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KEEWAY F-ACT EVO User Instruction

Manual is about: Two-wheeled Motorcycle F-ACT EVO

Summary of F-ACT EVO

  • Page 1

    Two-wheeled motorcycle f-act evo user’s instruction and maintenance manual keeway motorcycle co., ltd.

  • Page 2

    - 1 - content ................................................................. 错误！未定义书签。 preface .............................................................................. - 3 - preparation data ................................................................. - 4 - inspection/adjustment .........

  • Page 3

    - 2 - 7.3 front wheel ................................................................... - 93 - 7.4 direction handle................................................................ - 96 - 7.5 front fork ..................................................................... - 96 - 8. Rear wheel/rear ...

  • Page 4: Preface

    - 3 - 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 chec...

  • Page 5: Preparation Data

    - 4 - 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 ...

  • Page 6: Maintenance Regulations

    - 5 - 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 outsi...

  • Page 7

    - 6 - 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 gr...

  • Page 8

    - 7 - 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 route...

  • Page 9: Motorcycle Identification

    - 8 - motorcycle identification 1．the motorcycle indentification number is printed on the frame ① , please see figure 1-1. Indentification number: lbb11b05?????????. The ninth number of the vehicle indentification number is the chek code, the tenth one year code and the eleventh one assembly factory...

  • Page 10: Special Tools

    - 9 - 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 disa...

  • Page 11

    - 10 - figure 1-5 figure 1-6 figure 1-7 figure 1-8 figure 1-9 figure 1-10 ① handle figure 1-11 figure 1-12.

  • Page 12

    - 11 - ① opening pliers ②piston figure 1-13 figure 1-14 figure 1-15 figure 1-16 2．tools used for the overhaul of chassis the special tools list to assemble and disassemble the chassis parts and the corresponding physical figure, please see table 1-11 and 1-18. Table 1-17 name note torque wrench inne...

  • Page 13

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

  • Page 14

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

  • Page 15

    - 14 - specification table (qj50t-21t) model qj50t-21t e n gin e type of engine qj 1e40qmb -4 full length mm 1860 type of fuel lead-free gasoline （93/95） full width mm 680 number of cylinders 1 full height mm 1198 inside diameter*stroke 49.2×39.2 wheelbase mm 1290 total displacement 49.3cc weight of...

  • Page 16

    - 15 - qj50t-21t.

  • Page 17: Failure Diagnosis

    - 16 - no yes no yes yes no y trigg er windi ng es no 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 ...

  • Page 18

    - 17 - yes no spark plug electrode is moist spark plug electrode is dry check if there is oil leaking from carburetor instill small amount of fuel into the cylinder to have an experimental starting 1. Check if there is gap between the carburetor float needle valve and valve seat because of other mat...

  • Page 19

    - 18 - yes no yes no yes no no yes yes no the engine overheat failure diagonosis procedure engine overheat check if the operation method is proper 1. Check if the fuel no. Is too low or the fuel is out of date 2. Check if the engine runs at high speed or overload for a long time check the cooling sy...

  • Page 20

    - 19 - 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 engine is running at ...

  • Page 21

    - 20 - yes no 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 ...

  • Page 22

    - 21 - yes no yes no no yes yes no yes no failure diagonosis procedure of unstable engine idle speed bad idle speed of engine engine’s idle speed too high engine has no idle speed engine’s idle speed unstable check the cylinder compression pressure pull the air throttle of carburetor by hand and che...

  • Page 23

    - 22 - yes no yes no yes no yes no failure diagnosis procedure of engine’s excessive fuel consumption excessive fuel consumption of engine check if the operation method is right prop up the main jiffy stand and revolve wheel by hand 1. Check if the motorcycle is run overloaded, or run not at economi...

  • Page 24

    - 23 - yes no yes no yes no no yes yes no failure diagnosis procedure when the exhaust muffler of two-stroke engine gives off strong blue and white smoke failure diagnosis procedure when the gear shift is difficult to shift the exhaust muffler of two-stroke engine gives off strong blue and white smo...

  • Page 25

    - 24 - no yes no yes no yes yes no yes no no yes failure diagnosis procedure when there is trip dog of the gear shift failure diagnosis procedure when the clutch slips clutch slips automatic centrifugal dry block clutch slips check if the block friction dis of the clutch is over-worn replace the who...

