KEEWAY F-ACT EVO, Instruction & Maintenance Manual

Page 1: ...Two wheeled Motorcycle F ACT EVO User s Instruction and Maintenance Manual KEEWAY Motorcycle Co Ltd...

Page 2: ...tion 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...

Page 3: ...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 12...

Page 4: ...thod 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 com...

Page 5: ...s 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 e...

Page 6: ...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...

Page 7: ...age 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...

Page 8: ...ble 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 ro...

Page 9: ...to do the maintainence operation The metric bolt nut and screw are not interchangeable with the British fastener 3 When reassembling new washer O ring split pin and locking plate should be replaced 4...

Page 10: ...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...

Page 11: ...10 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...

Page 12: ...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 assembli...

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: ...d 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 3...

Page 15: ...20 70 12 Front wheel rim 3 50 12 Air cleaner 3XG Rear wheel tyre 130 70 12 Rear wheel rim 3 50 12 Fuel tank capacity 5 6L Driving mechanism Type of clutch Dry centrifugal type Carburetor model PZ19JB...

Page 16: ...15 QJ50T 21T...

Page 17: ...cap fails 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 sys...

Page 18: ...Check if the air cleaner blocks The engine stops after running a very short time Work continuously after starting The carburetor inside blocks or the float is too high Carburetor starting device star...

Page 19: ...time Check the cooling system Air cooled engine Check if the cooling fins are stained with silt or too much oil Wash Check if the cooling fans and wind scoop break compulsive air cooled engine Check...

Page 20: ...ombustible gas mixture is too strong 1 Check if the air cleaner blocks 2 Check if the carburetor starting device starting richer system works well 3 Check if the carburetor float is too low the mixtur...

Page 21: ...earability of piston ring and cylinder Start the engine and step on the gas slowly to watch the change of engine s rotating speed The rotating speed of the engine accelerates as the driver step on the...

Page 22: ...too large Check if the wire rope of accelerator control cable is flexible in cable cover and if the air throttle spring is too weak 1 Check if the CDI ignition apparatus fails 2 Check if the magneto f...

Page 23: ...o low Tire pressure is normal To charge as required Check there is fuel leaking in the fuel tank fuel cock fuel pipe and carburetor To exclude in accordance with the actual situation Check the mixture...

Page 24: ...shift Start the engine and check if the idle speed of the engine is too high Readjust Check if the gear shifting operation is coordinating Check if the clutch is separated completely Improve the opera...

Page 25: ...sitioned wheel spring breaks or the spring force is insufficient Replace Disassemble the crankcase check if the gear wheel engaging depths of various gears are up to requirement Engaging depth of gear...

Page 26: ...rake control cable then pull the brake rocker arm by hand to check Brake rocker arm revolves smoothly but you feel resistance when holding the brake handle Brake rocker arm revolves difficultly The ar...

Page 27: ...poor contact or broken No voltage indicates Voltage indicates Circuit from the insert connector to storage battery is broken Use the ohmmeter to test the commutator or test if the commutation regulato...

Page 28: ...ited The wire from the commutator or the commutation regulator or the storage battery to the ignition switch is shortcircuited Replace the charging coil 1 Check if the electrolyte in the storage batte...

Page 29: ...tery terminal on the start relay with the start motor terminal The start relay can rotate normally after connecting The start motor can rotate normally after shorting The start motor can not rotate af...

Page 30: ...rt motor is in poor contact 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 t...

Page 31: ...c horn does not sound and the steering lamp does not work The power supply of storage battery is normal Use a wire to touch the positive terminal and negative terminal of the storage battery quickly a...

Page 32: ...eck 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 commutatio...

Page 33: ...ormal after disconnecting The lamp light is still weak after disconnecting The stabilized voltage of commutation regulator is too low Check if wires in the magnetor charging coils and charging system...

Page 34: ...orn sounds loudly The electric horn does not sound or sounds raucously The electricity supply in storage battery is insufficient The electricity supply in storage battery is insufficient Remove the st...

