Baotian BT49QT-21B1 Service Manual
  1. Manuals
  2. Brands
  3. Baotian Manuals
  4. Scooter
  5. BT49QT-21B1
  6. Service manual
Baotian BT49QT-21B1 Service Manual

Baotian BT49QT-21B1 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

BT49QT-21B1 MODEL

SERVICE MANUAL

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the BT49QT-21B1 and is the answer not in the manual?

Questions and answers

Related Manuals for Baotian BT49QT-21B1

Summary of Contents for Baotian BT49QT-21B1

  • Page 1: Service Manual

    BT49QT-21B1 MODEL SERVICE MANUAL...
  • Page 2 BT49QT-21B1 MODEL SPARE PARTS NAME： ： ： ：...

  • Page 3: Table Of Contents

    CONTENTS SUMMARY CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE Ⅰ. ITEMS OF MAINTENANCE Ⅱ. PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS Ⅲ. MAINTENANCE SPECIFICATIONS Ⅳ. THROTTLE ACTUATION INSPECTION Ⅴ. AIR FILTER INSPECTION AND CLEANING Ⅵ . B R A K E B L O C K S I N S P E C T I O N Ⅶ.

  • Page 4: Summary

    This 2-stroke scooter BT49QT-21B1 is with low weight, enough power, low oil consumption and good operating performance. This manual is for maintenance men to repair and maintain BT49QT-21B1 and it is also useful when maintain other models. This manual holds the latest technical information. We reserve the right to amend the data, instructions and specifications without advice.

  • Page 5: Chapter One Maintenance Of The Motorcycle

    CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE Ⅰ Ⅰ Ⅰ Ⅰ . ITEMS OF MAINTENANCE When the motorcycle is used, parts loose and mechanical wear inevitably occur to varied extents. Neglecting of timely maintenance not only reduces its mechanical function, economic performance, stability and durability, but also threatens the safety of the motorcycle and the rider.
  • Page 6 1. Maintenance Schedule Maintenance Schedule time item Mileage 1000km 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 New R Engine oil 300km Engine oil strainer Gasoline strainer New R Gear oil Note 4 300km Throttle play Carburetor Note 3, Air filter...
  • Page 7 2. Maintenance locations...

  • Page 8: Ⅲ. Maintenance Specifications

    Ⅲ Ⅲ Ⅲ Ⅲ . MAINTENANCE SPECIFICATIONS The basic methods of motorcycle maintenance include inspection, adjustment, tightening, lubrication, cleaning, supplementing and replacement, which constitute the main elements of maintenance. 1. Inspection Inspection refers to basic inspecting operations in accordance with items and requirements specified in the user’s manual, including inspection with instruments or with eyes for abnormalities in machine parts, directly comparing related data and aligning with tools and gauges.

  • Page 9: Ⅳ. Throttle Actuation Inspection

    IV. THROTTLE ACTUATION INSPECTION Inspect throttle grip for easy and smooth movement. Inspect throttle free travel. Free travel: 2-6mm The main adjusting position is beside the carburetor. Remove rear luggage box cover. Adjust by loosening the fastening nut and turning the adjusting nut. Fine adjustment is effected on the side of the throttle grip.

  • Page 10: Ⅴ. Air Filter Inspection And Cleaning

    Ⅴ Ⅴ Ⅴ Ⅴ . AIR FILTER INSPECTION AND CLEANING After a certain mileage, dust and impurities will gather in air filter case and strainer, which will clog strainer pores and reduce inlet of air and thus lead to excessive concentration of mixed gas and reduce the performance of engine.

  • Page 11: Ⅶ. Brake System Inspection, Adjustment And Replacement

    VII. BRAKE SYSTEM INSPECTION, ADJUSTMENT AND REPLACEMENT 1. Front brake (disk brake) Remove the bolts linking brake caliper and front shock absorber. Remove brake caliper. * Do not pull brake lever when brake caliper is removed so as to prevent jamming of brake block.

  • Page 12: Ⅷ. Front And Rear Shock Absorber Inspection

    2. Rear Brake Inspect rear brake lever free travel. Free travel: 10-20mm Turn adjusting nut to effect adjustment when free travel exceeds limit. VIII. FRONT AND REAR SHOCK ABSORBER INSPECTION 1. Front Shock Absorber Tighten front brake lever, press front shock absorber up and down and inspect actuation.

  • Page 13: Ⅸ. Front Wheel And Rear Wheel Inspection

    IX. FRONT WHEEL AND REAR WHEEL INSPECTION Wheel Rim Inspection: Inspect wheel rim, remove rust stains and rubber chips. Deformation and fissures are causes of air leakage. Do not use wheel rims in the following cases: Bruise of wheel rim face contacting tire bead ring exceeds 0.5mm in depth and 1.0mm in width.

  • Page 14: Ⅹ. Steering Stem Inspection

    Inspect if front wheel nut is loose. Inspect if rear wheel nut is loose. If loose, tighten them to specified torques. Torques: front wheel nut 60N·m rear wheel nut 120N·m X. STEERING STEM INSPECTION Swing handlebar right and left to see if there is interference such as wire or other things.

  • Page 15: Chapter Two Maintenance Information

    CHAPTER TWO MAINTENANCE INFORMATION I. FRAME NUMBER AND ENGINE NUMBER LOCATION II. PRECAUTIONS IN OPERATION Removed washers, 0-rings, elastic retaining rings and split pins must be replaced with new ones. When mounting bolts, nuts and screws, proceed from trial tightening, from larger diameters to smaller diameters and inner ones to outer ones in a diagonally order.

