Fact Evo

Two-wheeled Motorcycle F-ACT EVO
Users Instruction and Maintenance Manual
KEEWAY Motorcycle Co., Ltd
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Content .................................................................
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 3.1 Material Preparation ........................................................ - 67 3.2 Failure Diagnosis ........................................................... - 68 3.3 Starting Motor .............................................................. - 68 3.4 Starting Relay .............................................................. - 70 4. Bulbs/Switches/Meters ............................................................ - 73 4.1 Material Preparation ........................................................ - 73 4.2 Failure Diagnosis ........................................................... - 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
1The motorcycle indentification number is printed on the
frame , 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 of the frame.
Figure 1-1
2The engine series number is printed on the outer shell

of crankcase, please see Figure 1-2.
Figure 1-2
Important Notices:
1Please 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.
2Use only the metric instruments to do the maintainence operation. The metric bolt, nut and screw are not
interchangeable with the British fastener.
3When reassembling, new washer, O ring, split pin and locking plate should be replaced.
4When 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.
5Wash the disassembled parts with cleaning solution. Lubricate all the sliding surfaces before assembling.
6After 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

clutch clamper
flywheel extractor
proof stick
bearing disassembling tool
bearing assembling tool
oil seal assembler/disassembler
dismantling tool handle
piston pin pulling off device
piston ring opening pliers
spark plug socket wrench
measuring the thickness of clutch
cylinder diameter determinator
dial gauge
Used for assembling and disassembling Flywheel Bolt, Figure 1-3

Figure 1-4
Figure 1-5
Figure 1-6
Figure 1-7
Figure 1-8
Figure 1-9
Figure 1-10
Figure 1-11
Figure 1-12
Figure 1-13
Figure 1-14
Figure 1-15
Measuring the inside diameter of piston pin holeFigure 1-16
Continuation Table 1-2
Figure 1-3
Figure 1-4
- 9 -
Figure 1-5
Figure 1-6
Figure 1-7
Figure 1-8
Figure 1-9
Figure 1-10
Handle
Figure 1-11
Figure 1-12
- 10 -
Opening pliers
Figure 1-13
Piston
Figure 1-14
Figure 1-15
Figure 1-16
2Tools 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
inner hexagonal wrench
socket wrench
micrometer
magnetic frame, V-block
dial gauge
vernier caliper
spring retaining ring pliers
knocker screwdriver
front fork oil seal assembling tool
front fork seal driver
steering nut wrench
Figure 1-19
Figure 1-20
Figure 1-21
Figure 1-22
Figure 1-23
Figure 1-24
Figure 1-25
Figure 1-26
Figure 1-27
Figure 1-28
Figure 1-29
Figure 1-30
1Universal tool for the overhaul of chassis

- 11 -
Figure 1-19
Figure 1-20
Figure 1-21
Figure 1-22
Figure 1-23
Figure 1-24
Figure 1-25
Figure 1-26
Figure 1-27
Figure 1-28
2Special tool for the overhaul of chassis: front fork seal driver.
- 12 -
Figure 1-29
3steering nut wrench.
Figure 1-30
3Tools 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
ignition tester
Figure 1-33
Figure 1-34
Figure 1-33
Figure 1-34
- 13 -
Specification Table (QJ50T-21T)

QJ50T-21T
Type of engine
QJ1E40QMB-4
Full length mm
1860
Type of fuel
lead-free gasoline
93/95
Full width mm
680
Full height mm
1198
49.239.2
Wheelbase mm
1290
Number of
cylinders
Inside
diameter*stroke
Total
displacement
Initiate mode
Electric/foot initiate
Cooling system
Wind cooling
Lubrication type
Separating lubrication
Air cleaner
3XG
Fuel tank
capacity
5.6L
Carburetor model
PZ19JB
Idling speed -rpm
1800100rpm/min
Maximum torque
4.0N.m/6500rpm
Maximum
horsepower
2.7kW/6500 rpm
Compression
ratio
6.91
Maximum speed
45km/h
Front brake disc

Diametermm
190mm
Rear brake drum

inside diameter
mm
175mm
Type of
clutch
Rear axle
59
Total
Front
wheel tyre
Front
wheel rim
Rear
wheel tyre
Rear
wheel rim
99
49.3cc
3.5012
130/70-12
3.5012
Dry centrifugal type
infinite variable speed
Driving type
belt transmission
Spark plug
120/70-12
Variable
speed
mechanism
Storage
battery
capacity
/Type
Magneto
capacity
Electrical installation
40
12V-3AH/dry-charged
89.6W/5000rpm
Performance
Driving mechanism
Wheel
specification
front axle
BR8HSA
Spark plug
gap
0.6-0.7mm
Ignition type
CDI
Brake
apparatus
Weight of vehicle
kg
Curb weight
Engine
Model
- 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
Strong blue spark
Yes
1. Check if the CDI ignition

apparatus fails
2. Check if the magneto
flywheel
and
trigger
winding loosen
Faint or no spark
Check if the spark plug, spark plug cap fails
Loosen carburetor fuel

draining screw, check if
there is fuel draining
from
the
carburetor
overflow pipe
Yes
Check
the
supply
of
ignition
power
Check
if
there is short
circuit
or
broken
circuit
of
ignition coil
Check if there
is short circuit
or
broken
circuit of the
internal system
of
ignition
system
No
Check if the
CDI ignition
apparatus
fails
Use
the
cylinder
pressure gauge to test
the
cylinder
compression pressure
Check if there
is fuel in the
fuel tank
No contact magneto ignition system
1. Check if there is short
Cylinder
Cylinder
circuit or broken circuit of
compression
compression
trigg
ignition power winding
pressure
pressure
er
2. Check if there is short
normal
insufficient
windi
ng es
circuit or broken circuit of

trigger winding
To
fill
the
fuel
- 16 -
No
Remove
the
spark plug to
test
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
5. Check if the carburetor
floater is too high
Spark plug electrode is moist
Spark plug electrode is dry
Check if there is oil leaking from

carburetor
Yes
Instill small amount of fuel into the cylinder to

have an experimental starting
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
2. Check if the conical
running a very short time
starting
surface of the carburetor

float needle valve is worn
into step shape
float breaks
Carburetor
The carburetor inside
device (starting richer
blocks or the float is
system) fails
too high
float is too low
- 17 -
starting
The engine overheat failure diagonosis procedure

Engine overheat
Check if the operation method is proper

Yes
No
Check the cooling system
1. Check if the fuel No. is too low

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
Check
No
and
Use ignition timing light to test
eliminate
whether engine ignition is timing
No
Yes
1. Check if the CDI

ignition apparatus
fails
2. Check if the
magneto flywheel
and trigger winding
loosen
Check if the clutch slips
Yes
Clutch slips
To treat the clutch

slip
failure
accordingly
- 18 -
No
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

exhaust muffler smokes or blast when the
spark plug insulator cluster is brown
white, the engine is intermittent
engine is running at medium and low speed, the

accelerating ability is bad, idle speed is unstable
the
and tends to stop easily, relatively normal when
combustible gas mixture is proper
mixture
ratio
of
the
running at high speed.
combustible gas mixture is too strong
1. Check if the air cleaner blocks