Page 35: ...h 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...

Page 36: ...ake lamp is broken or short circuited The lead between the ignition switch and the brake lamp switch is broken or short circuited Storage battery is undercharged Check if the brake lamp is on Adjust o...

Page 37: ...m 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...

Page 38: ...5kpa Rear rim 3 50 12 Torque value Front wheel spindle 55 62 N m Fixing nut for rear wheel 100 113 N m Certification for Related Parts Type Name Certificate No Remark Tyre Front outer tyre E11 75R 000...

Page 39: ...sorber working inspection I I I Ordinary tools Screw fastening inspection I I I I I I Torque spanner Oil leakage inspection for gearbox I I I I I I Ordinary tools Inspection or replacement of spark pl...

Page 40: ...lied 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...

Page 41: ...Free travel 5 10mm The main adjustment part is the side of the carburetor Loosen the fixed nut thenrotate and adust the adjusting nut Air filter Filter replacement Remove the body shield Remove the s...

Page 42: ...ore 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 plu...

Page 43: ...g Do not disconnect the battery during the adjustment of motorcycle otherwise inner component of the motorcycle may be damaged Charging state closed circuit voltage inspection Open the cover of batter...

Page 44: ...rging current standard 0 4A Emergency 4 0A Charging time standard 10 15h Emergency 30min Charging complete closed circuit voltage above12 8V Carburetor Idle speed adjustment Note Idle adjustment was m...

Page 45: ...llowing 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 a...

Page 46: ...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 mainten...

Page 47: ...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 T...

Page 48: ...ry 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 absorbe...

Page 49: ...Note Check the tyre air pressure when it is cold Regulated Pressure Unit Kpa Tyre specification QJ50T 21T Front outer tyre 120 70 12 Front rim 3 50 12 Rear outer tyre 130 70 12 Rear rim 3 50 12 Check...

Page 50: ...alue Front wheel axle 55 62 N m Rear wheel nut 100 113 N m Steering column bearings and handle fix Swing the handle in order to confirm there is no interference with wire Confirm the handle turn freel...

Page 51: ...g 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...

Page 52: ...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: ...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...

Page 54: ...m Charging limit 14 8V 0 4V 5000rpm Tightening torque force value Tool Rectifier bolt 5 0 N m Multiple fixing spanner High tension coil fixing bolt 9 0 N m Flywheel remover Flywheel Fixing bolt 5 0 N...

Page 55: ...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...

Page 56: ...witch 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...

Page 57: ...ition 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 ad...

Page 58: ...th multimeter Standard Value 2 0 2 5 20 Replace the magnetor coil when the measured value exceeds the standard value 1 7 2 Dismounting Remove the body shield Remove the right body cover Remove the 2 f...

Page 59: ...le 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...

Page 60: ...nition 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...

Page 61: ...ly 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 bur...

Page 62: ...ure 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 seconda...

Page 63: ...ct before testing Cylinder compression pressure normally refers to the test value when the spark plug is installed in the cylinder head Connect the wires of ignition coils Ground connect the two ends...

Page 64: ...rmal the charging coil may be broken please refer to the inspection method of charging coil 2 3 3 Trigger Note Install the spark plug in the cylinder head and carry out the measuring when the compress...

Page 65: ...alue 20 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 6 10 Secondary coil of the ignition...

Page 66: ...break in the coil Remove the spark plug cap measure the impedance value between a side wire and the negative end Standard Value 0 5 5 5K 10 20 2 6 Trigger Note Make sure the trigger could be carried o...

Page 67: ...CH 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...

Page 68: ...he 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...

Page 69: ...g line Broken starting motor 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...

Page 70: ...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 t...

Page 71: ...n 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 m...

Page 72: ...he 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 utt...

Page 73: ...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 001765 C Certificate No of rear lamp E4 50R 0014909 D...

