TX200 Service Manual

TX200 Service Manual
KEEWAY Motor Corporation Ltd.
- 1 -
Contents
Contents............................................................................................................................................................ - 2 -
Preface ...................................................................................................................................................... - 5 -
Preparing .................................................................................................................................................. - 6 -
Inspection/Adjustment ........................................................................................................................... - 17 -
1 Brake ........................................................................................................................................................... - 30 -
1.1 Maintenance Instructions ................................................................................................................. - 30 -
1.2 Failure Diagnosis.............................................................................................................................. - 30 -
1.3 Front Fluid Brake ............................................................................................................................. - 31 -
1.4 Rear Fluid Brake .............................................................................................................................. - 32 -
2 Body Panel………………………………………………………………………………………… - 32 -
3 Front Wheel/Front Suspension .................................................................................................................... - 39 -
3.1 Preparing .......................................................................................................................................... - 39 -
3.3 Front Wheel ...................................................................................................................................... - 40 -
3.4 Steering Handle ................................................................................................................................ - 43 -
3.5 Front Fork......................................................................................................................................... - 43 -
4 Rear Wheel/Rear Suspension ...................................................................................................................... - 47 -
4.1 Preparing .......................................................................................................................................... - 47 -
4.3 Rear Wheel ....................................................................................................................................... - 48 -
4.4 Rear Absorber/Rear Rocker.............................................................................................................. - 51 -
4.5 Drive Chain ...................................................................................................................................... - 52 -
5 Battery/Charging System ............................................................................................................................ - 55 -
5.1 Preparing .......................................................................................................................................... - 55 -
5.3 Battery .............................................................................................................................................. - 57 -
5.4 Charging System .............................................................................................................................. - 58 -
5.5 Voltage and Current Adjustor ........................................................................................................... - 59 -
5.6 Alternator Charging Coil .................................................................................................................. - 60 -
5.7 Alternator Lighting Coil ................................................................................................................... - 60 -
5.8 Removing the Alternator .................................................................................................................. - 60 -
6 Ignition System ........................................................................................................................................... - 63 -
6.1 Preparing .......................................................................................................................................... - 63 -
6.3 Ignition System Inspection ................................................................................. ……………………65-.
6.4 CDI Group ........................................................................................................................................... 67-
6.5 Ignition Coil ........................................................................................................................................ 68-
6.6 Trigger ................................................................................................................................................. 69-
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7 Starting System ........................................................................................................................................... 71-
7.1 Preparing ............................................................................................................................................. 71-
7.2 Failure Diagnosis................................................................................................................................. 72-
7.3 Starting motor ...................................................................................................................................... 72-
7.4 Starting Relay ...................................................................................................................................... 74-
8 Lithts/ Switches / meters ............................................................................................................................. 75-
8.1 Preparing ............................................................................................................................................. 76-
8.2 Failure Diagnosis................................................................................................................................. 76-
8.3 Headlight bulb replacement................................................................................................................. 76-
8.4 Front turn light bulb replacement ........................................................................................................ 77-
8.5 Taillight/Number Plate Lamp/Rear turn light bulb replacement ......................................................... 77-
8.6 Meters .................................................................................................................................................. 78-
8.7 Main Switch ........................................................................................................................................ 78-
8.8 Horn..................................................................................................................................................... 79-
8.9 Handle Switch ..................................................................................................................................... 79-
9 Engine Inspecion and Maintenace ............................................................................................................. 82-
10 Lubracation System ................................................................................................................................... 83-
10.1 Preparing Documents ........................................................................................................................ 84-
10.2 Failure Diagnosis............................................................................................................................... 84-
10.3 Oil Pump ........................................................................................................................................... 85-
11 Carburetor.................................................................................................................................................. 88-
11.1 Preparing ........................................................................................................................................... 89-
11.2 Failure Diagnosis ............................................................................................................................... 89-
11.3 Remove Carburetor ........................................................................................................................... 90-
11.4 Carburetor Installation ....................................................................................................................... 91-
12 Cylinder Head/ Cylinder vavle .................................................................................................................. 93-
12.1 Preparing Documents ........................................................................................................................ 93-
12.2 Failure Diagnosis............................................................................................................................... 94-
12.3 Cylinder Head ................................................................................................................................... 94-
12.4 Vavle examination ............................................................................................................................. 98-
12.5 remove Valve Guide .......................................................................................................................... 99-
12.6 Repair and maintance of the vavle seat ring .................................................................................... 100-
12.7 Cylinder Head Installation............................................................................................................... 101-
13 Cylinder block and piston ....................................................................................................................... 102-
13.1 Preparing ......................................................................................................................................... 103-
13.2 Failure Diagnosis............................................................................................................................. 104-
13.3 Cylinder Block ................................................................................................................................ 104-
13.4 piston ............................................................................................................................................... 106-
13.5 Cylinder block Installation .............................................................................................................. 109-
14 Clutch/Foot starting system ..................................................................................................................... 112-
14.1 Preparing ......................................................................................................................................... 112-
14.3 Clutch .............................................................................................................................................. 113-
14.4 Foot starting system ........................................................................................................................ 115-
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14.5 Disassembly of Main&Counter Shafts ...........................................................................................116.
15 Speed transmisson system ........................................................................................................................119.
15.1 Preparing ......................................................................................................................................... 119-
15.3 Gear Shifting Mechanism ................................................................................................................ 120-
15.4 Installation ....................................................................................................................................... 122-
16 Crankcase ................................................................................................................................................ 124-
16.1 Preparing ......................................................................................................................................... 124-
16.3 Crankcae .......................................................................................................................................... 125-
16.4 Crankshaft&Connecting Rod .......................................................................................................... 128-
17 The exhaust emission system .................................................................................................................. 131-
17.1 The Exhaust Emission System warranty ......................................................................................... 131-
17.2 Regular maintenance notice ............................................................................................................ 131-
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Preface
This manual is an introduction to the maintenance of TX200.
Preparing Documents include all the contents needed, so read it carefully
before operation.
Inspections introduce how to check and maintain your motorcycle, which
needs to be done regularly.
After the first chapter, the manual will explain parts of the engine, entire
motorcycle, electrical parts, and how to disassemble and reassemble these parts.
Each chapter has decomposition map and system diagrams, failure diagnosis
and maintenance instructions.
This manual does not separate the two motorcycles when they are described in
common parts.
The pictures and content are just for your reference. Please be subject to the
actual products if anything is different or updated. Please forgive me for not
informing you in advance.
KEEWAY Motor Corporation Ltd.
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Preparing Documents
General safety Maintenance rules
Specification table Failure diagnosis
General Safety
Carbon monoxide
Start the engine in a well ventilated place, not a confined one.
Note
Exhausted gas contains poisonous carbon monoxide, which may cause people unconscious and even death.
Do use the exhaust removal system when starting the engine in a confined place.
Petrol
Work in a well ventilated place. Open flames are prohibited at places for storing oil and its workplace.
Battery
Battery electrolyte contains sulfuric acid, so do not let the eyes, skin, clothes infected with the electrolyte.
Once the skin, clothing infected with electrolyte, they should be thoroughly washed with water immediately; if
the eyes are affected, you should go to the hospital as soon as possible.
Special tools
Choose common tools and special tools correctly when dismounting parts. Generic tools are not available to
replace the special tools at the same time. What is more, the using force should be appropriate in case that the
parts will be damaged.
High-temperature burns
Be careful when checking and operating the motorcycle; especially pay attention not to be burned by the
engine, exhaust pipe, muffler and other high temperature components. When you are inspecting the motorcycle
with others, do take care of each other and be careful.
- 6 -
Maintenance rules
In the maintenance of this bike, metric tools should be used as much as possible; otherwise, the bike will be
damaged using the improper tools.
Clean up the dirt of the parts or the assembly parts before removing or opening the motorcycle shield in the
maintenance work to prevent dirt falling into the engine, chassis or braking system.
After dismounting the parts, wash and blow the parts with
compressed air machines, at last measure wear values.
Wrong Wrong Wrong
Operation should not be bent or distorted. Otherwise, it will

cause operational difficulties or early damage.
Solvent or oil can easily damage aging rubber articles. So these

rubber articles should be checked before reassembling, change
them when necessary.。
Cover
Release parts with kinds of assemblies from outside to the

inside. Also, first loosen small assembly. A complex assembly
such as the gearbox should be stored in accordance with
appropriate assembly sequence in order to be easily assembled
in the future.
Pay great attention to the dismounting of the important

co-location of equipment. Parts which are no longer in use
should be replaced in time before dismounting.
- 7 -
The length of bolts or screws is different for different assemblies
and shields, so bolts and screws should be correctly mounted. If there is confusion,
you can put the bolt into the hole to see if it is appropriated.
To install the oil seal, first fill the oil seal groove with the grease
lubricant, then check whether the seal is smooth, otherwise it will
damage the oil seal.
When installing the hosepipe (fuel, vacuum, or cooling agent), you should Groove
insert its end to the bottom of the connector in order that there is enough
space for the hose clip clipping the connector. Rubber or plastic dirt-proof Cramp
boot should be installed according to the original design.
Connector
When dismantle the ball bearings, you should use a tool to resist one or
two (inner or outsider), otherwise the ball bearings may be damaged
during the demolition and must be replaced.
The above two examples will make the

Bearings crack.
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Specifications (TX200-AOff-road type)
Model QJ200GY-AOff-road type Engine type QJ164FML
Length mm 2100 Fuel type Above 90# White gasoline
Width mm 770 Cylinders 1
Height mm 1090 Engine Bore*Stroke 63.5mmx62.2mm
Wheel base mm 1365 Swept volume 197CC
Forward
45.9kg Starting system Electric/kick start
shaft
Weight kg Back
89.1kg Cooling system Air forced
shaft
Total 135kg Lubrication Force-feed and splash
Front(inside） Front(outside）
Oil capacity 1.2L
90/ 90-19 90/ 90-19
Tire size
Rear（inside） Rear（outside）
Air cleaner Sponge
110/90-17 110/ 90-17
Fuel capacity 12L
Multiple-disc oil friction disc

Clutch
Max speed 106 km/h
Transmission Gradeability Maximum permissible gradient>=15°

Gearshift Manually
Idling speed 1400±100rpm/min

Performances
Transmission Chain transmission
Max torque 14N.m/6000r/min
Battery
12V-9AH/dry charged cell Max Hp 9.5KW/7550r/min
capacity/type
Dynamo
Permanent AC motor Compression Ratio 8.3:1
type
Electric
Spark plug BR8ES/F10KC Cylinder pressure 1.0-1.1Mpa
installation
Spark plug
0.5-0.7mm Front fluid brake disc unit φ2 8 5 mm
gap
Braking
Ignition CDI system Rear fluid brake disc unit φ2 2 0 mm
- 9 -
Specifications (TX200 Street type)
QJ200GY-AStreet
Model Engine type Q J164FML
type
>90# White
Length mm 2100 Fuel type
gasoline
Width mm 770 Cylinders Cylinders
Height mm 1090 Bore*Stroke Bore*Stroke

Engine
Wheel base mm 1365 Swept volume Swept volume
Forward Electric/kick
45.9kg Starting system
shaft start
Back
Weight kg 89.1kg Cooling system Air forced
shaft
Force-feed and
Total 135kg Lubrication
splash
front（outside）
Oil capacity Oil capacity
100/80-17
Tire size
rear（outside）
Air cleaner Air cleaner
130/80-17
Fuel capacity 12L

Multiple-disc oil
Clutch friction disc Max speed 106 km/h
Maximum
Transmission Gradeability permissible
Gear shift Manually
gradient>=15°
1400±100rpm/
Idling speed
min
Transmission type Chain transmission Performances 14N.m/6000r/m
Max torque
in
12V-9AH/ dry 9.5KW/7550r/m
Battery capacity/type Max Hp
charged cell in
Compression
Engine type Permanent AC motor 8.3:1
Ratio
Electric
installation Spark plug BR8ES/F10KC Cylinder pressure 1.0- 1.1Mpa
Front fluid brake

Spark plug gap 0.5-0.7mm φ285mm
disc unit
Braking
Rear fluid brake
Ignition CDI system φ220 mm
disc unit
- 10 -
Failure diagnosis
Hard to start hard or can not start

Failure diagnosis Adjustment and inspection Source of trouble
Loosen the bolt of the carburetor

to check whether there is enough No petrol in the petrol tank
fuel Oil pipe of carburetor plugs up

Oil pipe of float chamber plugs up
Enough fuel for Not enough fuel for the Pipeline of the Evaporative Emissions Control
the carburetor carburetor System plugs up
Petrol filter plugs up
Remove the spark plug and Bad automatic oil control ring
put it into its cap, check Bad spark plug
whether it is work with the Polluted spark plug
engine ground Bad CDI
Bad trigger
Sparkplug Little or no spark Open circuit or short circuit of the lead of
has a jump ignition coil
Open circuit or short circuit of ignition coil
Measure the Bad main switch
compression Bad charging coil
pressure Bad starting clutch
Enough Not enough Bad piston and piston ring of the cylinder
pressure pressure
Air leakage of the cylinder ring
Fail to ignite the Close to ignite the Bad automatic choke
engine engine, but

also fail Air in induction manifold
Incorrect duration of ignition
Remove the spark plug Bad governing screw of the carburetor

for inspection
Overtopped oil lever of carburetor
Dry spark plug Wet spark plug Bad automatic choke
Oversized throttle opening
- 11 -
Unsmooth rotation（under speed）
Start the engine
Air filter plugs up
lightly
Bad petrol
Engine speed Not enough Pipeline of the Evaporative Emissions Control
rise engine speed System plugs up
Vent-pipe plugs up
Adjust the electronic spark Bad automatic choke
timing Cracked vacuum module for the carburetor
Bad automatic oil control ring
Correct ignition time Incorrect ignition time
Bad CDI
Bad trigger
Measure the compression
pressure
Bad piston and piston ring of the cylinder
normal Pressure too low

