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Summary of Contents for Baotian BT49QT-7
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Page 1: Service Manual
BT49QT-7&BT49QT-8 SERVICE MANUAL JIANGMEN SINO-HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO., LTD... -
Page 2: Table Of Contents
CONTENTS CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE . ITEMS OF MAINTENANCE . PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS . MAINTENANCE SPECIFICATIONS . THROTTLE ACTUATION INSPECTION . AIR FILTER INSPECTION AND CLEANING . REAR BRAKE FRICITION LINING INSPECTION . BRAKE SYSTEM INSPECTION, ADJUSTMENT AND REPLACEMENT . -
Page 3: Chapter One
CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE . ITEMS OF MAINTENANCE When the motorcycle is used, loosening of parts and mechanical wear inevitably occur to varied extents. Neglect of timely maintenance not only reduces its mechanical function, economic performance, stability and durability, but also threatens the safety of the motorcycle and the rider. Correct and timely maintenance of the motorcycle is a must. - Page 4 Maintenance Schedule time Mileage 1000km item 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 New R Engine oil 300km Engine oil strainer Gasoline strainer New R Gear oil Note 4 300km Throttle play Carburetor Note 3, Air filter Brake system Drive belt...
- Page 5 Spark plug Front shock absorber Throttle grip Oil tank damage,contamination actuation,play brake oil level damage,loosening £ ¨ £ © £ ¨ £ © £ ¨ £ © £ ¨ £ © Rear tire Rear rim Front rim Front tire wear,damage,tire pressure damage,oscillation damage,oscillation wear,damage,tire pressure...
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Page 6: Maintenance Specifications
. MAINTENANCE SPECIFICATIONS The basic methods of motorcycle maintenance include inspection, adjustment, tightening, lubrication, cleaning, supplementing and replacement, which constitute the main elements of maintenance. 1. Inspection Inspection refers to basic inspecting operations in accordance with items and requirements specified in the user’s manual, including inspection with instruments or with eyes for abnormalities in machine parts, directly comparing related data and aligning with tools and gauges. -
Page 7: Throttle Actuation Inspection
THROTTLE ACTUATION INSPECTION Inspect throttle grip for easy and smooth movement. free travel:2-6mm Inspect throttle free travel. Free travel: 2-6mm The main adjusting position is beside the carburetor. tightening nut adjusting nut Remove rear store case cover. Adjust by loosening the fastening nut and turning the adjusting nut. -
Page 8: Rear Brake Fricition Lining Inspection
2000-3000km and in dusty or rainy conditions strainer must be cleaned or replaced earlier. air filter Remove 5 tightening bolts of air filter. bolt 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. - Page 9 * Do not pull brake lever when brake caliper is removed so as to prevent jamming of brake block. If brake block is jammed, pry it with screwdriver and push piston back into caliper. brake caliper brake block Brake Block Replacement: Brake block must be replaced when it is worn to the limit of brake block pin use.
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Page 10: Front And Rear Shock Absorber Inspection
Inspect rear brake lever free travel. Free travel: 10-20mm Turn adjusting nut to effect adjustment when free travel exceeds limit. adjusting nut VIII. FRONT AND REAR SHOCK ABSORBER INSPECTION 1. Front Shock Absorber front brake lever Tighten front brake lever, press front shock absorber up and down and inspect actuation. - Page 11 Inspect wheel rim, remove rust stains and rubber chips. Deformation and fissures are causes of air leakage. Do not use wheel rims in the following cases: Bruise of wheel rim face contacting tire bead ring exceeds 0.5mm in depth and 1.0mm in width.
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Page 12: Steering Stem Inspection
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. -
Page 13: Precautions In Operation
II. PRECAUTIONS IN OPERATION Removed washers, 0-rings, elastic retaining rings and split pins must be replaced with new ones. When mounting bolts, nuts and screws, proceed from trial tightening, from larger diameters to smaller diameters and inner ones to outer ones in a diagonally order. Tighten them to specific torques. -
Page 14: Specified Torques
Wire bunches must be fixed away from 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. - Page 15 Handlebar mounting nut Upper bearing top Exhaust muffler connector nut Exhaust muffler mounting bolt Standard Torques: ·m Bolt, nut M5 Bolt, nut M6 Bolt, nutM8 21.5 Bolt, nut M10 Bolt, nut M12 Screw M5 Screw M6 Flange bolt, nut M6 Flange bolt, nut M8 Flange bolt, nut M10 CHAPTER THREE BODY TROUBLESHOOTING...
