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FACT 50 4s
Maintenance Manual
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Summary of Contents for KEEWAY FACT 50 4T

  • Page 1 FACT 50 4s Maintenance Manual Contents...
  • Page 2: Table Of Contents

    Contents .................. 2 Preface ................... 5 Preparing documents ..............5 Inspection/Adjustment ..........42 Inspection and Maintenance of Electrical System........... 55 1. Battery/Charging System ............... 58 1.1 Preparing documents .............. 58 1.2 Failure diagnosis ..............59 1.3 Battery ................60 1.4 Charging system ..............61 1.5 Voltage/current regulator ............
  • Page 3 7.2 Failure diagnosis ..............99 7.3 Front wheel ..............99 7.4 Steering handle ..............102 7.5 Front fork ..............102 8. Rear Wheel/Rear Suspension ............106 8.1 Preparing documents ............. 106 8.2 Failure diagnosis ............... 106 8.3 Rear wheel ..............107 8.4 Rear absorber ..............
  • Page 4 14.5 Clutch/driven wheel ............149 14.6 Breakdown of clutch and driven wheel..........150 14.7 Installation ..............153 14.8 Kickstart mechanism ............154 15. Decelerator ................. 156 15.1 Preparing documents ............156 15.2 Failure diagnosis .............. 156 15.3 Gearbox ................ 156 15.4 Assembly ...............
  • Page 5: Preface

    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.
  • Page 6 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.
  • Page 7 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.
  • Page 8 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 &...
  • Page 9 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;...
  • Page 10 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.
  • Page 11: Special Tools

    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.
  • Page 12 Fig.1-7 Fig.1-8 Fig.1-9 Fig.1-10 handle Fig.1-11 Fig.1-12 pliers piston Fig.1-13 Fig.1-14...
  • Page 13 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.
  • Page 14 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...
  • Page 15 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 ×...
  • Page 16 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 ×...
  • Page 17 (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...
  • Page 18 FACT 50 4T...
  • Page 19 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...
  • Page 20 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.
  • Page 21 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...
  • Page 22 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;...
  • Page 23 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.
  • Page 24 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.
  • Page 25 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.
  • Page 26 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.
  • Page 27 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...
  • Page 28 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.
  • Page 29 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...
  • Page 30 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.
  • Page 31 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.
  • Page 32 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;...
  • Page 33 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;...
  • Page 34 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.
  • Page 35 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.
  • Page 36 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...
  • Page 37 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...
  • Page 38 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.
  • Page 39 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.
  • Page 40: Inspection/Adjustment

    Inspection/Adjustment Preparing information Cylinder pressure Periodic Maintenance & Inspection Table Gear oil Engine oil/ Oil filter Replacement of gear oil Fixing steering stem bearing & handlebar Driving belt Inspection & adjustment of throttle cable Free stroke of front/rear brake Air filter Inspection of brake fluid level Spark plug Headlamp...
  • Page 41 Free stroke of rear brake lever 10-20mm Specification Tire pressure Front outer 120/70-12 tire 145-170kpa Tire pressure unit: Kpa Front rim 3.50×12 FACT 50 4T Rear outer 130/70-12 typre 170-195kpa Rear rim 3.50×12 Locking nut for front 55-62 N·m Torque wheel spindle...
  • Page 42 Periodic Maintenance & Inspection Table Service cycle and time 1000 3000 6000 12000 14500 Tools Inspection item Three Twelve Fifteen month months months months months Air filter Ordinary tools Petrol filter Ordinary tools Fuel filter Ordinary tools Replacement of engine Replacement every 1000KM Ordinary tools fuel...
  • Page 43: Oil Level

    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.
  • Page 44: Air Filter

    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.
  • Page 45: Spark Plug

    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.
  • Page 46 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.
  • Page 47: Idle Speed Adjustment

    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.
  • Page 48 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;...
  • Page 49: Drive Belt

