Two-Wheeled Motorcycle F-ACT EVO User's Instruction and Maintenance Manual

Two-wheeled Motorcycle F-ACT EVO
User’s Instruction and Maintenance Manual
KEEWAY Motorcycle Co., Ltd
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Content ................................................................. 错误！未定义书签。
Preface .............................................................................. - 3 -
Preparation Data ................................................................. - 4 -
Inspection/Adjustment ........................................................... - 36 -
Inspection and maintenance of electrical system ..................................... - 50 -
1. Battery/charging system .......................................................... - 52 -
1.1 Preparing documents ......................................................... - 52 -
1.2 Failure diagnosis ........................................................... - 53 -
1.3 Battery ..................................................................... - 54 -
1.4 Charging System ............................................................. - 55 -
1.5 Rectifier ................................................................... - 56 -
1.6 Magnetor Charging Coil ...................................................... - 56 -
1.7 Magnetor Lighting Coil ...................................................... - 57 -
2. Ignition System .................................................................. - 60 -
2.1 Material Preparation ........................................................ - 60 -
2.2 Failure Diagnosis ........................................................... - 61 -
2.3 Ignition System Inspection .................................................. - 62 -
2.4 CDI Group ................................................................... - 64 -
2.5 Ignition Coil ............................................................... - 64 -
2.6 Trigger ..................................................................... - 65 -
3. Activation System ................................................................ - 67 -
3.3 Starting Motor .............................................................. - 68 -
3.4 Starting Relay .............................................................. - 70 -
4. Bulbs/Switches/Meters ............................................................ - 73 -
4.3 Headlight Bulb Replacement .................................................. - 73 -
4.4 Front Turn Signal Lamp Bulb Replacement ..................................... - 74 -
4.5 Taillight Bulb Replacement .................................................. - 74 -
4.6 Meters ...................................................................... - 75 -
4.7 Power Lock .................................................................. - 75 -
4.8 Speaker .......................................................................... 76
4.9 Handle switch ..................................................................... 76
The check and maintenance of the chassis ...................................................... 77
5. Brake ................................................................................. 80
5.1 Maintenance instructions ............................................................. 80
5.3 Front hydraulic brake ............................................................ - 82 -
5.4 Rear hub brake ................................................................. - 83 -
6. Body cover ......................................................................... - 87 -
7. Front wheel/front suspension ........................................................... - 92 -
7.1 Preparation data ................................................................ - 92 -
7.2 Fault diagnosis ................................................................. - 92 -
- 1 -

7.3 Front wheel ................................................................... - 93 -
7.4 Direction handle................................................................ - 96 -
7.5 Front fork ..................................................................... - 96 -
8. Rear wheel/rear suspension ........................................................... - 100 -
8.1 Preparation data ............................................................... - 100 -
8.2 Fault diagnosis ................................................................ - 100 -
8.3 The rear wheel ............................................................. - 101 -
8.4 Rear muffler .................................................................. - 102 -
9. Tank/seat cushion................................................................... - 106 -
9.1 Preparation data ............................................................... - 106 -
9.2 Fault diagnosis ................................................................ - 106 -
9.3 Tank/seat cushion.............................................................. - 107 -
Check and maintenance of the engine ..................................................... - 108 -
10. Lubricating system................................................................. - 111 -
10.1 Preparation data .............................................................. - 111 -
10.2 Fault diagnosis ............................................................... - 111 -
10.3 Machine oil pump ............................................................ - 112 -
11.1 Preparation data .............................................................. - 115 -
Operation precautions ............................................................. - 115 -
11.2 Fault diagnosis ............................................................... - 115 -
11.3 Disassembly of carburetor ...................................................... - 116 -
11.4 Assembly and adjustment ...................................................... - 118 -
12. Cylinder cover .................................................................... - 121 -
12.1 Preparation materials .......................................................... - 121 -
12.2 Failure diagnosis ............................................................. - 121 -
12.3 Cylinder cover ............................................................... - 121 -
12.4 Checking of cylinder cover ..................................................... - 122 -
12.5 Assembly of cylinder cover ..................................................... - 122 -
Thirteenth, Cylinder block and piston ..................................................... - 124 -
13.1 Preparation materials .......................................................... - 124 -
13.3 Cylinder block ............................................................... - 125 -
13.4 Piston ...................................................................... - 126 -
13.5 Assembly of piston ........................................................... - 128 -
14.1 Preparation of materials ........................................................ - 131 -
14.3 Left crankcase cover .......................................................... - 132 -
14.4 Driving plate ................................................................ - 132 -
14.5 Clutch/Driven wheel .......................................................... - 134 -
14.6 Disassembly of clutch and driven wheel ........................................... - 136 -
14.7 Assembly ................................................................... - 139 -
14.8 Feet start mechanism .......................................................... - 139 -
- 2 -

Preface
This maintainence manual mainly describes the maintainence essentials of the
Qiangjiang QJ50T-21T.
The Preparation Data include all the operation precautions, please read this
maintainence manual carefully before any operation.
Check & Adjustment mainly describes the essentials of check and adjustment,
vehicle safety and the performance maintenance method of various components.
Check & Adjustment should be implemented from the time of periodic check.
The content after Chapter I mainly describe the assembly, disassembly and
check essentials of motor, complete vehicle and electric fittings.
Every Chapter is accompanied by an exploded view, system diagram, and failure
diagonosis and instructions during the editing.
Notice:
Actual product may differ from the photo or illustration on the manual. The style
or structure of the vehicle shall be subject to other changes without further notices.
KEEWAY Motorcycle Co., Ltd
- 3 -

Preparation Data
General Safety Maintenance Regulations
Specification Sheet Failure Diagonosis
General Safety
Carbon Monoxide (CO)
If the motor has to been started, make sure the working space is well ventilated, the motor can not be run in closed
space.
Caution
The exhaust gas contains toxic gas carbon monoxide (CO), which may render people unconscious or even cause
death.
The motor should be run in the open space, if in closed space, the gas scavenging system shall be used.
Gasoline
The vehicle shall be worked in a well ventilated place, no smoking or naked lights in working place or
gasolince-stored place.
Storage Battery
Storage battery may emit explosive gas, which should be far away from sparkles, naked fire and smoking areas.
The space shall be well ventilated when charging the battery.
Storage battery containes sulphuric acid (electrolyte). It will cause serious burns if it gets on the skin or eys.
Therefore, protective clothing and face mask should be worn in operation.
——Please flush with water immediately if the electrolyte gets on the skin.
——Immediately flush with large amounts of water for at least 15 minutes and seek medical attention
immediately if the electrolyte gets on the eyes.
The electrolyte is tocix. If swallow any of such electrolyte by mistake, immediately drink large amounts of water,
milk and milk of magnesia (a kind of laxative antacid) or vegetable oil and seek medical attention. Keep it out of
reach of children.
Users shall not disconnect the storage battery during the adjustment of complete vehicle, otherwise may cause
internal damage to the components of the whole vehicle.
- 4 -

Maintenance Regulations
During the maintence of the motorcycle, please use the metric instruments whenever possible, improper
instruments may cause damage to the motorcycle.
Before the maintainence operation of disconnecting or opening the protecting plate, please eliminate the pollution
outside the parts or assembly parts to prevent the pollution fall into the motor, bottom plate or brake system.
After disconnecting and before measuring the wear value, please

purge the components and blow through with the air compressor.
The rubber parts may deteriorate because of aging, which is

extremely damaged by solvents or oil. Therefore it should be
checked before reassembly and replaced when necessary.
When loosing the components which have many assembly parts,

the loosing sequence should be from exterior to interior, and the
samll assembly part should be loosed first.
The complex assembly part such as speed gear box shall be

stored in proper sequence for the easy assemble in the future.
Special attention should be paid to the important attachment

postions before disassembly. The non-used components should
be replaced in time before disassembly.
- 5 -

The length of bolt or screw is different in terms of assembly parts
and protective plate. It should be installed in the right position, if
confused, place the bolt into the hole to check whether it fits or
not.
When installing the oil seal, please fill the grease lubricant into
the oil seal groove, and check the oil seal is smooth or not,
otherwise it may damage the oil seal.
When installing the rubber hose (fuel oil, vacuum or coolant), the
end of the rubber hose shall be inserted into the connection
bottom, so that the hose clamp has enough space to grip the
connection. The rubber of plastic dust cover shall be put into the
original design position.
Disassembly of ball bearing: use the instrument to withstand one

or two (inside and outside) bearing race ring. If the strength is
only used on one race ring (no matter inside or outside), it may
cause damage to bearing when disassembling and the bearing has
to be replaced.
- 6 -

The loose cable is the potential electric safety hazard. After
clamping the cable, please check the following one to ensure
the electric safety;
The wire clip is not allowed to bend towards the welding spot
direction;
Please bind the cables at the specified position；
The cable can not be routed on the end or closed angle of the
frame;
The cable can not be routed on the end of bolt or screw;
The cable routing shall be kept away from a heat source or
the place which may clip the cable when moving;
Over tightening or over loosening shall be avoided when the
cable is routed along the cocket handle, and no contacting
with the adjacent components in any steering position;
The cable routing shall be smooth without twisting or
knotting;
Please confirm if there is any damage to the connector
assembly sheath or any excessive expansion of the connector
assembly before the butt joint of the onnector assembly;
If the cable is placed on the closed angle or corner, please use
tape or hose to protect;
Please use the tape to wrap the cable after repairing;

The control wire shall be free from twisting or knotting. Any
damage to the control wire may cause inadequate control;
- 7 -

Motorcycle Identification
1．The motorcycle indentification number is printed on the

frame ① , please see Figure 1-1. Indentification number:
LBB11B05?????????. The ninth number of the vehicle
indentification number is the chek code, the tenth one year code
and the eleventh one assembly factory code. The frame
nameplate is riveted on the left side ② of the frame.
Figure 1-1
2．The engine series number ① is printed on the outer shell
of crankcase, please see Figure 1-2.
Figure 1-2
Important Notices:
1．Please use the pure components manufactured by Qiangjiang. Use the components not complying with the
design specifications of Qiangjiang Company may cause damage to the engine.
2．Use only the metric instruments to do the maintainence operation. The metric bolt, nut and screw are not
interchangeable with the British fastener.
3．When reassembling, new washer, O ring, split pin and locking plate should be replaced.
4．When tightening bolt or nut, unless otherwise specified, bolt with larger diameter or near the inner side should
be tightened first, then along the diagonal line, gradually tighten the bolt to stated torque.
5．Wash the disassembled parts with cleaning solution. Lubricate all the sliding surfaces before assembling.
6．After assembling, please check all the components are assembled and operated in a proper way.
7. Eliminate the pollution and oil before measuring, and add the recommended lubricant onto the oil site when
assembling.
8. If the engine and drive system need to be stored for a long time after disassembling, please spread lubricant
onto the surface of the parts to prevent rusting and dust.
- 8 -

Special Tools
Special tools are the specially designed tools used for special positions in order to assemble or disassemble
certain parts of the motorcycle. Proper special tools are essential in terms of the complete and proper adjustment
and assembling. The special tools can assemble and disassemble parts safely, dependably and quickly, which can
improve working efficiency by saving labor and energy.
1 Tools used for the overhaul of engine
When assembling and disassembling the engine, specially designed tools are needed to properly assemble and
disassemble some parts.
The special tools list to assemble and disassemble the engine parts and the corresponding physical figure,
please see Table 1-1 and 1-2.
Table 1-1
Name Note
special socket wrench Used for assembling and disassembling Flywheel Bolt, Figure 1-3
clutch clamper Figure 1-4
flywheel extractor Figure 1-5
proof stick Figure 1-6
bearing disassembling tool Figure 1-7
bearing assembling tool Figure 1-8
oil seal assembler/disassembler Figure 1-9
dismantling tool handle Figure 1-10
piston pin pulling off device Figure 1-11
piston ring opening pliers Figure 1-12
spark plug socket wrench Figure 1-13
measuring the thickness of clutch Figure 1-14
cylinder diameter determinator Figure 1-15
dial gauge Measuring the inside diameter of piston pin hole，Figure 1-16
Continuation Table 1-2
Figure 1-3 Figure 1-4
- 9 -


① Handle
- 10 -

①Opening pliers ②Piston

2．Tools used for the overhaul of chassis
The special tools list to assemble and disassemble the chassis parts and the corresponding physical figure,
please see Table 1-11 and 1-18.
Table 1-17
Name Note
torque wrench Figure 1-19
inner hexagonal wrench Figure 1-20
socket wrench Figure 1-21
micrometer Figure 1-22
magnetic frame, V-block Figure 1-23
dial gauge Figure 1-24
vernier caliper Figure 1-25
spring retaining ring pliers Figure 1-26
knocker screwdriver Figure 1-27
front fork oil seal assembling tool Figure 1-28
front fork seal driver Figure 1-29
steering nut wrench Figure 1-30
（1）Universal tool for the overhaul of chassis
- 11 -


（2）Special tool for the overhaul of chassis: front fork seal driver.
- 12 -

Figure 1-29
（3）steering nut wrench.
Figure 1-30
3．Tools used for electrical parts
The special tools list to test the electrical parts and the corresponding physical figure, please see Table 1-31
and 1-32.
Table 1-31
Name Note
avometer Figure 1-33
ignition tester Figure 1-34
Figure 1-33
Figure 1-34
- 13 -

Specification Table (QJ50T-21T)
Model QJ50T-21T Type of engine QJ1E40QMB-4
lead-free gasoline
Full length mm 1860 Type of fuel （93/95）
Full width mm 680 Number of 1
cylinders
Full height mm 1198 Inside 49.2×39.2
diameter*stroke
Wheelbase mm 1290 Total 49.3cc
displacement
front axle 40 Initiate mode Electric/foot initiate
Weight of vehicle
Engine
kg Rear axle 59 Cooling system Wind cooling
（Curb weight）
Total 99
Front Lubrication type Separating lubrication
120/70-12
wheel tyre
Front
wheel rim 3.50×12
Wheel Air cleaner 3XG
specification Rear 130/70-12
wheel tyre
Rear
wheel rim 3.50×12
Fuel tank
capacity 5.6L
Type of
Driving mechanism
clutch Dry centrifugal type

Carburetor model PZ19JB
Variable
speed infinite variable speed
mechanism
Idling speed -rpm 1800±100rpm/min
Driving type belt transmission
Performance
Storage Maximum torque 4.0N.m/6500rpm

battery
12V-3AH/dry-charged
capacity
/Type Maximum
2.7kW/6500 rpm
Magneto horsepower
89.6W/5000rpm
capacity Compression 6.9：1
ratio
Electrical installation
Spark plug BR8HSA

Maximum speed 45km/h
Spark plug 0.6-0.7mm
gap Front brake disc
apparatus
φ190mm
Diameter（mm）
Brake
Ignition type CDI Rear brake drum

inside diameter φ175mm
（mm）
- 14 -

QJ50T-21T
- 15 -

Failure Diagnosis
Failure diagnosis procedure when the engine fails to start or start difficultly
Engine fails to start or start difficultly
Check the ignition system
Remove the spark plug, check the electrodes of spark plug are carbon connected
No Yes
Do the spark plug spark over test To clean out carbon
Faint or no spark between electrodes Strong blue or bluish violet spark from the electrodes
Screw off the spark plug cap, do high-voltage wire spark over test Use ignition timing light to test whether engine ignition is timing
No Yes
Strong blue spark Faint or no spark 1. Check if the CDI ignition Loosen carburetor fuel
apparatus fails draining screw, check if
2. Check if the magneto there is fuel draining
Check if the spark plug, spark plug cap fails flywheel and trigger from the carburetor
winding loosen overflow pipe
Yes No
Check the Check if Check if there Check if the
supply of there is short is short circuit
circuit or or broken CDI ignition Use the cylinder
ignition broken circuit of the pressure gauge to test
apparatus Check if there
power circuit of internal system the cylinder is fuel in the
ignition coil of ignition fails compression pressure
system fuel tank
No contact magneto ignition system
1. Check if there is short Cylinder Cylinder Y No

circuit or broken circuit of compression compression trigg
ignition power winding pressure pressure er
To
2. Check if there is short normal insufficient windi
fill
circuit or broken circuit of ng es
the
trigger winding
fuel
- 16 -

1. Check if there is gas leaking 1. Check if the venthole of
in external connections of the fuel tank cover blocks
engine 2. Check if the fuel filter and
2. Check if the piston ring sticks fuel cock block
in ring groove or insufficient 3. Check if the fuel cock
elasticity works well
3. Check the wearability of 4. Check if the carburetor inlet
piston ring and cylinder port blocks
Remove the
spark plug to 5. Check if the carburetor
test floater is too high
Spark plug electrode is moist Spark plug electrode is dry
Check if there is oil leaking from Instill small amount of fuel into the cylinder to
carburetor have an experimental starting
Yes No
1. Check if there is gap Check if the air

between the carburetor float cleaner blocks
needle valve and valve seat Work continuously after
because of other materials The engine stops after starting
2. Check if the conical running a very short time
surface of the carburetor
float needle valve is worn
Carburetor starting
into step shape
The carburetor inside device (starting richer
3. Check if the carburetor
blocks or the float is system) fails
float breaks
too high
4. Check if the carburetor
float is too low
- 17 -

