Page 1 ONYX Service Manual Holtvej 8-10, Høruphav, 6470 Sydals Telefon: +45 73 15 11 00 Fax: +45 73 15 11 01 info@scanmi.dk · www.scanmi.dk CVR: 27 73 31 07 www.genericmotor.dk Juli 2011...
Page 2 ONYX Service Manual Generic Motor GmbH...
Page 3: Table Of Contents
Contents Contents..............................- 1 - Preface..............................- 7 - Preparing documents........................- 8 - Inspection/Adjustment........................- 38 - Inspection and maintenance of electrical system..................- 53 - 1. Battery/charging system........................- 55 - 1.1 Preparing documents ....................... - 55 - 1.2 Failure diagnosis ........................
Page 4 3. Activation system ..........................- 72 - 3.1 Preparing documents ....................... - 72 - 3.2 Failure diagnosis ........................- 73 - 3.3 Starting motor ......................... - 73 - 3.4 Starting relay .......................... - 75 - 4. Bulbs/Switches/Meters........................- 79 - 4.1 Preparing documents .......................
Page 5 7.Front wheel/front suspension......................- 97 - 7.1 Preparation documents ......................- 97 - 7.2 Failure diagnosis ........................- 98 - 7.3 Front wheel..........................- 98 - 7.4 Steering handle ........................- 100 - 7.5 Front fork ..........................- 101 - 8.Rearwheel/rear suspension .......................
Page 6 11.1 Preparation documents ......................- 122 - 11.2 Failure diagnosis........................- 122 - 11.3 Machine oil pump ........................ - 123 - 12.Carburetor ............................ - 127 - 12.1 Preparation documents ......................- 127 - 12.2 Failure diagnosis ......................... - 128 - 12.3 Removal of carburetor......................
Page 7 15.2 Failure diagnosis ......................... - 146 - 15.3 Left crankcase cover ......................- 147 - 15.4 Driving disc ........................- 147 - 15.5 Clutch/driven wheel ......................- 149 - 15.6 Detach clutch and driven wheel..................... - 151 - 15.7 Install ..........................- 155 - 15.8 Foot starting device......................
Page 8 18.5 Solution for idle discharge value exceeding defined value (two-stroke) ........- 169 - - 6 -...
Page 9: Preface
Please note that photos, pictures or instructions are for your reference only. The actual object may differ from these mentioned here. We will not make notification for any discrepancy. Generic Motor GmbH - 7 -...
Page 10: Preparing Documents
Preparing documents General safety Maintenance rules Specification table Failure diagnosis General Safety Carbon monoxide Engine shall be started in a ventilated place, not in a closed area. Note Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human being.
Page 11 Maintenance Rules Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage. Clean up the surface of parts or assembly parts before removing or opening the shield for maintenance, which can prevent dirt from falling into the engine, chassis or braking system. Wash parts and dry with compressed air machine after disassembly and before measurement of attrition value.
Page 12 Bolts and screws with different length will be separately used for assembly parts and shields, and they shall be correctly mounted. Insert a bolt into a hole to check whether it is proper if you are confused. Fill the groove with grease before mounting an oil seal. Check whether the oil seal is smooth or damaged during assembly.
Page 13 Loose cables threaten electrical safety. Check each cable after they are all clamped to ensure the 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 14 Fig. 1-2 Significant Notes 1. Please apply valid Generic parts and accessories. Any part or accessory not in accordance with the design specification of Generic Company may cause damage to engine. 2. Only metric tools are valid for maintenance and repair. Metric screws, bolts and nuts can not be exchanged with imperial fasteners.
Page 15: 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.
Page 16 Thickness gauge (feeler gauge) Fig. 1-5 Fig. 1-6 Fig. 1-7 Fig. 1-8 Fig. 1-9 Fig. 1-10 handle Fig. 1-11 Fig. 1-12 - 14 -...
Page 17 pliers piston Fig. 1-13 Fig. 1-14 Fig. 1-15 Fig. 1-16 2．Tools for repairing chassis List 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.
Page 18 Fig. 1-19 Fig. 1-20 1. socket head 2. crank handle 3. ratchet spanner 4. connecting rod 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 chassis: tool for hammering seal of front fork - 16 -...
Page 19 Fig. 1-29 (3) Steering nut spanner Fig. 1-30 3．Tools for electric parts List and drawings (1-31, 1-32) of special tools for testing electric parts are as follows: Table 1-31 Name Remark Multimeter Fig. 1-33 Ignition tester Fig. 1-34 Table 1-32 (continued) Fig.
Page 20 Specification (QJ50QT-22D) Model QJ50QT-22D QJ1E40QMB-4 Engine type Unleaded petrol 1940 Length mm Fuel type (92/95) No. of Width mm cylinder Height mm 1110 40×39.2 ID × stroke Total Wheelbase mm 1305 49.2CC displacement Forward Electric/kick Startup shaft Weight kg Engine Air cooling Backshaft Cooling...
Page 21 I.D. of brake system φ140mm drum, rear wheel QJ50QT-22D - 19 -...
Page 22 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 23 Remove spark plug and check it Moist electrode of spark plug Dry electrode of spark plug Check whether there is oil Drop a little gasoline into the cylinder for trial startup spillover in the carburetor Check whether Check whether air float needle valve and filter is blocked valve...
Page 24 Diagnosis on engine overheating Engine overheating Check whether operation is correct Check whether gasoline grade is Check cooling system improper or 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 25 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 26 Diagnosis on power shortage of engine Power shortage of engine Raise the main kickstand and lift wheels; rotate wheels with hands Inflexible rotating of Flexible rotating wheels of wheels Check tyre Check whether there pressure braking drag. Check whether wheel bearing is excessively abraded or damaged.
Page 27 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 pressure of cylinder valve is completely closed with timely conducted with an your hand.