    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.
  • Page 50 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.
  • Page 51 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.
  • Page 52 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.
  • Page 53: Inspection And Maintenance Of Electrical System

    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...
  • Page 54 Charging system 1. Battery 12V,4AH 2. Seat lock assembly 3. Horn 4. Rectifier 5. Power lock assembly 6. CDI igniter 7. Relay 8. Release resistance...
  • Page 55: Preparing Documents

    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.
  • Page 56: Failure Diagnosis

    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 )...
  • Page 57 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.
  • Page 58: Charging System

    • 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.
  • Page 59: Voltage/Current Regulator

    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...
  • Page 60: Magnetor Lighting 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.
  • Page 61 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.
  • Page 62: Ignition System

    Ignition System 1. storage battery 12V,4AH 2. FBT assembly 3. rectifier 4. power lock assembly 5. CDI igniter 6. relay 7. 点火系统:Ignition System seat lock assembly 8. horn...
  • Page 63: Preparing Documents

    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.
  • Page 64: Failure Diagnosis

    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...
  • Page 65: Ignition System Check

    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.
  • Page 66 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.
  • Page 67: Cdi Group

    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...
  • Page 68: Trigger

    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...
  • Page 69: Startup System

    Startup System 1. storage battery 12V,4AH 2. seat lock assembly 3. horn 4. rectifier 5. power lock assembly 6. CDI igniter 7. relay 8. release resistance (启动示意图:Startup Schematic Diagram)...
  • Page 70: Preparing Documents

    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...
  • Page 71: Failure Diagnosis

    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 •...
  • Page 72 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.
  • Page 73: Starter Relay

    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; •...
  • Page 74 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.
  • Page 75: Bulbs/Switches/Meters

    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”...
  • Page 76: Replacement Of Rear Steering Lamp Bulbs

    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.
  • Page 77: Meter

    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.
  • Page 78: Handlebar Switch

    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...
  • Page 79: Inspection And Maintenance Of The Chassis

    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...
  • Page 80 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.
  • Page 81 Rear drum brake Torque for mounting nut 5: 100-113N·m I.D. of brake drum :110mm Abrasion limit: 111mm Thickness of brake shoe: 4.5mm Limit for use: 3.5mm Free stroke of rear brake handle: 10-20mm Torque for mounting bolt 4: 22-29N·m 1. rear absorber assembly 2. bolt M10Χ1.25Χ40 3. cotter pin 4. bolt M8Χ35 5. nut M14Χ1.5 6. brake shoe assembly 7.
  • Page 82: Brake

    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...
  • Page 83: Front Disc Brake

    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...
  • Page 84: Rear Drum Brake

    * 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:...
  • Page 85 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.
  • Page 86 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.
  • Page 87: Body

    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...
  • Page 88 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 ↓...
  • Page 89: Front Wheel

    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...
  • Page 90: Front Suspension

    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...
  • Page 91 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...
  • Page 92: Front Fork Assembly

    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.
  • Page 93 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.
  • Page 94: Bearing Replacement

    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.
  • Page 95: Steering Handle

    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...
  • Page 96: Front Fork

    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).
  • Page 97 Install the handlebar. Install the body guard. Install the front wheel. * Note: for the disassembly and assembly of the front fork , please see P89.
  • Page 98 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...
  • Page 99: Rear Wheel

    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...
  • Page 100 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...
  • Page 101 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...
  • Page 102: Rear Absorber

    8.4 Rear absorber 8.4.1 Disassembly Remove the seat and the rear left/right guard. Remove the rear storage box, rear rack assembly and rear fender. Remove fixing bolts of the rear absorber. Remove the rear absorber. 8.4.2 Installation Installation of the rear absorber: Torque force: Upper fixing nut: 37-44 N·m Lower fixing nut:22-29 N·m...
  • Page 103: Fuel Tank/Seat