The engine overheat failure diagonosis procedure
Engine overheat
Check if the operation method is proper
Yes No
1. Check if the fuel No. is too low Check the cooling system
or the fuel is out of date
2. Check if the engine runs at high
Air cooled engine
speed or overload for a long time
Check if the cooling fins are stained with silt or too much oil
Yes No
Wash
Check if the cooling fans and

wind scoop break (compulsive
air cooled engine)
Yes No
Check and Use ignition timing light to test

eliminate whether engine ignition is timing
No Yes
1. Check if the CDI Check if the clutch slips

ignition apparatus
fails
2. Check if the Yes No
magneto flywheel
and trigger winding
loosen Clutch slips
To treat the clutch

slip failure
accordingly
- 18 -

Remove the spark plug, watch the color of spark
plug insulator cluster and determine the mixture ratio
of the combustible gas mixture in accordance with
the different abnormal appearances
Spark plug insulator cluster is white, the

spark plug insulator cluster is brown Spark plug insulator cluster is
exhaust muffler smokes or blast when the
white, the engine is intermittent
engine is running at medium and low speed, the
when accelerating, carburetor
accelerating ability is bad, idle speed is unstable the mixture ratio of the
backfires and the engine power is
and tends to stop easily, relatively normal when combustible gas mixture is proper
insufficient etc
running at high speed.
combustible gas mixture is too strong Check if the vent of Check lubricating combustible gas mixture is
cylinder and exhaust system too weak
muffler block because
1. Check if the air cleaner blocks
of too much carbon
2. Check if the carburetor starting 1. Check if the fuel
cock works well
device (starting richer system) Two-stroke engine
2. Check if the
works well lubricating system carburetor float is too
3. Check if the carburetor float is high
too low 3. Check if the orifices
and pore canals on the
1. Check if the fuel in the
carburetor block
crankcase is insufficient
2. Check if the viscosity of fuel
in the crankcase is too low or the
fuel is too dirty
3. Check if the fuel filter blocks
4. Check if the fuel pump works
well
5. Check if the lubricating oil
path blocks
- 19 -

Underpowered engine failure diagnosis procedure
Engine underpowered
Prop up the main jiffy stand to make the wheels lift-off, revolve wheel by hand
Wheel spins smoothly Wheel spins stiffly
Check the tyre pressure 1. Check if the brake drags

2. Check if the wheel bearing is
overused or damaged
3. Check if the loading of hub’s
Air pressure too low Air pressure normal
central spacer is neglected or
shorter
Check if the tire valve core Remove the spark plug and block the spark
plug threaded hole with hand, then press the
leaks and if the tire breaks
starting button or step on the starting bar
quickly
Fingers can feel a strong gas blowing Fingers can not feel a strong gas blowing outside
outside, with the sound of pow at the
same time
Cylinder compression pressure insufficient

Cylinder compression pressure normal
1. Check if there is gas

Start the engine and step on the gas leaking in external
slowly to watch the change of connections of the engine
engine’s rotating speed 2. Check if the piston ring
sticks in ring groove or
insufficient elasticity
3. Check the wearability of
The rotating speed of the engine accelerates The rotating speed of the engine does piston ring and cylinder
as the driver step on the gas not accelerate as the driver step on the
gas
1. Check if the clutch skids Use ignition timing light to test

2. Check if the transmission belt is over worn
3. Check if the centrifugal roller of the whether engine ignition is timing
driving pulley is over worn
4. Check if the conical surfaces of driving Yes No
wheel and moving friction wheel are over
worn or worn into groove
5. Check if the conical surfaces of following 1. Check if the supply of fuel feeding 1. Check if the CDI
pulley and moving following pulley are system is smooth ignition apparatus fails
over worn or worn into groove 2. Check if the carburetor, air cleaner and
6. Check if the roller track on the internal exhaust muffler block 2. Check if the
side of moving friction wheel are over worn 3. Check if the vacuum diaphragm of magneto flywheel and
or extruded into a drop pit carburetor plunger valve cracks or
breaks trigger winding loosen
4. Check if carburetor float height is
improper
- 20 -

Failure diagonosis procedure of unstable engine idle speed
Bad idle speed of engine
Engine has no idle speed Engine’s idle speed too high Engine’s idle speed unstable
Check the cylinder compression pressure Pull the air throttle of carburetor by Use ignition timing light to test
hand and check if it is closed
completely whether engine ignition is timing
Yes No Yes No
cylinder compression
pressure insufficient cylinder compression
pressure normal Check if the
Check if Check if 1. Check if the CDI
the idling wire rope of the gap ignition apparatus fails
between
1. Check if there is gas Readjust the idle speed jet is too accelerator spark plug 2. Check if the magneto
leaking in external of carburetor large control cable is electrodes flywheel and trigger
is too
connections of the engine flexible in small winding loosen
2. Check if the piston cable cover and
ring sticks in ring groove Engine has idle Engine still has if the air
speed after no idle speed
or insufficient elasticity adjustment throttle spring
after adjustment
3. Check the wearability is too weak
Yes No
of piston ring and
cylinder The carburetor air Check if the idling jet of
adjusting screw carburetor, idling oil Adjust the gap of Check the mixture
or air throttle channel and air flue electrodes ratio of the
adjusting screw is block combustible gas
adjusted
improperly mixture
No Yes
Check if carburetor float is too high Wash and clear out
Yes No
Adjust the carburetor 1. Check if there is crackle in the carburetor

float height to standard insulator
value 2. Check if the retaining nut of carburetor
loosens
3. Check if the negative pressure pipe of fuel
cock breaks
4. Check if the leaf valve leaks
- 21 -

Failure diagnosis procedure of engine’s excessive fuel consumption
Excessive fuel consumption of engine
Check if the operation method is right
Yes No
Prop up the main jiffy stand and revolve wheel by hand 1. Check if the motorcycle is run
overloaded, or run not at
economical speed or run at low
gear
2. Check if the gasoline number is
Wheels revolve difficultly Wheels revolve smoothly right
1. Check if the brake Check the tire pressure

drags
2. Check if the wheel
bearing is overused
Tire pressure is too low Tire pressure is normal
3. Check if the loading
of hub’s central spacer
Check there is fuel leaking in
is neglected or shorter To charge as required the fuel tank, fuel cock, fuel
pipe and carburetor
Yes No
To exclude in accordance with the actual situation Check the mixture ratio of the
combustible gas mixture
The mixture ratio of the combustible Combustible gas mixture is too strong Combustible gas mixture is too weak
gas mixture is normal
Check if the engine idle speed is too high 1. Check if the air cleaner 1. Check if the inside of
blocks carburetor blocks
Yes No 2. Check if the carburetor 2. Check if the carburetor
float is too low float is too high
Check and adjust the Use ignition timing 3. Check if the main jet of
light to test whether
carburetor engine ignition is carburetor is too large
timing
Yes No
Check if the transmission Check ignition system

belt of clutch slips
- 22 -

Failure diagnosis procedure when the exhaust muffler of two-stroke engine gives off strong blue and white
smoke
The exhaust muffler of two-stroke engine gives off
strong blue and white smoke
Check if the engine oil level in the crankcase exceeds the upper label
Yes No
If the engine oil in the crankcase is Start the engine and make it run at high
overfilled, please drain out the excess speed, remove the engine oil scale to check if
oil and make sure the oil level does the engine oil filling port smokes
not exceed the upper label
1. Check if the cylinder, piston and piston

ring are over-worn
2. Check if the elasticity of piston ring is
insufficient or sticks in ring groove
3. Check if the opening positions of piston
ring are staggered
Failure diagnosis procedure when the gear shift is difficult to shift
The gear shift is difficult to shift
Start the engine and check if the idle speed of the engine is too high
Yes No
Readjust Check if the gear-shifting operation is coordinating
Yes No
Check if the clutch is separated completely Improve the operation method
No Yes
Check if the gear-shifting axis is deformed, and if the

gear-shifting arm is deformed or over-worn 1. Check if the free stroke of clutch
lever is within 10mm ~ 20mm
Yes No 2. Check if the spring force of clutch
is even
3. Check if the driving and driven hub
Replace 1. Check if the gear-shifting camshaft and
alveolus are worn to indention
cam groove are over-worn or damaged
4. Check if the clutch driven plate is
2. Check if the shift fork hole is over-worn
deformed
3. Check if the shift fork is deformed
5. Check if the parts of clutch control
4. Check if the declutch shift shaft is
mechanism are over-worn
deformed or over-worn
- 23 -

Failure diagnosis procedure when there is trip dog of the gear shift
Trip dog of the gear shift
Check if the positioned wheel spring breaks or the spring force is insufficient
Yes No
Replace Disassemble the crankcase, check if the gear wheel engaging depths of
various gears are up to requirement
Engaging depth of gear wheel is enough Engaging depth of gear wheel is insufficient
Check if the cam claw engaging end of the meshing gear end Check if the shift fork is
face is worn to conical or round shape, and if the over-worn or deformed
corresponding gear face groove is worn to pipe socket
No Yes
Yes No
1. Check if the shift fork hole and declutch Replace the shift
Check if the spline teeth of shift shaft are over-worn fork
Replace the gear
main shaft and counter shaft 2. Check if the fitting clearance between
wheel the shift fork pin and the gear-shifting gear
and the spline groove of
sliding gear are over-worn shaft and the cam groove are too large
Failure diagnosis procedure损when the clutch slips 3. Check if the installment of gear shift is
correct
Clutch slips
Automatic centrifugal dry block clutch slips
Check if the block friction dis of the clutch is stained with oil
No Yes
Check if the block friction Eliminate the oil

dis of the clutch is
over-worn
No Yes
Check if the contact area Replace the whole clutch block set
between the clutch block
friction dis and clutch
friction plate is less than No Yes
70％
Check if the contact area Repair or replace
between the clutch friction
clutch block
plate and block friction dis are
over-worn
- 24 -

Failure diagnosis procedure when the hydraulic disc brake fails
hydraulic disc brake fails
Check the brake fluid level in the brake primary pump liquid reserve tank
The brake fluid level below the lower limit of liquid The brake fluid level above the lower limit of
reserve tank liquid reserve tank
Fill the brake fluid to the Check if there is ―sponge‖

upper limit of liquid reserve feels when operating the
tank, at the same time brake lever
check if there is oil leaking
in the brake caliper, brake No Yes
hose and hose joints N
Check if the brake friction disc is There is residual air
worn to limit mark and if the brake in the fuel line of
plate is over-worn brake system
Yes No
1. Check if the surface of brake primary pump piston and oil

Replace the brake cylinder is over-worn
friction disc and 2. Check if the leather cup of brake primary pump piston cracks or
the brake plate is damaged or ageing
3. Check if the seal ring of brake caliper cracks or is damaged or
ageing
4. Check if the surface of brake caliper and oil cylinder is
over-worn
Failure diagnosis procedure when the drum brake fails

Drum brake fails
Check if the free stroke of brake lever is within 10mm

~ 20mm or check if the free stroke of brake pedal is
within 20mm ~ 30mm
No Yes
Readjust Separate the steel ropes of brake rocker arm and brake control cable, then
pull the brake rocker arm by hand to check
Brake rocker arm

revolves smoothly, but Brake rocker The arrow on the indicating The arrow on the indicating plate
you feel resistance plate of brake cam aligns with of brake cam does not align with
arm revolves
when holding the or exceeds the ―▽‖mark on the ―▽‖mark on the brake wheel
difficultly the brake wheel hub cap hub cap
brake handle
1. Check if the surface of brake
1. Check if the crown face of the brake block friction disc is stained with
The wire ropes of The movable cam is over-worn
brake control parts of the oil
2. Check if the brake block friction disc 2. Check if the contact area
cable can not be brake cam are is over-worn
pulled smoothly rusted or stuck between the brake block friction
3. Check if the brake wheel hub inside is dis and brake hub is less than 70％
in the cover in foreign over-worn
materials - 25 -

Failure diagnosis procedure when the storage battery can not be charged
The storage battery can not be charged
Disconnect the insert connector of magnetor wire

bundle and the complete vehicle cable, use the
ohmmeter to measure the resistance between the
output wire ends of charge oil, and check if it
meets the standard value
The resistance value is smaller than The resistance value is equal to

standard value standard value The resistance value is infinite
Connect the insert connector between the magnetor

Short circuit of wire bundle and the complete vehicle cable, disconnect Short circuit of charge
charge coil the insert connector between the commutator or
commutation regulator and the complete vehicle cable coil or its output wire
Use the ohmmeter to measure that if the resistance

between the output wire ends of charge oil in the insert
connector is equal to the resistance of the charge coil
itself
Yes No
Place the multimeter in the 0V~20V DC The circuit from the magnetor to
voltage, measure the voltage of the insert commutator or commutation
connector to the conductor terminal of storage regulator is in poor contact or
battery (generally red wire or red/white wire) broken
and negative pole
No voltage indicates Voltage indicates
Circuit from the Use the ohmmeter to test the

insert connector commutator or test if the
to storage battery commutation regulator fails
is broken
- 26 -

Failure diagnosis procedure when the storage battery is undercharged
Storage battery is undercharged
Check if the brake lamp is on
Yes No
Adjust or replace the brake Put the ignition switch in ―OFF‖ position, remove the negative pole wire from the
lamp switch storage battery, connect the ammeter negative pen to the negative ternminal of storage
battery and positive pen to the negative pole wire to check the leakage current
Leakage current is greater than the

Leakage current is less than the specified value specified value (it is generally required
that the leadkage current is no greater
Check if the charging coil of magnetor is than 1mA)
shortcircuited
The wire from the commutator
Yes No or the commutation regulator or
the storage battery to the ignition
Replace the 1. Check if the electrolyte in the storage battery switch is shortcircuited
charging coil is insufficient
2. Check if electrolyte concentration in the
storage battery is too low
3. Check if the polar plate in the storage battery
is sulfurized or shortcircuited
- 27 -

Failure diagnosis procedure when the start motor is unable to rotate
Start motor is unable to rotate
Turn on the ignition switch, press the horn button or toggle the turn signal switch
The electric horn does not sound The sound of the electric horn is
or the sound is weak, and the loud and the light of turn signal is
light of turn signal is pale bright
The electricity in the storage

battery is insufficient or the wire Hold the brake handle (seat-type motorcycle)
terminal connecting the storage tightly, or put the gear shift in neutral gear or hold
battery is in poor contact clutch handle tightly, press the start button
Press the start button, you can not hear the connection sound of Press the start button, you can hear the
the start relay connection sound of the start relay
Remove the insert connector of the start relay from the

complete vehicle cable, then use two wires to connect the Use the screwdriver or heavy gage wire
positive terminal and negative terminal of the storage battery to short-circuit the storage battery
and the two leading wires of start relay coil terminal on the start relay with the start
motor terminal
The start motor can not The start relay can The start motor can The start motor does
rotate after connecting, and rotate normally after rotate normally after not rotate after
the connection sound of connecting shorting shorting
start relay can not be heard
either
The start relay
Check if the line of electric start contact is burnt or Disassemble the start motor and do
The start relay coil control system damaged the following inspections:
is broken or 1. Check if the carbon brush is
Riding motorcycle Seat-type Motorcycle over-worn
short-circuited
2. Check if the carbon brush spring
Hold the brake handle tightly and check if the brake lamp
breaks or the spring force is
will light up
insufficient
1. Check if the starting
Yes No 3. Check if the surface of armature
button contact is in poor
commutator is over-worn
contact
4. Check if the armature coil is
2. Check if the Check if the starting The inside contact of brake broken or short-circuited
commutating diode is button contact is in lamp switch is in poor
damaged poor contact contact or its wires are
3. Check if the neutral gear broken
switch works well Yes No
4. Check if the line of
electric start control system
is broken or short-circuited Repair or replace Check if the line of electric
the starting button start control system is
broken or short-circuited
- 28 -

Failure diagnosis procedure when the start motor is weak in rotating
Start motor is weak in rotating
Turn on the ignition switch, press the horn button or toggle the turn signal switch
The electric horn does not sound The sound of the electric horn is
or the sound is weak, and the loud and the light of turn signal
light of turn signal is pale is bright
The electricity in the storage Check if the wire terminal between

battery is insufficient or the wire the relay and the start motor is in
terminal connecting the storage poor contact
battery is in poor contact
No Yes
Remove the start motor connecting wire and storage battery Check and exclude
connecting wire from the start relay, press the start button,
when the start relay makes the connection sound, use the
ohmmeter to measure the resistance between the storage
battery wiring terminalon the start relay and the start motor
wiring terminal, and check if the resistance is smooth
Yes No
Disassemble the start motor and do the The start relay contact is
following inspections:
burnt or damaged
1. Check if the carbon brush is over-worn
2. Check if the carbon brush spring breaks or
the spring force is insufficient
3. Check if the surface of armature commutator
is stained with dirt or is burnt or damaged
4. Check if the armature commutator is
over-worn
- 29 -

Failure diagnosis procedure when all the lamps don’t work
All the lamps don’t work
AC power supply illuminating system DC power supply illuminating system
Press the horn button or

Disconnect the insert connector between the magnetor
wire bundle and the complete vehicle cable, use the toggle the steering lamp
lamp-testing method to check if there is electrical energy switch
output from the output wire of magnetor lighting coil
The electric horn The electric horn does not

sounds loudly and the sound and the steering lamp
Testing lamp does not work Testing lamp works steering lamp works does not work
Start the engine, disconnect

The magnetor lighting the insert connector between The power supply of Use a wire to touch the
coil or its output wire is the commutation regulator and storage battery is positive terminal and
the complete vehicle cable negative terminal of the
broken or short-circuited normal
storage battery quickly, and
check if there is sparkle
The lamp still does not

