Generic Trigger SM 50ccm Owner'S Manual Download Page 31

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1 Brake

Maintenance instruction ------------------------ 1.1

Fault diagnosis ----------------------------------- 1.2

Front hydraulic brake ----------------------------1.3

Rear hydraulic brake ---------------------------- 1.4

1.1 Maintenance instruction

Matters needing attention in operation

* Note

*Inspect the brake before riding the motorcycle.*

1.1.1 Specification

Item

Standard value (mm)

Allowable limit(mm)

thickness of front brake disc

4.0

thickness of front brake pad

4.5

3.0

thickness of rear brake disc

4.0

thickness of rear brake pad

7.0

3.0

QJ50-23 diameter of front hydraulic brake

230mm Diameter of rear hydraulic brake

220mm

QJ50-23A

diameter of front hydraulic brake

280mm

Diameter of rear hydraulic brake

220mm

1.1.2 torque value

Fixing bolt of brake disc

22-29 N·m

Mounting bolt of brake caliper

22-29 N·m

1.2 Fault diagnosis

Brake

Bad braking quality Slow brake or tight rod

1. Unfavorable brake adjustment 1. Unfavorable brake adjustment

•The braking components can not be spoiled by oil stain in installation or disassembly.
•Rinse with stipulated cleaning agent in order to avoid reduction of braking quality.

Summary of Contents for Trigger SM 50ccm

Page 1: ...Preparation data 50 4 2 Fault diagnosis 50 4 3 Rear wheel 51 4 4 Rear shock absorber rear rocker 52 4 5 Driving chain 53 5 Battery charging system 56 5 1 Preparation data 56 5 2 Fault diagnosis 57 5 3 Battery 58 5 4 Charging system 59 5 5 Voltage and current regulator 60 5 6 Charge coil of the alternator 60 5 7 Illuminating coil of alternator 61 5 8 Disassembly of alternator 61 6 Ignition system 6...

Page 2: ...isassembly of carburetor 85 10 4 Carburetor cover 86 10 5 Float chamber 87 10 6 Installation of carburetor 87 11 Cylinder cover air cylinder piston 90 11 1 Preparation data 90 11 2 Fault diagnosis 91 11 3 Disassembly of air cylinder 91 11 4 Disassembly and installation of the piston 92 11 5 Installation of the air cylinder 95 11 6 Disassembly of cylinder cover 95 11 7 Installation of the cylinder ...

Page 3: ...xhaust emission and control system 118 15 1 Warranty of Exhaust emission and control system 118 15 2 Regular maintenance guideline 119 15 3 Mechanical function of the exhaust control system 120 15 4 Catalyst converter system 121 15 5 Countermeasure of idle speed emission exceeding specified value two stroke 122 ...

Page 4: ...pection After Chapter I is the explanation of the gist of disassembly assembly and inspection of engine entire vehicle and electric fittings There are exploded view system diagram maintenance fault diagnosis and explanation before each chapter Notice For the universal parts of both types of motorcycle this manual does not seperate the explanation There is no prior individual notification on the al...

Page 5: ...ention The exhaust contains toxic gas carbon monoxide which can numb people and may result in death The engine should be started in an open area and the exhaust scavenging system should be applied if the engine has to be started in a closed area Gasoline The operation should be made in a ventilated area and smoking or lighting fires should be strictly forbidden in working space or the place stored...

Page 6: ... please clean parts and purge it with compressor The operation should not be bended or distorted otherwise it will cause operational difficulties or demage ahead of time The rubber parts will be deteriorated due to aging which is prone to be damaged by solvent or oil and it should be inspected if necessary it should be replaced before reinstallation Loosen the parts with multiple assemblies that s...

Page 7: ... it should check the smoothness of oil seal whether it will likely damage the oil seal For the installation of rubber hose fuel vacuum or coolant the ends of which should plug into the bottom of the joint in order to ensure that there is enough space for hose clamp to clamp the joint The rubber or plastic soldering cup should restore its original design position As dismantling ball bearing please ...

Page 8: ...l capacity 0 8L Rear internal Rear external Tyre specification 4 10 18 4 10 18 Air cleaner Sponge Engine Petrol capacity 10 0 2 L Clutch type Wet multidisc brake Maximum speed 45km h Climbing capability Maximum climbing angle no less than 15 degree Transmission Manual Idling speed rpm 1400 100rpm min Gearing Driving mode Chain drive Maximum torque 2 60Nm 3000rpm Battery capacity type 12V 3AH Maxim...

Page 9: ...ity 0 8L Rear external Tyre specification 130 80 17 Air cleaner Sponge Engine Petrol capacity 10 0 2 L Clutch type Wet multidisc brake Maximum speed 45km h Climbing capability Maximum climbing angle no less than 15 degree Transmission Manual Idling speed rpm 1400 100rpm min Gearing Driving mode Chain drive Maximum torque 2 60Nm 3000rpm Battery capacity type 12V 3AH Maximum horsepower 1 39KW 5500 r...

Page 10: ... 9 ...

Page 11: ... 10 TRIGGER SM 50ccm ...