    Fuel tank/seat Note: disassembly of the fuel tank, turn fuel switch to “OFF”. Torque bolt 9:5-9N·m Torque for bolt10: 5-9N·m 1 seat assembly 2 fuel tank assembly 3 right cover sheet 4 left cover sheet 5 front cover of helmet box 6 rear storage box rack 7 seat steel rope 8 rear storage box rack holder 9 bolt M6×16 10 bolt M6×12...
  • Page 104 Fuel tank Gasoline capacity: 6.0±0.2L Torque for bolt 2: 5-9N·m Note: for the disassembly of the fuel tank, turn the fuel switch to “OFF”. 4 fuel tube 1 φ4.5Xφ8.5X80mm 5 thermal- 1 tank assembly 2 bolt M6×16 3 fuel tank switch assembly isolating spring 6 clampφ8 7 vacuum tube φ4Xφ8X360mm 8 clamp φ7 9 fuel tube 2 φ4.5Xφ8.5X250mm 10 filter assembly 11 oil level sensor...
  • Page 105 Seat Torque for bolt 4: 5- 9N·m Torque for bolt 6: 5- 9N·m 1 seat assembly 2 seat hinge assembly 3 O ring 84.4×3.1 4 boss bolt M6×14 5 helmet box 6 assembling bolt M6×20...
  • Page 106: Preparing Documents

    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.
  • Page 107 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.
  • Page 108 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...
  • Page 109: Disassembly/Installation Of Engine

    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.
  • Page 110: Disassembly Of Engine

    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.
  • Page 111 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...
  • Page 112 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...
  • Page 113: Lubricating System

    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.
  • Page 114: Preparing Documents

    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.
  • Page 115: Fuel Pump

    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...
  • Page 116 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。...
  • Page 117 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.
  • Page 118: Carburetor

    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.
  • Page 119: Preparing Documents

    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.
  • Page 120: Failure Diagnosis

    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...
  • Page 121 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.
  • Page 122: Installation And Adjustment

    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.
  • Page 123 (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.
  • Page 124: Cylinder Cover

    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)...
  • Page 125: Preparing Documents

    12. Cylinder Cover Preparing documents -----------------12.1 Failure diagnosis ----------------------12.2 Cylinder cover -------------------------12.3 Cylinder cover check -----------------12.4 Installation of cylinder cover --------12.5 12.1 Preparing documents Work Instructions The cylinder cover bears large bolt pretension to ensure sealing between the cylinder cover and the cylinder body. Pretension: 50Nm.
  • Page 126: Cylinder Cover Check

    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.
  • Page 127 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...
  • Page 128: Preparing Documents

    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.
  • Page 129: Failure Diagnosis

    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...
  • Page 130: Piston

    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.
  • Page 131 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.
  • Page 132: Installation

    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...
  • Page 133 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...
  • Page 134: Kickstart Mechanism

    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...
  • Page 135: Preparing Documents

    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.
  • Page 136: Left Crankcase Cover

    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.
  • Page 137 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...
  • Page 138 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.
  • Page 139 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.
  • Page 140 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。...
  • Page 141 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...
  • Page 142 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 )...
  • Page 143 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...
  • Page 144: Gearbox

    15. Decelerator Preparing documents -----------------15.1 Failure diagnosis ----------------------15.2 Gearbox --------------------------------15.3 Assembly-----------------------------15.4 15.1 Preparing documents Function: transfer torque and decide final output torque and rotational speed. 15.2 Failure diagnosis No run after engine startup Broken driving gear Burnt driving gear Leaked gear oil Too much gear oil Damaged oil seal 15.3 Gearbox...
  • Page 145: Assembly

    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.
  • Page 146: Crankcase

    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.
  • Page 147: Crankcase

    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.
  • Page 148: Crankcase Disassembly

    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.
  • Page 149 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).
  • Page 150 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.
  • Page 151 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...
  • Page 152 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 &...
  • Page 153 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>...
  • Page 154 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. ※...
  • Page 155 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...
  • Page 156 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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