The lamp works work No sparkle when Sparkle appears
touching when touching
The inside of
commutation regulator is No electricity
short-circuited in the storage 1. Check if the fuse is
Disconnect the head lamp battery burnt out
assembly, and check if the bulb 2. Check if the wires
of head lamp is burnt from the storage
battery to ignition
Yes No switch are broken or
short-circuited
3. Check if the ignition
Replace the bulb of head lamp, and Use the lamp-testing method to check if switch is broken or
check if the bulbs of other lamps there is electrical energy output from the short-circuited
are burnt one by one power input wire of lighting switch
Yes No
Use a wire to short circuit the power lead The wires between the
of lighting switch and the output lead magnetor or ignition switch to
the lighting switch are broken
or short-circuited
The lamp will work after shortcircuiting The lamp still doesn’t work after shortcircuiting
The internal contact of The wires between the

lighting switch is in poor lighting switch to lamps are
contact broken or short-circuited
- 30 -

Failure diagnosis procedure when the bulb of lamp is easily burnt out
The bulb of lamp is easily burnt out
Turn on the ignition switch, press the horn button or toggle the turn signal
switch
The sound of the electric horn is

The electric horn does not sound or loud and the light of turn signal
sound raucously, and the light of is bright
turn signal is pale
Remove the insert connector between the

1. Check if the terminal connecting the commutation regulator and the complete vehicle
storage battery is on poor contact cable, and use the ohmmeter to measure that if the
2. Check if the electrolyte in the storage wires from magnetor lighting charge coil to
battery is insufficient commutation regulator are broken
3. Check if electrolyte concentration in No Yes
the storage battery is too low
4. Check if the polar plate in the storage
battery is sulfurized or short-circuited Place the multimeter in the 0V~20V DC Connect
voltage, measure the voltage of the insert
connector to the conductor terminal of
storage battery (generally red wire or
red/white wire) and negative pole
No voltage indicates Voltage indicates
The leads from the insert connector to the Check if the commutation regulator fails
storage battery are broken
- 31 -

Failure diagnosis procedure when the light of lamp is weak
The light of lamp is weak
AC power supply illuminating system DC power supply illuminating system
Disconnect the insert connector between Turn on the ignition switch, press the horn button or toggle the
the magnetor wire bundle and the turn signal
complete vehicle cable, use the ohmmeter
measure that if the resistance between the
output conductor terminals of magnetor
lighting coils is less than standard value
The electric horn sounds raucously,
Yes No and the light of turn signal is pale
Start the engine and limit its

The lighting coils The sound of the
are short-circuited rotation speed, disconnect the The electricity supply in storage
insert connector between the electric horn is battery is insufficient or the
commutation regulator and the loud and the light connection between the storage
complete vehicle cable to check of turn signal is battery to ignition switch is in
bright bad contact
the brightness of lamps
The lamp lights return to The lamp light is still weak

normal after disconnecting after disconnecting
Check if wires in the

The stabilized voltage of magnetor charging coils and
commutation regulator is charging system are
too low short-circuited
Yes No
Check and exclude Disconnect the head lamp assembly,

and check if the bulb glass of head
lamp is black or yellowish-green
No Yes
Check if the bulb power used in Replace the bulb of

the illuminating system meets head lamp
the specified requirements
Yes No
1. Check if the internal contacts of Replace the bulb of lamp

lighting switch and dimmer switch
are in bad contact
2. Check if the insert connector in
the system and earth wire are in
bad contact
- 32 -

Failure diagnosis procedure when the steering lamp does not work
The steering lamp does not work
Some steering lamps on one

side do not work Steering lamps on one side do not work All the steering lamps do not work
Remove the steering lamp Remove the steering lamp Press the horn button to check the
cover and check if the bulb of cover and check if the bulb of working condition of electric horn
steering lamp is burnt out steering lamp is burnt out
Yes No Yes No
Use the voltmeter Disconnect the The electric horn The electric horn
Replace to measure the Replace steering lamp switch does not sound or
the bulb the bulb sounds loudly
voltage between insert connector, use sounds raucously
of the lamp stand of steering
steering lamp the ohmmeter to test
power line
lamp if the failure side of The electricity The electricity supply
contact and
negative pole steering lamp switch supply in storage in storage battery is
has been solved battery is insufficient
Yes No insufficient
Voltage No voltage Remove the steering lamp cover
The internal and check if the bulb of steering
indicates indicates The output contact of lamp is burnt out
power line steering lamp is
on the in bad contact No Yes
The lamp stand is The power failure side
grounded line of is broken or
improperly or the lamp Toggle the steering lamp switch, Replace the steering
the lamp
connection stand is use one lead or screwdriver to
stand is lamp bulb, at the
between steering broken short-circuit the two lugs of
lamp bulb and grounded same time check if
improperly scintillator the commutation
lamp stand is in
bad contact regulator works well
The steering lamp still does not work after

The steering lamp will
short-circuiting work after short-circuiting
Disconnect the insert connector of steering lamp switch, use

a lead to short-circuit the power input lead of the steering The scintillator
lamp switch with the power leads connecting to left and is damaged
right steering lamps respectively
The steering lamp will The steering lamp still does not work after
work after short-circuiting
short-circuiting
The internal contact of Use lamp-testing method to check if there is power output
steering lamp switch is in from the power input lead of the steering lamp switch
bad contact
Testing lamp works Testing lamp does not work
The line from ignition switch to

The power lead of the steering scintillator or the line from
lamp is broken or short-circuited scintillator to steering lamp switch
is broken or short-circuited
- 33 -

Failure diagnosis procedure when the electric horn does not work
The electric horn does not work
Turn on the ignition switch, and

toggle the steering lamp to check
the work of steering lamp
The steering lamp does not work or the The light of the steering lamp is bright
light is pale
The electricity supply of storage battery is The electricity supply of

insufficient or the wire from the storage storage battery is normal
battery to the ignition switch is broken or
short-circuited Remove the power lead from the power terminal of
electric horn, and touch the power lead with ground
earth quickly to check the sparkle
Sparkle appears when touching No sparkle when touching
Connect the power lead of the electric horn, use the

The power lead from the
screwdriver to contact the non-power terminal of electric ignition switch to the
horn (to the terminal of button) with the ground earth electric horn is broken
The electric horn sounds after The electric horn does not
contacting sound after contacting
The internal contact of horn Adjust the volume and tone of the electric horn
button is in bad contact or the
lead from the electric horn to the
button is broken
The electric horn still does not The sound of the electric horn returns
sound after adjustment to normal after adjustment
The electric horn is The electric horn is

damaged adjusted improperly
- 34 -

Failure diagnosis procedure when the brake lamp does not work
The brake lamp does not work
The brake lamp does not work
Remove the brake lamp cover and check if the circuit

board of brake lamp is burnt out
Yes No
Use a lead to short circuit the two terminals or two leading

Replace the circuit board of wires of the brake lamp switch
brake lamp
The brake lamp still does not work after short-circuiting The brake lamp will work after short-circuiting
Use the screwdriver or heavy gage wire to touch the The brake lamp switch is
power supply lead of brake lamp switch and the ground adjusted improperly or its
internal contact is in bad
earth quickly, and check if there is sparkle
contact
Sparkle appears when touching No sparkle when touching
The lead between the brake lamp switch and the The lead between the ignition switch and the brake
brake lamp is broken or short-circuited lamp switch is broken or short-circuited
Failure diagnosis procedure when the storage battery is undercharged
Storage battery is undercharged
Check if the brake lamp is on
Yes No
Put the ignition switch in ―OFF‖ position, remove the negative pole wire from
Adjust or replace the the storage battery, connect the ammeter negative pen to the negative
brake lamp switch ternminal of storage battery and positive pen to the negative pole wire to
check the leakage current
Leakage current is greater than the

Leakage current is less than the specified value specified value (it is generally required
that the leadkage current is no greater
than 1mA)
Check if the charging coil of magnetor is short-circuited
The wire from the commutator
Yes No or the commutation regulator or
the storage battery to the ignition
1. Check if the electrolyte in the storage
Replace the switch is short-circuited
battery is insufficient
charging coil 2. Check if electrolyte concentration in the
storage battery is too low
3. Check if the polar plate
- 35 - in the storage
battery is sulfurized or short-circuited

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
Battery Clutch
Carburetor Front/rear suspension system
Ignition timing Bolt/nut/fastener
Rim/tyre Tyre specification
Preparing principles
General
Warning 1
• Make sure that it is well ventilated before starting the engine. It is forbidden to start it in a closed area.
Exhaust gas, which contains monoxide, may cause unconsciousness or even death of human being.
• The petrol is liable to volatile or explode under certain condition. The working area or the oil storage area
shall be kept ventilated and fire is strictly forbidden.
Do not disconnect the battery during the adjustment of motorcycle, otherwise inner component of the
motorcycle may be damaged.
- 36 -

Specification
Engine
Idle speed 1800±100rpm/min

Clearance of spark plug 0.6-0.7mm
Spec. of spark plug BR7ES
Frame
Free stroke of front brake lever 10-20mm

Free stroke of rear brake lever 10-20mm
Specification Tyre pressure
Front outer
120/70-12
tyre 145-170kpa
Tyre pressure unit: Kpa
Front rim 3.50×12
QJ50T-21T
Rear outer
130/70-12
tyre 170-195kpa
Rear rim 3.50×12
Front wheel spindle 55-62 N·m
Torque
Fixing nut for rear 100-113 N·m
value
wheel
Certification for Related Parts
Type Name Certificate No. Remark

Front outer tyre E11 75R -000210
Tyre
Rear outer tyre E11 75R -000216
Headlamp E4 0014908
Tail lamp E4 50R-0014909
Lamps Front steering lamp E4 50R-001765
Rear steering lamp E4 50R-001765
Rear registration plate lamp E9 50R-001493
Rear-view mirror Rear-view mirror E3 001002 Complete black
Horn Horn E13 000612
Side reflector E11 020614 Amber
Reflector
Rear reflector E4 023272 Red
- 37 -

Periodic Maintenance & Inspection List
Mileage between Per Per Per Per
Per Per
services and time 300K 1000K 3000K 6000K
12000KM 14500KM Applicable tools
M M M M
Inspection item New 1M 3M 6M 12 M 15 M
* Air filter I C C R C Ordinary tools
* Petrol filter I I R Ordinary tools
* Oil filter C C C Ordinary tools
Replacement of engine
R Replacement every 1000KM Ordinary tools
oil
Tyre pressure
Tyre pressure I I I I I I
gauge, inflator
Densimeter,
Battery inspection I I I I I I
multimeter
Actuation gap inspection I I I I I I Ordinary tools
Inspection of steering
I I I Ordinary tools
handle fastening
Absorber working
I I I Ordinary tools
inspection
Screw fastening
I I I I I I Torque spanner
inspection
Oil leakage inspection
I I I I I I Ordinary tools
for gearbox
Inspection or
* replacement of spark I I R R I Ordinary tools
plug
Replacement of gearbox
* I Replacement every 5000KM Ordinary tools
oil
Lubrication of each part L L Lubricator
Muffler I I I I I I Ordinary tools
* Ignition timing I I I I I I Timing lamp
* Carburetor A I A A A A
Tachometer, CO
Exhaust gas inspection
* A I A A A A HC analyzer
at idle speed
* Accelerator inspection I I I I I Ordinary tools
Fuel pipeline inspection I I I I I Ordinary tools
Lighting/metering/electri
I I I I I I Visual multimeter
c devices
Main stand bracket I I I Ordinary tools
Absorber I I I I Ordinary tools
Torque force of engine
* I I I I I Torque spanner
bolt
- 38 -

Anticipated inspection
1 Ignition system—obviously continuous ignition abnormality, engine fire or overheating, which requires
inspection and maintenance.
2 Carbon fouling elimination—obviously insufficient horsepower, which requires carbon fouling removal from
cylinder cover, piston head and exhaust system.
3 Piston & cylinder—excessive abrasion; replace cylinder if it is blocked.
Please have your motorcycle inspected and adjusted periodically at KEEWAY distributors for being in best
condition.
The above table is established under the presupposition of 1000 km/month.
I—Inspection A—Adjustment R—Replacement C—Cleaning L—Lubrication
Note: 1. ―*‖ Regulations on exhaust emission made by the State Environmental Protection Agency shall be
complied with. Maintenance must be carried out in accordance with the instruction manual supplied by the
company. We are not responsible for any loss rising from private adjustment or maintenance.
2. Increase frequency of washing air filter if your motorcycle runs on the sandy/gravel road or under heavily
polluted environment so as to extend its service life.
3. Motorcycles which often run at high speed or with high mileage shall be maintained frequently.
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.
Add oil to the upper limit when alarm is made by sensor at the oil level.
Oil replacement
*Note
It will be easier to change the oil when the
engine is warming up.
Turn off the engine.

Remove the bolt at the bottom of the crankcase and release
oil.
- 39 -

When the oil leaks completely, you can install the bolt and packing washer after they are cleaned.
Add oil to proper level.
Check the oil leakage when the engine operates at its idling speed.
Check the oil capacity again.
Cable accelerator inspection/adjustment
Check whether the cable accelerator is smooth or not.

Check the free travel of accelerator
Free travel：5-10mm
The main adjustment part is the side of the carburetor,

Loosen the fixed nut，thenrotate and adust the adjusting nut.
Air filter
Filter replacement
Remove the body shield,
Remove the set bolt on the air filter,
Remove the upper cover of the air filter
Remove the filter element on the filter.
安装螺栓：bolts
Check weather the filter element is polluted or damaged.

And replace it with a new element if necessary
Remove the hoop compenent.
Remove the filter.
Check weather the filter is polluted or damaged.
And replace it with a new one if necessary.
- 40 -

Replacement time
Replace at an early time if the motorcycle is always running
on rainy days.
*Note
•Make sure the air filter cap is well installed before installing the filter
Spark plug
Remove the spark plug

Check the burning, pollution and carbon deposition situation
of the spark plug.
If there is the situation above, please clean with the spark
plug scavenger or steel brush.
火花塞间隙：spark gap
Examination of spark gap.
Gap：0.6-0.7mm
*Note
Fix the spark plug by hand, and then fasten it with a sprak plug sleeve.
- 41 -

Battery
Battery remova
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.
Install the battery following the opposite sequence.
Warning！
Do not disconnect the battery during the adjustment
of motorcycle, otherwise inner component of the motorcycle may be damaged.
Charging state（closed circuit voltage）
inspection
Open the cover of battery container. 。
First remove the negative wire and then
Take out the battery.
Measure the voltage between battery terminals.

Full charge：13.1V
Under charge：12.3V
* Note
Charge state examination must use a voltmeter operation.
Charge
Connection method：Connect the battery charger positive
pole and battery positive pole together.
Connect the battery charger negative pole
and battery negative pole together.
伏特表：voltmeter
- 42 -

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
• Except emergencies, you should not use emergency charge.
• Measure the voltage for every other 30 minutes.
Charging current：standard：0.4A
Emergency：4.0A
Charging time：standard：10-15h.
Emergency：30min.
Charging complete：closed circuit voltage: above12.8V
Carburetor
Idle speed adjustment

* Note
Idle adjustment was made in the implementation
of the engine warm-up state.
Implement after warm-up of the engine.

Connect the engine rotation meter after running the engine.
Adjust the screw of the cable accelerator to rotating velocity.
Idle speed：1800±100rpm/min
Adjust the idling adjusting screw when idle speed
is unstable or unsmooth after oiling lightly.
Ignition Timing
* Note
- 43 -

When the igniton is incorrect, please check the ignition
system.
Remove the bolt

Remove the guarding board
Use the ignition timing light to check and ensure the ignition
timing.
Cylinder pressure
Operate when the engine warm up.

Remove the cushion and body shield.
Remove the spark plug.
Install the cylinder pressure gauge.
At full throttle, measure the cylinder pressure by starting the
engine.
测气缸压力：cylinder pressure determination
The following items shall be check in case of a low pressure:

—Whether the gasket of cylinder cover is damaged;
—whether piston ring is damaged;
—whether the air inlet and piston ring is worn;
—whether the piston and cylinder is worn
When compression pressure is too high, please check the combustion chamber and carbon distribution at piston
head.
Gear oil
Inspection
* Note
Set the middle kickstand on a smooth surface, and keep the
motorcycle upright.
Remove the oil level gauge 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.
- 44 -

Install the oil level gauge.
* Note
Confirm whether the bolts wear or not.
Gear oil replacement
Remove the gear oil to check bolt

Remove the oil bolt, make the gear oil flow out
Fix the oil bolt.
* Note:
Confirm whether the bolts wear or not.
Supplement gear oil,

Check if there is leaking oil
Install gear oil to check bolt
Drive belt
Remove the cover of left crank case.

Check whether the drive belt is work or damaged.
Periodically maintenance shall be guaranteed, and replace the
drive belt with a new one if necessary.
驱动皮带：drive belt
Free path of front/rear brake
Free path of front brake

Measure the free path of front brake at the point of the brake
lever.
Free path: 10-20mm
- 45 -

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. In case the brake fluid level is at or
below the arrow in the picture, certain brake fluid shall be
added until it reach upper limit.
Note：
The oil pump component shall be paralleled with the ground
during the inspection.
Front light
Remove the front shield.

Disconnect the lead of front light.
Remove the front light
- 46 -

Clutch
Start the engine and increase its speed gradually to check the
working condition of the clutch.
If the motorcycle fails to go and the engine stops, you should
Check the clutch block. If necessary, change a new one.
Front/rear suspension system
Front
Pull the front brake tight and check the absorber.
Check whether the absorber has leakage or loose.
上下压缩：up / down compression
Rear
Check the rear absorber when operating.
Check whether part of the absorber is loose or wear.
Suspend the rear wheel and check it movingly.
Check whether the suspension bushing of the engine is
loose or not.
上下压缩：up / down compression
- 47 -

Nuts/bolts/fixed parts
Check whether nuts, bolts, fixed parts are loose or not.

