Preface This maintenance manual is used for operating and maintaining Motorcycle FACT 50 4T. Preparing Documents include all necessary instructions and statements. Please carefully read this manual before operation. Inspection & Adjustment states how to check and adjust your motorcycle. All safety rules and maintenance regulations shall be carried out from the beginning of periodic inspection.
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Start up engine in an open place. The exhaust cleaning system shall be adopted if engine is started up in a closed area. Petrol Ventilation is required for working places. Fire is strictly forbidden in any working place or where petroleum is stored.
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套:boot When loosening assembly parts, please start from outside to inside. Small assembly parts shall be loosened first. Complex assembly parts, such as gearbox, shall be stored in proper order for facilitating installation in the future. Please specially note important connections before disassembly. Replace parts which will not be in use before disassembly.
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When installing a hose (fuel, vacuum or cooling agent), insert its end into the bottom of the connector so that the hose clip can properly fix the connector. Rubber or plastic dirt-proof boot shall be mounted at the original design position. 槽:groove 夹子:clip 接头:connector During dismantling ball bearings, one or two (inside &...
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Loose cables threaten electrical safety. Check each cable after it is clamped to another for electrical safety; Wire clamps are not allowed to bend towards welding point; Bind cables at the designated place; Do not deploy cables at the end of frame or at sharp point; Do not deploy cables at the end of bolts or screws;...
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Identification 1.The identification number of motorcycle frame is *LBBTEBAA????????? marked at . The 10 digital and digital respectively indicate year code and factory code. “*” shall be added before and after the frame number. The frame sign is nailed at . See Fig. 1-1. Fig.
Special Tools Special tools refer to tools which are specially designed for assembling or disassembling some motorcycle parts on special positions. Applicable special tools are necessary for precise adjustment and installation. With them, parts and accessories can be mounted safely, reliably and rapidly, which improves efficiency and saves energy. 1.Tools for repairing the engine Special tools are required for properly disassembling/assembling some engine parts.
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Fig.1-15 Fig.1-16 2.Tools for repairing the chassis Table and drawing (1-17, 1-18) of ordinary tools and special tools for disassembling/assembling chassis parts are as follows: Table 1-17 Name Remark Torque spanner Fig. 1-19 Inner hexagon spanner Fig. 1-20 Socket spanner Fig.
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Fig. 1-21 Fig. 1-22 Fig. 1-23 Fig. 1-24 Fig. 1-25 Fig. 1-26 Fig. 1-27 Fig. 1-28 (2) Special tools for repairing the chassis: tool for hammering seal of front fork Fig. 1-29 (3) Steering nut spanner...
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Remark Multimeter Fig. 1-33 Ignition tester Fig. 1-34 Table 1-32 (continued) Fig. 1-33 Fig. 1-34 Specification (FACT 50 4T25Km) QJ137QMB Model FACT 50 4T Engine type Unleaded 1800 Fuel type Length mm petrol(92/95) No. of Width mm cylinder Height mm 1150 ID ×...
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φ190mm brake disc Braking (mm) system I.D. of rear Ignition φ110mm brake drum (mm) Specification (FACT 50 4T45Km) Model FACT 50 4T Engine type QJ137QMB Unleaded Length mm 1800 Fuel type petrol(92/95) No. of Width mm cylinder Height mm 1150 ID ×...
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(Curb weight) Backshaft Cooling Air cooling Total Lubrication Splash lubrication Front outer 120/70-12 tire Tire Front rim 3.50×12 Air filter e9QJAF-B70 Size Rear outer 130/70-12 tire Rear rim 3.50×12 Capacity of 6.0±0.2L gasoline tank Dry centrifugal clutch Clutch Carburetor PD19JB type Stepless Transmission...
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Failure Diagnosis Diagnosis on failure or difficulty in starting engine Failure or difficulty in starting engine Check ignition system Remove the spark plug and check whether there is carbon fouling between electrode. Sparkover test for spark plug Eliminate carbon fouling Weak spark or no spark between electrode Large blue or bluish purple spark between electrode Screw off spark plug cap and conduct...
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1. Check leakage on outer 1. Check whether the connections air vent in fuel tank engine. cover is blocked. 2. Check whether the piston 2. Check whether the ring is seized in the fuel filter and the groove or whether it has fuel switch enough elasticity.
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Diagnosis on engine overheating Engine overheating Check whether operation is correct Check whether gasoline grade is Check cooling system improper or gasoline is stored for a long time Check whether the engine works Air-cooled engine at high speed for a long time or with overload during driving Check whether heat sink is spotted or there is too much oil stain...
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Remove the spark plug; check the colors of spark plug insulators and judge the proportion of mixed combustible gas based on abnormity The spark plug insulators are black; The spark plug insulators are The spark plug insulators are brown the exhaust muffler emits black white;...
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Diagnosis on power shortage of engine Power shortage of engine Raise the main kickstand and suspend wheels; rotate wheels with hands Inflexible rotating of Flexible rotating of wheels wheels Check tire Check whether there is braking drag. pressure Check whether wheel bearing excessively abraded damaged.
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Diagnosis on abnormal idle speed of engine Abnormal idle speed of engine No idle speed High idle speed Unstable idle speed Check compression Check whether the carburetor Check whether ignition is throttle is completely closed with timely conducted with an pressure of cylinder ignition timing lamp.
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Diagnosis on excessive fuel consumption of engine Excessive fuel consumption of engine Check whether operation correct Raise the main kickstand and rotate Check whether the motorcycle runs with overload or not at wheels with hands economical speed or at low gear. Check whether petrol grade is proper.