2. Check if the carburetor starting
Spark plug insulator cluster is
when
carburetor
backfires and the engine power is

insufficient etc
Check if the vent of
Check lubricating
combustible gas mixture is
cylinder and exhaust
system
too weak
muffler block because

of too much carbon
device (starting richer system)
Two-stroke
works well
lubricating system
engine
3. Check if the carburetor float is

too low
1. Check if the fuel in the
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 -
accelerating,
1. Check if the fuel

cock works well
2. Check if the
carburetor float is too
high
3. Check if the orifices
and pore canals on the
carburetor block
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
Air pressure too low
3. Check if the loading of hubs
Air pressure normal
central spacer is neglected or

shorter
Check if the tire valve core

leaks and if the tire breaks
Remove the spark plug and block the spark

plug threaded hole with hand, then press the
starting button or step on the starting bar
quickly
Fingers can feel a strong gas blowing

outside, with the sound of pow at the
same time
Fingers can not feel a strong gas blowing outside
Cylinder compression pressure insufficient

Cylinder compression pressure normal
Start the engine and step on the gas

slowly to watch the change of
engines rotating speed
The rotating speed of the engine accelerates

as the driver step on the gas
1. Check if the clutch skids
2. Check if the transmission belt is over worn
3. Check if the centrifugal roller of the
driving pulley is over worn
4. Check if the conical surfaces of driving
wheel and moving friction wheel are over
worn or worn into groove
5. Check if the conical surfaces of following
pulley and moving following pulley are
over worn or worn into groove
6. Check if the roller track on the internal
side of moving friction wheel are over worn
or extruded into a drop pit
The rotating speed of the engine does

not accelerate as the driver step on the
gas
Yes
1. Check if the supply of fuel feeding
system is smooth
2. Check if the carburetor, air cleaner and
exhaust muffler block
3. Check if the vacuum diaphragm of
carburetor plunger valve cracks or
breaks
4. Check if carburetor float height is
improper
- 20 -
1. Check if there is gas

leaking
in
external
connections of the engine
2. Check if the piston ring
sticks in ring groove or
insufficient elasticity
3. Check the wearability of
piston ring and cylinder
No
1. Check if the CDI

ignition apparatus fails
2. Check if the
magneto flywheel and
trigger winding loosen
Failure diagonosis procedure of unstable engine idle speed

Bad idle speed of engine
Engines idle speed too high
Engine has no idle speed
Check the cylinder compression pressure
cylinder
compression
pressure insufficient
Yes
Readjust the idle speed
leaking
of carburetor
in
external
Pull the air throttle of carburetor by

hand and check if it is closed
completely
cylinder compression
pressure normal
1. Check if there is gas
Check if
the idling
jet is too
large
connections of the engine
or insufficient elasticity
piston
ring

Yes
Check if the
wire rope of
accelerator
control cable is
in
No
Check if
the
gap
between
spark plug
electrodes
is
too
small
1. Check if the CDI

ignition apparatus fails
2. Check if the magneto
flywheel
and
winding loosen
cable cover and

Engine has idle
speed
after
adjustment
3. Check the wearability

of
No
flexible
2. Check if the piston

ring sticks in ring groove
Engines idle speed unstable
Engine still has

no idle speed
after adjustment
if
the
air
throttle spring
is too weak
Yes
No
and
The carburetor air
adjusting screw
or air throttle
adjusting screw is
adjusted
improperly
No
cylinder
Check if the idling jet of

carburetor, idling oil
channel and air flue
block
Yes
ratio
the
of
combustible
Wash and clear out

No
1. Check if there is crackle in the carburetor

insulator
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 -
Check
electrodes
Yes
Check if carburetor float is too high
Adjust the carburetor

float height to standard
value
Adjust the gap of
mixture
mixture
the
gas
trigger
Failure diagnosis procedure of engines excessive fuel consumption

Excessive fuel consumption of engine
Check if the operation method is right

Yes
No
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
right
Prop up the main jiffy stand and revolve wheel by hand
Wheels revolve difficultly
Wheels revolve smoothly
1. Check if the brake
Check the tire pressure
drags
2. Check if the wheel
bearing is overused
Tire pressure is too low
3. Check if the loading
Tire pressure is normal
of hubs central spacer

is neglected or shorter
Check there is fuel leaking in

the fuel tank, fuel cock, fuel
pipe and carburetor
To charge as required
Yes
No
Check the mixture ratio of the

combustible gas mixture
To exclude in accordance with the actual situation
The mixture ratio of the combustible

gas mixture is normal
Combustible gas mixture is too strong
Check if the engine idle speed is too high

Yes
No
Check and adjust the

carburetor
Use ignition timing

light to test whether
engine ignition is
timing
Yes
Check if the transmission
1. Check if the air cleaner
1. Check if the inside of
blocks
carburetor blocks
float is too low
float is too high
3. Check if the main jet of

carburetor is too large
No
Check ignition system
belt of clutch slips
- 22 -
Combustible gas mixture is too weak
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

overfilled, please drain out the excess
oil and make sure the oil level does
not exceed the upper label
Start the engine and make it run at high

speed, remove the engine oil scale to check if
the engine oil filling port smokes
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
Improve the operation method
Check if the clutch is separated completely

No
Yes
Check if the gear-shifting axis is deformed, and if the

gear-shifting arm is deformed or over-worn
Yes
Replace
No
1. Check if the gear-shifting camshaft and

cam groove are over-worn or damaged
2. Check if the shift fork hole is over-worn
3. Check if the shift fork is deformed
4. Check if the declutch shift shaft is
deformed or over-worn
- 23 -
1. Check if the free stroke of clutch

lever is within 10mm ~ 20mm
2. Check if the spring force of clutch
is even
3. Check if the driving and driven hub
alveolus are worn to indention
4. Check if the clutch driven plate is
deformed
5. Check if the parts of clutch control
mechanism are over-worn
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
Disassemble the crankcase, check if the gear wheel engaging depths of
various gears are up to requirement
Replace
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
face is worn to conical or round shape, and if the
corresponding gear face groove is worn to pipe socket
Yes
the
No
Yes
No
Check if the spline teeth of

main shaft and counter shaft
wheel
and the spline groove of
sliding gear are over-worn
Failure diagnosis procedure
when the clutch slips
Replace
Check if the shift fork is

over-worn or deformed
gear
1. Check if the shift fork hole and declutch

shift shaft are over-worn
2. Check if the fitting clearance between
the shift fork pin and the gear-shifting gear
shaft and the cam groove are too large
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

dis of the clutch is
over-worn
Eliminate the oil
No
Check if the
between the
friction dis
friction plate
70
Yes
contact area
clutch block
and clutch
is less than
Replace the whole clutch block set
No
Yes
Check if the contact area

between the clutch friction
plate and block friction dis are
over-worn
- 24 -
Repair or replace
clutch block
Replace the shift

fork
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

reserve tank
The brake fluid level above the lower limit of

liquid reserve tank
Check if there is sponge
feels when operating the
brake lever
Fill the brake fluid to the

