Baotian BT49QT-3 Service Manual Download

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BT50QT-9&BT49QT-3

SERVICE MANUAL

JIANGMEN SINO-HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO., LTD

www.asiamotor.se Baotian European Spare parts Center

Summary of Contents for BT49QT-3

Page 1: ...BT50QT 9 BT49QT 3 SERVICE MANUAL JIANGMEN SINO HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO LTD w w w a s i a m o t o r s e B a o t i a n E u r o p e a n S p a r e p a r t s C e n t e r ...

Page 2: ...Ⅹ STEERING STEM INSPECTION 10 CHAPTER TWO MAINTENANCE INFORMATION Ⅰ FRAME NUMBER AND ENGINE NUMBER LOCATION 11 Ⅱ PRECAUTIONS IN OPERATION 11 Ⅲ SPECIFIED TORQUES 12 CHAPTER THREE BODY TROUBLESHOOTING SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION 14 SECTION TWO DETAILED DESCRIPTIONS OF BODY PARTS TROUBLES Ⅰ FRONT WHEEL SERVICE 17 Ⅱ FRONT BRAKE SERVICE DISK BRAKE 19 Ⅲ FRONT SHOCK ABSORBER SE...

Page 3: ...long time running of the engine z Replace engine oil at short intervals so that metal chips caused in the running in period can be discharged It is recommended to replace engine oil for 3 times during the running in period 2 Routine Maintenance Routine maintenance is the basis of all kinds of maintenances It refers to the daily maintenance including cleaning inspection and common troubleshooting 3...

Page 4: ...I Tire I I I Steering rod bearing I I I Screws and bolts of parts I I Rear brake cam C Notes 1 I Inspect and when necessary clean lubricate supplement modify or replace A adjust C clean R replace T tighten 2 Effect periodic maintenance according to the instructions in the user s manual 3 When the mileage exceeds the range specified in the schedule repeat the maintenance 4 In dusty or rainy conditi...

Page 5: ...e tire pressure Headlight beam adjustment Rear brake rod free play Rear shock absorber damage loosening Air filter contamination Front brake disc damage wear Front brake caliper wear of friction lining Rear brake wear of brake drum damage wear of friction lining gearcase engine oil quantity oil replacement Spark plug damage contamination 3 w w w a s i a m o t o r s e B a o t i a n E u r o p e a n ...

Page 6: ...ning is needed by machine parts and positions which call for cleanliness and tidiness Cleaning operations include all the means and measures taken to remove dust contamination metal chips oily stains and carbon deposits that might lead to pipe clogging or reduction in motorcycle performance Cleaning measures are washing carbon deposit removing rubbing cleaning and clearing 5 Lubrication In order t...

Page 7: ...djust by loosening the fastening nut and turning the adjusting nut Fine adjustment is effected on the side of the throttle grip Effected adjustment is by removing the dust cover loosening the tightening nut and turning the adjusting nut adjusting nut tightening nut free travel 2 6mm adjusting nut dust cover tightening nut 5 w w w a s i a m o t o r s e B a o t i a n E u r o p e a n S p a r e p a r ...

Page 8: ...strainer cover Take out the foam strainer Immerse foam strainer in gasoline and wash it to remove dust and impurities by gripping and pressing Press gasoline out of the foam Soak the cleaned foam with engine oil press out or throw out engine oil to leave it moist with oil Mount VI REAR BRAKE FRICTION LINING INSPECTION If the arrow on brake swing arm is aligned with the scotch on gear case when bra...

Page 9: ...k must be replaced when it is worn to the limit of use It is not necessary to remove brake oil pipe when replacing brake block Brake block must be replaced as a set Remove the brake block pin by means of a hexagon wrench Return brake caliper left part counter clockwise remove old brake block and mount new brake block Effect mounting in an order reversed to that of dismounting 7 brake caliper bolts...

Page 10: ...t when free travel exceeds limit VIII FRONT AND REAR SHOCK ABSORBER INSPECTION 1 Front Shock Absorber Tighten front brake lever press front shock absorber up and down and inspect actuation Inspect front shock absorber to see if there is leakage of oil and if there is damage or loosening 8 rear brake lever adjusting nut front brake lever w w w a s i a m o t o r s e B a o t i a n E u r o p e a n S p...