Page 28 Diagnosis on excessive fuel consumption of engine Excessive fuel consumption of engine Check whether operation correct Raise the main kickstand and rotate Check whether motorcycle runs wheels with hands with overload economical speed or with low gear. Check whether petrol grade is proper.
Page 29 Diagnosis on clutch slipping Clutch slipping Automatic shoe-type centrifugal & dry clutch is slipping. Check whether the shoe-type friction plate is spotted with oil stain. Check whether Clean shoe-type friction plate is remove oil stain excessively abraded. Check whether the contact Replace the whole set of surface between shoe-type clutch shoe blocks...
Page 30 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 31 Diagnosis on starter motor failure in rotation Starter motor failure in rotation Turn the ignition switch; press the horn; press or turn the steering lamp switch. The electric horn does not make The electric horn makes loud sound sound or makes weak sound; the and the steering lamp emits bright steering lamp emits weak light.
Page 32 Diagnosis on starter motor running weak Starter motor running weak Turn the ignition switch; press the horn; press or turn the steering lamp switch. The electric horn does not make The electric horn makes loud sound sound or makes weak sound; the and the steering lamp emits bright steering lamp emits weak light.
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 Diagnosis on burnt-out bulbs Burnt-out bulbs Turn the ignition switch; press the horn; turn the steering lamp switch. The horn works abnormally or The horn makes loud sound and the does not make sound; the steering lamp emits bright light. steering lamp emits weak light.
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; 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 Press the horn button and check whether check whether the bulbs are...
Page 37 Diagnosis on electric horn failure in making sound Electric horn failure in making sound Turn the ignition switch and steering lamp switch; check the work condition of steering lamp. The steering lamp is not The steering lamp emits bright light or emits weak light. light.
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 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 40: Inspection/Adjustment
Inspection/Adjustment Preparing information Cylinder pressure Periodic Maintenance & Inspection List 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 Spark plug Headlight...
Page 41 Specification Engine Idle speed 1900±100rpm/min Clearance of spark plug 0.6-0.7mm Spec. of spark plug BR8HSA(NGK) Max. power (KW/r) 2.60kW/6500rpm 4.36N.m/5250rpm Max. torque (N﹒m/r) Frame Free stroke of front brake lever 10-20mm Free stroke of rear brake lever 10-20mm Tyre Specification Tyre pressure unit: Kpa Front wheel 80/80-16...
Page 42 Periodic Maintenance & Inspection List Mileage between services and time 1000 3000 6000 12000 14500 Applicable tools Inspection item Three Twelve Fifteen vehicle month months months months months Air filter Ordinary tools Petrol filter Ordinary tools Oil filter Ordinary tools Replacement of engine Replacement every 1000KM Ordinary tools...
Page 43 Piston & cylinder—excessive abrasion; replace cylinder if it is blocked. Please have your motorcycle inspected and adjusted periodically at Generic distributors for being in best condition. The above table is established under the presupposition of 1000 km/month.
Page 44: Oil Level
Engine oil/filter Oil level *Note •The motorcycle should be parked on a flat ground when checking its oil level •2-3 minutes after the engine running, stop for about 2-3 minutes and then check the oil level. Check the oil level. Check the oil level.
Page 45: Spark Plug
Adjust the free tavel of accelerator. Fisrt loosen the locked nut ①, Fix or loosen the adjusting device ②, Until the free travel meet the standard value, Then fix the locking nut ①. Air filter Filter replacement Remove the body shield, Remove the set bolt (13) on the air filter, Remove the fixing component, Remove the air filter...
Page 46 Clean the spark plug by compressed air, thus to guarantee that no shatter is exist in the firebox. Remove the spark plug by special spanner or other tools. （1）Inspection: Carry out the following inspection, and make replacement when necessary: ．whether the insulator is damaged ．whether the electrode is worn ．Burning condition and color —...
Page 47: Battery Removal
Battery removal Remove the rubber pad (1) of pedal. Remove the clamp bolt and clamp of battery. irst remove the negative wire and then remove the positive wire. Take the battery (5) from the battery container. Warning！ The tools for removing the positive electrode should not contact the flame, otherwise it will be very dangerous that the damaged battery will cause fire.
Page 48: Idle Speed Adjustment
negative pole together. Warning: • Battery should be far away from fire source •Turn off the charger switches when starting or completing charging in order to prevent spark of the connections resulting in explosion. • You must follow the required current time when charging. *Note •...
Page 49: Gear Oil
Ignition timing inspection Warm up the engine for 3-5 minutes. Connect the timing light to the lead of spark plug after the engine is off. *Note: carefully read the instruction of timing light before carry out any operation. Remove the body shield. Start the engine and it idle running.
Page 50: Drive Belt
Remove the oil level gauge (1) after the engine stopped. The oil level between the upper limit and lower limit of oil level gauge is all right. Add gear oil when the oil level is below the lower limit. Install the oil level gauge. Gear oil replacement Warm-up the engine A lacquer tray shall be placed under the engine to hold the...
Page 51 Measure the free path of front brake at the point of the brake lever. Free path: 10-20mm Free path of rear brake Measure the free path of rear brake at the point of the brake pedal. Free path: 10-20mm Inspection of brake fluid level Use the front brake to the upper limit, and check the oil level thought the oil indicator.
Page 52 Clutch Start the engine and increase its speed gradually to check the working condition of the clutch. 摩擦片 If the motorcycle fails to go and the engine stops, you should check the clutch block. If necessary, change a new one. 摩擦片：friction piece Front/rear suspension system Front...
