Baotian BT49QT-7 Service Manual Download Page 1 | Manualshive

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BT49QT-7&BT49QT-8

SERVICE MANUAL

JIANGMEN SINO-HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO., LTD

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Summary of Contents for BT49QT-7

Page 1: ...BT49QT 7 BT49QT 8 SERVICE MANUAL JIANGMEN SINO HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO LTD ...

Page 2: ...BLESHOOTING 4 1 N O I T C E T E D E L B U O R T D N A S E L B U O R T N O M M O C Y D O B E N O N O I T C E S SECTION TWO DETAILED DESCRIPTIONS OF BODY PARTS TROUBLES FRONT WHEEL SERVICE 17 9 1 E K A R B K S I D E C I V R E S E K A R B T N O R F FRONT SHOCK ABSORBER SERVICE 1 2 FRONT FORK SERVICE 22 4 2 E C I V R E S R A B E L D N A H REAR WHEEL SERVICE 25 6 2 E C I V R E S E K A R B R A E R REAR ...

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

Page 4: ...I I I I I I I Drive belt I Suspension I I 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 t...

Page 5: ...e oscillation Front tire wear damage 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 ...

Page 6: ...n specified tightening torques 4 Cleaning Cleaning 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 ...

Page 7: ...the throttle grip Effected adjustment is by removing the dust cover loosening the tightening nut and turning the adjusting nut AIR FILTER INSPECTION AND CLEANING After a certain mileage dust and impurities will gather in air filter case and strainer which will clog strainer pores and reduce inlet of air and thus lead to excessive concentration of mixed gas and reduce the performance of engine That...

Page 8: ...s 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 brake lever is drawn to the stopping position friction linings must be replaced with new ones VII BRAKE SYSTEM INSPECTION ADJUSTMENT AND REPLACEMENT 1 Front brake disk brake Remove the bolts linking brake caliper and fr...

Page 9: ... Brake block must be replaced as a set Remove two pieces of brake block pins by means of a hexagon wrench Effect mounting in an order reversed to that of dismounting After effecting first tighten the brake caliper and put its hole right to the hole of brake caliper and then put the brake block pin in and tighten it Brake Disc Inspection Inspect brake disc thickness Limit of use 3 0mm Inspect brake...

Page 10: ...tion Inspect front shock absorber to see if there is leakage of oil and if there is damage or loosening 2 Rear Shock Absorber Press rear shock absorber to inspect actuation Inspect rear shock absorber to see if there is oil leakage and if there is damage or loosening in machine parts Lift rear wheel press rear wheel right and left to inspect if engine suspension lug buffer bush is loose IX FRONT W...

Page 11: ...ered tire Chunking of tread Damaged tire bead Broken tire bead or other tire bead damages Broken tire cord Damage due to forced dismounting Fissure extending to frame Abnormal inner lining Tire groove wear front wheel 0 8mm rear wheel 0 8mm Punctured or otherwise damaged tire flank Inspect tire pressure by means of a tire pressure gauge Tire pressure should be inspected when the motorcycle is in a...

Page 12: ... 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 CHAPTER TWO MAINTENANCE INFORMATION I FRAME NUMBER AND ENGINE NUMBER LOCATION engine number frame number ...

Page 13: ...st in case of a removed battery Connected terminals must be coated with lubricant The terminals must be completely covered with caps When a fuse is burnt inspect the cause and replace the fuse with a fuse of equivalent capacity At the completion of operation completely cover terminals with caps When removing connectors with locks they must be unlocked before operation When removing connectors the ...

Page 14: ...n or damage III SPECIFIED TORQUES Torques at important positions and standard torques of other positions are as follows SPECIFIED TORQUES Frame Designations of tightening positions Number Thread specification Torques N m Engine suspension lug mounting nut 1 M10 45 Engine mounting nut 1 M10 45 Front axle nut 1 M12 60 Rear axle nut 1 M16 120 Rear shock absorber upper mounting bolt 1 M10 40 Rear shoc...

Page 15: ...E BODY TROUBLESHOOTING SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION Body part common troubles and possible causes are as follows e c n e r e f e r s l i a t e D s e s u a C s e l b u o r T Over tightening of handlebar adjusting nut Handlebar rotation not easy strenuous turning or unstable tightness Steering stem over worn Refer to Front Fork Service Incorrect mounting of brake cable or t...

Page 16: ...block Drum brake failure Worn or slotted brake drum bore Refer to Brake System Inspection Adjustment and Replacement Rear Brake Service Bent brake lever Air in hydraulic device Leakage in hydraulic device Disk brake failure Feeble brake lever Clogged hydraulic passage Refer to Brake System Inspection Adjustment and Replacement Front Brake Service Chart continued e c n e r e f e r s l i a t e D s e...