Page 12: ...ne failed to start Spark plug is damp Spark plug is dry Dismantle the spark plug again to re inspect No gasoline in gasoline tank Oil tube clog of gasoline tank carburator Oil tube clog of float chamber Conduitclogofevaporationcontrolsystemoffueltank Gasoline filter clog Auto oil ring is broken Spark plug is broken Spark plug is polluted CDI group is broken Trigger is broken Theleadofsparkingcoili...

Page 13: ...e or operation Engine overheat Inspect the lubrication of air cylinder head Normal mobile oil level Too much mobile oil Check whether the mobile oil in crankcase is too much or polluted Air cleaner clogged Bad gasoline Conduit clog of evaporation control system of firing chamber Exhaust pipe clogged Auto choke is bad Carburetor vacuum module is broken Auto oil ring is broken CDI group is broken Tr...

Page 14: ...e and check whether the spark plug has flashover Favorable spark plug flashover Bad spark plug flashover Bad Favorable Intake air in carburetor shim CDI group is broken Trigger is broken Rare gas mixture loosen the bolt Too thick gas mixture locking screw Bad heat spacer shim Loosen fixing nut of carburetor Broken shock insulator Broken suction line Bad or polluted spark plug Bad CDI Bad sparking ...

Page 15: ...stment Normal Abnormal No clog Clogged Spring broken and slack elasticity Favorable Carburettor clogged CDI group is broken Trigger is broken Too little gasoline in gasoline tank Gasoline filter of gasoline pipe clogged Conduit clog of evaporation control system of fuel tank Auto oil ring is broken Purged Bad spring ...

Page 16: ...ed line of voltage regulator socket connects to avometer and positive and negative line connects the voltage of motorcycle Check the voltage regulator socket the red line connects universal meter and positive and negative line connect the voltage of motorcycle Improper charging Normal Slack and improper connection Inspect whether the connection of voltage regulator wiring is correct Voltage regula...

Page 17: ...f CDI group line trap and measure the resistance value Normal Abnormal Abnormal Normal Inspection of related position Inspect whether the CDI group plug is slack Normal Abnor Abnormal Check sparking coil by CDI tester Check CDI group by CDI tester Bad former spark plug Slack spark plug cover Bad contact of plug Main switch is broken Charge coil is broken Trigger is broken Bad sparking coil Main wi...

Page 18: ...r suspension system Ignition timing Bolt nut fixture Rim tyre Tyre specification Steering post bearing and handle fixture Preparation requirement General Warning Before starting engine please confirm whether there is favorable ventilation and do not start engine in a closed location for that the exhaust gas contains carbon monoxide which may numb or kill people Under certain condition gasoline is ...

Page 19: ...m Firing time BTDC12 degree 1degree 1400 100rpm Carriage Free stroke of front brake drawbar 20 30mm Free stroke of rear brake drawbar 20 30mm Specification Tire pressure Front wheel of inside 3 00 21 2 25 Bar Rear wheel of outside 4 10 18 2 25 Bar Front wheel 100 80 17 2 25 Bar Tire pressure unit Bar Rear wheel 130 80 17 2 25 Bar Front wheel spindle 55 62 N m Torque force value Rear wheel spindle ...

Page 20: ...er inspection I I I General purpose tool Bolt inspection I I I I I I Torque spanner Oil leak inspection of gear case I I I I I I General purpose tool Spark plug inspection or replacement I I R R I General purpose tool Replacement of gear case oil I Changed every 5000KM General purpose tool Lubrication of each part L L Lubrication filler Exhaust pipe I I I I I I General purpose tool Ignition timing...

Page 21: ...vironment of severe contamination the times of purging air filtrator should be increased to prolong the service life 3 For the motorcycle which is frequently driven at high speed or the milage is large the frequency of maintenance should be increased Engine mobile oil filtrator Mobile oil level Attention The motorcycle of which the mobile oil is to be inspected should be done on the flat floor Aft...

Page 22: ...eplacement of filtrator Dismantle the cushion and frame cover Dismantle the fastening screw of air cleaner cover and take down strainer cover Dismantle bolt and take down filtrator Dismantle the sponge from the filtrator Check whether the filtrator is polluted or damaged If it is polluted or damaged please replace with new one Changing time If the motorcycle is frequently driven on bad road or in ...

Page 23: ...ry Open cushion Dismantle left guard strip and the top cover of air filter Dismantle the negative lead of prior to the positive lead Take out battery Warning As dismantling positive pole the tools should not contact the carriage in order to avoid short circuit spark and igniting gasoline and the battery will be damaged that will be extremely dangerous The installtion is in the reverse order of dis...

Page 24: ...that of battery Warning Fire should be strictly prohibited around battery As starting to charge or upon the completion of charge the switch of charger should be turned off first in order to prevent the sparkle of connecting position from explosion hazard The current time specified on the battery should be the reference for charging Attention If quick charge of battery is abnormal the battery shoul...

Page 25: ...tion device Check the ignition system if the ignition timing is incorrect Dismantle the left cover of engine Use the ignition timing light to inspect and confirm ignition timing Cylinder pressure It should be made when the engine is warm Dismantle spark plug Install cylinder pressure meter Full throttle press Start to run motor and measure the cylinder pressure Compression pressure 1 1 1 3Mpa 1400...