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Page 16: Front Shock Absorber Service 1
Over tightening of steering stem top ball bearing retainer Damaged or broken ball bearing Refer to “Front Wheel Reduced tire air Service”, “Rear Wheel Service” Refer to “Front Shock Imbalance of right and left shock absorbers Absorber Service” Refer to “Front Fork Deflected steering stem Bent front fork Service”... - Page 17 Inability of brake caliper normal sliding Worn main cylinder piston seal ring Viscous or worn main cylinder piston Contaminated main cylinder Clogged narrow brake system Clogged narrow liquid passage Viscous worn brake caliper Stiff brake lever Inability of brake caliper normal sliding Worn seal ring of brake caliper piston...
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Page 18: Section Two Detailed Descriptions Of Body Parts Troubles
Bent front axle, incorrect wheel mounting Refer to “Front Wheel Roundness error of wheel rim Service” Deformation of wheel rim Inadequate tire pressure Deformed wheel rim Loose front wheel bearing Refer to “Front Wheel Front wheel oscillation Poor tire Service” Poor axle locking Refer to “Front Shock Soft front shock absorber... - Page 19 Remove front axle nut, brake calipers, front absorbers connecting bolt and remove brake calipers, front shock absorber, transmission gear box, front axle bush and the small bush, remove front axle. front wheel front shock Remove front wheel. absorber bolt brake disc brake caliper mounting bolt front axle...
- Page 20 dust cover front axle bush 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.
- Page 21 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 oils. Prevent brake oil from dripping onto rubber, plastic or painted parts. Brake Oil Exhausting oil reservoir cover Place main cylinder at a level place, remove oil reservoir...
- Page 22 Main Brake Oil Tank Dismounting and Mounting Dismounting Remove each 2 bolts and screws of front part and rear part of head cover rear part head cover front part head cover. Remove front part and rear part of head cover. set bolt Exhaust brake oil from front brake system.
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Page 23: Front Shock Absorber Service
Mount spring, piston, retaining ring and piston cap. Piston cup cannot be used inside out. Apply grease to brake lever axis pin. Mount brake lever and brake switch. Mount main cylinder, main cylinder bracket and lock them. Mount brake oil pipe. Connect brake light switch cable with switch. -
Page 24: Front Fork Service
IV. FRONT FORK SERVICE Dismounting body covering Remove motorcycle body covering parts. parts Remove nut and blot from handlebar; Remove handlebar. handlebar Remove steering stem setting nut. Remove upper bearing cup, upper bearing top and bearing set. bolt set nut upper bearing cup,bearing top and ball set... -
Page 25: H A N D L E B A R S E Rv
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 removers. -
Page 26: Rear Wheel Service
Remove 2 screws of left handlebar switch. Remove left handlebar switch. Remove left grip from handlebar. Remove front brake main cylinder. Remove connectors of right handlebar switch. right handlebar s wi tch s crews Remove 2 screws of right handlebar switch. throttle grip Remove right handlebar switch. -
Page 27: R E A R B R A K E S E Rv
Remove 2 connecting nuts and 2 mounting bolts of exhaust muffler. Remove exhaust muffler. Remove rear axle nut and rear axle. exhaust muffler mounting bolts Rear Wheel Oscillation Inspection Measure oscillation value on a correcting bench. Limit of use: Longitudinal >2.0 mm Traverse >2.0 mm Mounting Mount rear wheel and fasten rear axle nut. - Page 28 Limit of use: Ø111mm, effect replacement if the limit is exceeded. Rear Brake Block Replacement Remove rear brake block and return spring as a whole and replace them with new ones. set pin return spring See that no grease is with brake block friction surface. brake block return spring brake block...
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Page 29: Rear Shock Absorber Service
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. REAR SHOCK ABSORBER SERVICE Dismounting Remove motorcycle body covering parts. Remove 2 mounting bolts of air filter.
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