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Diagnosis on dense bluish white smoke from the exhaust muffler of the two-stroke engine The exhaust muffler of the two-stroke engine emits dense bluish white smoke. Check whether the fuel level in the crankcase exceeds the upper limit. Excessive fuel filling into the crankcase. Start up the engine and remove the dipstick Drain out the excessive part and make when it works at high speed.
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Diagnosis on transmission gear skip shift Transmission gear skip shift Check whether the positioning wheel spring is ruptured or lacks elasticity. Replacement Disassemble crankcase and check whether the engagement depth for each gear is in accordance with requirements. Proper depth Insufficient depth in engaging engaging...
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Diagnosis on malfunction of hydraulic disc brake Malfunction of hydraulic disc brake Check the level of brake fluid inside the brake fluid reservoir. The level of brake fluid is below the The level of brake fluid is beyond the lower limit of the reservoir. lower limit of the reservoir.
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Diagnosis on battery charging failure Battery charging failure Remove the connector between the conductor bundle of electromagnetic motor and the cable assembly; measure the resistance between the output conductor terminals of charging coil and check whether it is in accordance with the standard. Resistance value lower Resistance value in accordance Infinite resistance...
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Diagnosis on insufficient battery charging Insufficient battery charging Check whether the brake lamp is always light. Set the ignition switch to “OFF”; remove the negative cable from the battery; Adjust or replace the connect the negative electrode of the ammeter to the battery negative terminal and brake lamp switch.
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Diagnosis on starter motor failure in rotation Starter motor failure in rotation Turn the ignition switch; press the horn or turn the steering lamp switch. The electric horn makes loud sound and the steering lamp emits bright The electric horn does not make light.
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Repair Open circuit or short circuit replace starting inside the electric starting button control system Diagnosis on starter motor running weak Starter motor running weak Turn the ignition switch; press the horn or turn the steering lamp switch. The electric horn does not make The electric horn makes loud sound sound or makes weak sound;...
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Diagnosis on motorcycle lamp failure in illumination Motorcycle lamp failure in illumination AC power supply system power supply for illumination system for illumination Remove the connector between the conductor Press the horn button or bundle of electromagnetic motor and the cable turn the steering lamp assembly;...
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The lamp is light. The lamp is not light. Open circuit or short circuit Bad contact inside the between the illumination switch illumination switch. and the lamp. Diagnosis on burnt-out bulbs Burnt-out bulbs Turn the ignition switch; press the horn or turn the steering lamp switch.
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Diagnosis on weak light from lamps Weak light from lamps power supply power supply system for illumination system for illumination Remove the connector between the conductor bundle of Turn the ignition switch; press the horn or turn the electromagnetic motor and the cable assembly; check whether steering lamp switch.
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Diagnosis on steering lamp failure in illumination Steering lamp failure in illumination Steering lamps at one side Steering lamps at one side All the steering lamps are partly not light. are wholly not light. are not light. Remove the lamp covers and Remove the lamp covers and Press the horn button and check whether check whether the bulbs are...
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The test lamp The test lamp is light. is not light. Open circuit or short circuit of Open circuit or short circuit between the ignition switch and the flasher or between power cord of steering lamp. the flasher and the steering lamp switch. Diagnosis on electric horn failure in making sound Electric horn failure in making sound...
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Diagnosis on brake lamp failure in illumination Brake lamp failure in illumination Disassemble the cover of brake lamp and check whether the circuit board is burnt. Replace circuit Use a lead wire to short-circuit two terminals or two terminal pins board of brake lamp of brake lamp switch.
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Check whether short circuit occurs to the charging coil of electromagnetic motor. Short circuit between the rectifier or the rectifier regulator or the battery and the ignition switch. Replace charging 1. Check whether the electrolyte inside the coil battery is sufficient. 2.
Anticipated Inspection Ignition system—obviously continuous ignition abnormality, engine fire or overheating, which requires inspection and maintenance. Carbon fouling elimination—obviously insufficient horsepower, which requires carbon fouling removal from cylinder head, piston head and exhaust system. Piston & cylinder—excessive abrasion; replace cylinder if it is blocked. Please have your motorcycle inspected and adjusted periodically at Qianjiang distributors for being in best condition.
Check oil leakage when the engine operates at its idle speed for minutes. (放油螺栓:drain bolt) Check the oil level again. Throttle cable inspection/adjustment Check whether the throttle cable works smoothly. Check the free stroke of the throttle cable. Free stroke: 5-10mm It is mainly adjusted at the carburetor side.
the filter. Spark plug Remove the spark plug. Check whether the spark plug is damaged or stained or has carbon fouling. If yes, please clean it with spark plug cleaner or steel brush. Check spark plug gap. Gap: 0.6-0.8mm (火花塞间隙:spark plug gap) * Note For the installation of spark plug, it shall be installed with hand first and then fastened with spark plug sleeve.
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Warning! To prevent short circuit, connect the positive wire first and then the negative wire. Do not remove the battery during commissioning. Otherwise, it may cause damage to inner parts of the vehicle. Check the charging condition (closed circuit voltage) Open the battery box cover.
quick: 30 minutes Charging completed: open circuit voltage: above 12.8V Carburetor Idle speed adjustment * Note Idle speed adjustment is carried out when the engines warms up. It is carried out when the engines warms up. Operate the engine and connect the engine rotary meter. Adjust the adjusting screws of the throttle cable.
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Remove the spark plug. Install the cylinder pressure gauge. At full throttle, measure the cylinder pressure by starting the engine. Following items shall be checked in case of extra-low pressure: —whether the spacer of cylinder cover is damaged; —whether piston ring is damaged; —whether piston ring is worn;...
