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CONTENTS

SUMMARY

CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE

Ⅰ

. ITEMS OF MAINTENANCE 2

Ⅱ

. PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS

Ⅲ

. MAINTENANCE SPECIFICATIONS

Ⅳ

. THROTTLE ACTUATION INSPECTION 6

Ⅴ

. AIR FILTER INSPECTION AND CLEANING 7

Ⅵ

. B R A K E B L O C K S I N S P E C T I O N 7

Ⅶ

. BRAKE SYSTEM INSPECTION, ADJUSTMENT AND REPLACEMENT 8

Ⅷ

. FRONT AND REAR SHOCK ABSORBER INSPECTION 9

Ⅸ

. FRONT WHEEL AND REAR WHEEL INSPECTION 10

Ⅹ

. STEERING STEM INSPECTION 11

CHAPTER TWO MAINTENANCE INFORMATION

Ⅰ

. FRAME NUMBER AND ENGINE NUMBER LOCATION 12

Ⅱ

. PRECAUTIONS IN OPERATION 12

Ⅲ

. SPECIFIED TORQUES 13

CHAPTER THREE BODY TROUBLESHOOTING

SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION 15

SECTION TWO DETAILED DESCRIPTIONS OF BODY PARTS TROUBLES

Ⅰ

. FRONT WHEEL SE RVICE 18

Ⅱ

. FRONT BRAKE SERVICE ( DISK BRAKE ) 20

Ⅲ

. FRONT SHOCK ABSORBER SERVICE 23

Ⅳ

. FRONT FORK SERVICE 23

Ⅴ

. HANDLE BAR SE RVI CE 25

Ⅵ

. REAR WHEEL SERVICE 26

Ⅶ

. REAR BRAKE SERVICE 27

Ⅷ

. REAR SHOCK ABSORBER SERVICE 28

Содержание BT49QT-21B1

Страница 1: ...BT49QT 21B1 MODEL SERVICE MANUAL ...

Страница 2: ...BT49QT 21B1 MODEL SPARE PARTS NAME ...

Страница 3: ...ECTION 9 Ⅸ FRONT WHEEL AND REAR WHEEL INSPECTION 10 Ⅹ STEERING STEM INSPECTION 11 CHAPTER TWO MAINTENANCE INFORMATION Ⅰ FRAME NUMBER AND ENGINE NUMBER LOCATION 12 Ⅱ PRECAUTIONS IN OPERATION 12 Ⅲ SPECIFIED TORQUES 13 CHAPTER THREE BODY TROUBLESHOOTING SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION 15 SECTION TWO DETAILED DESCRIPTIONS OF BODY PARTS TROUBLES Ⅰ FRONT WHEEL SERVICE 18 Ⅱ FRONT B...

Страница 4: ... 254 kg Front tire pressure 225KPa Fuel tank capacity 4 5 0 5L Rear tire pressure 225KPa Max speed 45Km h Engine Type 139QMA A Lubricate method Pressure spray Stroke 4 Lubricant brand SAE15W 40SF Cylinder diameter driving distance 39mm 41 4mm Gasoline brand 90 or above Cylinder capacity 49cm3 Clutch type Automatic acentric Compression ratio 10 7 0 1 1 Transmission type Nonpolar Max torque N m r mi...

Страница 5: ...estrict the 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 cleanin...

Страница 6: ... I I 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 rep...

Страница 7: ...4 2 Maintenance locations ...

Страница 8: ...e parts and to obtain specified tightening torques 4 Cleaning Cleaning is needed where 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 an...

Страница 9: ... 2 6mm The main adjusting position is beside the carburetor Remove rear luggage box cover Adjust 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 ...

Страница 10: ...emove 5 tightening screws of air filter Remove 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 BRAKE BLOCKS INSPECTION Grip the brake lever and check the wear tear in...

Страница 11: ...er and push piston back into caliper Brake Block Replacement Brake block 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 pins Take out the old brake blocks and mount a set of new brake blocks Effect mounting in an order reversed to that of dismounting Brake Disc...

Страница 12: ...ss 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 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 ...

Страница 13: ...aced instead of repair Puncture of tire by a foreigner matter 6mm in diameter or tire fissure Layered 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 pressur...

Страница 14: ...ques Torques front wheel nut 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 ...

Страница 15: ...h designated or equivalent greases Parts must be tightened and their performances inspected at their positions when mounted The battery s negative terminal must be disconnected before operation Make sure that tools such as wrenches are not in contact with the frame At the completion of operations reconfirm correct connections and fastenings The positive terminal must be connected first in case of ...