upper limit of liquid reserve
tank, at the same time
check if there is oil leaking
in the brake caliper, brake
hose and hose joints
Yes
No
N
Check if the brake friction disc is
worn to limit mark and if the brake
plate is over-worn
There is residual air

in the fuel line of
brake system
Yes
No
Replace the brake

friction disc and
the brake plate
1. Check if the surface of brake primary pump piston and oil

cylinder is over-worn
2. Check if the leather cup of brake primary pump piston cracks or
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
Separate the steel ropes of brake rocker arm and brake control cable, then
pull the brake rocker arm by hand to check
Readjust
Brake rocker arm

revolves smoothly, but
you feel resistance
when holding the
brake handle
The wire ropes of
brake
control
cable can not be
pulled smoothly
in the cover
Brake rocker
arm revolves
difficultly
The movable
parts of the
brake cam are
rusted or stuck
in
foreign
materials
The arrow on the indicating

plate of brake cam aligns with
or exceeds the mark on
the brake wheel hub cap
1. Check if the crown face of the brake
cam is over-worn
2. Check if the brake block friction disc
is over-worn
3. Check if the brake wheel hub inside is
over-worn
- 25 -
The arrow on the indicating plate

of brake cam does not align with
the mark on the brake wheel
hub cap
1. Check if the surface of brake
block friction disc is stained with
oil
2. Check if the contact area
between the brake block friction
dis and brake hub is less than 70
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

standard value
Short circuit
charge coil
of
The resistance value is equal to

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

wire bundle and the complete vehicle cable, disconnect
the insert connector between the commutator or
commutation regulator and the complete vehicle cable
Short circuit of charge

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

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
The circuit from the magnetor to

commutator or commutation
regulator is in poor contact or
broken
No voltage indicates
Circuit from the

insert connector
to storage battery
is broken
Voltage indicates
Use the ohmmeter to test the

commutator or test if the
commutation regulator fails
- 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

lamp switch
Put the ignition switch in OFF position, remove the negative pole wire from the
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

specified value (it is generally required
that the leadkage current is no greater
than 1mA)
Leakage current is less than the specified value

Check if the charging coil of magnetor is
shortcircuited
Yes
Replace the
charging coil
No
1. Check if the electrolyte in the storage battery

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 -
The wire from the commutator

or the commutation regulator or
the storage battery to the ignition
switch is shortcircuited
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

or the sound is weak, and the
light of turn signal is pale
The sound of the electric horn is

loud and the light of turn signal is
bright
The electricity in the storage

battery is insufficient or the wire
terminal connecting the storage
battery is in poor contact
Hold the brake handle (seat-type motorcycle)

tightly, or put the gear shift in neutral gear or hold
clutch handle tightly, press the start button
Press the start button, you can not hear the connection sound of
the start relay
Press the start button, you can hear the

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
positive terminal and negative terminal of the storage battery
and the two leading wires of start relay coil
The start motor can not

rotate after connecting, and
the connection sound of
start relay can not be heard
either
The start relay coil

is
broken
or
short-circuited
The start relay can

rotate normally after
connecting
The start motor can

rotate normally after
shorting
Check if the line of electric start

control system
Riding motorcycle
Use the screwdriver or heavy gage wire

to short-circuit the storage battery
terminal on the start relay with the start
motor terminal
The start relay

contact is burnt or
damaged
Seat-type Motorcycle
Hold the brake handle tightly and check if the brake lamp
will light up
1. Check if the starting
button contact is in poor
contact
2.
Check
if
the
commutating
diode
is
damaged
3. Check if the neutral gear
switch works well
4. Check if the line of
electric start control system
is broken or short-circuited
Yes
Check if the starting

button contact is in
poor contact
Yes
Repair or replace
the starting button
No
The inside contact of brake

lamp switch is in poor
contact or its wires are
broken
No
Check if the line of electric

start control system is
broken or short-circuited
- 28 -
The start motor does

not rotate after
shorting
Disassemble the start motor and do

the following inspections:
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 over-worn
4. Check if the armature coil is
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

or the sound is weak, and the
light of turn signal is pale

loud and the light of turn signal
is bright
The electricity in the storage

battery is insufficient or the wire
terminal connecting the storage
battery is in poor contact
Check if the wire terminal between

the relay and the start motor is in
poor contact
No
Remove the start motor connecting wire and storage battery

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
Disassemble the start motor and do the

following inspections:
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
Check and exclude
No
The start relay contact is

burnt or damaged
- 29 -
Yes
Failure diagnosis procedure when all the lamps dont work

All the lamps dont work
AC power supply illuminating system
DC power supply illuminating system

Press the horn button or
toggle the steering lamp
switch
Disconnect the insert connector between the magnetor

wire bundle and the complete vehicle cable, use the
lamp-testing method to check if there is electrical energy
output from the output wire of magnetor lighting coil
Testing lamp does not work
The electric horn

sounds loudly and the
steering lamp works
Testing lamp works
Start the engine, disconnect

the insert connector between
the commutation regulator and
the complete vehicle cable
The magnetor lighting

coil or its output wire is
The power supply of

storage battery is
normal
The lamp still does not

work
The lamp works
The
inside
of
commutation regulator is
short-circuited
No sparkle
touching
Disconnect the head lamp

assembly, and check if the bulb
of head lamp is burnt
Yes
The electric horn does not

sound and the steering lamp
does not work
Use a wire to touch

positive
terminal
negative terminal of
storage battery quickly,
check if there is sparkle
when
No electricity
in the storage
battery
No
Replace the bulb of head lamp, and

check if the bulbs of other lamps
are burnt one by one
Use the lamp-testing method to check if

there is electrical energy output from the
power input wire of lighting switch
Yes
The internal contact of

lighting switch is in poor
contact
1. Check if the fuse is

burnt out
2. Check if the wires
from
the
storage
battery to ignition
switch are broken or
short-circuited
3. Check if the ignition
switch is broken or
short-circuited
The wires between the

magnetor or ignition switch to
the lighting switch are broken
or short-circuited
The lamp still doesnt work after shortcircuiting
The wires between the

lighting switch to lamps are
- 30 -
Sparkle appears
when touching
No
Use a wire to short circuit the power lead

of lighting switch and the output lead
The lamp will work after shortcircuiting
the
and
the
and
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
loud and the light of turn signal
is bright
The electric horn does not sound or

sound raucously, and the light of
turn signal is pale
1. Check if the terminal connecting the

storage battery is on poor contact
2. Check if the electrolyte in the storage
battery is insufficient
3. Check if electrolyte concentration in
the storage battery is too low
4. Check if the polar plate in the storage
battery is sulfurized or short-circuited
Remove the insert connector between the

commutation regulator and the complete vehicle
cable, and use the ohmmeter to measure that if the
wires from magnetor lighting charge coil to
commutation regulator are broken
Place the multimeter in the 0V~20V DC