Page 17: ...ake disc Bent or deformed brake disc Inability of brake caliper normal sliding Resisted braking Wheel not adjusted straight Chart continued e c n e r e f e r s l i a t e D s e s u a C s e l b u o r T Hardened brake block surface or dusty block Uneven or slotted brake block surface Serious wear of brake block lining Abnormal braking sound Serious slots inside brake drum Refer to Rear Brake Service ...

Page 18: ...ion Poor wheel Refer to Rear Wheel Service Soft rear shock absorber Spring fatigue Refer to Rear Shock Absorber Service SECTION TWO DETAILED DESCRIPTION OF BODY PARTS TROUBLES Precautions in Operation Forced mounting or dismounting of body cover parts will cause damage to claws and slots of corresponding hoods When mounting body cover parts be sure to align the corresponding parts of hoods When mo...

Page 19: ...ts Remove brake disc Axle Bending Inspection Place axle on a V seat and measure with a dial gauge The dial gauge indicates a 1 2 bending value Limit of use Replace if 0 2mm Wheel Rim Oscillation Inspection Measure oscillation value on a correcting bench Limit of use Replace if 2 0mm Traverse direction Replace if 2 0mm brake disc brake caliper bolt front axle mounting bolt front wheel front shock a...

Page 20: ... the bearing Drive in left bearings Mount spacer Drive in right bearings Bearings must be driven in parallel Dust cover must be driven in with the face out Apply grease to new dust cover lip Mount front axle bush Front Wheel Mounting Mount brake disc tighten brake disc mounting bolts Torque 27N m Spread front axle with a thin film of grease Mount front axle from left side Mount in order small bush...

Page 21: ...th specified brake oil It is not necessary to fill the oil reservoir to its full capacity Brake oil for replenishing should be the same as original The specification of brake oil is indicated on the reservoir cover Place diaphragm Connect a transparent hose to exhaust valve Grip brake lever fast and open exhaust valve 1 2 turn to let out air and lock exhaust valve Repeat this operation till no bub...

Page 22: ... switch and brake lever Remove retaining ring from main cylinder Use special retaining ring remover when removing retaining ring Remove piston cover piston and spring Clean oil reservoir and piston with pure brake oil Do not effect cleaning with gasoline as it is corrosive to rubber parts Inspection Inspect for wear or ageing of main and auxiliary cups on pistons Inspect for scratches and other da...

Page 23: ...oil and exhaust air in brake system III FRONT SHOCK ABSORBER SERVICE Dismounting Remove body covering parts Remove front wheel Remove 4 pieces of bolts on the upper part of front shock absorber Remove shock absorber Inspection Inspect if there is oil leakage in front shock absorber if there is deformation of shock absorber arm and if there is damage or loosening of any part Mounting Mount front sh...

Page 24: ...m bearing cup bearing top and bearing set is the same as the removing of the upper series Do not damage steering stem when removing bearing cup and bearing top Clean opening parts of motorcycle body covering parts with cloth Inspection Inspect if there is slot or pit in bearing cup and bearing top If there is effect replacement front fender screws shock absorber upper bearing cup bearing top and b...

Page 25: ...s steering stem through head tube Mount front fender on steering stem Mount front wheel Mount front shock absorber and other parts Apply grease to top bearing cup and bearing top Mount in order upper bearing cup bearing ball set and upper bearing top on the upper part of steering stem and fasten them Torque 15 N m Turn front fork right and left to effect close contact of bearing balls Loosen upper...

Page 26: ...ounting Mount handlebar on steering stem guide tube setting bolt and nut Torque 45 N m Mount left handlebar switch and fasten screws Torque 9 N m Mount front brake main cylinder and fasten bolts Mount right handlebar switch and fasten screws Torque 9 N m Apply grease to throttle cable Mount throttle grip and connect throttle cable Mount left grip Mount covering parts of front head cover and rear h...

Page 27: ...itudinal 2 0 mm Traverse 2 0 mm Mounting Mount rear wheel and fasten rear axle nut Torque 120N m Mount exhaust muffler Fasten exhaust muffler connecting nuts and bolts Torque Exhaust muffler connecting nut 12N m Exhaust muffler mounting bolt 35N m VII REAR BRAKE SERVICE Remove exhaust muffler Remove rear wheel Inspect rear brake drum Measure rear brake drum bore exhaust muffler mounting bolts exha...

Page 28: ... setting pin brake cam and brake block friction surface Apply grease to moving part of brake cam Do not apply grease to parts not specified Superfluous grease flows into brake friction linings of brake drum shall reduce braking effect Mount brake cam Mount brake swing arm on brake cam Notch on brake swing arm should be aligned with the cut off of brake cam Mount brake swing arm setting bolt and fa...

Page 29: ...necting rear shock absorber and motorcycle frame bolt connecting rear shock absorber and engine Withdraw air filter Remove rear shock absorber Inspection Inspect rear shock absorber oil seal for oil leakage inspect buffer bar and spring for deformation and other parts for damage and loosening Mounting Mount rear shock absorber Torque upper mounting bolt 40N m bottom mounting bolt 25N m Mount air f...

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