Zhejiang Qianjiang Motorcycle RKV 200 Скачать руководство пользователя | Manualshive

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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

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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

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Содержание RKV 200

Страница 1: ...1 RKV 200 Motorcycle Service Manual...

Страница 2: ...Fault diagnosis 72 2 3 Ignition system inspection 73 2 4 CDI Assembly 74 2 5 Ignition coil 75 2 6 Trigger 76 Starting System 78 3 1 Service Data 78 3 2 Fault Diagnosis 79 3 3 Starter Motor 79 3 4 Star...

Страница 3: ...3 Fuel Tank Seat Cushion Engine Inspection and Maintenance Lubricating System 10 1 Service Data 10 2 Fault Diagnosis 10 3 Engine Oil Pump Carburetor 11 1 Service Data 11 2 Fault Diagnosis 11 3 Remova...

Страница 4: ...haust System Inspection and Maintenance Emission Control System 15 1 Emission Control System Guarantee 15 2 Periodical Maintenance Instructions 15 3 Mechanical Functions of Emission Control System 15...

Страница 5: ...e 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...

Страница 6: ...ictly 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...

Страница 7: ...uring 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 repla...

Страница 8: ...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 t...

Страница 9: ...oving 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 pl...

Страница 10: ...tant 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 i...

Страница 11: ...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...

Страница 12: ...12 Figure 1 3 Figure 1 4 Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 Figure 1 10 Handle...

Страница 13: ...13 Figure 1 11 Figure 1 12 Pliers Piston Figure 1 13 Figure 1 14 Figure 1 15 Figure 1 16 Figure 1 17 Figure 1 18...

Страница 14: ...Table1 25 Name Remarks 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 Fron...

Страница 15: ...15 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...

Страница 16: ...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 Figu...

Страница 17: ...n Tire Front tire 100 80 17 Air cleaner Paper element Rear tire 130 70 17 Drive Train Clutch type Wet multi plate friction type Fuel tank capacity 17 0 5L Gearshift pattern Five speed gearshift Perfor...

Страница 18: ...18...

Страница 19: ...o flywheel or trigger coil for looseness Loosen drain screw of carburetor and check if overflow pipe is clogged Refuel gasoline Check compression pressure in the cylinder with a pressure gauge Check o...

Страница 20: ...Engine can continue to run when it is started Carburetor is clogged inside or float is too high Carburetor starter i e cranking enrichment system fails 1 Check leakage at external connection parts of...

Страница 21: ...k if cooling fan or wind scooper is damaged forced air cooled engine Basically temperature of radiator and engine is consistent Temperature of radiator is lower than that of engine Oil cooling system...

Страница 22: ...s explosion in the carburetor and power of the engine is insufficient Combustible gas mixture concentration is too high 1 Check if air cleaner is clogged 2 Check if Carburetor starter i e cranking enr...

Страница 23: ...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 worn or pitted due...

Страница 24: ...just carburetor idle speed Check if jet of idle is too big Check if throttle control cable can pull flexibly in the cable jacket and if throttle spring is too soft 1 Check CDI ignitor 2 Check if magne...

Страница 25: ...tire pressure Air pressure too low Air pressure normal Gas up as specified Check if fuel tank fuel switch delivery pipe or carburetor leaks oil Exclude as practice Check mixture ratio of combustible g...

Страница 26: ...or replace Check if contact area between braking shoe and friction disc is worn terribly Repair or replace clutch shoe Refill engine oil Check if viscosity of engine oil in the crankcase is too low o...

Страница 27: ...crankcase bleed surplus oil and decline oil level to upper limit line 1 Check if cylinder piston or piston ring is over worn 2 Check if elasticity of piston ring is not enough or stuck in the ring gr...

Страница 28: ...is properly adjusted Re adjust Check if elasticity of clutch spring is even Replace the whole set of clutch spring Check if splines on clutch active and drive hubs are worn into zigzag form Repair or...

Страница 29: ...Check if clearance of clutch handle bar is within 10mm 20mm 2 Check if elasticity of clutch spring is even 3 Check if splines on clutch active and drive hubs are worn into zigzag form 4 Check if clutc...

Страница 30: ...hing 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 Check if shift fork is overworn Replace gears Check...

Страница 31: ...tuck by foreign substances 1 Check if there is oil adhered to the surface of brake shoe friction disc 2 Check if contact area between braking shoe and friction disc is less than 70 Hydraulic disc brak...

Страница 32: ...ot be charged Resistance is less than standard Charging coil is shorted Resistance is infinitely great Resistance meets the standard Charging coil or its output wires are shorted Disconnect connectors...

Страница 33: ...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 sho...