If any, tightening them according to their torque force.
Rim/Tyre
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.
Regulated Pressure Unit：Kpa

Specification Tyre
pressure
Front
120/70-12
outer tyre 145-170
Front rim 3.50×12
QJ50T-21T
Rear
130/70-12
outer tyre 170-195
Rear rim 3.50×12
Tyre specification
Front outer
120/70-12
tyre
QJ50T-21T Front rim 3.50×12
Rear outer tyre 130/70-12
Rear rim 3.50×12
Check whether the front wheel axle is loose or not.

Check whether the rear wheel nut is loose or not.
- 48 -

In case there is any loosening, tightening them according to
the required torque force value.
Torque force value: Front wheel axle 55-62 N·m

Rear wheel nut 100-113 N·m
Steering column bearings and handle fix
Swing the handle in order to confirm there is no interference with wire.

Confirm the handle turn freely when the front wheel turns.
If the handle is loose or unsmooth, you should check the steering
column bearings.
- 49 -

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）
Clutch cover bolt of starting motors 12

Set screw nut of clutch cover of starting motors 95
Rectifier bolt 5.0
High tension coil fixing bolt 9.0
Flywheel Fixing bolt 5.0
Body Shield Bolt 9.0
- 50 -

Charging System
1 Battery 2 Horn 3 Power locking components 4 rectifier 5 Release resistance

6 Frequency conversion flash apparatus 7 Meters 8 Starting relay 9 igniter 10 Ignition coil assembly
- 51 -

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. Usually its performance decreases 2-3 years later. Battery with performance degradation, the
voltage will resume but sharply drops with load.
2. Battery overcharge：Generally we can judge its overcharge from its body. If the inside of the battery is
short-circuit, it is hard to detect the voltage between its terminals. Adjustment failure: the battery voltage is too
high; battery life span will be shortened.
3. If the battery has been place without using for a long time, it will be self-discharged and its capacity will drop.
Under this condition, it should be charged every 3 months.
4. Check the charging system following the sequence listed on the table.
5. Don’t remove the connector with current flowing through the electrical parts, otherwise the voltage will be too
high and these parts will be broken down. Switch off the main switch and operate.
6. Maintenance free battery (dry cell type) doesn’t have to be checked and added electrolyte and distilled water.
7. Check total electricity load.
8. Emergency charging can only be used in emergent situation.
9. Remove the battery from the motorcycle for emergency charging.
10. Add liquid battery cannot be used when changing the battery.
11. Use the voltage meter for measuring the voltage when charging.
12. Do not disconnect the battery during the adjustment of motorcycle, otherwise inner component of the
motorcycle may be damaged.
- 52 -

Preparing standards
Item Specifications
Capacity/Type 12V-4AH/dry cell
Voltage Full charge 13.1V
（20℃） Obligatory 12.3V(not working for 1h)
Battery
charge
Charging current standard：0.4A，rapid：4A
Charging time standard：10-15h，rapid：30min
capacity 90W/8000rpm
Magnetor Lighting coil impedance（20℃） Green/Red - Black 2.0-2.5Ω
Charging coil impedance(20℃) White – Black 1.5-2Ω
Type Single-phase semi-wave charge under short circuit
Voltage limit Lighting 14.0V±0.4V/5000rpm
Voltage
Limit 13.5V/5000rpm
adjuster
Charging 14.8V±0.4V/5000rpm
limit
Tightening torque force value Tool

Rectifier bolt 5.0 N·m Multiple fixing spanner
High tension coil fixing bolt 9.0 N·m Flywheel remover
Flywheel Fixing bolt 5.0 N·m Testing instrument
Body Shield Bolt 9.0 N·m Multimeter
1.2 Failure diagnosis
Power supply dead interrupted electric current

Battery overcharge Poor contact of the charging wire
Battery wire isn’t connected Poor contact of the charging system
Fuse blow Poor contact or short circuit of lighting system
Bad power switch
Low voltage Bad charging system

Bad battery charging Poor contact of the wire, short or open circuit
Poor contact Bad voltage current adjustor
Bad charging system Bad magnetor
- 53 -

1.3 Battery
1.3.1 Battery Removing

Remove the set screws of battery box cover.
Remove the cover of battery box.
First remove the negative wire and then
Take off the battery.
Warning！
When removing the positive terminal, the tools
should not be contacted with the bracket. It is
dangerous that spark caused by short circuit will
spark the petrol and break the battery.
Install the battery in an opposite order.
*Note
First positive terminal then negative terminal to prevent short circuit.
Do not disconnect the battery during the adjustment of motorcycle,
otherwise inner component of the motorcycle may be damaged.
Check the charging situation (open circuit voltage).

Open the battery cover, and remove the clamp component of battery.
Remove the lead of battery.
Measure the voltage of the terminals

Full charge：13.1V
Insufficient charge：12.3V （not working for 1h）
*Note
Use voltmeter when charging.
1.3.2 Charging
Connection Methods：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.
•Turn off the charger when starting charging or completing charging
•Take the marked current time as a standard when charging
*Note
•Except emergencies, you should not use emergency charge.
- 54 -

•Measure the voltage for every other 30 minutes.
Charging Current：Standard：0.4A
Emergency：4.0A
Charging Time： Standard：10-15h.
Emergency：30min.
Charging Completion：Open-circuit voltage：above 12.8V
1.4 Charging System
1.4.1Short Circuit Test

Remove the batter ground wire, and connect the
voltmeter between the negative terminal and ground wire.
Turn off the switch and check whether it is short circuit.
*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 Situation Inspection

Use the multimeter to checking the fully charged battery.
Mount the battery after the engine warming up.
Connect the voltmeter between terminals
Remove the fuse and connect the ammeter between its
terminals.
Start the engine slowly and measure the limiting voltage and
current.
Multimeter
Limiting voltage/rotating speed：14-15V （5.000rpm）
If the limiting voltage is not within the required range, check the voltage adjustor.
Check the limiting voltage of the lighting system.
*Note
Choose AC voltage of the multimeter.
Limiting voltage：13.1±0.5V/2500rpm
If the limiting voltage is not within the required range, check the current adjustor.
- 55 -

1.5 Rectifier
1.5.1Main Wiring Inspection

Remove the 4p plug of the rectifier.
Check the conducting state of the terminals

of the main wiring.
Item（wiring color） Judgments

Between Battery（red）and
With battery voltage
GND of the body
Between GND wire
（black）and GND of the With wiring
body
Between charging
There is resistance in
coil(white) and the GND
the magnetor coil
of the body
Between light wire
(green/red) and the GND
(plug of resistor, auto side There is resistance in
starter plug, inspect at OFF the magnetor coil
position after the removing
of lighting switch
1.5.2 Voltage and Current Adjustor Inspection

When the main wiring is completely normal, check the contact of the adjustor’s
plug, and measure the resistance value between the terminals of the adjustor.
*Note
• When checking the metal parts, your finger should not contact test bar of the multimeter.
•Different multimeter will show differently, so use the same multimeter while checking.
Replace the voltage adjustor when the resistance value between the terminals is abnormal.
1.6 Magnetor Charging Coil
*Note
Check the magnetor charging coil on the engine.
Inspection
Remove the 6p connector of the magnetor
- 56 -

Measure resistance value between the white coils of magnetor with multimeter.
Standard Value：1.5-2Ω（20℃）
Replace the magnetor coil when the measured value exceeds the standard value.
Bolt
1.7 Magnetor Lighting Coil
*Note
Check the magnetor lighting coil on the engine.
Cooling
1.7.1 Inspection Fan
Remove the 3p connector of the magnetor.
Measure resistance value between the green/red coils of
magnetor and the body GND with multimeter
Standard Value：2.0-2.5Ω（20℃） Bolt
Replace the magnetor coil when the measured value exceeds
the standard value.
1.7.2 Dismounting
Remove the body shield. Cooling
Fan
Remove the right body cover.
Remove the 2 fixing bolts and 2 screw, and remove the fan cover.
Remove the four fixing bolts of cooling fan, and

remove the cooling fan then.
Flywheel
Fix the flywheel using the universal spanner. Remover
Remove the fixing bolt of the flywheel.
Remove the flywheel using the flywheel remover.
Remove the solid key.
Remove the connector of the alternator wiring.
Remove the alternator stator.
- 57 -

1.7.3 Installation
Flywheel
Cooling Fan
Fan Cover
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.
*Note
Ensure there is no bolts inside of the flywheel.
Fix the flywheel with the universal spanner and tighten the fixing screw.
Torque Force Value：9.0 N·m
Install the left body fender.
- 58 -

Ignition System
Ignition System
1 Battery 2 Horn 3 Power Locking Components 4 Rectifier 5 Release Resistance 6 Frequency

Conversion Flash Apparatus 7 Meter 8 Starting Relay 9 Igniter 10 Ignition Coil Assembly
- 59 -

2. Ignition System
Material Preparation--------------2.1 CDI Group----------------2.4
Failure Diagnosis-----------------2.2 Ignition Coil--------------2.5
Ignition System Inspection----------2.3 Trigger------------------2.6
2.1 Material Preparation
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. Checking the ignition system following the sequence listed in the table of failure diagnosis.
4. CDI ignition system cannot subject to strong percussion (which is the main reason for failure), so you need to
pay great attention to that.
5. Check whether the connection is bad or not, because usually the reason for failure is poor contact socket.
6. The heat value of the spark plug should be appropriate. Improper spark plug will cause the engine running
unsmooth and even the spark plug will be burn-out.
7.Inspection in this chapter is based mainly on the maximum voltage，also inspection of the ignition coil
impedance is introduced.
8. Check the main switch according to the table.
9. Remove the alternator and stator according to the instructions.
Standards Preparation
Items Standard Value
Standard C5HSA(NGK)
Recommended
Hot C6HSA(NGK)
Spark Plug
Cold C7HSA(NGK)
Spark Gap 0.6-0.7mm
Ignition Coil Primary Coil 0.6Ω±10％
Impedance Secondary With plug cap 5-11KΩ
（20℃） Coil Without plug cap 0.5-5.5KΩ
Resistance of Trigger（20℃） 100-500Ω
Maximum Voltage Measurement of Ignition Coil 95-400V
Trigger Voltage Above 1.7V
Charging Coil Voltage 95-400V
Tools
Biggest Voltmeter Accessories
- 60 -

Multimeter
2.2 Failure Diagnosis
Spark plug fails to jump.
Error Reason（in compliance with the following order）

① The inner resistance is too small and it should be tested
by required tester.
② Low rotation speed of the bent axle.
Ignition
③ Tester is interfered. (It is normal that several measured
Coil Low Voltage
voltage is above the basic standard.).
④ Poor contact wire for the ignition system.
⑤ Bad ignition coil.
⑥ Bad charging coils (measure at maximum voltage).
① Wrong connection with the tester.
② Bad main switch.
③ Bad connector of the CDI group.
④ Poor contact of the CDI group or GND of the CDI
group is short-circuit.
Secondary No or interrupted high voltage electricity
⑤ Bad charging coil (measure at maximum voltage) .
Side
⑥ Bad trigger（measure at maximum voltage）.
Voltage
⑦ Bad high tension electricity connector.
⑧ Bad CDI group (when there is no spark for the plug or
①-⑦ is abnormal).
Normal high voltage electricity/no spark for the ① Bad plug or secondary ignition coil leakage.
plug ② Bad ignition coil.
① The inner resistance is too small and should be tested by
required tester.
② Low rotation speed of the bent axle.
No high voltage electricity
Charging ③ Tester is interfered. (It is normal that several measured
Coil voltage is above the basic standard.).
④ Bad charging coil（①-③ are normal）.
① Bad ignition coil.
No or interrupted high tension electricity ② Bad charging coil.
① The inner resistance is too small and should be tested by
required tester.
② Low rotation speed of the bent axle (It is normal that
Low high voltage electricity
several measured voltage is above the basic standard.)
Trigger
③ Tester is interfered.
④ Bad trigger（①-③ are normal）.
① Bad ignition coil.
No or interrupted high voltage electricity
② Bad trigger
- 61 -

2.3 Ignition System Inspection
万用表
Multimeter
*Note
• When there is no spark on the spark plug, check whether
there is loose wiring or poor contact of all components,
and make sure all voltage values are normal.
• There are various kinds of multimeters with different
internal impedances and different test values.
Connect a high-pressure shunt or an ammeter with

n input impedance above 10MΩ10CV to the multimeter.
2.3.1 Primary Voltage of Ignition Coil

If you replace the original spark plug with a better one,
make ground connection with the engine.
* Note Multimeter
万用表
Make sure the wire connection is

correct before testing.
Cylinder compression pressure
点火线圈
Ignition
normally refers to the test value when Coil
the spark plug is installed in the
cylinder head.
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.
Minimum Voltage：above 95V.
* Note
Never touch the metal of test prod when
measuring the voltage in case of electric shock.
2.3.2 Trigger
* Note
Install the spark plug in the cylinder head
and carry out the measuring when the
compression pressure is normal.
Remove the 4P and 2P joints of CDI group, connect
the high-voltage shunt between the 2P joint of charging
- 62 -

coil (black/red) and the 4P joint (black end). Start the
motor or step on the actuating lever to determine the
maximum voltage of charging coil.
Connection Method：black/red end to the positive
pole and black end to the negative pole.
Minimum Voltage：above 95V.
* Note
Never touch the metal of test prod when measuring the
voltage in case of electric shock. CDI group
Remove the adaptor of the alternator when the peak voltage

Black
Of the adaptor of CDI group is abnormal.
Connect the charging coil (black/red) with the shunt.
• If the obtained voltage of the end of CDI group is abnormal
while the one of the end of the alternator is normal, the Blue /White
problem should be poor contact or wire break.
• If both ends are abnormal, the charging coil may be broken,
please refer to the inspection method of charging coil.
2.3.3 Trigger
* Note
Install the spark plug in the cylinder head and carry out the
measuring when the compression pressure is normal.
Remove the 4p and 2P joints of CDI group, connect the

peak-voltage magnetor between the trigger with wiring 2p
end (blue / white end) and 4p end (black end). Press the
starting motor or step on the actuating lever to measuring the
peak voltage of the trigger.
白/绿 Ω
White/Green
Connection Method：Blue/white end to the positive pole and
black end to the negative pole.
Minimum Voltage：above 1.7V.
蓝/白
Blue /White
* Note
Never touch the metal of test prod when measuring
the voltage in case of electric shock.
Remove the adaptor of the alternator when the peak voltage

of the adaptor of CDI group is abnormal.
Connect the magnetor of and the trigger (blue/white).
- 63 -

• If the obtained voltage of the end of CDI group is abnormal
while the one of the nd of the alternator is normal, the problem
should be poor contact or wire break.
• If both ends are abnormal, the trigger may be broken, please
refer to the checking method in the failure diagnosis table.
2.4 CDI Group

Black
2.4.1 System Inspection

Black /White
System Inspection
Remove the CDI group, check the components connecting the
ignition system at the wiring end.
Green/White
Deep Green
Blue /White
Black / Red
2.4.2 Inspection
拆下 CDI 组，检查接头是否松动腐蚀。
Items Testing End Standard Value（20℃）

Main switch Red--red/white Breakover when the main switch is
―OFF‖
Trigger Blue/white – white/green 100-500Ω
Primary coil of the ignition coil Black/white--black 0.6Ω±10％
Secondary coil of the ignition Black--spark plug cap（without the 0.5-5.5KΩ
coil spark plug）
2.5 Ignition Coil
2.5.1 Dismounting Ignition Coil

点火线圈
Remove the body shield.
Remove the spark plug cap.
Remove the primary wire of the ignition coil.
Remove the fixed bolt of the ignition coil, remove the ignition coil.
Carry out the operations in the opposite order of dismounting
during installation.
* Note Ω
Use the black/white end of primary coil during installation.
- 64 -

2.5.2 Primary Coil Inspection
Impedance measuring between the ends of the primary coil.
Standard Value：0.6Ω±10％（20℃）
Impedance value within the range is good.
If the impedance value is "∞", there is wire break in the coil. Replace it with a new one.
2.5.3 Secondary Coil

With a spark plug attached. Measure the impedance value
between the wire side and the end of the spark plug cap.
Standard Value：5-11KΩ（20℃） Ignition Coil
点火线圈
If the impedance is "∞", there is wire break in the coil.
Remove the spark plug cap, measure the impedance
value between a side wire and the negative end.
Standard Value：0.5-5.5KΩ±10％（20℃）
Ω
2.6 Trigger
White/Green
白/绿 Ω
* Note
Make sure the trigger could be carried out on the engine.
Inspection 蓝/白
Blue/White
Remove the body shield.

Remove the wire adaptor of the trigger.。
Measure the impedance value between the blue/white end 磁电机接口
Magnetor Interface
of the wire at the engine side and the ground strap connection
绿/红
Black
黑
of the body. Green/Red White

白
Standard Value：100-500Ω（20℃） DJ7031-2.8-21

DJ621-2.8×0.5
Change the alternator when the value is beyond the range of
the standard value.
- 65 -

Activation System
BRAKE SWITCH BRAKE SWITCH BATTERY RELAY STARTOR MOTOR

STARTER SWITCH
Starting Drawing
启动示意图
1Battery 2Horn 3Power Locking Components 4 Rectifier 5 Release Resistance 6 Frequency

Conversion Flash Apparatus 7 Meter 8 Starting Relay 9 Igniter 10 Ignition Coil Assembly
- 66 -

3. Activation System
Material Preparation---------------3.1
Failure Diagnosis---------------3.2
Starting Motor---------------3.3
Starting Relay-------------3.4
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 Service Limits
Length of the motor brush of the 6.2mm 3mm
starting motor
Liner of the starting idler shaft 8.3mm
External diameter of the starting 7.94mm
idler shaft
Torque Tightening Value

Clutch cover bolt of starting motor 12 N·m
Set screw nut of clutch cover of starting motor 95 N·m
Instrument
Set screw nut wrench
Universal fixed wrench
- 67 -

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
•Broken starting clutch Blocked by foreign matters.
•Broken brake switch
•Broken stating relay
•poor contact of connecting line
•Broken starting motor
3.3 Starting Motor
3.3.1 Dismounting
Commutator
* Note
Before unloading the starting motor, turn the main switch
to "OFF" first; remove the bond strap of the storage battery,
then turn the power source on the see if the starting motor is
working to ensure the security.
Remove the wire clip of the starting motor first.

