highly volatile. Work in well-ventilated site. Fire and
smoking are strictly forbidden in working sites or gasoline storage places.
47
Specifications
Engine
Idle speed
1400±100r/min
Spark plug clearance
0.6-0.7mm
Spark plug type
CR9E
Combustion chamber
Spherical
Ignition time(angle of before top dead center)
1500RPM:15°CA/4000RPM:35°CA
Frame
Clearance of front brake handle
10-20mm
Clearance of rear brake pedal
20-30mm
Specification
Pneumatic pressure unit of tire:Kpa
Torque
Tire Pressure
Front wheel
100/80-17
190±10kPa
Rear wheel
130/70-17
210±10kPa
QJ200-2A
Rear wheel locknut
85-98 N·m
48
Periodic maintenance schedule chart
Mileage and
interval
Every
300 KM
Every
1000K
M
Every
3000
KM
Every
6000K
M
Every
12000
KM
Every
14500
KM
New
Vehicle
One
month
three
months
Six
months
Twelve
months
Fifteen
months
C
C
R
C
Tools
Items
*
Air cleaner
I
*
Gasoline filter
I
I
R
Common tool
*
Engine oil filter
C
C
C
Common tool
R
Replace every 5000KM.
Common tool
Engine oil Replacement
Tire gauge, air
inflator
Densimeter,
multimeter
Tire pressure
I
I
I
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Battery inspection
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Common tool
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Common tool
Actuating clearance
inspection
Inspection of steering
handle bar looseness
Shock absorber actuating
inspection
Inspection of looseness of
bolts at all positions
Check if gearbox leaks oil
*
Common tool
Spark plug inspection and
replacement
Lubrication of all the
places on the vehicle
Muffler
Common tool
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Torque wrench
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Common tool
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R
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Common tool
L
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Lubricant injector
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Common tool
Timing light
*
Ignition timing
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Carburetor
Idle exhaust gas
inspection
Throttle inspection
Fuel hose inspection
Lamps, instrument and
electric apparatus
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Tachometer,
CO HC analyzer
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Common tool
Common tool
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Visual multimeter
Main stand and side stand
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Common tool
Common tool
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Torque wrench
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Common tool
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Common tool
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Common tool
*
*
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Shock absorber
*
Torque of engine bolt
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Front/rear brake
Drive chain
Clutch
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*
Valve
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Feeler gauge
Expected Inspection
1
Ignition system—-perform maintenance inspection on obvious and continuous ignition
malfunctions, engine on fire, overheated back burning and others.
2
Carbon deposit removal—-obvious underpower, get rid of carbon deposited at cylinder head,
piston head and air exhaust system.
3
Piston and cylinder—-When cylinder is over worn or stuck, please replace it.
Please go to your local Qianjiang Motorcycle dealer periodically for inspection and adjustment to
keep your vehicle in best conditions.
In above table, monthly 1000km travel is employed as reference.
I— Inspect A—Adjust R—Replace C—Clean L—Lubricate
Note:1.“*” for items involved in exhaust gas, which meets regulations of China Environmental
Protection Agency. Normal maintenance shall be performed according to specifications on the
user’s manual; unauthorized repair and adjustment are forbidden. We will not be responsible for
the results.
2. You shall clean more frequently the air cleaner to extend its service life when your
motorcycle is used on sand-gravel roads or in severely polluted environment.
3. More frequent servicing may be required when the motorcycle is often driven at a high
speed or travels a long distance.
Engine oil/Oil filter
Engine oil level
*Attention
• Motorcycle shall stand on the flat ground while checking engine oil
level.
•Inspect engine oil level when the engine has run for 2~3mintues and
stopped for 2~3minutes.
Check engine oil level.
When the engine oil level sensor alarms, refill engine oil to its upper limit.
Engine oil replacement
*Attention
When the engine is warm, replace engine oil. The oil can flow out easily.
Shut down the engine.
Screw off the drain plug at the bottom of crankcase to drain engine oil.
50
When the engine oil is completely drained, put back cleaned drain plug and sealing ring.
Refill engine oil to specified level.
Check if there is engine oil leakage. Start the engine and run the engine on idle for a few minutes.
Check engine oil level again.
Throttle cable adjustment
*Attention
Adjust properly engine idle before adjustment of throttle cable clearance.
Check clearance of throttle cable,
clearance shall be 3-5mm.
If the clearance is not up to the
specified, adjust it.
Adjust clearance of throttle cable.
Procedures:
Loosen locknut.
Rotate adjusting nut inward or outward
till it achieves specified clearance.
Rotate inward to increase clearance;
rotate outward to reduce clearance.
Tighten locknut.
When the clearance is adjusted, rotate handle leftward and rightward to make sure idle of engine
does not change.
Air Cleaner
Replace air cleaner.
Take down the left protecting plate.
Remove air cleaner cover.
Take out filter element and guide of air cleaner.
Check if filter element is polluted or injured. If
necessary, replace it with a new one.
Replacing Time
If driving under dusty condition or in rainy days
frequently, replace the air cleaner earlier.
51
* Attention
While removing filter element of air cleaner, please do not run the engine, in case unfiltered air
comes into the engine, which may result in fast wear of some components or damage the engine.
On the other hand, rotation of engine without filter element may affect the carburetor and the
carburetor will not work normally afterwards, which may result in overheated engine. Install filter
element guide, filter element, air cleaner housing cover, stop valve assembly and left protecting
plate.
Spark plug
Disconnect lead wire of spark plug cap.
Remove spark plug with a spark plug wrench or equivalent tool.
Inspection
.If the insulator is cracked or damaged;
.If electrodes are worn;
.Combustion condition and color
—Light grey color means excellent combustion condition.
—Pale color indicates that ignition system fails or lean
fuel/air mixture.
—Wet appearing or dark carbon deposition means higher
fuel/air mixture.
If the above-mentioned appears, please remove them with
spark plug cleaner or wire brush. If necessary, replace the
spark plug.
Visually inspect the spark plug.
If the insulator is cracked or worn, please replace it with a new one.
Spark plug clearance inspection.
Clearance: 0.6-0.7mm
* Attention
Reinstall the spark plug into the cylinder head and tighten it with the specified torque.
Tightening torque:18N.m
Screw the spark plug into the cylinder head first with a hand, and then tighten it with spark plug
wrench.
52
Battery
Removal
Remove the seat cushion and take down the right protecting
plate.
Remove the battery from the battery case(1).
Disconnect the battery negative (-) lead wire first and then the
positive (+) lead wire.
Take out the battery.
Warning!
During positive lead wire disconnection, be sure to prevent the
tools being used from touching the frame; or it will result in
short circuit sparks, which may ignite gasoline and damage
battery. It is dangerous!
Install the battery in reverse order of removal.
Warning!
To avoid short circuit, please connect positive (+) lead wire
first and then the negative (-) lead wire.
Battery charging (circuit voltage) inspection
Open the seat cushion and take down the right protecting plate.
Take out the battery from the battery case.
Disconnect the battery negative (-) lead wire first and then the
positive (+) lead wire.
Remove the battery.
Measure the battery voltage between terminals.
Fully charged: 13.1V
Undercharge: 12.3V(battery not work for one hour)
* Attention
Voltmeter shall be used for charging-state inspection.
53
Charging
Connection method: Positive pole of battery charger is connected to battery positive lead
wire; Negative pole of battery charger is connected to battery negative lead wire.
Warning!
• Battery shall be away from fire source.
• Shut off charger switch first before or after charging in case sparks may be generated at
connection parts, which may result in explosion.
• During charging, please take the current time labeled on the battery as the basic time.
* Attention
• Battery quick charging is not recommended except in case of emergency.
• After charging, wait at least 30minutes and then measure the battery voltage.
Charging current: Standard: 0.3A
Quick charging: 3.0A
Charging time: Standard: 10-15hours
Quick charging: 30minutes
After completion of charging: open circuit voltage: higher than 12.8V
Carburetor
Idle speed adjustment
*Attention
Perform idle speed adjustment when the engine is warm.
Warm up the engine and then adjust idle speed.
Run the engine and connect engine tachometer.
Adjust the throttle cable lock-screw to specified RPM.
Idle speed RPM:1400±100rpm/min
If idle speed RPM is unsteady, or idle speed is not smooth when the vehicle is gently accelerated,
adjust idle speed and adjust screws again.
Ignition timing
*Attention
Inspect ignition system when the ignition timing is incorrect.
Warm up the engine for 3~5minutes.
54
Stop the engine and connect the timing lamp to lead wire of spark plug.
Remove timing hole cap.
Start engine and idle it.
Inspect ignition timing.
If symbol “F” aligns with the mark on the right crankcase, it indicates that the ignition timing is
correct.
Increase engine speed and check if Symbol “F” begins to move.
Compression pressure of cylinder
Warm up engine.
Insert the pressure gauge.
Turn choke valve to its full open position.
Set throttle handle to its full open position and kick start
the engine.
Compression pressure of cylinder:1~1.2mpa
* Attention
Start the engine till reading of pressure gauge does not
rise.
Causes for low pressure:
. Valve improperly adjusted
. Valve leaks air
. Worn piston ring or cylinder
Causes for high pressure:
. Carbon deposition in combustion chamber or on piston.
Stop engine and remove spark plug/ spark plug cap.
Engine oil
Engine oil level inspection
* Attention
During engine oil inspection, please do not tighten engine
dipstick.
When inspect oil level, stop the motorcycle on the flat
ground with its middle stand and stand the vehicle
vertically.
When engine oil is consumed continually, oil level shall be
inspected regularly and refill to proper position if necessary.
Engine oil volume: 0.8L for oil replacement
1.1L for engine overhaul
If engine oil level is too high, operation of engine and clutch
will be affected;
Too low engine oil level will result in overheated engine and
55
premature component wear.
Refilling engine oil of poor quality or different types or brands will reduce lubrication effects.
When the engine stops, clean dust on the oil level indicator on the right side cover with a piece of
clean cloth.
Stand the engine on a horizontal plane and check oil level in the oil level indicator.
If oil level is lower or approaches the lower limit (-L), add recommended oil to the upper limit
mark (-H).
Engine oil replacement
Warm up the engine.
Place an oil pan below the engine and remove the drain plug and oil
filler plug.
Kick start engine several times to drain thoroughly the engine oil.
After drainage, inspect and clean engine oil filter.
Be sure that filter screen, spring, O ring, drain plug (1) and sealing ring
(2) are perfect and then put them back onto the engine.
* Attention
Oil should be changed when the engine is warm. Place the
engine on the side stand. Make sure all the engine oil is
completely and quickly drained.
When the drain plug is removed, engine oil filter and spring
will be ejected.
Tighten the drain plug.
Add recommended engine oil into the crankcase.
Install engine oil filler plug. Start the engine and let it run for
2~3minutes at idle.
Stop the engine and check if engine oil level is at upper limit
mark in a few minutes.
Stand the engine vertically on the ground to check oil level.
Make sure no oil leaks.
Drive chain slackness
Stand vertically the motorcycle on the flat ground and check
drive chain slackness ○
a.
Drive chain slackness: 10-20mm
If the drive chain does not meet the specification, adjust it.
56
Adjust drive chain slackness:
Screw off rear shaft nut and locknuts of adjusters on both drive chains.
Rotate uniformly both adjusters till the drive chains gain normal slackness.
* Attention
Do not install new drive chains onto worn sprockets or install worn drive chains onto the new
sprockets.
Keep both sprocket and drive chain in good conditions, or
newly replaced chain or sprocket will be worn soon.
Clearance of front/rear brake
Front brake clearance
Measure clearance of front brake at the tip of front brake
handle.
Clearance: 10-20mm
Brake pedal clearance
Measure brake pedal clearance.
Clearance: 20-30mm.
If the clearance measured does not meet the specified value,
adjust it.
Adjust clearance of brake pedal.
Screw in or screw out the adjuster.
If the adjuster is screwed in, clearance is increased; if
screwed out, clearance is decreased.
Adjust till the clearance is up to the specification.
After adjustment, the brake shall not drag.
57
Headlamp
Remove the locknuts of headlamp .
Take down the headlamp.
Pull out connector of headlamp holder and remove the
reflector. Release the circlip and take out lamp holder.
* Attention
When the bulb is lit, keep you hands and inflammable
materials some distance away from it. Lighting bulb is hot,
touch it when it cools down.
Install a new small bulb (2), a new big bulb (3), lamp
holder, and reflector for the headlamp.
Screw tightly the new bulbs into the lamp holder.
Avoid touching bulb glass with your bare hands during
installation and avoid staining them with oil, which may
affect transparency, service life and luminous flux of bulbs.
If oil is adhered to the bulb, clean it with a cloth
moistened with alcohol or highly volatile rubber solution.
Install headlamp assembly.
Clutch
Check clearance of clutch cable.
Clearance: 10-20mm.
Adjust clearance of clutch cable.
First loosen lock nut(1).
Screw in or screw off adjuster(2)till clearance meets the
specified value.
Finally tighten the locknut.
58
Front/rear
suspension
system
Front suspension
Grasp the front brake handle and compress
upward and downward the front shock
absorber to check its actuation.
Check if the front shock absorber leaks oil
and if the components are loosened.
Rear Suspension
Compress upward and downward the rear
shock absorber to check its actuation.
Check if components on the rear shock
absorber are loosened or injured.
Lift and support the rear wheel and swing the
wheel to check if engine suspension bushing is
loosened.
Bolt/nut/fasteners
Inspect if bolts, nuts and fasteners at every part of the motorcycle are loosened.
If it is loosened, tighten it to specified torque.