Страница 34: ...ush starter button and the click from starter relay cannot be heard Push starter button and a click from starter relay can be heard Disassemble the connector of starter relay from cables of the whole...

Страница 35: ...heck if armature coil is broken or shorted 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 Che...

Страница 36: ...check it for breakover Check if starter button contact is poorly contacted Disassemble starter motor and make the following inspections 1 Check if the carbon brush is over worn 2 Check if carbon brush...

Страница 37: ...t engine and separate connectors of rectification regulator from cables of the whole vehicle Lights are lit Lights are not lit Short circuit inside rectifier Disassemble headlamp assembly and check if...

Страница 38: ...e of wire to short circuit power line and output line of lighting switch Wiring from magneto or ignition switch to lighting switch is broken or shorted Lamp is lit after short circuit Lamp is still no...

Страница 39: ...nsity of electrolyte in the battery is too low check if the base plate inside the battery is vulcanized or broken Separate conductors of rectification regulator from cables of the whole vehicle Measur...

Страница 40: ...ables of the whole vehicle Check brightness of headlamp Headlamp light recovers after separation Headlamp light is still dim after separation Stable voltage of rectification regulator is too low Check...

Страница 41: ...power of bulb in the lighting system is up to the requirement Replace the bulb 1 Check if headlamp switch and contact in the switch is poorly contacted 2 Check if connectors and earthing wire are poor...

Страница 42: ...d the ground with a voltmeter No voltage displays No voltage displays Grounding wire of lamp holder is of poor contact or bulb of turn signal lamp is badly contacted with lamp holder Power line to the...

Страница 43: ...ntact of turn signal lamp is poorly contacted Check if there is power output from power input line of turn signal lamp switch by lamp test Test lamp is on Test lamp is off power line of turn signal la...

Страница 44: ...44 Symptom Electric horn mutes Diagnosis procedures...

Страница 45: ...ound wire to check spark Spark at touch No spark at touch Connect well the power line of horn use a screwdriver to connect non power terminal terminal to button of horn with ground wire Power line bet...

Страница 46: ...mp is not lit after short circuit Brake lamp is lit after short circuit Use a screwdriver or a piece of wire to touch quickly power line of brake lamp switch and grounding wire and check sparks Brake...

Страница 47: ...sion 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 wel...

Страница 48: ...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 Pneumatic pressure unit of tire Kpa Speci...

Страница 49: ...tuating inspection I I I Common tool Inspection of looseness of bolts at all positions I I I I I I Torque wrench Check if gearbox leaks oil I I I I I I Common tool Spark plug inspection and replacemen...

Страница 50: ...tenance 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 frequentl...

Страница 51: ...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...

Страница 52: ...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...

Страница 53: ...d 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...

Страница 54: ...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...

Страница 55: ...oes 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 an...

Страница 56: ...e 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 si...

Страница 57: ...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 Measu...

Страница 58: ...or 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 s...

Страница 59: ...re 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...

Страница 60: ...ft is loosened Check if locknut of rear shaft is loosened If loosened tighten it to specified torque Tightening torque Rear wheel lock nut 85 98 N m Steering stem bearing and handlebar fixation Move l...

Страница 61: ...fasteners used in electric system Fastening positions and names of fasteners Tightening torque N m Starter motor clutch cover bolt Starter motor clutch locknut Rectifier bolt High voltage coil pinch b...

Страница 62: ...62 Charging system Charging System 1 Variable frequency scintillator 2 Ignitor 3 Battery 4 Voltage regulator 5 High voltage ignition coil 6 Electric horn 7 Rectifier...

Страница 63: ...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...

Страница 64: ...Type Full wave rectification Battery charging voltage 14 5V 0 4V 5 000rpm Tightening torque Tools Rectifier bolt 5 0 N m Universal non adjustable spanner High voltage coil pinch bolt 9 0 N m Flywheel...

Страница 65: ...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 th...

Страница 66: ...d 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 full...

Страница 67: ...terminals of voltage current regulator itself Attention Do not touch the metal part of multimeter probe with your finger Check with a multimeter If impedance values measured by different multimeters a...

Страница 68: ...eel 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 wir...

Страница 69: ...agnetism 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...

Страница 70: ...70 Ignition System 1 Variable frequency scintillator 2 Ignitor 3 Battery 4 Voltage regulator 5 High voltage ignition coil 6 Electric horn 7 Rectifier Ignition System...

Страница 71: ...stem 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...

Страница 72: ...Ignition coil is no good Charging coil is bad Peak voltage measurement Secondary side voltage While no high voltage power supply high voltage power is sporadic Tester is wrongly connected Poor igniti...

Страница 73: ...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 amm...

Страница 74: ...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 Pleas...