Remove the fixed bolt of the starting motor and unload the
motor.
Roll up the rubber overshoe and pull down the adaptor of the starting motor.
3.3.2 Breaking Down
Unload the screws in the outer cover, the front cover, the
motor cover and other parts.
3.3.3 Inspection
Check other component assembling.
Replace for a new one when there is wear, fragment or
- 68 -

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 turn on.
Conduction check between conduction terminators and electric brushes.
Change for a new one if there is anything abnormal.
Conduction measuring of the electric brush bracket.
Change for a new one if it turns on.
Measuring of the length of electric brushes.
Available Credit：change those below 3mm.
Check whether the needle bearing in the front
cover is rotating smoothly and whether there is
any loose when pressed in.
Change for a new one if there is anything abnormal.
Check whether there is any wear or damage of the oil seal.
3.3.4 Assembling
Oil seal and greasing coating in the front cover.
Install the electric brush on the electric brush bracket. Motor Shell
Grease coating on movable parts of the two ends of electric
brush.
Press all the electric brushes into the bracket, then fit on the O-ring
front cover of the electric motor.
* Note
• Damage is not allowed in the interface between the electric
brush and the armature, pay attention please. Armature
Front Cover O-ring
• The labial part of the oil seal should not be damaged by the
installation shaft, pay attention please.
Install new O-rings on the front cover.

Pair the screw of the motor shell with the one of the front cover
during installation.
Screw up the screw in the outer shell.
* Note
In the assembling of the outer shell and the front cover,
use the magnet to draw the front cover to make it easy to
pull out the armature, and then press it down softly.
- 69 -

3.3.5 Installation
Install wires of the starting motor; make sure the soldering
cup is properly installed.
Check whether the O-ring is damage, and replaced it with a
new one when necessary.
Cover the O-ring with engine oil, and install it onto the
starting motor.
Install the wire clip of the rear brake.
3.4 Starting Relay
3.4.1 Actuation Inspection

Remove the fender of the body.
Ensure there is a ―click‖ when turning on the starting motor
with the main switch remaining ―on‖.
If there is sound, it is ok.
If not：• check the voltage of the starting relay.
• check the ground loop of the starting relay.
• Actuate inspection on the starting relay.
启动Relay
Starting
3.4.2 Voltage Inspection of Starting Relay 继电器
Set up the main stand, measure the voltage between

the negative pole of the green/yellow wire in the
adaptor of the starting motor and the ground strap
connection of the body.
Hold on the brake tension rod with the main switch
emaining ―on‖, the voltage of the storage battery
must be in accordance with specification.
Continuity check and inspection of the wires when
the voltage between the ends of the starting motor is zero.
绿/黄
Ω
Green/Yellow
3.4.3 Inspection of Ground Loop of Starting Relay Black
Remove the adaptor of the starting relay.
黑
启动
Starting
Conduction inspection between the grey wire at the end
继电器
Relay
of conductor joint and the ground strap connection of
the body.
When pressing on the starting button, the conduction
Between the grey wire and the ground strap connection
of the body must be fine.
Inspection of the conduction of the starting button and wires when there is no conduction.
- 70 -

3.4.4 Actuation Inspection
Remove the storage battery out of the starting relay, Ω
and connect the end of the starting relay with a multimeter.
Connect the fully charged storage battery between the
black wire and the green/yellow wire of the relay.
The relay will utter a ―click‖ and the electric impedance
the multimeter shows is ―zero‖.
- 71 -

Bulbs/Switches/Meters
Certificate No. of front lamp:

A
E4 0014908
Certificate No. of front position lamp:
B
E4 50R-001765
Certificate No. of rear lamp:
C
E4 50R-0014909
Certificate No. of front turn light:
D
E4 50R-001765
Certificate No. of rear turn light:
E
E9 50R-001493
Certificate No. of rear license lamp:
F
E3 001002
1 Front signal lamp 2 Meter 3 Front left turn signal lamp 4 Front right turn signal lamp 5 Rear left
turn signal lamp 6 Taillight 7 Left rearview mirror 8 Right rearview mirror
- 72 -

4. Bulbs/Switches/Meters
Material 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 Bulb Replacement------4.4 Combined Switch--------4.9
Taillight Bulb Replacement -------4.5
Notice of Work
Conduct examination of the switch (The switch could be removed from the motorcar before being examined).
The main switch is not "ON".

• The bulb is broken.
• The switch is broken.
• Poor contact at the adaptor or wire break.
4.3 Headlight Bulb Replacement
4.3.1 Unloading
Remove the pedal components.
Remove the front shield.
Disconnect the wire of headlight bulb.
Remove the set screws so as to remove the headlamp.
Take off the headlamp.
Take off the glass lens of the headlamp.
Keep the headlight in place; rotate the outlet
clockwise to remove the bulb.
- 73 -

4.3.2 Installation
Install the bulb in the opposite order of removal.
4.4 Front Turn Signal Lamp Bulb

Replacement
4.4.1 Unloading
Remove the pedal components.
Remove the front shield and disconnect the wire of headlight bulb.
Loosen set screws of turn signal lamp (3).
Take off the bulb socket.
4.4.2 Installation
4.5 Taillight Bulb Replacement
4.5.1 Unloading
Take off the seat.
Remove the set screws so as to take off the lamp covers.
Disconnect the wire of taillight.
Take off the left and right backplates and taillight covers.
Take off the taillight.
4.5.2 Installation
4.5.3 Taillight Bulb Replacement
4.5.3.1 Unloading
Remove set screws on the taillight covers.
Take off the taillight covers so as to remove the bulbs.
Take off bulbs from the sockets.
- 74 -

4.5.3.2 Installation
4.6 Meters
Remove the rearview mirrors.

Remove set screws on the deckboards.
Take off the upper deckboard.
Take off milometer components.
Take off the meters.
Install the meters in the opposite order of removal.
4.7 Power Lock
4.7.1 Inspection
Take off the front shield.
Take off pedal boards.
Remove the main switch conductor joints.
Conduction inspection of the joint terminals.
Circuit Diagram
Red Red/White Black Black/White Grey

Red 灰
4.7.2 Power Lock Replacement

Take off the front shield.
Take off pedal boards.
Remove the set screws and take off the power lock.
Install the set screws and replace a new power lock.
- 75 -

4.8 Speaker
Check
Remove the speaker wires.
The speaker is good, if it can sound after
The speaker wires connect to a storage battery.
4.9 Handle switch
Remove the left and right rear-mirror

Remove the left and right combination switch fixing screw.
Loosen the left and right combination switch.
Remove the right grip assembly and left direction trip sleeve.
Remove the left and right combination switch.
蓝
淡蓝
绿/黑
橙
棕
红/白绿/白
G/R Y/R N/W LR Y
G/B O G/W BL Y/R LBL
绿/红
绿/黄
黄/红
紫
粉红
黄
棕/白
76

The check and maintenance of the chassis
The table of chassis fastener torque

Fastened parts and fastener names Fastening torque（N·m）
Oil pump body assembly mounting bolt 5-9
Front brake cylinder assembly 22-29
mounting bolt
Fluid brake fixing bolt 5-9
Muffler decoration cover screw 5-9
Tap welding assembly mounting bolt 40-60
Front wheel locking nut 55-62
Front shock absorber mounting bolt 37-44
Rear wheel mounting nut 100-113
Rear shock absorber top nut 37-44
Rear shock absorber bottom nut 22-29
Rear shelf fixing screw 22-29
Fuel tank mounting bolt 5-9
Helmet barrel fixing bolt 5-9
Muffler fixing bolt 22-29
Muffler joint fixing bolt 5-9
77

Front hydraulic brake
Front brake disc

A
diameter:190mm
Front disc thickness:4 m
B m
Use limit:3mm
Friction plate thickness:
C 5.0mm
Use limt:4.0mm
Installation torque valu
D e of bolt 8 in figure 8:
5-9N·m
Installation torque
E of value of nut 27 in fi
gure : 37-44N·m
Free stroke of brake
F handle:
10-20mm
1 Pump body assembly 2 Fluid brake assembly 3 Oil cup pad 4 Oil pump body gasket 5 Cup cover
6 Screw M4 x 10 7 Fixed cover 8 Bolt M6 x 23 9 Pump body 10 Connecting bolt 11 Washer 12
Brake hose assembly 13 Nut M6 14 Spring gasket 6 15 Handle fixing bolt 16 Handle reset spring
17 Hydraulic brake handle 18 Plunger component 19 Dust-proof cover of the discharging hole 20
Spring piece 21 Friction piece component 22 Front brake disc 23 Small pillar 24 Brake cylinder
78

assembly 25 Bolt M8 x 36 26 Front brake disc mounting bolt 27 Nut M10 x 1.25
Rear hub brake
Torque value of nut 5 in

A
figure: 100-113N·m
Inside diameter of hub bra
B ke: 110mm
wear limit:111mm
Brake shoe block thicknes
C s: 4.5mm
Use limt:3.5mm
Rear brake handle stroke:
D
10-20mm
Installation value of bolt4
E
in figure:22-29N·m
1 rear shock absorber component 2 bolt M10Χ1.25Χ40 3 split pin 4 bolt M8Χ35 5 nut M14Χ1.5 6 brake shoe
block component 7 brake shoe block spring 8 sealing ring 9 rear brake cam axis 10 rear brake return spring 11
rear brake rocker arm component 12 rocker mounting bolt 13 O-shaped ring
79

5. Brake
Maintenance instructions ----------------------5.1
Fault diagnosis ------------------------5.2
Front hydraulic brake--------------------------5.3
Rear hub brake-------------------------5.4
5.1 Maintenance instructions
Operation precautions
*Note:
• When installing and removing, the brake components can not be stained with grease.
• The brake should be cleaned with specified cleaning agent in order to avoid the degradation of the brake
performance.
*Check the brake before driving *
5.1.1Specifications
Item Standard value (mm) Available limit (mm)
Front disc thickness 4 3
Front friction plate thickness 5.0 4.0
Front brake disc diameter 190 -
Inside diameter of rear brake 110 -
hub
Rear brake shoe block 4.5
3.5
thickness
5.1.2 Torque value

pump body component fixing bolt 5-9 N·m Front cylinder component installation bolt
22-29 N·m
Hydraulic brake handle fixing bolt 5-9 N·m Rear fixing nut 100-113 N·m
5.2 Fault diagnosis
Brake
Poor braking performance

80

1. Improper brake adjustment
2. Wear of the brake shoe block and friction plate component
3. Improper installations of the brake shoe block and friction plate component
4. The brake shoe block and friction being polluted
Slow response of the brake or the tightness of the handle

1. Improper adjustment of the brake
3. Improper installation of the brake shoe block and friction plate component
81

The abnormal sound of the brake
2. The brake shoe block and friction being polluted
5.3 Front hydraulic brake
5.3.1 Removing
*Note
•The change of the friction plate component.
•If a friction plate will be used again, it should be
marked at its side in order to be installed back to the
original position.
Remove the following components from the right handle
and front shock absorber, respectively:
1.hydraulic brake handle（17）
2.oil pump body component（1）
3.brake hose assembly（12）
4.brake cylinder component（24）
5.front brake disc（22）
Note: referring to detail decomposition view on page
77
*Note
•When installing and removing, the brake shoe block can not be stained with grease.
•The brake should be cleaned with specific cleaning agent to avoid the degradation of the brake performance.
Loosen the brake cylinder component fixing bolt.
Remove the brake cylinder component from the front shock
absorber.
Remove the front wheel axle.
Remove the front wheel.
Remove the brake disc from the front wheel.
5.3.2 Check
Check whether the friction component have been worn
out and change the shoe block if needed.
Measure the friction plate component, front brake disc and
record the maximum value.
Specification
QJ50T-21T front brake disc diameter φ 190mm
Front brake disc thickness 4mm
*Note
- 82 -

•Must be measured with a micrometer.
Measure the thickness of the friction plate component.
Change the front brake disc and friction plate component, if their thickness are
less than the standard value or they have been polluted.
Available limit: friction plate 5.0mm

Front brake disc 2.6mm
Note: the friction should be changed in pairs.
5.3.3 Installation
Install front brake disc and front wheel.
Install front brake hose assembly and brake cylinder component.
Do not make friction plate and front brake disc stained with grease.
*Note
The brake being stained with grease will decreases the performance of the brake and results the failure of the
brake.
Screw the bolt and nut to specified torque value.
Torque value:
Oil pump body component fixing bolt 5-9 N·m
Front brake component installation bolt 22-29 N·m
Do not make the friction plate stained with grease.

It should be cleaned with brake cleaning fluid, if the
friction brake is stained with grease.
*Note
The friction plate being stained with grease will decrease
the performance of the brake.
5.4 Rear hub brake
5.4.1 Disassembly
Remove the muffler.
Remove the rear fixing nut.
Remove the rear wheel
Remove the brake shoe block component.
*Note
- 83 -

• Change the brake shoe block.
• The brake should be marked at its side before removing, if it
will be used again.
Remove the following components from the rear wheel.
Rear brake:
1. Rear rocker arm installation bolt（13）
7.Brake shoe block component（6）

2. Rear brake rocker arm component（12） 8. Brake shoe block tension spring（7）
3. Rear wheel fixing nut（1） 9. Tire E11 75R -000216
4. Sealing ring（10） 10. Rear rim component3.5×12
5. Rear brake return spring（11）
6.Rear brake cam shaft（8）
Note: referring to detailed composition view in page 78.
5.4.2 Check
Check whether the brake hub and brake shoe block have been
worn and change them if needed.
Measure the thickness of the brake shoe block and brake hub
inside diameter and record the maximum value.
*Note
•Must be measured with a micrometer.
。Measure the thickness of the brake inside diameter and
brake shoe block.
If the brake shoe have block is less than the maintenance

value, it should be changed.
Note: The brake shoe block should be changed in pairs.
Rear brake hub inside diameter φ 110mm
Rear brake shoe block thickness 4.5mm
Available limit: Brake hub inside diameter 111mm
Brake shoe block 3.5mm
制动鼓内径:Brake hub inside diameter
5.4.3 Installation
Install the brake shoe block component.
Install the rear wheel.
Install the muffler.
*Note:
The brake being stained with grease will decreases the
performance of the brake and results the failure of the brake.
- 84 -

Screw the bolt and nut to the specified torque value.
Torque value:
Rear wheel fixing nut: 100-113N·m
Do not make the brake shoe block and front brake disc stained with grease.
If the brake shoe block and front brake disc are stained with grease, they must be cleaned with brake cleaning
fluid.
Rear brake:
1. Rear rocker arm installation bolt（12） 7.Brake shoe block component（6）
2. Rear brake rocker arm component （11） 8.Brake shoe block tension spring（7）
3. Rear wheel fixing nut（5） 9.Tire E11 75R -000216
4. Sealing ring（8） 10. Rear rim component3.5×12
5. Rear brake return spring（10）
6. Rear brake cam shaft（9）
*Note
The brake shoe block being stained with grease will decrease the performance of the brake.
Note: referring to the detailed decomposition view on page 78.
Covering assemblies
- 85 -

*Note: The body cover
should not be damaged
when being assembled
and disassembled.
The hoop-claw part of
the body should not
be damaged when being
assembled and disassem
bled.
Align the panel and cov
er on the body with the
ir respective groove.
Correctly assemble the h
oop-claw part of each p
art.
The accessory should no
t be damaged when inst
alling the cover.
- 86 -

1 rear low fender 2 rear fender wing lapel 3 rear low fender 4 rear fender 5 rear reflector component
6 tap rear over 7 tap front cover 8 speedometer visor 9 pad component 10 helmet bucket 11
decoration plate of the front big cover panel 12 front big cover panel 13 front base plate 14 left
connection plate 15 right connection plate 16 low connection plate 17 foot protecting plate 18
storage battery box cover 19 frame number plate 20 rear pedal component 21 pedal left protection
cover 22 pedal 23 pad lock 24 spark plug cover plate 25 connection plate of left and right protection
plate 26 right protection plate 27 left protection plate 29 rear connection plate of left and right
protection plate 30 front fender 31 side reflector component 32 license light component 33 front
light 34taillight 35 decoration plate of right foot protection plate 36 right rear view mirror 36 left
rear view mirror 38 meter
6. Body cover
Remove the body in the following sequence
Handle cover1→left/right rear view mirror→handle cover2→foot protection plate→
protection plate in the base plate→front big cover→front light
→pad assembly→left/right protection stripe→low connection plate→front fender→
rear shelf assembly→decoration plate of the protection plate
→ left/right pedal cover → decoration plate of the left/right protection plate →
left/right protection plate→perspective hole cover→connection plate of the left/right
protection plate
→storage battery cover→pedal→taillight→rear fender→rear low fender
*Note:
The body cover should not be damaged when being assembled and disassembled.
The hoop-claw part of the body should not be damaged when being assembled and disassembled.
- 87 -

Align the panel and cover on the body with their respective groove.
Correctly assemble the hoop-claw part of each part.
The accessory should not be damaged when installing the cover
- 88 -

Front wheel
Tire
specification:tire120/70-12
A Certification number of front
wheel tire: E11 75R -0002
10
B Rim specification:3.50×12
Limit value of rim swing