59
Wheel rim/tire
Check if there is crack, nails and similar sharp objects, and
other injuries on the tyres.
* Attention
Measure cold inflation tire pressure.
Specified air pressure
Unit:Kpa
Tire specifications
Tyre pressure
Front tire
100/80-17
190±10kPa
Rear tire
130/70-17
210±10kPa
QJ200-2A
Tire Specifications
QJ200-2A
Outer tube of front wheel
100/80-17
Outer tube of rear wheel
130/70-17
Check if locknut of front shaft is loosened.
Check if locknut of rear shaft is loosened.
If loosened, tighten it to specified torque.
Tightening torque:Rear wheel lock nut
Steering
stem
bearing
85-98 N·m
and
handlebar
fixation
Move left and right the handlebar and check if lead wires disturb it.
Rotate front wheel and confirm the handlebar can move smoothly.
If the handlebar does not move smoothly and is loosened, check
steering stem bearing.
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Inspection and maintenance of electrical system
Tightening torque table for fasteners used in electric system
Fastening positions and names of fasteners
Tightening torque(N·m)
Starter motor clutch cover bolt
12
Starter motor clutch locknut
95
Rectifier bolt
5.0
High-voltage coil pinch bolt
9.0
Flywheel locknut
5.0
Vehicle block protecting plate bolt
9.0
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Charging system
Charging System
1.Variable frequency scintillator
2. Ignitor 3. Battery
High-voltage ignition coil 6. Electric horn 7. Rectifier
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4. Voltage regulator
5.
Ⅰ Battery/Charging System
Service Data-----------------------1.1
Fault
diagnosis----------------------1.
2
Battery-------------------------------1.
Charging
3
system--------------------1.4
Voltage/current regulator--------1.5
Magneto
charging
coil-------------1.6
Removal of magneto-------------1.7
1.1 Service Data
Precautions on operation
* Attentions
1. The battery can be charged and discharged, and used repeatedly. If a battery is laid aside after
discharging, its service life will be shortened and its performance is degraded. Performance of a
battery is usually reduced after about 2-3 years’ use. Voltage of the performance-reduced (capacity
drops) battery can be resumed, but the voltage will run down quickly while loading.
2. Overcharging of battery: Usually overcharging is demonstrated by the battery itself. If short
circuit occurs inside the battery, voltage or very low voltage on the terminals of the battery cannot
be inspected. If the regulator fails, it will have too high voltage on the battery and the life-span
of the battery will be shortened.
3. When the battery is laid aside for a long period, it will self-discharge and its capacitance will
drop. The battery should be recharged every three months.
4. Charging system inspection: please perform inspection in accordance with the sequence listed
in the fault diagnosis table.
5. If there is current going through the electric parts, the connector shall not be removed, or the
voltage will be very high and electronic components inside the voltage regulator will be damaged.
Set ignition switch at “Off” position and then begin your work.
6. It is not necessary to inspect maintenance-free (dry-charged type) battery. Electrolyte and
distilled water are not required to be added.
7. Inspect the entire electric load.
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8. Quick charging is forbidden except in emergency.
9. During quick charging, the battery must be removed from the motorcycle first and then be
charged.
10. While battery is exchanged, please do not use liquid-feeding battery.
11. A voltmeter shall be employed to check the state of charged battery.
Service Data
Item
Specification
Capacity/type
Battery
Magneto
Voltage
(20℃)
12V-9AH/ dry-charged type
Fully charged
13.1V
Must be charged
12.3V(stop working for one hour)
Charging current
Standard:0.9A,Quick:9A
Charging time
Standard:10-15hours; Quick:30minutes
Capacity
100W/8000rpm
Coiling impedance value(20℃)
White-white 0.5-10Ω
Type
Full-wave rectification
Battery charging voltage
14.5V±0.4V/5.000rpm
Voltage
regulator
Tightening torque
Rectifier bolt
spanner
High-voltage coil pinch bolt
Flywheel locknut
Vehicle block protecting plate bolt
Tools
5.0 N·m
9.0 N·m
5.0 N·m
9.0 N·m
Universal non-adjustable
Flywheel remover
Testing device
Multimeter
1.2 Fault Diagnosis
No power
Battery over discharged
Wiring of battery is not connected.
Fuse fails.
Power switch is poorly contacted.
Unstable power
Wiring of battery is poorly contacted.
Discharging system is of poor contact.
Lighting system is of poor contact or short circuit.
Low voltage
Battery is poorly charged.
short line.
Poor contact.
Poor charging system.
Poor voltage and current regulator
Poor charging system
Wire connector is of poor contact, short circuit or
Defective voltage and current regulator
Magneto does not work well.
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1.3 Battery
1.3.1 Battery Removal
Take down the right protecting plate .
Disconnect the battery negative lead wire first and
then the positive lead wire.
Remove the battery breather.
Remove battery mounting bracket.
Take out the battery.
Warning!
During positive lead wire disconnection, be sure to
prevent the tools being used from touching the frame;
or it will result in short circuit sparks, which may
ignite gasoline and damage battery. It is dangerous!
Install the battery in the reverse order of removal.
* Attention
To avoid short circuit, please connect positive lead wire first
and then the negative lead wire.
Battery charging (circuit voltage) inspection
Open the battery cover and remove battery pressure plate
assembly.
Disconnect lead wire of the battery connector.
Measure voltage between terminals of the battery.
Fully charged: 13.1V
Undercharged: 12.3V (battery stop working for 1hour)
* Attention
A voltmeter shall be employed to check the state of charged battery.
1.3.2 Charging
Connection method: Positive pole of battery charger is
connected to battery positive pole; Negative pole of
battery charger is connected to battery negative pole.
Warning!
• Battery shall be away from fire sources.
• Shut off charger first before or after charging in case that
sparks may be generated at connection parts, which may
result in explosion.
• During charging, please take the current time labeled on
the battery as the basic time.
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* Attention
• Battery quick charging is not recommended except in case of emergency.
• After charging, measure the battery voltage in 30minutes’ time.
Charging current: Standard: 0.3A
Quick charging: 3.0A
Charging time: Standard: 10-15hours
Quick charging: 30minutes
Charging completed: open circuit voltage: higher than 12.8V
1.4 Charging system
1.4.1 Short circuit test
Disconnect the grounding wire from the battery and use a voltmeter to connect battery negative
lead wire with grounding wire. Set the switch at OFF position and check if it is shorted.
* Attention
Positive lead wire of multimeter is connected to negative lead wire of battery.
If abnormality is found, check if there is short circuit on ignition switch and main wiring.
1.4.2 Charging State Inspection
While in inspection, if the battery is fully charged, a multimeter shall be used for the test.
Warm up the engine and then install the fully charged battery onto the motorcycle.
Connect voltmeter between terminals of the battery.
Remove the main fuse and connect an ammeter between the two terminals.
Start engine and slowly raise RPM. Measure limited voltage and current.
Limited voltage/rpm:14-15V (5.000rpm)
If limited voltage is beyond the specified range, check the voltage regulator.
Inspect limited voltage in lighting system.
* Attention
Set multimeter to AC voltage.
1.5 Voltage-current regulator
1.5.1 Loop inspection on main wiring terminals
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Disconnect the 6P plug on the voltage-current regulator.
Check continuity between main wiring terminals in the following way:
Item (wire color)
Judgment
Between battery (red) and
There is battery
ground of vehicle block
voltage.
Between ground wire (black)
and ground of vehicle block
There is a lead wire.
Between charging coil
No power flowing
(white) and ground of
between magneto coil
vehicle block
and ground
Between
charging
(while 1 and white 2)
coils
There is resistance
between coils
1.5.2 Voltage-current regulator inspection
When main wiring terminal is normal, check if plug of voltage-current regulator is of poor contact
and measure
Multimeter
impedance value between
White1 Red/white
Red
Black
White2
+
terminals of voltage-current
Unit:MΩ
regulator itself.
* Attention
White1
No
No
0.1~3
10~90
• Do not touch the metal part of
red/white
No
No
0.1~3
No
multimeter probe with your
Red
0.1~3
No
1.2~5
0.1~3
finger.
Black
No
No
No
No
• Check with a multimeter. If
White2
60~80
No
No
0.1~3
impedance values measured by
different multimeters are not the same, it indicates incorrect inspection..
When impedance value between terminals is abnormal, voltage regulator shall be replaced.
1.6 Magneto charging coil
* Attention
Inspection of magneto charging coil can be performed on the engine.
Inspection
Disconnect the 6P connector on the magneto.
Use a multimeter to measure impedance value between white coil of magneto and vehicle block.
Standard value:0.5-10Ω(20℃)
If measured value exceeds the standarde, the magneto coiling shall be replaced.
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1.7 Magneto Removal
1.7.1 Removal
Remove vehicle block protecting plate.
Remove protecting plate of engine on the left side.
Remove flywheel locknut.
Use a flywheel remover to take down the flywheel.
Remove the fixation key.
Disconnect lead-wire connector of magneto.
Disconnect magneto stator.
1.7.2 Installation
Install the magneto stator onto the engine case.
Connect connector of magneto lead wire.
Clean crankshaft and conical part of flywheel.
Make sure the fixation key is installed into the key slot on
the crankshaft.
Align the groove on the flywheel to the fixation key on the
crankshaft.
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** Attention
There is magnetism on the inner surface of
flywheel, and make sure there is no bolt.
Fix the flywheel using a universal non-adjustable
spanner and then tighten the locknut.
Torque value: 9.0 N·m
Install protecting plate on the left side.
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Ignition System
Ignition System
1.Variable frequency scintillator
2. Ignitor 3. Battery
High-voltage ignition coil 6. Electric horn 7. Rectifier
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4. Voltage regulator
5.
Ⅱ Ignition System
Service
CDI assembly----------------------2.4
data------------------------------2.1
Fault
Ignition
diagnosis---------------------------2.
coil--------------------------2.5
2
Ignition
system
Trigger--------------------------------2.
inspection-------------2.3
6
2.1 Service Data
Precautions on operation
1. Ignition system inspection: please perform inspection in accordance with the sequence listed in
the fault diagnosis table.
2. Ignition system uses electronic-type automatic timing device, which is solidified in the CDI
assembly, so ignition time adjustment is unnecessary.
3. Ignition system inspection: please perform inspection in accordance with the sequence listed in
the fault diagnosis table.
4. Ignition system CDI shall not be dropped and hung, or heavily knocked (this is also the main
reason for its failure). Pay special attention to this while removing it.
5. Most of the ignition system problems are due to poor contact of sockets. Please check first if
parts of the connector are well contacted.
6. Check if heat value of spark plug is proper. Improper spark plug may result in unsmooth engine
running or burnt of spark plug.
7. The maximum voltage is taken to introduce inspection items in this Part. Inspection methods for
impedance value of ignition coil are also recorded and judged.
8. Check ignition switch according to the continuity test table.
9. Remove magneto and stator on operation instructions.
Service data
Item
Standard Value
Spark plug
Standard
Spark plug clearance
CR9E
0.6-0.7mm
71
0.35±15%Ω
Primary coil
Ignition coil impedance value
(20℃)
With spark plug cap
Secondary
coil
Without spark plug
cap
8-11KΩ
4.2±15%KΩ
Impedance value of trigger(20℃)
100-200Ω
Impedance value of charging coil(20℃)
600-800Ω
Ignition coil primary peak voltage
95-400V
Trigger voltage
Higher than
1.7V
Tools
Accessories for the voltage with maximum range
Multimeter
2.2 Fault diagnosis
Spark plug not sparking
Symptom
Possible causes(Determine the cause from 1 in sequence)
①When inner impedance is too small, use the appointed tester to test.
②Crankshaft rpm is too low.
Ignition coil
③Tester is disturbed (it is normal when several times’ measured
When the high voltage power is too
voltages are above the basic).
low.
④Wiring
of
ignition
system
is
poorly
contacted.
⑤Ignition coil is no good.
⑥Charging coil is bad. (Peak voltage measurement)
①Tester is wrongly connected.
②Poor ignition switch.
③Connector of CDI assembly is poorly contacted.
While no high-voltage power supply,
Secondary
high voltage power is sporadic.
④Ground wire for CDI assembly is shorted or poorly contacted.
⑤ Poor charging coil (Peak voltage measurement).
⑥ Defective trigger (Peak voltage measurement).
side voltage
⑦ Poor connector of high voltage wire.
⑧ Inferior CDI assembly.(after items ①-⑦ are tested and proved
abnormal or spark plug no sparking.)
High-voltage power is normal, spark
①Inferior spark plug or secondary leakage of the ignition coil.
plug no sparking.
② Poor ignition coil.
①When inner impedance is too small, use appointed tester to test.
②Crankshaft rpm is too low.
Charging coil
③Tester is disturbed (it is normal when more than one time’s
No high-voltage power supply
measured voltage is above the basic).
④Charging coil is bad. (when items ①-③ are proved normal)
72
No high-voltage power supply or
①Defective ignition coil.
high voltage power is sporadic.
②Defective charging coil.
①Inner impedance is too low. Use appointed tester to test.
②Crankshaft rpm is too low.
High-voltage power supply is too
③Tester is disturbed (it is normal when more than one time’s
low.
Trigger
measured voltage is above the basic).
④Poor trigger (when items (①-③ are proved normal)
No high-voltage power supply or
①Poor ignition coil.
high voltage power is sporadic.
②Poor trigger.
2.3
Ignition
system
inspection
* Attention
• When the spark plug is not sparking, check
if components of wiring are loosened or
badly contacted and make sure all the
voltage values are normal.
• There are many brands of multimeters with
different interior impedance. The values they
measured are not the same.