Page 11: ...nspection Inspect if there is fissure or iron nail in the tire In one of the following conditions tires must be replaced instead of repair z Puncture of tire by a foreigner matter 6mm in diameter or tire fissure z Layered tire z Chunking of tread z Damaged tire bead z Broken tire bead or other tire bead damages z Broken tire cord z Damage due to forced dismounting z Fissure extending to frame z Ab...

Page 12: ...ut 60N m rear wheel nut 120N m X STEERING STEM INSPECTION Swing handlebar right and left to see if there is interference such as wire or other things Turn front wheel to see that handlebar is easy in operation In case of any difficulty in operation inspect steering stem bearing assembly front axle nut rear axle nut 10 w w w a s i a m o t o r s e B a o t i a n E u r o p e a n S p a r e p a r t s C ...

Page 13: ...ed or equivalent greases z Parts must be tightened and their performances inspected at their positions when mounted z The battery s negative terminal must be disconnected before operation Make sure that tools such as wrenches are not in contact with the frame z At the completion of operations reconfirm correct connections and fastenings The positive terminal must be connected first in case of a re...

Page 14: ...c sleeves should not be placed with the open side up z Wire bunch bands should be fixed at the specified position of motorcycle frame z Wire clamps must correctly keep wires in place Avoid welding stains of welded clamps when clamping wires z Wire bunches must be fixed away from turning or moving parts z Do not damage the covering of wire bunches In case of wire bunch defects remedy it with insula...

Page 15: ... 25 Front shock absorber upper lock bolt 4 M8 35 Steering stem lock nut 1 M25 70 Handlebar mounting nut 1 M10 45 Upper bearing top 1 M25 2 5 Exhaust muffler connector nut 2 M6 12 Exhaust muffler mounting bolt 2 M8 35 Standard Torques Designations Torques N m Bolt nut M5 5 Bolt nut M6 10 Bolt nutM8 21 5 Bolt nut M10 35 Bolt nut M12 55 Screw M5 4 Screw M6 9 Flange bolt nut M6 12 Flange bolt nut M8 2...

Page 16: ...ire air Refer to Front Wheel Service Rear Wheel Service Imbalance of right and left shock absorbers Refer to Front Shock Absorber Service Bent front fork Refer to Front Fork Service Deflected steering stem Bent front tire deflected tire Refer to Front Wheel Service Normal wear of brake lining Hardened brake block or dusty block Excessive front brake and rear brake Damaged brake cable Brake cam rot...

Page 17: ...ed main cylinder Clogged narrow brake system Clogged narrow liquid passage Viscous worn brake caliper Inability of brake caliper normal sliding Worn seal ring of brake caliper piston Stiff brake lever Viscous or worn main cylinder piston Contaminated brake block and brake disc Bent or deformed brake disc Inability of brake caliper normal sliding Disk brake failure Resisted braking Wheel not adjust...

Page 18: ...mounting Roundness error of wheel rim Deformation of wheel rim Deviation of motorcycle direction inclining to roadside Inadequate tire pressure Refer to Front Wheel Service Deformed wheel rim Loose front wheel bearing Poor tire Front wheel oscillation Poor axle locking Refer to Front Wheel Service Soft front shock absorber Spring fatigue Refer to Front Shock Absorber Service Deformed wheel rim Rea...

Page 19: ...unting Support the body bottom to lift front wheel Remove front axle nut brake calipers front absorbers connecting bolt and remove brake calipers front shock absorber transmission gear box front axle bush and the small bush remove front axle Remove front wheel Remove brake disc mounting bolts Remove brake disc 17 front shock absorber front axle transmission gear box front axle nut front axle bush ...

Page 20: ...m Front Wheel Bearing Inspection Remove front wheel bearing and dust cover Turn bearing inner race to inspect sliding Replace it with a new one in case of no sliding or damage or loosening of outer race Front Wheel Bearing Replacement Dismounting Remove front wheel bearing by means of a bearing remover take out spacer Mounting Apply grease to the bearing Drive in left bearings 18 dust cover front ...