Page 74: ...switch could be removed from the motorcar before being examined 4 2 Failure Diagnosis The main switch is not ON The bulb is broken The switch is broken Poor contact at the adaptor or wire break 4 3 H...

Page 75: ...ulb in the opposite order of removal 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...

Page 76: ...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 termi...

Page 77: ...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 ass...

Page 78: ...rake fixing bolt Muffler decoration cover screw Tap welding assembly mounting bolt Front wheel locking nut Front shock absorber mounting bolt Rear wheel mounting nut Rear shock absorber top nut Rear s...

Page 79: ...brake 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...

Page 80: ...onent 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 A Torque value of nut 5 in...

Page 81: ...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 N m Front cylinder component installation bolt 2...

Page 82: ...ake 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 2 Wear of th...

Page 83: ...24 5 front brake disc 22 Note referring to detail decomposition view on page 77 Note When installing and removing the brake shoe block can not be stained with grease The brake should be cleaned with...

Page 84: ...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 val...

Page 85: ...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 thickn...

Page 86: ...g fluid Rear brake 1 Rear rocker arm installation bolt 12 7 Brake shoe block component 6 2 Rear brake rocker arm component 11 8 Brake shoe block tension spring 7 3 Rear wheel fixing nut 5 9 Tire E11 7...

Page 87: ...ed 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 pa...

Page 88: ...eflector 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 Rem...

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 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 A Tire specification tire120 70 12 Certification number of fron...

Page 91: ...acket1 8 boltM10 1 25 30 9 boltM6 12 10 hydraulic tube clip 11 low connection plate welding component 12 clip 13 nut 14 dustproof cover 15 integral steel bowl 16 ball5 17 low bearing high steel bowl 1...

Page 92: ...llation bolt 11 fixing cover 12 boltM6 22 13 handle installation seat 14 rear brake switch 15 nutM6 16 bolt M10 1 25 45 17 self locking nut M10 1 25 18rear brake component 19 accelerator wire componen...

Page 93: ...erating do not make the brake shoe block friction plate component front brake disc stained with grease Vehicle standard Measured position Item Standard value mm Available limit mm Front wheel axle Ben...

Page 94: ...s 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 t...

Page 95: ...ing 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...

Page 96: ...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 rec...

Page 97: ...xing bolt 16 Remove the tap welding component 3 7 4 2 Installation Note referring to the assembly and disassembly view of the QJ50T 21T direction handle on page 87 Install in a sequence contrary to th...

Page 98: ...andle 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...

Page 99: ...11 rear brake rocker arm 12 rear rocker arm installation bolt 13 O shaped ring 14 bolt M10 1 25 40 15 rear muffler component A Torque value of the rear wheel fixing nut5 in figure 100 113N m B Instal...

Page 100: ...rear brake cam shaft 9 rear brake wire limit plate 10 sealing ring I 11 rear brake return spring 12 rear brake rocker arm component 13 bolt M6 35 A Tire specification 130 70 12 B Rim specification 3 5...

Page 101: ...Item Standard value mm Available limit mm Rear wheel swing degree Longitudinal 2 0 Horizontal 2 0 Locking torque Rear wheel fixing nut 100 113 N m Rear muffler top bolt 37 44 N m Rear muffler bottom...

Page 102: ...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 wh...

Page 103: ...elf assembly rear fender Remove the rear muffler fixing bolt Remove the muffler 8 4 2 Installation Install the rear muffler Torque value High fixing bolt 37 44 N m Low fixing bolt 22 29 N m The instal...

Page 104: ...ushion lock seat component 7 cable component 8 inside hexagonal screw M8 25 9 rear strengthen plate of the helmet bucket 10 self locking nut M10 1 25 11 bush 12 engine bracket A Note when removing the...

Page 105: ...k body 2 fuel sensor component 3 combination screw M5 14 4 tank cap 5 tank inlet jacket 6 steel wire clamp 10 7 connection tube 8 tubing 7 2 300 9 steel wire clamp ca 7 5 10 tubing A Gasoline tank cap...