Air leakage of the cylinder ring
Check whether the carburetor plugs up or not

Clear up dirt
No plugging Plug up
Remove the spark plug
for inspection Clear up dirt
Heat value of spark plug is not appropriate
Clean Polluted, discolored
Check oil in the crankcase is

contaminated or not Too much oil
Normal oil level Too much oil Insufficient oil
Check the cylinder for lube Unchangeable oil
condition Cylinder wear
Normal Abnormal Mixed gas is too thin

Engine overheat Bad petrol
Too much carbon distribution in the firebox
no yes Too early ignition time

Too much carbon distribution in the firebox
Accelerate operation Bad petrol

Clutch slip
Without Detonation Detonation Mixed gas is too thin

Too early ignition time
- 12 -
Unsmooth rotation（especially low speed）
Failure diagnosis Adjustment and injection Source of trouble
Adjust ignition time
Bad CDI
Normal Abnormal
Bad trigger
Adjust the bolt to change the oil

level of the carburetor
Mixed gas is too thin (loosen the screw)

Well Bad adjustment
adjusted Mixed gas is too thick (tighten the screw)
Inhaled air in the

carburetor gasket Bad heat shield
Loosen the nut of the carburetor
No yes Broken heat shield
Broken negative pressure tube
Remove the spark plug and

put it into its cap, check Bad spark plug or it is polluted
whether it is work with the Bad CDI
engine ground Bad ignition coil
Spark plug Cannot jump
Open circuit or short circuit of the lead of the spark
work well spark
plug
Bad main switch
Broken negative pressure tube

Yes No
Air holes are blocked
- 13 -
Unsmooth rotation（especially high speed）
Failure diagnosis adjustment and inspection Source of trouble
Adjust ignition time
Bad CDI
Normal Abnormal
Bad trigger
Insufficient petrol in the petrol tank

Petrol filter plugs up
Normal Abnormal
Pipeline of the Evaporative Emissions Control
System plugs up
Bad automatic oil-control ring
Carburetor plug up
Unblocked Blocked
Clear up
Good Spring has no

Bad spring
elasticity
- 14 -
Bad battery（over discharged or overcharged）
Start the engine and measure the
battery voltage
Life of the battery is over
Voltage don’t The voltage rises to the normal

rise level and is back to original
Bad battery
after switch off the bike
Check whether the voltage adjuster is

loose or not
Normal Abnormal
Poor contact of the plug
Open circuit of the red wire
Check the socket of the voltage
adjuster. Connect the read wire and
positive terminal of the multimeter
together. Connect the negative
Voltage adjuster
Voltage exist No voltage terminal and the body together
Open circuit of the white wire
Measure the coil impedance of the

alternator
Bad coil
Normal Abnormal
Poor contact of the connection
Broken white wire of the alternator
Bad battery
Overcharged
Start the engine, Connect the read wire
and positive terminal of the multimeter
together. Connect the negative terminal
Higher than normal Normal voltage
voltage
Check whether the contact of voltage
adapter is good or not
Normal Poor contact Poor contact of the connection or wire
Measure the impedance of the
Voltage adapter Bad voltage adjuster
- 15 -
Spark plug cannot jump
Change a new spark plug
No jump spark or Intense

Old spark plug is bad
little jump spark spark
Check the spark plug
Loose spark plug cap

tight loose
Check whether the CDI plug is

loose or not
Normal Abnormal
Poor plug contact
Check whether wire between
terminals is open or not and
measure the resistance Bad main switch
Bad charging coil
Normal Abnormal
Bad trigger
Bad ignition coil
Check related parts
Normal Abnormal
Broken main wiring
Poor contact of the socket
Check CDI using CDI tester
Normal Abnormal Bad CDI
Check the ignition coil using CDI

tester
Abnormal
Bad ignition coil
- 16 -
Inspection/Adjustment
Preparing information Cylinder pressure
Check list for periodical maintenance Gear oil
Engine oil/Oil filter screen Gear oil change
Petrol filter Drive chain
Cable accelerator inspection/adjustment Front/Rear travel clearance
Air cleaner Front brake shoe wear
Spark plug Headlight
Battery Clutch
Carburetor Front/Rear suspension system
Electronic spark timing bolt/nut/mounting block
Rim/tire tire type
Direction column bearing and knob mounting block
Preparation Principles
In a general way
Warning！
•Start the engine in a well ventilated place, not a confined one. Exhausted gas contains poisonous carbon
monoxide, which may cause people unconscious and even death.
•Under certain condition, petrol is easy to volatile and explode, so its workplace should be ventilated and it
should be stopped. Flames are prohibitive in its workplace and fuel storage place.
- 17 -
Specification
Engine
Idling speed 1400±100rpm/min

Plug gap gauge 0.5-0.7mm Oil capacity 0.5L
Spark plug type BR8ES/F10KC
Cylinder compression 1.1-1.3Mpa/1400rpm
pressure
Duration of ignition BTDC12°（+/-）1° 1400±100rpm
Frame
Front brake lever free 10-20mm

stroke
Rear brake pedal free play 10-20mm
Specification Tire pressure
Front 90/ 90-19 225kpa
QJ200GY-AOff-road wheel
type Rear 110/90-17 225kpa
wheel
Tire pressure unit ：Kpa
Front 100/80-17 225kpa
QJ200GY-AStreet wheel
type Rear 130/80-17 225kpa
wheel
Torque Front axle nut 100-113 N·m
force Rear axle nut 100-113 N·m
value
- 18 -
Check list for periodical maintenance
maintenance
mileage and time Every Every Every Every Every
every
1000 3000 6000 12000 14500
300 KM
KM KM KM KM KM Using tools
Check item
3mon 6mont 12month
1month 15months
New ths hs s
* Air filter I C C R C Common tools
* Petrol filter I I R Common tools

* Oil filter C C C Common tools
Engine oil replacement R Change oil every 1500KM Common tools
Tire pressure I I I I I I Tire gauge, inflator
Densimeter
Battery inspection I I I I I I
multimeter
Actuate gap inspection I I I I I I Common tools
Loose steering control

I I I Common tools
inspection
Absorber inspection I I I Common tools
loose screw inspection I I I I I I Torque spanner
Leakage of the gearbox

I I I I I I Common tools
inspection
Spark plug inspection or
* I I R R I Common tools
replacement
* Gearbox oil replacement I Change oil every 5000KM Common tools
Each part lubrication L L Oil lubricator
Exhaust pipe I I I I I I Common tools
* Electronic spark timing I I I I I I Timing light

* Carburetor A I A A A A
Tachometer
Emission check at idling
* A I A A A A CO HC analyzer
speed
* Accelerator speed I I I I I Common tools
Fuel pipe inspection I I I I I Common tools
Integral instrument lighting
I I I I I I Common tools
electric equipment
Main stand bracket I I I Common tools
Absorber I I I I Common tools
Bolt torque force of the
* I I I I I Torque spanner
engine
- 19 -
Prospective inspection
1 Ignition system—-a clear continuity of ignition disorders, the engine catch fire, overheating
phenomenon, do maintenance check.
2 Carbon distribution—-clearly insufficient power，carbon distribution should be done at places such as
cylinder head, valve head and exhaust system.
3 Valve, cylinder—-excessive wear of the cylinder，replace the old ones.
Please go to KEEWAY dealer for inspection on a regular basis. The bike should be adjusted regularly to ensure
the best driving Status.
In the table, suppose the bike works 1000KM per month.
I—inspection A—adjustment R—replacement C—clean L—lubrication
Notes：1.“*”Emissions projects should follow the State Environmental Protection Agency requirements .you
must use the instructions provided by the company to implement regular maintenance, it is strictly prohibited
for you to maintain it by yourself, otherwise you handle your own risk.
2. In the gravel road or driving under heavily polluted environment, you should increase the frequency of
cleaning the air filter in order to extend its life span.
3. Often driving at very high speed or higher traveling mileage, you should increase your maintenance
frequency
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, and stop about 2-3
minutes and then check the oil level.
Check the oil level.
When the oil level is below the lower limit, add it to the upper limit.
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。
When the oil leaks completely, you can install the bolt
and packing washer after they are cleaned.
Add oil to the required level。
- 20 - Right cap
Oil drain bolt
Oil capacity：0.5L
Check the oil leakage when the engine operates at its idling speed.
Check the oil capacity again.
Petrol filter
Fuel pipe deterioration and damage inspection

If there is any deterioration, damage, fuel leaks and other phenomena, it should be replaced。
Warning！
No open flames!
Cable accelerator inspection/adjustment
Check whether the cable accelerator is smooth or not.

Check the travel clearance.
Travel clearance：2-6mm
The carburetor side needs mainly adjusted
Loosen the fixed nut, and adjust the adjusting nut. Fixing nut
Adjusting nut
Air filter
admitting pot
Filter replacement
Remove the cushion and body shield
Remove the set screw on the air filter cap in order to
remove the filter cap.
Remove the filter vent port
Remove the sponge from the filter from falling
Check whether the filter has been polluted or damaged, if

any, replace the old ones.
Replacement time admitting pot

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 vent port
- 21 -
Spark plug
Spark
Remove the spark plug
plug
Check the burning, pollution, carbon distribution of the plug
In the above condition, use the spark plug cleaner
or steel brusher.
Cylinder
head
Check spark plug gap
gap：0.5-0.7mm
spark plug
clearance
*Note
When installing the plug, first install it
by hand and then use the spark plug box
(socket) spanner to make it tight
Battery
Battery removal
Open the cushion.
Remove the left sheeting.
First remove the negative wire and then
remove the positive wire. Battery bracket
Remove the battery.
Warning！
The tools for removing the positive electrode
should not contact the frame, otherwise it will
be very dangerous that
the damaged battery will cause fire.
Install the battery following the opposite sequence.
warning！
First positive and then negative to
prevent short circuit.
- 22 -
Charging state（closed circuit voltage）inspection
Open the cushion
Open the air filter cap, remove the battery connector wires.
Measure the voltage between battery terminals

Full charge：13.1V
Under charge：12.3V
*Note
Charge state examination must use a
voltmeter operation.
Charge
Connection method： Connect the battery charger positive pole and battery positive pole together.
Connect the battery charger negative pole and battery negative pole together.
Warning！
•Battery should be far away from fire
source
•Turn off the charger switches when
starting or completing charging in order
to prevent spark of the connections
resulting in explosion.
•You must follow the required current
time when charging.
*Note
•Except emergencies, you should not use
emergency charge
•Measure the voltage for every other 30
minutes
Charging current：standard：0.4A
Rapid：4.0A
Charging time：standard：10-15 hours
Rapid：30 minutes
Charging complete：closed circuit voltage：Above 12.8V
- 23 -
Carburetor
Idle speed Adjustment

*Note
Idle adjustment was made in the Screw for
implementation of the engine warm-up
adjusting
state.
idle speed
Implement after warm-up of the engine
Connect the engine rotation meter after running the engine
Adjust the screw of the cable accelerator to rotating velocity
Idle speed：1400±100rpm/min
Adjust the idling adjusting screw when idle speed
is unstable or unsmooth after oiling lightly.
Ignition timing
*Note
CDI ignition system does not need adjust
ignition timing.
Check the ignition system when ignition
timing is not right.
Remove the left bonnet of the engine.

Check the ignition timing to make sure the
ignition right
Manometer
Cylinder pressure
Operate when the engine warm up.

Remove the spark plug.
Install the cylinder pressure gauge.
At full throttle, measure the cylinder pressure Measure the
Manometer cylinder pressure
Measure the cylinder pressure
Compression pressure：1.1-1.3Mpa/1400rpm
When compression pressure is too low, check the following items：
—Cylinder head gasket damage
- 24 -
—Piston ring damage
—Piston ring wear
—Piston, cylinder wear and tear
When compression pressure is too high, check the Combustion chamber and too much carbon distribution at
piston head.
Gear oil
Inspection
*Note
Stop on smooth, level ground, turn the
ignition OFF remove the key.Use the center
stand to park the scooter and allow the engine
to cool.
Remove and check the bolt after the engine stopped.

Oil
Add gear oil when the oil level is low.
Install the checking bolt.
Right
*Note Oil drain cover
Check whether the leak tightness of the bolt
bolt wears or not.
Gear oil replacement
Remove the gear oil checking bolt

Remove the oil drain bolt and let the gear go out.
Install the drain bolt.
*Note
Confirm whether the bolts wear or not.
Add gear oil

Check whether there is leakage in every part after operation.
Drive chain
Remove the oil seal and check whether it wears or not. Drive chain
Pinion stand
Check whether the rear bearings are damaged and remove the
- 25 -
bearings.
Remove the bushing.
Remove the drive chain and bolt of the chain wheel
from the chain wheel seat.
Check whether the drain chain and chain wheel exceed
Limits size.
Front/Rear braking free path
Front braking free path

Measure the front braking free path at the point of the brake
lever.
Travelling clearance：10-20mm
Rear braking free path

Measure the rear braking free path at the point of the brake
pedal.
Travelling clearance：10-20mm
Brake clearance
Front brake shoe wear Oil pump body
When you press the brake in the end, you can check the oil
level from the oil mirror. If the level of the brake fluid is right
aligned with the
Arrow showed in the picture, you should change the shoe.
Oil immersion lens
Front light Adjusting

screw
- 26 -
Adjustment
Loosen the adjusting screw of the front light in order to adjust the optical axis.
Clutch
Start the engine and increase its speed gradually to check the
clutch.
If the motorcycle fails to go and the engine stops, you should
check the clutch block. If necessary, change a new one.
Clutch clearance：10-20mm
Press ups and downs

Front/rear suspension system
Front
Pull the front brake tight and check the absorber.
Check whether the absorber has leakage or loose.
Rear
Check the rear absorber when operating.
Check whether part of the absorber is loose or wear. Operate ups
Suspend the rear wheel and check it movingly. and downs
Check whether the suspension bushing of the engine is loose or
not.
Rear absorber
Axle fixing nut
Nuts/bolts/fixed parts
Check whether nuts, bolts, fixed parts are loose or not.