Page 26: ...e inspection bolt of gear oil Dismantle the oil drain bolt the gear oil will effuse Install the oil drain bolt Attention Confirm the airtightness of bolt and whether it is out of clutch and damage Supplement gear oil Check the oil leak of each position after operation Driving chain Dismantle oil seal check whether the fringe of oil seal is broken Check whether the rear wheel bearing is broken and ...

Page 27: ...he brake is down to bottom if the liquid level of brake fluid is against the arrow in the figure please replace the brake shoe Head lighting Adjustment The optical axis adjustment of head lighting is done by turning after unscrew the rotation adjustable bolt of head lighting Clutch Start engine and increase the winding number slowly to inspect the actuation of clutch and check the clutch block if ...

Page 28: ...absorber is damaged or loosened Suspense the rear wheel and swing it to check whether the engine suspension bush is loosened Nut bolt fixture Check whether the bolt nut and fixture of the motorcycle is loosened If so please tighten to specified torque force value Rim tyre Check whether there is crack nail or other damage of the tyre Check the tire pressure Attention The tire pressure should be mea...

Page 29: ... QJ50 23A Rear wheel 130 80 17 Check whether the front wheel spindle is loosened Check whether the nuts of rear wheel are loosened If so please tighten to specified torque force value Torque force value Front wheel spindle 55 62 N m Rear wheel spindle nut 85 98 N m Steering post bearing and handle fixture Swing the handle to check and confirm whether the leads are interfered Turn the front wheel a...

Page 30: ... 29 Front liquid brake Rear liquid brake brake shoe Rear brake assembly ...

Page 31: ...ss of rear brake pad 7 0 3 0 QJ50 23 diameter of front hydraulic brake φ230mm Diameter of rear hydraulic brake φ220mm QJ50 23A diameter of front hydraulic brake φ280mm Diameter of rear hydraulic brake φ220mm 1 1 2 torque value Fixing bolt of brake disc 22 29 N m Mounting bolt of brake caliper 22 29 N m 1 2 Fault diagnosis Brake Bad braking quality Slow brake or tight rod 1 Unfavorable brake adjust...

Page 32: ...in installation or disassembly Rinse with stipulated cleaning agent in order to avoid reduction of braking quality Disassemble the front wheel spindle Unload the front wheel 1 3 1 Disassembly Note Always replace the brake pad in pairs If a brake pad is reused mark a signal on its side before disassembly so that it can be installed to the original position Disassemble the brake cylinder set from th...

Page 33: ...laced Measure the thickness of brake pad If the thickness of brake pad is less than the maintenance value or it is polluted by grease just replace it Allowable limit brake pad 3 0mm 1 3 3 Installation Install the front wheel Install the brake cylinder set Keep the brake pad free of grease Note Grease on the brake pad may reduce brake ability and invalidate the brake Screw bolt and nut to the stipu...

Page 34: ...nd brake pad are worn out and replace them if necessary Measure the brake pad and brake disc and put down the maximal value Note Clean the rust off the brake disc with _120 sandpaper It must be measured with a bore groove vernier caliper or microcaliper Measure the thickness of brake pad If the thickness of brake pad is less than the maintenance value or it is polluted by grease just replace it QJ...

Page 35: ...he stipulated torque force value Torque value mounting bolt of brake caliper 22 29 N m Keep the brake pad and brake disc free of oil stain If the brake pad and brake disc are polluted with oil rinse them with brake cleaning fluid Note Grease on the brake pad may reduce brake ability Brake pad Rear brake system ...

Page 36: ...uard right lower board Connecting board of left and right guard Rear mudguard I front mudguard inner rear mudguard Rear mudguard II left guard strip right guard strip downward air sleeve left front lower board left front lower board right frame guard left frame guard cushion lock left rear board ...

Page 37: ...ng board of left and right guard Rear mudguard I Rear mudguard II Inner Rear mudguard Left guard Left and right guard of the frame Note Do not damage any body cover during installation or disassembly Do not damage the knuckle on body cover during installation or disassembly Align the panel and cover plate on the body cover with their own grooves Correctly install the knuckle of each part in assemb...

Page 38: ... 37 Front wheel front suspension QJ50 23 ...

Page 39: ... 38 Front wheel front suspension QJ50 23A ...

Page 40: ...g bolt of brake disc left shaft sleeve of front wheel rolling bearing oil seal of front wheel front rim set front brake disc front rim front wheel spindle oil seal of front wheel vacuum tyre rolling bearing odometer gear stand middle shaft sleeve of front wheel mounting bolt of brake disc left shaft sleeve of front whee front brake disc oil seal of front wheel rolling bearing ...

Page 41: ...e entire motorcycle Measuring position Item standard value mm Allowable limit mm front wheel spindle bending 0 2 vertical direction 2 0 front wheel run out of rim transverse direction Within 1 0 2 0 Torque value Tools Fixing bolt of steering lever 5 9 N m Bearing puller Front wheel spindle 55 62 N m 3 2 Fault diagnosis 3 2 1 Actuation difficulty of steering lever The Steering column nuts are over ...

Page 42: ...dy bottom up so that the front wheel can be suspended Remove bolts and unload the front mudguard and odometer wire Disassemble the front brake wire Disassemble the front wheel spindle Unload the front wheel Remark please refer to Page 41 for the disassembly and assembly diagram of QJ50 23 and QJ50 23A 3 3 2 Inspection 3 3 2 1 Inspect bending of the wheel spindle Place the wheel spindle on the V sh...