  • Page 26

    - 25 - no n yes yes no no yes failure diagnosis procedure when the hydraulic disc brake fails failure diagnosis procedure when the drum 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 liqu...

  • Page 27

    - 26 - yes no failure diagnosis procedure when the storage battery can not be charged the storage battery can not be charged the resistance value is smaller than standard value short circuit of charge coil the resistance value is infinite the resistance value is equal to standard value short circuit...

  • Page 28

    - 27 - yes no yes no failure diagnosis procedure when the storage battery is undercharged storage battery is undercharged check if the brake lamp is on adjust or replace the brake lamp switch leakage current is less than the specified value leakage current is greater than the specified value (it is ...

  • Page 29

    - 28 - riding motorcycle seat-type motorcycle yes no yes no failure diagnosis procedure when the start motor is unable to rotate 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 t...

  • Page 30

    - 29 - no yes yes no 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 th...

  • Page 31

    - 30 - yes no yes no failure diagnosis procedure when all the lamps don’t work all the lamps don’t work ac power supply illuminating system dc power supply illuminating system disconnect the insert connector between the magnetor wire bundle and the complete vehicle cable, use the lamp-testing method...

  • Page 32

    - 31 - no yes failure diagnosis procedure when the bulb of lamp is easily burnt out the bulb of lamp is easily burnt out turn on the ignition switch, press the horn button or toggle the turn signal switch the electric horn does not sound or sound raucously, and the light of turn signal is pale the s...

  • Page 33

    - 32 - yes no yes no yes no yes no 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 ohm...

  • Page 34

    - 33 - yes no yes no yes no no yes 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 bu...

  • Page 35

    - 34 - failure diagnosis procedure when the electric horn does not work the electric horn does not work turn on the ignition switch, and toggle the steering lamp to check the work of steering lamp the steering lamp does not work or the light is pale the light of the steering lamp is bright the elect...

  • Page 36

    - 35 - yes no yes no yes no failure diagnosis procedure when the brake lamp does not work the brake lamp does not work failure diagnosis procedure when the storage battery is undercharged the brake lamp does not work remove the brake lamp cover and check if the circuit board of brake lamp is burnt o...

  • Page 37: Inspection/adjustment

    - 36 - 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 filt...

  • Page 38

    - 37 - specification engine idle speed 1800±100rpm/min clearance of spark plug 0.6-0.7mm spec. Of spark plug br7es frame free stroke of front brake lever 10-20mm free stroke of rear brake lever 10-20mm tyre pressure unit: kpa specification tyre pressure qj50t-21t front outer tyre 120/70-12 145-170kp...

  • Page 39

    - 38 - 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 applicable tools new 1 m 3 m 6 m 12 m 15 m * air filter i c c r c ordinary tools * petrol filter i i r ordinary tools * oil filter c ...

  • Page 40: Engine Oil/filter

    - 39 - anticipated inspection 1 ignition system—obviously continuous ignition abnormality, engine fire or overheating, which requires inspection and maintenance. 2 carbon fouling elimination—obviously insufficient horsepower, which requires carbon fouling removal from cylinder cover, piston head and...

  • Page 41: Air Filter

    - 40 - 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 acceler...

  • Page 42: Spark Plug

    - 41 - 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 t...

  • Page 43: Battery

    - 42 - 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 th...

  • Page 44: Carburetor

    - 43 - 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 no...

  • Page 45: Cylinder Pressure

    - 44 - 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. Insta...

  • Page 46: Gear Oil Replacement

    - 45 - 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...

  • Page 47: Front Light

    - 46 - free path of rear brake measure the free path of rear brake at the point of the brake pedal. Free path ：10-20mm inspection of brake fluid level use the front brake to the upper limit, and check the oil level thought the oil indicator. In case the brake fluid level is at or below the arrow in ...

  • Page 48: Clutch

    - 47 - 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...

  • Page 49: Nuts/bolts/fixed Parts

    - 48 - 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. Re...

  • Page 50

    - 49 - in case there is any loosening, tightening them according to the required torque force value. Torque force value: front wheel axle 55-62 n·m rear wheel nut 100-113 n·m steering column bearings and handle fix swing the handle in order to confirm there is no interference with wire. Confirm the ...