If any, tightening them according to their torque force.
- 27 -
Rim/Tire
Check whether the tire or rim has crack, screw or any other
damage.
Check the tire pressure.
*Note
Check the tire air pressure when it is cold.
Standard air pressure Unit：Kpa
Specification Tire pressure
QJ200GY-AOff-road Front wheel 90/90-19 225
type Rear wheel 110/90-17 225
QJ200GY-AStreet Front wheel 100/80-17 225
type Rear wheel 130/80-17 225
Tire specifications
Front wheel inside 90/90-19

QJ200GY-A
Front wheel outside 90/90-19
Off-road
Rear wheel inside 110/90-17
type
Rear wheel outside 110/90-17
QJ200GY-A Front wheel 100/80-17
Street type Rear wheel 130/80-17
Check whether the front wheel axle is loose or not.
Check whether the rear wheel nut is loose or not.
If there is any loosening, tightening them according to
the required torque force value.
Check
Torque force value: Front wheel axle 100-113 N·m
from
Rear wheel nut 100-113 N·m
side to
side
Steering column bearings and handle

fixed
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.
- 28 -
Front fluid brake
Rear fluid brake
Yoke Brake shoe

plate bushing
Rear fluid
brake
assembly
- 29 -
1 Brake
Maintenance instruction------------------------1.1
Failure diagnosis------------------------1.2
Front fluid brake--------------------------1.3
Rear fluid brake--------------------------1.4
1.1 Maintenance instruction
Operation notes
*Note
•Parts of the braking system should not be polluted when installing or removing.
•Use the required cleaner to prevent affecting the function of the braking system.
*Check the brake before riding*
1.1.1Specifications
Items Standard value(mm) Available limits (mm)
front brake disc thickness 4.0 -
front brake shoe thickness 4.5 3.0
rear brake disc thickness 4.0 -
Rear brake shoe thickness 4.5 3.0
QJ200GY-A（Off-road type） front fluid brake disc diameter φ285mm rear fluid brake disc diameter
φ220mm
QJ200GY-A（Street type） front fluid brake disc diameter φ285mm rear fluid brake disc diameter
φ220mm
1.1.2 Torque force

Brake disc fixed bolt 22-29 N·m
Fluid brake mounting bolt 22-29 N·m
1.2 Failure Diagnosis
Brake
Poor performance of the braking system Slow reaction and tight lever
- 30 -
1. Improper adjustments for the brake 1. Improper adjustments for the brake
2. Brake shoe wears 2. Brake shoe wear
3. Improper installation for the brake shoe 3. Improper installation for the brake shoe
4. Polluted brake shoe
Abnormal noise
1. Brake shoe wears
2. Polluted brake shoe
1.3 Front fluid brake
1.3.1 Remove
*Note
•Replacement of the brake shoe assembly.

•Mark the replaced shoe for the next use
Remove the following parts from the front absorber

Front brake：
1. Brake shoe
2. Oil pipe of front fluid brake Front
3. Part of brake cylinder brake
*Note assembly
• Oil should not be allowed to pollute the brake shoe
during installing and removing.
•Use the required cleaner to prevent affecting the function
of the braking system.
Remove the front wheel axle.
Remove the front wheel.
Loosen the fixed bolt of the brake cylinder.
Remove the brake cylinder from the front absorber.
1.3.2 Inspection
Replace the shoe when necessary.
Measure the brake shoe and disc and write down the maximum.
Specialties
QJ200GY-A（Off-road type） Front fluid brake disc diameter φ285mm
QJ200GY-A（Street type） Front fluid brake disc diameter φ285mm
*Note
•Use inside micrometer or caliper only to
measure.
- 31 -
Measure the thickness of the brake shoe.
If the thickness of the brake disc and shoe is smaller than the Measuring thickness
maintenance value or polluted by oil, they should be
replaced.
Available limits: Brake shoe 3.0 mm
Brake shoe
1.3.3 Installation
Install front wheel.
Install the oil pipe for the fluid brake and brake cylinder assembly.
Don’t let the oil stains pollute the brake shoe.
*Note
If there is oil stains on the brake shoe, the performance of the brake will go bad.
Tighten the nuts and bolts according to their torque force value.
Torque force value：
Brake disc fixing bolt 22-29 N·m
Brake shoe
Fluid brake mounting bolt 22-29 N·m
Don’t let oil stains pollute the shoe.

If the shoe is polluted by oil stains, you should us special
cleaner to clean it up.
*Note
Yoke Brake shoe

plate
1.4 Rear fluid brake bushing
1.4.1 Remove
Remove the rear brake cylinder assembly. Rear fluid
Remove rear wheel. brake
Remove the brake disc from the rear wheel hub. assembly
- 32 -
Note：The brake disc cannot be removed unless it is be heated.
*Note
•Brake shoe replacement.
•Mark the replaced shoe for the next use
Remove the follow parts from the rear wheel
Rear brake：
1. Rear fluid brake assembly
2. Brake shoe assembly
3. Bushing
4. Link Plate
1.4.2 Inspection
Check whether the brake shoe and disc wear, if necessary,
replace new ones.
Measure the brake shoe and disc and write down the
maximum.
*Note
•If the disc get rust, clean it with#120 sand paper.
•Use micrometer only to measure.
Measure the thickness of the brake shoe.

If the thickness of the brake disc and shoe is smaller than the
Measuring thickness
maintenance value or polluted by oil, they should be
replaced.
Note：Replace the shoe in pairs
Rear fluid brake diameter φ220mm
Available limits: brake shoe 3.0 mm
Brake shoe
1.4.3Installation
Install rear wheel.
Install the rear brake disc.
Install the rear brake cylinder.
*Note
Tighten the nuts and bolts according to their torque force value.
Torque force value：
Brake disc fixing bolts： 22-29 N·m
- 33 -
Don’t let oil stains pollute the shoe.
If the shoe is polluted by oil stains, you should us special cleaner to clean it up
*Note
- 34 -
bracket for
front mudguard
rear rear reflector
mounting pad
rear mudguard front lower

mudguard
R
e
a
r
l
a
m
p
left front fender

rear air guide sleeve
- 35 -
left fender left foot
board
left rear fender
right rear fender right foot board left front

left oil decorated
box fender
base cover
right fender
right oil front air guide sleeve

left and right fender
box
junction plate
instrument bracket
left and right
front decorated
left and right instrument
fender right front
front fender
fender
junction plate
2 Body panel
Following the follow sequence to tear down the body
Rearview mirror→ front air guide sleeve → instrument bracket → instrument →
rear air guide sleeve → front mudguard → cushion→ left and right front decorated
fender → left and right fender → left and right fender junction plate → cover at the
end→ left and right fender for oil box → left and right rear fender → left and right
foot board → tail light→ rear mudguard → bracket for rear license plate
*Note
Do not damage the body when removing.
Do not damage the hook of the body.
Do match the grooves for the panels.
Correctly install the hooks of each part.
Do not damage the accessories while installing.
- 36 -
Front wheel/Front suspension（TX200 Off-road type）
- 37 -
TX200（Off-road type）Front wheel
tire front rim
fluid brake disc mounting bolt

Front axle
front wheel
front axle oil seal rolling bearings left sleeve
rolling
bearings
odometer pinion stand middle front front axle oil seal

assembly wheel sleeve
Front brake disc

front wheel
hub assembly
TX200（Street type）Front wheel
tubeless front rim
Front brake disc

front axle oil seal
Front axle rolling bearings
front axle oil seal
odometer pinion stand assembly

front wheel left sleeve
rolling bearings
middle front wheel sleeve
fluid brake disc mounting bolt
- 38 -
3 Front wheel/Front suspension
Preparing -----------------------3.1
Failure diagnosis-------------------------3.2
Front wheel-------------------------3.3
Steering control---------------------------3.4
Front fork-------------------------3.5
3.1 Preparing
Notes
Before removing the front wheel, you should use jack to let it float above the ground and it cannot be rotated.
Pay attention that no oil stains sticking to the brake shoe while operating.
Entire motorcycle standards

Standard
Measuring position Item Available limits(mm)
value(mm)
Front wheel axle Bow 0.2
Rim vertical 2.0
Front wheel
shimmy horizontal 1.0 以内 2.0
Torque force Tools

Fixing bolt for the steering control 22-29 N·m bearings replacing bar
Front wheel axle 100-113 N·m
3.2 Failure diagnosis
3.2.1 Steering hard

The fixing bolt is too tight
Larger deformation of the steering wheel
Low air pressure for the tire
3.2.2 Unsteady steering
- 39 -
Bearings of the steering handle are broken
Not enough tire air pressure
Bent front fork
Bent front tire
3.2.3 Shimmy of front wheels

Deformed tire
Loose front wheel bearings
Bad tire
3.2.4 Difficulty of turning the wheel

Trouble of the wheel and bearings
3.2.5 Abnormal noise of front absorber

Loose bolts of the parts of absorber
3.3 Front wheel
3.3.1 Remove
Before removing the front wheel, you should use jack to let it
float above the ground.
Remove the screw, front mudguard and odometer wire. Axle
Remove the front brake tube.
Remove the front axle tightening screw.

Remove the front axle.
Remove the front wheel
Remove the oil seal and bearings separately with their removers.
*Note: QJ200GY-A（Off-road type）, QJ200GY-A（Street type）disassembly/assembly drawing in page
41.
3.3.2 Check
3.3.2.1 Axle bent inspection

Put the axle on the V-pedestal and measure the eccentricity
ratio with dial indicator
Available limits：Replace if it is above 0.2mm
3.3.2.2 Swinging of rim inspection

Available limits：
Vertical：Replace if it is above 2mm.
- 40 -
Horizontal：Replace if it is above 2mm.
3.3.2.3 Front wheel bearings inspection Middle front

wheel bushing
Remove the bushing from the front wheel, and take down the oil
seal.
front axle oil seal

Windage
Windage
Check the rolling condition of bearings.
If the bearings cannot roll, wear or loose, replace new ones.
Axial direction radical direction
3.3.2.4 Spoke inspection

Check spoke ① if it is bent or wears, replace new one; if it is
loose, tighten it.
Tighten the spoke, the torque force of the screw should be 3.0
N·m.
- 41 -
3.3.3 Bearings replacement
Remove the front wheel, front axle and front bushing.
Remove the oil seal and bearings with their removers.
Note：Replace new bearings for the removed ones.
Fill the bearing with lubricating grease and install the bearings with installation tools.
*Note
•Press the bearings paralleled.
•The oil seal of the bearings should be pressed toward the outside.
3.3.4 Installation
Fill the oil seal with the lubricating grease.
Fill the gearing mesh part and the movable part of
the speed indicator and 。
After pairing the pinion stand of the odometer,
Install the brake disc.
Note
•pinion stand of Odometer will be deformed if it is not tightened
with the front axle.
•after installing the axle, rotate the wheel, and confirm
Whether the drive axle of the speedometer rotate or not
Install and tighten the front axle.
*Note：TX200（Off-road type）, TX200（Street type）disassembly/assembly drawing in page 41.
Torque force\ Front axle 100-113 N·m
rear mirror water string

right handle
throttle stand assembly

steering handle weld
assembly left/right rear mirror left handle cover
eft/right handle jacket
clutch jacket
accelerator cable
assembly
choke cable assembly left handle assembly
clutch cable assembly
- 42 -
3.4 Steering handle
3.4.1 Removing Fixing bolt

Remove the steering handle jacket and back Handle stand
mirror.
Remove the front brake lever and left lever.
Take down the throttle stand and right lever.
Take down the accelerator cable.
Take down the left side grip. Steering lever
Take down the clutch cable and choke cable. tightening bolt
Take down the fixing bolt of the handle and
remove the Steering handle
Handle. weld assembly
Upper connection board

3.4.2 Installation
Installation order is opposite to the removing order.
Fixing screw
Torque force value：22-29 N·m
upper
3.5 Front fork connection
instrument stand
board
weld assembly
3.5.1 Removing bearings

Remove the front mudguard.
Remove the front wheel
Remove the brake tube and speedometer wire. lower
Remove the front absorber. conne
Remove the steering fixing bolt. ction
Front suspensio
remove the steering handle board
n
Tools:
Steering handle fixing screw spanner
Fixing bolt spanner
*Note：
•Clean up the opening portion of the body fender.
- 43 -
3.5.3 Installation
Tools:
Fixing bolt spanner
Turn the front fork to confirm its rounding.