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
Connect
Voltage indicates
The leads from the insert connector to the

storage battery are broken
- 31 -
Yes
No
Check if the commutation regulator fails
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

the magnetor wire bundle and the
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
Yes
Turn on the ignition switch, press the horn button or toggle the
turn signal
The electric horn sounds raucously,

and the light of turn signal is pale
No
The lighting coils

are short-circuited
Start the engine and limit its

rotation speed, disconnect the
insert connector between the
commutation regulator and the
complete vehicle cable to check
the brightness of lamps
The sound of the

electric horn is
loud and the light
of turn signal is
bright
The electricity supply in storage

battery is insufficient or the
connection between the storage
battery to ignition switch is in
bad contact
The lamp light is still weak

after disconnecting
The lamp lights return to

normal after disconnecting
Check if wires in the

magnetor charging coils and
charging
system
are
short-circuited
The stabilized voltage of

commutation regulator is
too low
Yes
No
Disconnect the head lamp assembly,
and check if the bulb glass of head
lamp is black or yellowish-green
Check and exclude
No
Yes
Check if the bulb power used in

the illuminating system meets
the specified requirements
Replace the bulb of

head lamp
Yes
1. Check if the internal contacts of
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
No
Replace the bulb of lamp
- 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

cover and check if the bulb of
steering lamp is burnt out
Remove the steering lamp

cover and check if the bulb of
steering lamp is burnt out
Press the horn button to check the

working condition of electric horn
No
Yes
Use the voltmeter

to measure the
voltage between
the lamp stand
power
line
contact
and
negative pole
Replace
the bulb
of
steering
lamp
No
Yes
Replace
the bulb
of steering
lamp
Disconnect
the
steering lamp switch
insert connector, use
the ohmmeter to test
if the failure side of
steering lamp switch
has been solved
Yes
Voltage
indicates
No voltage
indicates
The lamp stand is

grounded
improperly or the
connection
between steering
lamp bulb and
lamp stand is in
bad contact
The power
line
of
lamp
stand
is
broken
The output
power line
on
the
failure side
is broken or
the
lamp
stand
is
grounded
improperly
No
The
internal
contact
of
steering lamp is
in bad contact
Disconnect the insert connector of steering lamp switch, use

a lead to short-circuit the power input lead of the steering
lamp switch with the power leads connecting to left and
right steering lamps respectively
The steering lamp will

work after short-circuiting
The
electricity
The electricity supply
supply in storage
in storage battery is
battery
is
insufficient
insufficient
Remove the steering lamp cover
and check if the bulb of steering
lamp is burnt out
Yes
No
Toggle the steering lamp switch,

use one lead or screwdriver to
short-circuit the two lugs of
scintillator
The steering lamp still does not work after

short-circuiting
The electric horn

does not sound or
sounds raucously
The electric horn

sounds loudly
Replace the steering

lamp bulb, at the
same time check if
the
commutation
regulator works well
The steering lamp will

work after short-circuiting
The scintillator
is damaged
The steering lamp still does not work after

short-circuiting
The internal contact of

steering lamp switch is in
bad contact
Use lamp-testing method to check if there is power output

from the power input lead of the steering lamp switch
Testing lamp works
The power lead of the steering

lamp is broken or short-circuited
- 33 -
Testing lamp does not work

The line from ignition switch to
scintillator or the line from
scintillator to steering lamp switch
is broken or short-circuited
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 light of the steering lamp is bright
The steering lamp does not work or the

light is pale
The electricity supply of

storage battery is normal
The electricity supply of storage battery is

insufficient or the wire from the storage
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

screwdriver to contact the non-power terminal of electric
horn (to the terminal of button) with the ground earth
The electric horn sounds after

contacting
The electric horn does not

sound after contacting
The internal contact of horn

button is in bad contact or the
lead from the electric horn to the
button is broken
Adjust the volume and tone of the electric horn
The electric horn still does not

sound after adjustment
The electric
damaged
horn
- 34 -
The power lead from the

ignition switch to the
electric horn is broken
The sound of the electric horn returns

to normal after adjustment
is
The electric horn

adjusted improperly
is
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
wires of the brake lamp switch
Replace the circuit board of

brake lamp
The brake lamp still does not work after short-circuiting
The brake lamp will work after short-circuiting
The brake lamp switch is

adjusted improperly or its
internal contact is in bad
contact
Use the screwdriver or heavy gage wire to touch the

power supply lead of brake lamp switch and the ground
earth quickly, and check if there is sparkle
Sparkle appears when touching
No sparkle when touching
The lead between the brake lamp switch and the

brake lamp is broken or short-circuited
The lead between the ignition switch and the brake

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
Adjust or replace the

brake lamp switch
Put the ignition switch in OFF position, remove the negative pole wire from
the 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

specified value (it is generally required
that the leadkage current is no greater
than 1mA)
Leakage current is less than the specified value
Check if the charging coil of magnetor is short-circuited

Yes
Replace
the
charging coil
No
1. Check if the electrolyte in the storage
battery is insufficient
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
The wire from the commutator

or the commutation regulator or
the storage battery to the ignition
switch is 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
1800100rpm/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 unit: Kpa

QJ50T-21T
Torque
value
Tyre pressure
Front outer
tyre
120/70-12
Front rim
3.5012
Rear outer
tyre
130/70-12
Rear rim
3.5012
Front wheel spindle
55-62
Fixing nut for rear

wheel
145-170kpa
170-195kpa
Nm
100-113 Nm
Certification for Related Parts

Type
Tyre
Lamps
Name
Certificate No.
Front outer tyre
E11 75R -000210
Rear outer tyre
E11 75R -000216
Headlamp
E4 0014908
Tail lamp
E4 50R-0014909
Front steering lamp
E4 50R-001765
Rear steering lamp
E4 50R-001765
Remark
Rear registration plate lamp
E9 50R-001493
Rear-view mirror
Rear-view mirror
E3 001002
Horn
Horn
E13 000612
Side reflector
E11 020614
Amber
Rear reflector
E4 023272
Red
Reflector
- 37 -
Complete black
Periodic Maintenance & Inspection List

Mileage between
services and time
Inspection item
Per
300K
M
Per
1000K
M
Per
3000K
M
Per
6000K
M
Per
12000KM
Per
14500KM
New
1M
3M
6M
12 M
15 M
Applicable tools
Air filter
Petrol filter
Ordinary tools
Oil filter
Ordinary tools
Replacement of engine
oil
Ordinary tools
Replacement every 1000KM
Ordinary tools
Tyre pressure
Tyre pressure
gauge, inflator
Battery inspection
Densimeter,
multimeter
Actuation gap inspection
Ordinary tools
Inspection of steering
handle fastening
Ordinary tools
Absorber working
inspection
Ordinary tools
Screw fastening
inspection
Torque spanner
Oil leakage inspection

for gearbox
Ordinary tools
Inspection or
replacement of spark
plug
Ordinary tools
Replacement of gearbox
oil
Replacement every 5000KM
Lubrication of each part
Ordinary tools
Lubricator
Muffler
Ordinary tools
Ignition timing
Timing lamp
Carburetor
Exhaust gas inspection

at idle speed
Tachometer, CO
HC analyzer
Accelerator inspection
Ordinary tools
Fuel pipeline inspection
Ordinary tools
Lighting/metering/electri
c devices
Visual multimeter
Main stand bracket
Ordinary tools
Torque spanner
Absorber
*
Torque force of engine

bolt
- 38 -
Ordinary tools
Anticipated inspection
1
Ignition systemobviously continuous ignition abnormality, engine fire or overheating, which requires
inspection and maintenance.
Carbon fouling eliminationobviously insufficient horsepower, which requires carbon fouling removal from
cylinder cover, piston head and exhaust system.
Piston & cylinderexcessive 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.
IInspection AAdjustment RReplacement CCleaning LLubrication
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 travel5-10mm
The main adjustment part is the side of the carburetor,

Loosen the fixed nutthenrotate 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.
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.
spark gap
Examination of spark gap.

