Generic Race 50 Service Manual
  1. Manuals
  2. Brands
  3. Generic Manuals
  4. Scooter
  5. Race 50
  6. Service manual

Generic Race 50 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Race 50

Service Manual

Holtvej 8-10, Høruphav, 6470 Sydals
Telefon: +45 73 15 11 00
Fax: +45 73 15 11 01
E-mail: info@scanmi.dk · www.scanmi.dk
CVR: 27 73 31 07
November 2010

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Race 50 and is the answer not in the manual?

Questions and answers

Related Manuals for Generic Race 50

Summary of Contents for Generic Race 50

  • Page 1: Service Manual

    Race 50 Service Manual Holtvej 8-10, Høruphav, 6470 Sydals Telefon: +45 73 15 11 00 Fax: +45 73 15 11 01 E-mail: info@scanmi.dk · www.scanmi.dk CVR: 27 73 31 07 November 2010...
  • Page 2 User's operation and maintenance manual for double-wheel motorcycle RACE 50...

  • Page 3: Table Of Contents

    Zhejiang Qianjiang Motorcycle Co., Ltd. Contents Contents 2 Preface 4 Documents to be prepared ...........................5 Inspection/adjustment ............................6 Inspection and Service of Electrical System 63 I. Battery/ Charging system 67 1.1 Preparation data ............................53 1.2 Fault diagnosis .............................53 1.3 Battery .................................71 1.4 Charging system ............................72 1.5 Voltage and current regulator........................73 1.6 Charge coil of the alternator ........................74...
  • Page 4 4.3 Replace the head light bulb..........................99 4.4 Replace bulb of the front turning light.......................100 4.5 Disassembly/replace the bulb of the taillight and rear-right turning light ..........100 4.6 Instrument ..............................101 4.7 Main switch ...............................101 4.8 Horn ................................102 4.9 Handle switch ............................102 Inspection and Service of Chassis 103 V.
  • Page 5 13.1 Preparation data ............................162 13.2 Fault diagnosis ............................163 13.3 Cylinder body ............................163 13.4 Piston ...............................165 13.5 Installation of piston ..........................170 XIV. Drive disk/Clutch/Driven Wheel / Foot start mechanism 14.1 Preparation data ............................174 14.2 Fault diagnosis ............................174 14.3 Left crankcase cover ..........................175 14.4 Drive disk..............................175 14.5 Clutch/driven wheel..........................178 14.6 Disassemble the clutch and the driven wheel ..................180...

  • Page 6: Preface

    Preface This Manual explains the maintenance of Qianjiang RACE 50. The documents to be prepared are the maintenance manual and all the operations are included in, please read the manual prior to operation. Inspection and Adjustment explains the gist of inspection and adjustment; the maintenance of safety of vehicle and the performance of each part should come into force since regular inspection.

  • Page 7: Documents To Be Prepared

    Documents to be prepared General safety Maintenance regulation Specififcation sheet Troubleshooting General safety Carbon monoxide If the engine must be activated, make sure that the workplace is well ventilated. The engine can not be running in a confined place. Attention The exhaust contains toxic gas, carbon monoxide, which can numb people and may result in death.
  • Page 8 Maintenance regulation As maintaining this vehicle, the instrument of metric system should be applied as possible for the reason that the application of incorrect instrument may demage this vehicle. Before dismantling from or frame cover of vehicle to maintain the dirt of parts or external subassembly should be purged in order to prevent that falling into engine , chasis or braking system.
  • Page 9 Loosen the parts with multiple assemblies that should be made from outside to inside and started from small one. The complicated assembly, transmission case, for instance, should be stored according to proper assembly sequence in order to facilitate the assembly in the future.
  • Page 10 For the important assembly position, it should be given special attention before dismantling. The parts out of use should be replaced before dismantling in time. The length of bolts to assemblies and frame cover are different which should be installed in correct position and the bolts may placed in the hole to find out whether they are suitable if they are mixed.
  • Page 11 original design position. As dismantling ball bearing, please use the tool to withstand one or two (internal and external) bearing runners. If the strength is only applied onto a rolling ring (no matter internal or external), the bearing may be damaged as dismantling and has to be replaced.
  • Page 12 Loose cable is a hidden trouble to electrical safety. After clamped, check each cable to ensure electrical safety; It is not allowed to leave any wire clip bending towards bonding points; Bind each cable to its designated position; It is not allowed to lay a cable to end or a sharp corner on frame;...

  • Page 13: Important Notices

    Motorcycle Identification 1. The vehicle identification number (VIN) is inscribed at ① on the frame. See Figure 1-1. Identification number: LBBB9212?????????. On the VIN, the 10 digit shows the year of manufacture and the 11 digit shows the code of the manufacture plant.
  • Page 14 2. During servicing, use metric tools only. Do not interchange a metric bolt, nut or screw and an English system fastener. 3. During reassembly, replace with new washers, O-rings, cotter pins and locking pieces. 4. When tightening bolts or nuts, tighten the ones with larger diameters or comparatively located at inside first, and then tighten all bolts or nuts diagonally to specified torques step by step unless described otherwise.
  • Page 15 Specific tools The so-called specific tools refer to those specifically designed for assemble or dismantle of certain components of the motorcycle. These tools are usually used in specific locations. Appropriate specific tools are indispensable in the complete and accurate adjustment as well as in the assembly operations. By taking advantage of specific tools, the components can be safely, reliably and quickly assemble or dismantle, thus enhancing the work efficiency and saving lots of efforts.
  • Page 16 Thickness gauge (clearance gauge) Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Figure 1-9 Figure 1-10 ①Handle Figure 1-11 Figure 1-12...
  • Page 17 ① opening pincer ② piston Figure 1-13 Figure 1-14 Figure 1-15 Figure 1-16 2．Tools used for the underpan-overhaul The list of general tolls and specific tools for the dismounting of underpan components as well as the figure of real objects can be seen in table 1-17 and table 1-18. Figure 1-17 Name Remarks...
  • Page 18 Figure 1-19 Figure 1-20 1. Bush-head 2.Shake-handle 3.Ratchet type wrench 4.Connecting-rod Figure 1-21 Figure 1-22 Figure 1-23 Figure 1-24 Figure 1-25 Figure 1-26 Figure 1-27 Figure 1-28...
  • Page 19 （2）Specific tools for underpan-overhaul: front fork seal element driving-in tools Figure 1-29 （3）Steering nut wrench Figure 1-30 3．Tools used for electric apparatus components The list of specific tools for the testing of electric apparatus components, as well as the figure of real objects can be seen in table 1-31 and table 1-32.
  • Page 20 Figure 1-34...
  • Page 21 Specififcation Sheet (RACE 50) RACE 50 QJ1E40QMB-4 Model Engine Type Unleaded gasoline 1820 Full length mm Fuel type （92/95） Number of Full width mm cylinders Inside measure 1140 40×39.2 Full height mm * stroke 1280 49.2 Wheelbase mm Total flow rate...
  • Page 22 RACE 50...