Connect a high-voltage shunt or an ammeter with input impedance higher than 10MΩ 10CV to the
multimeter.
2.3.1 Primary voltage of ignition coil
If an old spark plug is removed and replaced with a good one,
ground it with engine.
* Attention
Test when wirings of all the circuits are correct.
Normal cylinder compression pressure means to test
with spark plug installed on the cylinder head.
Connect lead wire of ignition coil and a shunt is connected
between terminal (black/white) of primary coil and grounding wire of vehicle block.
Press starter motor button or kick starter pedal to measure primary peak voltage of ignition coil.
Min. voltage: higher than 95V.
73
*Attention
Please do not touch the metal parts of testing probe with your fingers while
measuring voltage, or you will be shocked. Please take care.
2.3.3 Trigger
* Attention
Inspect when spark plug is installed on the cylinder head
and compression pressure is normal.
Disconnect connector 4P and 2P from CDI assembly. A
peak-voltage shunt is connected between the 4P connector
(black terminal) on trigger (blue/white terminal) for 2P
connector of wiring-terminal. Press starter motor button or
kick pedal level to measure primary peak voltage of trigger.
Connecting method: positive to blue/white, negative to
green/white.
Min. voltage: higher than 1.7V.
*Attention
Please do not touch the metal parts of testing probe with
your fingers while measuring voltage, or you will be
shocked. Please take care.
Ω
白
/绿
/白 白 1(A)
蓝
白1(A)
白2(A)
(A)
白2
A)
白(
(1
白(A)
00
When the peak voltage measured at connector of CDI
assembly is abnormal, take down the protecting plate on the
right side of vehicle and remove connector of magneto. The
trigger (blue/white) is connected with a shunt.
)
• When the measured voltage at CDI assembly terminal is abnormal, but measured voltage at
magneto terminal is normal, it indicates that the connector is of poor contact or wiring is broken.
• When measured results at both sides are abnormal, the trigger is damaged. Please check with a
reference to items listed in Diagnosis Table
74
2.4 CDI Assembly
2.4.1 System Inspection
System inspection.
Remove CDI assembly and check components related to
ignition system at wiring terminal.
2.4.2 Inspection
Remove CDI assembly and check if connectors are
loosened
or corrosive.
Item
Measured terminal
Standard Value(20℃)
Main switch
Red—Red/White
On continuity when main switch is
“OFF”.
Trigger
Blue/White-White/Green
100-200Ω
Primary coil of ignition coil
Black/White—Black
0.4Ω±10%
Secondary coil of ignition
coil
Black—spark plug cap
(excluding spark plug)
3-5.5KΩ±10%
2.5 Ignition coil
2.5.1 Removal
Remove protecting plate of vehicle block.
Remove spark plug cap.
Remove primary lead wire of ignition coil.
Unscrew locknut of ignition coil and take
out the ignition coil.
Install it in the reverse order of removal.
*Attention
The primary coil is installed
black/white wire connector.
with
2.5.2 Primary coil inspection
75
Measure impedance between terminals of
primary coil.
Standard value:0.4Ω±10%(20℃)
Impedance value within the range is good.
Impedance value “∞” indicates broken wire
inside the coil. The coil shall be replaced.
2.5.3 Secondary coil
Provided with a spark plug. Measure impedance between lead-wire side of spark plug cap and
terminal.
Standard value:8-11KΩ(20℃)
Impedance value within the range is good.
Impedance value “∞” indicates broken wire inside the coil.
Remove the spark plug cap and measure impedance value between primary side lead-wire of
ignition coil cap and negative terminal.
Standard value:3-5.5KΩ±10%(20℃)
2.6 Trigger
** Attention
Trigger inspection can be performed on the engine.
Inspection
Remove protecting plate of vehicle block.
Remove lead-wire connector of trigger.
Measure impedance between blue/white terminal
of lead wire on the engine side and ground wire of
vehicle block.
Standard value:100-200Ω(20℃)
If measured impedance value is beyond the range,
please replace the magneto.
76
Starting System
Starting Schematic Diagram
1.Variable frequency scintillator
2. Ignitor 3. Battery
High-voltage ignition coil 6. Electric horn 7. Rectifier
77
4. Voltage regulator
5.
Ⅲ Starting System
Service Data-----------3.1
Fault diagnosis--------3.2
Starter motor-----------3.3
Starter relay------------3.4
3.1 Service Data
Precautions on operation
Starter motor removal can be performed on the engine.
Starter clutch removal refers to removal instruction.
Basic data
Item
Standard
Service Limit
Length of starter motor
electric carbon brush
12.5mm
8.5mm
Starter idler shaft bushing
8.3mm
Starter idler shaft OD
7.94mm
Tightening torque
Starter motor clutch cap bolt
Starter motor clutch locknut
12 N·m
95 N·m
Tools
Locknut wrench
Universal un-adjustable wrench
78
3.2 Fault Diagnosis
Stator motor cannot run
Stator motor runs weakly
Starter motor rotates but the engine
does not
•Broken Fuse
•Low battery
•Defective starter clutch
•Low battery
•Poor connecting wire contact
•Starter motor counter-rotate
•Defective ignition switch
•Stator motor gear stuck by
•Low battery
•Defective starter clutch
foreign substances
•Defective braking switch
•Defective starter relay
•Defective connecting wire contact
•Defective starter motor
3.3 Starter Motor
3.3.1 Removal
* Attention
Before removing starter motor, the ignition switch must be
set at “OFF” position. Disconnect battery grounding wire
and then turn on the power supply to check if the starter
motor runs to confirm safety.
First remove the lead-wire clip of starter engine.
Remove starter motor pinch bolt and take down the starter
motor.
Roll up the rubber waterproof jacket and remove starter motor connector.
3.3.2 Disassembly
Disassemble housing screw, front cover, motor housing and
other parts.
3.3.3 Inspection
Inspect other component assemblies.
Replace with a new one when there is surface partial friction,
injuries or burning loss.
Commutator shall be cleaned when there is metal particles
adhered to its surface.
Inspect for continuity between contact surfaces of other
79
assemblies.
Confirm uncontinuity of armature shaft among surfaces of commutator.
Inspect for continuity of starter motor housing.
Confirm incontinuity between conducting terminal and starter motor housing.
Inspect continuity between conducting terminal and brush.
Replace it with a new one if abnormality exits.
Inspect carbon brush holder for continuity. If there is continuity, replace it.
Measure carbon brush length.
Service limit: replace it when it is shorter than 8.5mm
Check rotation smoothness of the needle bearing in the front cover and whether it is loosened
when it is pressed in.
If there is abnormality, replace it with a new one.
Check if the oil seal is worn or damaged.
3.3.4 Assembly
Apply lubricating grease on the oil seal in the front cover.
Install brush onto the carbon brush holder.
Apply lubricating grease on movable parts at both ends of
brush shaft.
Press carbon brush into its holder and install front cover of
electrodes.
* Attention
• There should be no hurt on the contact surface of carbon brush and armature. Take care.
• Installation shaft of armature cannot hurt lip of oil seal. Take care.
Install a new O ring onto the front cover.
Align and install the boss of motor housing to the recess of front cover.
Tighten housing screws.
* Attention
When assembling housing and front cover, armature can work as a magnet to easily pull the front
cover up; and then gently press it down with hands to complete the assembly.
3.3.5 Installation
Install lead wire of starter motor and be sure to install the dust seal.
Check if the O ring is damaged and replace it with a new one if it is inspected as abnormal.
Apply some engine oil onto the O ring and then install the starter motor.
Install rear brake wire clip.
80
3.4 Starter Relay
3.4.1 Actuation Inspection
Take down the protecting plate of vehicle block.
When the ignition switch is set at “ON” position, press
starter motor and a “Click” sound can be heard.
“Click” sound indicates normal.
No sound: • Check starter relay voltage.
• Check starter relay ground wire loop.
• Inspect starter relay actuation.
3.4.2 Starter relay voltage inspection
Lift and support the main stand. Measure the voltage
between negative pole (green/yellow) of starter relay
connector and vehicle ground wire.
Set ignition switch at “ON” position and catch the brake lever. Battery voltage shall meet the
specified.
When there is no voltage at wire terminal of starter relay,
inspect braking switch continuity and lead wire.
3.4.3
Starter
relay
ground
loop
inspection
Remove starter relay connector.
Inspect continuity between black wire of connector
terminal and vehicle ground wire.
When the starter button is pressed, continuity between
black wire of connector and vehicle ground wire shall be
fine.
If there is no continuity, inspect starter button continuity and lead wire.
3.4.4 Actuation inspection
Connect starter relay with battery and connect terminal of
starter motor with multimeter.
Connect fully charged battery between black wire and
green/yellow wire of relay. A “tap” sound of operation can
be heard on the relay and resistance displayed by
multimeter is “zero”.
81
Bulbs/Switches/Instruments
A
Headlamp certification No.:
E4 0014699
Front
B
turn
signal
lamp
certification No.:
E4 50R 001732
C
Tail lamp certification No.:
E4 50R 0014700
Rear
D
turn
signal
lamp
certification No.:
E4 50R 001732
E
Side reflector certification No.:
E11 020612
Rear
F
license
plate
certification No.:
E11 50R 000066
1 Instrument
2 Headlamp
3 Front right turn signal lamp 4 Side reflector
6 Rear license plate lamp
7 Rear right turn signal lamp
82
5 Tail lamp
lamp
Bulbs/Switches/Instruments
Service
Instrument----------------4.
data----------------------------------------4.1
6
Fault
Ignition
diagnosis------------------------------------4.
switch-----------4.7
2
Headlamp
bulb
replacement---------------4.3
Front
turn
signal
lamp
Electric
horn-------------4.8
bulb
Handle switch-----------4.9
replacement-------------4.4
Tail
lamp
bulb
replacement
----------------4.5
4.1 Service Data
Precautions on operation
Remove switches from the motorcycle and perform
continuity test.
All the plastic connectors have pawls on them.
Release clamping of the pawl before removal. Align
pawl to its hole when it is reinstalled.
While trouble shooting electric faults, please check
continuity of electric component as current flowing
over it.
Confirm state of battery before any inspection,
including battery voltage.
83
4.2 Fault Diagnosis
“ON” lamp of ignition switch is not lit.
• Defective bulb.
• Defective switch.
• Poor contact of connector or broken wire.
• Low battery power or no voltage.
4.3 Headlamp bulb replacement
4.3.1 Removal
Screw off with a wrench locknut of headlamp and take
down the headlamp.
Pull out connector of headlamp socket and remove the rear
cover. Release circlip in the arrow direction and take out of
the lamp socket
* Attention
When the bulb is lit, keep you hands and inflammable
materials some distance away from it. Lighting bulb is hot;
touch it when it cools down.
4.3.2 Installation
Install a new bulb, lamp adapter and headlamp rear cover.
Tighten the new bulb into the socket.
Avoid touching bulb glass with your bare hands
during installation and avoid staining it with oil,
which may affect transparency, service life and
luminous flux of bulb.
If oil is adhered to the bulb, clean it with a cloth
moistened with alcohol or highly volatile rubber
solution.
Install headlamp assembly.
84
4.4 Front turn signal lamp bulb replacement
4.4.1 Removal
Disconnect wire to turn signal lamp.
Screw off self-tapping screw on the turn signal lamp.
Remove the bulb socket from the lamp.
Remove the bulb from lamp adapter.
4.4.2 Installation
Install the bulb in the reverse order of removal.
4.5 Tail lamp bulb replacement
4.5.1 Removal
Screw off the two bolts.
Remove the tail lamp hood.
Disconnect wire connector to the tail
lamp.
While pressing down the tail lamp,
rotate it counterclockwise.
Remove the tail lamp.
4.5.2 Installation
Install the tail lamp in the reverse order
of removal.
* Attention
While installing tail lamp, be sure that sealing washer on the tail lamp hood is in good condition
and correct position.
4.5.3 Tail lamp bulb replacement
85
4.5.3.1 Removal
Screw off mounting bolts on the tail lamp hood.
Remove tail lamp hood(1)so that tail lamp bulb can be removed.
Remove the tail lamp bulb from lamp adapter.
4.5.3.2 Installation
Install the tail lamp bulb in the reverse order of removal.
4.6 Instrument
Remove rear mirror.
Take down the handle
hood
and
pull
out
waterproof connector.
Remove the bolts.
Remove
odometer
assembly to take down the
instrument.
Install the instrument
orderly in the reverse order of removal.
4.7 Main switch
4.7.1 Inspection
Remove the front protecting plate.
Disconnect connector of main switch lead wire.
Check the connector terminal for continuity.
4.7.2 Replacement of main switch
86
Remove the front protecting plate.
Unscrew the mounting bolt and take down the main switch holder.
Remove the mounting bolt and replace the main switch.
4.8 Electric horn
Inspection
Disconnect wire to the electric horn.
Connect lead wire of horn with the battery. When the
electric horn sounds, it indicates the horn is in good
condition
4.9 Handle switch
Remove protecting plate of steering handle.
Screw off mounting bolt on the brake lever and take down the bracket.
Remove bracket for the rear brake lever.
Remove throttle handle and bolts.
Take down the throttle handle from the handle and remove the throttle cable.
Remove mounting bolt on the handle and
take down the handle.