  • Page 16: Ⅲ. Specified Torques

    Connectors must be inserted home. When connecting connectors with locks, confirm that their locks are fastened. Confirm that the wires are not loose. Confirm that connectors’ plastic sleeves completely cover the connectors without fail. Before connecting the connectors, confirm that their sleeves are free from breakage and their terminals are not oversized.
  • Page 17 Standard Torques: Designations Torques: N·m Bolt, nut M5 Bolt, nut M6 Bolt, nutM8 21.5 Bolt, nut M10 Bolt, nut M12 Screw M5 Screw M6 Flange bolt, nut M6 Flange bolt, nut M8 Flange bolt, nut M10...

  • Page 18: Section One Body Common Troubles And Trouble Detection

    CHAPTER THREE BODY TROUBLESHOOTING SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION Body part common troubles and possible causes are as follows: Troubles Causes Details (reference) Handlebar rotation Over tightening of handlebar not easy (strenuous Refer to “Front Fork adjusting nut Service”...
  • Page 19 Chart continued Troubles Causes Details (reference) Inadequate liquid Contaminated brake block and brake disc Bent or deformed brake disc Contaminated brake caliper Worn seal ring of brake caliper piston Feeble brake Viscous or worn lever brake caliper piston Inability of brake caliper normal sliding Worn main cylinder...
  • Page 20 Chart continued Details (reference) Troubles Causes Hardened brake block surface or dusty block Abnormal braking Uneven or slotted brake block Refer to “Rear Brake Service” sound surface Serious wear of brake block lining Serious slots inside brake drum Refer to “Front Fork Steering stem rotation not easy Service”...

  • Page 21: Ⅰ. Front Wheel Se Rvice

    SECTION TWO DETAILED DESCRIPTION OF BODY PARTS MALFUNCTION Precautions in Operation: Forced mounting or dismounting of body cover parts will cause damage to claws and slots of corresponding hoods. When mounting body cover parts, be sure to align the corresponding parts of hoods.
  • Page 22 Axle Bending Inspection Place axle on a V-seat and measure with a dial gauge. The dial gauge indicates a 1/2 bending value. Limit of use: Replace if >0.2mm. Wheel Rim Oscillation Inspection Measure oscillation value on a correcting bench. Limit of use: Replace if >2.0mm. Traverse direction: Replace if >2.0mm.

  • Page 23: Ⅱ. Front Brake Service ( Disk Brake )

    Front Wheel Bearing Replacement Dismounting: Remove front wheel bearing by means of a bearing remover, take out spacer. Mounting: Apply grease to the bearing. Drive in left bearings. Mount spacer. Drive in right bearings. Bearings must be driven in parallel. Dust cover must be driven in with the face out.
  • Page 24 Brake Oil Replenishing Lock exhaust valve. Replenish oil reservoir with specified brake oil. ·It is not necessary to fill the oil reservoir to the full capacity. ·Brake oil for replenishing should be the same as original. The specification of brake oil is indicated on the reservoir cover.
  • Page 25 Exhaust brake oil from front brake system. Pull out brake switch plug from main cable. Remove bracket bolts from handlebar, Remove main cylinder. Remove brake oil pipe from main cylinder. · Prevent brake oil from splashing to rubber, plastic or painted surfaces. Cover the above-mentioned parts with a cloth.

  • Page 26: Ⅲ. Front Shock Absorber Service

    Ⅲ Ⅲ Ⅲ Ⅲ . FRONT SHOCK ABSORBER SERVICE Dismounting Remove front body covering parts. Remove front brake calliper. Remove front wheel. Remove front fender mounting bolts and front fender mounting bracket. Remove front fender. Remove 2 pieces of bolts on the upper part of front shock absorber.
  • Page 27 Remove front wheel and front shock absorber together with front fender and steering stem from head tube. The removing of the bottom bearing cup, bearing top and bearing set is the same as the removing of the upper series. Do not damage steering stem when removing bearing cup and bearing top.

  • Page 28: Ⅴ. Handle Bar Se Rvice

    Pass steering stem through head tube. Apply grease to top bearing cup and bearing top. Mount in order upper bearing cup, bearing ball set and upper bearing top on the upper part of steering stem and fasten them. Torque: 15 N·m Turn front fork right and left to effect close contact of bearing balls.

  • Page 29: Ⅵ. Rear Wheel Service

    ·When removing left grip and throttle grip, remove contamination and grease from contacting face. Mounting Mount handlebar on steering stem guide tube, fit bush, setting bolt and nut. Torque: 45 N·m Mount left brake lever and fasten bolts. Torque: 9 N·m Mount front brake main cylinder.

  • Page 30: Ⅶ. Rear Brake Service

    Mounting Mount rear wheel and fasten rear axle nut. Torque: 120N·m Mount exhaust muffler. Fasten exhaust muffler connecting nuts and bolts. Torque: Exhaust muffler connecting nut: 12N·m Exhaust muffler mounting bolt: 35N·m Ⅶ Ⅶ Ⅶ Ⅶ . REAR BRAKE SERVICE Remove exhaust muffler.

  • Page 31: Ⅷ. Rear Shock Absorber Service

    Do not apply grease to parts not specified. Superfluous grease flows into brake friction linings of brake drum shall reduce braking effect. Mount brake cam. Mount brake swing arm on brake cam. Notch on brake swing arm should be aligned with the cut-off of brake cam. Mount brake swing arm setting bolt and fasten it.
  • Page 32 Inspection Inspect rear shock absorber oil seal for oil leakage, inspect buffer bar and spring for deformation and other parts for damage and loosening. Mounting Mount rear shock absorber. Torque: upper mounting bolt: 40N·m bottom mounting bolt: 25N·m Mount air filter. Mount motorcycle body covering parts.

Table of Contents

Save PDF