  • Page 24: Troubleshooting

    Troubleshooting Trouble diagnosis program for engine start failure or difficulty Engine fails or is difficult to start Check ignition system Remove spark plug to check between its electrodes for carbon connection Clear carbon deposit Perform spark over test of spark plug Sparks between electrodes weak or Strong blue or purple blue sparks can jump out none at all...
  • Page 25 1. Check all joints outside 1. Check breather on engine for air leak fuel tank 2. Check for the piston ring clogging locked in groove or having 2. Check fuel filter and insufficient elastic force fuel cock for clogging 3. Check piston ring and 3.
  • Page 26 Trouble diagnosis program for engine overheat Engine overheats Check for improper method of operation and usage 1. Check gasoline for inferior Check cooling brand or extended storage system 2. Check if engine has ever run at high speed or worked under overload during running Air cooling engine...
  • Page 27 Remove spark plug, observe color of spark plug insulator skirt and determine mixture ratio of combustible mixture according to various abnormal situations. Spark plug insulator skirt Spark plug insulator skirt Spark plug insulator skirt renders black; addition, renders chocolate-brown renders white; in addition, exhaust muffler gives off black intermittent engine...
  • Page 28 Trouble diagnosis program for engine power lack Engine power lacks Erect main jiffy stand to enable wheels to be lifted off ground and then rotate them by hand Wheels rotate Wheels rotate freely dully Check tire 1. Check brake for retard pressure 2.
  • Page 29 Trouble diagnosis program for poor engine idle speed Engine idle speed is poor Engine idle Engine idle speed Engine idle speed speed disabled too high unstable Check compression Pull carburetor throttle valve Use an ignition timing pressure of cylinder by hand to check if it has been light to detect if engine completely closed ignition timing is correct...
  • Page 30 Trouble diagnosis program for excessive fuel consumption Engine fuel consumption is excessive Check for correct method of operation and usage Erect main jiffy stand and rotate 1. Check if motorcycle has ever run wheels by hand under overload, at non economical vehicle speed, or in low gear 2.
  • Page 31 Trouble diagnosis program for the malfunction that exhaust muffler on a 2 stroke engine gives off strong blue-white smoke Exhaust muffler on 2 stroke engine gives off strong blue-white smoke Check if engine oil level in crankcase exceeds the upper scale line marked If crankcase is overfilled with engine Start engine and then screw off oil oil, drain redundant engine oil until...
  • Page 32 Trouble diagnosis for trip stop of transmission Trip stop transmission Check for the spring of stationary wheel broken or having insufficient elastic Repl Disassemble crankcase to check if approach depths of gears are satisfactory Approach depths of Approach depths of gears sufficient gears insufficient Check if approach end of cam claw on end face of meshing...
  • Page 33 Trouble diagnosis program for hydraulic disc brake failure Hydraulic disc brake fails Check brake fluid level in fluid reservoir of brake master cylinder Brake fluid level is below lower Brake fluid level is above lower limit line on fluid reservoir limit line on fluid reservoir Refill brake fluid If you have a sponge-like...
  • Page 34 Trouble diagnosis program for charge failure of battery Battery can not be charged Disconnect bundle conductor magneto from connector of complete vehicle cable and then use an ohm meter to measure if resistance between output conductor ends of charge coil conforms to standard value Resistance is less Resistance...
  • Page 35 Trouble diagnosis program for undercharge of battery Battery undercharged Check if brake lamp keeps illuminating Adjust or replace brake Set ignition switch to “OFF” position, remove negative cable from battery, lamp switch connect negative meter pen of an ammeter to negative terminal of battery and positive meter pen to negative cable, and then detect and measure leakage current.
  • Page 36 Trouble diagnosis program for rotation failure of starting motor Starting motor does not rotate Turn on ignition switch, depress horn button, or toggle turn signal lamp switch. Electric horn does Electric horn can make loud and sound or only makes low clear sound and turn signal lamp sound and turn signal lamp can give off bright light...
  • Page 37 Trouble diagnosis program for weak rotation of starting motor Starting motor rotates weakly Turn on ignition switch, depress horn button, or toggle turn signal lamp switch. Electric horn does Electric horn can make loud and sound or only makes low clear sound and turn signal lamp sound and turn signal lamp can give off bright light...
  • Page 38 Trouble diagnosis program for the malfunction that none of illuminating lamps comes on None illuminating power supply DC power supply lighting system lighting system Disconnect bundle conductor Depress horn button or toggle turn signal magneto from connector of complete lamp switch vehicle cable and then use test lamp method to check if electric power is output from output conductor of...
  • Page 39 Trouble diagnosis program for the malfunction that illuminating lamp bulb is liable to burn-out Illuminating lamp is liable to burn-out Turn on ignition switch, depress horn button, or toggle turn signal lamp switch. Electric horn is hoarse Electric horn can make loud and or does not make any clear sound and turn signal lamp sound and turn signal...
  • Page 40 Trouble diagnosis program for weak illuminating lamp light Illuminating lamp light is dim AC power supply DC power supply lighting system lighting system Disconnect bundle conductor of magneto Turn on ignition switch, depress horn button, or from connector of complete vehicle cable toggle turn signal lamp switch.
  • Page 41 Trouble diagnosis program for the malfunction that turn signal lamp does not come on Turn signal lamp does not come on Part of turn signal lamps at None of turn signal lamps at None of turn signal one side does not come on one side comes on lamps comes on Remove turn signal lamp...
  • Page 42 Trouble diagnosis program for the malfunction that electric horn does not sound Electric horn does not sound Turn on ignition switch and toggle turn signal lamp switch to check operation of turn signal lamp Turn signal lamp does not come on or Turn signal lamp can give only gives off dim light off bright light...
  • Page 43 Trouble diagnosis program for the malfunction that brake lamp does not come on Brake lamp does not come on Remove brake lamp shade to check circuit board of brake lamp for burn-out 是 Replace circuit Short plugs on two terminals or lead wires of brake lamp board of brake lamp switch with a conductor After shorted, brake lamp...

  • Page 44: Inspection/Adjustment

    Inspection/adjustment Preparation of documents Cylinder pressure Check list of constant maintenance Gear mobile oil Engine mobile oil/oil filter Changing gear oil direction column bearing and handle fixing Diving belt Inspection/adjustment of accelerator's pull wire Front/back brake free displacement Air cleaner The liquid volume examination of break fluid Spark plug Head lamp...
  • Page 46 Free stroke of rear brake drawbar 10-20mm Specification Tire pressure Outer cover of front 120/70-12 wheel 145-170kpa Tire pressure unit：Kpa Front rim 3.50×12 RACE 50 Outer cover of rear wheel 130/70-12 170-195kpa Rear rim 3.50×12 Torque front wheel-axle 100-113 N·m force clamping nut...
  • Page 47 E3 001024 Rear turn signal lamp E3 001002 Rear-view mirror Rear-view mirror E4 000066 Horn Horn E11 020614 Side reflector Reflector E11 020613 Rear reflector EUR02-CAT Muffler Muffler...
  • Page 48 Check list of constant maintenance Mileage and time of maintenance Ever Every Every Every Every Every 3000 6000 12000 14500 1000 Inspection items Tools motor mont mont mont A year months cycle General purpose Air cleaner tool General purpose Gasoline filter tool General purpose Oil cleaner...
  • Page 49 Pre-inspection Ignition system - maintenance and inspection of ignition malfunction of distinct continuity, engine failed to start and superheat of afterburning. Carbon laydown purging - purging the carbon laydown in the head of air cylinder, piston head and exhaust air system when the horsepower is in distinct deficiency. Piston, air cylinder - excessive wear of air cylinder and cylinder smoothness, please replace.
  • Page 50 Reinspect mobile oil level.

