Page 1 User's operation and maintenance manual for double-wheel motorcycle QJ150T-10 Zhejiang Qianjiang Motorcycle Co., Ltd...
Page 2: Table Of Contents
Contents Contents.................................- 1 - Preface ...................................- 4 - Documents to be prepared ..........................- 5 - Inspection/adjustment ..........................- 21 - 1 Battery/charging system ...........................- 34 - 1.1 Preparation data .............................- 34 - 1.2 Fault diagnosis............................- 35 - 1.3 Battery ..............................- 36 - 1.4 Charging system ............................- 37 - 5.5 Voltage and current regulator.........................- 38 - 1.6 Charge coil of the alternator ........................- 39 -...
Page 3 7.1 Preparation data .............................- 66 - 7.2 Fault diagnosis............................- 66 - 7.3 Front wheel ............................- 67 - 7.4 Direction handle.............................- 69 - 7.5 Front fork...............................- 69 - 7.6 Radiator/expansion kettle components ....................- 70 - 8 Rear wheel/rear suspension ..........................- 73 - 8.1 Preparation data .............................- 73 - 8.2 Fault diagnosis............................- 73 - 8.3 Rear wheel .............................- 74 -...
Page 4 13.5 Clutch/driven wheel...........................- 107 - 13.6 Disassemble the clutch and the driven wheel ..................- 108 - 13.7 Installation ............................- 111 - 14 Decelerator..............................- 113 - 14.1 Preparation data ..........................- 113 - 14.2 Fault diagnosis ...........................- 113 - 14.3 Gear Case............................- 113 - 14.4 Installation ............................- 114 - 15 Crankcase ..............................- 116 - 15.1 Preparation data ..........................- 116 -...
Page 5: Preface
Preface This Manual explains the maintenance of Qianjiang QJ150T-10. The documents to be prepared are the maintenance manual and all the operations are included in, please read the manual prior to operation. Inspection and Adjustment explains the gist of inspection and adjustment; the maintenance of safety of vehicle and the performance of each part should come into force since regular inspection.
Page 6: Documents To Be Prepared
Documents to be prepared General safety Maintenance regulation Specififcation sheet Troubleshooting General safety Carbon monoxide If the engine must be activated, make sure that the workplace is well ventilated. The engine can not be running in a confined place. Attention The exhaust contains toxic gas, carbon monoxide, which can numb people and may result in death.
Page 7 Maintenance regulation As maintaining this vehicle, the instrument of metric system should be applied as possible for the reason that the application of incorrect instrument may demage this vehicle. Before dismantling from or frame cover of vehicle to maintain the dirt of parts or external subassembly should be purged in order to prevent that falling into engine , chasis or braking system.
Page 8 For the important assembly position, it should be given special attention before dismantling. The parts out of use should be replaced before dismantling in time. The length of bolts to assemblies and frame cover are different which should be installed in correct position and the bolts may placed in the hole to find out whether they are suitable if they are mixed.
Page 9 The so-called specific tools refer to those specifically designed for assemble or dismantle of certain components of the motorcycle. These tools are usually used in specific locations. Appropriate specific tools are indispensable in the complete and accurate adjustment as well as in the assembly operations. By taking advantage of specific tools, the components can be safely, reliably and quickly assemble or dismantle, thus enhancing the work efficiency and saving lots of efforts.
Page 10 Figure 1-7 Figure 1-8 Figure 1-9 Figure 1-10 ①手柄 Figure 1-11 Figure 1-12 opening pincer piston ① ② Figure 1-13 Figure 1-14 - 9 -...
Page 11 Figure 1-15 Figure 1-16 2． Tools used for the underpan-overhaul The list of general tolls and specific tools for the dismounting of underpan components as well as the figure of real objects can be seen in table 1-17 and table 1-18. Figure 1-17 name remarks...
Page 12 Figure 1-23 Figure 1-24 Figure 1-25 Figure 1-26 Figure 1-27 Figure 1-28 （2）Specific tools for underpan-overhaul: front fork seal element driving-in tools Figure 1-29 （3）Steering nut wrench Figure 1-30 - 11 -...
Page 13 3． Tools used for electric apparatus components The list of specific tools for the testing of electric apparatus components, as well as the figure of real objects can be seen in table 1-31 and table 1-32. Table 1-31 name remarks universal meter Figure 1-33 ignition tester...
Page 14 Specififcation Sheet (QJ150T-10 ) Model Engine Type 158MJ-2 QJ150T-10 Unleaded gasoline Full length mm Fuel type 2070 （92/95） Number of Full width mm cylinders Inside Full height mm measure * 1260 φ57.5*57.8 stroke Total flow Wheelbase mm 1360 150ml rate...
Page 15 QJ150-10 - 14 -...