  • Page 51

    - 50 - inspection and maintenance of electrical system torque force list of fixing parts in electrical system position and name of fixing componen torque of fixing（n·m） clutch cover bolt of starting motors set screw nut of clutch cover of starting motors rectifier bolt high tension coil fixing bolt ...

  • Page 52: Charging System

    - 51 - charging system 1 battery 2 horn 3 power locking components 4 rectifier 5 release resistance 6 frequency conversion flash apparatus 7 meters 8 starting relay 9 igniter 10 ignition coil assembly.

  • Page 53: 1. Battery/charging System

    - 52 - 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:...

  • Page 54

    - 53 - preparing standards item specifications battery capacity/type 12v-4ah/dry cell voltage （20℃） full charge 13.1v obligatory charge 12.3v(not working for 1h) charging current standard：0.4a，rapid：4a charging time standard：10-15h，rapid：30min magnetor capacity 90w/8000rpm lighting coil impedance（20...

  • Page 55

    - 54 - 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 remove the positive wire. Take off the battery. Warning！ when removing the positive terminal, the tools should not be contacted with the brac...

  • Page 56

    - 55 - •measure the voltage for every other 30 minutes. Charging current：standard：0.4a emergency：4.0a charging time： standard：10-15h. Emergency：30min. Charging completion：open-circuit voltage：above 12.8v 1.4 charging system 1.4.1short circuit test remove the batter ground wire, and connect the voltm...

  • Page 57

    - 56 - 1.5 rectifier 1.5.1main wiring inspection remove the 4p plug of the rectifier. Check the conducting state of the terminals of the main wiring. Item（wiring color） judgments between battery（red）and gnd of the body with battery voltage between gnd wire （black）and gnd of the body with wiring betw...

  • Page 58

    - 57 - measure resistance value between the white coils of magnetor with multimeter. Standard value：1.5-2Ω（20℃） replace the magnetor coil when the measured value exceeds the standard value. 1.7 magnetor lighting coil *note check the magnetor lighting coil on the engine. 1.7.1 inspection remove the 3...

  • Page 59

    - 58 - 1.7.3 installation install the stator on the body of the engine. Connect the magnetor terminator. Clean up the taper part of the bent axle and flywheel. Install the solid key of the flywheel into the bent axle. Aim the flywheel groove at the solid key on the axle. *note ensure there is no bol...

  • Page 60

    - 59 - ignition system 1 battery 2 horn 3 power locking components 4 rectifier 5 release resistance 6 frequency conversion flash apparatus 7 meter 8 starting relay 9 igniter 10 ignition coil assembly ignition system.

  • Page 61: 2. Ignition System

    - 60 - 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 syste...

  • Page 62: 2.2 Failure Diagnosis

    - 61 - multimeter 2.2 failure diagnosis spark plug fails to jump. Ignition coil error reason（in compliance with the following order） low voltage ① the inner resistance is too small and it should be tested by required tester. ② low rotation speed of the bent axle. ③ tester is interfered. (it is norma...

  • Page 63: 2.3

    - 62 - 点火线圈 万用表 2.3 ignition system inspection *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 differe...

  • Page 64

    - 63 - coil (black/red) and the 4p joint (black end). Start the motor or step on the actuating lever to determine the maximum voltage of charging coil. Connection method：black/red end to the positive pole and black end to the negative pole. Minimum voltage：above 95v. * note never touch the metal of ...

  • Page 65: 2.4 Cdi Group

    - 64 - • 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 ...

  • Page 66: 2.6 Trigger

    - 65 - 2.5.2 primary coil inspection impedance measuring between the ends of the primary coil. Standard value：0.6Ω±10％（20℃） impedance value within the range is good. If the impedance value is "∞", there is wire break in the coil. Replace it with a new one. 2.5.3 secondary coil with a spark plug atta...

  • Page 67: Activation System

    - 66 - 启动示意图 battery relay brake switch brake switch starter switch startor motor activation system 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 starting drawing.

  • Page 68: 3. Activation System

    - 67 - 3. Activation system material preparation---------------3.1 failure diagnosis---------------3.2 starting motor---------------3.3 starting relay-------------3.4 3.1 material preparation notes of working the unloading of the starting engine could be carried out on the engine. Refer to the metho...