Page 21: ...E Brake Oil Replacing z Prevent dust or water from entering brake system z Do not use brake oils of different specifications or impure brake oils z Prevent brake oil from dripping onto rubber plastic or painted parts Brake Oil Exhausting Place main cylinder at a level place remove oil reservoir cover and diaphragm Connect a hose to oil exhaust valve loosen exhaust valve grip and release brake leve...

Page 22: ...eservoir cover bolt Main Brake Oil Tank Dismounting and Mounting Dismounting Remove 4 screws of front part and rear part of head cover Remove front part and rear part of head cover Exhaust brake oil from front brake system Pull out brake switch plug from main cable Remove bracket bolts from handlebar Remove main cylinder Remove brake oil pipe from main cylinder z Prevent brake oil from splashing t...

Page 23: ...ton at the end of auxiliary cup Mounting Apply pure brake oil to piston main cup and auxiliary cup Mount spring piston retaining ring and piston cap z Piston cup cannot be used inside out Apply grease to brake lever axis pin Mount brake lever and brake switch Mount main cylinder main cylinder bracket and lock them Mount brake oil pipe Connect brake light switch cable with switch Mount head cover f...

Page 24: ...ount 4 bolts Torque upper bolt 35N m Mount front wheel Mount front fender IV FRONT FORK SERVICE Dismounting Remove motorcycle body covering parts Remove handlebar bolt bush and nut from handlebar Remove handlebar Remove steering stem setting nut Remove upper bearing cup upper bearing top and bearing set 22 nut bush bolt shock bolt absorber upper bearing cup bearing top and ball set steering stem h...

Page 25: ...adjustment and fasten it Inspect for correct position of bearing cup and bearing top and if not effect correct mounting front wheel shock front fender bracket bottom bearing cup bearing top and ball set head tube absorber upper bearing top ball set ball set bottom bearing cup bottom bearing top upper bearing cup Bearing Cup and Bearing Top Replacement Remove bearing cup and bearing top with specia...

Page 26: ...of front part and rear part Remove connectors of left handlebar switch Remove 2 screws of left handlebar switch Remove left handlebar switch Remove left grip from handlebar Remove front brake main cylinder Remove connectors of right handlebar switch Remove 2 screws of right handlebar switch Remove right handlebar switch Remove throttle cable from throttle grip Remove throttle grip from handlebar R...

Page 27: ...ad cover z Confirm easy rotation of throttle grip z When mounting handlebar rubber apply a thin film of adhesive to contacting face and then mount grip in a turning manner VI REAR WHEEL SERVICE Dismounting Remove 2 connecting nuts and 2 mounting bolts of exhaust muffler Remove exhaust muffler Remove rear axle nut and rear axle Rear Wheel Oscillation Inspection Measure oscillation value on a correc...

Page 28: ...k Replacement Remove rear brake block and return spring as a whole and replace them with new ones z See that no grease is with brake block friction surface Rear Brake Disassembling Remove rear brake adjusting nut remove rear brake cable from brake swing arm Remove brake block assembly Remove brake swing arm setting bolt and swing arm Remove brake cam 26 µ brake block brake cam return spring brake ...

Page 29: ...h on brake swing arm should be aligned with the cut off of brake cam Mount brake swing arm setting bolt and fasten it Torque 10N m Mount brake block assembled with spring Mount rear wheel Mount exhaust muffler Mount brake swing arm pin and rear brake cable z Mount return spring of brake cable with the spring aligned with the recess hole of left crankcase cover Mount adjusting nut Adjust brake syst...

Page 30: ...on Inspect rear shock absorber oil seal for oil leakage inspect buffer bar and spring for deformation and other parts for damage and loosening Mounting Mount rear shock absorber Torque upper mounting bolt 40N m bottom mounting bolt 25N m Mount air filter Mount motorcycle body covering parts 28 rear shock absorber mounting bolt mounting nut upper mounting bolt rear shock absorber mounting bolts air...

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