Add gear oil. Check whether there is oil leakage in any part. Install the dipstick. (放油螺栓:drain bolt) Drive belt Remove the cover of left crankcase. Check whether the drive belt is ruptured or abraded. Periodically maintenance shall be guaranteed, and replace the drive belt if necessary.
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Brake to the maximum and check the oil level through the oil sight glass. In case the brake fluid level is at or below the arrow in the picture, certain brake fluid shall be added until it reaches the upper limit. Note: The fuel pump assembly shall be parallel with the ground during inspection.
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whether any component is damaged or loosened. (上下压缩:compress upwards or downwards) Rear Compress the rear absorber upwards or downwards for check. Check whether each part of the rear absorber is damaged or loosened. Suspend the rear wheel and check shimmy. Check whether the suspension bushing of the engine is loose or not.
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Tire specification Front outer tire 120/70-12 Front rim 3.50×12 FACT 50 4T Rear outer tire 130/70-12 Rear rim 3.50×12 Check whether the locking nut of the front wheel spindle is loose. Check whether the fixing nut of the rear wheel is loose.
Inspection and Maintenance of Electrical System Table of Torque Force of Electrical System Fasteners Name of fastening parts and fasteners Tightening torque(N·m) Clutch cover bolt of the startup motor Clutch fixing nut of the startup motor Rectifier bolt High-voltage coil fixing bolt Flywheel fixing nut Body guard bolt...
1. Battery/Charging System Preparing documents -------------1.1 Failure diagnosis -------------1.2 Battery ---------------1.3 Charging system -------------1.4 Voltage/current regulator -------1.5 Charging coil of magnetor---1.6 Disassembly of magnetor-----1.7 1.1 Preparing documents Work Instructions *Note 1. Battery can be charged or discharged repeatedly. If it is placed after discharge, its service life will be shortened and performance is undermined.
Preparing principles Item Specifications Capacity/Type 12V-4AH/ dry-charged Voltage Fully charged 13.1V (20 ) Necessary 12.3V(not working for 1h) Battery charging Charging current Standard: 0.4A,quick: 4A Charging time Standard: 10-15 hours,quick: 30 mins Capacity 90W/8000rpm Impedance of lighting coil Between green/red-black 2.0-2.5Ω (20 )...
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1.3 Battery 1.3.1 Battery disassembly Remove fixing screws of the battery box cover. Remove the battery box cover. Remove the negative wire and then the positive wire. Remove the battery. Warning! When the positive wire is disassembled, do not make the tool contact with the frame.
• Except emergencies, you should not use emergency charging. • Measure voltage in 30 minutes after the battery is charged. Charging current: standard: 0.4A quick: 4.0A Charging time: standard: 10-15 hours quick: 30 minutes Charging completed: open circuit voltage: above 12.8V 1.4 Charging system 1.4.1 Short-circuit test Remove the earth lead from the battery.
1.5 Voltage/current regulator 1.5.1 Main wiring check Remove 4p plug of the voltage/current regulator. Check conductivity between main wiring terminals. Item (wire color) Judgment Between With battery voltage Battery(red) and GND of the body Between GND With lead wire (black) and GND of the body Between charging Resistance in the coil...
Check Remove the 6p connector of the magnetor. Measure impedance between the white coil of the magnetor and the body with multimeter. Standard: 1.5-2Ω(20 ) Replace the magnetor coil when the measured value exceeds the standard value. 1.7 Magnetor lighting coil * Note Check the magnetor lighting coil on the engine.
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1.7.3 Installation 飞轮:flywheel 冷却风扇:cooling fan 风扇盖:fan cover Install the stator on the body of the engine. Connect the magnetor joint. Clean up the crankshaft and the taper part of the flywheel. Install the solid key into the groove above the upper crankshaft key and confirm it.
2. Ignition System Preparing documents--------------2.1 CDI Group ----------------2.4 Failure diagnosis --------------2.2 Ignition coil --------------2.5 Ignition system check----------2.3 Trigger --------------------2.6 2.1 Preparing documents Work Instructions 1. Check the ignition system following the sequence listed in the table of failure diagnosis. 2. This ignition system is an electronically and automatically angling device. It is solidified in the CDI group and you don’t have to adjust the ignition time.
2.2 Failure diagnosis Non-sparking of spark plug Abnormality Cause (confirm it sequentially as follows) The inner resistance is too small and it should be tested by required tester. Low speed of the crankshaft. Interfered tester (It is normal that voltage is Ignition always beyond the required value upon several coil...
2.3 Ignition system check * Note • When there is no spark, check whether there is loose wiring 万 用 表 or poor contact, and make sure all voltage values are normal. • There are kinds of multimeters with different impedances and different test values.
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Connection: positive pole to black/red; negative pole to black. Minimum voltage: above 95V * Note Never touch any metal part of the test rod with your finger to avoid electric shock. When the maximum voltage measured at the terminal of CDI Group is abnormal, dismantle the body guard and the magnetor terminal.
2.4 CDI Group 2.4.1 System check Check the system. Remove the CDI Group, and check components of the ignition system at the terminal. (黑:black 红:red 白:white 绿:green 蓝:blue 墨绿: blackish green 2.4.2 Check Remove CDI Group and check whether the terminal is loose or corrosive Item Test terminal...
2.5.3 Secondary coil Attached with spark plug. Measure the impedance between the wiring side of the spark plug cap and the terminals. Standard: 5-11KΩ(20 ) It shows good if the impedance is within the range of standard values. The impedance ∞ indicates that the coil breaks. Ω...
3. Startup System Preparing documents---------------3.1 Failure diagnosis -------------------3.2 Startup motor------------------------3.3 Starter relay--------------------------3.4 3.1 Preparing documents Work Instructions Disassemble the startup motor on the engine. For the disassembly of the startup clutch, please comply with related regulations Preparing principles Item Standard Limit for use Length of the brush of the startup 6.2mm...