Loosening is not allowed.
Steps：
Install the steering handle
Install the front absorber
Install the front wheel
Rear Wheel/Rear Suspension（TX200 Off-road type）
- 44 -
Rear wheel/Rear suspension（TX200 Street type）
- 45 -
Rear absorber/rear rocker
1. weld assembly of the rear rocker2.inner steel sleeve 3.spacer 4.rear rocker cap 5.screw M14 6.rear
rocker cap 7.rear rocker axle 8.Chain protective block 9.chain cover 10.bolt M6X12 11.screw M5X12
12.spacer 2 13.bolt M8X50 14.chain tensioner 15.nut M8 16.fixing bolt M6X16 17.bushing 18.chain
jacket 19.spacer 1 20.bolt M6X16 21.chain adjustor subassembly
- 46 -
4 Rear wheel/Rear suspension
Preparing documents-----------------4.1
Failure diagnosis-----------------4.2
Rear wheel-----------------4.3
Rear wheel/ Rear rocker----------4.4
Drive drain-----------------4.5
4.1 Preparing documents
Notes
No oil stains sticking to the brake shoe and disc.
Preparing standards
Item Standard Available limits（mm）

value
（mm）
Amplitude of fluctuation of Vertical 2.0
the rear wheel Horizontal 2.0
Tightening torque force

Rear axle screw 100-113 N·m
Rear absorber screw at the top 37-44 N·m
Rear absorber screw at the bottom 37-44 N·m
4.2.1 Rear wheel swinging

Deformed rim
Bad tire
4.2.2 Too soft absorber

- 47 -
Elastic fatigue of the spring
4.3 Rear wheel

Rear rocker
4.3.1 Removing
Loosen the rear axle screw
Remove the rear axle screw and take down the chain.
Take down the rear axle
Take the rear wheel
Rear axle
4.3.2 Inspection
4.3.2.1 Axle bent inspection

Put the axle on the V-pedestal and measure the eccentricity ratio
with dial indicator
Available limits：Replace if it is above 0.2mm
4.3.2.2 Rim swinging inspection

Rotate the wheel and measure eccentricity ratio using
Dial indicator Axle
Available limits：
vertical：Replace if it is above 2.0mm
horizontal：Replace if it is above 2.0mm
When the amplitude of fluctuation of the rear wheel outweighs
the available limits and the bearings is loose resulting in the bent
rear axle, replace new rear axle
4.3.3 Installation
Install the rear wheel in the opposite sequence of removing and
tighten the axle screw.
Rear axle tighten screw
Torque force value：100-113 N·m
- 48 -
TX200（Off-road type）rear wheel
chain fluid brake mounting bolt
chain mounting bolt rear brake disc

nut
bearing bushing
rear wheel left sleeve

rear axle
rolling bearings rear wheel hub rear wheel pressure

oil seal board
TX200（Street type）rear wheel
1.tire 2.screw M16 3.rear wheel platen 4.fluid brake disc mounting bolt 5.rear brake disc 6.dust
ring 7.rolling bearing 6203-2RS 8.middle sleeve assemblies 9.rear rim 10.inflating valve 11.valve
cap 12 .rear wheel bumper block 13.chain transmission sleeve 14.rolling bearings 6005-2RS
- 49 -
15.dust ring assemblies 16.rear wheel sleeve 17.chain wheel mounting bolt 18.chain pulley seat
19.chain wheel 20.chain 21.screw M12 22. rear axle
- 50 -
4.4 Rear absorber/rear rocker
4.4.1 Rear absorber removing

Remove the body fender
Remove the rear mud guard
Fixing screw
Remove the tool box
Remove the air fifer
Remove the rear absorber fixing screw
Take down the rear absorber
4.4.2 Installation
Install the rear absorber.
Torque force value： Fixing nut

Upper fixing nut：37-44 N·m
Lower fixing nut：37-44 N·m
Installations of air filter and tool box.
Install the mud guard.
Install the body defender.
4.4.3 Remove the rear rocker

Remove the chain fender.
Remove the chain tensioner and rear axle.
Remove the rear wheel and rear absorber
Remove the rear rocker mounting axle.
Remove the weld assembly of the rear rocker.
4.4.4 Check rear rocker

Check its mounting axle. Rotate the axle on a flat ground or
measure it with clock gauge. If it bends, replace new ones.
*Note
Don’t try to straighten the bent axle.
Rear rocker mounting

axle
Clean the parts of the rear rocker mounting axle in the
solvent.
Check the rear rocker sleeve assemblies and the middle sleeve. Replace them when damaged.
- 51 -
4.5 Drive chain
4.5.1．Removing
Put the motorcycle on the ground.
Remove the shift lever rocker, side cover, drive chain.
Remove the rear wheel, chain fender and drive chain
4.5.2．Inspection
Clean the drive chain and put it into the kerosene to clean up the dust.
Take out the chain of the kerosene and make it dry.
Check the roller ① and the side panel ②, if they are damaged or wear, replace with new drive chain.
Lubricate the drive chain with lubricant.

Check the drive chain, if it is hard, clean lubricate or replace
it.
Check the drive chain and driven sprocket, if 1/4 of the wheel tooth wear or the tooth bends, replace the chain.
Check the wheel bearings，if there is bearing clearance in the hub for vehicle wheel or the wheel rotate is in
imbalance , replace the bearings. If the oil seal wear or is damaged, replace them with new ones.
- 52 -
4.5.3 Adjustment of the relaxation degree of the drive chain
Place the motorcycle on a flat ground and keep it upright
Check the degree of relaxation of the drive chain○ a ，the
degree is between 10-20mm.
Adjust the relaxation degree if it is not accord with the
standard.
Loosen the rear axle screw ①.
Adjust the relaxation degree of the drive chain.
The steps as follows:
Loosen the tightening screw ②，adjust the device ③ until the
degree is accord with the standard value.
Screw in, the degree increase；
Screw out, the degree decrease.
Note:
The number of turns of each adjusting device should be the same in order to install the axle
correctly.
At last, screw the tightening nut.
4.5.4．Installation
Installation sequence is opposite to the removing sequence.
Install the drive chain, casting, rear absorber (left), rear wheel,
drive chain cover.
Adjust the relaxation degree and free play of the brake.
The degree should be accord with the standard value.
If the degree is too small, the engine and other important
parts will be overloaded.
- 53 -
rectifier
flame battery
lighter
ignition
alternator
coil
Charging system
- 54 -
5 Battery/Charging system
Preparing documents------5.1 Failure diagnosis--------5.2
Battery------------------5.3 Charging system-------5.4
Voltage current adjustor--5.5 Alternator charging coil---5.6
Alternator lighting coil-5.7 Removing alternator------5.8
5.1 Preparing
Notes
*Note
1. Battery charge and discharge can be repeated use, its life span can be shortened and performance decreases
after discharging. Usually its performance decreases 2-3 years later. Battery with performance degradation,
the voltage will resume but sharply drops with load.
2. Battery overcharge：Generally we can judge its overcharge from its body. If the inside of the battery is
short-circuit, it is hard to detect the voltage between its terminals. Adjustment failure: the battery voltage is
too high; battery life span will be shortened.
3. If the battery has been place without using for a long time, it will be self-discharged and its capacity will
drop. Under this condition, it should be charged every 3 months.
5. Check the charging system following the sequence listed on the table.
6. Don’t remove the connector with current flowing through the electrical parts, otherwise the voltage will be
too high and these parts will be broken down. Switch off the main switch and operate.
7. Maintenance free battery (dry cell type) doesn’t have to be checked and added electrolyte and distilled
water.
8. Check total electricity load.
9. Emergency charging can only be used in emergent situation.
10. Remove the battery from the motorcycle for emergency charging.
11. Add liquid battery cannot be used when changing the battery.
12. Use the voltage meter for measuring the voltage when charging.
- 55 -
Preparing standards
Item Specifications
Capacity/Type 12V-9AH/dry cell
voltage Full charge 13.1V
（20℃） Obligatory 12.3V(not working 1h)
Battery
charge
Charging current standard：0.9A，rapid：9A
Charging time standard：10-15h，rapid：30min
capacity 100W/8000rpm
Magnetor
Coil impedance（20℃） White-White 0.5-10Ω
type Full wave rectifier
Voltage
adjuster Battery charging voltage 14.5V±0.4V/5.000rpm
Tightening torque force value Tools

Rectifier bolt 5.0 N·m multiple fixing spanner
High tension coil fixing bolt 9.0 N·m flywheel remover
Testing instrument
Multimeter
Power supply dead interrupted electric current

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

Bad battery charging poor contact of the wire, short or open circuit
Poor contact bad voltage current adjustor
Bad charging system bad alternator
Bad voltage current adjustor
- 56 -
5.3 Battery
5.3.1 Battery removing
Open the cushion 电瓶的安

Mounting position
Remove the left fender of battery
装位置
First remove the negative wire and then the positive
Take out 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.
Check the charging situation.

Open the cushion
Open the air filter cap and remove the connector wire.
Measure the voltage of the terminals
Full charge：13.1V
Insufficient charge：12.3V （not working for 1h）
*Note
Use voltmeter when charging.
5.3.2 Charging
Connection method：Connect the positive terminal of the battery
charge and the battery
Connect the negative terminal of the battery charge and
the battery
Warning！
•The battery should be far away from fire source.
•Turn off the charger when starting charging or completing charging
•Take the marked current time as a standard when charging
- 57 -
*Note
••Except emergencies, you should not use emergency charge
•Measure the voltage for every other 30 minutes
Charging current：standard0.4A
emergency：4.0A
Charging time：standard：10-15h
emergency：30min
Charging completes：open-circuit voltage：above12.8V
5.4 Charging system
5.4.1 Short 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.
5.4.2 Charging 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.
Limiting voltage/rotating speed：14-15V （5.000rpm）
If the limiting voltage is not within the required range, check the voltage adjustor.
Check the limiting voltage of the lighting system
*Note
choose AC voltage of the multimeter
Limiting voltage：13.1（+/-）0.5V/5.000rpm
If the limiting voltage is not within the required range, check the current adjustor.
- 58 -
Item（wiring
Judgments
color）
5.5 Voltage and current adjustor
Between Battery
（red）and GND With battery voltage
1.5.1 Main wiring inspection of the body
Between GND
Remove the adjustor’s 6p plug.
wire（black）and With wiring
GND of the body
Check the conducting state of the
Between charging
terminals of the main wiring. No connection between the
coil(white) and
magneto coil and the
the GND of the
ground
body
Between the
charging There is resistance in the
coil(white 1 and magnetor coil
white 2)
output connect
输出-
black wire
AC
交流输入
接黑线
input/connect
接白线
white wire
Inspection 检测
connect
red/white
接红/白
交流输入
AC
Output/red输出+
wire 接白线
input/connect
接红线 white wire
5.5.2 Voltage and current

Multimeter red/
adjustor inspection +
white1
white
red black white2
The main wiring is completely normal, - unit ：MΩ

check the contact of the adjustor’s plug, and white1 without without 0.1~3 10~90
measure the resistance value between the red/
without without 0.1~3 without
terminals of the adjustor. white
*Note red 0.1~3 without 1.2~5 0.1~3
•When checking the metal parts, your black without without without without
finger should not contact test bar of the white2 60~80 without without 0.1~3
multimeter.
- 59 -
•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.
5.6 Alternator charging coil
*Note
Check the alternator charging coil on the engine.
Check
Remove the 4p connector of the alternator.
Measure resistance value between the white coil and the body
Standard value：0.6-1Ω（20℃）
Replace the alternator coil when the measured value exceeds the standard value
5.7 Alternator lighting coil
*Note
Check the alternator lighting coil on the engine.
Check
Remove the 4p connector of the alternator.
Measure resistance value between the white coil and the ground of the body.
Standard value：0.6-1Ω（20℃）
Replace the alternator coil when the measured value exceeds the standard value
5.8 Removing the alternator
5.8.1 Removing Bolt

螺栓
Remove the fixing bolt and screw。
Take down the left cap
Fix the flywheel using the universal spanner.