Page 43: ...ke Inspect the spoke if it is bent damaged please change it If it is relaxed please fasten it Screw up the spoke with the tightening torque on screw cap of 0 3 10 N m 3 3 3 Replace the bearing Unload the front wheel spindle and the sleeve Spread grease on the bearing Punch in the left bearing Reload the sleeve Punch the bearing in Note The bearing must be punched in horizontally The oil seal must ...

Page 44: ...Disassemble the steering handle sleeve Disassemble the fixing bolts on brake rod and unload the bracket Disassemble the bracket of rear brake rod Remove the throttle handle and bolts Remove the throttle handle and the Throttle cable Remove the fixing bolts of handle and unload the handle 3 4 2 Installation Installation is conducted in the reverse order of disassembly Fixing bolt Torque value 5 9 N...

Page 45: ...ssion stroke 200mm 3 5 3 Installation Tools Fixing nut spanner Rotate the front fork left and right to confirm there is no loosening Steps Install the steering handle Install the front shock absorber Install the front wheel upper connecting board lower connecting board bearing weld assembly of instrument support front shock absorber fixing bolt of steering column fixing bolt shock absorber guard ...

Page 46: ... 45 Rear wheel rear suspension QJ50 23 ...

Page 47: ... 46 Rear wheel rear suspension QJ50 23A ...

Page 48: ...ndle sleeve 6 Weld assembly of rear rocker 7 Chain sleeve 8 Chain guard 9 Wire clamp of hydraulic brake 10 Connecting rod set of rear shock absorber 11 Rocker set of rear rocker 12 Chain tensioner sprocket 13 Decorative board of rear rocker 14 Weld assembly of reinforcing plate 15 Rear shock absorber set 16 Fixing bolt and nut 17 Adjusting bolt ...

Page 49: ... the brake disc or brake pad Preparation reference Item Standard value mm Allowable limit mm Vertical direction 2 0 Run out of rear wheel Transverse direction 2 0 Torque value Nut of Rear wheel spindle 85 98 N m Topping nut of the rear shock absorber 37 44 N m Bottom nut of the rear shock absorber 37 44 N m 4 2 Fault diagnosis 4 2 1 Run out of rear wheel The rim is distorted The tyre is not good 4...

Page 50: ... the allowable limit the bearing of final drive shaft will be loosened resulting in bending of bearing shafts Replace the bearing after inspection 4 3 3 Installation Install the rear wheel in the reverse order of disassembly and screw the spindle nut Locknut of rear wheel spindle Torque value 85 98 N m QJ50 23 rear wheel rear rocker rear wheel spindle chain wheel fixing bolt on chain wheel bearing...

Page 51: ...tion of the rear shock absorber Length 418mm Angle 42 Compression stroke 60mm Outer diameter of spring 62mm Torque value Upper fixing bolt 37 44 N m Lower fixing bolt 37 44 N m Install the air filter and tool box Install the rear mudguard Install the body guard fixing bolt on chain wheel press plate of rear wheel chain wheel bearing sleeve vacuum tyre rear rim rear brake disc fixing bolt of hydrau...

Page 52: ...wing shaft in solvent Inspect the components of the swing shaft sleeve and middle shaft sleeve If they are damaged please replace 4 5Driving chain 4 5 1 Disassembly Place the motorcycle on flat ground and tightly fasten it Disassemble the shift lever rocker left rear cover and driving wheel Disassemble the rear wheel chain guard and driving chain 4 5 2 Inspection Clean the driving chain by dipping...

Page 53: ... with the specification please make adjustment Unscrew the axle nut Adjust the relax degree of the driving chain The adjusting steps are Unscrew the locknut and screw or unscrew the adjusting device until the relax degree conforms to specification Screw it in and the relax degree will increase unscrew it and the relax degree will decrease Note Finally screw up the lock nut 4 5 4 Installation Insta...

Page 54: ... 53 ...

Page 55: ...Invalidation of the regulator the battery will have too high voltage which may shorten its service life 3 Long rest of the battery will result in self discharge and the electric capacity will reduce therefore it must be charged every 3 months 5 Inspect the charging system in accordance with the order stipulated in the fault diagnosis table 6 If there is electric current passes through an electrica...

Page 56: ...imit 14 15 0V 5 000rpm Torque value Tools Rectifier bolt 5 0 N m Multiple use fixing spanner Fixing bolt of high tension coil 9 0 N m Flywheel dissembler Testing instrument Avometer 5 2 Fault diagnosis No power supply Discontinuous current Over discharge of battery Poor wiring contact of battery Battery wire not connected Poor contact of discharge system Fuse blown Poor contact or short circuit in...

Page 57: ...lose the pad Unclose the top cap of the air filter and disassemble the connector wire of the battery Measure the voltage between battery terminals Fully charged 13 1V Undercharged 12 3V The battery does not work for an hour Note Inspection of charging state must be performed with a voltage meter 5 3 2 Charge Connecting method Connecting the positive pole of charger and the positive pole of battery...

