TX200 Service Manual
TX200 Service Manual
- 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 -
3.2 Failure Diagnosis.............................................................................................................................. - 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 -
4.2 Failure Diagnosis.............................................................................................................................. - 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 -
5.2 Failure Diagnosis.............................................................................................................................. - 56 -
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 -
6.2 Failure Diagnosis.............................................................................................................................. - 64 -
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-
14.2 Failure Diagnosis............................................................................................................................. 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-
15.2 Failure Diagnosis............................................................................................................................. 119-
15.3 Gear Shifting Mechanism ................................................................................................................ 120-
15.4 Installation ....................................................................................................................................... 122-
16 Crankcase ................................................................................................................................................ 124-
16.1 Preparing ......................................................................................................................................... 124-
16.2 Failure Diagnosis............................................................................................................................. 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-
- 4 -
Preface
before operation.
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
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
- 5 -
Preparing Documents
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.
Cover
- 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.
- 8 -
Specifications (TX200-AOff-road type)
Forward
45.9kg Starting system Electric/kick start
shaft
Weight kg Back
89.1kg Cooling system Air forced
shaft
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
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
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
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
- 10 -
Failure diagnosis
- 11 -
Unsmooth rotation(under speed)
Failure diagnosis Adjustment and inspection Source of trouble
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
- 12 -
Unsmooth rotation(especially low speed)
Failure diagnosis Adjustment and injection Source of trouble
Adjust ignition time
Bad CDI
Normal Abnormal
Bad trigger
- 13 -
Unsmooth rotation(especially high speed)
Failure diagnosis adjustment and inspection Source of trouble
Adjust ignition time
Bad CDI
Normal Abnormal
Bad trigger
Normal Abnormal
Pipeline of the Evaporative Emissions Control
System plugs up
Bad automatic oil-control ring
Carburetor plug up
Unblocked Blocked
Clear up
- 14 -
Bad battery(over discharged or overcharged)
Failure diagnosis Adjustment and inspection Source of trouble
Start the engine and measure the
battery voltage
Life of the battery is over
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
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
Failure diagnosis Adjustment and inspection Source of trouble
Change a new spark plug
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
- 16 -
Inspection/Adjustment
Battery Clutch
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
Frame
- 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
- 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.
- 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
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
- 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
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.
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:1400±100rpm/min
Adjust the idling adjusting screw when idle speed
Ignition timing
*Note
CDI ignition system does not need adjust
ignition timing.
Check the ignition system when ignition
timing is not right.
Manometer
Cylinder pressure
- 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.
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.
Travelling clearance:10-20mm
Travelling clearance:10-20mm
Brake clearance
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
- 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
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
Nuts/bolts/fixed parts
- 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
- 28 -
Front fluid brake
Rear fluid
brake
assembly
- 29 -
1 Brake
Maintenance instruction------------------------1.1
Failure diagnosis------------------------1.2
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.
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
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
1.3.1 Remove
*Note
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.
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
*Note
If there is oil stains on the brake shoe, the performance of the brake will go bad.
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.
Brake shoe
1.4.3Installation
Install rear wheel.
Install the rear brake disc.
Install the rear brake cylinder.
*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 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
If there is oil stains on the brake shoe, the performance of the brake will go bad.
- 34 -
bracket for
front mudguard
rear rear reflector
mounting pad
- 35 -
left fender left foot
board
left rear fender
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
- 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.
- 39 -
Bearings of the steering handle are broken
Not enough tire air pressure
Bent front fork
Bent front tire
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.
3.3.2 Check
Windage
Check the rolling condition of bearings.
If the bearings cannot roll, wear or loose, replace new ones.
- 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
clutch jacket
accelerator cable
assembly
choke cable assembly left handle assembly
clutch cable assembly
- 42 -
3.4 Steering handle
upper
3.5 Front fork connection
instrument stand
board
weld assembly
- 43 -
3.5.3 Installation
Tools:
Fixing bolt spanner
Steps:
Install the steering handle
Install the front absorber
Install the front wheel
- 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
Drive drain-----------------4.5
Notes
No oil stains sticking to the brake shoe and disc.
Preparing standards
4.3.2 Inspection
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
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
4.4.2 Installation
Install the rear absorber.
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.
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.
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
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
- 56 -
5.3 Battery
Warning!
*Note
First positive terminal then negative terminal to prevent short
circuit.