  • Page 51: Race

    Inspection/adjustmentof accelerator's pull wire Check the smoothness of accelerator pull wire. Examination of the free replacement of accelerator stayguy Free displacement：5-10mm The main adjusting position is on the carburator side. Loosen the fixing nut and adjust by turning adjusting nut. Air cleaner Replacement of the filtrator Remove body fender.
  • Page 52 *Attention •Please confirm whether the air cleaner is installed as installing air cleaner cover.

  • Page 53: Spark Plug

    Spark plug Dismantle spark plug. Check the overburning, pollution and carbon laydown of Spark plug gap spark plug. If there is the said problem, please purge it with cleaner of spark plug or steel brush. Inspection of spark plug gap Clearance：0.6-0.7mm *Attention As installing spark plug, pleae install it with hands and tighten by spark-plug socket.
  • Page 54 extremely dangerous. The installtion is in the reverse order of dismantling. Warning! In order to prevent short circuit, please connect positive pole prior to the negative one. Please do not disconnect battery when you perform overall lineup; otherwise, internal damage of complete vehicle components may result.
  • Page 55 *Attention • If the storage cell is rapidly charged, it can not be used generally except in emergency. •The voltage should be measured every 30 minutes after charging. Charging current： standard：0.4 A Quick：4.0A Charging period: standard：10 - 15 hours Quick：30 minutes Completion of charge: open-circuit voltage: above 12.8V...

  • Page 56: Idle Adjustment

    Carburator Idle adjustment *Attention The idle adjustment should be made when the engine is warm. It should be conducted after the warm-up of engine. Start engine and connect the turnmeter of engine. Adjust the accelerator pull wire and bolt stopper to specifiy the winding number.
  • Page 57 high.
  • Page 58 Gear mobile oil Inspection *Attention Fuel check, let down the middle supporter to be perpendicular to motorcycle on the flat floor. Dismantle the inspection bolt of gear oil after stopping engine.（1）. The oil level is below the lower limit of bolt hole is good. Please supplement gear oil when the oil level is too low.
  • Page 59 Check to see if the driving belt is broken or worn out. Replace for new products when necessary or periodically. Free displacement of the front/rear brake Free displacement of the front brake Measure the free displacement of the front brake handle at the tip of the brake handle.

  • Page 60: Head Lamp

    Examination on the liquid amount of the brake liquid When braking to its end, check up the oil amount through the oil lens. If the liquid level of the brake fluid is vertical to or is lower than the graphic arrow, brake liquid should be injected in till the ceiling level.
  • Page 61 Clutch Start engine and increase the winding number slowly to inspect the actuation of clutch and check the clutch block if the motorcycle does not move or the engine misses. Replace the new part if necessary. Front/rear suspension system Compress up Front and down Strain the front brake and compress the front shock absorber up...
  • Page 62 Rear Compress the rear shock absorber up and down to check the actuation. Compress up and down Check whether each part of the rear shock absorber is damaged or loosened. Suspense the rear wheel and swing it to check whether the engine suspension bush is loosened.
  • Page 63 Specified pressure Unit：Kpa Tire Specification pressure Outer cover of 120/70-12 front wheel Tyre specification 145-170 Front rim 3.50×12 RACE 50 Outer cover of 130/70-12 rear wheel 170-195 Rear rim 3.50×12 Outer cover of front wheel 120/70-12 Front rim 3.50×12 RACE 50...

  • Page 65: Inspection And Service Of Electrical System

    Inspection and Service of Electrical System Table of Torques for Fasteners in Electrical System Fastening location and name of fastener Tightening torque (N·m) Starting motor clutch cover bolt Fixing nut of starting motor clutch cover Rectifier bolt Fixing bolt of ignition coil Fixing nut of flywheel Body fender bolt...
  • Page 67 Charging system...
  • Page 68 1. Battery 12V, 4AH 2. Cushion lock module 3. Horn 4. Rectifier 5. Power lock module 6. Igniter 7. Relay 8. Release resistor...

  • Page 69: Battery/Charging System

    I. Battery/charging system Preparation data ----------------------1.1 Fault diagnosis -------------------1.2 Battery ---------------------------------1.3 Charging system -----------------1.4 Voltage and current regulator -------1.5 Charge coil of the alternator ---1.6 Disassembly of alternator -----------1.7 1.1 Preparation data Matters needing attention in operation * Note 1. The battery can be charged and discharged over again. If the battery is unused after discharge, the service life will shorten and the performance will degrade.
  • Page 70 Preparation reference Item Specification Capacity/ type 12V-4AH/ charge type Voltage Fully charged 13.1V Must be charge （20℃） 12.3V(not work for an hour) Battery Charging current Standard：0.4A，Fast：4A Charging time Standard：10-15h，Fast：30m Capacity 90W/8000rpm Impedance value of lighting Between green/red and black 2.0-2.5Ω Magneto coil (20 ) Impedance value of charge coil...
  • Page 71 Bad act of voltage and current regulator...

  • Page 72: Battery

    1.3 Battery 1.3.1 Disassembly of the battery Open the battery-cell lid. Dismantle the clamping bar components of battery cell. Disassemble the negative wire and then the positive wire. Take out the battery. Warning! In the disassembly of positive pole the tools mustn't contact the frame because the short-circuit spark will ignite gasoline and damage the battery.

  • Page 73: Charging System

    1.3.2 Charge Connecting method： Connecting the positive pole of charger and the positive pole of battery. Connecting the negative pole of charger and the negative pole of battery. Warning！ •Keep the battery away from ignition sources. •Shut off the charger first once charge is started or finished so as to prevent explosion hazard caused by flashes at the interconnecting part.

  • Page 74: Voltage And Current Regulator

    are disassembled to the main fuse. Start the engine and measure the clamping voltage and current when the rotation speed gradually increases. Clamping voltage/rotation speed ：14-15V （2500rpm） If the clamping voltage exceeds the specified value range, inspect the voltage regulator. Inspect the clamping voltage of the lighting system.

  • Page 75: Charge Coil Of The Alternator

    （L） 10~50 19~21 1.5.2 Inspect the voltage and current Green （ B） 5~15 regulator Black （E） Check plug of voltage and current regulator for poor contact and measure impedance values between terminals on voltage and current regulator body. *Attention •The metal area of the avometer prod mustn't be touched by fingers during inspection.
  • Page 76 Use a multimeter to measure the impedance value between green/red wire on magneto and body ground. Standard value ：2.0-2.5Ω（20℃） When the measured value exceeds the standard value, replace the magneto coil. 1.7.2 Disassembly Disassemble the body guard. Remove right body fender. Remove fixing bolts and screws and take off fan cover.
  • Page 77 1.7.3 Installation Flywheel Cooling fan Fan cover Install magneto stator on engine case. Connect wire terminals of magneto. Clean the tapered part of the crankshaft and flywheel. Install the retaining key of flywheel in the key groove on the crankshaft and confirm. Align the flywheel groove with the retaining key of the shaft.
  • Page 78 Ignition system...
  • Page 79 点火系统 Ignition system 1. Battery 12, 4AH 2. Ignition coil assembly 3. Rectifier 4. Power lock module 5. Igniter 6. Relay 7. Cushion lock module 8. Horn...