  • Page 69: 3.2 Failure Diagnosis

    - 68 - 3.2 failure diagnosis activation failure weak rotating force starting motor is rotating of the starting motor well while the engine is not •burnt out fuse ·low storage battery •broken starting clutch •low storage battery •poor contact of connecting line •anticlockwise revolution of the starti...

  • Page 70

    - 69 - 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...

  • Page 71: 3.4 Starting Relay

    - 70 - 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 ...

  • Page 72

    - 71 - 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 electri...

  • Page 73: Bulbs/switches/meters

    - 72 - bulbs/switches/meters 1 front signal lamp 2 meter 3 front left turn signal lamp 4 front right turn signal lamp 5 rear left turn signal lamp 6 taillight 7 left rearview mirror 8 right rearview mirror a certificate no. Of front lamp: e4 0014908 b certificate no. Of front position lamp: e4 50r-0...

  • Page 74: 4. Bulbs/switches/meters

    - 73 - 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-...

  • Page 75: Replacement

    - 74 - 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...

  • Page 76: 4.6 Meters

    - 75 - 4.5.3.2 installation install the bulb in the opposite order of removal. 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...

  • Page 77: 4.8 Speaker

    76 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. R...

  • Page 78

    77 the check and maintenance of the chassis the table of chassis fastener torque fastened parts and fastener names fastening torque（n·m） oil pump body assembly mounting bolt front brake cylinder assembly mounting bolt fluid brake fixing bolt muffler decoration cover screw tap welding assembly mounti...

  • Page 79: Front Hydraulic Brake

    78 front hydraulic brake a front brake disc diameter:190mm b front disc thickness:4 m m use limit:3mm c friction plate thickness: 5.0mm use limt:4.0mm d installation torque valu e of bolt 8 in figure 8: 5-9n·m e installation torque of value of nut 27 in fi gure : 37-44n·m f free stroke of brake hand...

  • Page 80: Rear Hub Brake

    79 assembly 25 bolt m8 x 36 26 front brake disc mounting bolt 27 nut m10 x 1.25 rear hub brake 1 rear shock absorber component 2 bolt m10Χ1.25Χ40 3 split pin 4 bolt m8Χ35 5 nut m14Χ1.5 6 brake shoe block component 7 brake shoe block spring 8 sealing ring 9 rear brake cam axis 10 rear brake return sp...

  • Page 81: 5. Brake

    80 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: *check the brake before driving * 5.1.1sp...

  • Page 82

    81 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 adjust...

  • Page 83: 5.3 Front Hydraulic Brake

    - 82 - the abnormal sound of the brake 1. Wear of the brake shoe block and friction plate component 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 ma...

  • Page 84: 5.4 Rear Hub Brake

    - 83 - •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 no...

  • Page 85

    - 84 - • change the brake shoe block. • the brake should be marked at its side before removing, if it will be used again. Remove the following components from the rear wheel. Rear brake: 1. Rear rocker arm installation bolt（13） 7.Brake shoe block component（6） 2. Rear brake rocker arm component（12） 8...

  • Page 86: Covering Assemblies

    - 85 - screw the bolt and nut to the specified torque value. Torque value: rear wheel fixing nut: 100-113n·m do not make the brake shoe block and front brake disc stained with grease. If the brake shoe block and front brake disc are stained with grease, they must be cleaned with brake cleaning fluid...

  • Page 87

    - 86 - *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 ...

  • Page 88: 6. Body Cover

    - 87 - 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 co...

  • Page 89

    - 88 - 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.

  • Page 90: Front Wheel

    - 89 - front wheel 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...

  • Page 91: Front Suspension

    - 90 - front suspension 1 bolt m6×16 2 front fender bracket2 3 odometer clip 4 front right muffler component 5 front left muffler component 6=hydraulic brake wire clip 7 front fender bracket1 8 boltm10×1.25×30 9 boltm6×12 10 hydraulic tube clip 11 low connection plate welding component 12 clip 13 nu...

  • Page 92: Direction Handle

    - 91 - direction handle 1 right grip component 2 right combination switch 3 tap melding component 4 right rear view mirror component 5 left rear view mirror component 6 left combination switch 7 left grip 8 left handle component 9 left handle 10 installation bolt 11 fixing cover 12 boltm6×22 13 hand...