Page 16: Troubleshooting
Troubleshooting Difficult to start or unable to start Troubleshooting Tune-up inspection Failure cause Loosen the oil drain bolt of carburator to check whether there is oil within the No gasoline in gasoline tank carburator Oil tube clog of gasoline tank carburator No gasoline Enough oil to Oil tube clog of float chamber...
Page 17 Improper gyration (impotent velocity) Troubleshooting Tune-up inspection Failure cause Start the engine slightly accelerate Air cleaner clogged Bad gasoline Engine revolution Winding number Conduit clog of evaporation control unable to increase engine system of firing chamber completely increases Exhaust pipe clogged Auto choke is bad Adjust ignition...
Page 18 Improper gyration（especially at low speed） Troubleshooting Tune-up inspection Failure cause Ignition time adjustment CDI group is broken Normal Abnormal Trigger is broken Adjust adjustable screw of carburetor oil level Rare gas mixture（loosen the bolt） Favorable Maladjusted Too thick gas mixture （locking adjustment screw）...
Page 19 Improper gyration（high speed） Troubleshooting Tune-up inspection Failure cause Ignition time adjustment CDI group is broken Normal Abnormal Trigger is broken Too little gasoline in gasoline tank Gasoline filter of gasoline pipe clogged Normal Abnormal Conduit clog of evaporation control system of fuel tank Auto oil ring is broken Carburettor clogged No clog...
Page 20 Improper charging (overdischarge or over charge of battery) Troubleshooting Tune-up inspection Failure cause Measure the voltages of the both ends of battery, start engine Expired battery Battery voltage No increase of rised normal battery voltage value and restore its Bad battery original voltage after killing engine...
Page 21 Spark plug has no flashover Troubleshooting Tune-up inspection Failure cause Replace new spark plug and examine it again Weak Strong spark Bad former spark plug flashover spark plug Inspect spark plug and examine it again No slack Slack Slack spark plug cover Inspect whether group plug is slack...
Page 22: Inspection/Adjustment
Inspection/adjustment Preparation of documents Cylinder pressure Check list of constant maintenance Gear mobile oil Engine mobile oil/oil filter Changing gear oil direction column bearing and handle fixing Diving belt Inspection/adjustment of accelerator's pull wire front/back brake free displacement Air cleaner The liquid volume examination of break fluid Spark plug Head lamp...
Page 23 Free stroke of front brake 10-20mm drawbar Free stroke of rear brake 10-20mm drawbar Specification Tire pressure 100/80-16 Front wheel 225kpa Tire pressure unit：Kpa QJ150T-10 120/80-16 Rear wheel 225kpa front wheel-axle 55-62 N·m Torque clamping nut force rear wheel fixed 100-113 N·m value...
Page 24 Check list of constant maintenance Mileage and time Every Every Every Every Every Every of maintenance 1000 3000 6000 12000 14500 Tools Inspection items motor A year month months months months cycle General purpose Air cleaner tool General purpose Gasoline filter tool General purpose Oil cleaner...
Page 25 Pre-inspection Ignition system - maintenance and inspection of ignition malfunction of distinct continuity, engine failed to start and superheat of afterburning. Carbon laydown purging - purging the carbon laydown in the head of air cylinder, piston head and exhaust air system when the horsepower is in distinct deficiency. Piston, air cylinder - excessive wear of air cylinder and cylinder smoothness, please replace.
Page 26: Air Cleaner
Inspection/adjustmentof accelerator's pull wire Check the smoothness of accelerator pull wire. The examination of the free replacement of accelerator stayguy. free displacement：5-10mm The main adjusting position is on the carburator side. fixing nut Loosen the fixing nut and adjust by turning adjusting nut. adjusting nut Air cleaner Replacement of filtrator.
Page 27: Spark Plug
Spark plug Dismantle spark plug. Check the overburning, pollution and carbon laydown of spark plug. spark plug gap If there is the said problem, please purge it with cleaner of spark plug or steel brush. Inspection of spark plug gap Clearance：0.6-0.7mm *Attention As installing spark plug, pleae install it...
Page 28 Inspection of charging state (CCU) Open the battery-cell lid. Dismantle the clamping bar components of battery cell. Remove the negative pole wire first, and then the positive pole wire. Take out battery. Measure the voltage between the battery terminals. Fully charged: 13.1V Undercharge：12.3V *Attention The inspection of charging state should be made by...
Page 29: Idle Adjustment
Carburator Idle adjustment Carburettor *Attention The idle adjustment should be made when the engine is Fixed pipe clamp warm. It should be conducted after the warm-up of engine. Start engine and connect the turnmeter of engine. Adjust the accelerator pull wire and bolt stopper to specifiy the winding number.
Page 30 Inspection *Attention Fuel check, let down the middle supporter to be perpendicular to motorcycle on the flat floor. Dismantle the inspection bolt of gear oil after stopping engine. The oil level is below the lower limit of bolt hole is good. Right Please supplement gear oil when the oil level is too low.