Page 58: ... and main wire are in short circuit condition 5 4 2 Inspect the charging state Test with an avometer when the battery is fully charged Mount the fully charged battery after the engine warms up Connect a voltage meter between the battery terminals Connect an amperemeter at the position where two terminals are disassembled to the main fuse Start the engine and measure the clamping voltage and curren...

Page 59: ...urrent regulator If the main wire terminal proves fine after inspection inspect whether the current regulator plug is in poor contact and measure the resistance value between the terminals of the voltage and current regulator Note The metal area of the avometer prod mustn t be touched by fingers during inspection Inspect with an avometer Different avometers will give different resistance values an...

Page 60: ... coil of alternator and the body ground with an avometer Standard value 0 6 1Ω 20 If the measured value exceeds the standard value replace the alternator coil 5 8 Disassembly of alternator 5 8 1 Disassembly Disassemble the fixing bolts Unload the left cover Fix the flywheel with a multiple use fixing spanner Disassemble the flywheel fixing nut Remove the flywheel with a flywheel puller Disassemble...

Page 61: ...retaining key of flywheel in the key groove on the crankshaft and confirm Align the flywheel groove with the retaining key of the shaft Note Confirm no bolts are on the inner face of the flywheel because of magnetism of the inner face Fix the flywheel with a multiple use fixing spanner and screw the fixing nut Torque value 9 0 N m Install the left body guard 螺栓固定螺母 Fixing nut bolt ...

Page 62: ... 61 BATTERY MAIN SW FUSE 10A W G SPARK PLUG IGNITION COIL B B W W G BL W R W W W G BL W B MAGNETO 点火系统 Ignition system ...

Page 63: ...t is in poor contact or not 6 Inspect whether the spark plug is utilized at a proper thermal value Improper spark plug may lead to unsmooth operation of engine or burn out of the spark plug 7 Inspection in the chapter is based on explanation of peak voltage and the judgment whether the resistance value of ignition coil is OK or not according to records after the inspection 8 Inspection of the main...

Page 64: ...ct of CDI group when item is abnormal or when there is no spark in the sparkplug side voltage Normal high voltage no spark bad act of spark plug or power leak in secondary coil bad act of ignition coil no high voltage The interior resistance is too low and test it with a designated tester The cranking speed is too low The tester is disturbed if the voltage measured for several times is above stand...

Page 65: ...e the middle cover Connect the wire of ignition coil and connect the primary coil terminal black white with the diverter at the Ground Press the startup electrical machinery or step on the actuating lever to measure the primary peak voltage of the ignition coil Minimum voltage 95V or above Note The metal area of the avometer prod mustn t be touched by fingers to prevent electroshock 6 3 2 Charge c...

Page 66: ...age diverter between the trigger of 4P joint blue white terminal to the wire and the 4P joint black terminal Press the startup electrical machinery or step on the actuating lever to measure the peak voltage of the trigger Connecting method positive pole connected with blue white line and negative pole connected with black line Minimum voltage 1 7V or above Note The metal area of the avometer prod ...

Page 67: ... 5 5 5KΩ 10 6 5 Ignition coil 6 5 1 Disassembly Disassemble the body cover Disassemble the spark plug cover Disassemble the primary ignition coil Disassemble the ignition coil fixing bolts and unload the ignition coil Installation is conducted in the reverse order of disassembly Note The primary coil is installed in accordance with the black white wire 6 5 2 Inspect the primary coil Measure the re...

Page 68: ...oil and the negative terminal Standard value 4 5 5 5KΩ 10 20 6 6 Trigger Note Inspection of the trigger can be conducted on the engine Inspection Disassemble the body guard Disassemble the lead connector of the trigger Measure the resistance value between the blue white terminal at the engine side and the body ground Standard value 100 200Ω 20 If the measured value exceeds the standard value repla...

Page 69: ... 68 启动示意图 BATTERY RELAY BRAKE SWITCH BRAKE SWITCH STARTER SWITCH STARTOR MOTOR startup diagram ...

Page 70: ...ngine Please refer to disassembly operation in disassembly Preparation reference Item Standard value Allowable limit Brush length of startup motor 12 5mm 8 5mm Liner of startup idler shaft 8 3mm Outer diameter of startup idler shaft 7 94mm Torque value Bolt in the clutch cover of the startup electrical machinery 12 N m Fixing nut in the clutch of the startup electrical machinery 95 N m Tools Fixin...

Page 71: ... must be switched to OFF before disassembly of the startup electrical machinery Dismantle the bonding strip of the battery and turn on the power supply to see whether the startup electrical machinery will run so as to confirm security First take down the wire clamp of the startup electrical machinery Disassemble the fixing bolts on the startup electrical machinery and unload the electrical machine...

Page 72: ...hether the oil seal is worn out or damaged 7 3 4 Assembly Oil seal in the front cover and coating of grease Mount the electric brush on the brush holder Spread grease on the active parts of the electric brush ends Press each electric brush into the holder and mount the front cover Note Take particular care that the contact surface of the electric brush and armature can not be damaged Take care in ...

Page 73: ...orm to regulations If there is no voltage on the starting relay line inspect the wire and conduction of the brake switch 7 4 3 Inspect the earth line of the start relay Inspect conduction between the gray line at the lead connector terminal and the body ground When pressing the start button the gray line of the connector and the body ground are in good conduction If no conduction occurs inspect th...