Gap0.6-0.7mm
*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 stateclosed 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 charge13.1V
Under charge12.3V
* Note
Charge state examination must use a voltmeter operation.
Charge
Connection methodConnect the battery charger positive
pole and battery positive pole together.
Connect the battery charger negative pole
and battery negative pole together.
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 currentstandard0.4A
Emergency4.0A
Charging timestandard10-15h.
Emergency30min.
Charging completeclosed 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 speed1800100rpm/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.
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.
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 path10-20mm
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.
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.
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
UnitKpa
Specification
QJ50T-21T
Tyre
pressure
Front
outer tyre
120/70-12
Front rim
3.5012
Rear
outer tyre
130/70-12
Rear rim
3.5012
145-170
170-195
Tyre specification
QJ50T-21T
Front outer
tyre
120/70-12
Front rim
3.5012
Rear outer tyre
130/70-12
Rear rim
3.5012
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
Rear wheel nut
55-62
100-113
Nm
Nm
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 fixingNm
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
6 Frequency conversion flash apparatus 7 Meters 8 Starting relay
- 51 -
Release resistance
9 igniter 10 Ignition coil assembly
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 overchargeGenerally 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. Dont 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) doesnt 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
Battery
Magnetor
Voltage
20
12V-4AH/dry cell
Full charge
13.1V
Obligatory
charge
12.3V(not working for 1h)
Charging current
standard0.4Arapid4A
Charging time
standard10-15hrapid30min
capacity
90W/8000rpm
Lighting coil impedance20
Green/Red - Black 2.0-2.5

White Black 1.5-2
Charging coil impedance(20)

Type
Voltage
adjuster
Voltage limit
Single-phase semi-wave charge under short circuit

Lighting
Limit
14.0V0.4V/5000rpm
Charging
limit
14.8V0.4V/5000rpm
13.5V/5000rpm
Tightening torque force value

Rectifier bolt
High tension coil fixing bolt
Flywheel Fixing bolt
Body Shield Bolt
Tool
5.0 Nm
9.0 Nm
5.0 Nm
9.0 Nm
Multiple fixing spanner

Flywheel remover
Testing instrument
Multimeter
1.2 Failure diagnosis

Power supply dead
interrupted electric current
Battery overcharge
Battery wire isnt connected
Fuse blow
Bad power switch
Poor contact of the charging wire

Poor contact of the charging system
Poor contact or short circuit of lighting system
Low voltage
Bad charging system
Bad battery charging

Poor contact
Bad charging system
Poor contact of the wire, short or open circuit

Bad voltage current adjustor
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 charge13.1V
Insufficient charge12.3V not working for 1h
*Note
Use voltmeter when charging.
1.3.2 Charging
Connection MethodsConnect 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 CurrentStandard0.4A
Emergency4.0A
Charging Time Standard10-15h.
Emergency30min.
Charging CompletionOpen-circuit voltageabove 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 speed14-15V 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 voltage13.10.5V/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.
Itemwiring color
Judgments
Between Batteryredand
GND of the body
With battery voltage
Between GND wire

blackand GND of the
body
With wiring
Between charging
coil(white) and the GND
of the body
There is resistance in
the magnetor coil
Between light wire

(green/red) and the GND
(plug of resistor, auto side
starter plug, inspect at OFF
position after the removing
of lighting switch
There is resistance in
the magnetor coil
1.5.2 Voltage and Current Adjustor Inspection

When the main wiring is completely normal, check the contact of the adjustors
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 Value1.5-220
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
Fan
1.7.1 Inspection
Remove the 3p connector of the magnetor.
Measure resistance value between the green/red coils of
magnetor and the body GND with multimeter
Standard Value2.0-2.520
Replace the magnetor coil when the measured value exceeds
the standard value.
Bolt
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
Remover
Fix the flywheel using the universal spanner.

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 Value9.0 Nm
Install the left body fender.
- 58 -
Ignition System
Ignition System
1 Battery 2 Horn
3 Power Locking Components
Conversion Flash Apparatus 7 Meter 8 Starting Relay
- 59 -
4 Rectifier
5 Release Resistance 6 Frequency
9 Igniter 10 Ignition Coil Assembly
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 dont 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 voltagealso 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
Recommended
Spark Plug
Standard Value
Standard
C5HSA(NGK)
Hot
C6HSA(NGK)
Cold
C7HSA(NGK)
Spark Gap
Ignition Coil
Impedance
20
0.6-0.7mm
0.610
Primary Coil
Secondary
Coil
With plug cap
5-11K
Without plug cap
0.5-5.5K
Resistance of Trigger20
100-500
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
Reasonin compliance with the following order

The inner resistance is too small and it should be tested
by required tester.
Ignition
Coil
Low rotation speed of the bent axle.

Tester is interfered. (It is normal that several measured
Low Voltage
voltage is above the basic standard.).
Poor contact wire for the ignition system.

Bad ignition coil.
Bad charging coils (measure at maximum voltage).
Secondary
Side
Voltage
No or interrupted high voltage electricity
Wrong connection with the tester.

Bad main switch.
Bad connector of the CDI group.
Poor contact of the CDI group or GND of the CDI
group is short-circuit.
Bad charging coil (measure at maximum voltage) .

Bad triggermeasure at maximum voltage.
Bad high tension electricity connector.
Bad CDI group (when there is no spark for the plug or
- is abnormal).
Normal high voltage electricity/no spark for the

plug
Bad plug or secondary ignition coil leakage.

Bad ignition coil.
The inner resistance is too small and should be tested by
required tester.
Charging
Coil
No high voltage electricity
Low rotation speed of the bent axle.

Tester is interfered. (It is normal that several measured
voltage is above the basic standard.).
Bad charging coil- are normal.

No or interrupted high tension electricity
Bad ignition coil.

Bad charging coil.
The inner resistance is too small and should be tested by
required tester.
Low high voltage electricity

Trigger
Low rotation speed of the bent axle (It is normal that

several measured voltage is above the basic standard.)
Tester is interfered.
Bad trigger- are normal.
No or interrupted high voltage electricity
Bad ignition coil.