1 Stop switch
2 Grip adjuster of the front brake
3 Light switch
4 Motor Starter button
5 Passing lamp switch
6 Dimmer switch
7 Grip adjuster of the front brake
8 Horn switch
9 Turn signal switch
87
Chassis Inspection and Maintenance
Tightening Torque of Fasteners on Chassis
Fastening positions and names of fasteners
Tightening Torque(N·m)
Oil pump assembly mounting bolt
5-9
Front brake cylinder assembly mounting bolt
22-29
Rear brake rocker arm mounting bolt
5-9
Rear shaft locknut
85-98
Steering handle welding assembly mounting bolt
22-29
Front wheel shaft locknut
None
Front shock absorber mounting bolt
37-44
Rear wheel locknut
85-98
Rear shock absorber top nut
37-44
Rear shock absorber bottom nut
37-44
Rear handrail mounting bolt
22-29
Fuel tank mounting bolt
5-9
Helmet case mounting bolt
5-9
Muffler mounting bolt
22-29
Muffler connector mounting bolt
5-9
Rear swing arm shaft nut
70-83
88
Front Hydraulic Brake
A
B
C
D
E
Front brake disc diameter:260mm
Front brake disc thickness:4.0mm
Service limit:3.0
Thickness of friction lining:4mm
Service limit:3.0mm
Mounting torque for Bolt 3 in the
diagram:5-9 N·m
Mounting torque for Bolt 6 in the
diagram:5-9 N·m
F
Clearance of brake handle:
10-20mm
1 Oil pump block assembly 2 Front brake handle 3 Bolt 4 Nut
5 Fixing cover 6
Bolt M6×23 7 Front hydraulic brake mounting bolt 8 Front hydraulic brake assembly 9
Washer
10 Oil hose mounting bolt
11 Brake hose assembly
12 Brake cylinder assembly
13 Friction lining assembly
14 Oil hose mounting bolt
89
Rear Hydraulic Brake
A
B
C
Mounting torque for Nut 17 in the diagram:
5-9 N·m
Rear brake drum ID:130
Service limit:131
Thickness of friction lining:4.0mm
Service limit:3.0mm
D
Mounting torque for Bolt 6 in the diagram:22-29 N·m
E
Mounting torque for Bolt 22 in the diagram:5-9 N·m
1 Rear hydraulic brake assembly 2 Bushing Ⅱ 3 Yoke plate 4 Friction lining assembly
5 Brake cylinder assembly 6 Bolt M8×22 7 Sealing washer 8 Hex. Flange head bolt
9 Brake hose assembly (rear hydraulic brake) 10 Oil cup assembly
11 Hoop
12 Oil
hose
13 Protecting spring
14 Brake switch assembly (rear hydraulic brake) 15 Oil pump block
assembly 16 Bolt M6×20
17 Nut M6
18 Lever
19 Draw-bar
20 Cotter pin 2×18
21 Mounting bolt 22 Bolt M6×12
23 Washer
24 Spring washer
25 Washer
90
Ⅴ Braking System
Maintenance instruction-------------------5.1
Fault diagnosis-------------------------------5.2
Front hydraulic brake-----------------------5.3
Rear hydraulic brake-----------------------5.4
5.1 Maintenance Instructions
Precautions on operation
* Attention
• Please do not contaminate braking assembly with oil while assembly or disassembly.
• Please use specified detergent to clean the braking assembly, or it may reduce braking performance.
* Please check braking system before driving your motorcycle.*
5.1.1 Specifications
Item
Standard Value (mm)
Service Limit (mm)
Front hydraulic brake disc
diameter
φ260
-
Front hydraulic brake disc
thickness
4.0
3.0
Front friction lining
thickness
6.0
5.0
Rear hydraulic brake disc
diameter
φ240
-
Rear hydraulic brake disc
thickness
4.0
3.0
Rear friction lining
thickness
6.0
5.0
5.1.2 Tightening Torque Value
Rear hydraulic brake disc mounting bolt
5-9 N·m
Front brake cylinder assembly mounting bolt 22-29 N·m
Rear brake cylinder assembly mounting bolt 22-29 N·m
91
5.2 Fault Diagnosis
Braking System
Poor braking performance
Brake drags or tight handle
1. Improper brake adjustment
1. Improper brake adjustment
2. Worn friction lining assembly
2. Worn friction lining assembly
3. Friction lining assembly improperly installed
3. Friction lining assembly improperly
installed
4. Friction lining assembly and hydraulic brake disc are contaminated.
Noisy Braking
1. Friction lining assembly is worn out.
2. Friction lining assembly and hydraulic brake disc are contaminated.
5.3 Front Hydraulic Brake
5.3.1 Removal
* Attention
• Replace friction lining assembly.
• If a friction lining assembly will be used again,
please mark it on the side before removal so as to
re-install it to its original place.
Steadily stand the motorcycle.
Disconnect brake hose and speedometer cable.
Loosen the front wheel axle.
Place a proper support under the engine to lift the front wheel.
Remove the front wheel axle and the front wheel. When the front
wheel is taken down from the motorcycle, please do not squeeze the
brake.
Remove the braking disc.
Remove washer, gear seat and front brake cam shaft.
* Attention
•Please do not contaminate braking shoe assembly with oil while
assembly or disassembly
•Please use specified detergent to clean the braking assembly, or it may reduce braking
performance.
92
5.3.2 Inspection
Check if the friction linings are worn out. Replace them if necessary.
Measure friction lining and hydraulic brake disc and record the maximum values.
Specifications
QJ200-2A
Front hydraulic brake disc diameter
Front hydraulic brake disc thickness
φ260mm
4.0mm
* Attention
• A micrometer shall be used for the measurement.
Measure thickness of friction lining.
If hydraulic brake disc and friction lining are contaminated
by grease or their thickness is smaller than service limit,
replace them.
Service limit:
Friction lining: 5.0mm
Hydraulic brake disc: 3.0mm
Note:
Friction linings shall be replaced in pairs.
5.3.3 Installation
Install hydraulic brake discs and front wheel.
Install front brake hose assembly and hydraulic brake
assembly.
Please do not contaminate friction linings and brake
discs with oil.
* Attention
A contaminated braking shoe will reduce braking
performance and result in brake failure.
Tighten bolt and nut to their specified torque value.
Torque value:
Front wheel axle locknut
40-60 N·m
Front brake cylinder assembly mounting bolt
22-29 N·m
93
Do not contaminate friction linings with oil.
If a friction lining is polluted by oil, clean it with brake cleaner.
*Attention
A contaminated friction lining will weaken braking performance.
5.4 Rear Hydraulic Brake
5.4.1 Removal
Remove seat cushion assembly and
protecting plate assembly.
Remove the engine assembly, air filter
assembly and muffler assembly.
Take down the rear brake cylinder assembly.
Remove the rear wheel.
Remove the rear hydraulic brake discs from
the rear wheel hub.
* Attention
• Replace braking shoes.
• If a braking shoe will be used again,
please mark it on the side before
removal so as to re-install it onto its
original place.
Remove the following assemblies from the rear wheel
Rear brake:
1.Friction lining assembly(4)
2.Rear brake hose assembly(9)
3.Braking cylinder(5)
4.Rear hydraulic brake yoke plate(3)
Note: Detailed exploded view refers to P86.
5.4.2 Inspection
Check if braking shoe and hydraulic brake disc are worn out.
Replace them if necessary.
Measure braking shoe and hydraulic brake disc and record the maximum values.
* Attention
•If the hydraulic brake disc is rusty, please polish it with #120 abrasive paper.
•A micrometer shall be used for the measurement.
94
Measure thickness of braking shoes and hydraulic brake discs.
If the braking shoes are contaminated by oil or their
thickness is smaller than the service limit, replace them.
Measurement of hydraulic brake discs can be performed
on the motorcycle and removal is not required.
Note: Braking shoes shall be replaced in pairs.
Diameter of rear hydraulic brake disc
φ240mm
Thickness of rear hydraulic brake disc
4.0mm
Service limit: Friction lining 5.0mm
Brake disc 3.0mm
5.4.3 Installation
Install rear hydraulic brake discs and rear wheel.
Install rear brake cylinder assembly.
Install engine assembly and air cleaner assembly.
Install muffler assembly, protecting plate assembly
and seat cushion assembly.
* Attention
A contaminated braking shoe will
decrease braking performance and result
in braking failure.
.
Tighten bolts and nuts to their specified torque value.
Torque value:
Rear hydraulic brake disc mounting bolts 5-9N·m
Rear braking shoe installation bolts: 22-29 N·m
Do not contaminate brake shoes and hydraulic brake discs with oil.
If a braking shoe or a hydraulic brake disc is polluted by oil, clean it with a brake cleaner.
* Attention
A contaminated brake shoe will decrease braking performance and result in braking failure.
Note: Detailed breakdown drawing refers to P87.
95
Exterior
*Attention
Do not damage the exterior during disassembly.
Do not damage falcula on the exterior during disassembly.
Align insert plates and covers on the exterior with their slots.
Correctly install falculas on each position during assembly.
Do not damage auxiliaries during installation of the exterior.
1. Mounting plate, right guiding cover 2. Mounting plate, guiding cover 3. Mounting plate, left guiding cover,
4. Left trim board, front mud fender 5 Right trim board, front mud fender 6. Front mud fender 7. Right
guard 8. Right tail cap 9. Interconnecting plate, tail cap 10. Trim board, right guard 11. Left guard 12.
Trim board, left guard 13. Left tail cap 14. Front part, rear mud fender 15. Front part 1, rear mud fender 16.
Rear mud fender 1 17. Rear mud fender 2
96
VI.
Motorcycle exterior
Disassemble the motorcycle body in the following sequence.
Seat cushion assembly→ Left guard component→ Right guard component→ LR tail
cap→ RR tail cap→ Left pedal→
↓
Right pedal→ Reinforcing plate, front mud fender→ Front mud fender→ Rear mud
fender component→ Connecting plate, rear tail cap→Tail lamp
↓
→ Tail lamp bracket→ Rear carrier assembly
97
Front wheel
Rim runout limit:
A
Vertical: 2.0mm
Horizontal: 2.0mm
B
Wearing limit:
1.0mm
1 Front wheel shaft 2 Gear housing assembly 3 Rolling bearing 4 Intermediate sleeve, front wheel 5 Gear housing
oil seal component 6 Front wheel disk 7 Big gear drive vane 8 Oil seal component, front wheel 9 Left bearing
sleeve, front wheel 10 Front braking disk 11 Mounting bolt, hydraulic braking disk 12 Right lining, front wheel 13
Sub-assembly, front wheel 14 Vacuum tyre 100/80-17 15 Inflating valve Z2-01-1/direct
98
Steering handlebar
1 RR mirror assembly 2 LR mirror assembly 3 Handlebar stop 4 Right handlebar component 5 Right combined
switch 6 Welded component, steering handlebar 7 Left combined switch 8 Left steering handlebar sleeve 9 Left
handle component 10 Left handle 11 Handle fixing bolt 12 Bolt M6×25 13 Bolt M6×20 14 Fixed cover 15
Adjusting screw 16 Adjusting nut 17 Left handle base 18 Clutch wire sleeve 19 Socket head cap screw M6×35 20
Check valve flexible wire clamp 21 Bolt M6×25 22 Nut M6 23 Mounting screw, brake pedal 24 Spring washer 10
25 Lining 26 Welded component, brake pedal 27 Brake pedal tensioning spring 28 Valve steel cable component 29
Clutch cable component 30 Accelerator cable component 31 Rear mirror assembly 32 Clutch switch
99
Front fork
1 Steering shaft rod nut 2 Dust shield 3 Upper steel bowel, upper bearing 4 Steel ball 3/16’’ 5 Lower steel
bowel, upper bearing 6 Upper steel bowel, lower bearing 7 Steel ball 1/4’’ 8 Lower steel bowel, lower bearing 9
Lower bracket, lamp 10 Cable clamp 11 Socket head cap screw M8×30 12 Upper base, steering handlebar
13 Bottom cushion, bracket 14 Upper interconnecting plate assembly 15 Bolt M6×12 16 Bolt M6×12 17
Socket head cap screw M6×30 18 Strut bolt 19 Lower interconnecting plate assembly 20 Combined screw M6×12
21 Hydraulic tube clamp 22 Hexagon socket set screws with flat point M4×6 23 Side reflective assembly 24
Washer 10 25 Bolt M10×16 26 Cable clamp 27 Combined screw M6×16 28 Locating pin 29 FR shock
absorber assembly 30 FL shock absorber assembly 31 Left bracket II assembly, front fender 32 Left bracket I
assembly, front fender 33 Screw M6×15.2 34 Socket head cap screw M6×16 35 Front license mounting bolt
M10×1. 25×30 36 Socket head cap screw M6×30 37 Right bracket I assembly, front fender 38 Right bracket II
assembly, front fender 39
100
VII.
Front wheel/Front suspension
Service Data-----------------------------7. 1
Fault Diagnosis-------------------------7. 2
Front Wheel-----------------------------7. 3
Steering Handlebar---------------------7. 4
Front Fork-------------------------------7. 5
7. 1 Service Data
Precautions
Prior to disassembly of the front wheel, use a jack to support against bottom of the motorcycle, and it is important
that the front wheels must not rotate reversely when they keep away from the ground.
During operation, it is important that any grease must not be attached on friction disc and its assembly, as well as
hydraulic braking disk.
Reference for motorcycle
Measuring position
Item
Front wheel shaft
Bending
Front wheel
Wheel disk
shimmy
Standard
value (mm)
0. 2
Longitudinal
direction
Horizontal
direction
2. 0
Not less than
1. 0
Torque force value
2. 0
Tool
Fixing bolt, welded component, steering handlebar 22-29
Fixing bolt, front shock absorber
Allowable limit (mm)
37-44
N·m
N·m
7. 2 Fault Diagnosis
7. 2. 1 Steering handlebar rotating without flexibility
101
Dismantling rod, bearing
Locking nut wrench
The handlebar bearing is faculty.
The handlebar bearing is damaged.
