Baotian BT49QT-3 Service Manual

Summary of BT49QT-3

  • Page 1

    Bt50qt-9&bt49qt-3 service manual jiangmen sino-hongkong baotian motorcycle industrial co., ltd www.Asiamotor.Se baotian european spare parts center.

  • Page 2: Contents

    Contents chapter one maintenance of the motorcycle Ⅰ. Items of maintenance 1 Ⅱ. Periodic maintenance schedule and maintenance locations 1 Ⅲ. Maintenance specifications 4 Ⅳ. Throttle actuation inspection 5 Ⅴ. Air filter inspection and cleaning 6 Ⅵ. Rear brake fricition lining inspection 6 Ⅶ. Brake sy...

  • Page 3

    Chapter one maintenance of the motorcycle Ⅰ. Items of maintenance when the motorcycle is used, loosening of parts and mechanical wear inevitably occur to varied extents. Neglect of timely maintenance not only reduces its mechanical function, economic performance, stability and durability, but also t...

  • Page 4

    1. Maintenance schedule maintenance schedule time item mileage 1000km 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 engine oil new r 300km r r r r r r r r r r r engine oil strainer c c gasoline strainer r gear oil note 4 new r 300km r r throttle play a a a a carburetor i i c air fil...

  • Page 5: 2. Maintenance Locations

    2. Maintenance locations throttle grip actuation,play £¨ £© oil tank brake oil level £¨ £© front shock absorber damage,loosening £¨ £© rear tire wear,damage,tire pressure £¨ £© rear rim damage,oscillation £¨ £© front rim damage,oscillation £¨ £© front tire wear,damage,tire pressure £¨ £© headlight b...

  • Page 6

    Ⅲ. Maintenance specifications the basic methods of motorcycle maintenance include inspection, adjustment, tightening, lubrication, cleaning, supplementing and replacement, which constitute the main elements of maintenance. 1. Inspection inspection refers to basic inspecting operations in accordance ...

  • Page 7: IV.

    Iv. Throttle actuation inspection inspect throttle grip for easy and smooth movement. Inspect throttle free travel. Free travel: 2-6mm the main adjusting position is beside the carburetor. Remove rear store case cover. Adjust by loosening the fastening nut and turning the adjusting nut. Fine adjustm...

  • Page 8: VI.

    Ⅴ. Air filter inspection and cleaning after a certain mileage, dust and impurities will gather in air filter case and strainer, which will clog strainer pores and reduce inlet of air and thus lead to excessive concentration of mixed gas and reduce the performance of engine. That’s why the strainer m...

  • Page 9: 1. Front Brake (Disk Brake)

    Vii. Brake system inspection, adjustment and replacement 1. Front brake (disk brake) remove the bolts linking brake caliper and front shock absorber; remove brake caliper. * do not pull brake lever when brake caliper is removed so as to prevent jamming of brake block. If brake block is jammed, pry i...

  • Page 10

    Brake disc inspection: inspect brake disc thickness. Limit of use: 3.0mm inspect brake disc angularity. Limit of use: 0.3mm 2. Rear brake inspect rear brake lever free travel. Free travel: 10-20mm turn adjusting nut to effect adjustment when free travel exceeds limit. Viii. Front and rear shock abso...

  • Page 11: Ix.

    2. Rear shock absorber press rear shock absorber to inspect actuation. Inspect rear shock absorber to see if there is oil leakage and if there is damage or loosening in machine parts. Lift rear wheel, press rear wheel right and left to inspect if engine suspension lug buffer bush is loose. Ix. Front...

  • Page 12

    Tire specifications: front wheel 3.0-10/3.50-10 rear wheel 3.0-10/3.50-10 inspect if front wheel nut is loose. Inspect if rear wheel nut is loose. If loose, tighten them to specified torques. Torques: front wheel nut 60n·m rear wheel nut 120n·m x. Steering stem inspection swing handlebar right and l...

  • Page 13

    Chapter two maintenance information i. Frame number and engine number location ii. Precautions in operation z removed washers, 0-rings, elastic retaining rings and split pins must be replaced with new ones. Z when mounting bolts, nuts and screws, proceed from trial tightening, from larger diameters ...

  • Page 14

    Z before connecting connectors, confirm that they are free from breakage, bending, over length or loosening. Z connectors must be inserted home. When connecting connectors with locks, confirm that their locks are fastened. Confirm that the wires are not loose. Z confirm that connectors’ plastic slee...

  • Page 15

    Specified torques frame: designations of tightening positions number thread specification torques: n·m engine suspension lug mounting nut 1 m10 45 engine mounting nut 1 m10 45 front axle nut 1 m12 60 rear axle nut 1 m16 120 rear shock absorber upper mounting bolt 1 m10 40 rear shock absorber lower m...