C difference:vertical:2.0mm
Horizontal:2.0mm
Limit value of front axle

D
bending degree: 0.2mm
1 self-locking nut M12 x 1.25 2 gear seat component 3 rolling bearing 6201-2RS 4 intermediate shaft sleeve
component 5 vacuum tire 120 / 70-12 / K-413 6 front rim 7 front wheel oil sealing component/ 22 x 35 x 7 8 front
brake disc 9 front wheel left shaft sleeve 10 bolt M8 x 20 11 front axle 12 valve
- 89 -

Front suspension
Installation torque value

A of bolt12 in figure:
37-44N·
m
Installation torque value
B of bolt13 in
figure:5-9N·
m
Rear ball amount:22
C
Low ball amount:22
:
1 bolt M6×16 2 front fender bracket2 3 odometer clip 4 front right muffler component 5 front left muffler
component 6=hydraulic brake wire clip 7 front fender bracket1 8 boltM10×1.25×30 9 boltM6×12 10
hydraulic tube clip 11 low connection plate welding component 12 clip 13 nut 14 dustproof cover 15
integral steel bowl 16 ball5 17 low bearing high steel bowl 18 low bearing low steel bowl
- 90 -

Direction handle
Installation torque value of

A bolt2(direction handle fixing
bolt) in figure:40-60 N·m
Front brake handle free stro
B ke:
10-20mm
Rear brake handle free stro
C ke:
10-20mm
Accelerator manipulation ha
D ndle(figure6) free stroke:2-5
mm
1 right grip component 2 right combination switch 3 tap melding component 4 right rear view mirror
component 5 left rear view mirror component 6 left combination switch 7 left grip 8 left handle
component 9 left handle 10 installation bolt 11 fixing cover 12 boltM6×22 13 handle installation seat
14 rear brake switch 15 nutM6 16 bolt M10×1.25×45 17 self-locking nut M10×1.25 18rear brake
component 19 accelerator wire component 20 screw M5×10
- 91 -

7. Front wheel/front suspension
Preparation data-------------------------7.1
Fault diagnosis-------------------------7.2
Front wheel-------------------------7.3
Manipulation-------------------------7.4
Front fork assembly-------------------------7.5
7.1 Preparation data
Operation precaution
Before removing the front wheel, support the bottom body with jack etc to make the front wheel float on the
ground (Note: do not make the front wheel reverse).
When operating ,do not make the brake shoe block，friction plate component, front brake disc stained with grease.
Vehicle standard
Standard
Measured position Item Available limit (mm)
value(mm)
Front wheel axle Bending degree 0.2
Longitudinal 2.0
direction
Rim
Front wheel
shimmy
Horizontal Within 1.0 2.0
direction
Torque value Tools
Tap welding component fixing bolt 40-60 N·m Bearing removing pole
Front axle locking nut 55-62 N·m Locking nut wrench
Front muffler fixing bolt 37-44 N·m
7.2 Fault diagnosis
7.2.1 Turning hardness of direction handle
- 92 -

The direction handle bearing has failed.
The direction handle bearing has been damaged.
The tire pressure is too low.
The tire leaks.
7.2.2 Direction unstable

The direction handle bearing has been damaged.
The tire pressure is not sufficient.
The front fork bends and the front axle bends.
The front wire deforms or skews.
7.2.3 Front wheel swing

The tire deforms.
The front axle bearing looses.
The tire is not good.
7.2.4 Turning hardness of rotor

The axle bearing has failed or the gear has failed.
7.2.5 Abnormal sound of front muffler

The muffler makes friction sound.
Each part bolt of the muffler loose.
7.3 Front wheel
7.3.1 Removing
Note:
The motorcycle must be supported firmly.
Loosen the brake cylinder component installation bolt.
Remove the brake cylinder component.
Put an appropriate bearing under the engine to raise the front wheel.
Loosen the front axle fixing nut（1）.
Remove the front axel（11）and front wheel.
Remove the gear seat component（2）.
Remove the front brake disc.
Remove the sleeve, oil sealing, bearing 6201-2RS, intermediate sleeve component, bearing 6201-2RS.
* Note: referring to the assembly and disassembly view of the QJ50T-21T front wheel on page 86.
7.3.2 Check
- 93 -

7.3.2.1 Axle bending check
Put the axle on the V-shape seat and measure its
eccentricity with a dial gauge.
Available limit: change above 0.2mm.
7.3.2.2 Swing check of the rim

Put the rim on a precise support and check its
swing degree.
Turn the wire with hands and read the swing degree.
Available limit:
Longitudinal direction: change above 2.0mm.
Horizontal direction: change above 2.0mm.
7.3.2.3 Front wheel bearing check

Remove the axle and front brake disc.
Remove the left sleeve of the front wheel and remove the
oil sealing.
Remove the bearing.
Check the bearing rolling condition.

If the bearing does not roll, has been damaged or looses, then
change it.
- 94 -

车轴 Axle
游隙 Clearance
轴向 Axial
径向 Radial
7.3.3 Bearing change

Remove the front axle, front wheel and the left sleeve of the front wheel, intermediate sleeve component of the
front wheel.
Remove the oil sealing and bearing with the oil sealing puller and bearing puller.
Note: the removed bearing should be replaced with a new bearing.

When installing, smear the bearing with lubricating oil, then press in the bearing with bearing installation tools.
* Note:
• The bear must be pressed in parallel.
7.3.4 Installation
Conduct in accordance with the steps contrary to the
―removing‖
Take care to the following items:
Lubricate the front axle, gear seat component, oil sealing
(opening), sleeve, bearing 6201-2RS, intermediate sleeve
component.
The recommended lubricating oil is calcium-based
lubricating oil.
Install the front axle (11), front wheel, gear seat component (2), nut (1).
When installing the gear seat component (2), take care to combine the odometer gear seat well. If the front axle
has not been locked in combination, the odometer gear seat will deform.
Install the brake cylinder component onto the front
hub.
Tighten the front axle (as shown in the right
figure)
* Note: referring to the assembly and

disassembly view of the QJ50T-21T front
wheel on page 86.
Torque value
- 95 -

Front axle locking nut 55-62 N·m
7.4 Direction handle
7.4.1 Removing
Remove the rear view mirror component.
Remove the fixing screw of the handle high and low cover decoration.
Remove the handle high cover decoration cap and remove the meter.
Remove the front big cover component.
Remove the left/right combination switch
component.
Remove the oil pump body component.
Remove the left grip and the accelerator
Manipulation handle component.
Loosen the tap welding component fixing bolt
（16）.
Remove the tap welding component（3）.
7.4.2 Installation
* Note: referring to the assembly and
disassembly view of the QJ50T-21T direction
handle on page 87.
Install in a sequence contrary to the removing.

Tap welding component fixing bolt
Torque value: 40-60 N·m
7.5 Front fork
7.5.1 Removing
Remove the wheel.
Remove the body protection plate.
Remove the brake tube and the odometer wire.
Remove the direction handle.
Remove the compressing bolt (13) and dustproof cover in
turn.
Remove the integral steel bowl (15) and steel ball (16).
Remove the front fork.
（16）。Remove the high and low steel bowl of the low
bearing (17, 18) and steel ball (16).
Loosen the front muffler fixing bolt (8).
- 96 -

Remove the front left/right muffler component (4, 5).
Tools:
Direction handle welding component fixing bolt wrench.
Fixing nuts wrench.
Special tools of the Bearing steel bowl removing.
* Note:
Wipe the openings of the body protection plate with rage.
Remove the high and low bearing steel bowl with special tools of bearing bowl removing.
7.5.3 Installation
Smear the bottom bearing steel bowl with lubricating oil and confirm the amount of the steel ball（22）.
When installing the steering rod, the direction handle shall not be turned (in order to prevent the steel ball from
falling).
Supporting the direction handle, smear the top bearing steel bowl with lubricating oil and confirm the amount of
the steel ball (22).
Smear the top seat ring with lubricating oil.
Turn the direction handle in left and right to make the steel ball contact close with each other.
Tools:
Fixing nuts wrench.
Turn the front fork in left and right to confirm it’s smooth and unloosing.
Steps:
Install the front left/right muffler component.
Install the direction handle.
Install the body protection plate.
Install the front wheel.
*Note: referring to the assembly and disassembly view of QJ50T-21T front fork on page 88.
Rear wheel/rear suspension
- 97 -

Torque value of the rear
A wheel fixing nut5 in figure:
100-113N·m
B the bolt4 in figure:
22-29N·m
D the bolt14 in figure:
37-44N·m
Brake hub inside

E
diameter( wear limit): 111mm
Brake shoe block lining(wear

F
limit): 3.5mm
1 tire 130/70-12 2 rim 3.50×12 3 split pin 4 bolt M8×35 5 nut M14×1.5 6 brake shoe block
component 7 brake shoe block tension spring 8 sealing rim 9 rear brake cam shaft 10 rear brake
return spring 11 rear brake rocker arm 12 rear rocker arm installation bolt 13 O shaped ring 14 bolt
M10×1.25×40 15 rear muffler component
- 98 -

Rear wheel
Tire
A
specification:130/70-12
Rim specification:
B
3.50×12
Rim swing difference
limit:
C
Vertical:2.0mm
Horizontal:2.0mm
Torque value of the rear
D wheel fixing nut in
figure:100-113N·m
Rear tire certification
E
number:E11 75R -000216
1 self-locking nut M14×1.5 2 dustproof cover 3 vacuum tire 130/70-12/K-413 4 valve 5 rear rim
component 6 brake shoe block component 7 shoe block tension spring 8 rear brake cam shaft 9 rear
brake wire limit plate 10 sealing ring I 11 rear brake return spring 12 rear brake rocker arm component
13 bolt M6×35
- 99 -

8. Rear wheel/rear suspension
Preparation data-----------------8.1
Fault diagnosis-----------------8.2
Rear wheel-----------------8.3
Rear muffler-----------------8.4
Do not make the brake hub and brake shoe block stained with grease.
Preparation standard
Item Standard value（mm） Available limit（mm）
Rear wheel Longitudinal 2.0
swing degree Horizontal 2.0
Locking torque
Rear wheel fixing nut 100-113 N·m
Rear muffler top bolt 37-44 N·m
Rear muffler bottom bolt 22-29 N·m
8.2 Fault diagnosis
8.2.1 Rear wheel swing

The rim has deformed.
The tire has failed.
The rear wheel has not been fastened.
The tire pressure is not sufficient.
8.2.2 Muffler too soft

The elasticity of the spring is in fatigue.
- 100 -

8.3 The rear wheel
8.3.1 Removing
Remove the muffler component.
Remove the rear inside fender.
Remove the rear axle fixing nut.
Remove the rear wheel.
8.3.2 Check
8.3.2.1 Rim swing check

Turn the wheel with hands and measure the eccentricity of it
with dial gauge.
Available limit:
Longitudinal: change above 2.0mm.
Horizontal: change above 2.0mm.
When the rear swing degree exceeds the available limit, the
rear wheel will loose, which will result in the swing of the
rear wheel. Change the rear wheel bearing after check.
8.3.3 Installation
Install the rear wheel in sequence contrary to the ―removing‖
and lock the nut.
Rear fixing nut
Torque value: 100-113 N·m
- 101 -

QJ50T-21T rear wheel
8.4 Rear muffler
8.4.1 Removing
Remove the seat pad and the left and right protection plate.
Remove the rear container, rear shelf assembly, rear fender.
Remove the rear muffler fixing bolt.
Remove the muffler.
8.4.2 Installation
Install the rear muffler.
Torque value:
High fixing bolt:37-44 N·m
Low fixing bolt:22-29 N·m
The installation of the rear muffler

Install the rear container, rear shelf assembly, rear fender.
Install the seat pad and the left and right rear protection plate.
- 102 -

Tank/seat cushion
Note: when removing

the tank, the switch
A
of it must be turned
at “OFF”.
The torque value of
B the bolt10 in
figure:5-9 N·m
The torque value of

D the bolt11 in
figure:5-9 N·m
1 frame component 2 rear handrail 3 seat cushion component 4 tank component 5 seat cushion lock
installation plate 6 seat cushion lock seat component 7 cable component 8 inside hexagonal screw M8×25
9 rear strengthen plate of the helmet bucket 10 self-locking nut M10×1.25 11 bush 12 engine bracket
- 103 -

installation bolt 13 rear rocker arm installation shaft 14 power hanger welding component 15 self-locking
nut M12×1.25
Tank
Gasoline tank
A capacity:
5.6±0.2L
The torque value of
B the bolt16 in
figure:5-9 N·m
Note: when removing
the tank, the
D
switch of it must be
turned at “OFF”.
1 tank body 2 fuel sensor component 3 combination screw M5×14 4 tank cap 5 tank inlet jacket 6 steel
wire clampφ 10 7 connection tube 8 tubing Φ 7×2×300 9 steel wire clamp caφ 7.5 10 tubing Φ
- 104 -

4×2×340 11 bolt M6×12 12 tank cock component(14*1 clip spring type) 13 steel wire clampφ 8 14
tubing Φ 4.5×2×70 15 filter component 16 tubing Φ 4.5×2×190 17 clip component
Seat cushion
The torque value of

A the bolt4 in
figure:5-9 N·m
The torque value of
B the bolt7 in
fiure:5-9 N·m
1 seat cushion component 2 bolt 3 nut M6 4 bolt M6×12 5 helmet bucket 6 helmet bucket bottom cover
- 105 -

7 self-tapping screw ST4.2×13 8 clip sheet ST4.2
9. Tank/seat cushion
Preparation data-----------9.1
Fault diagnosis-----------9.2
Tank/seat cushion----------9.3
Operation precaution
Removing site should be away from the fire source.
When removing the tank, the switch of it must be turned at ―OFF‖.
When assembling, fasten the bolt and nut to the specified torque value.
After assembling, check whether all the parts have been installed correctly and whether the operation is correct.
Standard value
Item Standard Available limit
Tank capacity 5.2±0.2L /
Locking torque
Rear shelf fixing screw 22-29 N·m
Tank fixing bolt 5 - 9 N·m
Helmet bucket fixing bolt 5 - 9 N·m
9.2 Fault diagnosis
Gasoline reducing
Gas naturally consumes
- 106 -

Gas leaks
9.3 Tank/seat cushion
9.3.1 Removing
Open the seat cushion（1）。
Remove the seat cushion fixing bolt（4）。
Remove machine oiler protection cover.
Remove the machine oiler.
Remove the cushion and helmet bucket.
Remove the rear container assembly.

Remove the left/right rear protection plate
component.
Remove the rear shelf assembly and rear installation
component of the helmet bucket.
Turn the tank switch to ―OFF‖

Disconnection: fuel hose
Remove the tank from the frame.
Note:
Refer to the detailed assembly and disassembly view on page
99,100,101.
9.3.1Installation
Conduct in a sequence contrary to the ―removing‖
Installation value:
Rear shelf fixing bolt 22-29 N·m
Tank fixing bolt 5 - 9 N·m
Helmet bucket fixing bolt 5 - 9 N·m
- 107 -

Check and maintenance of the engine
- 108 -

Table of the engine fastener torque value
Fastened parts and fastener names Fastening torque（N·m）
Fan wind guiding cover locking bolt 10-12

Cylinder cover locking nut 15-18
Spark plug 22-25
Inlet pipe locking bolt 10-12
Cooling fan impeller locking screw 10-12
Flywheel locking bolt 45-50
Magnetic motor coil locking screw 10-12
Right crankcase locking bolt 10-12
Bearing pressure plate locking bolt 10-12
Cylinder stud bolt 15-18
Motor fixing bolt 10-12
Crankcase left cover locking screw 10-12
Crankcase left cover locking bolt 10-12
Driving wheel disc locking nut 40-45
Driven wheel disc locking nut 40-45
Driven wheel disc clutch clocking nut 55-60
Overrunning clutch outer ring 10-12
Electric actuating idler pulley locking 10-12
screw
Gear box cover locking bolt 10-12
Left crankcase oil drain hole locking
bolt 18-22
Left crankcase positioning pin locking
nut 18-22
- 109 -

Lubrication system
Note: rod worm should

rotate flexible,
without stagnation and
unilateral tightness
while worm gear should
have a little axial
movement and the machine
oil pump o-shaped ring
shall not have cutting
1 edge.
Each plug of the machine
oil pump should not leak
and the sealing ring
should be complete.
1 crankcase 2 carburetor 3 machine oil tank 4 machine oil pump
- 110 -

10. Lubricating system
Preparation data-----------10.1
Fault diagnosis-----------10.2
Machined oil pump-------------10.3
Rod worm should rotate flexible, without stagnation and unilateral tightness while worm gear should have a little
axial movement and the machine oil pump o-shaped ring shall not have cutting edge.
Each plug of the machine oil pump should not leak and the sealing ring should be complete.
After installation, the bolt3 should be removed in trial running and fasten it up when there is
continuous oil flowing out.
The function of the lubricating system: the function of the engine lubricating system is to provide
lubricating oil for machine parts friction surface to turn dry friction of the surface into wet friction,
thus reducing the wear between the parts; to cool down the parts with high heat load; to absorb the
impact of the bearing and other machine parts and reduce the noise; to increase the sealing between
the piston ring and cylinder; to clean the parts and take away the impurity on them.
Preparation standard
Item Standard Available limit
Machine oil tank During changing oil 0.1L /
capacity During removing 0.11L /
10.2 Fault diagnosis
Machine oil amount decreasing Engine being burned out

Machine oil decreases naturally No machine oil or the oil pressure is too low
Machine oil leaks piston pathway obstructs
The piston ring has been worn out

or the installation is not good No machine oil has been used
- 111 -

10.3 Machine oil pump
10.3.1 Removing
Loosen the bolt and remove the wind guiding cover
component.
Wind guiding cover
Loosen the screw on the fan and remove the fan.
Fan
Screw
Remove the magnetic motor, rotor and bracket.
Magnetic motor stator, rotator,

bracket
Machine oil pump component
Remove the worm gear and machine oil component from the crane
- 112 -

Installing the oil machine
Shown as the following figure
Machine oil pump
Machine oil pump body
Plunger spring
Plunger
Machine
Gear
oil pump
cover
10.3.2 Installation
Conduct in a sequence contrary to the ―removing‖.
10.3.3 Check
Check whether the worm gear surface has been damaged.
Check whether the keyway has been damaged.
Plunger outside
diameter
Measure the plunger outside diameter.