Pressure within the tyre is too low.
Air leaks from the tyre.
7. 2. 2 Direction not steady
The handlebar bearing is damaged.
Pressure within the tyre is insufficient.
Front fork is bent and its bearing is bent.
Front wheel tyre is subjected deformation and the tyre is not aligned.
7. 2. 3 Front wheel wobbling
Wheel disk is deformed.
Front wheel bearing is worn.
Tyre is in poor condition.
7. 2. 4 Wheel failing to rotate
Wheel shaft bearing is faulty or gear housing is faulty.
7. 2. 5 Abnormal noises from front shock absorber
Noises due to friction against absorber guard.
Bolts of the absorber are loosened.
7. 3 Front wheel
7. 3. 1 Disassembly
Attention:
The motorcycle must be securely supported against the ground.
Remove the fixing screw of speed meter and its cables.
Remove the locking nut of front wheel shaft.
Remove the front wheel shaft (1).
Remove the gear housing component (2) and front
wheel.
Unscrew to remove the front mud fender and
odometer cable.
Remove the braking hose of front brake.
Oil seal removing appliance and bearing removing
appliance must be used.
Remove oil seal (8) and bearing (3).
*Note: See P75 of this manual for disassembly of
102
Motorcycle shaft
QJ200-2A front wheel.
7. 3. 2 Check
7. 3. 2. 1Check of wheel shaft bending
Place the wheel shaft onto a V-shaped base, and the measure eccentricity with a micrometer gauge.
Allowable limit: replacing is required in case of exceeding 0. 2mm.
7. 3. 2. 2 Check of wheel disk wobbling
Place the wheel disk onto an accurate rack.
Check swinging degree of wheel disk.
Manually turn the wheel and read the swinging degree.
Allowable limit
Longitudinal direction: replacing in case of exceeding 2. 0mm
Horizontal direction: replacing in case of exceeding 2. 0mm
7. 3. 2. 3 Check of front wheel bearing
Remove the front wheel shaft (1) and hydraulic braking disc (10).
Remove the left bearing sleeve (9) of the front wheel to remove the oil
seal (8).
Remove the bearing (3).
Check rotation of bearing.
If the bearing is found not to rotate or its rotation is found not to be smooth or steady, it indicates that the bearing
is worn or loosened, and it shall be replaced with new bearing.
Play
7. 3. 3 Replacing bearing
Remove the front wheel shaft, front wheel and its left bearing sleeve.
Intermediate sleeve (4) of front wheel
Oil seal removing appliance and bearing removing appliance must be
used to remove the lower oil seal and bearing respectively.
Note: the removed bearing must be replaced with new bearing.
During installation, apply the lubricating grease onto the bearing.
And then, use the bearing mounting tool to press the bearing.
*Attention
The bearing must be pressed in a parallel manner.
103
Play
Radial
Axial
7. 3. 4 Installation
Installation must be initiated in the reverse sequence of disassembly.
Attention:
Lubricate the front wheel shaft, gear housing component, oil seal, bearing sleeve, rolling bearing (6301) and
intermediate sleeve.
The recommended lubricant is calcium-base grease.
Install the front wheel shaft (1), front wheel, gear housing component (2)
and nut M12Χ1.25.
It is important that the gear housing component should be aligned when it is
being installed.
Odometer gear housing
The odometer gear housing component will deform if the component is not
aligned to the locked front wheel shaft.
The front hydraulic bake component is mounted onto the hydraulic braking
disc.
Tighten the front wheel shaft.
*Note: See P75 of this manual for disassembly of QJ200-2A front wheel.
7. 4 Steering handlebar
7. 4. 1 Disassembly
Dismantle the right and left rear mirrors (1) and (2).
Open the fixed cover.
Remove the left handle component (9) of the front brake.
Remove the balancing block component (3)
Remove the right and left combined switches (5) and (7).
Remove the left handle grip (8) and throttle control handle (4) and
fixed screws onto the upper base of steering handlebar.
Remove the upper base.
Remove the steering handlebar component.
7. 4. 2 Installation
104
*Note: See P96 of this manual for disassembly of QJ200-2A steering handlebar.
It should be installed by reversing the sequence of disassembly.
Fixing bolt, welded component, steering handlebar
Torque force value22-29 N·m
7. 5 Front fork
7. 5. 1 Disassembly
Support the main stand of the motorcycle.
Remove the front wheel.
Remove the brake clamp and tube clamp.
Dismantle the front fender and the reflector.
Remove the handle pipe.
Loosen the clamping bolt (upper interconnecting plate)
and the clamping bolt (lower interconnecting plate).
Remove head light bracket.
Remove the front fork.
Tool
Fixing bolt, welded component, steering handlebar
Locking nut wrench
Tool special for removing steel bowel of bearing.
*Attention:
105
Clean the opening on the body opening with dust rag.
The steel bowels of the upper and lower bearings are removed by means of special tool.
7. 5. 3 Installation
Apply grease onto the steel bowel of bottom bearing
confirm the number of steel balls (23 balls).
The steering handlebar is non-turnable (to prevent
steel balls from falling) and then install the steering
handle.
Support the steering handle, apply grease onto steel
bowel of the top bearing and confirm the number of
steel balls (19 balls).
Apply grease onto the top housing washer.
Rotate the steering handle left and right so that steel
balls are contacted and mated with each other
closely.
and
the
Tool:
Fixing nut wrench
Turn the front fork left and right to confirm its smoothness and it is not loosened.
Procedures:
Installation must be initiated in the reverse sequence of disassembly.
To install the front fork, tighten the clamping bolt firstly.
Make sure that the fork end is flushed with handle head.
Tighten the clamping bolt (lower interconnecting plate) (11)
and tightening bolt of steering stem (18).
*Note: See P92 of this manual for assembly and disassembly of QJ200-2A front fork.
106
Rear wheel
A
B
Tyre dimensions: vacuum tyre 130/70-17
Rim runout limit:
C
Vertical: 2.0mm
Horizontal: 2.0mm
D
Wearing limit: 1.0mm
E
Rear hydraulic braking disk diameter: 240mm
F
Torque force value of bolt 12 in the figure:
85-98 N·m
1 Self-locking nut M14×1.5 2 Right oil seal assembly of front wheel 3 Rolling bearing 6202-2RS 4 Mounting
bolt M6×16 of hydraulic braking disk 5 Rear braking disk 6 Rolling bearing 6302-2RS 7 Rear wheel disk 8
Bearing sleeve 9 Washer φ16×φ32×2 10 Damper, rear wheel 11 Left bearing sleeve component of rear wheel
12 Rear wheel shaft M14×1.5×292 13 Sub-assembly of rear wheel 14 Vacuum tyre 15 Inflating valve
107
Rear shock absorber
1 Domed nut M10×1. 25 2 Mounting gasket, rear shock absorber 3 Rear shock absorber component 4 Washer 12
Bolt M10×1.25×40
108
Rear swing arm
Side play limit (for swingarm opening
A
end): 1.0mm
Torque force value of nut 1 in the figure:
B
70-83 N·m
1 Self-locking nut M14×1.5 2 Mounting washer, rear swingarm 3 Intermediate bearing sleeve 4 Mounting shaft,
rear swingarm 5 Chain protective pad 6 Rear swingarm welding set, 7 Chain regulator 8 Screw M5×12 9 Sleeve
2 10 Holddown plate, chain regulator 11 Nut M8 12 Rear hydraulic brake cable clamp 13 Screw M6×12
14 Intermediate sleeve 15 Lining of rear swingarm 16 Dust shield component
109
Chain drive assembly
Torque force value of
A
bolt 11 in the figure:5-9
N·m
B
Looseness
of
drive
chain: 20-40mm
Torque force value of
C
bolt 1 in the figure:
37-244 N·m
1 Mounting bolt M10×1. 25×38, sprocket 2 Sprocket hub 3 Chain driving sleeve 4 Rolling bearing 6204-2RS
5 Dust shield component 6 Toothed sprocket, sprocket 40 7 Anti-loosening locking pad, sprocket 8 Nut
M10×1. 25 9 Chain 428HG-1×124 10 Chain cover 11 Boss bolt 12 Dust shield, sprocket hub 13
Sub-assembly, sprocket 11 Chain regulation mark
110
VIII.
Rear wheel/Rear suspension
Service Data---------------------------------------8. 1
Fault Diagnosis------------------------------------8. 2
Rear Wheel-----------------------------------------8. 3
Rear Shock Absorber/Rear Swingarm----------8. 4
Chain Drive Assembly----------------------------8. 5
8. 1 Service Data
Precautions
Any grease spot is not allowed on the hydraulic braking disk and friction disc.
Reference
Item
Rear wheel
wobbling
Standard value (mm)
Allowable limit (mm)
Longitudinal
direction
2. 0
Horizontal
direction
2. 0
Locking torque force
Fixing nut, rear wheel
Top nut, rear shock absorber
Bottom nut, rear shock absorber
85 - 98 N·m
37 - 44 N·m
37 - 44 N·m
8. 2Fault Diagnosis
8. 2. 1 Rear wheel wobbling
Wheel disk is deformed.
Rear wheel bearing is worn.
Tyre is faulty.
Swingarm pivot bushing is worn or damaged.
Driving chain regulator adjusts incorrectly.
111
Motorcycle frame or swingarm is bent.
8. 2. 2 Wheel rotating without flexibility
Brake regulates incorrectly.
Rear wheel bearing is worn.
Driving chain is too tightened.
8. 2. 3 Bad braking performances
Brake regulates incorrectly.
Brake friction disc is worn.
Hydraulic braking disk is worn.
Brake friction disc is installed incorrectly.
8. 2. 4 Brake pedal not flexible or returning slowly
Return spring is worn or broken.
Brake regulates incorrectly.
Hydraulic braking disk is worn or dirty.
Brake friction disc is installed incorrectly.
8. 2. 5 Brake jarring
Brake friction disc is worn.
Hydraulic braking disk is worn.
Brake friction disc is dirty.
Hydraulic barking disk is dirty.
8. 3 Rear wheel
8. 3. 1 Disassembly
The motorcycle should be supported against the
ground securely so that the wheels can keep away
from the ground.
Remove the muffler .
Remove the rear brake cylinder component,
Remove the rear wheel shaft nut,
Remove the rear wheel.
Remove the torque transmission arm from the rear hydraulic braking disk.
Remove the drive chain regulating nut (4).
Dismantle the rear wheel shaft locking nut (1) and rear wheel shaft (12).
Move the rear wheel forward and then remove driving chain from the driving sprocket.
Dismantle the rear wheel.
112
8. 3. 2 Check
8. 3. 2. 1 Check of wheel disk wobbling
Turn the rear wheel manually and measure eccentricity with a
micrometer gauge.
Allowable limit
Longitudinal direction: replacing in case of exceeding 2. 0mm
Horizontal direction: replacing in case of exceeding 2. 0mm
If the rear wheel wobbling exceeds the allowable limit, the rear
wheel bearing is loosened, consequently the rear wheel wobbling.
Replace the rear wheel bearing after check.
8. 3. 3 Installation
Install the rear wheel in reverse sequence of disassembly and lock the nut.
Fixing nut, rear wheel
Torque force value : 85-98N·m
QJ200-2A Rear wheel
113
8. 4 Rear shock absorber/rear swingarm
8. 4. 1 Dismantling rear shock absorber
Remove the sealing cover.
Remove the upper and lower fixing bolts (5) and nut (1) from the
shock absorber.
Remove the rear shock absorber.
8. 4. 2 Check of rear shock absorber
Check rear shock absorber rod, and if it is bent or damaged,
replace the rear shock absorber component.
Check the spring, and if it is fatigued, replace the rear shock
absorber component.
8. 4 Installation of rear shock absorber
Installation must be initiated in the reverse sequence of dismantling.
Mount the upper fixing nut and lower fixing bolt on the rear shock absorber.
Lock to the specified torque force.
Fixing nut
Torque force value : 37-44 N·m
8. 4. 4 Removal of rear swingarm
Dismantle the rear wheel.
Remove the two bolts and driving chain cover.
Remove the lower fixing bolt from the shock
absorber on both sides.
Remove the swingarm pivot nut, rear swingarm
shaft and swingarm from the frame.
114
rear
Note: See P101 for details of removal and installation.
8. 4. 5 Check of rear swingarm
Check the mounting shaft of rear swingarm and turn the shaft or measure it with a micrometer gauge after it is
placed onto a flat surface. If the shaft is bent, replace it.
*Attention
Do not attempt to straighten bent shaft.
Clean parts of rear swingarm mounting shaft with a solvent.
Check rear swingarm shaft sleeve component (2) and intermediate sleeve (3),
and if any damage is found, replace it.
8. 4. 6 Installation of rear swingarm
Installation must be initiated in the reverse sequence of disassembly.
Apply grease onto the pivot bushing.
Check rear swingarm shaft sleeve component (2) and intermediate sleeve (3).
Install chain guard.
Load the swingarm onto the frame and insert the rear swingarm,
Install the swingarm shaft nut to the specified torque force.
Install the lower fixing screw of the rear shock absorber.
Install the driving chain cover.
Install the two connecting bolts.
Install the rear wheel.
Nut, rear swingarm shaft
Torque force value : 70-83N·m
8. 5 Chain drive assembly
8. 5. 1. Disassembly
Stop the motorcycle on the flat ground, and support it securely.
Remove the connector of gear shift pedal, driving sprocket cover
and driving sprocket.
Remove the rear wheel, rear shock absorber, sprocket housing and
driving chain.
115
Rear swingarm shaft
8. 5. 2. Check
Measure length of 10 links
, and if it does not meet specified value, replace the driving chain.