Страница 75: ...h is OFF Trigger Blue White White Green 100 200 Primary coil of ignition coil Black White Black 0 4 10 Secondary coil of ignition coil Black spark plug cap excluding spark plug 3 5 5K 10 2 5 Ignition...

Страница 76: ...d 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...

Страница 77: ...77 Starting System 1 Variable frequency scintillator 2 Ignitor 3 Battery 4 Voltage regulator 5 High voltage ignition coil 6 Electric horn 7 Rectifier Starting Schematic Diagram...

Страница 78: ...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...

Страница 79: ...tor 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...

Страница 80: ...nstall 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...

Страница 81: ...tage 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...

Страница 82: ...e lamp 7 Rear right turn signal lamp A Headlamp certification No E4 0014699 B Front turn signal lamp certification No E4 50R 001732 C Tail lamp certification No E4 50R 0014700 D Rear turn signal lamp...

Страница 83: ...ent 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 remo...

Страница 84: ...ake 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 Instal...

Страница 85: ...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 c...

Страница 86: ...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 instru...

Страница 87: ...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 bo...

Страница 88: ...bolt Rear shaft locknut Steering handle welding assembly mounting bolt Front wheel shaft locknut Front shock absorber mounting bolt Rear wheel locknut Rear shock absorber top nut Rear shock absorber b...

Страница 89: ...se mounting bolt 11 Brake hose assembly 12 Brake cylinder assembly 13 Friction lining assembly 14 Oil hose mounting bolt A Front brake disc diameter 260mm B Front brake disc thickness 4 0mm Service li...

Страница 90: ...9 N m 1 Rear hydraulic brake assembly 2 Bushing 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 hydra...

Страница 91: ...brake disc thickness 4 0 3 0 Front friction lining thickness 6 0 5 0 Rear hydraulic brake disc diameter 240 Rear hydraulic brake disc thickness 4 0 3 0 Rear friction lining thickness 6 0 5 0 5 1 2 Ti...

Страница 92: ...tion 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 motorcy...

Страница 93: ...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 Installati...

Страница 94: ...tion 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 w...

Страница 95: ...Install rear brake cylinder assembly Install engine assembly and air cleaner assembly Install muffler assembly protecting plate assembly and seat cushion assembly Attention Tighten bolts and nuts to t...

Страница 96: ...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 Attention Do not dama...

Страница 97: ...quence 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 Con...

Страница 98: ...t 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 a...

Страница 99: ...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 2...

Страница 100: ...ad 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 2...

Страница 101: ...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 Standard value mm Allowable limit...

Страница 102: ...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...

Страница 103: ...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...

Страница 104: ...t 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 o...

Страница 105: ...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...

Страница 106: ...he 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 Tool Fixing nut...

Страница 107: ...disk 8 Bearing sleeve 9 Washer 16 32 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 val...

Страница 108: ...108 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...

Страница 109: ...tive 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...

Страница 110: ...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 regulati...

Страница 111: ...isc Reference Item Standard value mm Allowable limit mm Rear wheel wobbling Longitudinal direction 2 0 Horizontal direction 2 0 Locking torque force Fixing nut rear wheel 85 98 N m Top nut rear shock...

Страница 112: ...talled 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 moto...

Страница 113: ...g 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...

Страница 114: ...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...

Страница 115: ...equence 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 re...

Страница 116: ...gth 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 and side panel I...

Страница 117: ...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 shoc...

Страница 118: ...ne tank turn the fuel switch to OFF B Torque force value of bolt 2 in the figure 22 29 N m C 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...

Страница 119: ...nting 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 mountin...

Страница 120: ...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 All...

Страница 121: ...engage 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 Take tank from the...

Страница 122: ...ouble end studs Flywheel locking bolt Valve clearance adjustment nut Gear shift locator bolt Closer bolt Right and left crankcase cover bolts Coil screw Oil filter cover bolt Clutch Fixing nut Cylinde...

Страница 123: ...ncreasing 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 pu...

Страница 124: ...124 10 2Fault Diagnosis Gasoline volume decreases Engine damaged Gasoline is consumed naturally No or too low oil pressure Oil leakage Oil circuit clogged...

Страница 125: ...nscrew the pump fixing screw after engine oil filter is removed and then remove the pump body driving gear and pump shaft Remove screws Remove the pump base Remove the pump cover and dismantle the pum...

Страница 126: ...en inner and outer rotors Allowable limit 0 25mm Check clearance between outer rotor and pump base Allowable limit 0 25mm Check rotor face to face clearance Allowable limit 0 15mm Testing gauge Testin...

Страница 127: ...ombined 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 sys...

Страница 128: ...128 Swingarm Cam mechanism Piston Oil filter Engine oil pump Engine oil filtration net Cranksha ft...