Available limit: 2.61mm.
Carburetor
- 113 -

Note: Since the gasoline is
very dangerous, smoke and
fire is strictly prohibited in
the operation site.
After carburetor being
removed, use rag to block
the inlet pipe in order to
prevent foreign body in.
1 screw 2 float chamber 3 needle valve component 4 float 5 float pin 6 main hole 7 idle
nozzle 8 main foam tube
9 idle adjusting screw
- 114 -

11. Carburetor
Preparation data-------------11.1
Fault diagnosis-------------11.2
Removing of the carburetor---------11.3
Installation of the carburetor---------11.4
Adjustment of the carburetor ---------11.5
·Gasoline is very dangerous, smoke and fire is prohibited in the operation site.
·Take special care to spark.
·The wire should not be pulled and bended with force, since deformation and damage will affect the its
performance.
·After carburetor being removed, use rag to block the inlet pipe in order to prevent foreign body in.
·When having not been used for more than a month, the gas in carburetor buoy should be released, since they
will deteriorate the idle nozzle blockage, making the idling not safe.
The function of the carburetor: the carburetor is a key component of the engine fuel supply
system and its work condition has a direct effect on the stale working, power and economic
indicators. It atomizes a certain amount of gas into tiny oil drops and mixes them with different
amounts of air, forming mist flammable mixed air of different concentration degree according to the
need of different engine working condition, which is provided to the engine in time to ensure its
normal operation.
Preparation standard unit: mm
Item Standard value

Main nozzle 47.5
Main hole 80#
Idle hole 15#
Oil needle B05-2
11.2 Fault diagnosis
Bad start Hard start, flameout after start, unstable idle

- 115 -

Carburetor has on fuel Carburetor has been obstructed
Gas filter is obstructed mixed air is too concentrated or too thin
Gas tube is obstructed Expiratory system has second air suction
Needle valve is in sticking Idle adjustment is not good
Oil surface adjustment is not good oil amount adjustment is not good
Idle system or electric concentration valve has been
obstructed
Too much fuel in engine Too thin mixed air

Too much oil overflows Oil nozzle has been obstructed
Fuel system has the second air suction Needle valve has been obstructed
Fuel degradation Oil surface is too low
Bad concentration Fuel system has been obstructed
Idle system or windproof system is obstructed Bad plunger work
Expiratory system has second air suction
Too concentrated mixed air Intermittent flameout
In acceleration
Bad concentration valve work Too thin mixed air
Dad needle valve work
Too high oil surface
Carburetor overflow
Air passage has been obstructed
Filthy in air filter
11.3 Disassembly of carburetor
11.3.1 Disassembly
Guy wire of
Inlet oil hose
oil valve
- 116 -

Turn the fuel switch to―OFF‖ position.
Pull out the inlet oil hose and to loosen the guy wire of oil
valve. Electrical
Pull out stopper at the end of outlet oil hose. Put the fuel oil enrichment valve
in the floating bowl into another box. interface
Pull out the electrical enrichment valve interface.
Loosen the screw in the engine interface and air filter
interface and to take out the carburetor from the two
interfaces.
11.3.2 Disassembly of carburetor

Loosen the screw of electrical enrichment valve and to take the electrical enrichment valve module.
Electrical
enrichment valve
module
Fixing screw
组件
Fixed flange
Enrichment valve
组件
module
Check the wear of electrical enrichment valve
and injector needle. Injector needle
If it is worn badly, then electrical enrichment module
valve module should be replaced.
Loosen the screw and to dismantle the Plunger Injector

top head. spring needle
Take out the spring and plunger module. Injector needle
Screw Top head Plunger
jam nut
Check the wear of plunger. If it is worn
badly, then it should be replaced.
Check the wear of injector needle.
If it is worn badly, then it should be
replaced.
- 117 -

Loosen the screw and to take out the float bowl.
Dismantle the floating module, floating pin and needle valve module.
11.3.3 Checking
To check the wear of needle valve module, needle valve seat and floating module.
Screw
Floating
bowl
If the needle valve core is worn, it should Needle valve

be replaced. module
If the needle valve seat is worn, the main body of
carburetor should be replaced.
If the floating tongue is worn, it should be replaced. Floating pin
heck the injector needle. If it is worn or broken, the
needle and the two main nozzles should be replaced.
Check the idle metering jet, main jet and main nozzle.
If they are worn, damaged or polluted, they should Float
be changed. Idle nozzle
Check the plunger. If it is worn, it should be Main
replaced. metering
Check carburetor and fuel pipe. If it is polluted, they jet
should be cleaned according to the manual.
Main foam
pipe
11.4 Assembly and adjustment
The assembly should be carried out according to the Idle adjustment screw
opposite order of disassembly.
Adjustment of carburetor
Attentions: Before leaving the factory, the idle speed screw of carburetor has been adjusted. So it generally does
- 118 -

not need any adjustment. The turnover number should be recorded preparing for the assembly.
The engine should be started and operated for 3 minutes to make sure it is operated in normal operation
temperature.
The idle adjustment screw should be adjusted to make the engine speed in 1800rpm;
The mixture control screw should be rotated to the end gently.
At this time, the engine should be shut off (if it is not shut off, to check whether the air filter interface is leak,
whether the screw is tightened, whether the inlet of air filter is plugged).
The mixture control screw should be withdrawn for one circle;
Re-starting, the idle speed screw should be adjusted to make the rotation speed achieve 2000-2500rpm;
The mix screw should be adjusted slowly (anti-clockwise) until the engine speed achieving the highest (The mix
screw would be withdrawn from 2 circles at most);
The idle adjustment screw would be reset to make the engine speed drop to 1800±100rpm;
Draw the throttle for several times to check whether the idle speed rotation is stable.
Emissions would be tested and be compared with stipulation standard.
Cylinder head
- 119 -

Note: In order to guarantee
the seal between cylinder
cover and cylinder block,
1 the cylinder cover would
withstand very big
pre-tightening force of bolt.
Pre-tightening force value:
50Nm
2
5
4
1. Spark plug 2. Mounting bolts of cylinder cover 3. Cylinder cover 4.Cylinder gasket
5. Cylinder
- 120 -

12. Cylinder cover
Preparation materials---------------12.1
Failure diagnosis ---------------12.2
Cylinder cover -----------------12.3
Checking of cylinder cover -------------12.4
Assembly of cylinder cover -------------12.5
12.1 Preparation materials
Attentions
In order to guarantee the seal between cylinder cover and cylinder block, the cylinder cover would withstand very
big pre-tightening force of bolt. Pre-tightening force value: 50Nm
All components should be washed and blew with compressed air before checking.
Functions of cylinder cover: The cylinder cover is used to seal the cylinder and constitute combustion chamber
with piston withstanding high temperature and high pressure gas. Besides, inlet and exhaust would be achieved
through valve actuating mechanism
In the process of operation, air leak existed between cylinder cover and cylinder block or excessive high
combustion pressure.
Cylinder cover gasket is broken through
Bottom plane of cylinder cover is warp
Too much carbon in the combustion chamber
12.3 Cylinder cover
12.3.1Disassembly
Loosen fixing bolt of wind guide cover. Bolt
Dismantle the wind guide cover. Wind guide cover
- 121 -

Loosen fixing nut and spark plug. Dismantle the cylinder Cylinder
cover. Fixing nut
cover
Spark plug
12.4 Checking of cylinder cover
Check whether the cylinder cover is broken through. Ruler

To check the flatness of the bottom plan of cylinder
cover
Acceptable limit: 0.04mm Test ruler
Cylinder
cover
12.5 Assembly of cylinder cover
The assembly should be in the reverse procedure of that for disassembly.
- 122 -

Cylinder block and piston
Note:
All components should
be washed and blew
with compressed air
before checking.
1. Piston 2. Piston pin 3. Cylinder block 4. Cylinder gasket 5. Cylinder cover 6. Nut
7.Spark plug
- 123 -

Thirteenth, Cylinder block and piston
Preparation of materials-----------------13.1 Piston-------------------13.4
Failure diagnosis----------------13.2
Assembly of piston -------------13.5
Cylinder block-------------------13.3
13.1 Preparation materials
Points for Attentions:

All components should be washed and blew with compressed air before checking.
Functions of cylinder block: it provides space for gas compression, combustion and expansion, and
guide for the movement of piston. It also transfer some heat in the cylinder to the surrounding
cooling medium.
Functions of piston:
Withstand the pressure generated by the combustion of mixed gas in the cylinder, and to pass the
pressure to the connecting rod so as to drive the rotation of crankshaft.
To form combustion chamber together with cylinder head, etc.
To act as slide valve of air intake and air outlet, to timely press the fresh gas mixture in the
crankcase into the cylinder, to timely discharge the exhaust gas after combustion in the cylinder.
Preparation reference Unit：mm

Acceptable
Item Standard value
limit
inside diameter 39.995-40.015 40.05
Bending - 0.05
Cylinder cylindricity 0.006 0.05
Flatness 0.03 0.05
Roundness - 0.05
Top ring 0.015－0.05 0.09
clearance between piston ring and
Second
ring groove 0.015－0.05 0.09
ring
Piston/
Top ring 0.1-0.25 0.5
Piston
end gap Second
ring 0.1-0.25 0.5
ring
External diameter of piston 39.97-39.99 39.9
Clearance between the piston and cylinder 0.005-0.015 0.1
- 124 -

inside diameter of piston pin hole 12.002-12.008 12.04
external diameter of piston pin 11.994-12 11.96
Clearance between piston pin hole and piston pin 0.002-0.014 0.02
Inside diameter of wrist-pin end of connecting rod 14.016-14.034 14.06
Low compression pressure Smoking on the exhaust pipe

Piston is worn; burnt or broken The piston ring is worn or damaged
Cylinder and piston is worn or damaged Piston and cylinder is worn or damaged
Gasket is damaged; Air leakage existed between the crankcase and cylinder
Over-high compression pressure Abnormal sound of piston
Too much carbon deposits in combustion chamber damage of cylinder, piston and piston ring
wear of piston pin hole and piston pin
13.3 Cylinder block
13.3.1Disassembly of cylinder block

To take out the cylinder block after the disassembly of
cylinder head.
Cylinder
block
13.3.2 Checking of cylinder block

Check the wear of inside wall of cylinder
If it is badly worn, it should be replaced.
Cylinder
Check the flatness of cylinder block and cylinder
Ruler block
surface
Allowable limits: 0.05
Test ruler
- 125 -

13.4 Piston
13.4.1 Disassembly
Remove the piston pin retainer.
Attentions: Do not drop the retainer to the crankcase.
Remove the piston pin and to remove the piston.
Piston pin, retainer
Check piston, piston pin and piston ring

Remove piston ring
Attentions: do not break or damage piston ring
To remove the carbon deposits in the piston ring groove
Remove piston rings and put them in the bottom of the Piston
cylinder
Attentions：press the piston ring into the cylinder with piston
head
Measure the end gap of piston ring
Allowable limit: 0.05mm
Test ruler
Piston ring
Measure the inside diameter of piston pin hole

Test ruler
- 126 -

Measure the external diameter of piston pin
Clearance between piston pin hole and piston pin
Allowable limit: 0.02mm 1
2
Check external diameter of piston

Attentions: Measuring position should be 90 degree with the
piston pin, 11.5mm lower than the piston skirt

2
11.5mm
Check the scratch and wear of inside wall of cylinder

Attentions：measure the inside diameter of cylinder in the
direction of 90 degree with piston pin at the upper, middle tester
and lower positions
Measure the clearance between cylinder and piston, the
maximum value shall prevail.
Measure the roundness of inside wall of cylinder（the inside

diameter difference between X direction and Y direction）
Allowable limit:0.05mm。
Measure the cylindricity of inside wall of cylinder（the
difference of inside diameter among upper, middle and lower
positions in X direction or Y direction）
Allowable limit:0.05mm。
- 127 -

Measure the wrist-pin end of connecting rod
Wrist-pin end of
Allowable limit: 14.06mm。
connecting rod
13.4.2 Assembly of piston

Assemble the pin
Apply machine oil to all piston rings and pistons. To assemble the Top ring
piston ring with upward slope
Attentions： Second ring
The piston should not be scratched; the piston ring should not be broken
The piston ring can be rotated freely in the groove after assembly.
Oil ring
Clean the gasket on the crankcase

Attentions:
No foreign materials in the crankcase
Install piston, piston pin and piston pin retainer
Attentions:
The side of piston skirt with gap should be installed facing
the inlet
gap
13.5 Assembly of piston
Install the gasket on the crankcase

Apply machine oil to the inside wall of cylinder, piston and piston ring
Be careful to put the piston ring into the cylinder
Attentions:
No damage to piston ring
- 128 -

Driving plate / clutch / driven wheel
Note: During the operation,

oil is not allowed to be left
on the surface of v-shaped
belt. It should be removed if
there is any oil left so as to
reduce the slippage between
v-shaped belt and pulley.
- 129 -

Feet startup mechanism
Note: During the operation,
oil is not allowed to be left
on the surface of v-shaped
belt. It should be removed if
there is any oil left so as to
reduce the slippage between
v-shaped belt and pulley.
1. Retainer
2. Start claw
3. Idler gear
4. Idler shaft
5. Starting shaft assembly
6. Feet start shaft spring
- 130 -

14. Driving plate / clutch / driven wheel/ feet startup
mechanism
Preparation materials--------------------14.1 Clutch /driven wheel---------14.5

Failure diagnosis---------------------14.2 Disassembly of clutch and driven
wheel ----14.6
Left crankcase cover -------------------14.3 Assembly------------------14.7
Driving plate-----------------------14.4 Feet startup mechanism------------14.8
14.1 Preparation of materials
Points for attentions

During the operation, oil is not allowed to be left on the surface of v-shaped belt. It should be removed if there is
any oil left so as to reduce the slippage between v-shaped belt and pulley.
Function: Driving plate/clutch/driven wheel constitute continuously variable transmission (CVT) together. The
torque is transmitted through v-shaped belt between the driving plate and driven wheel.
Preparation reference Unit: mm
Item Standard value Acceptable limits

Inside diameter of right half driving wheel 25.989-26.052 26.06
outside diameter of sliding sleeve 25.96-25.974 25.94
width of v-shaped belt 17 16
thickness of clutch friction lining 1.8 1.5
inside diameter of clutch sleeve 118-118.3 118.5
free length of clutch-pressing spring 68-70 68
outside diameter of right half bushing of driven wheel 32.95-32.975 32.94
inside diameter of left half sliding sleeve of driven wheel 33-33.025 33.06
outside diameter of ball 14.92-15.08 14.4
It cannot be operated after starting of engine insufficient horsepower vibration during operation
Wear of v-shaped belt wear of v-shaped belt breakage of spring of clutch friction lining
Breakage of driven wheel Deformation of clutch-pressing spring
- 131 -

Broken or damaged clutch friction lining wear of ball
Broken clutch-pressing spring polluted driving pulley surface
14.3 Left crankcase cover
Disassembly
Remove the fixing bolt of cover, and to remove the gasket
and fixed pin.
Left cover
Attentions:
Cross disassemble the fixed bolts. Fixing bolt
Remove the pilot pin.
14.4 Driving plate Pilot pin
14.4.1 Disassembly
Remove the fixing bolt of driving plate and to remove the left
half driving plate.
Remove the V-shaped belt from driving plate. Fixer
V-shaped belt
Left half driving

wheel Wrench
Check whether the v-shaped belt is cracking, whether the

rubber and cotton is falling off or abnormally worn
Measure the width of v-shaped belt.
- 132 -
Width

Allowable limit: 16mm。
Please use the original parts when replacing.
Remove right half components of driving wheel.
Right half components of

driving wheel
14.4.2 Disassembly of right half
components of driving wheel
Check the wear of ball

Measure the outside diameter of ball
- 133 -

Measure the outside diameter of right half driving wheel
Allowable limit: 26.06mm。 Right half
Measure the outside diameter of sliding sleeve driving wheel
Sliding sleeve
14.5 Clutch/Driven wheel
14.5.1 Disassembly
Fix clutch sleeve using fixer and remove fixing nut.
Remove clutch sleeve, clutch/driven wheel.
从动轮：driven wheel 固定器：fixer

离合器外套：clutch sleeve
套筒扳手：sleeve wrench
14.5.2 Disassembly of clutch

Remove the retainer ring and to disassemble the clutch.
Attentions:
Oil should not be existed on the clutch friction lining when disassembling.
挡圈：retainer ring
摩擦片：friction lining
- 134 -

- 135 -

Check the wear of clutch sleeve.
Measure the outside diameter of clutch sleeve.
Check the wear of clutch friction lining.