Limit length of the 10 links is 127mm.
*Attention:
Measurement shall be made only after the chain is straightened manually.
11
Measurement shall cover from link roller ① to ○
Measure length of 10 links.
2-3 measurements shall be made for length of 10 links on
different positions.
Clean the driving chain and place it into kerosene.
Clear dust as much as possible.
And then, take the chain out of kerosene, and dry it.
Check rotor ① and side panel ②.
If either of them is worn or damaged, replace the driving
chain.
Lubricate the driving chain, and the lubricant can be
outsourced from a shop.
Check hardness of driving chain.
If the chain is hard, clean, lubricate or replace it.
Check driving sprocket and driven sprocket.
If 1/4 teeth
is worn, replace the sprocket.
If the sprocket is bent, replace it.
116
Check rear hydraulic brake, and if any crack or wearing is found, replace it.
Check rear wheel damping sleeve, and if it is worn or damaged, replace it.
Check wheel bearing, and if bearing clearance is found within the hub or the wheel cannot rotate in a balanced
manner, replace it.
Check oil seal, and replace it if it is damaged or worn.
8. 5. 4.Installation
Installation must be initiated in the reverse sequence of disassembly.
Install the driving chain, chain cover, LR shock absorber, rear wheel and driving sprocket cover.
Adjust the looseness of driving chain and free stroke of brake pedal.
If the looseness is too small, the engine and other key parts will be consequently overloaded.
Maintain the chain looseness within the specified limits.
117
Seat cushion
A
B
C
Notes:
To dismantle gasoline tank, turn the fuel
switch to OFF.
Torque force value of bolt 2 in the figure:
22-29
N·m
Torque force value of bolt 5 in the figure:
22-29
N·m
1 Cushion assembly 2 Bolt M8×20 3 RR rack, rear carrier screw I4 5 RR rack (flat black B4) 6 LR rack
118
Fuel tank
A
Gasoline capacity:
17±0. 5L
Torque force value of screw 13
B
in the figure:
5-9 N·m
Torque force value of nut 6 in
D
the figure:
5-9 N·m
Notes:
E
To dismantle gasoline
tank, turn the fuel switch to
OFF.
1 Tank cover support component 2 Tank body component 3 Tank mounting pad 4 Fuel sensor component 5
Sensor rubber gasket 6 Nut M6 7 Tank switch component 8 Sealing gasket, tank cover 9 Tank
mounting pad 10 Tank mounting shaft sleeve 11 Rubber sleeve 12 Tank mounting gasket 13 Bolt
M6×35
14 Socket head cap screw M5×14
15 Socket head cap screw M5×30 16 Steel wire
clampΦ10. 5 17 Oil tubeφ7×11×500 18 Fuel tube φ4. 5×8. 5×140 19 Steel wire clamp 8 20 Guard
rubber gasket 21 Guard rubber gasket 22 Tank mounting pad 23 Switch lever 24 Screw M4×25
119
IX.
Fuel tank/Seat cushion
Service Data-----------------------9. 1
Fault Diagnosis--------------------9. 2
Fuel Tank/Seat Cushion----------9. 3
9. 1 Service Data
Precautions
The dismantling site shall keep away from source of spark.
To dismantle gasoline tank, turn the fuel switch to OFF.
During assembly, tighten the bolt and nut to specified torque force value.
After assembly, check if all parts are installed correctly and operated correctly.
Reference
Item
Standard
Allowable limit
Gasoline capacity
17±0.5L
/
Locking torque force
Rear rack fixing bolt
Gasoline tank fixed bolt
22-29 N·m
5 - 9 N·m
9. 2 Fault Diagnosis
Gasoline volume decreases.
Gasoline is consumed naturally.
Gasoline leaks.
120
9. 3 Fuel tank/Seat cushion
9. 3. 1 Disassembly
Dismantle the right and left guards.
Insert the ignition key into the seat lock, turn
the key clockwise and open the lock.
Insert the ignition key into the seat lock, turn
the key clockwise and open the lock.
Pull out the helmet hook downward, disengage
the hook with frame
and then remove the cushion (1).
Remove the fuel level sensor cable connector.
Turn fuel switch to OFF.
OFF: fuel hose
Remove bolt, gasket, cushion and fuel tank.
Fuel hose
Take tank from the frame.
Notes:
See P91 and P92 for details of installation and removal.
9. 3. 1 Installation
Gasoline tank
Installation must be initiated in the reverse sequence of
disassembly.
Mounting torque force:
Rear rack fixing bolt
22-29 N·m
Gasoline tank fixing bolt
5 - 9 N·m
121
Bolt
Pad
Damping pad
Maintenance and check of engine
Fastener Torque Force Value Table
Fastening position and fastener description
Fastening torque (Nm)
Cylinder head nut
24~30
Cylinder head cover bolt
9~12
Cylinder double end studs
24~30
Flywheel locking bolt
40~55
Valve clearance adjustment nut
9~12
Gear shift locator bolt
9~12
Closer bolt
9~12
Right and left crankcase cover bolts
9~12
Coil screw
9~12
Oil filter cover bolt
9~12
Clutch Fixing nut
190~210
Cylinder body fixing bolt
9~12
Output sprocket nut
190~210
Fuel pump screw
9~12
Gear shift locating plate bolt
9~12
Spark plug
10~15
122
X.
Lubricating system
Service Data------------------10. 1
Fault Diagnosis---------------10. 2
Engine Oil Pump-------------10. 3
10. 1 Service Data
Function of lubricating system: engine lubricating system is to supply lubrication oil to friction
surface of engine elements, turning the dry friction on the surface into liquid friction between
lubrication oil particles, thus mitigating part wearing, cooling down parts with high thermal load,
absorbing impact from bearing and the elements and consequently reducing noises, increasing
tightness between cylinder ring and wall, and cleaning and taking away foreign matters from
surface of parts.
Precautions
After engine oil pump is disassembled, carefully clean its parts and purge the surface with
high-pressure gas.
To disassemble engine oil pump, it is important to prevent any foreign matter from falling into
crankcase.
Table for Standard Value and Allowable Limit of Reference Items
Standard
Allowable
limit
For changing oil
1. 2L
_
For disassembly
1. 4L
_
0. 04~0. 1
0. 15
0. 11~0. 176
0. 22
0. 016-0. 063
0. 11
Item
Engine oil capacity
Pump rotor
Radial clearance
between inner and outer
rotors
Clearance between
outer rotor and pump
Rotor face-to-face
clearance
123
10. 2Fault Diagnosis
Gasoline volume decreases
Gasoline is consumed naturally.
Oil leakage
Engine damaged
No or too low oil pressure
Oil circuit clogged.
124
10. 3 Engine oil pump
10. 3. 1 Disassembly
Remove the right cover, unscrew the pump fixing screw after engine oil filter is removed, and then
remove the pump body, driving gear and pump shaft.
Engine oil
filter
Engine oil pump body
Remove screws.
Remove the pump base.
Screw
Engine oil pump
base
Remove the pump cover and dismantle the pump.
125
Check radial clearance between inner and outer rotors
Allowable limit: 0. 25mm.
Testing gauge
Check clearance between outer rotor and pump
base.
Allowable limit: 0. 25mm.
Testing gauge
Check rotor face-to-face clearance
Allowable limit: 0. 15mm.
Flat plate
Testing gauge
126
10. 3. 2 Assembly of engine oil pump
As shown in the following figure.
Driving gear
Engine oil pump shaft
Engine oil pump body Outer rotor Inner rotor
Engine oil
pump base
Attention: After these parts are combined into the pump, the inner and outer rotors must be free to
rotate without jamming.
10. 3. 2 Installation
These parts are assembled in the reverse sequence of disassembly.
Diagram for lubricating system
127
Swingarm
Cam mechanism
Piston
Oil filter
Cranksha
ft
Engine oil filtration net
Engine
oil pump
128
XI.
Carburetor
Service Data--------------------------11. 1
Fault Diagnosis----------------------11. 2
Disassembly of carburetor---------11. 3
Installation of carburetor-----------11. 4
11. 1 Service Data
Function of carburetor: It is a key part of engine fuel supply system, and its operation status has
a direct bearing on operation stability, power and economic indexes of the engine. It atomizes a
certain amount of gasoline into fine oil droplets and mixes these droplets with different amounts of
air evenly, thus forming combustible mixed gas mist with different density depending on the needs
of engine under different operating conditions and promptly supplying the gas to engine, ensuring
continuous and normal operation of engine.
Precautions
The gasoline is combustible and explosive, therefore operation must be conducted in a
well-ventilated place.
After the carburetor is disassembled, take necessary measures to prevent ingress of any foreign
matter.
If a carburetor has not been used for one month, oil in the float chamber shall be released to prevent
idling jet from being clogged as a consequence of gasoline degradation.
Table of Standard Items of Reference Items
Item
Standard value
Main metering jet
Idling metering jet
Oil needle
262
70
C03-0
11. 2 Fault Diagnosis
Poor startup
Difficult to startup, flaming out after
startup or unstable during idling
Clogged carburetor
Too thick or thin mixed gas
Secondary air entering into intake system
No fuel in carburetor
Gasoline filter clogged
Gasoline tube clogged
129
Needle valve locked
Bad oil surface adjustment
Bad idle adjustment
Bad oil volume adjustment
Idle system or power enrichment valve
clogged.
Too many fuels in engine
Too much oil and overflow
Secondary air entering into fuel system
Fuel degradation
Enrichment valve working badly
Idle system or air suppression system clogged
Too thin mixed gas
Jet clogged
Needle valve clogged
Too low oil level
Fuel system clogged
Plunger working badly
Secondary air entering into intake system
Too thick mixed gas
Enrichment valve working badly
Needle valve acting badly
Too high oil level
Carburetor oil overflow
Air circuit clogged and dirty air filter
Intermittent sparking during acceleration
Too thin mixed gas
11. 3 Disassembly of carburetor
11. 3. 1 Disassembly
Turn off tank switch, loosen oil drain plug screw to
release gasoline from the float chamber, and then
remove the rubber fuel oil tube.
Remove the throttle steel cable.
Loosen fixing pipe clamp and fixing screw on the air
intake pipe.
Dismantle carburetor assembly.
Carburetor
Throttle
cable
130
Fixed pipe
clamp
11. 3. 2 Decomposition of carburetor
Remove the fixing plate of throttle cable.
Take down the throttle valve bonnet, spring and throttle valve.
Throttle
valve
cover
Throttle
valve
Throttle
cable
fixing plate
Spring
Upper cover
Unscrew screws and
remove the upper cover.
Take out spring and
plunger component.
Screw
Plunger
componen
t
Screw
Check
wearing
of
plunger.
If any wearing is found,
replace the component.
Check wearing of oil
needle.
If any wearing is found,
replace it.
Spring
Shell components
Oil needle
Seal ring
Loosen connecting screw of lower housing to remove the lower housing
component and seal ring.
Remove the float component, float pin and needle valve core.
Remove idling metering jet, main jet, main nozzle and main foam tube.
131
Lower housing component
Remove the idling adjusting screws and their springs.
Dismantle mixture screw and its spring.
11. 3. 4 Assembly and installation
Assembly and installation are in the reverse sequence of disassembly.
11. 3. 4 Adjustment of carburetor
Attention: The idling adjusting screws have been adjusted when the carburetor is delivered, so no
adjustment is needed in general. To decompose the carburetor, record the number of rotations for
future combination.
Start and warm for around 3 minutes so that the engine runs at normal operating temperature;
Adjust the idling adjusting screw so that the engine speed is 1,500rpm;
Tighten the mixture adjusting screw completely and do not apply too big force;
Now, the engine flames out (if it does not flame out, check if the air filter connection leaks air,
screws are tightened and air filter air inlet is clogged);
Reversely turn the mixture adjusting screw for one turn;
Restart and adjust the idling adjusting screw so that the speed is 2,000—2,500rpm;
Keep adjusting the mixture screw (counterclockwise) slowly until the engine rotates at its maximum
speed (the screw is withdrawn for 2 turns at its maximum);
Re-adjust the idling adjusting screw so that the engine speed is 1,400±100rpm;
Increase frequency of throttle acceleration to check if the idle speed is stable;
Test emission and make comparison against specified standard.
132
XII Cylinder head/Valve
Service Data-----------------------------------12. 1
Fault Diagnosis--------------------------------12. 2
Cylinder Head----------------------------------12. 3
Inspection----------------------------------------12. 4
Valve Guide Replacement----------------------12. 5
Valve Race Fixing and Adjustment------------12. 6
133
Installation-----------------------------------------12. 7
Adjustment of Valve Clearance-----------------12. 8
12. 1 Service Data
Function of cylinder head: It is used to seal cylinder and form the combustion chamber along
with the piston in order to withstand high-temperature and high-pressure combustible gas.
Through the valve system, the cylinder head intakes and discharges gas.
Precautions
To ensure seal between the cylinder head and cylinder body, the head withstand large pre-tension
force from bolt. Pre-tension value: 50Nm
All parts must be cleaned before being checked, and purged with high-pressure air.