Page 106: ...8 14 tubing 4 5 2 70 15 filter component 16 tubing 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: ...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 ope...

Page 108: ...eft 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 t...

Page 109: ...108 Check and maintenance of the engine...

Page 110: ...late locking bolt Cylinder stud bolt Motor fixing bolt Crankcase left cover locking screw Crankcase left cover locking bolt Driving wheel disc locking nut Driven wheel disc locking nut Driven wheel di...

Page 111: ...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...

Page 112: ...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...

Page 113: ...ind 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...

Page 114: ...y 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 Mac...

Page 115: ...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 remov...

Page 116: ...uretor 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 suppl...

Page 117: ...h oil overflows Oil nozzle has been obstructed Fuel system has the second air suction Needle valve has been obstructed Fuel degradation Oil surface is too low Bad concentration Fuel system has been ob...

Page 118: ...ve and to take the electrical enrichment valve module Check the wear of electrical enrichment valve and injector needle If it is worn badly then electrical enrichment valve module should be replaced L...

Page 119: ...n 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 Chec...

Page 120: ...ace 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 t...

Page 121: ...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 b...

Page 122: ...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...

Page 123: ...k 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 the reverse...

Page 124: ...3 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 checki...

Page 125: ...ss 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...

Page 126: ...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 damag...

Page 127: ...g 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 Attentions press the piston ring...

Page 128: ...e inside diameter of cylinder in the direction of 90 degree with piston pin at the upper middle and lower positions Allowable limit 40 05mm Measure the clearance between cylinder and piston the maximu...

Page 129: ...y in the groove after assembly 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...

Page 130: ...e 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 shape...

Page 131: ...r 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 lef...

Page 132: ...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 slid...

Page 133: ...disassemble the fixed bolts Remove the pilot pin 14 4 Driving plate 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...

Page 134: ...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 li...

Page 135: ...isassembly 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...

Page 136: ...135...

Page 137: ...y 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 t...

Page 138: ...driven wheel Allowable limit 32 94mm Measure the inside diameter of left half sliding sleeve of driven wheel Allowable limit 33 06mm 14 6 1 Replacement of right half of the driven wheel bearing Remov...

Page 139: ...with the tool shown in the figure 14 6 2 Combinations of clutch driven wheel Clear out the oil left on the surface of driven wheel Install the oil seal in the left sliding sleeve of the driven wheel...

Page 140: ...sed 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...

Page 141: ...he 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 Re...

Page 142: ...141 Function it is a transmission torque and could determine the final output torque and speed...

Page 143: ...rque 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 w...

Page 144: ...g 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 Not...

Page 145: ...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...

Page 146: ...r 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 co...

Page 147: ...olt of crankcase Dismantle the crankcase on both sides Note The gasket should be avoided from damage Remove the gasket and dowel Remove the crank axle from the crankcase Clean the gasket on the faying...

Page 148: ...m the right crank case 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 dir...

Page 149: ...component Note The dismantled grease seal cannot be reused The disassembly of grease seal should adopt professional tools 16 4 Assembly The assembly of the crank case should be in reversible order of...

Page 150: ...n Ring 6 14 Gland 15 Silencer Anchor Ear 16 Gasket 17 Shell Assembly 18 Plate Bar Clasp 19 3 19 Check Valve And Silencer Connection Pipe 20 Check Valve 21 Bolt M6 35 22 Oil Pipe 13 18 50 23 Plate Bar...

Page 151: ...cy 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 a...

Page 152: ...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 sys...

Page 153: ...nction Equipment Component Purpose and Function Exhaust Gas System Accelerant Device Accelerant Transformer Canned oxidated accelerant equipped in the center of exhaust gas pipe makes CO HC and NOX ox...

Page 154: ...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...

Page 155: ...ean Leave the Factory Qualified Qualified Qualified Qualified Qualified Qualified 8 When repairing the motor ignition system to dismantle the ignition plug is not allowed If necessary time should be l...

Page 156: ...155...