Bad trigger
- 61 -
2.3 Ignition System Inspection
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 10M10CV 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.
Multimeter
* Note
Make sure the wire connection is
correct before testing.
Cylinder compression pressure
normally refers to the test value when
the spark plug is installed in the
cylinder head.
Ignition
Coil
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 Voltageabove 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 Methodblack/red end to the positive
pole and black end to the negative pole.
Minimum Voltageabove 95V.
* 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 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
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.
CDI group
Black
Blue /White
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.
/
White/Green
Connection MethodBlue/white end to the positive pole and

black end to the negative pole.
Minimum Voltageabove 1.7V.
* 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 -
/
Blue
/White
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
CDI
Items
Testing End
Standard Value20
Main switch
Red--red/white
Breakover when the main switch is

OFF
Trigger
Blue/white white/green
100-500
Primary coil of the ignition coil
Black/white--black
0.610
Secondary coil of the ignition

coil
Black--spark plug capwithout the

spark plug
0.5-5.5K
2.5 Ignition Coil

2.5.1 Dismounting
Ignition Coil

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
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 Value0.61020
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 Value5-11K20
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 Value0.5-5.5K1020
Ignition Coil
2.6 Trigger
White/Green
/
* Note
Make sure the trigger could be carried out on the engine.
Inspection
/
Blue/White
- 65 -
Black
Green/Red
White
Magnetor Interface

Remove the wire adaptor of the trigger.
Measure the impedance value between the blue/white end
of the wire at the engine side and the ground strap connection
of the body.
Standard Value100-50020
Change the alternator when the value is beyond the range of
the standard value.
DJ7031-2.8-21
DJ621-2.80.5
Activation System
BRAKE SWITCH BRAKE SWITCH

STARTER SWITCH
BATTERY
RELAY
STARTOR MOTOR
Starting Drawing
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

starting motor
6.2mm
3mm
Liner of the starting idler shaft
8.3mm
External diameter of the starting

idler shaft
7.94mm
Torque Tightening Value

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

Activation failure
Weak rotating force

of the starting motor
Starting motor is rotating

well while the engine is not
Burnt out fuse

Low storage battery
Low storage battery
Poor contact of connecting line
Broken main switch
The gear of the starting motor is
Broken starting clutch Blocked by foreign matters.
Broken brake switch
Broken stating relay
poor contact of connecting line
Broken starting motor
Broken starting clutch

anticlockwise revolution of the starting motor
Low storage battery
3.3 Starting Motor

3.3.1 Dismounting
* 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.
Commutator
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 Creditchange 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.
Grease coating on movable parts of the two ends of electric
brush.
Press all the electric brushes into the bracket, then fit on the
front cover of the electric motor.
* Note
Damage is not allowed in the interface between the electric
brush and the armature, pay attention please.
The labial part of the oil seal should not be damaged by the
installation shaft, pay attention please.
Install new O-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 -
Motor Shell
O-ring
Armature
Front Cover
O-ring
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.
Starting
Relay
3.4.2 Voltage Inspection of Starting Relay

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.
3.4.3 Inspection of Ground Loop of Starting Relay

Remove the adaptor of the starting relay.
Starting
Conduction inspection between the grey wire at the end
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 -
Green/Yellow
/
Black
3.4.4 Actuation Inspection

Remove the storage battery out of the starting relay,
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:

E4 0014908
Certificate No. of front position lamp:
E4 50R-001765
Certificate No. of rear lamp:
E4 50R-0014909
Certificate No. of front turn light:
E4 50R-001765
Certificate No. of rear turn light:
E9 50R-001493
Certificate No. of rear license lamp:
E3 001002
1 Front signal lamp

2 Meter 3 Front left turn signal lamp
4 Front right turn signal lamp
turn signal lamp
6 Taillight 7 Left rearview mirror
8 Right rearview mirror
- 72 -
5 Rear left
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
Red/White Black Black/White Grey
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.
G/R Y/R N/W LR
G/B O G/W
BL Y/R LBL
/
/
/
76
The check and maintenance of the chassis

The table of chassis fastener torque
Fastened parts and fastener names
Fastening torqueNm
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

A
Front
brake
disc
diameter:190mm
Front disc thickness:4 m
m
Use limit:3mm
Friction plate thickness:
5.0mm
Use limt:4.0mm
Installation
torque valu
e of bolt 8 in figure 8:
5-9Nm
Installation torque
of value of nut 27 in fi
gure : 37-44Nm
Free
stroke
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
of
brake
assembly 25 Bolt M8 x 36 26 Front brake disc mounting bolt 27 Nut M10 x 1.25
Rear hub brake

A
Torque value of nut 5 in

figure: 100-113Nm
Inside diameter of hub bra
ke: 110mm
wear limit:111mm
Brake shoe block thicknes
s: 4.5mm
Use limt:3.5mm
Rear brake handle stroke:

10-20mm
Installation value of bolt4

in figure:22-29Nm
1 rear shock absorber component 2 bolt M101.2540 3 split pin 4 bolt M835 5 nut M141.5
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
6 brake shoe
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
Front disc thickness
Standard value (mm)

4
Available limit (mm)

3
Front friction plate thickness
5.0
4.0
Front brake disc diameter
190
Inside diameter of rear brake

hub
110
Rear brake shoe block

thickness
4.5
3.5
5.1.2 Torque value

pump body component fixing bolt 5-9 Nm Front cylinder component installation bolt
22-29 Nm
Hydraulic brake handle fixing bolt 5-9 Nm Rear fixing nut
100-113 Nm
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 handle17
2.oil pump body component1
3.brake hose assembly12
4.brake cylinder component24
5.front brake disc22
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 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
Front brake component installation bolt
5-9 Nm
22-29 Nm
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 bolt13
7.Brake shoe block component6
2. Rear brake rocker arm component12
3. Rear wheel fixing nut1
4. Sealing ring10
5. Rear brake return spring11
6.Rear brake cam shaft8
8. Brake shoe block tension spring7

9. Tire E11 75R -000216
10. Rear rim component3.512
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
110mm
Rear brake shoe block thickness
4.5mm
Available limit: Brake hub inside diameter 111mm
Brake shoe block 3.5mm
: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: 100-113Nm
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 bolt12 7.Brake shoe block component6
2. Rear brake rocker arm component 11 8.Brake shoe block tension spring7
3. Rear wheel fixing nut5
9.Tire E11 75R -000216
4. Sealing ring8
10. Rear rim component3.512
5. Rear brake return spring10
6. Rear brake cam shaft9
*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 cover1left/right rear view mirrorhandle cover2foot protection plate

protection plate in the base platefront big coverfront light
pad assemblyleft/right protection stripelow connection platefront fender

rear shelf assemblydecoration plate of the protection plate
left/right pedal cover decoration plate of the left/right protection plate

left/right protection plateperspective hole coverconnection plate of the left/right
protection plate
storage battery coverpedaltaillightrear fenderrear 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
Rim specification:3.5012
Limit value of rim swing
difference:vertical:2.0mm
Horizontal:2.0mm
Limit value of front axle

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
of bolt13 in
figure:5-9N
m
Rear ball amount:22

Low ball amount:22
1 bolt M616 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 boltM101.2530 9 boltM612 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 Nm
Front brake handle free stro
ke:
10-20mm
Rear brake handle free stro
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 boltM622 13 handle installation seat
14 rear brake switch 15 nutM6 16 bolt M101.2545
17 self-locking nut M101.25 18rear brake
component 19 accelerator wire component 20 screw M510
- 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 blockfriction plate component, front brake disc stained with grease.
Vehicle standard
Measured position
Item
Front wheel axle
Bending degree
Front wheel
Rim
shimmy
Standard
value(mm)
0.2
Longitudinal
direction
Horizontal
direction
Torque value
2.0
Within 1.0
2.0
Tools
Tap welding component fixing bolt 40-60 Nm