3.2 Failure diagnosis Startup failure Weak in rotation No rotation of RE rotary engine of the startup motor of the startup motor • Fuse blow • Low battery • Poor startup clutch • Low battery • Poor wiring contact • Reversal rotation of the startup motor •...
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attached to it. Check conduction between the surfaces of other components. Ensure non-conduction between armature shafts of the commutator. Check the conduction of the shell of the startup motor. Ensure non-conduction between the conduction terminal and the startup motor shell. Check conduction between the conduction terminal and the brush.
3.4 Starter relay 3.4.1 Check Remove the body guard. When the main switch is “on”, check there is “click” sound at the time of pressing the startup motor. With click sound, it is normal. Without click sound: • check voltage of the starter relay; •...
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Bulbs/switches/meters Iden. No. of headlamp: E3 00 1006 Iden. No. of front steering lamp: 50R-001024 Iden. No. of tail lamp: 50R-000054 Iden. No. of rear steering lamp: 50R-001024 Iden. No. of front position lamp: E3 50 R001023 Iden. No. of rearview mirror: 001002 1.
4. Bulbs/Switches/Meters Preparing documents ---------------------4.1 Meters -------------------------4.6 Failure diagnosis--------------------------4.2 Main switch ------------------4.7 Replacement of headlamp bulbs --------4.3 Horn ---------------------------4.8 Replacement of front steering lamp bulbs------4.4 Handlebar switch -------4.9 Replacement of tail lamp bulbs---------4.5 4.1 Preparing documents Work Instructions Remove the switch from the vehicle to measure its conduction 4.2 Failure diagnosis When the main switch “ON”...
4.3.2 Installation Install the bulb in reverse order. 4.4 Replacement of rear steering lamp bulbs 4.4.1 Disassembly Remove the foot guard and pedal assembly. Remove the front shield, and disconnect the steering lamp connecting wire. Loosen the fixing nuts (4) of the steering lamp. Remove the bulb from the socket.
4.6 Meter Remove the left and right rearview mirror. Remove fixing screws of the handlebar cover. Remove the decorating cover of the upper handlebar shade. Remove the odometer assembly to dismantle the odometer. Install the speedometer in reverse order. 4.7 Main switch 4.7.1 Check Remove the front guard.
4.9 Handlebar switch Remove the left/right rearview mirror assembly. Remove the fixing screws of the left/right combined switch. Loosen the left/right combined switch. Remove the right grip assembly and the left steering grip. Remove the left/right combined switch. 逻辑图: Logic Diagram...
Inspection and maintenance of the chassis Torque Force Table of Chassis Fasteners Name of fastening parts and fasteners Tightening torque(N·m) Fuel pump assembly fixing bolt Mounting bolt of front brake cylinder assembly 22-29 Brake handle fixing bolt Fixing screw of muffler decorating shade Fixing bolt of handlebar weld assembly 40-60 Front wheel spindle locking nut...
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Front disc brake Dia. of front brake disc: 190mm Thickness of front brake disc: 3.6 Limit for use: 2.6mm Thickness of friction disc: 5.0mm Limit for use: 4.0mm Torque for mounting bolt 8: 5- 9N·m Torque for mounting nut 27: 37- 44N·m Free stroke of brake handle: 1.
5. Brake Maintenance instruction ------------------------5.1 Failure diagnosis --------------------------------5.2 Front disc brake ---------------------------------5.3 Rear drum brake --------------------------------5.4 5.1 Maintenance instruction Work Instructions * Note • Do not stain the brake assembly with oil spots during installation or disassembly. • Clean it with required cleaning agent to maintain the brake performance. *Check brake before riding.* 5.1.1 Specification Item...
Check whether the friction disc assembly is abraded. Replace brake shoes if necessary. Measure the friction disc assembly and the front brake disc. Record maximum values. Specification FACT 50 4T Diameter of the front brake disc φ190mm Thickness of the front brake disc 3.6mm...
* Note • Measurement with micrometer. Measure the thickness of the friction disc assembly. If the thickness of the front brake disc or the friction disc assembly is below the required value for maintenance or it is stained with grease, please replace it. Limit for use: friction disc 5.0mm Front brake disc 2.6mm Note:...
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Remove the muffler. Remove the fixing nuts of the rear wheel. Remove the rear wheel. Remove the brake shoe assembly. * Note • Replace the brake shoe assembly. • If the brake shoe will be used again, mark it before disassembly so as to reinstall it at the original place.
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5.4.3 Installation Install the brake shoe assembly. Install the rear wheel. Install the muffler. * Note Any grease on brake shoes will reduce the brake performance and even lead to failure. Tighten bolts and nuts to the required torque force. torque force: Fixing nuts for rear wheel: 100-113 N·m Do not stain brake shoes and brake disc with oil spots.
Body *Note: Do not damage any body part during disassembly. Do not damage any hook or claw in the body during disassembly. Aim panels in the body at each corresponding groove. Ensure correct installation of each 1seat assembly 2rear rack 3 tapping screw ST3×10 4 tapping screw ST5×16 5 battery box cover 6 helmet box front cover 7odometer shade 8 handlebar cover 1 9 handlebar cover 2 10 right guard 11left guard 12 connecting bracket of the left/right guard I 13 screw M6×14 14 decorating panel of the front shield 15 tapping screw ST4.2×16 16 front shield 17 tapping screw ST5×16 18 tapping screw ST4.8×16 19 headlamp 20helmet hook...