  • Page 93: 7.1

    - 92 - 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 b...

  • Page 94: 7.3 Front Wheel

    - 93 - 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...

  • Page 95

    - 94 - 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. Avai...

  • Page 96

    - 95 - 车轴 axle 游隙 clearance 轴向 axial 径向 radial 7.3.3 bearing change remove the front axle, front wheel and the left sleeve of the front wheel, intermediate sleeve component of the front wheel. Remove the oil sealing and bearing with the oil sealing puller and bearing puller. Note: the removed bearin...

  • Page 97: 7.4 Direction Handle

    - 96 - front axle locking nut 55-62 n·m 7.4 direction handle 7.4.1 removing remove the rear view mirror component. Remove the fixing screw of the handle high and low cover decoration. Remove the handle high cover decoration cap and remove the meter. Remove the front big cover component. Remove the l...

  • Page 98: Rear Wheel/rear Suspension

    - 97 - 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 bow...

  • Page 99

    - 98 - 1 tire 130/70-12 2 rim 3.50×12 3 split pin 4 bolt m8×35 5 nut m14×1.5 6 brake shoe block component 7 brake shoe block tension spring 8 sealing rim 9 rear brake cam shaft 10 rear brake return spring 11 rear brake rocker arm 12 rear rocker arm installation bolt 13 o shaped ring 14 bolt m10×1.25...

  • Page 100: Rear Wheel

    - 99 - rear wheel 1 self-locking nut m14×1.5 2 dustproof cover 3 vacuum tire 130/70-12/k-413 4 valve 5 rear rim component 6 brake shoe block component 7 shoe block tension spring 8 rear brake cam shaft 9 rear brake wire limit plate 10 sealing ring i 11 rear brake return spring 12 rear brake rocker a...

  • Page 101: 8.1

    - 100 - 8. Rear wheel/rear suspension preparation data-----------------8.1 fault diagnosis-----------------8.2 rear wheel-----------------8.3 rear muffler-----------------8.4 8.1 preparation data operation precautions do not make the brake hub and brake shoe block stained with grease. Preparation st...

  • Page 102: 8.3 The Rear Wheel

    - 101 - 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: longitudin...

  • Page 103: Qj50T-21T Rear Wheel

    - 102 - 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: h...

  • Page 104: Tank/seat Cushion

    - 103 - tank/seat cushion 1 frame component 2 rear handrail 3 seat cushion component 4 tank component 5 seat cushion lock installation plate 6 seat cushion lock seat component 7 cable component 8 inside hexagonal screw m8×25 9 rear strengthen plate of the helmet bucket 10 self-locking nut m10×1.25 1...

  • Page 105: Tank

    - 104 - installation bolt 13 rear rocker arm installation shaft 14 power hanger welding component 15 self-locking nut m12×1.25 tank 1 tank body 2 fuel sensor component 3 combination screw m5×14 4 tank cap 5 tank inlet jacket 6 steel wire clampφ 10 7 connection tube 8 tubing Φ 7×2×300 9 steel wire cl...

  • Page 106: Seat Cushion

    - 105 - 4×2×340 11 bolt m6×12 12 tank cock component(14*1 clip spring type) 13 steel wire clampφ 8 14 tubing Φ 4.5×2×70 15 filter component 16 tubing Φ 4.5×2×190 17 clip component seat cushion 1 seat cushion component 2 bolt 3 nut m6 4 bolt m6×12 5 helmet bucket 6 helmet bucket bottom cover a the to...

  • Page 107: 9. Tank/seat Cushion

    - 106 - 7 self-tapping screw st4.2×13 8 clip sheet st4.2 9. Tank/seat cushion preparation data-----------9.1 fault diagnosis-----------9.2 tank/seat cushion----------9.3 9.1 preparation data operation precaution removing site should be away from the fire source. When removing the tank, the switch of...

  • Page 108

    - 107 - gas leaks 9.3 tank/seat cushion 9.3.1 removing open the seat cushion（1） 。 remove the seat cushion fixing bolt（4） 。 remove machine oiler protection cover. Remove the machine oiler. Remove the cushion and helmet bucket. Remove the rear container assembly. Remove the left/right rear protection ...