Страница 129: ...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 t...

Страница 130: ...rking badly Secondary air entering into intake system Too thick mixed gas Intermittent sparking during acceleration Enrichment valve working badly Too thin mixed gas Needle valve acting badly Too high...

Страница 131: ...the component Check wearing of oil needle If any wearing is found replace it Loosen connecting screw of lower housing to remove the lower housing component and seal ring Remove the float component fl...

Страница 132: ...t 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...

Страница 133: ...133 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...

Страница 134: ...head 0 03 0 05 Valve Valve guide Valve clearance Intake 0 09 0 1 Discharge 0 09 0 1 OD valve rod Intake 4 965 4 975 4 9 Discharge 4 95 4 96 4 9 ID valve guide Intake 5 0 5 012 5 1 Discharge 5 0 5 012...

Страница 135: ...3 1 Disassembly Loosen the two fixing bolts and remove the cylinder head cover swingarm and its shaft Release the tightener loosen the chain and unscrew cover nut to take down cam shaft bracket swing...

Страница 136: ...m Clearance between swingarm hole and swingarm shaft Allowable limit 0 075mm Directly remove the cylinder head cover and compress the valve spring with the valve spring compression tool and remove the...

Страница 137: ...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 Measure free len...

Страница 138: ...use a reamer to eliminate carbon accumulated within the guide Attention the reamer shall be turned clockwise and do not turn it counterclockwise Measure inner diameters of valve guides Allowable limi...

Страница 139: ...g 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...

Страница 140: ...th of valve contact surface valve race width Allowable limit Intake discharge 1 3mm 12 6 Valve race fixing and adjustment Use a 45 cutter to clear coarse or uneven parts on the surface of valve race N...

Страница 141: ...utter 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 unevenne...

Страница 142: ...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 cover engine cover and engine cover and...

Страница 143: ...143...

Страница 144: ...144...

Страница 145: ...mber 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 Sta...

Страница 146: ...e between crankcase and gas Too high compression pressure Abnormal noise from piston Too much accumulated carbon in Cylinder piston and piston ring worn or damaged combustion chamber Piston pin hole a...

Страница 147: ...e 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 Remove th...

Страница 148: ...t such position as to form 90 with piston pin and around 11mm from the piston skirt bottom Allowable limit 67 91mm Check of cylinder inner wall scratch and wearing Attention measure cylinder inner dia...

Страница 149: ...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 p...

Страница 150: ...op is installed facing the intake valve 13 5 Installation of cylinder Install the gasket and locating pin on the crankcase Apply engine oil across the cylinder inner wall piston and piston ring Care s...

Страница 151: ...rts 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 I...

Страница 152: ...uiding 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 tee...

Страница 153: ...uding sprocket and remove the idle gear of motor Remove the gasket Remove the gear display 14 3 2 Removal of right crankcase cover Loosen the fixing bolt and remove the right crankcase cover gasket an...

Страница 154: ...ng for dismounted components 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...

Страница 155: ...iction 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 w...

Страница 156: ...below 29 7 mm Measure the thickness of the friction disc with a vernier caliper Replace it if the limit is below 2 6mm Measure the flatness of the driven friction disc with a plug gauge Replace it if...

Страница 157: ...he plane needle roller bearing Replace it if the limit is below 1 8mm Crank connecting rod combination and gearbox assembly Bolt Left crank case Locating pin Right crank case Crank connecting rod comb...

Страница 158: ...158 Gearshift drum Shifting fork Shift rail Principal shaft assembly Vice shaft assembly...

Страница 159: ...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 paw...

Страница 160: ...t with electric or compression tools Dismount the two wheels and the flat key Dismount the retainer ring remove the wheel gear on the fuel pump unscrew the nut in the fuel pump dismount the fuel pump...

Страница 161: ...case 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 connectin...

Страница 162: ...ing Replace it if so 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 Crank...

Страница 163: ...ole Allowable limit 10 05mm Measure the thickness of the shifting fork Allowable limit respectively 5 1mm and 5 35mm Measure the external diameter of the gearshift drum Allowable limit 39 75mm Measure...

Страница 164: ...er 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...

Страница 165: ...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 Remove the bearing in the right crank c...

Страница 166: ...rication 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 c...

Страница 167: ...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 A Torsion force of the locating bolt 5 in the connect...

Страница 168: ...d 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 ma...

Страница 169: ...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 N...

Страница 170: ...and repair the engine Valve leakage Piston abrasion Combustion cleaning Qualified finished product Qualified Qualified Qualified Qualified Qualified 15 4 Solutions to the problem of idle exhaust excee...

Страница 171: ...171 Complete QJ200 2A Schematic Circuit Diagram...

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