  • Page 80: Preparation Data

    II.Ignition system Preparation data ----------------- CDI group ----------------------2.4 Fault diagnosis ------------------ Ignition coil ------------------- 2.5 Ignition system inspection ----- Trigger ------------------------- 2.6 2.1 Preparation data Matters needing attention in operation 1. Inspect the ignition system in accordance with the order stipulated in the fault diagnosis table. 2.
  • Page 81 Avometer...

  • Page 82: Fault Diagnosis

    2.2 Fault diagnosis No flashover in spark plug Abnormal circumstance Cause of badness（confirm in order from 1） The interior resistance is too low and test it with a designated tester. The cranking speed is too low. ignition high voltage too low The tester is disturbed（if the voltage measured for several coil times is above standard, then the value is normal）.

  • Page 84: Ignition System Inspection

    2.3 Ignition system inspection 万用表 Multimeter *Attention •When there is no spark in the spark plug， inspect whether the wire or part is loosen or in poor contact and confirm whether each voltage value is normal. •Since there are a great many of avometer brands with different interior resistance, the values tested will differ accordingly.

  • Page 85: Cdi Group

    2.3.2 Trigger *Attention Install the spark plug on the air cylinder head and inspect with normal compression pressure. Remove the 6P joint of CDI group, and connect a peak voltage diverter between the trigger of 6P joint （blue/white terminal） to the wire and the 4P joint （black terminal） . Press the startup electrical machinery or step on the actuating lever to measure the peak voltage of the trigger.
  • Page 86 2.4.2 Inspection Disassemble the CDI group and inspect whether the joint is loosen or eroded. Standard value （20 ） Inspection item Testing terminal Main switch red—red/white Conducted when main switch at " OFF " Trigger Blue/white—white green 100-500Ω primary ignition coil black/white—black 0.6Ω±10％...

  • Page 87: Ignition Coil

    2.5 Ignition coil 2.5.1 Disassembly Ignition line figure 点火线圈 Disassemble the body guard. Disassemble the spark plug cover. Disassemble the primary ignition coil. Disassemble the ignition coil fixing bolts and unload the ignition coil. Installation is conducted in the reverse order of disassembly. *Attention The primary coil is installed in accordance with the black/ Ω...
  • Page 88 Disassemble the body guard. Disassemble the lead connector of the trigger.
  • Page 89 Measure the resistance value between the blue/white terminal 磁电机接口 Interface of magnetor at the engine side and the body ground. Standard value ：100-500Ω（20℃） D J7031- 2. 8- 21 D J621- 2. 8× 0. 5 If the measured value exceeds the standard value, replace the alternator.
  • Page 90 Startup system BR AKE SW I TC H BR AKE SW I TC H BATTER Y R ELAY STAR TO R M O TO R STAR TER SW I TC H Startup diagram 启动示意图...
  • Page 91 1. Battery 12V, 4AH 2. Cushion lock module 3. Horn 4. Rectifier 5. Power lock module 6. Igniter 7. Relay 8. Release resistor...

  • Page 92: Preparation Data

    III. Startup system Preparation data --------------------------3.1 Fault diagnosis ---------------------------3.2 Start electrical machinery ---------------3.3 Start relay ---------------------------------3.4 3.1 Preparation data Matters needing attention in operation Disassembly of the start electrical machinery may be conducted on the engine. Please refer to disassembly operation in disassembly. Preparation reference Item Standard value...

  • Page 94: Fault Diagnosis

    3.2 Fault diagnosis Unable to startup Rotating force of start machinery too weak No revolution in the RE Rotary Engine •Fuse blown •Power shortage in battery •Bad act of startup clutch •Power shortage in battery •Poor contact of connecting wire •Reverse revolution of startup electrical machinery •Bad acts of main switch •Gear of the startup machinery jammed with foreign body •Power shortage in battery...
  • Page 95 must be cleaned away. Inspect conduction of contact surfaces between other assemblies. Confirm the armature shafts between each surface of the commutator cannot be connected. Inspect conduction of the housing of startup. Confirm the terminal and housing of the startup electric machinery cannot be connected.
  • Page 96 confirm the soldering cup is installed. Check the O-ring for damage. If abnormal situation is found, replace it with a new one. Apply engine oil to the O-ring and then fit it on the starting motor. Install the wire clamp of the rear brake.

  • Page 97: Start Relay

    3.4 Start relay 3.4.1 Actuation inspection Disassemble the body guard. Push the main switch to "ON" and press the startup electrical machinery with a "click ". Sound means normal. No sound： •Inspect voltage of the start relay •Inspect the earth line of the start relay. •Inspect actuation of the start relay 3.4.2 Inspect voltage of the start relay Start relay...
  • Page 98 reads "0".
  • Page 99 Bulbs/ switch/instrument Certification number of head lamp: E4 0012026 Certification number of front turn signal lamp: E3 001024 Certification number of tail lamp: E11 000054 Certification number of rear turn signal lamp: E3 001024 Certification number of rear reflector: E11 020613...

  • Page 100: Preparation Data

    1. Head lamp 2. Turn signal lamp (FL) 3. Turn signal lamp (RL) 4. Side reflector 5. Turn signal lamp (RR) 6. Meter 7. Tail lamp 8. Turn signal lamp (FR) 9. Rear reflector IV. Bulbs/ switch/instrument Preparation data -------------------------------4.1 Instrument----------------4.6 Fault diagnosis --------------------------------4.2 Main switch --------------4.7...

  • Page 101: Replace Bulb Of The Front Turning Light

    4.4 Replace bulb of the front turning light 4.4.1 Disassembly Remove front shield of handle pipe. Disconnect connecting wire of front turn signal lamp. Unscrew the setscrew on the turning light. Remove the bulb socket from the light. 4.4.2 Installation Install the bulb back to the original position in the reverse order of disassembly.

  • Page 102: Instrument

    4.5.3.2 Installation Install the bulb back to the original position in the reverse take turns of disassembly. Install the bulb back to the original position in the reverse take turns of disassembly. 4.6 Instrument Remove set screws of front shield of handle pipe. Remove set screws of instrument.

  • Page 103: Horn

    4.8 Horn Inspection Disassemble the horn wire. If the horn rings when the horn wire is connected with the battery, then it is the fine conditions. 4.9 Handle switch Remove left and right rear-view mirrors. Remove set screws of left and right combination switches. Loosen left and right combination switches.

  • Page 105: Inspection And Service Of Chassis

    Inspection and Service of Chassis Table of Torques for Fasteners on Chassis Fastening location and name of fastener Tightening torque (N·m) Fixing bolt of oil pump body module Mounting bolt of front brake cylinder module 22-29 Fixing bolt of rear brake rocker arm Fixing nut of rear wheel 100-113 Fixing bolt of welded module of steering handle...
  • Page 106 Front liquid brake Diameter of front brake disc: 190mm Thickness of front brake disc: 4.0mm Service limit: 3.0mm Thickness of friction lining: 6.0mm Service limit: 5.0mm Mounting torque value of the bolt (9) shown in the figure: 5-9N·m Mounting torque value of the nut (29) shown in the figure: 37-44N·m Free stroke of brake lever: 10-20mm...
  • Page 107 module 25. Front brake switch 26. Oil pump body gasket 27. Small pillar 28. Washer 29. Mounting nut of front brake disc M10×1.25 Rear brake drum Mounting torque value of the nut (11) shown in the figure: 100-113N·m Bore of brake drum: 110mm Wear limit: 111mm Thickness of brake shoe: 6.0mm...