Front axle locking nut
55-62 Nm
Front muffler fixing bolt
37-44 Nm
7.2 Fault diagnosis

7.2.1 Turning hardness of direction handle
- 92 -
Available limit (mm)
Bearing removing pole

Locking nut wrench
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 nut1.
Remove the front axel11and front wheel.
Remove the gear seat component2.
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 -
Axle
Clearance
Axial
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 Nm
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 component3.
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 Nm
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 ball22.
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 its 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:

100-113Nm
the
bolt4
in
figure:
22-29Nm
D
the
bolt14
in
figure:
37-44Nm
Brake
hub
inside
diameter( wear limit): 111mm

Brake shoe block lining(wear
limit): 3.5mm
1 tire 130/70-12
2 rim 3.5012
3 split pin
4 bolt M835 5 nut M141.5
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
M101.2540 15 rear muffler component
- 98 -
Rear wheel
Tire
specification:130/70-12
Rim
specification:
3.5012
Rim
swing
difference
limit:
C
Vertical:2.0mm
Horizontal:2.0mm
Torque value of the rear
wheel
fixing
nut
in
figure:100-113Nm
E
Rear
tire
certification
number:E11 75R -000216
1 self-locking nut M141.5 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 M635
- 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
Rear wheel
swing degree
Standard valuemm
Available limitmm
Longitudinal
2.0
Horizontal
2.0
Locking torque
Rear wheel fixing nut
Rear muffler top bolt
Rear muffler bottom bolt
100-113 Nm
37-44 Nm
22-29 Nm
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 Nm
- 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 Nm
Low fixing bolt:22-29 Nm
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
A
the tank, the switch

of it must be turned
at OFF.
The torque value of
the
bolt10
in
figure:5-9 Nm
The torque value of

D
the
bolt11
in
figure:5-9 Nm
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 M825
9 rear strengthen plate of the helmet bucket 10 self-locking nut M101.25 11 bush 12 engine bracket
- 103 -
installation bolt 13 rear rocker arm installation shaft 14 power hanger welding component 15 self-locking
nut M121.25
Tank
Gasoline
A
tank
capacity:
5.60.2L
The torque value of
the
bolt16
in
figure:5-9 Nm
Note: when removing
D
the
tank,
the
switch of it must be
turned at OFF.
1 tank body 2 fuel sensor component 3 combination screw M514 4 tank cap 5 tank inlet jacket 6 steel
wire clamp 10 7 connection tube 8 tubing 72300
9 steel wire clamp ca 7.5 10 tubing
- 104 -
42340 11 bolt M612 12 tank cock component(14*1 clip spring type) 13 steel wire clamp 8
tubing 4.5270 15 filter component 16 tubing 4.52190 17 clip component
14
Seat cushion
The torque value of

A
the
bolt4
in
figure:5-9 Nm
The torque value of
B
the
bolt7
in
fiure:5-9 Nm
1 seat cushion component
2 bolt 3 nut M6
4 bolt M612
- 105 -
5 helmet bucket 6 helmet bucket bottom cover
7 self-tapping screw ST4.213
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
5.20.2L
Locking torque
Rear shelf fixing screw
Tank fixing bolt
Helmet bucket fixing bolt
22-29 Nm
5 - 9 Nm
5 - 9 Nm
9.2 Fault diagnosis

Gasoline reducing
Gas naturally consumes
- 106 -
Gas leaks
9.3 Tank/seat cushion

9.3.1 Removing
Open the seat cushion1
Remove the seat cushion fixing bolt4
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 Nm
Tank fixing bolt
5 - 9 Nm
Helmet bucket fixing bolt
5 - 9 Nm
- 107 -
Check and maintenance of the engine
- 108 -
Table of the engine fastener torque value

Fastened parts and fastener names
Fastening torqueNm
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
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.
4
3
1 crankcase
2 carburetor
3 machine oil tank
- 110 -
4 machine oil pump
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.
Item
During changing oil
Machine oil tank

capacity
During removing
Standard
Available limit
0.1L
0.11L
10.2 Fault diagnosis

Machine oil amount decreasing
Engine being burned out
Machine oil decreases

Machine oil leaks
No machine oil or the oil pressure is too low

piston pathway obstructs
naturally
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
bracket
motor
stator,
rotator,
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
oil pump
cover
Gear
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.
Measure the plunger outside diameter.

Available limit: 2.61mm.
Carburetor
- 113 -
Plunger
diameter
outside
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
nozzle 8 main foam tube
9 idle adjusting screw
3 needle valve component
- 114 -
4 float
5 float pin
6 main hole
7 idle
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.
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

Gas filter is obstructed
Gas tube is obstructed
Needle valve is in sticking
Oil surface adjustment is not good
Carburetor has been obstructed

mixed air is too concentrated or too thin
Expiratory system has second air suction
Idle 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

Fuel system has the second air suction
Fuel degradation
Bad concentration
Idle system or windproof system is obstructed
Oil nozzle has been obstructed

Needle valve has been obstructed
Oil surface is too low
Fuel system has been obstructed
Bad plunger work
Expiratory system has second air suction
Too concentrated mixed air
Intermittent flameout
In acceleration
Bad concentration valve work

Dad needle valve work
Too high oil surface
Carburetor overflow
Air passage has been obstructed
Filthy in air filter
Too thin mixed air
11.3 Disassembly of carburetor

11.3.1 Disassembly
Inlet oil hose
- 116 -
Guy wire of
oil valve
Turn the fuel switch toOFF position.

Pull out the inlet oil hose and to loosen the guy wire of oil
valve.
Pull out stopper at the end of outlet oil hose. Put the fuel oil
in the floating bowl into another box.
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.
Electrical
enrichment valve
interface
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
Fixed flange
Enrichment
module
Check the wear of electrical enrichment valve

and injector needle.
If it is worn badly, then electrical enrichment
valve module should be replaced.
Loosen the screw and to dismantle the

top head.
Take out the spring and plunger module.
Screw
Injector needle
module
Top head
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 -
Plunger
Injector
spring
needle
Injector needle
jam nut
Plunger
valve
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
be replaced.
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.
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
be changed.
Check the plunger. If it is worn, it should be
replaced.
Check carburetor and fuel pipe. If it is polluted, they
should be cleaned according to the manual.
Needle valve
module
Floating pin
Float
Idle nozzle
Main
metering
jet
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 1800100rpm;
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,
the cylinder cover would
withstand very big
pre-tightening force of bolt.
Pre-tightening force value:
50Nm
1. Spark plug
5. Cylinder
2. Mounting bolts of cylinder cover
- 120 -
3. Cylinder cover
4.Cylinder gasket
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
Bolt
Wind guide cover
Loosen fixing bolt of wind guide cover.