Remove the fixing bolt of the flywheel.
- 60 -
Remove the flywheel using the flywheel remover.
Remove the solid key.
Remove the connector of the alternator wiring.
Remove the alternator stator.
固定
螺母
5.8.2 Installation
Install the stator on the body of the engine.
Connect the alternator 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.
固定
Fixing
*Note
螺母
Confirm the inside of the flywheel do not have bolts. nut
Fix the flywheel with the universal spanner and tighten the fixing screw.
Torque force value：9.0 N·m
Install the left body fender
- 61 -
rectifier
flame battery
lighter
ignition
alternator
coil
W/G MAIN SW
B/W B W/G
SPARK PLUG BL/W R/W FUSE
10A
BL/W B W
W/G
IGNITION COIL
MAGNETO
BATTERY
点火系统
Ignition system
- 62 -
6 Ignition system
Preparing system--------6.1 Ignition coil---------6.5
Failure diagnosis---------6.2 Trigger---------------6.6
Ignition system checking--6.3 Charging coil---------6.7
CDI group-----------------6.4
6.1 Preparing
Notes
1. Checking the ignition system following the sequence listed in the table of failure diagnosis.
2. The ignition system is solidified in the CDI group and you don’t have to adjust the ignition time.
3. Checking the ignition system following the sequence listed in the table of failure diagnosis.
4. CDI ignition system cannot subject to strong percussion (which is the main reason for failure), so you need
to pay great attention to that.
5. Check whether the connection is bad or not, because usually the reason for failure is poor contact socket.
6. The heat value of the spark plug should be appropriate. Improper spark plug will cause the engine running
unsmooth and even the spark plug will be burn-out.
7.Inspection in this chapter is based mainly on the maximum voltage，also inspection of the ignition coil
impedance is introduced.
8. Check the main switch according to the table.
9. Remove the alternator and stator according to the instructions
Preparing standards
Items Standard value
Standard C5HSA(NGK)
Spark plug
Hot type C6HSA(NGK)
recommended
Cold type C7HSA(NGK)
Spark gap 0.5-0.7mm
Primary coil 0.4Ω（+/-）10％
Ignition coil With plug cap 8-11KΩ
Secondary coil
impedance（20℃） Without plug cap 4.5-5.5KΩ
Resistance of trigger（20℃） 100-200Ω
Measure the maximum voltage after ignition coil rotates once 95-400V
Trigger voltage Above 1.7V
Tools
- 63 -
Voltmeter
Multimeter
Spark plug unable to jump

Abnormal situations Source of trouble (confirming in order)
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 normal that several measured voltage is above the basic standard.)
Ignition too low high tension electricity ④ Poor contact wire for the ignition system。
coil ⑤ Bad ignition coil。
⑥ Bad charging coil（measure at maximum voltage）
① Wrong connection with the tester.
② Bad main switch
③ Bad connector of the CDI group
No or interrupted high tension ④ Poor contact of the CDI group or GND of the CDI group is short-circuit.
Secondary electricity ⑤ Bad charging coil（measure at maximum voltage）
Measured ⑥ Bad trigger（measure at maximum voltage）
voltage ⑦ Bad high tension electricity connector
⑧ Bad CDI group（when there is no spark for the plug or ①-⑦ is abnormal）。
Normal high tension electricity/no ① Bad plug or secondary ignition coil leakage
spark for the plug ② Bad ignition coil
①The inner resistance is too small and should be tested by required tester.
②Low rotation speed of the bent axle
No high tension electricity ③Tester is interfered. (It is normal that several measured voltage is above the basic standard.)
Charging ④Bad charging coil（①-③ are normal）
coil No or interrupted high tension ① Bad ignition coil
electricity ② Bad charging coil
①The inner resistance is too small and should be tested by required tester.
②Low rotation speed of the bent axle (It is normal that several measured voltage is above the
Low high tension electricity basic standard.)
Trigger ③Tester is interfered.
④Bad trigger（①-③ are normal）
No or interrupted high tension ① Bad ignition coil
electricity ② Bad trigger
- 64 -
6.3 Checking the ignition system
Multimeter
* Attention
•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. High-voltage
Connect a high-pressure shunt or an shunt
ammeter with an input impedance above
10MΩ10CV to the multimeter.
6.3.1 Voltage of the ignition
Coil at a time
If you replace the original spark plug
with a better one, make ground connection
with the engine.
* Attention
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.
Remove the intermediate cap.
Connect the wires of ignition coils.
Ground connect the two ends (black/white)
of the primary coil to the car body to
create current divider.
Press the staring motor or step on the
actuating lever to measure the voltage of
the ignition coil at a time.
Minimum voltage：Above 95V.
* Attention
Never touch the metal of test prod when
measuring the voltage in case of electric
shock.
- 65 -
6.3.2 Charge coil
*Attention
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 charge coil with short
wiring 2p end(red/white end) and 4p end
(Black end).
Press the starting motor or step on the
actuating lever to measure the peak
voltage of the charge coil.
Method of attachment: Red/white end to
the positive pole and black end to the
negative pole.
Minimum voltage: Above 95V.
*Attention
Never touch the metal of test prod when black
黑
measuring the voltage in case of electric Red/White
红/白
shock.
Remove the adaptor of the alternator
when the maximum voltage of the end
of CDI group is abnormal.
Connect the current divider with the
charge coil.
·If the obtained voltage of the CDI section
group is abnormal while the one of the
alternator end is normal, the problem
should be poor contact or wire break.
·If both ends are abnormal, the charge
coil may be broken, please refer to the
check of the charging coil table.
6.3.3 Trigger
*Attention
Install the spark plug in the cylinder head
and carry out the measuring when the
compression pressure is normal.
- 66 -
Remove the 4p joints of CDI group,
connect the peak-voltage current divider
between the trigger with wiring 4p end black
黑
(blue / white end) and 4p end (black end).
Press the starting motor or step on the 蓝/白
actuating lever to measuring the peak Red/White
voltage of the trigger.
Method of attachment: Blue/white end to
the positive pole and black end to the
negative pole.
Minimum voltage：Above 1.7V.
*Attention
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 current divider of and the
trigger (blue/white).
·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 trigger
may be broken, please refer to the checking
black黑
method in the failure diagnosis table. 红/黑
Red/white
蓝/白
Blue/white
6.4 CDI
黑/白
Black/white
6.4.1 System check

Check the system.
Remove the CDI Group, check the components
concerning the ignition system at the wiring end.
6.4.2 Check
Remove CDI Group, check whether there is loose or corrosion in the adaptor.
- 67 -
Checking item Testing end Standard value（20℃）
Main switch Red--red/white Breakover when the main switch
is “OFF”
Trigger Red—car body ground 100-200Ω
Primary coil of the ignition coil Black/white--black 0.4Ω（+/-）10％
Secondary coil of the ignition coil Black--spark plug cap（without 4.5-5.5KΩ（+/-）10％
the spark plug）
6.5 Ignition coil
6.5.1 Unload
Unload the body cover.
Unload the spark plug cap.
Unload the primary wire of the ignition coil.
Unload the fixed bolt of the ignition coil,
remove the ignition coil.
Carry out the operations in the opposite order
of unloading during installation.
*Attention
Use the black/white end of primary coil
during installation.
Picture of the
点火线图
ignition wire
6.5.2 Check the primary coil

Impedance measuring between the ends of the
primary coil.
Standard value：0.4Ω（+/-）10％（20℃）
If the impedance value is within the range
of the standard value, it is fine.
If the impedance is “∞”, there is wire Ω
break in the coil, replace it with a new one.
Picture of the
ignition wire
点火线图
6.5.3 Secondary coil

With a spark plug attached. Measure the impedance Ω
value between the wire side and the end of
- 68 -
the spark plug cap.
Standard value：8-11KΩ（20℃）
If the impedance value is within the range
of the standard value, it is fine.
If the impedance is “∞”, there is wire
break in the coil.
Remove the spark plug cap, measure the impedance
value between a side wire and the negative end.
Standard value：4.5-5.5KΩ（+/-）10％（20℃）
6.6 Trigger
*Attention
Check of the trigger could be carried out on the
engine.
Check
Remove the fender of the car body.
Remove the wire adaptor of the trigger.
Measure the impedance value between the
blue/white end of the wire at the engine 磁电机接口
Magneto interface
side and the ground strap connection of the
car body.
DJ7068-6.3-21
Standard value：100-200Ω（20℃） DJ623-E6.3A
Change the alternator when the value is
beyond the range of the standard value.
白/绿
White/green
蓝/白
Blue/white
白
white
白
white
- 69 -
rectifier
flame battery
lighter
ignition
alternator
coil
BRAKE SWITCH BRAKE SWITCH BATTERY RELAY STARTOR MOTOR

STARTER SWITCH
启动示意图
Schematic diagram of starting
- 70 -
7 starting system
Preparing---------------7.1
Failure diagnosis---------------7.2
Starting motor--------------7.3
Starting relay------------7.4
7.1 Preparing
Notes for operation

The unloading of the starting engine could be carried out on the engine.
Refer to the method of unloading when unloading the engine.
Preparation standard
item Standard value Service limits
Length of the motor brush of 12.5mm 8.5mm
the starting motor
Liner of the starting idler shaft 8.3mm
External diameter of the 7.94mm
starting idler shaft
Torque tightening value

Clutch cover bolt of starting motors 12 N·m
Set screw nut of the clutch cover of starting motors 95 N·m
Instrument
Set screw nut wrench
Universal fixed wrench
- 71 -
Activation failure Weak rotating force starting motor is rotating

of the starting motor well while the engine is not
•Burnt out fuse ·Low storage battery •Broken starting clutch

•Low storage battery •Poor contact of connecting line •anticlockwise revolution of the starting motor
•Broken main switch •The gear of the starting motor is •Low storage battery
•Broken starting clutch stuck by foreign matters.
•Broken brake switch
•Broken stating relay
•poor contact of connecting line
•Broken starting motor
7.3 Starting motor
7.3.1 Unloading
*Attention
Before unloading the starting motor, turn
the main switch to “OFF” first; remove the
bond strap of the storage battery, then turn
the power source on the see if the starting
motor is working to ensure the security.
Remove the wire clip of the starting motor first. commutator

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.
7.3.2 Breaking down
Unload the screws in the outer cover, the

Electric
电刷 brush
front cover, the motor cover and other parts.
- 72 -
7.3.3 Check
Check other component assembling.
Replace for a new one when there is wear,
fragment or burning loss in the surface.
Clean the metal powder on the surface of the
commutators.
Conduction check between all interfaces of Electric brush

电刷
other components
Make sure armature shafts of all interfaces
could not turn on.
Conduction check of the outer cover of
the starting motor
Make sure the conduction terminator and the
outer cover of the starting motor could not
turn on.
Conduction check between conduction terminators
and electric brushes
Change for a new one if there is anything abnormal.
Conduction measuring of the electric brush bracket
Change for a new one if it turns on.
Measuring of the length of electric brushes
Available credit: Change for a new one if the
length value is less than 8.5mm
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.
7.3.4 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.
*Attention
Damage is not allowed in the interface
- 73 -
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 packing 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.
*Attention
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.
7.3.5 Installation
Install wires of the starting motor, make sure the solderingcup is properly installed.
Then install the starting motor.
Install the wire clip of the rear brake.
7.4 Starting relay
7.4.1 Actuation examination

Remove the fender of the body.
Ensure there is a “click” when turning on the starting motor with
the main switch remaining “on”.
Starting
If there is sound, it is ok.
relay
If no sound appears: ·check the voltage of the starting relay.
·Check the ground loop of the starting relay.
·Actuation examination of the starting relay.
7.4.2 Voltage examination of the starting relay

Set up the main stand, measure the voltage between
the negative pole of the green/yellow wire in the
Ω
adaptor of the starting motor and the ground strap 灰
grey
connection of the body.
Hold on the brake tension rod with the main switch
remaining “on”, the voltage of the storage battery
- 74 -
must be in accordance with specification.
Continuity check and examination of the wires when

the voltage between the ends of the starting motor iszero.
7.4.3 Examination of the ground loop of the starting relay

Remove the adaptor of the starting relay.
Conduction examination between the grey wire at the
end 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.
Examination of the conduction of the starting button and
wires when there is no conduction.
7.4.4 Actuation examination Ω
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”.
8 lights/Switches/Meters
Preparing------------8.1 Meters----------------8.6
Failure diagnosis------8.2 Main switches---------8.7
Headlight bulb replacement----8.3 Speakers-----------------8.8
Front turn signal lamp bulb replacement --8.4 Handle switches ------------8.9
Taillight /Number plate lamp/Rear turn signal lamp bulb replacement ------8.5
- 75 -
8.1 Preparing
Matters need attention on operation

Conduction examination of the switch (The switch could be
removed from the motorcar before being examined)
The bulb can not light up when the main switch

is turned to “on”.
·The bulb is broken.
·The switch is broken.
·poor contact at the adaptor or wire break.
8.3 Headlight bulb replacement
8.3. Unloading
Headlight
Remove the air guide sleeve. left-right
Remove the screw in order to unload the headlight. steering lamp
Remove the glass lens of the headlight.
Keep the headlight in place; rotate the outlet
clockwise to remove the bulb.
8.3.2 Installation
Install the bulb in the opposite order of removal.
.
- 76 -
8.4 Front turn light bulb replacement
8.4.1 Unloading
Unscrew the setscrew of the turn light.
Remove the bulb outlet from the lamp.
8.4.2 Installation
Install the bulb in the opposite order of
removal.
adjusting screw
8.5 Taillight/Number plate lamp/Rear turn signal light bulb

replacement
8.5.1 Unloading
Remove the screw to unload the lampshade of the taillight.
Remove the bulb from the outlet.
8.5.2 Installation
8.5.3 Rear turn signal lamp bulb
replacement
8.5.3.1 Unloading
Remove the screw to unload the lampshade of the taillight.
Remove the bulb from the outlet.
8.5.3.2 Installation
- 77 -
8.6 Meters Meter
panel
Remove the rearview mirror.
Remove the protective guard of the handlebar, pull up the
waterproof connector.
Remove the screw.
Remove the meter housing to unload the meter.
Install the speedometer in the opposite order of removal.
8.7 Main switches
4.7.1 Examination
Remove the apron plate.
Remove the conductor joint of the main switch.
Conduction examination of the ends of the adaptor
接线 wiring
Schematic 原理diagram
图
线color
Wire 色
档位
红
red 红 /白
Red/white
shift
8.7.2 Main switch replacement

Remove the apron plate.
Remove the standing bolt; unload the permanent
seat of the main switch.
Remove the standing bolt to replace the main switch.
- 78 -
8.8 Horn
Examination
Remove the wires of the speaker.
Connect the speaker to the storage battery. light
If there is sound, it is working. blue
淡蓝
Yellow/red
黄/红 Red/white
红/白
blue蓝
棕
brown
8.9 Handle switches
orange橙绿/白
Green/white
Remove the apron of the steering gear arm. 绿/黑
Green
Remove the standing bolt of the brake tension rod, black
unload the bracket.
Remove the bracket of the rear brake tension rod.
Remove the accelerator handle and the screw.
Remove the accelerator handle from the handle.
Yellow/red
Remove the accelerator cable.
Remove the standing bolt of the handle to unload the handle.
schematic wiring diagram

simmer switch pole changer speaker button overtake switch
yellow Yellow/ Light

red blue
紫
purple
黄/红
Yellow/red 红/白
Red/white
黄
yellow
黑/红
Black/red 墨绿
atrovirens
绿/黄
Green/
-yellow
79 -
schematic wiring diagram
- 80 -
Electrical diagrams
- 81 -
Inspection and maintenance of the engine
Engine fastener torque value table
Fastening parts and fasteners Name Tightening torque（N·m）
cylinder head nut 25～28