  • Page 108: Brake

    1. Rear rim 2. Tire 130/70-12 3. Tire valve 4. Brake shoe module 5. Brake shoe tension spring 6. Rear brake camshaft 7. Rear brake rocker arm module 8. Rear indicator 9. Return spring of rear brake 10. Rear rocker arm bolt 11.

  • Page 109: Fault Diagnosis

    22-29 N·m Assemble bolt for the front brake cylinder components 5-9 N·m Fixing bolt of rear brake rocker arm 100-113 N·m Fixing bolt of rear brake rocker arm 5.2 Fault diagnosis Brake Bad braking quality Slow brake or handle tightening 1.
  • Page 110 Measure the brake pad and brake disc and put down the maximal value. Specification RACE 50 diameter of front hydraulic brake φ190mm diameter of front hydraulic brake 4.0mm *Attention •It must be measured with microcaliper. Measure the thickness of brake pad.

  • Page 111: Rear Drum Brake

    Install the brake hose assembly of the front brake, and the brake cylinder components（2）. Prevent brake clutch（3）and break disk from greasing. *Attention Presence of grease on friction lining will reduce braking performance resulting in brake failure. Screw bolt and nut to the stipulated torque force value. Torque value ：...
  • Page 112 disassembly so that it can be installed to the original position. Remove the following components from the rear wheel. Rear brake: 1. Bolt 7. Brake shoe module (4) 2. Rear brake rocker arm module (7) 8. Brake shoe tension spring (5) 3.
  • Page 113 *Attention Grease on the brake pad may reduce brake ability and invalidate the brake. Screw the bolt and nut to the stipulated torque force value. Torque value： 100-113N·m Fixing nut of rear wheel: Keep the brake pad and brake disc free of oil stain. If the brake pad and brake disc are polluted with oil, rinse them with brake cleaning fluid.
  • Page 114 Body cover *Attention The cover of car body must not be damaged when taken apart. The hook claws of the body cover must not be damaged when taken apart. Correspond the embedded panel and spear plate of car body with respective slot. In the composition, hook in each part must be installed correctly.

  • Page 115: Body Cover

    VI. Body cover Disassemble the motorcycle body according to the following order: Cushion covers components →front big cover panel components→ front shielding → back shielding →front mudguards→ ↓ Back shelf → helmet box front cover →-boards linking plate I →boards linking plate II → left / right protection components ↓...

  • Page 116: Front Wheel/ Front Suspension 90 7.1 Preparation Data

    Front wheel...
  • Page 117 Tire specifications: outer tire120/70-12 Wheels specifications: 3.50 × 12 Rims facing poor limits: vertical: horizontal: 2.0 mm Front wheel axle degree limits: 0.2 mm Outer tire of front wheel certification of: E11 75R 1 Front wheel rim 2 intermediate bushings components 3 SEAL 22Χ35Χ7 4 bearing 6201-2RS 5 tires...

  • Page 118: Front Suspension

    Front suspension Installed torque value in the map of bolt 11: 5-9 N.m Installed torque value in the map of bolt 14:40-60 N • m The number of steel ball on the top: 21 The number of steel ball on the bottom: 1 Front right before shock absorber 2 front left shock absorber lockwasher 3 down yoke plate seal...
  • Page 119 cadres of brake fluid Clamps 2 13 cadres of brake fluid Clamps 1 14 bolts M10 × 1.25 × 30 15 bolts M6 × Manipulation assembly Installation torque values of bolts 2 (direction knob fixes the bolts) in the map 2: 40-60 N •...

  • Page 120: Fault Diagnosis

    left rear view mirror components 11 Right rear rearview mirror components 12 Left combination switch 13 left handle 14 Fixed handle screw M5 15 Nut M5 16-17 Right combination switch 17 Flat screw M5 × 20 VII. Front wheel/ front suspension Preparation data -------------------------7.1 Fault diagnosis --------------------------7.2 Front wheel ------------------------------7.3...
  • Page 121 The direction handle bearing is damaged. The air pressure of tire is ultra-low. Air leakage of tire. 7.2.2 The direction is not stable. The direction handle bearing is damaged. The tire compression is not sufficient. The front fork and the front wheel axle are crooked. The tire of the front wheel is deformed, with crooked tire.
  • Page 122 Remove the braking disk Remove axle sheath, oil seal, axle (6201-2RS), axle insulating sheath、axle(6201-2RS). *Note：see P87 for figure RACE 50 for dismantling and mounting front wheel。...
  • Page 123 7.3.2 Inspection 7.3.2.1 Inspect bending of the wheel spindle Put the wheel axle on a V-shape seat and use dial indicator to measure its excentricity. Allowable limit：if the value exceeds 2.0mm, replace the rim. Bolt 7.3.2.2 Inspect yawing of rim Put the wheel ring on an accurate bracket, and examine its swinging degree.

  • Page 124: Steering Bar

    Mount the braking cylinder to the front wheel hub. Screw down the front wheel axle（as the figure of right side） * Note：see P87 for figure RACE 50 for dismantling and mounting front wheel. Value of Torsion：...

  • Page 125: Front Fork

    Remove components of the front cover. Remove components of left/right switch combination. Remove components of fuel pump. Remove the left holding bar, and components of the fuel control bar. Loose screw bolts of welded components of the steering bar. Remove the welded components of the steering bar. 7.4.2 Installation *Note：see P88 for figure for dismantling and mounting steering bar。...
  • Page 126 Don’t rotate the steering bar when the steering bar is not completely mounted ( to avoid falling of steel balls). Support the steering bar well, lubricate the upside axle steel bowl with grease and confirm the amounts of steel balls. （21pcs）...
  • Page 127 Rear wheel /rear suspension Torsion for screw bolts 11 of rear wheel：100 -113 N·m Torsion for screw bolts 3：37-44 N·m Torsion for screw bolts13：22-29 N·m Inner radius braking hub(abrasion limit)：111mm 1 Rim 2 tyre130/70-12 3 screw M10×1.25×40 4 components of braking plate 5 tension spring of braking plate 6 camshaft of rear brake...
  • Page 128 Real wheel Specification of outer tire： 130/70-12 Speciation of rim：3.50×12 Wobbling limit： Vertical：2.0mm Horizontal：2.0mm Torsion for screw bolts 11 of rear wheel：100-113N·m 1 rear rim 2 rear tire 130/70-12 3 valve 4 components of braking plate 5 tension spring of braking plate 6 cram shaft of rear brake 7 crank components of rear brake...

  • Page 129: Preparation Data

    spring of rear brake 10 screw of rear crank 11 bolts 12 dust proof washer 13 valve cap VIII. Rear wheel/rear suspension Preparation data -----------------------------8.1 Fault diagnosis ------------------------------8.2 Rear wheel -----------------------------------8.3 Rear shock absorber/rear rocker ----------8.4 8.1 Preparation data Matters needing attention in operation There cannot be any oil stain stuck to the surface of the brake disc or brake pad.

  • Page 130: Real Wheel

    The tire pressure is not enough 8.2.2 Shock absorber too soft Elasticity fatigue of spring 8.3 Real wheel 8.3.1 Disassembly Remove muffle components（1）. Remove rear inner mudguard. Remove screw bolts of rear wheel axle. Remove rear wheel components（2）. 8.3.2 Inspection 8.3.2.1 an examination on the swinging of wheel ring Rotate the wheel by hand, and measure the eccentricity through the dial gauge.