  • Page 16

    Chapter three body troubleshooting section one body common troubles and trouble detection body part common troubles and possible causes are as follows: troubles causes details (reference) over tightening of handlebar adjusting nut handlebar rotation not easy (strenuous turning or unstable tightness)...

  • Page 17

    Chart continued troubles causes details (reference) inadequate liquid contaminated brake block and brake disc bent or deformed brake disc contaminated brake caliper worn seal ring of brake caliper piston viscous or worn brake caliper piston inability of brake caliper normal sliding worn main cylinde...

  • Page 18

    Chart continued troubles causes details (reference) hardened brake block surface or dusty block uneven or slotted brake block surface serious wear of brake block lining abnormal braking sound serious slots inside brake drum refer to “rear brake service” steering stem rotation not easy refer to “fron...

  • Page 19: Precautions In Operation:

    Section two detailed description of body parts troubles precautions in operation: z forced mounting or dismounting of body cover parts will cause damage to claws and slots of corresponding hoods. Z when mounting body cover parts, be sure to align the corresponding parts of hoods. Z when mounting bod...

  • Page 20

    Axle bending inspection place axle on a v-seat and measure with a dial gauge. The dial gauge indicates a 1/2 bending value. Limit of use: replace if >0.2mm. Wheel rim oscillation inspection measure oscillation value on a correcting bench. Limit of use: replace if >2.0mm. Traverse direction: replace ...

  • Page 21

    Mount spacer. Drive in right bearings. Z bearings must be driven in parallel. Z dust cover must be driven in with the face out. Apply grease to new dust cover lip. Mount front axle bush. Front wheel mounting mount brake disc, tighten brake disc mounting bolts. Torque: 27n·m spread front axle with a ...

  • Page 22

    The specification of brake oil is indicated on the reservoir cover. Place diaphragm. Connect a transparent hose to exhaust valve. Grip brake lever fast and open exhaust valve 1/2 turn to let out air and lock exhaust valve. Repeat this operation till no bubbles are exhausted from brake oil passage. Z...

  • Page 23

    Remove brake light switch and brake lever. Remove retaining ring from main cylinder. Z use special retaining ring remover when removing retaining ring. Remove piston cover, piston and spring. Clean oil reservoir and piston with pure brake oil. Z do not effect cleaning with gasoline as it is corrosiv...

  • Page 24

    Remove 4 pieces of bolts on the upper part of front shock absorber. Remove shock absorber. Inspection inspect if there is oil leakage in front shock absorber, if there is deformation of shock absorber arm and if there is damage or loosening of any part. Mounting mount front shock absorber on front f...

  • Page 25

    Remove front wheel; remove front shock absorber, front fender bracket, etc. Remove steering stem from head tube. The removing of the bottom bearing cup, bearing top and bearing set is the same as the removing of the upper series. Z do not damage steering stem when removing bearing cup and bearing to...

  • Page 26

    Apply grease to top bearing cup and bearing top. Mount in order upper bearing cup, bearing ball set and upper bearing top on the upper part of steering stem and fasten them. Torque: 15 n·m turn front fork right and left to effect close contact of bearing balls. Loosen upper bearing top to torque 0 a...

  • Page 27

    Mounting mount handlebar on steering stem guide tube, fit bush, setting bolt and nut. Torque: 45 n·m mount left handlebar switch and fasten screws. Torque: 9 n·m mount front brake main cylinder and fasten bolts. Mount right handlebar switch and fasten screws. Torque: 9 n·m apply grease to throttle c...

  • Page 28

    Mounting mount rear wheel and fasten rear axle nut. Torque: 120n·m mount exhaust muffler. Fasten exhaust muffler connecting nuts and bolts. Torque: exhaust muffler connecting nut: 12n·m exhaust muffler mounting bolt: 35n·m vii. Rear brake service remove exhaust muffler. Remove rear wheel. Inspect re...

  • Page 29

    Rear brake device assembling apply grease to setting pin, brake cam and brake block friction surface. Apply grease to moving part of brake cam. Z do not apply grease to parts not specified. Superfluous grease flows into brake friction linings of brake drum shall reduce braking effect. Mount brake ca...

  • Page 30

    Viii. Rear shock absorber service dismounting remove motorcycle body covering parts. Remove 2 mounting bolts of air filter. Remove mounting bolt connecting rear shock absorber and motorcycle frame, bolt connecting rear shock absorber and engine. Withdraw air filter; remove rear shock absorber. Inspe...