Page 53 Check whether the tyre or rim has crack, screw or any other damage. Check the tyre pressure. *Note Check the tyre air pressure when it is cold. Specification: Tyre specification Front Wheel 80/80-16 QJ50QT-22D Rear Wheel 90/80-16 Tyre specification Specification Front Wheel 80/80-16 QJ50QT-22D...
Page 54 - 52 -...
Page 55: Inspection And Maintenance Of Electrical System
Inspection and maintenance of electrical system Torque force list of fixing parts in electrical system Position and name of fixing componen Torque of fixing（N·m） Rectifier bolt High tension coil fixing bolt Flywheel Fixing bolt Body Shield Bolt Clutch cover bolt of starting motors Set screw nut of clutch cover of starting motors - 53 -...
Page 56: Charging System
Charging System 1 Meters assembly 2 Horn 3 Power locking components 4 Frequency conversion flash apparatus 5 Battery 6Temperature controlled 7 Pressure adjuster 8 Ignition coil - 54 -...
Page 57: Preparing Documents
9 Starting relay 10 Starting switch 1. Battery/charging system Preparing documents --------1.1 Failure diagnosis -------------1.2 Battery---------------1.3 Charging system -------------1.4 Voltage current adjustor -------1.5 Magnetor charging coil -------1.6 Removal of magnetor ---------1.7 1.1 Preparing documents Note of work: *Note 1. Battery charge and discharge can be repeated use, its life span can be shortened and performance decreases after discharging.
Page 58: Failure Diagnosis
Preparing standards Item Specifications Capacity/Type 12V-4AH/dry cell Voltage Full charge 13.1V Obligatory 12.3V(not working for 1h) （20℃） charge Battery Charging current standard：0.4A，rapid：4A Charging time standard：10-15h，rapid：30min capacity 90W/8000rpm Green/Red - Black 2.0-2.5Ω Lighting coil impedance （ 20℃） Magnetor White – Black 1.5-2Ω Charging coil impedance(20℃) Type Single-phase semi-wave charge under short circuit...
Page 59 Bad voltage current adjustor 1.3 Battery 1.3.1 Battery removing Rmove the rubber pad of pedal Remove the clamp bolt and clamp of battery. irst remove the negative wire and then remove the positive wire. Take the battery from the battery container. Warning！...
Page 60: Charging System
* Note Use voltmeter when charging. 1.3.2 Charging Connection method： Connect the positive terminal of the battery charge and the battery Connect the negative terminal of the battery charge and the battery Warning！ •The battery should be far away from fire source.
Page 61: Rectifier
* Note Connect the positive terminal of the multimeter and the negative terminal of the battery together Check whether the main switch and main wire are short circuit under abnormal conditions. 1.4.2 Charging inspection Use the multimeter to checking the fully charged battery. Mount the battery after the engine warming up.
Page 62: Magnetor Charging Coil
（red）and GND of the body Between GND With wiring wire（black）and GND of the body Between charging coil(white) and There is resistance in the GND of the the magnetor coil body Between light wire (green/red) White Green/Red Black Multimeter and the GND There is resistance in （A）...
Page 63: Replacement Of Magnetor
Remove the 6p connector of the magnetor Measure resistance value between the white coils of magnetor with multimeter Standard value：0.5-10Ω（20 ） Replace the magnetor coil when the measured value exceeds the standard value 1.6.1 Magnetor lighting coil *Note Check the magnetor lighting coil on the engine.
Page 64 Remove the alternator stator. 飞轮拔取器：flywheel remover 1.7.2 Installation Install the stator on the body of the engine. Connect the magnetor terminator. Clean up the taper part of the bent axle and flywheel. Install the solid key of the flywheel into the bent axle. Aim the flywheel groove at the solid key on the axle.
Page 65: Ignition System
Ignition system 1 Meters assembly 2 Power locking components 3 Horn 4 Battery 5 Starting relay 6 CID DC igniter 7 Frequency conversion flash apparatus 8 Ignition coil 9 Release resistances - 63 -...
Page 66: Preparing Documents
2. Ignition system Preparation system --------------2.1 CDI Group----------------2.4 Failure diagnosis --------------2.2 Ignition coil --------------2.5 Ignition system checking ----------2.3 Trigger-----------------2.6 Preparing documents Note of work: 1. Checking the ignition system following the sequence listed in the table of failure diagnosis. 2. The ignition system is solidified in the CDI group and you don’t have to adjust the ignition time. 3.
Page 67: Failure Diagnosis
Trigger voltage Above 1.7V Charging coil voltage 95-400V Tools Voltmeter Multimeter 2.2 Failure diagnosis Spark plug unable to jump Error Reason (identify according to the following order) The inner resistance is too small and it should be tested by required tester Low rotation speed of the bent axle.
Page 68: Checking The Ignition System
The inner resistance is too small and should be tested by required tester. Low rotation speed of the bent axle (It is normal that several measured voltage is above the basic standard.) Low high voltage electricity Trigger Tester is interfered. Bad trigger（...
Page 69 Remove the intermediate cap. Connect the wires of ignition coils. Ground connect the two ends (black/white) of the primary coil to the car body to create current divider. Press the staring motor or step on the actuating lever to measure the voltage of the ignition coil at a time.
Page 70: Cdi Group
Remove the adaptor of the alternator when 白：white 绿：green 蓝：blue the peak voltage of the adaptor of CDI Group is abnormal. Connect the magnetor of and the trigger (blue/white). ·If the obtained voltage of the end of CDI Group is abnormal while the one of the end of the alternator is normal, the problem should be poor contact or wire break.
Page 71: Ignition Coil
2.5 Ignition coil 2.5.1 Unload Unload the body shield. 点火线图 Unload the spark plug cap. Unload the primary wire of the ignition coil. Unload the fixed bolt of the ignition coil, remove the ignition coil. Ω Carry out the operations in the opposite order of unloading during installation.
Page 72: Trigger
2.6 Trigger *Note: Ω 白/ 绿 Check of the trigger could be carried out on the engine. Check 蓝/ 白 Remove the body shield. 白/绿：white/green 蓝/白：blue/white Remove the wire adaptor of the trigger.。 Measure the impedance value between the blue/white end of the wire at the engine 磁电机接口...
Page 73 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 启动示意图 1 Meters assembly 2 Power locking components 3 Horn 4 Battery 5 Starting relay 6 CID DC igniter 7 Frequency conversion flash apparatus...
Page 74: Activation System