  • Page 131: Rear Shock Absorber

    Rear wheel 8.4 Rear shock absorber...

  • Page 132: Rear Shock Absorber

    8.4 Rear shock absorber 8.4.1 Disassembly Dismantle the cushion, the left-rear guard plate and the right-rear guard plate. Dismantle the rear handrail and the rear mudguard. Remove the fixing bolts of rear shock absorber. Unload the rear shock absorber. 8.4.2 Installation Install the rear shock absorber.
  • Page 134 Fuel tank/seat mat Caution：must turn the fuel switch to the “OFF”position when dismantling the fuel tank Torsion for bolts 4： 37-44 N·m Torsion for screw 10：5-9 N·m 1 welded components for vehicle frame 2 screw axle for engine 3 bolts M12×1.25 4 screw bolts for hanging rack M10×41×1.25 5 bolts M10×1.25...

  • Page 135: Fuel Tank

    output hanging rack 7 seat mat assembly 8 fuel tank assembly 9 components of seat mat lock 10 screw M6×20 11 prop for rear luggage rack 12 screw M6×12 13 tight wire of seat mat 14 rivet3.2×7 Fuel tank Fuel capacity ： 5±0.2L Torsion for screw 2：...
  • Page 136 1 tank components 2 screw M6×16 3 components of fuel tank switch 4 fuel tube 180mm 5 heat insulation spring 6 hoopФ8 7 vacuum tube 360mm 8 hoopФ7 9 fuel tube 2250mm 10 filter components 11 fuel position sensor 12 screw M5×16 13 gasket of fuel position sensor 14 seal rubber...

  • Page 137: Fuel Tank/Seat Mat

    1 components of seat mat 2 components of rotating leaf 3 0 shape ring 84.4×3.1 4 protruding screw M6×14 5 helmet bucket 6 gasket8 7 screw M6×12 8 rear luggage rack 9 screw nail M8×45 plastic gasket 11 bottom lid of helmet bucket IX.
  • Page 138 Normal consuming of fuel Leakage of fuel 9.3 Fuel tank/seat mat 9.3.1 Disassembly Open seat mat. Remove the screw bolts of seat mat（4 pcs）. Remove oil pot shielding lid. Remove oil pot. Remove seat mat (7）and helmet bucket. Remove rear luggage rack（8）. Remove left/right shielding plate.
  • Page 139 9.3.1 Installation Mounting should follow the reversed procedure of dismantling. Torsion for mounting： 5 - 9 N·m Screw bolts for rear luggage rack prop 5 - 9 N·m Screw bolts for fuel tank 5 - 9 N·m Screw bolts for helmet bucket...
  • Page 140 Inspection and maintenance of engine Table of torque value of engine fastener Tightening torque （N·m） Fastening area and fastener name...
  • Page 141 10-12 15-18 22-25 Lock bolt Shroud 10-12 Lock nut of cylinder cover 10-12 Spark plug Air intake tube screw bolt 45-50 Cooling fan impeller screw bolt 10-12 Fly wheel screw bolt 10-12 Screw nail of stator of Magnetic motor Right crank box screw bolt 10-12 Axle tightening plate screw bolt 15-18...

  • Page 143: Lubrication System

    Lubrication system Note ： Worm and worm wheel should run flexibly without block and one side locking meanwhile worm wheel has a little leap axially, “O” ring in oil pump must have edge-cutting. No oil leakage comes from the plugs in oil pump, the sealing ring should be in good order.

  • Page 144: Preparation Data

    X. Lubrication system Preparation data -----------10.1 Fault diagnosis ------------10.2 Oil pump -------------------10.3 10.1 Preparation data Matters needing attention in operation Worm and worm wheel should run flexibly without block and one side locking meanwhile the worm wheel has a little leap axially, “O” ring in oil pump must not have edge-cutting. No oil leakage comes from the plugs in oil pump, the sealing ring should be in good order.

  • Page 145: Fault Diagnosis

    10.2 Fault diagnosis Decrease of machine oil Engine burnt out Natural loss of machine oil Absence of oil or oil pressure too low Machine oil leak Oil path blocked Wear and improper installation of the piston ring Machine oil not used 10.3 Oil pump 10.3.1 Disassembly Loosen the fixed bolt, and take off the chain cover.
  • Page 146 Take off the magnetic motor stator, rotator and bracket. Take off worm wheel from the crankshaft, take off oil pump component.
  • Page 147 Oil pump assembling Shown in the following Fig. Oil pump shanft Oil pump body Element spring Element Oil pump cover Gear 10.3.2 Installation Carry out the installation according to the reversed sequence of dismantle. 10.3.3 Inspection Inspect worm wheel teeth surface whether there is damage. Inspect key slot whether there is breakage.
  • Page 148 Measure element outside diameter. Allowable limit :2.61mm。 Carburetor...
  • Page 149 Note: Gasoline is very dangerous, no smoke at work place. Use cloth to block the intake manifold after dismounting carburetor to avoid other article entry. 1. Screw. 2. Float chamber 3. Needle-valve component. 4. Floater. 5. Floater pin 6. Main jet. 7.

  • Page 150: Preparation Data

    XI. Carburetor Preparation data------------------------11.1 Fault diagnosis-------------------------11.2 Disassembly of carburetor------------11.3 Installation of carburetor -------------11.4 Adjustment of carburetor ------------11.5 11.1 Preparation data Matters needing attention in operation ·Gasoline is extremely dangerous，so smoking or lighting is strictly forbidden in operational field. ·Pay special attention to flakes. ·No wire should be pulled and bent with rudeness.

  • Page 151: Fault Diagnosis

    B05-2 Needle valve 11.2 Fault diagnosis Bad startup Startup difficulty，flameout after startup， unsteady idle speed ·Carburetor short of fuel Fuel system blockage Gasoline filter blocked Too dense or sparse gas mixture Gasoline pipe blocked Secondary air inlet of suction system Needle valve conglutination Bad idle adjustment Bad adjustment of oil level...
  • Page 153 11.3.2 Decomposition of carburetor Loosen the electric starting valve bolt, and take off the electric starting valve components. Electric enriching Electric enriching valve component valve component Fixing flange Enriching valve Examine the electric starting valve and the attrition condition of the needle valve. If the needle valve is seriously worn, electric starting valve components should be replaced.
  • Page 154 the plunger. If the plunger is worn down, it should be replaced. Examine the attrition condition of the needle valve. If the needle valve is worn down, it should be replaced. Loosen screws, take off the float chamber. Dismantle the float components, floater-pin and needle valve component. 11.3.3 Examination Examine if the needle valve core, needle valve and the float components are damaged or worn down .
  • Page 155 Idle speed injection nozzle Idle adjusting screw 怠速调节螺钉...

  • Page 156: Installation & Adjustment

    11.4 Installation & adjustment Assembly and installatioj is conducted in the reverse order of disassembly. Adjustment of carburetor Attention: When the carburettor is ready for sell, the idle adjusting bolts have already been adjusted, so they generally require no adjustment. When dismantling the carburettor, the number of turning of the bolts should be recorded which is very helpful during the installation.
  • Page 157 Cylinder cover Note: In order to guarrante the sealing between cylinder head and cylinder block, the cylinder head undertakes a very big bolt pretightening force. Pretightening force value: 50Nm. 1. Spark plug. 2. Cylinder head fixing bolt. 3. Cylinder head. 4. Cylinder gasket. 5. Cylinder block.