Table for Standard Value and Allowable Limit of Reference Items
Item
Flatness of cylinder head
Valve clearance
OD, valve rod
Valve
Valve guide
ID, valve guide
Clearance between valve guide
and valve guide
Valve base width
Valve spring
ID, swingarm hole
Clearance between swingarm
shaft and swingarm hole
Cam
Discharge
Intake/
discharge
Free length
OD, swingarm shaft
Swingarm
Intake
Discharge
Intake
Discharge
Intake
Discharge
Intake
Cam height
Intake/
discharge
Intake/
discharge
Intake/
discharge
Intake
Discharge
(in mm)
Standard
0. 03
0. 09-0. 1
0. 09-0. 1
4. 965-4. 975
4. 95-4. 96
5. 0-5. 012
5. 0-5. 012
0. 03-0. 041
Allowable limit
0. 05
_
_
4. 9
4. 9
5. 1
5. 1
0. 072
0. 045-0. 056
0. 077
1
1. 3
35. 4
32
11. 985-11. 989
11. 93
12-12. 018
12. 05
0. 01-0. 033
0. 075
32. 343
32. 107
32. 14
31. 91
12. 2 Fault Diagnosis
Low compression pressure
Bad valve clearance adjustment
Valve burned or bent
Bad valve base air tightness
Abnormal noise in cylinder head
Bad valve clearance adjustment
Valve spring damaged
Too high compression pressure
134
Air leakage from cylinder head gasket
Too much accumulated carbon in
combustion chamber
Poor installation of spark plug
12. 3 Cylinder head
12. 3. 1 Disassembly
Loosen the two fixing bolts and remove the cylinder head cover (swingarm and its shaft).
Cylinder head cover
Bolt
Release the tightener, loosen the chain and unscrew cover nut to take down cam shaft bracket,
swingarm shaft, swingarm and cam shaft.
Chain
Cylinder cover nut
Cam shaft
Cam shaft bracket
Swingarm shaft
Tightener
Swingarm
135
Measure outer diameter of swingarm shaft.
Allowable limit: 11. 93mm
Micrometer
千分尺
Measure inner diameter of swingarm hole.
Allowable limit: 12. 05mm
Clearance between swingarm hole and swingarm shaft
Allowable limit:0. 075mm
Tester
Directly remove the cylinder head cover and compress the valve spring with the valve spring
compression tool and remove the valve locking clamp.
Take down the spring disk, valve spring and its gasket, and valve in turns.
Valve locking clamp
136
12. 3. 2 Decomposition of valve
Valve locking clamp
Gasket
Valve
Spring disk
Valve spring
Valve oil seal
12. 4 Inspection
Clear carbon accumulated on the cylinder cover.
Measure flatness of the interfacing surface on the
cover.
Allowable limit: 0. 05mm
If the flatness exceeds the allowable limit, place fine
sands on a flat board, engage the interfacing surface with the board, and then grind in a “8” shape.
Testing
gauge
Measure free length of valve spring.
Allowable limit: 32mm
Vernier caliper
游标卡尺
137
Measure outer diameter of valve rod.
Allowable limit: 4. 92mm for discharge
and 4. 935 for intake
Micrometer
Check the valve guide. Prior to check, use a reamer to eliminate carbon accumulated within the
guide.
Attention: the reamer shall be turned clockwise and do not turn it counterclockwise.
Reamer
Measure inner diameters of valve guides.
Allowable limit: Intake/discharge: 5. 06mm
Allowable limit for clearance between valve and its guide: intake:
Discharge: 0. 077mm.
138
0. 072mm
Tester
12. 5 Valve guide replacement
Attention: If clearance between the valve and its guide, replace the guide. After the guide is
replaced, trim surface of the valve washer.
Place the guide into the freezing chamber of electrical refrigerator for one-hour cooling.
Heat the cylinder head to 100-150℃ with an electric oven or thermal oven.
Fix cylinder head, and use the guide disassembly tool to remove the guide out of the head.
Place a new O ring onto the new guide.
Fit the guide from the head top.
Attention: Do not damage the head when fit the valve.
Driver
After the guide is inserted, trim it with a reamer.
Attention: Inject right amount of cutting oil when cut with the reamer. The reamer rotates
counterclockwise.
139
Reamer
Clear carbon accumulated within the combustion
chamber and valve, and thoroughly clean the intake
and discharge valves.
Check width of valve contact surface (valve race
width).
Allowable limit: Intake/discharge: 1. 3mm.
Racer contact surface
12. 6 Valve race fixing and adjustment
Use a 45° cutter to clear coarse or uneven parts on the surface of valve race.
Notes: apply a layer of transparent or Prussian blue coating across the race for more visibility.
Uneven
140
Use a 32° cutter to clear 1/4 of external end of race.
Use a 60° cutter to clear 1/4 of bottom of race.
Remove the cutter and check the processed locations.
Use a 45° trimming cutter to grind the race so that it
meets the suitable width.
Make sure all caves and unevenness are eliminated.
Standard race width:
Intake: 1mm
Discharge: 1mm
141
1mm
If the contact is higher part in the valve, use a 32°
cutter to lower the race to its minimum height.
High
contact
If the contact is lower part in the valve, use a 60° surface
cutter to raise the race to its minimum height.
Use a 45°trimming cutter to trim the race so that it
meets the required specifications.
contact
After the race is ground, apply polishing agent across Low
surface
the valve surface to polish the valve gently.
32°
60°
12. 7 Installation
Installation is executed in the reverse sequence of disassembly.
Attention: To install the valve spring, it shall be
such installed that the end with smaller spring
pitch faces the combustion chamber.
To install valve locking clamp, compress the
spring with its compression tool. To install the
valve, apply a right amount of engine oil across
the valve rod, and then place the rod into the
guide.
12. 8 Adjustment of valve clearance
Check and adjust valve clearance when the engine has been in cooling status.
1. Remove the eyelet cover①, engine cover, and engine cover and intake/discharge adjusting
screw cover on the cylinder head cover.
2 Turn the engine rotor counterclockwise, after the discharge valve and the intake valve are
compressed, align the mark “—“ (on the engine rotor) with the scale mark ② above the engine case,
and make sure the piston is located at the top of compression stroke.
3. Insert the feeler gauge③ between the adjusting screw and valve rod, and check clearance of the
intake and discharge valves.
4. Standard valve clearance: intake stroke 0. 06-0. 08mm and discharge stroke 0. 06-0. 08mm.
5. Adjustment is made by loosening the locking nut ⑤ and then tightening screw ④. After the
adjustment is made, tighten the locking nut, and then measure the clearance until it meets the
standard value.
142
143
144
XIII Cylinder block and piston
Service Data--------------------13. 1
Piston----------------------------13. 4
Fault Diagnosis-----------------13. 2
Installation----------------------13. 5
Cylinder block------------------13. 3
13. 1 Service Data
Precautions
All parts must be cleaned before being checked, and purged with high-pressure air.
Function of cylinder block: It offers a space for gas compression, combustion and expansion,
and guides in piston motion.
It also transfers some of heat to surrounding cooling media.
Function of piston:
1. Withstand pressure as a result of combustion of combustible mixed gas, and transfer such
pressure to the connecting rod to drive the crankshaft.
2. Form the combustion chamber along with the cylinder cover.
Precautions
All parts must be cleaned before being checked, and purged with high-pressure air.
Table for Standard Value and Allowable Limit of Reference Items
Item
ID
Cylindricality
Roundness
Flatness
Piston OD (measuring point)
Cylinder
Piston pin hole ID
Piston pin OD:
Clearance between piston and piston pin
Clearance between piston ring and
ring slot
Piston ring closure clearance
Ring 1
Ring 2
Ring 1
Ring 2
Oil ring
Piston pin end ID
Clearance between connecting rod and piston
pin
145
Standard value
Allowable limit
68. 010-68. 020
0. 02
67. 96-67. 97
(11mm from piston skirt bottom)
16. 002-16. 008
15. 992-16
0. 002-0. 016
0. 03-0. 07
0. 02-0. 06
0. 15-0. 3
0. 15-0. 3
0. 02-0. 06
16. 010-16. 018
68. 120
0. 005
0. 004
0. 05
0. 01-0. 026
0. 10
67. 91
16. 04
15. 960
0. 024
0. 09
0. 09
0. 5
0. 5
0. 12
16. 05
13. 2Fault Diagnosis
Low compression pressure
Piston worn, burnt or broken
Cylinder and piston worn or damaged
Gasket damaged and air leakage
between crankcase and gas
Too high compression pressure
Too much accumulated carbon in
combustion chamber
White smoke from discharge duct
Piston ring worn or damaged
Cylinder and piston worn or damaged
Abnormal noise from piston
Cylinder, piston and piston ring worn or damaged
Piston pin hole and piston pin worn
13. 3 Cylinder block
13. 3. 1 Disassembly
Remove the cylinder block.
Cylinder block
13. 3. 2 Inspection
Check wearing of inner wall of cylinder.
If serious wearing is found, replace it.
Gasket
Remove the gasket and locating pin.
146
13. 4 Piston
13. 4. 1 Disassembly
Remove the piston retaining ring.
Attention: During removal, do not fall the retaining
ring into crankcase.
Take out the piston pin and remove the piston.
Wrist pin
活塞销挡圈,活塞销
Remove the piston ring.
Check piston, piston pin and piston ring.
Attention: do not break or damage the piston ring.
Clear the accumulated carbon within the piston ring.
Install the piston ring.
Measure clearance between the piston ring and its
slot.
Allowable limit: Top ring: 0. 09mm
Ring 2:0. 09mm
Testing
gauge
Piston
Push in
Piston
推入
Remove the piston ring and install the piston rings at
the bottom of cylinder.
Attention: use the piston head to press the piston ring
into the cylinder.
Measure piston ring closure clearance
Allowable limit: 0. 5mm.
Testing
Piston ring
147
Testin
g gauge
Measure piston pin hole ID.
Allowable limit: 16. 04mm.
Tester
Measure piston pin hole OD.
Allowable limit: 15. 96mm
Clearance between piston pin hole and piston pin
Allowable limit: 0. 024mm
1
2
3
90°
Measure piston OD.
Attention: measurement is made at such position as to
form 90° with piston pin and around 11mm
from the piston skirt bottom.
Allowable limit: 67. 91mm
11mm
Check of cylinder inner wall scratch and wearing.
Attention: measure cylinder inner diameter at upper,
middle and lower positions at 90° with the piston pin.
Allowable limit: 68. 12mm
Measure the clearance between the cylinder and piston, and the
maximum value prevails.
Allowable limit: 0. 17mm
148
Tester
Measure the roundness of cylinder inner wall
(difference between X ID and Y ID).
Allowable limit: 0. 05mm
Measure the cylindricality of cylinder inner wall (ID
difference at the upper, middle and lower positions
between X and Y).
Allowable limit: 0. 05mm
Check the flatness of cylinder surface.
Allowable limit: 0. 05mm
Upper
Middle
Lower
Ruler
Testing gauge
Cylinder
Connecting rod small end ID
Measure connecting rod small end ID.
Allowable limit: 16. 05mm.
13. 4. 2 Installation of piston
Install locating pin.
Apply engine oil on the piston rings and pistons, and
install the piston rings at their positions with the
marking face upward.
Attention: do not scratch the piston and do not
break the piston ring.
After the piston ring is installed, the piston ring is
capable to rotate within the piston slot freely.
149
Top ring
Ring 2
Oil ring
Clear all of gaskets attached on the crankcase.
Attention: any foreign matter shall not fall into the crankcase.
Install piston, piston pin and its retaining ring.
Attention: the mark “IN” at the piston top is installed
facing the intake valve.
Mark “IN”
13. 5 Installation of cylinder
Install the gasket and locating pin on the crankcase.
Locating pin
定位销
Apply engine oil across the cylinder inner wall, piston and piston ring.
Care shall be excised to locate the piston ring into the cylinder.
Attention: do not damage piston ring.
XIV Crankcase
Service Data--------------------14. 1
Fault Diagnosis-----------------14. 2
Crankcase-----------------------14. 3
150
Cylinder block
14. 1 Service Data
Function of crankcase: It is a bearing component in the engine. It is provided to support the
crankshaft, clutch, gearbox, cylinder block and head, withstand impact from combustion and inertia
force due to crankshaft connecting rod mechanism, and it also forms some enclosed spaces (oil-seal
and gas-seal).
Suspension hole is provided on the crankshaft, and it is connected with the suspension hole on the
motorcycle so that the engine is connected with frame and other parts.
Precautions
Crankcase is thin-wall casting, so it is required to avoid impact during operation for fear of
deformation or breaking.
All parts must be cleaned before being checked, and purged with high-pressure air.
Prior to any operation, release lubricating oil from the crankcase.
Table for Standard Value and Allowable Limit of Reference Items (in mm)
Allowable
Item
Standard value
limit
Right-left clearance of connecting
0. 1-0. 3
0. 8
rod large end
Crank
connecting rod
Radial clearance of connecting rod
0. 008-0. 018
0. 06
component
large end
Run-out
0. 03
0. 1
Friction disc component thickness
2. 9-3. 1
2. 6
Flatness of driven friction disc
0. 04
0. 2
Clutch
Length of compression spring
30. 4-31. 6
29. 7
Thickness of roller needle bearing
1. 88-2
1. 8
Shaft lock OD
9. 98-9. 995
9. 96
Shaft lock inner hole diameter
10-10. 015
10. 05
Gear shift
Shaft lock thickness
5. 3-5. 4/5. 5-5. 65
5. 1/5. 35
mechanism
Gear shift hub OD
39. 8-40
39. 75
Gear shift hub lock slot width
6. 1-6. 2
6. 35
151
14. 2Fault Diagnosis
Low compression pressure
Abnormal noise in the crankcase
Crankcase air leakage
Parts loosened or broken in crankcase
Overheating engine
Automatic engine shutdown
Clutch sliding
Clutch jammed
Poor lubrication
Failure to put into gear
Difficulty in gear shifting
Gear shifter broken or deformed
Clutch disengaged incompletely
Shifter guiding pin broken
Bad action of gearbox return spring
Gear dog worn
Gear shifting drum slot worn
Automatic out-of-gear
Joint dog worn and edge rounded
Gear shift return spring force reduced
Spline teeth on spline shaft and spline slot of sliding gear worn, consequently generating large axial
force when the gear is operating.