3. Activation system Preparation ---------------3.1 Failure diagnosis ---------------3.2 Starting motor ---------------3.3 Starting relay -------------3.4 3.1 Preparing documents Notes of working The unloading of the starting engine could be carried out on the engine. Refer to the method of unloading when unloading the engine. Preparation standards Item Standard value...
Page 75: Failure Diagnosis
3.2 Failure diagnosis Activation failure Weak rotating force Starting motor is rotating of the starting motor well while the engine is not •Burnt out fuse ·Low storage battery •Broken starting clutch •Low storage battery •Poor contact of connecting line •anticlockwise revolution of the starting motor •Broken main switch •The gear of the starting motor is •Low storage battery...
Page 76 fragment or burning loss in the surface. Clean the metal powder on the surface of the commutators. Conduction check between all interfaces of other components Make sure armature shafts of all interfaces could not turn on. Conduction check of the outer cover of the starting motor Make sure the conduction terminator and the outer cover of the starting motor could not...
Page 77: Starting Relay
• Damage is not allowed in the interface between the electric brush and the armature, pay attention please. The labial part of the oil seal should not be damaged by the installation shaft, pay attention please. Install new O-shape rings on the front cover. Pair the screw of the motor shell with the one of the front cover during installation.
Page 78 3.4.2 绿/黄/黑 green/yellow/black Voltage examination of the starting relay Set up the main stand, measure the voltage between the negative pole of the green/yellow wire in th adaptor of the starting motor and the ground strap connection of the body. 绿/ 黄...
Page 79: Bulbs/Switches/Meters
Bulbs/Switches/Meters - 77 -...
Page 80 Certificate No. of front lamp: E9-00 1555 Certificate No. of front position lamp:E9 50R-001555 Certificate No. of rear lamp: E9 50R-001556 Certificate No. of front turn light: 1 Front signal lamp 2 Right rearview mirror 3 Left rearview mirror 4 Front right turn signal lamp 5 Front left turn signal lamp 6 Rear left turn signal lamp 7 Taillight 8 Rear reflector 9 Meters assembly - 78 -...
Page 81: Preparing Documents
4. Bulbs/Switches/Meters Preparation --------------4.1 Meters ------------4.6 Failure diagnosis --------------4.2 Main switches --------------4.7 Headlight bulb replacement --------4.3 Speaker----------------4.8 Front turn signal lamp replacement----------4.4 Combined switch------------4.9 Replacement of taillight, rear left/right turn signal lamp -------4.5 4.1 Preparing documents Notice of work Conduct examination of the switch (The switch could be removed from the motorcar before being examined) 4.2 Failure diagnosis The main switch can not be turned "On"...
Page 82: Front Turn Signal Lamp Bulb Replacement
4.3.2 Installation Install the bulb in the opposite order of removal. Front turn signal lamp bulb replacement 4.4.1 Unloading Unscrew the setscrew of the turn light. Remove the front turn signal lamp bulb 4.4.2 Installation Install the bulb in the opposite order of removal. 4.5 Taillight/Rear turn signal lamp replacement 4.5.1 Unloading...
Page 83: Meters
4.6 Meters Remove the decorative parts of meters Remove the back protective guard of the handlebar, Disconnect the wire of meters Remove the meters Install the speedometer in the opposite order of removal. 4.7 Main switches 4.7.1 Check Remove the helmet hook, front basket and rear board. Remove the added board and foot protective plate of front basket and rear board.
Page 84: Combined Switch
Remove the wires of the speaker. Connect the speaker to the storage battery. If there is sound, it is working. 4.9 Combined switch Displacement and installation Remove the rearview mirror component. Remove the decorative screw of meter. Remove the meters and back protective guard of the handlebar.
Page 85: Examination And Maintenance Of Chassis
Examination and maintenance of chassis chassis Torque force list of set parts on Position and name of fixing part Fixing torque（N·m） Installing bolt of front fluid brake disc 5-9 N·m Bolt component of front absorber 37-44 N·m Set bolt of rear brake rocker 5-9 N·m Set bolt for welding of handlebar 40-60 N·m...
Page 86 Front Fluid Brake Dia of front brake disc: φ 2 2 0 mm Thickness front brake disc: 4.0mm Limit: 3.0 Thickness front brake disc: 4.0mm Limit: 3.0 Installing torque of bolt 9 in the picture: 5-9 N·m Free path of brake handle: 10-20mm - 84 -...
Page 87 1 Front brake component 2 Friction piece component 3 Oil pump component 4 Liquid brake handle 5 Brake tube assembly 6 Brake cylinder component 7 Switch assembly 8 Shield 9 Bolt M6×20 10Front brake plate Rear Drum Brake Torque of bolt 3 in the picture: 100-113 N·m Inner dia.
Page 88: Brake
1 Vacuum tyre 90/80-16 2 Rear wheel component 16×1.85 3Bolt M16X1.5 4 Dust cover 5 nozzle 6 nozzle 7 Brake pad component 8 Rear brake camshaft 9 Drag spring of brake pad 10Bolt M6X30 11 Rear brake rocker component 12 Bolt M6 5.
Page 89: Failure Diagnosis
5.2 Failure Diagnosis Brake Poor performance of the braking system Slow reaction and tight lever 1. Improper adjustments for the brake 1. Improper adjustments for the brake 2. Brake shoe or brake plate wears 2. Brake shoe or brake plate wears 3.
Page 90 Remove the front wheel axis, and dismantle the front wheel。 Remove the brake plate from front wheel. 5.3.2 Check Check whether the friction piece of front fluid brake is worn， Replace the shoe when necessary. Measure the thickness of friction piece of front fluid brake， Measure the front brake disc and write down the maximum value Specification: QJ50QT-22D Dia.
Page 91: Rear Drum Brake
Installing bolt of front liquid brake: 5-9 N·m Don’t let oil stains pollute the friction piece of front liquid brake. If the friction piece of front liquid brake is polluted by oil stains, you should use special cleaner to clean it up. *Note Any oil stains in the friction piece of front liquid brake may reduce the performance of brake.
Page 92 Measure the inner diameter of brake drum, as well as friction piece of brake shoe. If the thickness of the brake shoe is smaller than the maintenance value or polluted by oil, they should be replaced. Note: the brake shoes shall be replaced in pairs. Inner diameter of rear brake drum φ140mm Thickness of friction piece in rear brake shoe...