Page 31: Head Lamp
Free displacement of the front/rear brake Free displacement of the front brake Measure the free displacement of the front brake handle at the tip of the brake handle. Free displacement: 10-20mm The displacement of the rear brake Measure the free displacement of the rear brake handle at the tip of the brake handle.
Page 32 Clutch Start engine and increase the winding number slowly to inspect the actuation of clutch and check the clutch block if the motorcycle does not move or the engine misses. Replace the new part if necessary. Front/rear suspension system Compress up and down Front Strain the front brake and compress the front shock absorber...
Page 33 *Attention The tire pressure should be measured under cold condition. Measure tire pressure Specified pressure unit：Kpa Specification Tire pressure Front 100/80-16 wheel QJ150T-10 Rear 120/80-16 wheel Tyre specification Front wheel 100/80-16 QJ150T-10 Rear wheel 120/80-16 Check whether the front wheel spindle is loosened.
Page 34 high pressure bag Lock component for power supply Voltage stabilizer storage battery start up electric engine charging system - 33 -...
Page 35: Battery/Charging System
1 Battery/charging system Preparation data ----------------------1.1 Fault diagnosis -------------------1.2 Battery ---------------------------------1.3 Charging system -----------------1.4 Voltage and current regulator -------1.5 Charge coil of the alternator ---1.6 Disassembly of alternator -----------1.7 1.1 Preparation data Matters needing attention in operation * Note 1. The battery can be charged and discharged over again. If the battery is unused after discharge, the service life will shorten and the performance will degrade.
Page 36: Fault Diagnosis
Preparation reference Item Specification capacity/ type 12V-6AH/Dry charge type Voltage Fully charged 13.1V （20℃） Must be charge 12.3V(not work for an hour) Battery Charging current Standard：0.6A，Fast：6A Charging time Standard：10-15h，Fast：30m Capacity 200W/8500rpm Alternator Between white and black 3.3-3.5Ω Coil impedance value （20℃） Voltage regulator Type Three-phase full wave...
Page 37: Battery
1.3 Battery 1.3.1 Disassembly of the battery Battery-cell lid Open the battery-cell lid. Dismantle the clamping bar components of battery cell. Clamping plate Disassemble the negative wire and then the positive wire. components of battery cell Take out the battery. Battery-cell Warning! Battery-cell lid...
Page 38: Charging System
*Note •Fast charging cannot be used except in contingency situations. •Do not measure the voltage until 30 minutes after the charge. Charging current ：Standard：0.6A Fast：6.0A Charging time ： Standard：10-15h Fast：30m Charge completed：open-circuit voltage：12.8V or above 1.4 Charging system 1.4.1Short circuit test Remove the ground wire off the battery, connect the voltmeter between the battery negative pole and ground wire with the switch at OFF and inspect whether there is short circuit.
Page 39: Voltage And Current Regulator
5.5 Voltage and current regulator 5.5.1 Inspect the main wire circuit Disassemble the 4P plug of the voltage and current regulator. Inspect the conduction between main wire terminals with the following methods. Item（wire color） Judging method between the battery there being battery （red）and body ground voltage between the ground...
Page 40: Charge Coil Of The Alternator
1.6 Charge coil of the alternator *Note Inspection of the charge coil of alternator may be conducted on the engine. Inspection Disassemble the 6P joint of alternator. Measure the resistance value between the white coil of alternator and the motorcycle frame with an avometer. Standard value ：0.6-1Ω（20℃）...
Page 41: Ignition System
Lock component for power supply Electric horn Flame ignitor Storage battery Relay MAIN SW SPARK PLUG BL/W W/G W W W BL/W IGNITION COIL MAGNETO BATTERY 点火系统 Ignition system - 40 -...
Page 42: Preparation Data
2 Ignition system Preparation data ----------------- 2.1 CDI group ----------------------2.4 Fault diagnosis ------------------ 2.2 Ignition coil ------------------- 2.5 Ignition system inspection ----- 2.3 Trigger ------------------------- 2.6 2.1 Preparation data Matters needing attention in operation 1. Inspect the ignition system in accordance with the order stipulated in the fault diagnosis table. 2.
Page 43: Fault Diagnosis
2.2 Fault diagnosis No flashover in spark plug Abnormal circumstance Cause of badness（confirm in order from 1） The interior resistance is too low and test it with a ① designated tester. The cranking speed is too low. ② ignition high voltage too low The tester is disturbed（if the voltage measured for ③...
Page 44: Ignition System Inspection
2.3 Ignition system inspection multimeter 万用表 *Note •When there is no spark in the spark plug， inspect whether the wire or part is loosen or in poor contact and confirm whether each voltage value is normal. •Since there are a great many of avometer brands with different interior resistance, the values tested will differ accordingly.