Gear shift drum and shifter worn.
14. 3 Crankcase
14. 3. 1 Removal of left crankcase cover
Loosen the fixing bolt on the startup motor and remove the motor.
Loosen LF cover fixing bolt and remove the LF cover.
Startup motor
Bolt
LF cover
152
Use the electrical or pneumatic tool to
loosen flywheel locking nut.
Take out the flywheel component (including sprocket),
and remove the idle gear of motor.
Remove the gasket.
Gasket
Idle gear of motor
Flywheel components
Remove the gear display.
Gear
display
14. 3. 2 Removal of right crankcase cover
Loosen the fixing bolt and remove the right crankcase cover, gasket and locating pin.
Mould assembling
bolt
Right cover
153
14.4 Clutch
14.4.1 Dismounting
Unscrew the five bolts in the pressure plate with the
diagonal cross method.
Dismount the clutch spring, pressure plate, thrust
washer, plane needle roller bearing and bearing
support.
Refer to the breakdown drawing for dismounted
components.
Bolt on separating disc
Unscrew the lock nut with special tool to dismount the
lock nut and thrust washer.
Dismount the center bearing bracket on the clutch.
Dismount the drive and driven friction blocks on the
clutch.
Refer to the breakdown drawing for dismounted
components.
Dismount the thrust washer.
Dismount the shell components.
Clutch assembly is done in the reverse order.
Four jaw socket wrench
Shell components
154
14.4.2 Clutch disassembly
1 nut; 2 Phillips adjusting screw; 3 thrust washer; 4 plane needle roller bearing; 5 lock nut; 6 bearing support; 7
lock washer; 8 bolt assembly; 9 pressure plate; 10 clutch spring; 11 friction disc assembly; 12 driven friction disc
assembly; 13 center bearing bracket; 14 shaft sleeve; 15 thrust washer; 16 shell components
Check
Check if there are burrs or damage in the shell components of the
clutch, and get rid of them with a file. Replace the clutch if too much
such work needs doing.
Shell components
Check if there is damage in the dents of the pressure plate and the
center bearing support. Replace it if there is damage.
Center bearing support
155
Pressure plate
Measure the free length of the pressure spring.
Replace it if the limit is below 29.7 mm.
Free length
Measure the thickness of the friction disc with a
vernier caliper.
Replace it if the limit is below 2.6mm.
Thickness
Measure the flatness of the driven friction disc with a
plug gauge.
Replace it if the limit is above 0.2mm.
Plug gauge
156
Driven friction disc
Measure the thickness of the plane needle roller
bearing.
Replace it if the limit is below 1.8mm.
Needle roller bearing
Crank connecting rod combination and gearbox assembly
Crank connecting rod combination
Right crank case
Locating pin
Bolt
Left crank case
157
Gearshift drum
Shifting fork
Shift rail
Principal shaft assembly
Vice shaft assembly
158
14.4 Gearshift Mechanism
14.4.1 Dismounting
Dismount the gearshift combination.
Dismount the upper baffle bolt, the upper baffle and
gearshift ratchet wheel gear ring.
Dismount the lower baffle bolt, the lower baffle and
the ratchet wheel.
Dismounted components are revealed in the
dismantling drawing.
Gearshift mechanism
Upper baffle on the
ratchet wheel
Gearshift ratchet wheel
gear ring
14.4.2 Dismantling drawing of the gearshift mechanism
1 gearshift mechanism; 2 shaft sleeve; 3 restoring spring; 4 gearshift ratchet wheel; 5 nut; 6 upper baffle on the
ratchet wheel; 7 lower baffle on the ratchet wheel; 8 pawl; 9 jack-prop on the pawl; 10 contact spring; 11 gearshift
ratchet wheel
14.4.3 Check
Before dismounting, the gearshift baffle should work sound and without difficulty in restoring.
Check the abrasion of the baffle and the gearshift mechanism. Replace it if there is too much abrasion.
159
Check the abrasion of the locating plate of the gearshift. Replace it if there is too much abrasion.
Check if the gearshift shaft is bent. Replace it if it is excessively bent.
Check the elasticity of the restoring spring. Replace
Clutch drive wheel gear
it if necessary.
Unscrew the bolt and washer on the right crank shaft
Drive wheel gear
with electric or compression tools. Dismount the two
lubrication oil pump
wheels and the flat key.
Dismount the retainer ring; remove the wheel gear
Bolt
on the fuel pump; unscrew the nut in the fuel pump;
dismount the fuel pump assembly.
Wheel gear on lubrication
oil pump
Retainer ring
Unscrew the bolt in the veneer case.
Open the crank case.
Note: do not damage the surface of the case.
Remove the left part of the case.
Left crank case
Case connecting screw
160
on
14.5 Crankshaft connecting rod assembly
14.5.1 Dismounting
Remove the crankshaft connecting rod assembly from the
right crank case.
Note: do not damage the surface of the case.
Plug gauge
14.5.2 Check
Measure the clearance on the left and right side of the big
end of the collecting rod.
Allowable limit: 0.05mm.
Measure the clearance along X-Y direction of the big end
of the connecting rod.
Allowable limit: 0.8mm.
Measuring point
Point of measuring the
Measure the dislocation of the crank shaft.
Allowable limit: 0.1mm.
big end of the connecting
rod
161
Check if the crank shaft is noisy or loose while restoring.
Replace it if so.
Crank shaft bearing
Note: both the crank connecting rod and the gearshift mechanism are installed on the crank case.
Draw out the shifting fork.
Remove the gearshift drum.
Remove the gearshift fork.
Shifting fork
Gearshift
Gearshift drum
162
fork
14.5.3 Check
Measure the external diameter of the shifting fork.
Allowable limit: 9.96mm.
Micrometer
Measure the inner diameter of the fork hole.
Allowable limit: 10.05mm.
Tester
Measure the thickness of the shifting fork.
Allowable limit: respectively 5.1mm and 5.35mm.
Vernier caliper
Measure the external diameter of the gearshift drum.
Allowable limit: 39.75mm.
Measure the width of the hinge slot in the gearshift drum.
Allowable limit: 6.35mm.
Width of the lock slot
163
Principal shaft
assembly
14.6 Gear box assembly
Vice shaft
Remove the principal shaft assembly.
Remove the vice shaft assembly.
assembly
Dismantling drawing of the principal and vice shaft assemblies
Principal shaft assembly
Vice shaft
assembly
1 plug; 2 shaft sleeve; 3 washer; 4 first gear wheel on the vice shaft; 5 needle roller bearing; 6 fifth gear wheel on the vice shaft; 7
spline washer; 8 fourth gear wheel on the vice shaft; 9 third gear wheel on the vice shaft; 10 gearshift wheel; 11 shaft sleeve; 12
second gear wheel on the vice shaft; 13 vice shaft; 14 thrust washer; 15 O-seal ring; 16 shaft sleeve; 17 second gear wheel on the
principal shaft; 18 third and fourth gear wheel on the principal shaft; 19 fifth gear wheel on the principal shaft; 20 retainer ring; 21
plugging column; 22 principal shaft
164
Check
Check the abrasion of the wheel gear surface and the
drive claw.
Replace it if there is too much abrasion or damage.
Wheel gear surface
Drive claw
Remove the bearing in the left crank case.
Check possible damages on the bearing and the oil seal. Replace them if there are damages.
Note: the removed bearing can not be used any more. It should be replaced with a new one.
Special tool should be used to dismount the bearing and oil seal.
Bearing
Remove the bearing in the right crank case.
Check possible damages. If there are damages, replace it.
Note: the bearing removed can not be used any more. It should be replaced with new one.
Special tool should be used to dismount the bearing and oil seal.
165
Bearing
Principal and vice shaft assemblies
Note: lubrication oil should be used on the wheel gears and shafts while assembling them. Ensure the wheel gear
works normally after the completion of the assembling work.
Note: the assembling work of the crank case should be done in the reverse order.
166
Exhaust System Inspection and Maintenance
Muffler
A
Torsion force of the locating bolt 5
in the connector of the muffler in
the figure: 5-9N·m
B
Torsion force of the protective
shield 6 in the connector of the
muffler in the figure: 5-9N·m
1 welded components on the muffler; 2 socket head cap screw; 3 liner components on the exhaust pipe; 4 welded
components on the muffler tail cover; 5 combination screw M6×10; 6 spring washer 8; 7 protective shield on the
exhaust pipe
167
ⅩⅦ Emission Control System
Emission Control System Guarantee……………………………………...…...…..15.1
Periodical Maintenance Instructions/Ensuring Emissions Standards.………..……15.2
Mechanical Functions of Emission Control System……………………………….15.3
Solutions to the problem of idle exhaust exceeding specified value (four-stroke)...15.4
15.1 Emission Control System Guarantee
1. This emission control system is in accordance with the revised versions of the EU EC/97/24/5/I and
2003/77/EC B. Our guarantee is set for products in effective service life that are maintained absolutely following
our instruction.
2. Scope of guarantee
a. guarantee on the function of the emissions control system
During the service life (15,000 km), it can pass all the periodic and non-periodic emissions control inspection of
the government authorities.
3. The following cases are out of the scope of the guarantee. If maintenance services are needed, services from the
franchisers or service centers of our company in different places will be available for the customers at a
reasonable price.
a. maintenance is not conducted according to the intervals or distance of drive specified in our instructions.
b. periodic maintenance, adjustments or repair work is not done in our franchisers or service centers, or no
evidence of maintenance is available.
c. overload or improper use.
d. the vehicle is modified, the original components are removed or replaced with other components privately.
e. the vehicle is used in racing or frequently operated in roads that are used for non-motor vehicles.
f. the vehicle is damaged by such climate disasters as typhoons and floods, or in improper use, car accidents and
clashes;
g. not in use for a long time and lack of periodic maintenance.
h. the odometer is damaged but not repaired immediately, or it is modified, stopped or replaced.
i. please send the vehicle to the inspection place every three months to check emission control.
 The new vehicles produced in our company have passed the EU standard of EC 97/24/9.
15.2 Periodical Maintenance Instructions

To prevent deterioration of environmental pollution, the government requires all the manufacturers to ensure
their products meet the emissions control standards. Our products meet those standards. We are also making
our due contribution to air purification and reducing air pollution.
168



This vehicle has passed strict inspection. It completely meets the emissions control standards. Due to the
varying concrete conditions of use of the vehicles, we made the following inspection table for periodic
emissions inspection. To ensure normal levels of emissions, the user should follow the specified intervals of
maintenance, adjustment or repair.
Please consult the franchisers or the service centers of Qianjiang if you have other problems.
Relevant emission standards are as follows:
Emission regulation
CO
HC
NOX
Emission standard
≤2.0g/km
≤0.3g/km
0.5 g/km
※effective emission standards are subject to the newest updated changes made by the government.
 If periodic maintenance is not done in our franchisers or service centers, we will not be responsible for
possible case of being canceled. Please do necessary checks at all times to ensure optimal functions of the
vehicle.
Note: ① the air filters on vehicles running on gravel pavements or severely polluted environment need to be
cleaned more frequently, so as to lengthen their service life.
② better maintenance should be given to vehicles that are constantly used or frequently running at high
speeds.
Please notice the following items to ensure consistence with emission standards:
a. fuel: only 92# or 95# unleaded gas can be used.
b. Lubricant oil: only specified lubricant oil can be used.
c. maintain it according to the instruction in the periodic maintenance table.
d. no private adjustment or replacement can be done to the emissions control system, including: use of spark plug,
idling adjustment, ignition timing and adjustment to the carburetor.
e. Note:
 Problems in ignition system, charging system and fuel system have great impacts on the catalytic device, so
if there are problems in the engine, please send it to the franchisers or service centers for check, adjustment
or repair without delay.
 Only 92# or 95# unleaded gas can be used in the vehicle, or else, the catalytic device (four stroke system) can
be damaged.
f. the emissions control system of this vehicle complies with the national regulation, so only the components
produced in our company can be used while replacing any components in the system, and it should be done in our
franchisers or service centers.
15.3 Mechanical Functions of Emission Control System
Profile
The emission solution is based on the use of the four stroke single cylinder engine and the carburetor, air inhaling
device, high standards of emission control and use of charcoal canister for emission evaporation.
※ Improvements in the engine
Exhaust and combustion are improved by improving the spark plug, spherical combustion chamber, compression
ratio, ignition time and exhaust system in the engine.
※ Air inhaling device
Air is led into the exhaust pipe to compose the CO and HC that are not completely burned into harmless emission.
Division
Device
Component
Purposes and functions
Exhaust
system
Catalytic device
Catalytic converter
Canned oxidation catalyst contained in the center
of the exhaust pipe oxidizes CO, HC and NOX.
169
15.4 Solutions to the problem of idle exhaust exceeding specified value (four- stroke)
Implement periodic check (maintenance plan)
Qualified
Idling emissions measurement (Note 1)
Qualified
Carburetor adjustment (Note 2)
Qualified
Qualified & finished
product
Dismount and clean the carburetor
(SJ, MJ, SAJ, MAJ and so on)
Qualified
Carburetor replacement
Dismount and repair the engine
•Valve (leakage)
•Piston (abrasion)
•Combustion (cleaning)
Qualified
合格
Note 1: test it according to the idling testing procedure.
Note 2: adjust the speed of the engine to reach the specific value with the lock screw, and test CO/HC in idling.
170
Complete QJ200-2A Schematic Circuit Diagram
171