Page 74: ...be measured after disassembled from the motorcycle 8 2 Fault diagnosis Main switch is pushed to ON but the light doesn t work Bad act of the bulb Bad act of the switch Poor contact of the connector or broken line 8 3 Replace the head light bulb 8 3 1 Disassembly Disassemble the air guide sleeve Disassemble the bolts so that the head light could be disassembled Disassemble the glass sheet on the he...

Page 75: ...turning light 8 5 1Disassembly Disassemble the bolts so that the taillight cover can be disassembled Remove the bulb from the socket 8 5 2 Installation Install the bulb back to the original position in the reverse order of disassembly 8 5 3 Replace the bulb of the rear turning light 8 5 3 1Disassembly Disassemble the bolts so that the turning light cover can be disassembled Remove the bulb from th...

Page 76: ...r of disassembly 8 7 Main switch 8 7 1 Inspection Disassemble the setscrews Unload the fixing pad of the main switch Disassemble the setscrews and replace the main switch 8 8 Horn Inspection Disassemble the horn wire If the horn rings when the horn wire is connected with the battery then it is the fine conditions 8 9 Handle switch Disassemble the rearview mirror and the handle cover Disassemble th...

Page 77: ... 76 绿白白红绿黑棕蓝黑橙淡蓝粉红绿黄紫 white red green white orange black pink Baby blue blue brown green black violet green yellow ...

Page 78: ...Limiting screw of the feet starting lever Shift positioned bolt Mould assembling bolt Bolt on the right and left crankcase cover Loop bolt Motor fixing bolt Separating disk bolt of clutch Fixing bolt of inlet valve Setscrew of shift display Setscrew of constant temperature set Setscrew of electric wire clamp Fixing bolt of water pump 18 22 50 60 18 22 50 60 35 40 10 15 40 50 10 16 10 12 10 12 10 1...

Page 79: ... 78 piston crankcase carburetor oil tank oil pump ...

Page 80: ...ning dry friction between surfaces into liquid friction between lubricating oil particles cooling high load parts absorbing impact from the bearing and other parts and reducing noises increasing air tightness between the piston ring and cylinder wall cleaning and carrying away impurities on part surfaces 9 2 Fault diagnosis Decrease of machine oil Engine burnt out Natural loss of machine oil Absen...

Page 81: ... set as well as the oil tube sleeve Unscrew the bolts and take down the oil pump 9 3 2 Dismantling Dismantle the oil pump as shown in the diagram elastic collar flat gasket drive gear set oil pump cover bolt oil tube sleeve oil pump tight wire fixing set of the oil pump bolt bolt oil pump cover piston spring worm wheel regulating plate piston torsion spring camshaft throttle handle set oil pump bo...

Page 82: ...pump body oil tube sleeve and tight wire fixing set of the oil pump Fix the tight wire of throttle Install the oil pump cover Install the drive gear set of oil pump When in assembly inspect and ensure there s no oil leaking in each part of the oil pump The oil seal should be in good shape After assembly the gear wheel and gear should be flexible in rotation without clamping stagnation 外径 outer dia...

Page 83: ...ill deteriorate and block the idle speed nozzle resulting in insecurity of idle speed Function of the carburetor the carburetor is a critical component in the fuel delivery system of the engine the operating mode of which carries direct influence on the steady operation of the engine its driving force and economical indicator The carburetor atomizes a given amount of gasoline into mini drops which...

Page 84: ...o sparse gas mixture Bad operation of needle valve Too high oil level Oilflow in carburetor Air channel blocked Filth in air filter 10 3 Disassembly of carburetor 10 3 1 Disassembly Switch the fuel control switch to OFF Pull out the oil inlet hose Pull out the throttle wire Pull out the enrichment valve wire Unscrew the bolts at the interface between the carburetor and engine and at the interface ...

Page 85: ... 10 3 2 3 Installation Install the enrichment valve by aligning its flange with the carburetor and fasten the bolts 10 4 Carburetor cover 10 4 1 Dismantling Unscrew the two bolts on the cover and unload the cover shim piston spring compression cap needle valve and piston in turn 10 4 2 Inspection Inspect the wear and tear of the needle valve and piston If the wear is severe replace them 10 4 3 Ass...

Page 86: ...r Assembly is conducted in the reverse order of disassembly Note Assembly is conducted in the reverse order of disassembly Install the carburetor in the reverse order of disassembly 10 6 1Adjustment of carburetor Note The idle adjustment bolt was adjusted when delivered out of the factory and needs no readjustment When dismantling take down the turning circle number for the benefit of installation...

Page 87: ...he idle adjustment screw so that the rotation speed reaches 2000 2500rpm Slowly adjust the mixture adjustment bolts anticlockwise till the engine speed reaches its utmost mixture bolt is withdrawn for two circles at most Reset the idle adjustment screw and set the engine speed down to 1400 100rpm min Pull the throttle for several times for acceleration and inspect whether the idle speed is steady ...

Page 88: ... 87 constant temperature set gasket spark plug temperature controller nut cylinder cover ...

Page 89: ...th high pressure air Function of the cylinder the cylinder body provides space for the compression burning and expansion of air and plays a steering function to piston motion It also transmits part of the heat in the air cylinder to the surrounding cooling media Function of piston 1 Bearing the pressure caused by burning of combustible mixture gas and pass the pressure to the connecting rod drivin...