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6. Body Dismantle the body in following order: Left/right rearview cover→ odometer shade→ handlebar cover 1→ handlebar cover 2→ front inner fender→ helmet ↓ Hook → frame number cover→ foot protection board → front shield→ headlamp → set assembly→ helmet ↓...
Front wheel Tire size: outer tire 120/70-12 Auth. No. of the front wheel outer tire: E11 75R 000210 Rim size:3.50×12 Rim run-out limit: Vertically: 2.0mm Horizontally: 2.0mm Front wheel spindle bending limit: 0.2mm 1 front wheel spindle M12Χ1.25Χ224 2 left spindle sleeve of front wheel 3 oil seal 22×35×7 4 bearing 6201-2RS 5 middle spindle sleeve assembly 6 front rim 3.50×12 7 tire 120/70-12 8 gear housing assembly 9 nut M12Χ1.25 10 valve cap 11 valve 12 front brake disc 13 installation nut of front brake disc 14 nut...
Front suspension Torque for mounting N·m bolt 12: 37-44 Torque for mounting N·m bolt: 5-9 Number of upper steel balls: 21 Number of lower steel balls::21 1 front right absorber assembly 2 front left absorber assembly 3 weld assembly of lower connecting bracket 4 odometer cable clamp 5 brake cable clamp 6 gland nut 7 dust cover 8 one-piece cup 9 steel ball φ5 10 upper cup of the lower bearing 11 lower cup of the lower bearing 12 bolt M10×1.25×30 13 bolt M6×16...
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Handlebar Torque for mounting bolt 2 (handlebar fixing N·m bolts): 40-60 Free stroke of front brake handle: 10-20mm Free stroke rear brake handle: 10-20mm Free stroke of throttle lever (Fig. 6): 2-5mm 1 handlebar weld assembly 2 bolt M10×1.25×45 3 nut M10×1.25 4 left grip 5 throttle lever assembly 6 left handle 7 right combined switch 8 right combined switch fitting seat 9 screw M5×20 10 screw M5×25 11 left combined switch assembly 12 left combined switch assembly fitting seat 13 spring washer 5 14 nut M5 15 screw M5×20 16 right combined switch assembly 17 handle set screw M5 18 right rearview mirror 19 left rearview...
7. Front Wheel / Front Suspension Preparing documents-------------------------7.1 Failure diagnosis -----------------------------7.2 Front wheel -----------------------------------7.3 Handlebar -------------------------------------7.4 Front fork assembly -------------------------7.5 7.1 Preparing documents Work Instructions Before removing the front wheel, you should use jack to support the body bottom and suspend the front wheel which shall not be reversely rotated.
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7.2.2 Unsteady steering Damaged steering handle bearing. Low tire pressure. Bending of the front fork or the front wheel spindle. Deformed or unbalanced front tire. 7.2.3 Front tire shimmy Deformed rim. Loose front wheel bearing. Poor tire. 7.2.4 Difficulty in wheel rolling Failure of wheel bearing or gear housing.
7.3.2 Check 7.3.2.1 Check the bending of the wheel spindle Place the wheel spindle on the V-base and measure the eccentricity ratio with a dial indicator. Limit for use: replacement when beyond 0.2mm 7.3.2.2 Check the rim shimmy Place the rim on a precision bracket and check the rim shimmy.
Tighten the front wheel spindle (shown in the right picture). * Note: for the disassembly and assembly of the front suspension of FACT 50 4T, please see P88. Torque force: Locking nuts for the front wheel spindle 55-62 N·m 7.4 Steering handle 7.4.1 Disassembly...
Install it in reverse order. Fixing bolt of handlebar weld assembly Torque force: 40-60 N·m 7.5 Front fork 7.5.1 Disassembly Remove the front wheel. Remove the body guard. Remove the brake hose and the odometer cable. Remove the handlebar. Remove the gland nut (6) and the dust cover (7). Remove the one-piece cup (8) and steel balls (9).
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Install the handlebar. Install the body guard. Install the front wheel. * Note: for the disassembly and assembly of the front fork , please see P89.
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Rear wheel/rear suspension Torque for fixing nut 5 of the rear wheel: 100- 113N·m Torque for mounting bolt 4: 22-29N·m Torque for mounting bolt 14: 37-44N·m I.D. brake (friction limit): 111mm Thickness of brake pad (wear limit): 3.5mm 1 outer tire 130/70-12 2 rim 3.50×12 3 cotter pin 4 bolt M8×31 5 nut M16×1.5 6 brake shoe assembly 7 brake shoe spring 8 rear indicator 9 rear brake camshaft 10 rear brake return spring 11 rear brake swing arm 12 rear swing arm mounting bolt 13 o-ring 14 bolt M10×1.25×40 15 rear absorber assembly...
Rear wheel Tire size: 130/70-12 Rim size: 3.50×12 Rim run-out limit: Vertically: 2.0mm Horizontally: 2.0mm Torque of fixing nut 5 of the rear wheel: 100-113N·m Auth. No. of rear tire: E11 75R 000216 1 outer tire 130/70-12 2 rim 3.50×12 3 valve cap 4 valve 5 nut M16Χ1.5 6 brake shoe assembly 7 brake shoe spring 8 rear indicator...
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8. Rear Wheel/Rear Suspension Preparing documents -----------------8.1 Failure diagnosis ----------------------8.2 Rear wheel -----------------------------8.3 Rear absorber --------------------------8.4 8.1 Preparing documents Work Instructions The surface of the brake drum and brake shoes shall not be stained with oil spots. Preparing Principles Item Standard (mm) Limit for use (mm) Vertically...
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Check and replace the rear wheel bearings. 8.3.3 Installation Install the rear wheel in reverse order and lock nuts. Fixing nuts for the rear wheel Torque force: 100-113 N·m FACT 50 4T rear wheel...