Measure the thickness of friction lining. Friction
Allowable limit: 1.5mm。 lining
14.6 Disassembly of clutch and driven wheel
Clutch spring compressor should be used for disassembling

clutch-pressing spring
Attentions:
Clutch spring compressor should be used for disassembling to
avoid any damage to the spring.
Fix the spring compressor and to remove the clutch fixing nut.
Relax the compressor and disassemble the clutch and driven
wheel
扳手：Wrench
离合器弹簧压缩器：Clutch spring compressor
Remove the spring sheath.
弹簧护套：Spring sheath
- 136 -

Remove pilot pin.
Remove the left half weldment of driven wheel Left half weldment of driven wheel
Disassemble the oil seal on the left half driven wheel
Pilot pin Oil seal
Check the free length of clutch spring

Allowable limit: 68mm。
自由长度：free length
Check the wear of driven wheel\ Left

Right driven driven wheel
Measure the outside diameter of right half bushing of driven
wheel
wheel
Measure the inside diameter of left half sliding sleeve of

driven wheel
14.6.1 Replacement of right half of the driven wheel
bearing
Remove needle bearing on the right half of driven wheel
Remove cir-clip and outside rolling bearing
Attentions:
The removed bearing cannot be used any more
滚动轴承：roller bearing 滚针轴承: needle bearing
弹性挡圈：circlip
- 137 -

Put the outside rolling bearing coated with oil in the bushing.
Attentions: Bearing
When pressing the outside rolling bearing into the bushing, screwdriver
the side with mark should be placed outward. And then fill
the bearing chamber with 8-9g oil.
Mount cir-clip
Designated oil Ball bearing
Install needle roller bearing Bearing screwdriver Needle roller

Needle roller bearing should be pressed in with the tool bearing
shown in the figure
14.6.2 Combinations of clutch/driven wheel

Clear out the oil left on the surface of driven wheel
Install the oil seal in the left sliding sleeve of the driven wheel
Apply oil to the O-ring and to mount on the left driven wheel
component
润滑油脂：lubricating grease
O 型圈：O-ring
油封：Oil seal
Assemble the left and right driven wheel together

Put pilot pin coated with oil in the guide slot
Pilot pin Guide slot

- 138 -

Install spring sheath.
Wipe clean the spilled oil.
弹簧护套：Spring sleeve
Install the clutch-pressing spring and clutch on the driven

wheel.
Use clutch spring pressing combination. After the
compression, the lock nut should be installed.
Attentions:
The spring should be compressed appropriately, otherwise it
would be damaged.
扳手：Wrench
离合器弹簧压缩器：Clutch spring compressor
14.7 Assembly
The assembly of driving plate/ clutch / driven wheel should be in the reverse order of disassembly.
14.8 Feet start mechanism
Disassembly/Checking
Remove the left crankcase cover
Loosen screws and remove the baffle.
Remove start claw components
Remove start-axis components
Check the wear of start shaft.

Check the wear situations of start bushings and force
part of idler shaft
- 139 -

Check the wear of idler gear
Measure the clamping force of retainer
General standard value: 8-12N
Note: 1.retainer
2. Starting claw
3. Idler gear
4. Idler shaft
5. Start shaft assembly 6. Feet start shaft spring
Reduction gear
- 140 -

Function: it is a transmission
torque and could determine the
final output torque and speed.
- 141 -

15. Speed Reducer
Preparation Data----------------- 15.1
Fault Diagnosis ----------------- 15.2
Gearbox ------------------- 15.3
Installation --------------------- 15.4
15.1 Preparation Data

Effect: Transfer the torque and determine the final output torque and rotational speed.
15.2 Fault Diagnosis
Vehicle can not move in spite of the starting engine;

Drive gear was damaged;
Drive gear was burned;
Gear oil was leaked;

Gear oil was too much;
Grease seal was damaged;
Gear Box Cover

Bolt
15.3 Gear Box
15.3.1 Disassembly
Remove the oil drain nut and release the gear oil out from gear box.
Loosen the bolts and remove the gear box cover.
- 142 -

Remove the gasket and dowel.
Remove the principal axis of clutch and output shaft gear. Gasket Output Shaft
Remove the central jack shaft and central gear. Gear
Jack Shaft Principal Axis

Central Gear of Clutch
15.3.2 Examination of Output Gear Box
Cover
Examination of the tear and damage on the principal axis of
clutch, gear and bearing. Principal Axis of
Bearing exchange of gear box cover. Clutch
During the bearing exchange of the principal axis of Grease Seal Bearing
Clutch, the principal axis of clutch should be punched and
removed from the gear box cover.
Note:
The punched bearing cannot be reused and should be
changed into new one. The disassembly of bearing and
grease seal should be applied with professional tools.
Remove the grease seal from gear box and make the bearing.
Note:
The punched bearing cannot be reused and should be changed into new one. The disassembly of bearing and
grease seal should be applied with professional tools.
15.4 Assembly
The assembly should be conducted in the adverse order of disassembly.
Note: The assembly of bearing and grease seal should be applied with the professional tools to avoid damage.
- 143 -

Crankcase
Note: The crankcase is

thin-wall casting and
should be prevented
from impact to produce
distortion or rupture.
All components
should be cleaned
before examination and
test and blew clean with
pressure air.
Before operation,
please release lubricant
oil from the crankcase.
- 144 -

16. Crankcase
Preparation Data-----------------16.1
Fault Analysis-----------------16.2
Crankcase -------------------16.3
Assembly---------------------16.4
16.1 Preparation Data

Attentions to operation:
The crankcase is thin-wall casting and should be prevented from impact to produce distortion or rupture.
All components should be cleaned before examination and test and blew clean with pressure air.
Before operation, please release lubricant oil from the crankcase.
Effect of crankcase: The crankcase is the force bearing component for engine. Its main role is to support
crankshaft, clutch, gearbox, cylinder block and cylinder head and bear the burn outbreak impact and the inertial
force of crank linkage motion and form some closed space (airproof to oil and gas). The crankcase is also
equipped with hang hole by which to make the motor connect with car frame and other parts.
Preparation Datum Unit：mm
Item Standard Value Allowed Limit
Clearance between both big ends of the
0.25-0.40 0.55
connection rod
Crank Axle
Radial clearance between big end of the
0.015-0.025 0.05
connection rod
Tool
Universal Holder Clutch Spring Compressor
Screwdriver Rod Jacket Wrenches
Guide Bar Bearing Screwdriver
16.2 Fault Analysis
There is some odd voice inside the crankcase.

There are components scattered or broken inside the crankcase. The crankshaft bearing is loose.
The crank pin bearing is loose. The clutch is stuck.
- 145 -

16.3 Crankcase
16.3.1 The Disassembly of Crankcase Bolt

Unscrew the bolt and remove the driving motion gear.
Driving
Remove the gear.
Motion
Gear
Dismantle the fixed bolt of crankcase Gear

Dismantle the crankcase on both sides.
Note:
The gasket should be avoided from damage.
Bolt
Remove the gasket and dowel.

Dowel
Gasket
Remove the crank axle from the crankcase.

Clean the gasket on the faying surface of crankcase.
Note:
No damage should be done to the faying surface of Crank Axle
crankcase.
- 146 -

Remove the grease seal from the left crank case.
Grease Seal
Remove the grease seal from the right crank case.
Grease Seal
16.3.2 Examination
The measurement of clearance between the connecting rod.
Allowed Limit: 0.6mm
连杆大端测量位置
Measurement Location of the Connecting Rod
The measurement of clearance in X-Y direction between the

connecting rod.
Allowed Limit: 0.05mm
- 147 -

Check if there is odd voice or loose in the rotation of crank
axle bearing.
If there is odd voice or loose, please change the crank axle
component.
Note:
The dismantled grease seal cannot be reused. Crank Axle Bearing
The disassembly of grease seal should adopt professional tools.
16.4 Assembly
The assembly of the crank case should be in reversible order of the disassembly.
Note:
The disassembly of grease seal should adopt professional tools so as to avoid damage to grease seal.
- 148 -

Examination and Maintenance of the Exhaust Gas Emission System Silencer
The torque force value of set

bolt 13 in the joint of
A
silencer in the picture is 5-9
N·m
B bolt 6 in the joint of silencer
in the picture is 22-29 N·m
bolt 12 in the joint of
C silencer decoration
component in the picture：
5-9 N·m
1.Graphite Winding Gasket 2. Exhaust Pipe Assembly 3. Socket Head Cap Screws M6×25 4.Broken Bolt
M6×25 5. Bolt M6×16 6. Connected Flange Gasket Assembly 7. Cushion Ring 6 8.Spring Cushion Ring 6
9. Nut M6 10. Bolt M8×20 11. Muffler Tube Assembly 12. Cap Nut 13.Cushion Ring 6 14.Gland 15.
Silencer Anchor Ear 16.Gasket 17.Shell Assembly 18. Plate Bar Clasp 19.3 19. Check Valve And Silencer
Connection Pipe 20. Check Valve 21. Bolt M6×35 22. Oil Pipe 13×18×50 23. Plate Bar Clasp 17.5 24.Small
Strainer 25.Rubber PipeⅡ
- 149 -

17. Exhaust Gas Emission Control System
Guaranty of Exhaust Gas Emission Control System---------------17.1
Regular Maintenance Notice/Guarantee of the Emission Standard ------------17.2
Exhaust Gas Control System Machinery Function-----------------17.3
Accelerant Transformation System -------------------------17.4
Solutions for Idling Emission Amount Surpassing the Rated Value ---------17.5
17.1 Guaranty of Exhaust Gas Emission Control System

1. The exhaust gas emission control system of the vehicle conforms to the revision of EUEC/97/24/5/I and
2002/81/EC B phase. The company will guarantee when the users normally use and maintain it as stipulated
within the shelf life of exhaust emission control system.
2. Guaranty Scope
2.1 Function guarantee for the exhaust emission control system
The company guarantees that it complies with the regular or irregular exhaust gas test implemented by the
government agency when the stroke is less than 15,000 km.
3. The guarantee clause is not applicable for the following situations. But if the customer still needs maintenance,
the sales agency or service department of the company in all provinces and municipalities can provide service to
customers with reasonable price.
3.1 No regular maintenance is conducted in accordance with the specified time or mileage;
3.2 No regular check, adjustment or maintenance is conducted in our sales agency or service center or those
cannot provide maintenance record certification.
3.3 Overload or inappropriate application;
3.4 Customers who renovate vehicle at will and dismantle original component or assembly other equipment;
3.5 Applicable to racing or other road that is not appropriate for non-motor vehicle;
3.6 Damages caused by Typhoon or flood and other kind of natural disaster, or caused by mistakes, car accidents
or impact of foreign object.
3.7 Customers who terminate use for a long term and do not keep regular maintenance;
3.8 The odometer was damaged but customers did not immediately maintain or construct, stop using or change
3.9 Please come to the inspection station for regular exhaust gas test every three months;
New vehicles produced by the company have been certified to EC 97/24/9 standard implemented by EU after
noise test.
17.2 Regular Maintenance Notice

To prevent from the increasing damage caused by environment pollution, the country asked all manufacturers to
comply with the air pollution emission standard. Our company has not only conformed to the air pollution
emission standard but also strive to purify the air and work hard to cut air pollution.
This vehicle has been strictly inspected before sale to conform to the air pollution emission standard. But due to
different circumstances, we have implemented the following regular examination list related to exhaust emission.
To ensure the normal emission, the users should conduct inspection, adjustment and maintenance at required time.
- 150 -

For other problems, please inquire KEEWAY Sales Agency or KEEWAY Service Center.
Related emission regulations are listed below:
Emission Regulation CO HC+ NOX
Emission Standard ≤1.0g/km ≤1.2g/km
※ If the emission standard has any changes, please refer to the latest national standard.
For customers who do not conduct regular test from sales agency or service center, our company will not be
responsible when they are banned. Please conduct necessary and regular examinations to ensure the best car
condition.
Note: 1. Please clean the air filters more frequently to prolong the lifespan of motor on sand road or in
serious environment pollution.
2. For customers who always drive on expressway or drive frequently or have relatively much mileage, the
maintenance should be enhanced.
To ensure emission standard please pay attention to the following aspects:
1. For fuel use, please make sure to use 92# and 95# unleaded gasoline;
2. For oil use, please make sure to use the designated specification of oil;
3. Please maintain it with regulations of regular maintenance list.
4. As for exhaust gas control system, casual adjustment or change is prohibited (including spark plug use, idle
speed adjustment, ignition timing and carburetor adjustment, etc.)
5. Attentions:
Since the unsmooth operation of ignition system, charging system and fuel system have a significant impact on
the accelerant, so please immediately come to our designated sales agency or service center for check, adjustment
or maintenance when you find the motor is not smooth.
Please make sure to use 92# and 95# unleaded gasoline or else it will damage the accelerant facility (Two-stroke
system).
6. Our exhaust gas control system complies with national standard. So if you need to change any component,
please make sure to use our component through our designated sales agency or service center.
17.3 Exhaust Gas Control System Machinery Function

Summary
The solution to exhaust gas is to take two-stroke single-cylinder engine and carburetor means as fundamental and
adopt air leading-in device and maintain excellent exhaust gas standard. In addition, fuel evaporation exhaust gas
should adopt active carbon canister.
Motor Improvement
The semi-circular combustion room equipped with spark plug, in addition to compression ratio, ignition
timing and improvement of motor element in exhaust gas system along with high intake and exhaust
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efficiency seek the improvement on fuel efficiency.
Air Guide Equipment
Guide the air into exhaust gas pipe. The incomplete burned CO and HC will become harmless gas again.
Distinction Equipment Component Purpose and Function
Canned oxidated accelerant equipped in
Exhaust Gas Accelerant
Accelerant Device the center of exhaust gas pipe makes CO,
System Transformer
HC and NOX oxidated.
Adjustable Parameter and Recommended Set Point

Idling Adjustment-Motor Speed 1800 ±100rpm/Min
CO Concentration 0.5-1.0%
17.4 Accelerant Transformation System

17.4.1 Structure:
- 152 -

触媒加放点
Accelerant Adding Point
17.4.2 Introduction:
1. The effect of transformed accelerant is to change the exhaust gas HC, CO and NOx into harmless gas H2O,
CO2 and N2 and discharge them.
2. The transformed accelerant contains Platinum and Rhodium and other rare metal. Unleaded gasoline is the
only alternative.
Note: Leaded gasoline will make the accelerant loose efficacy.
General attentions for checking the vehicle (exhaust pipe) equipped with accelerant transformer
1. As for vehicle equipped with transformed accelerant, please do not touch the motor during the work process
of motor or fire cutoff because its temperature is too high.
2. Vehicle equipped with transformed accelerant is not allowed to approach the inflammable.
3. The exhaust pipe contains CO and is harmful to health so please do not run the motor in closure space.
4. Vehicle equipped with transformed accelerant is not allowed to use leaded gas. (To prevent from accelerant
poisoning)
5. To start motor by pushing vehicles is not allowed. If one has to start motor by pushing vehicles, please wait
for the temperature reducing of motor and accelerant transformer.
6. When going downhill, to drive vehicle by engaging gear or cutoff is not allowed;
7. To drive vehicle with bad ignition is not allowed;
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8. When repairing the motor ignition system, to dismantle the ignition plug is not allowed. If necessary, time
should be limited.
17.5 Solutions for Idling Emission Amount Surpassing the Rated Value (Two Strokes)
Implement Regular Inspection (Maintenance Plan)
Qualified
Measure Idling Emission (Note 1)
Qualified
Adjust the Carbureter (Note 2)
Qualified Leave the Factory

Strip and Clean Carbureter
Qualified
(SJ, MJ, SAJ and MAJ)
Qualified
Change the Carbureter
Strip and Clean the Motor

•Valve (Leakage) Qualified
•Plug (Wear-out) 合格
•Combustion Chamber(Clean)
Note 1: Measure with idling measurement process
Note 2: Adjust the motor revolution speed to be within the regulation with retention bolt and measure the idling
CO/HC.
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155

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Two-wheeled Motorcycle F-ACT EVO

User’s Instruction and Maintenance Manual

KEEWAY Motorcycle Co., Ltd

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This maintainence manual mainly describes the maintainence essentials of the

maintainence manual carefully before any operation.

vehicle safety and the performance maintenance method of various components.

check essentials of motor, complete vehicle and electric fittings.

Every Chapter is accompanied by an exploded view, system diagram, and failure

diagonosis and instructions during the editing.

KEEWAY Motorcycle Co., Ltd

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After disconnecting and before measuring the wear value, please

The rubber parts may deteriorate because of aging, which is

When loosing the components which have many assembly parts,

The complex assembly part such as speed gear box shall be

Special attention should be paid to the important attachment

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Disassembly of ball bearing: use the instrument to withstand one

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clamping the cable, please check the following one to ensure

the electric safety;

Please bind the cables at the specified position；

The cable can not be routed on the end of bolt or screw;

The cable routing shall be kept away from a heat source or

the place which may clip the cable when moving;

Over tightening or over loosening shall be avoided when the

cable is routed along the cocket handle, and no contacting

with the adjacent components in any steering position;

The cable routing shall be smooth without twisting or

Please confirm if there is any damage to the connector

assembly sheath or any excessive expansion of the connector

assembly before the butt joint of the onnector assembly;

If the cable is placed on the closed angle or corner, please use

tape or hose to protect;

Please use the tape to wrap the cable after repairing;

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1．The motorcycle indentification number is printed on the

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Figure 1-3 Figure 1-4

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Figure 1-7 Figure 1-8

Figure 1-9 Figure 1-10

Figure 1-11 Figure 1-12

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Figure 1-13 Figure 1-14

Figure 1-15 Figure 1-16

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Figure 1-21 Figure 1-22

Figure 1-23 Figure 1-24

Figure 1-25 Figure 1-26

Figure 1-27 Figure 1-28

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Model QJ50T-21T Type of engine QJ1E40QMB-4

clutch Dry centrifugal type