Page 90: ...smooth low speed occurs inspect whether white fume is ejected out of the crankcase breather If the crankcase vent hole does have white fume ejected the piston ring must be worn out burnt out or the piston must be broken Low compression pressure ite fume in vent pipe The piston ring is worn out burnt out or broken The piston ring is worn out or damaged The air cylinder piston is worn out or damaged...

Page 91: ...n away the carbon deposit in the piston ring groove Install the piston ring Measure the clearance of the piston ring and piston ring groove Allowable limit Top ring 0 09mm Second ring 0 09mm Unload the piston ring and install each piston ring at the bottom of the cylinder Note Press the piston ring into the air cylinder with the piston crown Measure the interface clearance of the piston ring Allow...

Page 92: ...low the skirt of piston Allowable limit 40 20mm Clearance of the piston pin hole and piston pin Allowable limit 0 08mm Inspect the abrasion and wear of the cylinder inner wall Note Measure the bore diameter of the cylinder at the upper middle and lower part when keeping an angle of 90 degree from the piston pin Allowable limit 40 3mm Measure the clearance of the cylinder and piston and take the ma...

Page 93: ... bore diameter of connecting rod small end Allowable limit 15 06mm 11 4 1 Installation of piston Install the guide pin Evenly spread machine oil on each piston ring and piston and correctly install the piston ring by aligning it with the guide pin on the piston Note The piston should not be scratched and the piston ring should not be broken The piston ring should be assembled with its marked side ...

Page 94: ...allation of the air cylinder Install the gasket on the crankcase Evenly spread machine oil on cylinder inner wall piston and piston ring Take care to install the piston ring in the cylinder Note The piston ring should not be damaged 11 6 Disassembly of cylinder cover 11 6 1 Disassembly Disassemble the spark plug and unscrew the temperature controller Unscrew the four nuts and unload the cylinder c...

Page 95: ...of the bottom surface of the cylinder Allowable limit 0 05mm Remove the carbon deposit on the cylinder cover with a bamboo scraper 11 7 Installation of the cylinder cover Installation is conducted in the reverse order of disassembly constant temperature set gasket spark plug temperature controller nut cylinder cover gasket constant temperature set bolt ruler Testing gauge cylinder cover ...

Page 96: ... chamber left crankcase Housing set internal gear gasket center wearing plate iron friction plate fixing gasket Locknut clamp nut flat gasket dish gasket bearing ball inward release lever outward release lever pressure cover pressure spring Bolt and gasket adjustment bolt ...

Page 97: ...g impact of combustion and movement inertia force of crankshaft connecting rod system and constituting some closed oil air seal space The crankcase has a hanging hole which links the engine and the frame with other parts by connecting with the hanging hole Preparation reference Unit mm Item Standard value Allowable limit clearance of connecting rod big end in right and left direction 0 1 0 35 0 55...

Page 98: ...r Locked groove wear of shift drum Automatic off gear Joint cam is worn out and the edge turns round Weakening elasticity of return spring The spline gear of the spline shaft and spline groove of the slide gear are worn out resulting in considerable axial force in gear movement The shift drum and shift fork are worn out 12 3 Crankcase 12 3 1 Disassembly of left crankcase cover Unscrew the binding ...

Page 99: ...g the right cover disassemble the oil pump set and water pump set together 12 3 3 Installation of crankcase cover Install in the reverse order of operation 12 4 Clutch 12 4 1 Disassembly Unload the right cover and then unload the gasket and guide pin Remove the adhesive gasket on the joint face of the right cover and crankcase guide pin gasket water pump set oil pump set binding bolts right cover ...

Page 100: ...lease lever of the clutch Unload the wearing plate set centre wearing plate set and iron friction plate See the dismantling diagram for parts Unload the internal gear gasket Unload the housing set Unload the dish gasket and flat gasket Assembly of clutch is conducted in the reverse order of disassembly bolt adjustment bolt bolt pressure spring clutch pressure plate multiple use fixer box spanner i...

Page 101: ... central gears are damaged If it s true replacement is necessary Measure the free length of the spring Allowable limit 29 0mm Dismantling Housing set internal gear gasket center wearing plate iron friction plate fixing gasket Locknut flat gasket dish gasket bearing ball inward release lever outward release lever pressure cover pressure spring Bolt and gasket clamp nut adjustment bolt gear shape ce...

Page 102: ... elasticity of the return spring and ratchet spring and if there is damage replace them Inspect the mesh between the spline and return spring holder and ratchet If the mesh is relaxed replacement is necessary 12 5 4 Assembly Assembly is conducted in the reverse order of dismantling and disassembly thickthick actuating lever set ratchet elastic collar ratchet spring return spring O shape ring retur...

Page 103: ... right crankcase bolt balancing shaft shift chamber left crankcase main shaft set sub shaft set pin of return spring shift shaft set middle fork shaft middle fork fixer set shift drum left and right fork shaft left and right fork shaft ...

Page 104: ...d before inspection and test and should be blow dry with high pressure air Before operation discharge the lubricating oil in the crankcase 13 2 Crankshaft and connecting rod set 13 2 1 Disassembly Unload the driving gear of the clutch Unload the driving gear of the balancing shaft Unload the driven gear of the balancing shaft Unscrew the mould assembling bolt Disconnect the crankcase Note The gask...