  • Page 109

    - 108 - check and maintenance of the engine.

  • Page 110

    - 109 - table of the engine fastener torque value fastened parts and fastener names fastening torque（n·m） fan wind guiding cover locking bolt cylinder cover locking nut spark plug inlet pipe locking bolt cooling fan impeller locking screw flywheel locking bolt magnetic motor coil locking screw right...

  • Page 111: Lubrication System

    - 110 - lubrication system 1 crankcase 2 carburetor 3 machine oil tank 4 machine oil pump note: rod worm should rotate flexible, without stagnation and unilateral tightness while worm gear should have a little axial movement and the machine oil pump o-shaped ring shall not have cutting edge. Each pl...

  • Page 112: 10. Lubricating System

    - 111 - 10. Lubricating system preparation data-----------10.1 fault diagnosis-----------10.2 machined oil pump-------------10.3 10.1 preparation data operation precautions rod worm should rotate flexible, without stagnation and unilateral tightness while worm gear should have a little axial movemen...

  • Page 113

    - 112 - 10.3 machine oil pump 10.3.1 removing loosen the bolt and remove the wind guiding cover component. Loosen the screw on the fan and remove the fan. Remove the magnetic motor, rotor and bracket. Remove the worm gear and machine oil component from the crane wind guiding cover machine oil pump c...

  • Page 114: Carburetor

    - 113 - installing the oil machine shown as the following figure 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: ...

  • Page 115

    - 114 - 1 screw 2 float chamber 3 needle valve component 4 float 5 float pin 6 main hole 7 idle nozzle 8 main foam tube 9 idle adjusting screw 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...

  • Page 116: 11. Carburetor

    - 115 - 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 11.1 preparation data operation precautions ·gasoline is very dangerous, smoke and ...

  • Page 117

    - 116 - carburetor has on fuel carburetor has been obstructed gas filter is obstructed mixed air is too concentrated or too thin gas tube is obstructed expiratory system has second air suction needle valve is in sticking idle adjustment is not good oil surface adjustment is not good oil amount adjus...

  • Page 118

    - 117 - turn the fuel switch to―off‖ 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 engi...

  • Page 119

    - 118 - 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. If the needle valve core is worn, it should be replaced. If the needle valve ...

  • Page 120: Cylinder Head

    - 119 - 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; t...

  • Page 121

    - 120 - 1. Spark plug 2. Mounting bolts of cylinder cover 3. Cylinder cover 4.Cylinder gasket 5. Cylinder 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 曲轴箱 化油器...

  • Page 122: 12. C

    - 121 - 12. C ylinder 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 se...

  • Page 123

    - 122 - loosen fixing nut and spark plug. Dismantle the cylinder cover. 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 12.5 assembly of cylinder cover the assembly should be in th...

  • Page 124: Cylinder Block And Piston

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

  • Page 125

    - 124 - 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 ...

  • Page 126

    - 125 - 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 13.2 failure diagnosis low compression pressure smok...

  • Page 127

    - 126 - 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. Check piston, piston pin and piston ring remove piston ring attentions: do not break or damage piston ring to remove the carbo...

  • Page 128

    - 127 - measure the external diameter of piston pin allowable limit: 11.96mm clearance between piston pin hole and piston pin allowable limit: 0.02mm check external diameter of piston attentions: measuring position should be 90 degree with the piston pin, 11.5mm lower than the piston skirt allowable...

  • Page 129

    - 128 - measure the wrist-pin end of connecting rod allowable limit: 14.06mm。 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 brok...

  • Page 130

    - 129 - 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..

  • Page 131: Feet Startup Mechanism

    - 130 - feet startup mechanism 1. Retainer 2. Start claw 3. Idler gear 4. Idler shaft 5. Starting shaft assembly 6. Feet start shaft spring 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 sli...

  • Page 132: Mechanism

    - 131 - 14. Driving plate / clutch / driven wheel/ feet startup mechanism preparation materials--------------------14.1 clutch /driven wheel---------14.5 failure diagnosis---------------------14.2 disassembly of clutch and driven wheel ----14.6 left crankcase cover -------------------14.3 assembly--...

  • Page 133

    - 132 - broken or damaged clutch friction lining wear of ball broken clutch-pressing spring polluted driving pulley surface 14.3 left crankcase cover disassembly remove the fixing bolt of cover, and to remove the gasket and fixed pin. Attentions: cross disassemble the fixed bolts. Remove the pilot p...