Page 93: Body Panel
Body Panel - 91 -...
Page 94 *Note Do not damage the body when removing. Do not damage the hook of the body. Do match the grooves for the panels. Correctly install the hooks of each part. damage accessories while installing. 1Soket head cap screw M8×25 2 gasket 8 3 bolt M8×25 4 rubber cover 5 rear rack assembly 6 cushion assembly 7 headlamp 8 instrument decorative part 9 front handle bar shield 10 rear handle bar shield 11 bolt M6×25 12 gasket Φ6 13 odometer wire clip 14 front mudguard...
Page 95 47 rear mudguard 48 lower junction plate II 49 panel 50 secondary rear mudguard 51 upper cover of front shield 6. Body panel Follows the sequence below to tear down the body Instrument decorative part → Front shield of handle bar → Rear shield of handle bar →...
Page 96: Front Wheel
Front wheel Front wheel tyre specification: Outer tyre 80/80-16 Item 12(front axle)mounting torque force: N·m 55-62 Rim tilt limit: Vertical: 2.0mm Horizontal: 2.0mm Front wheel axle bend limit: 0.2mm Front outer tyre certificate No.: E11 75R-001062...
Page 97: Front Suspension
1 front rim 16×1.6 2 vacuum tyre 80/80-16 3 front outer bushing 4 front axle oil seal 5 bearing 6201-2RS 6 screw M6×20 7 front brake disc 8 valve cap 9 valve 10 front wheel middle bushing 11 pinion stand assembly 12 front wheel axle M12×1.5×153.7 Front suspension Bolt 3 mounting torque...
Page 98: Steering Handle
1 lower connection board welding assembly 2 front left shock absorber assembly 3 bolt M8×30 4socket head screw M6×20 5 front right shock absorber assembly 6 bolt M10×1.25×30 7 lower bearing lower steel bow 8 steel ball assembly 9 upper bearing lower steel bowl 10 upper bearing upper steel bowl 11 gasket 12 compression nut Steering handle...
Page 99: Preparation Documents
1 steering handle welding assembly 2 left handle gloves 3 left nut 4 left rearview mirror assembly 5 right rearview mirror assembly 6 right nut 7 right handle assembly 8 throttle line assembly 9 bolt M10X1.25X50 10 handle stand compression block 11 nut M10X1.25 12 left rocker arm support 13 rear brake cable assembly 14 pin 12 X22 15 regulating nut CM6-12X15 16 rear brake spring 17 cable clamp assembly 18 front brake switch assembly 7.Front wheel/front suspension...
Page 100: Failure Diagnosis
7.2 Failure diagnosis 7.2.1 Difficulty of steering The steering handle bearing has problems Steering handle bearing is damaged Low gas pressure for the tyre Gas leakage of tyre 7.2.2 Unsteady steering Bearing of the steering handle is broken Not enough tire gas pressure Bent front fork and front wheel axle Deformed or tilting front tyre 7.2.3 Shimmy of front wheel...
Page 101 Put a support under the driver to raise front wheel. Loose front wheel axle① and remove front wheel assembly. Remove pinion stand assembly. Remove front brake disc ②. Remove front wheel oil seal, front wheel outer bushing, Bearing 6201-2RS and front wheel middle bushing. * Note：QJ50QT-22D front wheel removal diagram is available in P85 of the instruction.
Page 102: Bearing Replacement
7.3.3 Bearing replacement Remove front wheel axle, front wheel brake disc and front wheel outer bushing. Remove front wheel middle bushing and then remove oil seal and bearing by oil seal remover and bearing remover. Note: removed bearing shall be replaced by new bearing. Lay grease on bearing in installation.
Page 103: Front Fork
assembly（7）. Remove throttle line assembly（8）. Remove front brake switch assembly（18）. Remove cable clamp assembly（17）. Remove rear brake cable assembly（13）. Remove steering handle welding assembly（1）. 7.4.2 Installation *Note: QJ50QT-22D steering handle is available in P87 of the instruction. Do the installation according to reversed procedures of removal. Standing screw of steering handle Torque force: 40-60 N·m 7.5 Front fork...
Page 104 Installation of front wheel Front shock absorber assembly standing bolt Torque force: 37-44 N·m Onyx 50 front fork oil volume: 80ml - Castrol SAE 10W *Note: QJ50QT-22D front fork removing diagram is available in P86 of the instruction. - 102 -...
Page 105 Rear wheel/rear suspension - 103 -...
Page 106: Rear Wheel
Item rear wheel standing nut torque force: 100-113 N·m Bolt 4 mounting torque force: 37-44 N·m Bolt 5 mounting torque force: 22-29 N·m Brake ID:φ 1 4 0 mm Abrasion limit:φ 1 4 1 mm Brake shoe thickness: 6.9mm Abrasion limit: 5.9mm 1 self-tapping screw ST4.8X16 2 gas filter standing rubber sleeve 3 gas filter assembly...
Page 107 Wheel dimension: 90/80-16 Wheel rim tilt limit: Vertical: 2.0mm Horizontal: 2.0mm Item 10 rear wheel standing torque force: 100-113 N·m Rear wheel certificate No.:E11 75R-001063 1 vacuum tyre 90/80-16 2 rear tyre rim assembly 16×1.85 3 nut M16X1.5 4 dustproof cover 5 valve 6 valve 7 brake shoe assembly...
Page 108: Preparing Documents
8.Rearwheel/rear suspension Preparing documents -----------------8.1 Failure diagnosis -----------------8.2 Rear wheel -----------------8.3 Rear shock absorber-----------------8.4 8.1 Preparing documents Notes No oil stains sticking to the brake shoe and disc. Preparing standards Item Standard Available limits（mm） value （mm） Amplitude of fluctuation of Vertical the rear wheel Horizontal...
Page 109 Elastic fatigue of the spring 8.3 Rear wheel 8.3.1 Removal Remove the muffler（11） and gas filter assembly（3）. Remove rear mudguard and rear small mudguard assembly. Remove the rear mudguard assembly and rear license plate support assembly. Remove the rear wheel axle standing nut（12）. Remove the rear wheel assembly.
Page 110: Rear Shock Absorber
8.4 Rear shock absorber 8.4.1 Removal Remove the seat assembly and left body guard plate. Loose the upper standing bolt of absorber. Loose the lower standing bolt of absorber. Remove the standing bolt of rear absorber. Remove the rear absorber. 8.4.2 Inspection and adjustment Note: Set the same preload value for each shock absorber.
Page 111: Fuel Tank/Seat
Adjust device location: standard location of 2; minimum location of 1; maximum location of 5. 8.4.3 Installation Install rear shock absorber. Torque force: Upper standing bolt: 37-44 N·m Lower standing bolt: 22-29 N·m Install rear shock absorber. Install rear mudguard, rear small mudguard and rear mud guard plate.
Page 112 Note: in removing fuel tank, turn fuel switch to "OFF". do not damage body cover removal installation. damage hook on cover. Match panel and cover plate of body cover with slot respectively. Location of hook of each part shall be right in installation.