Rocker arm shaft support bolt 15～20
Cylinder double end bolt 10～17
CMFLR Cam Follower shaft standing bolt 18～23
Flywheel locking screw nut 30～40
Filter spring blind nut 15～30
Valve-lash adjuster screw nut 10～15
Shift locator bolt 10～16
Assemble mould bolt 9.8～11
Left and right crankcase bolts 9.8～11
Loop screw 9.8～11
Oil filter cover screw 4～7
Clutch separating plate bolt 10～16
Cylinder head cover bolt 9.8～11
Cylinder block fastening bolt 9.8～11
Engine oil filter rotor screw nut 40～50
drive sprocket bolt 10～16
Oil pump body bolt 9.8～11
Shift locating plate bolt 10～16
Spark plug 15～26
- 82 -
Lubrication system
Attention ： After unloading the
oil pump, all the components must
be carefully washed, and the
surface of the components should
be blown clean with high pressure
gas.
Don’t let foreign matter

fall into the crankcase during
the unloading and installation of
the oil pump.
1 rocker 2 cam mechanism 3 bent axle 4 engine oil filter 5 piston 6 oil filter 7 oil pump
10 Lubrication systems
- 83 -
Preparing-----------10.1
Failure diagnosis-----------10.2
Oil pump-------------10.3
10.1 Preparing
Matters need attention on operation：

After unloading the oil pump, all the components must be carefully washed, and the surface of the components should be blew
clean with high pressure gas.
Don’t let foreign matter fall into the crankcase during the unloading and installation of the oil pump.
Use of the lubrication system：

Function of the engine lubrication system is to supply lubricant to component surface, transforming the dry
friction on the surface to liquid friction among the lubricant particles, in order to reduce wear of the
components; cooling components with higher heat load; absorbing the shock of bearings and other machine
components to reducing noises; increasing leak tightness between the piston ring and the cylinder wall; clean
and wash away the impurity on the surfaces of components.
Preparation standard
item standard Operating limit
During oil change 0.8L ＿

Oil level
During unloading 1.1L ＿
Radial clearance between
0.10-0.15 0.25
inner and outer rotors
Oil pump rotor Clearance between the
0.10-0.15 0.25
outer rotor and the pump
Rotor end clearance 0.07-0.12 0.15
Decrease of oil level Engine burning loss
- 84 -
Normal consumption of oil No oil pressure or low oil pressure
Oil leak Oil line block
Oil filter
10.3 Oil pump
10.3.1 Unloading
Remove the right cover, unload the oil filter,
unscrew the set screw of the oil pump, and remove
the driver gear and the oil pump shaft.
Remove the bolt.

Unload the oil pump body.
Oil pump body
Bolt
Remove the bolt, unload the oil pump cover.

Disassemble the oil pump.
Oil pump cover
Test calliper
Examine the radial clearance between inner and outer rotors.

Operating limit: 0.25mm
Examine the clearance between outer rotors and
- 85 -
oil pump seat.
Test calliper
Examine end clearance of rotors.

- 86 -
10.3.2 Assembling the oil pump
As the following picture shows:
oil pump gear
oil pump body

机油泵座
snap spring
inner rotor
pin
oil pump cover
oil pump shaft
outer rotor
oil pump carrier sheet

blot
*Attention：
After assembling, inner and outer rotors should rotate smoothly without stagnation.
10.3.2 Assembling
In the opposite order of unloading
Carburetor
- 87 -
Attention：Gasoline is very
dangerous, fireworks is
strictly prohibited in
workplace.
After disassembling of
the carburetor, block the
intake manifold with cloth in
case of the entering of
foreign matter.
1-roof cover 2-roof cover airproof 3- plunger spring 4-plunger piston component 5-lower casing coupling
screw 6-lower casing component 7- sealing ring 8-float component 9-float pin 10-needle valve 11-idle
metering jet 12-main entering jet 13-mian jet 14-mian foam pipe 15-mixing ratio screw 16-mixing ratio
screw spring 17-mixing ratio screw spacer 18- mixing ratio screw sealing ring 19- plunger adjusting
screw spring 20-plunger adjusting screw
11 Carburetor
- 88 -
Preparing-------------11.1
Failure diagnosis-------------11.2
Disassembling of the Carburetor ---------11.3
Assembling of the Carburetor---------11.4
11.1 Preparing

·Gasoline is very dangerous, fireworks is strictly prohibited in workplace.
·Pay special attention to sparks.
·Forcibly pulling and bending of wires is not allowed. Distortion and damage will affect the wires.
·After disassembling of the carburetor, block the intake manifold with cloth in case of the entering of foreign
matter.
·Unused for more than a month, the gas in carburetors of displacer type should be let out, as the gas in the
displacer type may go bad, blocking the idling jet to make idle speed not safe.
Use of carburetor： Carburetor is a critical component in the fuel feed system of the engine; its working
directly affects the stability of the engine and dynamic, economic indicators. Certain amount of gasoline is
atomized into little oil drops in it, and mixed with different quantities of air homogeneously, forming vaporific
fuel mixture of different thickness according to needs of different working condition of the engine and
supplied to the engine to ensure continuous and normal operation of the engine.
Preparation standard Unit: mm
Item Standard value

Main jet A07
Main jet 0.9
Idle metering jet.. 0.34
Oil injection needle A08-3
Starting disorder hard starting Flameout after starting unstable idling speed
No fuel in the carburetor Carburetor blockage
Gas filter blockage too thick or too thin gas mixture
Gas pipe blockage secondary air suction in the inspiration system
Needle valve ankylosis idle speed maladjustment
- 89 -
Oil level maladjustment oil volume maladjustment
Blockage in the idling system or the electric enrichment valve
Excessive fuel in the engine too thin gas mixture

Outflow due to excessive oil oil jet blockage
Secondary air suction in the inspiration system needle valve blockage
Fuel deteriorate low oil level
Enrichment valve disorder fuel system blockage
Blockage in the idling system or the choke system secondary air suction in the inspiration system
Over thick gas mixture flashover interruption on acceleration

Enrichment valve disorder too thin gas mixture
Needle valve disorder
Over high oil level
Carburetor outflow
Air channel blockage
Dirty air cleaner
11.3 Remove carburetor
11.3.1 Remove
Remove the set screw nut between the carburetor and the Bakelite layer on the cylinder head.
Remove the carburetor.
11.3.2 Disassembling of carburetor

Remove the roof cover, unload the sealing ring of the roof cover, plunger spring and plunger components.
Remove the coupling screw of the lower casing; knock down components of the lower casing and the sealing
ring.
Remove float components, float pins and needle valve case.
Remove the idle metering jet, the main metering jet, the main jet and the main foam pipe.
Remove mixing ratio screws and mixing ratio screw springs.
Remove mixing ratio screw spacer and sealing rings of the mixing ratio screws.
Remove plunger adjustment screws and plunger adjustment screw springs.
11.3.3 Check
Check if there is any wear or damage in needle valve components, needle valve seating and float components.
- 90 -
Change the needle valve for a new one if there is any wear or
damage.
Change the carburetor body for a new one if there
is any wear or damage in the needle valve seat.
Change the float tongue piece for a new one if there is
any wear and tear.
Examine the spindle of the carburetor. If there
is any wear or damage, change it for a new one and
change the main jet at the same time.
Check if there is any wear, damage or contamination
in the idle metering jet, the main metering jet and
the main jet. If there is, change them.
Check if there is any wear and tear in the plunger.
If there is, change it.
Examine the carburetor and fuel lines. If they’re
contaminated, clean them according to the specification.
11.4 Carburetor Installation
Assembling
Install the idling meter jet, the main metering jet,

the main jet and the main foam pipe.
Install the float, the float pin and the needle valve.
Install sealing rings of the top housing and the
lower casing, lower casing components and lower
casing coupling screws.
Install mixing ratio screw spacers, sealing rings
of mixing ratio screws, mixing ratio screw springs and
mixing ratio screws.
Install the mixing ratio screws into the body.
Install plunger adjustment screw springs and plunger
adjustment screws.
Install plunger springs and plunger components.
Install roof cover sealing rings and the roof cover.
Installation
- 91 -
Installation is carried out in the opposite order of unloading.
Cylinder head/Valve
Attention: The cylinder cover bears large bolt

preload to ensure seal between the cylinder
cover and the cylinder body.
Preload value: 50 Nm
1 cylinder cover hood 2 bolt 3 spark plug 4 cylinder head gasket 5 cylinder
Attention: The cylinder cover bears large bolt preload to ensure seal between the cylinder cover
and the cylinder body.
Preload value: 50 Nm
- 92 -
12.Cylinder head/ Valve
Preparing-------12.1 valve guide pipe replacement ----12.5
Failure diagnosis---12.2 valve seating ring correction ----12.6
Cylinder head-----12.3 cylinder head installation ------12.7
Valve examination-----12.4
12.1 Preparing

For air tightness between the cylinder head and the cylinder body, the head bears tremendous bolt
pretightening force. Pretightening force value: 50 Nm.
All components must be cleaned and dried with high-pressure air before examination.
Function of the cylinder head: The cylinder head is used to seal the cylinder and form the combustion
chamber with the piston. It bears HPHT fuel gas, and carries out air entering and exhaust distribution devices.
Preparation standard unit: mm
Item Standard Service limit

Flatness of the cylinder head 0.03 0.05
inlet 0.03-0.05 ＿
valve clearance
outlet 0.03-0.05 ＿
External diameter of the inlet 5.44-5.45 5.40
valve rod outlet 5.435-5.445 5.40
valve
inner diameter of valve inlet 5.475-5.485 5.50
Valve guide
guides outlet 5.475-5.485 5.50
clearance between the valve inlet 0.025-0.045 0.08
rod and the valve guide outlet 0.03-0.05 0.10
Width of valve seat Inlet/outlet 0.8-1.0 1.6
internal 33.5 30
Valve spring Free length
external 40.9 39.5
external diameter of rocker
rocker Inlet/outlet 11.98-11.988 11.95
shafts
- 93 -
internal diameter of the
Inlet/outlet 12-12.018 12.05
rocker
clearance between the rocker
Inlet/outlet 0.012-0.038 0.08
shaft and the rocker hole
Low compression pressure abnormal sound in the cylinder head

Maladjustment of the valve Maladjustment of the valve clearance
Valve burning or bending valve spring damage
Bad air tightness in the valve seat excessive compression pressure
Air leak in the cylinder head spacer redundant carbon deposit in the combustion chamber
Poor installation of the spark plug
12.3 Cylinder head
Cylinder
12.3.1 Unloading
cover
Unscrew three standing bolt and Standing

unload the valve mechanism cover. bolt
Remove the gasket.

Unscrew three fastening bolt and unload the
rocker arm bracket (rocker). Gasket Bolt
Rocker arm bracket
- 94 -
Valve push
Remove the valve push rod. rod bracket
Unscrew the screws in the cylinder head and unload
the push rod bracket.
Measure the external diameter of the rocker shaft.

Allowable limit: 11.95mm
Cylinder cover screw
Measure the internal diameter of the rocker shaft.

Allowable limit:：12.05mm。
measure the clearance between the rocker arm hole
and the wayshaft. Micrometer
Allowable limit:：0.08mm。
Remove the standing bolt of the cam follower shaft and

unload the cylinder head.
Tester
Cylinder head Standing bolt of

cam follower shaf
- 95 -
Valve lock clamp
Compress the valve spring with valve spring compression

instrument.
Remove the valve lock clamp.
Remove the spring plate, inner and outer valve spring, the
spring shim of the outer valve and the valve one by one.
- 96 -
12.3.2 Valve disassembling
valve lock clamp

inner valve spring
gasket
valve
spring plate
outer valve spring
valve oil seal
Ruler
Test calliper
- 97 -
12.4 Valve examination Vernier caliper
Clean the carbon deposit on the cylinder head.

Measure the flatness of the junction surface of the cylinder
head.
Allowable limit：0.05mm.
Place the crocus paper on the panel when the flatness of the
junction surface of the cylinder head exceeds the allowable
limit.
Joint the junction surface of the cylinder head
with the crocus paper and mill it in the direction like writing an Micrometer
8.
Measure the free length of the inner and outer

valve spring.
Allowable limit：inner spring：30mm。
outer spring：39.5mm。
Measure the external diameter of the valve rod.
Allowable limit：5.40mm.
Valve reamer
Examine the valve guide. Before examination,
Use a reamer to clear the carbon deposit in the guide.

Attention: use the reamer clockwise, never Tester
use it anticlockwise.
Measure internal diameters of all valve guides

Allowable limit：inlet/outlet：5.5mm。
Measure the clearance between the valve and the valve guide.
Allowable limit：intake valve：0.08mm。
exhaust valve：1.0mm。
- 98 -
12.5 Remove valve guide
Screwdriv
*Attention
Displace the valve guide if the clearance between
the valve and the valve guide exceeds the allowable
limit. After displacement, correct the surface of
the valve gate seat ring.
Place the valve guide in the freezing Chamber of
the fridge for an hour.
Heat the cylinder head on an electric furnace or in
an oven to 100-150℃.
Place the cylinder head; remove the valve guide out
Valve reamer
of the cylinder head with valve guide unloading instrument.
起子：Screwdriver
Place a new O ring on the new valve guide.