Страница 16: ...om turning or moving parts Do not damage the covering of wire bunches In case of wire bunch defects remedy it with insulating bands Wire bunches must not be covered with mounted parts Do not twist or bend cables by force Deformed or damaged cables would result in poor rotation or damage Ⅲ Ⅲ Ⅲ Ⅲ SPECIFIED TORQUES Torques at important positions and standard torques of other positions are as follows ...

Страница 17: ...tandard 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 27 Flange bolt nut M10 40 ...

Страница 18: ...rk Service Heavy steering stem turning Reduced tire 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 ...

Страница 19: ...in cylinder piston Feeble brake lever Contaminated 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...

Страница 20: ...bsorber Service Bent front axle incorrect wheel 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 Fro...

Страница 21: ...ts of hoods When mounting body cover parts avoid pressing wires cables or pipes I FRONT WHEEL SERVICE Front Wheel Dismounting Support the body bottom to lift front wheel Remove the connecting bolts linking brake calipers and front absorber remove brake calipers loosen axle nut remove the front axle nut front shock absorber transmission gearbox front axle bush and the small bush remove front axle R...

Страница 22: ... 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 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 ...

Страница 23: ... grease Mount front axle from left side Mount in order small bush left front shock absorber bush front wheel transmission gearbox right front shock absorber front axle nut and fasten it Torque 60N m Mount brake caliper as specified II FRONT BRAKE SERVICE DISK BRAKE Brake Oil Replacing Prevent dust or water from entering brake system Do not use brake oils of different specifications or impure brake...

Страница 24: ...ever fast and open exhaust valve 1 2 turn to let out air and lock exhaust valve Repeat this operation till no bubbles are exhausted from brake oil passage Do not release brake lever before exhaust valve is closed At the completion of adjustment replenish brake oil till oil is over the lower limit line of the oil reservoir Mount diaphragm set and oil reservoir cover Tighten oil reservoir cover bolt...

Страница 25: ...ot 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 damages on main cylinder and piston Measure main cylinder bore Measure outside diameter of piston at the end of auxiliary cup Mounting Apply pure brake oil to piston main cup and auxiliary cup Mount spring piston retaining r...

Страница 26: ...ere 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 shock absorber on front fork and mount 2 bolts Torque upper bolt 40N m Mount front body covering parts Mount front fender mounting bracket Mount front fender Mount front wheel Ⅳ Ⅳ Ⅳ Ⅳ FRONT FORK SERVICE Dismounting Remove front body covering ...

Страница 27: ...t Inspect for completeness of bearing balls and if there is effect replacement with new ones Inspect for proper tightness of steering stem and if not effect adjustment and fasten it Inspect for correct position of bearing cup and bearing top and if not effect correct mounting Bearing Cup and Bearing Top Replacement Remove bearing cup and bearing top with special bearing cup and bearing top remover...

Страница 28: ...5N m Fix upper bearing top and tighten steering stem setting nut Torque 70N m Turn front fork and confirm easy rotation without loosening Lock set nut Mount handlebar bolt bush and nut Mount handlebar Mount front body covering parts Ⅴ Ⅴ Ⅴ Ⅴ HANDLEBAR SERVICE Dismounting Remove covering parts of front part and rear part Remove left brake lever Remove left grip from handlebar Remove front brake main...

Страница 29: ...ottle cable Mount throttle grip Mount covering parts of front head cover and rear head cover Confirm easy rotation of throttle grip When mounting handlebar rubber apply a thin film of adhesive to contacting face and then mount grip in a turning manner Ⅵ Ⅵ Ⅵ Ⅵ REAR WHEEL SERVICE Dismounting Remove 2 connecting nuts and 2 mounting bolts of exhaust muffler Remove exhaust muffler Remove rear axle nut ...

Страница 30: ...eplacement Remove rear brake block and return spring as a whole and replace them with new ones 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 Rear Brake Device Assembling Apply grease to setting...

Страница 31: ...g Mount rear wheel Mount exhaust muffler Mount brake swing arm pin and rear brake cable Mount return spring of brake cable with the spring aligned with the recess hole of left crankcase cover Mount adjusting nut Adjust brake system Ⅷ Ⅷ Ⅷ Ⅷ REAR SHOCK ABSORBER SERVICE Dismounting Remove motorcycle body covering parts Remove 3 mounting bolts of air filter Withdraw air filter Remove mounting bolt con...

Страница 32: ... 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 ...

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