Page 105: ...se should not be damaged 13 2 2 Inspection Clearance measurement of connecting rod big end in right and left direction Allowable limit 0 55mm Clearance measurement of connecting rod big end in X and Y direction Allowable limit 0 05mm Measure the vibration of crankshaft Allowable limit 0 1mm measuring position of connecting rod big end crankshaft ...

Page 106: ...ssory shaft and the right and left shift forks Unload the middle shift fork shaft and middle shift fork Unload the shift drum Unload the positioning set located under the shift drum Unload the main shaft set Unload the sub shaft set t Install the crankshaft connecting rod assembly on the crankcase along with the gear change mechanism main shaft set sub shaft set crank shaft bearing shift shaft set...

Page 107: ...ld be flexible in return without clamping stagnation Inspect the wear and tear of the spread plate and shift shaft set Severe wear and replace them Inspect the bent or distortion of shift forks If the bent or distortion is severe replace them Inspect whether the shift shaft is bent if it is then replace it Inspect elasticity of the return spring weakens and replace it if necessary Measure the bore...

Page 108: ...e limit 3 90mm Measure the outer diameter of the shift drum Allowable limit 41 75mm Measure the cotterway width of the shift drum Allowable limit 6 3mm 13 5 Main shaft and sub shaft 13 5 1 Dismantling sub shaft set main shaft set cotterway width thickness ...

Page 109: ... and replace them 13 5 3 Main shaft and sub shaft assembly Note In the assembly evenly spread lubricating oil on each gear and shaft to ensure no clamping stagnation after assembly Note Assembly of the clutch is conducted in the reverse order of disassembly gear surface driving pawl main shaft set sub shaft set ...

Page 110: ... 109 flow back to the water tank connected to the water tank water bump ...

Page 111: ...he cylinder through the crankcase watercourse passes through the cylinder cover and finally enters the radiator through piping for heat rejection and transfers heat to ambient air by means of the fins of radiator 14 2 Fault diagnosis Water leak overheat in cylinder body Seal ring damaged Water pump impeller damaged Pump body rupture No cooling liquid Water pipe broken 14 3 Water pump water tank 14...

Page 112: ...ection Inspect the wear and tear of the impeller set Severe wear and replace it 14 3 1 3 Installation Assembly is conducted in the reverse order of disassembly 14 3 2 Disassembly and installation of the water tank Unscrew the setscrews of water tank and unload it Dismantle the power line of the cooling fan Dismantle pipes to the water tank Dismantle the water tank water pump covear outlet pipe hol...

Page 113: ... are crushed or distorted trim them with a small pin Inspection of the liquid in the radiator Confirm the liquid has adequately cooled down before dismantling the radiator cover Eject all cooling liquid out Gradually inject the formulated cooling liquid through the filling hole mounting hole of the radiator till reaching the margin of the filling hole Mount the radiator cover Note Please use the c...

Page 114: ...set pressure lower than the open valve pressure of the cover on the cooling system with a radiator cover tester and confirm whether the condition can maintain 6 seconds within the rated pressure range when there is pressure leak inspect whether leak appears in the hose each joint mounting point or checkhole of the water pump 14 3 2 2 Installation Install in the reverse order of disassembly cooling...

Page 115: ... 114 Muffler ...

Page 116: ... 115 vent pipe set front shell set rear shell set ...

Page 117: ...applicable but maintenance and service at a reasonable price will be provided to customers by our dealers or service departments at province or city level 1 Regular maintenance is not performed in accordance with the specified time or service kilometers by our Company 2 Those who do not have regular inspection adjustment or service at our dealers or service centers or who fail to bring forward the...

Page 118: ...d vehicle conditions Note Increase cleaning times of air filter if the motorcycle is used on sandstone roadways or in severely polluted environment so that service life of the engine may be extended When the vehicle is driven at high speed or in frequent use with considerable service kilometers its maintenance degree should be increased Ensure the emission standards and pay attention to the follow...

Page 119: ...exhaust efficiency which enables increase of combustion efficiency Air induction device Introduce the air into the vent pipe so that the CO and HC incomplete combustion could be turned into innocuous gas in the second reaction difference Device Constituting part Objective and function Combustion system Combustion chamber Hemispherical combustion chamber Middle spark plug and hemispherical combusti...

Page 120: ...hed shortly after it is started or stalled 2 Keep the vehicles loaded with catalyst converter away from inflammable materials 3 The vent pipe contains CO that does harm to health therefore don t run the engine in enclosed space 4 The vehicle loaded with catalyst converter can not use leaded gasoline To guard against catalyst poisoning 5 do not start the engine by pushing the vehicle If startup mus...

Page 121: ...e engine valve leak piston wear combustion chamber Qualified for delivery Qualified Qualified Qualified Qualified Qualified 15 5 Countermeasure of idle speed emission exceeding specified value two stroke Remark 1 Measure with idle speed measuring procedure Remark 2 Adjust the engine speed within the stipulation with a set screw and measure idle speed CO HC Meanwhile adjust the air bolt so that CO ...

Page 122: ... 121 ...

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