Install the valve guide from the top of the
cylinder head.
*Attention： Don’t damage the cylinder head during the
installation of the valve guide.
After the valve guide is embedded, correct it

with a valve guide reamer.
*Attention: Add some cutting oil when using the reamer. Use the
reamer clockwise.
Valve seat contact
Clear the carbon deposit in the combustion chamber

and the valve, and clean the inlet and outlet gate completely. Rough surfaces
Allowable limit：inlet/outlet：1.6mm。
- 99 -
12.6 Repair and maintenance of the valve seat ring
Use the milling cutter of 45°cutting angle to eliminate coarse or bumpy places.
Note：
Smear the valve seat ring with a transparent
or Prussian blue layer to make it easily seen.
Use a milling cutter of 32°cutting angle to remove 1/4 of the

outer part of the valve seat ring.
32°
Use a milling cutter of 60° cutting angle to remove

1/4 of the base of the valve seat ring
Put down the milling cutter and examine worked places.
1mm
Use a fine repair milling cutter to wear the 60°

valve sear ring to attain a proper width.
45°
Make sure to eliminate all the dents and bumpy parts.
Width of standard valve seat rings: inlet: 1.0mm
Outlet: 1.0mm
Use a plain milling cutter of 32°cutting angle to lower the

valve seat ring if the touched place is because part of the
32°
valve is too high. Use an
The contact surface is too high
internal milling cutter of 60°to raise lower parts of the valve
seat ring if the touched place is because part of the valve is
too low. Use the fine repair
The contact surface is too low 60°

milling cutter to repair the valve seat ring again to make it
meet the requirement.
Coat the valve surface with brightener after
mill of the valve seat ring to polish the valve softly.
- 100 -
12.7 Cylinder heads installation
Installation is carried out in the opposite order of unloading.

*Attention：
Install the valve spring with the end with smaller
spring pitch pointing to the combustion chamber.
In the installation the valve lock clamp,
use valve spring compression instrument to compress
the spring.
In the installation of the valve, coat the valve stem
with some oil, and then install it into the valve guide.
- 101 -
13.Cylinder block and piston
Attention: All components

should be cleaned and dried
with high-pressure air before
test.
1 bolt 2 cylinder body 3 spacing piece 4 piston 5 piston pin 6 locating pin
- 102 -
Preparing -----13.1 piston------------13.4
Failure diagnosis----13.2 installation of the cylinder ---13.5
Cylinder block-------------------13.3
13.1 Preparing

All components must be cleaned before examination and dried with high-pressure air.
Function of the cylinder body: The cylinder provides a space for the air to compress combust and
expand, and direct the movement of the piston. It also propagate pass some of the heat in the cylinder to the
surrounding cooling medium.
Function of the piston:
It bears the pressure of the fuel gas mixture in the cylinder and propagate the pressure to the connecting bar to
drive the rotation of the crankshaft, thus forming the combustion chamber with the cylinder.
It also act as the slide valve of the gas port, pressing the fresh gas mixture in the crankcase into the cylinder
and discharge the waste gas after combustion in the cylinder regularly.
Preparation standard unit：mm
item Standard value Service limit

Internal diameter 62-62.01 62.01
Cylindricity - 0.005
Circular degree - 0.005
Flatness 0.03 0.05
61.965-61.975
External diameter of the piston (measuring
(11mm below the piston 61.975
point)
skirt)
Internal diameter of the piston pin 15.002-15.008 15.04
Cylinder External diameter of the piston pin 14.994-15.000 14.96
Clearance between the piston and the piston
0.002-0.014 0.07
pin
Clearance between the first ring 0.035-0.065 0.09
piston ring and the ring
second ring 0.020-0.050 0.09
groove
first ring 0.15-0.30 0.5
Clearance of the mouth of
second ring 0.10-0.30 0.5
the piston ring
Oil ring 0.20-0.30 -
- 103 -
Internal diameter of the small end of the
15.010-15.018 15.06
connecting rod
Clearance between the connecting rod and
0.010-0.024 0.10
the piston pin
Internal diameter of the cam follower hole 12.01-12.018 12.05
Cam Follower
External diameter of the camshaft 11.986-11.994 11.93
Cam Follower
Clearance between the cam follower hole
shaft 0.016-0.032 0.08
and the camshaft
Height of the cam 32.6-32.8478 32.5
Camshaft Internal diameter of the camshaft bushing 14.06-14.078 14.10
sprocket Clearance between the camshaft drive and
0.025-0.053 0.08
camshaft drive the bushing
Low compression pressure white smoke from the vent pipe

wear, burning or snap in the piston wear and damage in the piston ring
wear or damage in the cylinder or the piston wear and damage in the piston or the cylinder
damaged spacer，gas leak between the crankcase and the gas
Higher compression pressure abnormal sound from the piston
Excessive carbon deposit in the damage in the cylinder, the piston or
combustion chamber the piston ring
Wear in the piston pin hole and the piston pin
ylinder body
13.3 Cylinder block
13.3.1 Unloading of the cylinder body

standing bolt
Remove the standing bolt of the cylinder body.
Unload the cylinder body (with the cam follower) cam follower
13.3.2 Examination of the cylinder body

Examine the wear pattern inside the cylinder body. Gasket
If seriously worn, replace it for a new one.
Unload the spacer and the locating plunger.
Locating plunger
- 104 -
13.3.3 Disassembling the cam follower
Tester
Measure the internal diameter of the cam follower.

Allowable limit：12.05mm。
Measure the external diameter of the cam follower.

Allowable limit：11.93mm. Micrometer
Measure the clearance between the cam follower hole and the
camshaft.
- 105 -
13.4 Pistons
Retaining ring for piston
13.4.1 Unloading
*Attention：
Remove the retaining ring for piston pin.
Don’t allow the retaining ring fall into the crankcase during
unloading.
Remove the piston pin and unload the piston.
Remove the piston ring.

Examine the piston, the piston pin and the piston ring.
*Attention: don’t break off or damage the piston ring.
Clear the carbon deposit in the piston ring groove.
Piston Test calliper
Fit on the piston ring.

Measure the clearance between the piston ring and the piston Piston ring
ring groove.
Allowable limit：apical ring：0.09mm。
Second ring：0.09mm。
Remove the piston ring, and install all of them into the
Test calliper
bottom of the cylinder.
*Attention: press the piston ring into the cylinder Piston ring
with piston head.
Measure the clearance at the mouth of the piston ring.
- 106 -
Tester
Measure the internal diameter of the piston pin hole.
1
2
Measure the external diameter of the piston pin. 3
Measure the clearance of the piston pin hole and the piston
pin.
Measure the external diameter of the piston. 90°

*Attention: The angle between the measuring point and the 11mm
piston pin is 90 degree. The measuring point is about 11mm
below the piston skirt.
Scratch and wear examination inside the cylinder. Tester

*Attention： 90-degree angle direction with the piston pin
测试计：Tester
Measure the internal diameter of the cylinder at Upper,
middle and lower parts of the cylinder respectively.
Measure the clearance between the cylinder and the piston,
choose the maximum result.
- 107 -
Measure the circular degree of the cylinder inwall.
（internal diameter difference between X direction and Y
direction）. upper
Measure the cylindricity of the cylinder inwall.
middle
（internal diameter difference between X direction and Y
direction at upper, middle and lower parts of the cylinder ）。
Allowable limit：0.05mm。 lower
Examine the planeness of the cylinder surface. Ruler

Test calliper Cylinder
Internal diameter of small end of rod

Measure the internal diameter of the small end of the
connecting rod.
Primary ring
13.4.2 Installation of the piston
Install the locating plunger. secondary ring
coat piston rings and pistons with engine oil.
Put the piston ring into place with inclined plane of the piston
ring upside.
*Attention： Oil ring
Don’t scratch the piston or break off the piston ring.
The piston ring must rotate freely in the piston
- 108 -
ring glove after installation.
Chip the adherent spacers to the crankcase away.

*Attention：
Don’t allow foreign matter fall into the crankcase.
Install the piston, piston pin and retaining ring of piston
pin.
*Attention： The “In” mark
Install the piston with the “IN” at the piston head pointing
to the valve.
13.5 cylinder block installation
Install the spacer and the locating plunger onto the crankcase.
locating plunger
Gasket
Coat the cylinder inwall, the piston and the piston ring with
engine oil.
Install the piston ring into the cylinder carefully.
*Attention: Don’t damage the piston ring.
Cylinder
- 109 -
Clutch
Attention: It is not necessary to unload

the engine during examination of clutch.
The viscosity of the engine oil and the oil
level will affect the operation of the
clutch. Make sure to examine the oil and
oil lever before examination. If any of the
clutch spring, disk or plate doesn’t work,
displace it.
1 adjusting bolt 2 push rod 3 bearing 4 split disc 5 pressure spring 6 center bearing bracket 7 primary
plate 8 driven plate 9 lock nut 10 sliding key gasket 11 platen 12 Shell Widgets
Attention: It is not necessary to unload the engine during examination of clutch.
The viscosity of the engine oil and the oil level will affect the operation of the clutch. Make sure to examine the oil and oil
lever before examination. If any of the clutch spring, disk or plate doesn’t work, displace it.
- 110 -
Foot actuating mechanism
Attention: Check if there is any

spring force reduction or damage in
the foot start return spring or retchet
wheel on operation. Check if there is
any wear of damage in the start
retchet wheel.
1 recoil start shaft 2 recoil start ratchet wheel 3 ratchet spring 4 ratchet counter vane module 5 recoil
start gear 6 spring retainer 7 shaft liner 8 offsetting spring
- 111 -
14 Clutch/ Foot starting system
Preparing-------14.1 Foot starting system-----14.4
Failure diagnosis---14.2 main shaft/counter shaft disassembling ---14.5
Clutch-------------------14.3
14.1 Preparing

It is not necessary to unload the engine during the overhaul of the clutch.
The viscosity of the oil and the oil level of the engine will influence the operation of clutch. Thus they have to
be examined before the overhaul of the clutch.
Function： The clutch and driven gear together form the variable speed case.
Thickness of the friction plate 2.9-3 2.6

clutch
Length of the pressure spring 35.45-36.5 34.2
Too tight clutch release lever clutch slipping during acceleration loose gear at speed changer
Clutch cable is damaged, twisted or contaminated no windage in the clutch release lever weakened
scotch arm return spring force or fracture
Injured clutch lifting poker wear in the clutch plate injured scotch arm
Bearing malfunction in clutch lifting poker weakened clutch spring force wear or damage in shift cam
Glued clutch lifting poker
Difficulty in speed change clutch release difficulty or motorcar sluggish after clutch release
Clutch regulation error oversize windage in the clutch release lever
Bent speed change mandrel twisting clutch plate
Injured shift cam malfunction in clutch push rod
Bent or damaged gear shifting quadrant abnormal in engine oil and oil level
- 112 -
14.3 Clutch
adjusting bolt
14.3.1 Unloading
Unscrew four bolts on the split disc in the
direction of diagonal cross.
Remove the disengaging rod, the shaft housing, the
bearing, the split disc and the clutch spring.
Please refer to the exploded view for removing
components.
分离盘螺栓:Split disc bolt
Socket key of
grapnel
Screw the nuts with special tools.
Remove the locknut and the gasket.
Remove the center bearing bracket of the clutch.
Remove primary plate and driven plate of the clutch.
Remove the clutch compressing disc.
Please refer to the exploded view for removing
components.
Universal retainer
Shell widgets
Remove the spline gasket.

Remove shell widgets
Installation of the clutch is carried out in the opposite direction of unloading.
- 113 -
14.3.2 Assembling the clutch
1 adjusting bolt 2 push rod 3 bearing 4 split disc 5 pressure spring 6 center bearing bracket 7 primary
plate 8 driven plate 9 locknut 10 sliding key gasket 11 pressure plate 12 shell widgets
14.3.3 Examination
Center bearing Pressure plate
Check if there is any burr or trace of damage on the
crust of clutch. if there is, repair it with a file.
If the repair expectancy is overlarge, displace it.
Check if there is any damage in the tooth shape of the
pressure plate and the center bearing bracket.
If there is, displace it.
Measure the free length of the pressure spring.

Allowable limit: displace it below 34.2mm.
Free length
- 114 -
Measure the thickness of the wearing piece with a slide
caliper.
Allowable limit: Displace it below 2.6mm.
Thickne
14.4 Foot starting system

Foot starting mechanism
modules
Unloading
Remove the foot starting mechanism components from the
right crankcase.
Main shaft modules
examination Counter shaft modules

Examine the elasticity of return spring and
ratchet spring. If damaged, displace them.
Examine the gearing of starting shaft spline and internal
spline of the ratchet. If loose, displace them.
Assembling
Installation is in the opposite order of unloading.
Remove main shaft components.

Remove counter shaft components.
- 115 -
14.5 Disassembling of main shaft & counter shaft
main shaft modules
Counter shaft modules
- 116 -
Examination
Examine the wear of tooth surface and driving pawl of the

gear. If damaged seriously or injured, displace it.
Tooth surface
Driving pawl
Remove the bearing and oil seal of the left crankcase.

Check if there is any damage in the bearing or the oil seal. If Bearing oil seal
there is, displace it.
*Attention：
The removed bearing can not be reused. Change it for a new
one.
Use special tools in the removal of bearing and oil seal.
Remove the bearing of right crankcase.