Dismantle the wind guide cover.
- 121 -
Loosen fixing nut and spark plug. Dismantle the cylinder

cover.
Fixing nut
Cylinder
cover
Spark plug
12.4 Checking of cylinder cover

Check whether the cylinder cover is broken through.
To check the flatness of the bottom plan of cylinder
cover
Acceptable limit: 0.04mm
Ruler
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
7.Spark plug
3. Cylinder block
4. Cylinder gasket
- 123 -
5. Cylinder cover
6. Nut
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
Unitmm
Item
inside diameter
Acceptable
limit
39.995-40.015
40.05
Bending
0.05
cylindricity
0.006
0.05
Flatness
0.03
0.05
Roundness
0.05
Top ring
0.0150.05
0.09
Second
ring
0.0150.05
0.09
Top ring
0.1-0.25
0.5
Second
ring
0.1-0.25
0.5
External diameter of piston
39.97-39.99
39.9
Clearance between the piston and cylinder
0.005-0.015
0.1
Cylinder
clearance between piston ring and

ring groove
Piston/
Piston
ring
Standard value
end gap
- 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.
Check the flatness of cylinder block and cylinder
surface
Allowable limits: 0.05
Cylinder
block
Ruler
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

cylinder
Attentionspress the piston ring into the cylinder with piston
head
Measure the end gap of piston ring
Allowable limit: 0.05mm
Piston
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
1
2
3
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

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

diameter difference between X direction and Y direction
Allowable limit:0.05mm
Measure the cylindricity of inside wall of cylinderthe
difference of inside diameter among upper, middle and lower
positions in X direction or Y direction
Allowable limit:0.05mm
- 127 -
tester
Measure the wrist-pin end of connecting rod

Wrist-pin
end
of
connecting rod
13.4.2 Assembly of piston

Assemble the pin
Apply machine oil to all piston rings and pistons. To assemble the
piston ring with upward slope
Attentions
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.
Top ring
Second ring
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
Failure diagnosis---------------------14.2
wheel ----14.6
Left crankcase cover -------------------14.3
Driving plate-----------------------14.4
Clutch /driven wheel---------14.5

Disassembly of clutch and driven
Assembly------------------14.7
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
Wear of v-shaped belt

Breakage of driven wheel
insufficient horsepower
wear of v-shaped belt
breakage of spring of clutch friction lining

Deformation of clutch-pressing spring
- 131 -
vibration during operation
Broken or damaged clutch friction lining

Broken clutch-pressing spring
wear of ball
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
wheel
half
driving
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

Measure the outside diameter of sliding sleeve
Right
half
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.
driven wheel fixer
clutch sleeve
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.
retainer ring
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
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
Wrench
Clutch spring compressor
Remove the spring sheath.
Spring sheath
- 136 -
Remove pilot pin.

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

Allowable limit: 68mm
free length
Check the wear of driven wheel\

Measure the outside diameter of right half bushing of driven
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
roller bearing : needle bearing
circlip
- 137 -
Right
wheel
driven
Left
driven wheel
Put the outside rolling bearing coated with oil in the bushing.
Attentions:
When pressing the outside rolling bearing into the bushing,
the side with mark should be placed outward. And then fill
the bearing chamber with 8-9g oil.
Mount cir-clip
Bearing
screwdriver
Designated oil
Install needle roller bearing

Needle roller bearing should be pressed in with the tool
shown in the figure
Bearing screwdriver
Ball bearing
Needle
bearing
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
lubricating grease
O O-ring
Oil seal
Assemble the left and right driven wheel together

Put pilot pin coated with oil in the guide slot
Pilot pin
- 138 -
Guide slot
roller
Install spring sheath.

Wipe clean the spilled oil.
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.
Wrench
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
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 -
Bolt
Remove the gasket and dowel.

Remove the principal axis of clutch and output shaft gear.
Remove the central jack shaft and central gear.
Output
Gear
Gasket
Jack Shaft
Shaft
Principal Axis
of Clutch
Central Gear
15.3.2 Examination of Output Gear Box

Cover
Examination of the tear and damage on the principal axis of
clutch, gear and bearing.
Bearing exchange of gear box cover.
During the bearing exchange of the principal axis of
Clutch, the principal axis of clutch should be punched and
removed from the gear box cover.
Principal Axis of
Clutch
Grease Seal 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.
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
Unitmm
Item
Crank Axle
Tool
Universal Holder
Screwdriver Rod
Guide Bar
Standard Value
Allowed Limit
Clearance between both big ends of the

connection rod
0.25-0.40
0.55
Radial clearance between big end of the

connection rod
0.015-0.025
0.05
Clutch Spring Compressor

Jacket Wrenches
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
Driving
Motion
Gear
Unscrew the bolt and remove the driving motion gear.

Remove the gear.
Dismantle the fixed bolt of crankcase

Dismantle the crankcase on both sides.
Gear
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
crankcase.
- 146 -
Crank Axle
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
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.
The disassembly of grease seal should adopt professional tools.
Crank Axle Bearing
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
silencer in the picture is 5-9
Nm

bolt 6 in the joint of silencer
in the picture is 22-29 Nm

bolt 12 in the joint of
silencer
decoration
component in the picture
5-9 Nm
1.Graphite Winding Gasket 2. Exhaust Pipe Assembly 3. Socket Head Cap Screws M625 4.Broken Bolt
M625 5. Bolt M616 6. Connected Flange Gasket Assembly 7. Cushion Ring 6 8.Spring Cushion Ring 6
9. Nut M6 10. Bolt M820 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 M635 22. Oil Pipe 131850 23. Plate Bar Clasp 17.5 24.Small
Strainer 25.Rubber Pipe
- 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
- 151 -
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
Exhaust Gas
System
Equipment
Component
Purpose and Function
Accelerant Device
Accelerant
Transformer
Canned oxidated accelerant equipped in

the center of exhaust gas pipe makes CO,
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 -

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;
- 153 -
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
Strip and Clean Carbureter
(SJ, MJ, SAJ and MAJ)
Leave the Factory

Qualified
Qualified
Change the Carbureter
Strip and Clean the Motor

Valve (Leakage)
Plug (Wear-out)
Combustion Chamber(Clean)
Qualified
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.
- 154 -
155

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Two-wheeled Motorcycle F-ACT EVO

Users Instruction and Maintenance Manual

KEEWAY Motorcycle Co., Ltd

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7.3 Front wheel ................................................................... - 93

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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,

Special attention should be paid to the important attachment

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The length of bolt or screw is different in terms of assembly parts

Disassembly of ball bearing: use the instrument to withstand one

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The loose cable is the potential electric safety hazard. After

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2The engine series number is printed on the outer shell

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1 Tools used for the overhaul of engine

special socket wrench

Used for assembling and disassembling Flywheel Bolt, Figure 1-3

Continuation Table 1-2

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2Tools used for the overhaul of chassis

1Universal tool for the overhaul of chassis

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3Tools used for electrical parts

Continuation Table 1-32

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Specification Table (QJ50T-21T)

Idling speed -rpm

Front brake disc

Rear brake drum

Dry centrifugal type

infinite variable speed

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Check the ignition system

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

Use ignition timing light to test whether engine ignition is timing

Strong blue spark

1. Check if the CDI ignition

Check if the spark plug, spark plug cap fails

Loosen carburetor fuel

No contact magneto ignition system

1. Check if there is short

circuit or broken circuit of

ignition power winding

2. Check if there is short

circuit or broken circuit of

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1. Check if there is gas leaking

1. Check if the venthole of

in external connections of the