9.Fuel Tank/Seat Preparing documents -----------9.1 Failure diagnosis ---------------9.2 Fuel tank/seat -------------------9.3 9.1 Preparing documents Work Instructions It shall be dismantled far from fire sources. Turn the fuel switch to “OFF” when the fuel tank is dismantled. Tighten all the bolts and screws to the required torque value for assembly. After assembly, check whether all the parts are correctly installed and operated.
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9.3 Fuel tank/seat 9.3.1 Disassembly Open the seat. Remove (four) fixing bolts of the seat. Remove the machine oil pot guard. Remove the machine oil pot. Remove the seat and the helmet box (1). Remove the rear storage box rack. Remove the rear left/right guard assembly.
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Disassembly and Installation of Engine torque force of engine stationary axis 1: 55- 62N·m torque force of bolt 2: 37-44N·m torque force of bolt4: 22-29N·m 1 engine stationary axis M12×1.25×280 2 bolt M10×1.25×40 3 seat steel rope 4 bolt M8×31 5 rear shock absorber assembly 6 engine assembly 7 rear wheel assembly 8 rear brake rocker arm assembly...
10. Disassembly/installation of engine Preparing documents -----------10.1 Failure diagnosis ---------------10.2 Engine ----------------------------10.3 Engine suspension standing clamp------10.3 10.1 Preparing documents Work Instructions Make motorcycle not tilt in removing motor. Remove motor when maintain crankshaft and final drive shaft. When maintaining magnetogenerator, camshaft, carburetor, driving wheel, clutch, driven wheel and oil pump, the motor can stay at the frame and needs not to be removed.
10.3 Disassembly of engine 10.3.1 Disassembly Remove bolt and left crankcase ventilated tube. Disassembly procedures: -remove frame cover. -remove gas filter. -remove primary cable of ignition coil. -remove starter motor cable. -remove fuel tube and vacuum tube. -remove starter valve 2P connector. -remove magnetogenerator/ pulser 3P connector.
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Connect carburetor fuel tube and vacuum tube. Connect the engine suspension assembly to engine assembly. Install bolt and nut of engine suspension temporarily. 10.3.3 Installation Install according reversed procedures “disassembly”. Note: For details, see P106. Torsion value of installation: engine stationary axle 55-62 N·m rear shock absorber standing bolt (upper) 37-44 N·m rear shock absorber standing bolt (lower) 22-29 N·m...
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Inspection and Maintenance of Engine Table of Torque Force of Engine Fasteners Name of fastening parts and fasteners Tightening torque(N·m) Fan cowl locking bolt 10-12 Cylinder cover locking nut 15-18 Spark plug 22-25 Air intake pipe locking bolt 10-12 Cooling fan blade locking screw 10-12 Flywheel locking bolt 45-50...
Lubricating System Note: Worm gears and worm wheels shall rotate flexibly without being seized or imbalanced tightening. A little axial movement shall be allowed for worm wheels. Fuel pump O-ring shall not cut the edge. Machine oil pump plugs shall not leak and sealing gaskets shall be in good condition.
10. Lubricating System Preparing documents -----------10.1 Failure diagnosis ----------------10.2 Fuel pump ------------------------10.3 10.1 Preparing documents Work Instructions Worm gears and worm wheels shall rotate flexibly without being seized or imbalanced tightening. A little axial movement shall be allowed for worm wheels. Fuel pump O-ring shall not cut the edge. Machine oil pump plugs shall not leak and sealing gaskets shall be in good condition.
10.3 Fuel pump 10.3.1 Disassembly Loosen the bolt and remove the fan cowl assembly. 导风罩 Loosen fan screws and remove the fan. Screw Remove the right cover. 磁电机定、转 Right cover 子、支架 Remove the worm wheel from the crank and also the fuel pump assembly. Fuel pump...
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Screw Remove screw, take down the fuel pump base, and disassemble the fuel pump. Fuel pump Check the radial clearance between inner and outer rotors. Limit for use: 0.19mm。 Gauge Check the clearance between outer rotor and fuel pump base. Limit for use: 0.21mm。...
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Check the end clearance of rotors. Limit for use: 0.11mm. Flat palte Gauge Assembly of fuel pump As shown below 1. cross recessed small pan head screws2. locating pin 3. O ring 4. fuel pump base 5. inner rotor 6. outer rotor 7.
Measure the outer diameter of the plunder. Limit for use: 2.61mm。 Carburetor Note: Gasoline very dangerous. Fire strictly forbidden in workplace. After the carburetor is disassembled, block the intake manifold with cloth in case that any foreign matter enters. 1. screw 2. float chamber 3. needle valve assembly 4. float 5. float pin 6. main metering jet 7. idling jet 8. main foam pipe 9.
11.Carburetor Preparing documents --------------11.1 Failure diagnosis -------------------11.2 Carburetor disassembly -----------11.3 Carburetor installation ------------11.4 Carburetor adjustment ------------11.5 11.1 Preparing documents Work Instructions ·Gasoline is very dangerous. Fire is strictly forbidden in workplace. ·Pay special attention to spark. ·Forcibly pulling and bending of wires is not allowed. Distortion and damage will affect their function. ·After the carburetor is disassembled, block the intake manifold with cloth in case that any foreign matter enters.
11.2 Failure diagnosis Abnormal startup Difficulty in startup, flameout after startup, unstable idle speed No fuel in the carburetor Blocked carburetor Blocked oil filter Too dense or dilute mixed gas Blocked oil pipe Secondary air suction into the air intake system Adhesive needle valve Idle speed maladjustment Oil level maladjustment...