Check if there is any damage in the bearing. If there is,
displace it.
*Attention：
The removed bearing can not be reused. Change it for a new
one.
Use special tools in the removal of bearing and oil seal.
Assembling the main shaft and the counter
shaft
*Attention： Coat the gears and shafts with lubricant in
Bearing oil seal
installation.
Make sure no gear gets stuck after installation.
- 117 -
Note：
Installation of the crankcase is in the opposite order of unloading.
Speed control system
Function: Transmitting
torque moment, and
determine the final
output torque and
t ti d
1 shift drum 2 shift fork 3 fork shaft 4 main shaft module 5 counter shaft module 6 recoil foot starting
module
- 118 -
15 Speed transmission system
Preparing-----------------15.1
Failure diagnosis-----------------15.2
Shift mechanism-----------------15.3
Installation---------------------15.4
15.1 Preparing
Function： Transmitting torquemoment, and determine the final output torque and rotating speed.
external diameter of shifting fork shaft 11.97-12 11.95

Internal diameter of shifting fork shaft 12-12.018 12.05
Shift mechanism thickness of shifting fork 4.93-5.0 4.7
External diameter of shift drum 35.8-36 35.75
Hinge slot of shift drum 7.05-7.15 7.3
Transmission problem shift difficulty

Snapped or deformed gear shift fork incomplete separation of clutch
Snapped fork fitting pin improper movement of return spring of the speed changer
Wearing gear convex wearing shift drum hinge slot
Automatically out of gear

Wearing knuckle claw to form circular bead at the edge
Weakened return spring force in shift mechanism
Too big axial force in during working hours of gears as a result of wear between spline teeth of the spline shaft
and the spline slot of the sliding gear
Wearing shift drum and fork
- 119 -
15.3 Gear Shifting mechanism
15.3.1 Unloading
Remove the shift shaft combination.
Remove the bolt and shift locating plate.
Remove the bolt, locking arm and springs.
Remove the locating plunger.
Refer to the exploded view for removing components.
Locking arm
Shift shaft combination

15.3.2 Disassembling
Locking arm
Locking arm spring Shift locating
shift plate
shift plate spring
shift return spring
shift shaft components
Assemble mould bolt

15.3.3 Examination
The shift plate should return smoothly without stuck
before disassembling.
Examine the wear in the combination of shift plate and shift
shaft. If seriously worn, displace the components.
Examine the wear in the shift locating plate. If seriously
worn, displace the components.
Left tank body
Check if there is bending in the shift shaft. If over bent,

displace it.
Check if the spring force of the return spring is weakened, displace it when necessary.
- 120 -
Unscrew mould assembling bolt to separate the crankcase.
*Attention： Don’t damage the gasket and the mould assembling surface.
shifting fork shaft
Remove the left tank body.
Pull out the shifting fork shaft.
Remove the shifting fork.
shift drum
shifting fork
Measure the external diameter of the shifting fork shaft.
Micrometer
Measure the internal diameter of the shifting fork hole.

Tester
Vernier caliper
Measure the thickness of the shifting fork.
- 121 -
Measure the external diameter of the shift drum.
Measure the width of the hinge slot of the shift drum.
Width of the hinge slot
Remove the gear of the balance shaft. Balance shaft gear
15.4 Installation
Installation is in the opposite order of unloading.
- 122 -
Crankcase
Attention: The crankcase is

thin-section casting thus has to
avoid shock on operation in case
of deformation and fracture.
All components must be cleaned
and dried with high-pressure air
before test.
The lubricant in the crankcase
should be released before
operation.
1 right crankcase 2 left crankcase 3 the combination of crankshaft and the connecting bar 4 balance
shaft 5 bolt
.
- 123 -
16 Crankcase
Preparing-----------------16.1
Failure diagnosis----------------16.2
Crankcase-------------------16.3
16.1 Preparing

The crankcase is thin-section casting thus has to avoid shock on operation in case of deformation and fracture.
All components must be cleaned and dried with high-pressure air before test.
The lubricant in the crankcase should be released before operation.
Function of the crankcase： The crankcase is the force-bearing part of the engine. Its main function is
bearing crankshaft, clutch, transmission case, cylinder body and cylinder head, bearing the inertia force from
combustion shock and the movement of crankshaft connecting rod system, and forming a closed space(oil
sealing, air sealing)
There are suspension holes in the crankcase, connecting the engine to other parts of the body through the
connection with suspension holes in the car circuit.
Preparation standard unit：mm
item Standard value Service limit

Left-right clearance at the end of rod 0.1-0.3 0.55
crankshaft Radial clearance at the end of the rod 0.005-0.01 0.05
shimmy - 0.1
Tools
Universal holder spring compressor of the clutch
Screwdriver lever socket wrench
Guide rod bearing driver
Abnormal sound in the crankcase automatic stop of the engine

Scattering or snapped component in the crankcase stuck clutch
- 124 -
starting motor
16.3 Crankcase
16.3.1 Unloading crankcase
Unscrew the standing bolt of the starting motor.

Unload the starting motor. bolt
Unscrew the standing bolt in the gear room cover gear room cover
of the starting motor.
Remove the cover of the gear room.
Remove the electric starting gear, the needle
bearing and the gasket.
Unscrew the bolt in the left front cover and rear

cover of the crankcase.
left front cover
Remove the left front cover and rear
Cover.
left rear cover
Remove the idle gear of the starting motor. Gasket

Remove the gasket and the locating plunger.
Idle gear of the
motor
Locating plunger
- 125 -
Use electric or air-powered instrument to unscrew the flywheel
locknut.
Pull out flywheel modules (including star wheel).
Flywheel modules
Camshaf
t retainer
Remove the gear monitor.
Remove the camshaft limiting plate.
Remove the cam modules.
Remove the gear locating equipment. Bearing locating
device
Gear
monitor
16.3.2 Disassembling cam modules
Camshaft gear
Cam mechanism
Camshaft spring
Cam
Measure the internal diameter of the cam bush.

Measure the height of the cam.

Tester
- 126 -
16.3.3 Unloading the right rear cover of
bolt
the crankcase
Unscrew the binding bolt.
Unload the right cover of the crankcase (the right cover for
short in the picture)
Remove clutch release lever components from the

right cover. right cover
release lever components
right cover
Remove bolts, rotor cover of oil filter and the

gasket of the rotor cover.
Remove the gasket and the locating plunger.
t Gasket
:
Oil filter rotor cover
locating plunger
- 127 -
Use electric or air-powered instrument locknut
to unscrew locknuts. 主动齿轮
Remove the oil filter rotor, unload the
oil filter rotor
driving gear.
Unscrew the screws of the oil pump, unload
oil pump component.
driving gear
oil pump
16.4 Crankshaft & Connecting rod driving

gear
Crankshaft & Connecting
Unloading Locating
Unload the left crankcase. plunger
Unload the gasket and the locating plunger.
Unload the driving gear. Gasket
Remove the Crankshaft & Connecting from the right
crankcase.
*Attention： Don’t injure the gasket and the surface of the assemblemould.
Examination
Measure the left-right clearance of the big end of the
connecting rod.
Allowable limit ：0.55mm。
Measure the clearance in X-Y direction at the big end of the Measuring point at the big end
connecting rod. of the connecting rod
- 128 -
Measure the shimmy of the crankshaft.
Allowable limit ：0.01mm。
Check if there is any abnormal sound or looseness of the crankshaft bearing on revolution. If there is, displace
the crankshaft components.
*Attention：
Install the Crankshaft & Connecting bar to the crankcase with
gear shift mechanism together.
Crankshaft bearing
- 129 -
Muffler
1. exhaust mainfold subassembly 2.acorn nut M6 3.vent-pipe protective shield 4.bolt M6X20 5.Clamp
component 6.bolt M6X20 7.gasket 6 8.rubber gasket 9.bolt M6X12 10.bull bar components of muffler
11.gasket 6 12.bolt M8X40 13.muffler component 14.gasket 8 15.screw nut M8 16.bolt M5X10
17. Gasket 5 19.rear ornamental shade component
- 130 -
17 The exhaust emission system
Exhaust emission system warranty-------------17.1
Regular maintenance notes/guarantee of discharge standard --------17.2
17.1 Exhaust gas discharge control system warranty
1. The exhaust gas discharge system of this motorcycle is in conformity with the revision of EC/97/24/5/I and
2003/77/EC B stage by EU. We can assure you the quality under absolute normal use and proper maintenance
according to the provision within effective service life.
2. Warranty scope
1) Function guarantee of exhaust gas discharge system
We can guarantee the motorcycle in conformity with all regular or irregular exhaust gas examination from
the government offices within the service limit (15000 kilometers).
3. For the need of maintenance, distributors or service departments of our company of all provinces/cities are
willing to provide service at reasonable prices if any of the following cases occurs, though this warranty does
not apply to them.
1) Regular maintenance is not carried out within necessary time or road haul according to the provision by
our company.
2) Those don’t carry out regular examination, adjustment or maintenance at distributors or service centers of
our company, or those who can’t provide full service history.
3) Overload or improper use.
4) Reconstructing the motorcycle, removing the original components or reload other equipment at will.
5) Using it as a motor chaser or riding it on non-motor vehicle roads frequently.
6) Damage caused by Extreme Weather such as typhoon, flood, etc. or damage and fault as a result of misuse,
traffic accidents or foreign object struck.
7) Long-term out of service without regular maintenance.
8) Those that do not carry out immediate maintenance of the odometer, or modify, suspend or replace it on
one’s own authority.
9) Please carry out exhaust gas examination regularly in the inspection station every three months.
17.2 Regular maintenance notice
·The state gives provisions for motor vehicles to conform air pollutant emission standards to all manufacturers
to ensure that the environmental pollution doesn’t get worse. Apart from keeping with the air pollutant
emission standard in our production, our company makes great effort in air purification and air pollutant
- 131 -
reduction.
·This motorcycle undergoes strict examination before leaving the factory with all qualities in conformity with
air pollutant emission standards. We formulate the regular check list concerning gas emission as follows in
consideration of different use condition by customers. The use is requested to carry out regular check,
adjustment or maintenance according to the scheduled time to ensure normal emission.
·If other problems occur, please contact KEEWAY distributors or KEEWAY service center for help.
·Relevant discharge provisions are shown as follows：
Discharge provision CO HC+NOX
Discharge standard ≤1.0g/km ≤1.2g/km
※The standard is subject to the latest provision of our country if there is any modification in the discharge
standard.
·For those who haven’t carried out regular examination according to the requirements form the distributor and
service center of our company, we assume no responsibility if the motorcycle is clamped down. Please carry
out necessary examination to guarantee the best vehicle condition.
Note: ①Please increase the frequency of washing the air cleaner if riding on gravel roads or seriously polluted
environment to extend the life of the engine.
②For high speed or frequent riders, the maintenance level should be increases.
Guarantee of discharge standard, please pay attention to the following:

1) Oil use: please use the designated engine oil.
2) Maintain the vehicle according to the regular maintenance table.
3 As to the exhaust gas emission control system, arbitrary adjustment or replacement is forbidden (including
the adjustment on the use of spark plug, idle speed, ignition timing, carburetor, etc).
4) Matters need attention：
·Since the disorder of ignition system, the charging system, and the fuel system has great influence on the
catalytic system, please come to designated distributors or service center of our company for examination,
adjustment or maintenance if any disorder of the above ones occurs.
5) The exhaust gas emission control system of the vehicle is in line with relevant provision of our country,
make sure to use the quality components of our factory if needed, and receive service from designated
distributors and service centers.
- 132 -

TX200 Service Manual

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TX200 Service Manual

KEEWAY Motor Corporation Ltd.

This manual is an introduction to the maintenance of TX200.

Preparing Documents include all the contents needed, so read it carefully

Inspections introduce how to check and maintain your motorcycle, which

needs to be done regularly.

and maintenance instructions.

actual products if anything is different or updated. Please forgive me for not

informing you in advance.

KEEWAY Motor Corporation Ltd.

General safety Maintenance rules

Specification table Failure diagnosis

Wrong Wrong Wrong

Operation should not be bent or distorted. Otherwise, it will

Solvent or oil can easily damage aging rubber articles. So these

Release parts with kinds of assemblies from outside to the

Pay great attention to the dismounting of the important

The above two examples will make the

Model QJ200GY-AOff-road type Engine type QJ164FML

Length mm 2100 Fuel type Above 90# White gasoline

Width mm 770 Cylinders 1

Height mm 1090 Engine Bore*Stroke 63.5mmx62.2mm

Wheel base mm 1365 Swept volume 197CC

Total 135kg Lubrication Force-feed and splash

Fuel capacity 12L

Multiple-disc oil friction disc

Transmission Gradeability Maximum permissible gradient>=15°

Idling speed 1400±100rpm/min

Width mm 770 Cylinders Cylinders

Height mm 1090 Bore*Stroke Bore*Stroke

Fuel capacity 12L

Front fluid brake

Hard to start hard or can not start

Loosen the bolt of the carburetor

fuel Oil pipe of carburetor plugs up

Air leakage of the cylinder ring

Fail to ignite the Close to ignite the Bad automatic choke

engine engine, but

Remove the spark plug Bad governing screw of the carburetor

Overtopped oil lever of carburetor

Dry spark plug Wet spark plug Bad automatic choke

Oversized throttle opening

normal Pressure too low

Check whether the carburetor plugs up or not

Check oil in the crankcase is

Normal Abnormal Mixed gas is too thin

no yes Too early ignition time

Accelerate operation Bad petrol

Without Detonation Detonation Mixed gas is too thin

Adjust the bolt to change the oil

Mixed gas is too thin (loosen the screw)

Inhaled air in the

Remove the spark plug and

Broken negative pressure tube

Air holes are blocked

Insufficient petrol in the petrol tank

Good Spring has no

Voltage don’t The voltage rises to the normal

Check whether the voltage adjuster is

Measure the coil impedance of the

No jump spark or Intense

Check the spark plug

Height mm 1090 BoreStroke BoreStroke

Check the brake before riding