Page 113: Fuel Tank
Fuel tank - 111 -...
Page 114 Fuel tank capacity: 5.5 L±0.2L Bolt 9(standing bolt of oil tank) torque force: 5-9 N·m Note: in removing fuel tank, turn fuel switch to "OFF". 1 oil tank assembly 2 waterproof gasket 3 fuel tank assembly 4 connecting tube 5 fuel tube assembled screw M5×14 7 fuel level sensor cushion 8 fuel sensor assembly...
Page 115 Bolt 11 torque force: 5-9 N·m Exclusive for seat 1 seat assembly 2 helmet case 3 sealing strip 4 rubber cushion 5 nut M6 6 pin roll 7 gasket 8 elastic gasket 6 9 helmet bottom cap 10 self-tapping screw ST4.2×13 11 bolt M6×16 - 113 -...
Page 116: Preparation Documents
9.Fuel tank/seat Preparation documents-----------9.1 Failure diagnosis-----------9.2 Fuel tank/seat--------9.3 9.1 Preparation documents Note: The removing site shall be ventilated and away from fire. Before removing fuel tank, shut motor and turn fuel switch to "OFF". In installation tighten the bolt nut to defined torque force. After installation, check and see whether all parts and operation are right.
Page 117 9.3 Fuel tank/seat 9.3.1 Removal Remove rear storage rack assembly. Open seat. Remove sparking-plug cover and machine oil pot cap. Remove pedal rubber mat. Open storage battery case cap. Remove storage battery. Remove seat assembly and helmet case standing bolt. Remove seat assembly and helmet case.
Page 118 Removal and installation of motor Kinetic force hanger support fulcrum axle standing torque force: 55-62N·m Square bolt torque force: 37-44N·m Bolt torque force: 37-44N·m 1 fuel tank 2 rear shock absorber assembly 3 gas filter assembly 4 muffler 5 fulcrum axle 6 square bolt M10X1.25X41 7 locking nut M10X1.25...
Page 119: Removal / Installation Of Motor
10.Removal / installation of motor Preparation documents---------------------------10.1 Failure diagnosis ---------------------------10.2 Removal of motor/suspension standing clamp------------10.3 Installation of motor-----------------------10.4 10.1 Preparation documents Note 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 120: Removal Of Motor
Loose motor suspension bolt 10.3 Removal of motor 10.3.1 Removal Remove bolt and left crankcase ventilated tube. Removal 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.
Page 121: Installation Of Motor
10.3.2.3 Installation Install bolt and ignition coil. Install fuel tube, vacuum tube and bolt. Install spark plug cap. Connect carburetor fuel tube and vacuum tube. Connect motor kinetic force hanger support to motor assembly. Install temporarily bolt and nut of motor kinetic force hanger support.
Page 122: Inspection And Maintenance Of Motor
Inspection and maintenance of motor Motor fastener torque force table Fastening parts and fasteners Name Torque force（N·m） cylinder head nut 25～28 oil drain nut 22～35 Spark plug 10～15 Assemble mould bolt Speed shift case cap bolt 10～12 Motor standing bolt 10～12 Machine oil pump standing bolt 10～12...
Page 123: Lubrication System
Lubrication system Note: worm gear and worm wheel shall rotate flexibly without stagnation or single side tightness, while the worm wheel shall allow certain axial movement. Machine oil pump O shape gasket shall not cut the edge. Machine oil pump plugs shall not leak and sealing gasket 1 crankcase 2 carburetor...
Page 124: Lubricaiton System
11.Lubricaiton system Preparation documents-----------11.1 Failure diagnosis -----------11.2 Machine oil pump -------------11.3 11.1 Preparation documents Note: Worm gear and worm wheel shall rotate flexibly without stagnation or single side tightness, while the worm wheel shall allow certain axial movement. Machine oil pump O shape gasket shall not cut the edge. Machine oil pump plugs shall not leak and sealing gasket shall be normal.
Page 125: Machine Oil Pump
Natural consumption of oil No oil or low oil pressure Oil leakage Oil line block Abraded or badly installed piston ring No machine oil is used 11.3 Machine oil pump 11.3.1 Removal Loose the bolt and remove gas director assembly. 导风罩...
Page 126 oil pump assembly. 机油泵组件 machine oil pump assembly 机油泵组件 - 124 -...
Page 127 Installation of machine oil pump as follows Machine oil pump shaft Machine oil pump body Plunger spring Plunger Machine oil pump cap 齿轮 11.3.2 Installation Install according to reversed procedures of removal. 11.3.3 Inspection Check whether worm wheel teeth are damaged, or whether key slot is damaged.
Page 128: Carburetor
Carburetor Attention：gasoline is very dangerous, fireworks is strictly prohibited workplace. After disassembling of the carburetor, block the intake manifold with cloth in case of the entering of foreign material. 1 screw 2 float room 3 needle valve part 4 float part 5 float pin 6 main metering hole idle spray nozzle...
Page 129: Preparation Documents
12.Carburetor Preparation documents-------------12.1 Failure diagnosis -------------12.2 Removal of carburetor---------12.3 Installation of carburetor---------12.4 Adjustment of carburetor---------12.5 12.1 Preparation documents Note Gasoline is very dangerous, fireworks is strictly prohibited in workplace. ·Pay special attention to sparks. ·Forcibly pulling and bending of wires is not allowed. Distortion and damage will affect the wires.
Page 130: Failure Diagnosis
12.2 Failure diagnosis Starting disorder hard starting Flameout after starting unstable idling speed No fuel in the carburetor Carburetor blockage Gas filter blockage too thick or too thin gas mixture Gas pipe blockage secondary gas suction in the inspiration system Needle valve ankylosis idle speed maladjustment Oil level maladjustment...
Page 131: Disassembly Of Carburetor
接口 interface 12.3.2 Disassembly of carburetor Loose screws of electronic enrichment valve and remove electronic enrichment valve components. Electronic enrichment Standing screw Standing flange Check abrasion condition of electronic enrichment Enrichment valve valve and oil needle. Oil needle If the abrasion is severe, change the electronic enrichment valve component.
Page 132: Installation And Adjustment
Check main body of carburetor and fuel tube, if dirty, clean them according to instruction. Screw Float component room Float Needle valve assembly Main metering hole Float Idle spray nozzle Main bubble tube Idle adjusting screw 12.4 Installation and adjustment Assemble and install it according to reversed sequence of removal.