  • Page 158: Preparation Data

    XII. Cylinder cover Preparation data------------------------------------12.1 Fault diagnosis-------------------------------------12.2 Cylinder head --------------------------------------12.3 Examination of the cylinder head----------------12.4 Installation of the cylinder head --------------12.5 12.1 Preparation data Matters needing attention in operation In order to guarrante the sealing between cylinder head and cylinder block, the cylinder head undertakes a very big bolt pretightening force.

  • Page 160: Examination On Cylinder Head

    12.4 Examination on cylinder head Inspect the cylinder head whether it is broken. Ruler Inspect the planeness of the cylinder head bottom plane. Allowable limit ：0.04mm。 Measuring gauge Cylinder head 12.5 Cylinder head installation Implement mounting in a reverse order with dismounting.
  • Page 161 Air cylinder/piston...
  • Page 162 1. Piston 2. Piston pin. 3. Cylinder block. 4. Cylinder gasket. 5. Cylinder head. 6. Nut. 7. Spark plug...

  • Page 163: Preparation Data

    XIII. Air cylinder/piston Preparation data------------------------13.1 Piston------------------------------13.4 Fault diagnosis ------------------------13.2 Installation of the piston---------13.5 Cylinder body -------------------------13.3 13.1 Preparation data Matters needing attention in operation All parts should be cleaned before inspection and test and should be blow dry with high pressure air. Function of the cylinder body：...

  • Page 164: Fault Diagnosis

    0.05 roundness 0.015－0.05 0.09 Top ring clearance between the piston ring and ring groove Second 0.015－0.05 0.09 ring 0.1-0.25 Top ring Joint face clearance Piston Second 0.1-0.25 Piston ring ring 39.97-39.99 39.9 Piston outer diameter 0.005-0.015 Clearance of cylinder and piston 12.002-12.008 12.04 Piston pin hole inner diameter...
  • Page 165 13.3.1 Disassembly of air cylinder body Remove the air cylinder body, after dismantle the air cylinder cover. Cylinder 气缸体 Cylinder Ruler 13.3.2 Inspectionof air cylinder body Testing gauge Inspect the wear and tear of the cylinder inner wall. Severe wear and replace it. Inspect the cylinder face planeness of the cylinder block.

  • Page 166: Piston

    13.4 Piston 13.4.1 Disassembly Disassemble the retaining ring for piston pin. *Attention: When disassembling，do not drop the retaining ring into the crankcase. Piston pin, retaining ring Withdraw the piston pin and unload the piston. Inspect the piston, piston pin and piston ring. Unload the piston ring.
  • Page 167 Measure the interface clearance of the piston ring. Allowable limit：0.5mm. 测试规 Measure the bore diameter of the piston pin hole. Allowable limit：12.04mm. 90° Measure the outer diameter of the piston pin. 11 5m Allowable limit：11.96mm. Clearance of piston pin hole and piston pin. Allowable limit：0.02mm.
  • Page 168 Measure the outer diameter of the piston. *Attention: The measuring position and the piston pin form an angle of 90 degree, some 11.5mm below the skirt of piston. Allowable limit：39.9mm. Inspect the abrasion and wear of the cylinder inner wall. *Attention: Measure the bore diameter of the cylinder at the upper, middle and lower part when keeping an angle of 90 degree from the piston pin.

  • Page 170: Installation Of Piston

    Measure the roundness of inner wall （ bore diameter difference between X and Y direction ）. Upper Allowable limit：0.05mm. Middle Measure the cylindricity of inner wall （ bore diameter Lower difference at the upper , middle and lower part in X or Y direction）.

  • Page 171: Installation Of Piston

    *Attention: No foreign objects should fall into the crankcase. Install the piston, piston ring and retaining ring. *Attention: Install the notch face of the pistion skirt towards air intake duct. 13.5 Installation of piston Install the guide pin. Paint the engine oil on each piston ring and piston. Install the piston in the right place.
  • Page 172 Drive disk/Clutch/Driven Wheel Note: The grease can not attach on the surface of the V-belt during operation, it must be removed if it is attached to reduce the slip between the V-belt and belt wheel to the minimum.
  • Page 173 Foot start mechanism Note: The grease can not attach on the surface of the V-belt during operation, it must be removed if it is attached to reduce the slip between the V-belt and belt wheel to the minimum.
  • Page 174 1. Snap ring. 2. Start claw. 3. Idle gear. 4. Idle gear shaft. 5. Start shaft component. 6. Foot start shaft spring.

  • Page 175: Xiv. Drive Disk/Clutch/Driven Wheel / Foot Start Mechanism

    XIV. Drive disk/Clutch/Driven Wheel / Foot start mechanism Preparation data -------14.1 Clutch/Driven Wheel -----------------------------14.5 Fault diagnosis---------14.2 Disassemble the clutch and the driven wheel -14.6 Left crankcase cover --14.3 Installation------------------------------------------14.7 Drive disk --------------14.4 Foot start mechanism ----------------------------14.8 14.1 Preparation data Matters needing attention in operation In the operation, there should be no grease on the surface of the triangle belt.

  • Page 176: Drive Disk/Clutch/Driven Wheel / Foot Start Mechanism 174 14.1 Preparation Data

    The triangle belt is worn out The triangle belt is worn out The friction-plate spring of clutch is broken out. The driven wheel is worn out The clutch spring is deformed The clutch friction plate is damaged or worn out. The ball bearing is worn out The clutch spring is broke The surface of the driving pulley is stained.
  • Page 177 14.4.1 Disassembly Dismantle the fixing nut of the drive disk and take down the left half of the drive disk. Take down the triangle belt from the drive disk. Check whether the triangle belt is chapped and whether the rubber and cotton yarn fall off or are abnormally worn out.
  • Page 178 14.4.2 Decompose the right-half components of the drive wheel. Check the abrasion of the ball bearing. Measure the external diameter of the ball bearing. Allowable limit ：14.4mm.

  • Page 179: Clutch/Driven Wheel

    Measure the right-half internal diameter of the driven wheel. Right-half components Allowable limit ：26.06mm. of the drive wheel Measure the external diameter of the sliding sleeve. Allowable limit ：25.94mm. Sliding sleeve Driven wheel Fixer 14.5 Clutch/driven wheel Clutch coating 14.5.1 Disassembly Box wrench Fix the outer part of clutch with the fixing tool and dismantle the fixing nut.
  • Page 180 Retainer ring Friction plate...

  • Page 181: Disassemble The Clutch And The Driven Wheel

    Check the abrasion of the outer part of clutch. Measure the internal diameter of the outer part of clutch. Allowable limit ：118.5mm. Friction plate Check the abrasion of the friction plate of clutch. Measure the thickness of the friction plate. Allowable limit ：1.5mm.
  • Page 182 Loosen the compressor and decompose the clutch and driven wheel.
  • Page 183 Take down the protective jacket of the spring. Protective jacket of the spring The left-half weldment of the driven wheel Guide pin Oil seal Dismantle the guide pin. Take down the left-half weldment of the driven wheel. Dismantle the oil seal from the left-half part of the driven wheel.
  • Page 184 Allowable limit ：68mm. Needle bearing Rolling bearing Elastic check ring Check the abrasion of the driven wheel. Measure the external diameter of the right-half shaft sleeve of the driven wheel. Allowable limit ：32.94mm. Measure the internal diameter of the left-half sliding sleeve Bearing opener of the driven wheel.
  • Page 185 Paint grease on the outer rolling bearing and put it into the shaft sleeve. *Attention: Compress the outer rolling bearing into the shaft sleeve with the marked side outward. Then fill the 8-9g grease in the whole shaft cavity. Assemble the elastic check ring. Install the needle bearing.
  • Page 186 14.6.2 Combination of clutch and driven Grease Oil seal wheel Clean the grease on the driven wheel surface. Install the oil seal in the left-half sliding sleeve of the driven wheel. Paint grease on the O-typed ring and install it on the left-half sliding sleeve of the driven wheel.