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11.3.2 Carburetor breakdown Loose screws of the electric enrichment valve and remove the electric enrichment valve assembly. Electric enrichment valve Fixing screw Fixing flange 组件 Enrichment valve 组件 Check abrasion of electric enrichment Oil needle valve and oil needle. 组件 If it is severe, replace the electric enrichment valve assembly.
11.3.3 Check Check whether the needle valve assembly, needle valve seat and float assembly are abrasive or damaged. Screw Float chamber Replace any abrasive or damaged needle valve core. Needle valve assembly Replace the carburetor body if the needle valve seat is abrasive.
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(retreat the screw by 2 circles to the maximum); Readjust the idle adjusting screw to lower the engine speed to 1800±100rpm; Pull the throttle to speed up for several times and check whether the idle speed is steady; Test exhaust and compare it with standard.
Cylinder cover Note: The cylinder cover bears large bolt pretension to ensure sealing between the cylinder cover and the cylinder body. Pretension: 50Nm cylinder cover gasket 1 cylinder cover assembly 3 intake valve 4 spark plug 5 exhaust valve locating pin(Ф10×14)7 valve spring gasket 8 valve spring 9 exhaust double end stud 10 valve oil seal assembly 11 O ring(40×2.65)...
Fixing nut Cylinder Loosen fixing nuts and spark plug, remove the cylinder cover. cover Sprocket cover 12.4 Cylinder cover check Check whether cylinder cover is broken. Check flarness of cylinder cover bottom surface. Ruler Limit for use: 0.04mm。 Gauge 12.5 Installation of cylinder cover Cylinder cover Install it in reverse order.
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注意:所有零件在检查测 定前应清洗,并用高压空 气吹干净。 Note: all parts shall be cleaned and blown by high pressure air before check. 1. piston 2. piston pin 3. cylinder block 4. cylinder gasket 5. cylinder cover 6. nut...
13.Cylinder Block and Piston Preparing documents-----------------13.1 Piston---------------------------13.4 Failure diagnosis --------------------13.2 Piston installation-------------13.5 Cylinder block-----------------------13.3 13.1 Preparing documents Work Instructions All parts shall be cleaned and blown by high pressure air before check. Function of the cylinder block: cylinder block provides space for gas compression, combustion and expansion, and also guides piston movement.
13.2 Failure diagnosis Low compression pressure White smoke from the exhaust pipe Abrasive, burnt or ruptured piston Abrasive or damaged piston ring Abrasive or damaged cylinder or piston Abrasive or damaged cylinder or piston Damaged spacer or crankcase leakage Over-high compression pressure Abnormal noise of the piston Too much carbon deposit in the combustion chamber Damaged cylinder, piston or piston ring Abrasive piston pin hole and piston pin...
13.4 Piston 13.4.1 Disassembly Remove the retainer ring of the piston. Note: during assembly, do not make the retainer ring fall into the crankcase. Remove the piston pin and the piston. Piston pin, retainer ring Check the piston, piston pin and piston ring. Remove the piston ring.
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Measure the outer diameter of the piston pin. Limit for use: 9.94mm。 clearance between the piston pin holr an the piston pin Limit for use: 0.014mm。 Measure the outer diameter of the piston. 90° Note: The measuring point shall be at 90°with the piston pin, and at 11.5mm below the piston skirt.
Measure the inner diameter of the smaller end of the Smaller end of the connecting rod connecting rod. Limit for use: 10.018mm。 13.4.2 Piston Installation Install the locating pin. 顶环 Apply fuel to each piston ring and pistion. Install the piston 第二环...
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Drive face/clutch/driven wheel Note: During operation, the surface of the triangle belt can not be stained with any grease which must be removed. It helps avoid slipping between the triangle belt and the belt pulley as much as possible. 1 gasket 2 spring 3 friction plate 4 check ring...
Kickstart Mechanism Note: During operation, the surface of the triangle belt can not be stained with any grease which must removed. It helps avoid slipping between triangle belt and the belt pulley as much as possible. 1. snap spring 2. start claw 3. idle gear 4. idler shaft 5. start shaft assembly 6. kickstart shaft spring...
14. Drive Face/Clutch/Driven Wheel/Kickstart Mechanism Preparing documents -------------------14.1 Clutch/driven wheel ---------14.5 Failure diagnosis --------14.2 Breakdown of clutch and driven wheel -----14.6 Left crankcase cover ----------------14.3 Installation --------------------14.7 Drive face ----------------------------14.4 Kickstart mechanism------------14.8 14.1 Preparing documents During operation, the surface of the triangle belt cannot be stained with any grease that must be removed.
Ruptured clutch spring Stained surface of the driving pulley 14.3 Left crankcase cover Disassembly Remove fixing bolts, spacer and locating pin. Left cover Note: Fixing bolt Fixing bolts should be removed in staggered sequence. Remove the locating pin. 14.4 Drive face Locating pin 14.4.1 Disassembly Remove fixing nuts for drive face and the left half-drive face.
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Remove the right half drive wheel assembly Right half drive wheel assembly 14.4.2 Breakdown of right half drive wheel assembly Check abrasion of the ball. Measure the outer diameter of the ball. Limit for use: 15.8mm...
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Right half drive wheel Measure the inner diameter of the right half drive wheel. 驱动轮右半 Limit for use: 20.05mm。 Sliding sleeve Measure the outer diameter of the sliding sleeve. Limit for use: 19.94mm。 滑套 14.5 Clutch/driven wheel 14.5.1 Disassembly Install the clutch sleeve with the fixer and remove fixing nuts.
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Check abrasion of the clutch sleeve. Measure the outer diameter of the clutch sleeve. Limit for use: 107.2mm。 Check abrasion of the clutch facing. Clutch facin Measure the thickness of the clutch facing. Limit for use: 3.5mm 14.6 Breakdown of clutch and driven wheel Clutch spring compressor must be used for disassembling the clutch spring.