Page 133 Retreat mixture adjustment screw for one circle; Restart, and adjust idle adjustment screw to make the rev reach 2000-2500rpm; Adjust mixture screw counter-clockwise slowly until the motor rev reaches the maximum (mixture screw shall be retreat 2 circles at most); Readjust idle adjustment screw to make motor rev decrease to 1900±100rpm;...
Page 134 Attention: cylinder cap bears large bolt preload to ensure seal between the cylinder cap and the cylinder body. Preload value: 50 Nm 1 spark plug 2 cylinder cap standing bolt 3 cylinder cap 4 cylinder gasket 5 Cylinder - 132 -...
Page 135: Cylinder Cap
13.Cylinder cap Preparation documents---------------13.1 Failure diagnosis ---------------13.2 Cylinder cap -----------------13.3 Cylinder cap inspection-------------13.4 Installation of cylinder cap-------------13.5 13.1 Preparation documents Note For gas tightness between the cylinder cap and the cylinder body, the cap bears tremendous bolt pre-tightening force. Pre-tightening force value: 50 Nm. All components must be cleaned and dried with high-pressure gas before examination.
Page 136: Cylinder Cap Inspection
Air director Loose standing nut and spark plug and remove cylinder cap. Cylinder cap Standing nut Spark plug 13.4 Cylinder cap inspection Check whether cylinder cap is broken. Ruler Check flatness of cylinder cap bottom surface. Usage limit: 0.04mm。 Tester Cylinder cap 13.5 Installation of cylinder cap Install according to reversed sequence of removal.
Page 137: Cylinder Body And Piston
Cylinder body and piston - 135 -...
Page 138 Note: all parts shall be cleaned and blown by high pressure air before test. 1 piston 2 piston pin 3 cylinder body 4 cylinder gasket 5 cylinder cap 6 nut 7 spark plug - 136 -...
Page 139: Preparation Documents
14.Cylinder body and piston Preparation documents-----------------14.1 Piston------------------14.4 Failure diagnosis--------14.2 Installation of piston-----14.5 Cylinder body-------------------14.3 14.1 Preparation documents Note All parts shall be cleaned and blown by high pressure gas before test. Function of cylinder body: cylinder body provides space for gas compression, combustion and expansion.
Page 140: Failure Diagnosis
39.995-40.015 40.05 Curvature 0.05 Cylinder Cylindricity 0.006 0.05 Flatness 0.03 0.05 Circular degree 0.05 first ring 0.09 0.015－0.05 Clearance between piston ring and ring groove second 0.09 0.015－0.05 ring Piston first ring 0.1-0.25 Clearance of the mouth of piston ring ring second 0.1-0.25...
Page 141: Piston
14.3.2 Cylinder body inspection Check abrasion of inner wall of cylinder. Change it if abrasion is severe. Check flatness of cylinder face. Cylinder body Usage limit: 0.05 Straight ruler Tester 14.4 Piston 14.4.1 Removal Remove retaining ring of piston pin. Note: don’t allow the retaining ring fall into the crankcase during unloading.
Page 142: Piston Ring
Remove piston ring and install piston ring at the bottom of cylinder. Piston Note: press piston ring into cylinder with piston head. Measure clearance of piston ring mouth. Usage limit: 0.5mm。 Tester Piston ring Measure ID of piston pin hole. Usage limit：...
Page 143 Check scratch and abrasion of inner wall of cylinder. Note: it shall be perpendicular to piston pin, and the cylinder ID shall be measured at upper, middle and lower locations. Tester Usage limit: 40.05mm。 Measure clearance between cylinder and piston. Take the maximum value.
Page 144: Installation Of Piston
14.4.2 Installation of piston Install location pin. Lubricate piston ring and piston with machine oil and install 顶环 the slope upwards. 第二环 Note: Piston shall not be scratched and piston ring shall not break. After installation of piston ring, it shall revolve easily inside piston ring groove.
Page 145 Driving disc/clutch/driven wheel - 143 -...
Page 146 Note: in operation, no oil shall stick to triangular belt, and shall be cleaned if any to minimize possibility of sliding between triangular belt and wheel. 1 gasket 2 spring 3 abrasion piece 4 retaining ring - 144 -...
Page 147 Foot starting device Note: in operation, no oil shall stick to triangular belt, and shall be cleaned if any to minimize possibility of sliding between triangular belt and wheel. 1 snap spring 2 starting claw 3 dile gear 4 idle shaft 5 starting shaft component 6 foot starting shaft spring...
Page 148: Driving /Clutch/Driven Wheel/Foot Driving Device
15.Driving /clutch/driven wheel/foot driving device Preparation documents-----15.1 Clutch/driven wheel----15.5 Failure diagnosis -15.2 Disassemble clutch and driven wheel --15.6 Left crankcase cover---15.3 Installation---------15.7 Driven disc------------------15.4 Foot starting device---15.8 15.1 Preparation documents Note in operation, no 注 oil shall stick to triangular belt, and shall be cleaned if any to minimize possibility of sliding between triangular belt and wheel.
Page 149: Left Crankcase Cover
Broken driven wheel deformed clutch compression spring Broken or damaged clutch abrasion piece worn ball bearing Broken clutch compression spring dirty main belt wheel surface 15.3 Left crankcase cover Removal Remove cover standing bolt and remove gasket as well as standing pin.
Page 150 Usage limit: 16mm。 Note: Choose original factory parts in changing. Remove driving wheel right semi part. Right semi part of driving wheel 15.4.2 Disassemble driving wheel right semi part Check abrasion of ball bearing. Measure OD of ball bearing. Usage limit: 14.4mm。 - 148 -...
Page 151: Clutch/Driven Wheel
Measure right semi ID of driving wheel. Usage limit: 26.06mm。 Right semi part of driving wheel Measure OD of slide bushing. Usage limit: 25.94mm。从动轮 driven wheel Slide bushing 固定器 retainer 离合器外套 clutch bushing 套筒扳手 sleeve spanner 15.5 Clutch/driven wheel 15.5.1 Removal Use retainer to fix clutch bushing and remove standing nut.
Page 152 挡圈 retaining ring 摩擦片 abrasion piece - 150 -...
Page 153: Detach Clutch And Driven Wheel
Check abrasion of clutch bushing. Measure ID of clutch bushing. Usage limit:118.5mm。 Check abrasion of clutch abrasion piece. Measure thickness of abrasion piece. Abrasion piece Usage limit: 1.5mm。 15.6 Detach clutch and driven wheel Use clutch spring compressor in disassembling clutch.
Page 154 离合器弹簧压缩器 clutch spring compressor 弹簧护套 spring sleeve Remove spring bushing. Driven wheel left semi welding Remove directing pin. Remove left Remove oil s Check free length of clutch spring. Oil seal Guiding pin Usage limit: 68mm。自由长度 free length 从动轮右半 right semi part of driven wheel 从动轮左半...