  • Page 187: Installation

    Install the clutch-pressing spring and clutch on the driven wheel. Use clutch spring to compress and compose. After compression, install the locking nut. *Attention: the spring should be compressed properly. Otherwise, the spring will be damaged. 14.7 Installation The order of assembling the driven disk, clutch and driven wheel is opposite to that of disassembly.
  • Page 188 idle wheel shaft force position. Inspect the wear condition of the idle wheel. Measure the clamping force of the snip ring. General standard value: 8-12N。 Note: 1. Snap ring. 2. Start claw. 3. Idle gear. 4. Idle gear shaft. 5. Start shaft component. 6. Foot start shaft spring.
  • Page 189 Decelerator Function: Transfer torque and decide final output torque and revolution.

  • Page 190: Preparation Data

    XV. Decelerator Preparation data --------------15.1 Fault diagnosis----------------15.2 Gear case ----------------------15.3 Installation---------------------15.4 15.1 Preparation data Function: convey the torque and determine the torque and rev of the final output. 15.2 Fault diagnosis The motor can not move when the engine is started. The drive gear is broken.

  • Page 192: Installation

    Take down the gasket and the guide pin. Output axle gear Take off the clutch main shaft, output shaft gear. Gasket Take off the middle shaft, middle shaft gear. Clutch Input axle main shaft Middle shaft gear Clutch main shaft Oil seal bearing 15.3.2 Output gearbox cover inspection Clutch main shaft, gear, bearing wear, damage inspection.

  • Page 193: Crankcase

    *Attention: The assembly of bearings and oil seal should use special tools to prevent damage. Crankcase...
  • Page 194 Note: The crankcase is a thin wall casting part, avoid stamp during the work prevent deformation and breakage. All parts should clean and blow cleanlily by high compressed before inspecting and measuring. The oil in crankcase should be drained out before work.
  • Page 195 XVI. Crankcase Preparation data ---------------16.1 Fault diagnosis-----------------16.2 Crankcase-----------------------16.3 Installation ---------------------16.4 16.1 Preparation data Matters needing attention in operation Since the crankcase is a thin-section casting, please avoid impact on it during operation in case there is any distortion or rupture. All parts should be cleaned before inspection and test and should be blow dry with high pressure air.
  • Page 196 16.2 Fault diagnosis Strange noises in crankcase Parts shattered or broken in crankcase The crankshaft bearings are loosened. The bearings of crankshaft pin are loosened. Clutch depressed 16.3 Crankcase 16.3.1 Disassembly of crankcase Bolt Starting indolent gears Loosen bolt, take off the start drive gear. Take off the gear on the satellite wheel seat.
  • Page 197 Take down the gasket and the guide pin. Oil sealing Oil sealing Take off the crankshaft from the crankcase. Scrape off the gasket on the crankcase joint face. *Attention: Don’t damage the crankcase joint face. Dismount oil sealing from the left crankcase. Measuring position of connecting rod big end...
  • Page 198 Dismount oil sealing from the right crankcase. 16.3.2 Inspection Clearance measurement of connecting rod big end in right and left direction Allowable limit ：0.6mm.
  • Page 199 Clearance measurement of connecting rod big end in X and Y direction Allowable limit ：0.05mm. Inspect whether there are strange noises or loosening in rotation of the crank shaft bearing. If there is strange noises or loosening，replace the crankshaft set. Crankcase bearing...

  • Page 200: Installation

    *Attention: The dismantled oil seal can not be used again. The dismantling of the oil seal should use special tools. 16.4 Installation The order of assembling crankcase is opposite to that of the disassembly. *Attention: The installation of oil seal should use special tools in order to prevent the damage against the oil seal.

  • Page 201: Exhaust Emission System Inspection And Maintenance

    Exhaust emission system inspection and maintenance Muffler Torque value for bolt 5 in Fig.:5-9 N·m Torque value for bolt 5 in Fig.:22-29 N·m Torque value for bolt 5 1. Silencer assembly. 2. Silencer body. 3. Silencer decoration cover. 4. Silencer front section. 5. Bolt M6×16. 6. Bolt M8×35.

  • Page 202: Exhaust Emission And Control System

    Connecting flange sealing gasket. 12. Screw M6×10. 13. Screw M6×25. 14. Spring washer 6. 15. Washer 6. XVII. Exhaust emission and control system Warranty of Exhaust emission and control system ---------------------------17.1 Regular maintenance guideline/ensurance of emission standard -----------17.2 Mechanical function of the exhaust control system --------------------------17.3 Catalyst converter system --------------------------------------------------------17.4 Countermeasures to idle speed emission exceeding specified value -------17.5 17.1 Warranty of Exhaust emission and control system...

  • Page 203: Regular Maintenance Guideline

    8〉Odometer damaged without immediate repair or factitious reconstruction, disuse and replacement 9〉Please go to the check point for regular exhaust inspection every 3 months. ·The new motorcycle produced by the Company has passed EC 97/24/9 standards implemented by the European Union after noise inspection.

  • Page 204: Mechanical Function Of The Exhaust Control System

    Note： Increase cleaning times of air filter if the motorcycle is used on sandstone roadways or in severely polluted environment, so that service life of the engine may be extended. When the vehicle is driven at high speed or in frequent use with considerable service kilometers, its maintenance degree should be increased.
  • Page 205 ※ Improvement of engine Middle spark plug ,semicircular combustion chamber and improvement of compression ratio， ignition time， such improvement in exhaust system alone has achieved high intake and exhaust efficiency which enables increase of combustion efficiency. ※ Air induction device Introduce the air into the vent-pipe so that the CO and HC incomplete combustion could be turned into innocuous gas in the second reaction.

  • Page 206: Catalyst Converter System

    17.4 Catalyst converter system 17.4.1 Structure： Catalyst placing 17.4.2 Description 1.The function of the converter catalyst is to convert HC, CO and NO after incomplete combustion into innocuous gas such as H2O,CO2、 and N2 then discharge them out. 2. The converter catalyst contains rare metal like platinum and rhodium and only unleaded gasoline can be used. Note that leaded gasoline will invalidate the catalyst.
  • Page 207 7〉Do not drive vehicle with bad ignition. 8〉Do not repair the engine ignition system by dismantling the spark plug and starting the engine to inspect whether the spark plug is sparkless. If such operation is necessary, it cannot be performed for a long time. 17.5 Countermeasure of idle speed emission exceeding specified value （Two-stroke）...
  • Page 208 Remark 1: Measure with idle speed measuring procedure. Remark 2: Adjust the engine speed within the stipulation with a set screw and measure idle speed CO/HC.

Table of Contents

Save PDF