  • Page 134

    - 133 - allowable limit: 16mm。 please use the original parts when replacing. Remove 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 allowable limit: 14.4mm。 right half components of drivi...

  • Page 135

    - 134 - measure the outside diameter of right half driving wheel allowable limit: 26.06mm。 measure the outside diameter of sliding sleeve allowable limit: 25.94mm。 14.5 clutch/driven wheel 14.5.1 disassembly fix clutch sleeve using fixer and remove fixing nut. Remove clutch sleeve, clutch/driven whe...

  • Page 136

    - 135 -.

  • Page 137

    - 136 - check the wear of clutch sleeve. Measure the outside diameter of clutch sleeve. Allowable limit: 118.5mm。 check the wear of clutch friction lining. Measure the thickness of friction lining. Allowable limit: 1.5mm。 14.6 disassembly of clutch and driven wheel clutch spring compressor should be...

  • Page 138

    - 137 - remove pilot pin. Remove the left half weldment of driven wheel disassemble the oil seal on the left half driven wheel check the free length of clutch spring allowable limit: 68mm。 自由长度：free length check the wear of driven wheel\ measure the outside diameter of right half bushing of driven w...

  • Page 139

    - 138 - 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 install needle roller bearing needle roller bea...

  • Page 140

    - 139 - install spring sheath. Wipe clean the spilled oil. 弹簧护套：spring sleeve install the clutch-pressing spring and clutch on the driven wheel. Use clutch spring pressing combination. After the compression, the lock nut should be installed. Attentions: the spring should be compressed appropriately,...

  • Page 141: Reduction Gear

    - 140 - 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.

  • Page 142

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

  • Page 143

    - 142 - 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 di...

  • Page 144

    - 143 - remove the gasket and dowel. Remove the principal axis of clutch and output shaft gear. Remove the central jack shaft and 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 b...

  • Page 145

    - 144 - 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..

  • Page 146

    - 145 - 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 distort...

  • Page 147

    - 146 - 16.3 crankcase 16.3.1 the disassembly of crankcase unscrew the bolt and remove the driving motion gear. Remove the gear. Dismantle the fixed bolt of crankcase dismantle the crankcase on both sides. Note: the gasket should be avoided from damage. Remove the gasket and dowel. Remove the crank ...

  • Page 148

    - 147 - remove the grease seal from the left crank case. Remove the grease seal from the right crank case. 16.3.2 examination the measurement of clearance between the connecting rod. Allowed limit: 0.6mm 连杆大端测量位置 measurement location of the connecting rod the measurement of clearance in x-y directio...

  • Page 149

    - 148 - 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. 16.4 assembly the assembly of...

  • Page 150

    - 149 - examination and maintenance of the exhaust gas emission system silencer 1.Graphite winding gasket 2. Exhaust pipe assembly 3. Socket head cap screws m6×25 4.Broken bolt m6×25 5. Bolt m6×16 6. Connected flange gasket assembly 7. Cushion ring 6 8.Spring cushion ring 6 9. Nut m6 10. Bolt m8×20 ...

  • Page 151

    - 150 - 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 ------...

  • Page 152

    - 151 - 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 cus...

  • Page 153

    - 152 - efficiency seek the improvement on fuel efficiency. Air guide equipment guide the air into exhaust gas pipe. The incomplete burned co and hc will become harmless gas again. Distinction equipment component purpose and function exhaust gas system accelerant device accelerant transformer canned...

  • Page 154

    - 153 - 触媒加放点 accelerant adding point 17.4.2 introduction: 1. The effect of transformed accelerant is to change the exhaust gas hc, co and nox into harmless gas h 2 o, co 2 and n 2 and discharge them. 2. The transformed accelerant contains platinum and rhodium and other rare metal. Unleaded gasoline...

  • Page 155

    - 154 - implement regular inspection (maintenance plan) measure idling emission (note 1) adjust the carbureter (note 2) strip and clean carbureter (sj, mj, saj and maj) change the carbureter strip and clean the motor •valve (leakage) •plug (wear-out) •combustion chamber(clean) leave the factory qual...

  • Page 156

    155.