*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
*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.
*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
- 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.
*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
*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
- 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.
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
- 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
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
- 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.
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.
6.4 CDI
黑/白
Black/white
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)
6.5.1 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
- 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
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
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
Instrument
Set screw nut wrench
Universal fixed wrench
- 71 -
7.2 Failure diagnosis
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.
- 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.
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.
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.
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
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
8.5.1 Unloading
Remove the screw to unload the lampshade of the taillight.
Remove the bulb from the outlet.
8.5.2 Installation
Install the bulb in the opposite order of removal.
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.
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
- 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.
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)
- 82 -
Lubrication system
gas.
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
Don’t let foreign matter fall into the crankcase during the unloading and installation of the oil pump.
Preparation standard
item standard Operating limit
- 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.
Bolt
Test calliper
- 85 -
oil pump seat.
Operating limit: 0.25mm
Test calliper
- 86 -
10.3.2 Assembling the oil pump
As the following picture shows:
snap spring
inner rotor
pin
outer rotor
*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
11.1 Preparing
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.
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
11.3.1 Remove
Remove the set screw nut between the carburetor and the Bakelite layer on the cylinder head.
Remove the carburetor.
11.3.3 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.
Assembling
Installation
- 91 -
Installation is carried out in the opposite order of unloading.
Cylinder head/Valve
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
Valve examination-----12.4
12.1 Preparing
- 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
Cylinder
12.3.1 Unloading
cover
- 94 -
Valve push
Remove the valve push rod. rod bracket
Unscrew the screws in the cylinder head and unload
the push rod bracket.
- 95 -
Valve lock clamp
- 96 -
12.3.2 Valve disassembling
spring plate
Ruler
Test calliper
- 97 -
12.4 Valve examination Vernier caliper
Valve reamer
- 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
- 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.
32°
- 101 -
13.Cylinder block and piston
1 bolt 2 cylinder body 3 spacing piece 4 piston 5 piston pin 6 locating pin
- 102 -
Preparing -----13.1 piston------------13.4
Cylinder block-------------------13.3
13.1 Preparing
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.
ylinder body
Locating plunger
- 104 -
13.3.3 Disassembling the cam follower
Tester
- 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, 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.
Allowable limit:0.5mm。
- 106 -
Tester
Measure the internal diameter of the piston pin hole.
Allowable limit:15.04mm。
1
2
Measure the external diameter of the piston pin. 3
Allowable limit:14.96mm。
Measure the clearance of the piston pin hole and the piston
pin.
Allowable limit:0.02mm。
- 107 -
Measure the circular degree of the cylinder inwall.
(internal diameter difference between X direction and Y
direction). upper
Allowable limit:0.05mm。
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
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.
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
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
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
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
- 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.
Free length
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Measure the thickness of the wearing piece with a slide
caliper.
Allowable limit: Displace it below 2.6mm.
Thickne
Assembling
Installation is in the opposite order of unloading.
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14.5 Disassembling of main shaft & counter shaft
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Examination
Driving pawl
*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.
shaft
*Attention: Coat the gears and shafts with lubricant in
Bearing oil seal
installation.
Make sure no gear gets stuck after installation.
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Note:
Installation of the crankcase is in the opposite order of unloading.
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
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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.
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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 plate
shift plate spring
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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.
Allowable limit:11.95mm。
Micrometer
Tester
Vernier caliper
Measure the thickness of the shifting fork.
Allowable limit:4.7mm。
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Measure the external diameter of the shift drum.
Allowable limit:35.75mm。
Measure the width of the hinge slot of the shift drum.
Allowable limit:7.3mm。
Width of the hinge slot
15.4 Installation
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Crankcase
1 right crankcase 2 left crankcase 3 the combination of crankshaft and the connecting bar 4 balance
shaft 5 bolt
.
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16 Crankcase
Preparing-----------------16.1
Failure diagnosis----------------16.2
Crankcase-------------------16.3
16.1 Preparing
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.
Tools
Universal holder spring compressor of the clutch
Screwdriver lever socket wrench
Guide rod bearing driver
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starting motor
16.3 Crankcase
Locating plunger
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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
Camshaft gear
Cam mechanism
Camshaft spring
Cam
Tester
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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)
right cover
locating plunger
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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
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
Allowable limit:0.05mm。
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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
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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
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17 The exhaust emission system
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.
·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
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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.
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