Page 155 Measure left semi slide bushing ID of driven wheel. Usage limit: 33.06mm。 15.6.1 Change right semi bearing of driven wheel Remove needle bearing from right semi driven wheel. Remove elastic retaining ring and outer rolling bearing. 。 Note: Disassembled bearing is unusable. 滚针轴承...
Page 156 Clean grease on the driven wheel surface. Install oil seal of driven left semi slide bushing. Defined grease Ball bearing Install greased O shape ring in driven left semi part. 润滑油脂 Lubricating grease 油封 Oil seal O 型圈 O shape ring Bearing driver Needle bearing Assemble left and right parts of driven wheel together.
Page 157: Install
Install clutch compression spring and clutch on driven wheel. Use clutch spring compression assembly, after compression install locking nut. Directing pin Directing groove Note: Compress spring moderately. Do not damage it. 15.7 Install Install driven disc/clutch/driven wheel in reversed sequence of removal. 15.8 Foot starting device Removal/inspection Remove left crankcase cover.
Page 158 离合器弹簧压缩器 spring compressor of clutch Decelerator device - 156 -...
Page 159 Function: transfer torsion and decide final output torsion and rev. 1 middle gear 2 middle shaft 3 main shaft of clutch 4 output shaft gear 5 bearing 6 oil seal 7 bolt 8 gasket 9 gear room cover - 157 -...
Page 160: Preparation Documents
16.Decelerator device Preparation documents-----------------16.1 Failure diagnosis-----------------16.2 Gear box-------------------16.3 Installation ---------------------16.4 16.1 Preparation documents Function: transfer torsion and decide final output torsion and rev. 16.2 Failure diagnosis Motor fails to make motorcycle run Broken driving gear Burnt driving gear Leaked gear oil Too much gear oil Damaged oil seal 16.3 Gear box...
Page 161: Installation
Output shaft gear Remove clutch main shaft and output shaft gear. Gasket Remove middle shaft and middle gear. Clutch main Middle shaft Middle gear 16.3.2 Output gear box cover inspection Check abrasion and damage condition of clutch main shaft, gear and bearing. Clutch main shaft Change gear room cover bearing.
Page 162 Crankcase Note: The crankcase is thin-section casting thus has to avoid shock on operation case deformation and fracture. All components must be cleaned and dried with high-pressure air before test. lubricant crankcase should released before operation. 1 crankshaft 2 bolt 3 oil seal 4 location pin - 160 -...
Page 163: 17．Crankcase
17．Crankcase Preparation documents-----------------17.1 Failure diagnosis-----------------17.2 Crankcase-------------------17.3 Installation--------------------17.4 17.1 Preparation documents Note The crankcase is thin-section casting thus has to avoid shock on operation in case of deformation and fracture. All components must be cleaned and dried with high-pressure gas before test. The lubricant in the crankcase should be released before operation.
Page 164: Crankcase
Loose or broken parts inside crankcase loose crankshaft bearing Loose crankshaft pink bearing blocked clutch 17.3 Crankcase 17.3.1 Removal of crankcase Loose bolt, remove starting driving gear. Remove star gear. Bolt Starting Remove crankcase standing bolt Star gear Remove left and right crankcase. Note: Gasket shall not be damaged.
Page 165 Remove oil seal from left crankcase. Oil seal Remove oil seal from right crankcase. Oil seal 17.3.2 Inspection Right-left clearance of connecting rod big end. Usage limit：0.6mm。连杆大端测量位置 Measuring location of connecting rod Clearance between X-Y orientation of connecting rod big end.
Page 166: Installation
Check whether crankshaft bearing revolution has noise or loose condition. If there is noise or loose condition, replace the crankshaft component. Note: Crankshaft bearing Oil seal disassembled shall not be used again. Use special tools to remove oil seal. 17.4 Installation Assemble crankcase according to reversed sequence of removal.
Page 167 Muffler Torque force of muffler connector standing bolt 5-9 N·m Torque force of muffler standing bolt 18: 5-9 N·m Torque force of standing bolt 13: 22-29 N·m Torque force of bolt 14: 22-92 N·m 1 muffler shell component 2 gas discharge component 3 muffler decoration plate 4 standing spacer rubber spacer 6 bolt...
Page 168: Exhaust Gas Discharge Control System
The use is requested to carry out regular check, adjustment or maintenance according to the scheduled time to ensure normal emission. ·If other problems occur, please contact Generic distributors or Generic service center for help. ·Relevant discharge provisions are shown as follows:...
Page 169: Mechanic Function Of Exhaust Gas Discharge Control System
Please pay attention to the following to make discharge meet standard: 1〉use of fuel: please use 92# or 95 lead-free gasoline, or catalytic device (two-stroke) may be damaged. 。 2〉Please use defined machine oil. Since the disorder of ignition system, the charging system, and the fuel system has great influence on the catalytic system, please come to designated distributors or service center of our company for examination, adjustment or maintenance if any disorder of the above ones occurs.
Page 170 触媒加放点 catalyst location 18.4.2 Instruction： 1. Function of transfer catalyst is to transfer completely burnt HC, CO and NO to harmless gas such as H for discharge. 、 2、 2. Transfer catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used. Note that lead gasoline may invalidate catalyst.
Page 171 18.5 Solution for idle discharge value exceeding defined value (two-stroke) Qualified Regular inspection（maintenance plan） Qualified Measure idle discharge（note1） Qualified t （ t 2） Adj t Qualified Qualified Remove carburetor leave factory （SJ MJ SAJ MAJ etc ）） Qualified Change carburetor Remove motor •valve（leaked）...
Page 172 Note 1: test with idle test programme. Note2: adjust motor rev with check screw to be qualified, and test idle CO/HC. - 170 -...

Generic Onyx 50 Service Manual

1 Battery/Charging System

2 Ignition System

3 Activation System

4 Bulbs/Switches/Meters

5 Brake

6 Body Panel

7 Front Wheel/Front Suspension

8 Rearwheel/Rear Suspension

9 Fuel Tank/Seat

10 Removal / Installation of Motor

11 Lubricaiton System

12 Carburetor

13 Cylinder Cap

14 Cylinder Body and Piston

15 Driving /Clutch/Driven Wheel/Foot Driving Device

17 ．Crankcase

18 Exhaust Gas Discharge Control System

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