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Weldment on the left half driven Remove the guide pin. wheel Remove the weldment on the left half driven wheel. Remove the oil seal on the left half driven wheel. Guide pin Oil seal Check the free length of the clutch spring. Limit for use: 93mm。...
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Apply grease evenly to the outer rolling bearing and then place it into the sleeve. Note: Bearing screwdriver Place the outer rolling bearing into the sleeve with its marked side outwards. Then fill the sleeve with 8-9g grease. Install the elastic retainer ring. Required grease Ball bearing Bearing screwdriver...
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Install the spring guard. Eliminateleaked grease. (弹簧护套:spring guard) Install the clutch spring and the clutch on the driven wheel. Compress the set with the clutch spring. Install locking nuts after compression. Note: Properly compress the spring to avoid damage to the spring 扳手(锁紧螺母):spanner (locking nut) 离合器弹簧压缩器:clutch spring compressor )...
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Decelerator Function: transfer torque and decide final output torque and rotational speed. 1 gearbox cover gasket 2 input shaft 3 hex flange bolt 4 output shaft assembly 5 input shaft gear intermediate shaft assembly 7 hex flange nut 8 rolling bearing 9 gasket 10 output shaft seal ring 11rolling bearing 12 gearbox cover 13 hex flange lock nut 14 O-ring 15 anchor pin...
Remove the spacer and the locating pin. Remove the clutch spindle and gear of output shaft. Output shaft gear Remove the middle shaft and the middle gear. Spacer Clutch spindle 15.3.2 Check the Output Gearbox Cover Middle shaft Middle gear Check abrasion and damage of the clutch spindle, gear and bearing.
Crankcase Note: The crankcase is thin- section casting thus shall not suffer impact during operation which may cause deformation or fracture. components must cleaned and blown with high- pressure gas before test. Lubricant in the crankcase should be drained out before operation.
16 Crankcase Preparing documents -----------------16.1 Failure diagnosis ----------------------16.2 Crankcase ------------------------------16.3 Assembly ------------------------------16.4 16.1 Preparing documents Work instructions The crankcase is thin-section casting thus shall not suffer impact during operation which may cause deformation or fracture. All components must be cleaned and blown with high-pressure gas before test. Lubricant in the crankcase should be drained out before operation.
16.2 Failure diagnosis Noise in crankcase Loose or broken parts inside the crankcase Loose crankshaft bearing Loose crankpin bearing Seized clutch 16.3 Crankcase 16.3.1 Crankcase disassembly Loosen the bolts and remove the fan, flywheel and coil. Fan, flywheel and coil Remove right cover and fixing bolts of the crankcase.
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Remove the oil seal from the left crankcase. Oil seal Check 16.3.2 Measure the left-right clearance of the larger end of the connecting rod. Limit for use: 0.3mm. (连杆大端测量位置:measuring point at the larger end of the connecting rod) Measure the clearance of the larger end of the connecting rod (X-Y direction).
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Note: Removed oil seal cannot be used any more. Remove the oil seal with a special tool 16.4 Assembly Install the crankcase in reverse order. Note: Install the oil seal with special tools to avoid any damage to it.
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Inspection and Maintenance of Exhaust Emission System Muffler Torque for fastening fixing screw muffler connecter: 5-9 N·m Torque for fastening fixing bolt 8 of the muffler: 5-9 N·m Torque for fastening fixing bolt 3 of the muffler hoop: 5-9 N·m 1 muffler assembly 2 muffler tube assembly 3 bolt M6×20 4 gasket 6mm 5 sealing gasket 6 tube assembly 7 bolt M8×20 8 bolt M6×16 9 exhaust pipe gasket assembly 10 heat-insulating rubber...
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18. Exhaust Emission & Control System Warranty on the exhaust emission & control system ---------------------------18.1 Instructions on the periodic maintenance/ compliance with standards-------18.2 Mechanical function of the exhaust control system ----------------------------18.3 Catalytic conversion system -------------------------------------------------------18.4 Measures when the idle speed emission value exceeds the standard---------18.5 18.1 Warranty on the exhaust emission &...
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3〉Please comply with periodic maintenance requirements. The exhaust control system of this motorcycle is in accordance with the national regulation. For replacement of any component, please use our original parts and have our designated distributor or service center carry out such replacement. 4>...
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18.4.2 Instruction: 1. The function of convertible catalyst is to converse exhaust gas HC, CO and NO after complete combustion to harmless gas such as H O, CO before emission. 、 2、 2. Convertible catalyst contains rare metal such as platinum and rhodium. Only lead-free gasoline can be used. ※...
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18.5 Measures when the idle speed emission value exceeds the standard (Four-Stroke) Satisfactory Periodic inspection (maintenance plan ) Satisfactory Measure idle emission (note 1) Satisfactory Adjust Carburetor (note2) Satisfactory Qualified for Remove and clean the carburetor delivery (SJ, MJ, SAJ, MAJ, etc.) Satisfactory Replace the carburetor Dismantle...
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B08 ELECTRICITY PRINCIPLE DIAGRAM OIL INDICATOR LIGHT 2W BEAM INDICATOR LIGHT 2W INSTRUMENT LIGHT 2W×2 TURN SIGNAL INDICATOR LIGHT 3W BRAKE SWITCH STARTOR MOTOR BATTERY IGNITION SWITCH THERMO ELEMENT RELAY RECTIFIER FUELMETER ELECTRIC CLOCK G/W G/B BL B Gr B R/W B G Y/G B G/R W R B Dg B/R...
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