Page 45 *Note The metal area of the avometer prod mustn't be touched by fingers to prevent electroshock. Black/White Blue/White 蓝/白 If the peak voltage of the CDI terminal has an abnormal value, disassemble the body guard and the alternator joint. 黑/红 Black/Red Connect the charge coil（red / white）...
Page 46: Cdi Group
2.4 CDI group 2.4.1 System inspection System inspection. Disassemble the CDI group and inspect the parts related with the ignition system at the wire terminal. 2.4.2 Inspection Disassemble the CDI group and inspect whether the joint is loosen or eroded. Inspection item Testing terminal Standard value （20℃）...
Page 47: Trigger
2.5.3 Secondary coil Measure the resistance value between the wire of spark plug cover (with the spark plug) and the terminal. 点火线图 ignition line figure Standard value ：8-11KΩ（20℃） If the resistance value is within standard value range, the primary coil is good. The resistance value "∞"...
Page 48 Lock component for high pressure bag power supply Voltage stabilizer storage battery start up electric engine BRAKE SWITCH BRAKE SWITCH BATTERY RELAY STARTOR MOTOR STARTER SWITCH Startup diagram 启动示意图 - 47 -...
Page 49: Startup System
3 Startup system Preparation data --------------------------3.1 Fault diagnosis ---------------------------3.2 Start electrical machinery ---------------3.3 Start relay ---------------------------------3.4 3.1 Preparation data Matters needing attention in operation Disassembly of the start electrical machinery may be conducted on the engine. Please refer to disassembly operation in disassembly. Preparation reference Item Standard value...
Page 50: Fault Diagnosis
3.2 Fault diagnosis Unable to startup Rotating force of start machinery too weak No revolution in the RE Rotary Engine •Fuse blown •Power shortage in battery •Bad act of startup clutch •Power shortage in battery •Poor contact of connecting wire •Reverse revolution of startup electrical machinery •Bad acts of main switch •Gear of the startup machinery jammed with foreign body •Power shortage in battery...
Page 51 Inspect conduction of the housing of startup. Confirm the terminal and housing of the startup electric machinery cannot be connected. . Inspect conduction of the terminal and electric brush. If there is disorder, replace is with a new one. Inspect conduction of the brush holder. If there is conduction, replace is with a new one.
Page 52: Start Relay
3.4 Start relay 3.4.1 Actuation inspection Disassemble the body guard. Push the main switch to "ON" and press the startup electrical machinery with a "click ". Inspect by sound. Sound means normal. no sound： Inspect voltage of the start relay •...
Page 53: Bulbs/ Switch/Instrument
4 Bulbs/ switch/instrument Preparation data -------------------------------4.1 Instrument----------------4.6 Fault diagnosis --------------------------------4.2 Main switch --------------4.7 Replace the head light bulb -----------------4.3 Horn-----------------------4.8 Replace bulb of the front turning light-----4.4 Handle switch ------------4.9 Replace the bulb of the taillight ------------4.5 4.1 Preparation data Matters needing attention in operation The conduction of switches may be measured after disassembled from the motorcycle.
Page 54: Replace Bulb Of The Front Turning Light
4.4 Replace bulb of the front turning light 4.4.1Disassembly Remove the handle cover. Unscrew the setscrew on the turning light. Remove the bulb socket from the light. 4.4.2Installation Install the bulb back to the original position in the reverse order of disassembly. direction indicator lamp 4.5 Replace the bulb of the taillight 4.5.1Disassembly...
Page 55: Instrument
4.6 Instrument Disassemble the rearview mirror； Disassemble the handle shield and unplug the waterproof connector. Disassemble the bolts. Disassemble the odograph subassembly so that the instrument could be disassembled. Install the speed indicator back to the original position in the reverse order of disassembly.
Page 56: Handle Switch
4.9 Handle switch ① 1、 light-changing switch 2、 direction indicator lamp switch PASSING ② 3、 bugle switch ④ 4、 lamplight switch ③ 5、 startup switch ⑤ - 55 -...
Page 57 Front liquid brake 1. front liquid brake component 2. handle 3. handle screw 4. hexagonal flange clamping nut 5. hexagonal flange bolt 6. seal gasket 7. oil pump body component 8. bolt 9. fixed flat 10. brake switch component 11.screw 12.
Page 58 Rear liquid brake 1. rear liquid brake component 2. oil pump body component 3. brake cylinder component 4. brake hose assembly 5. handle 6. seal gasket 7. hexagonal flange bolt 8. hexagonal flange bolt 9. fixed cover 10. brake switch component 11.
Page 59: Brake
QJ150T-10 diameter of front hydraulic brake φ240mm Diameter of rear hydraulic brake φ240mm 5.1.2 torque value front/rear brake disk fixed bolt 22-29 N·m assemble bolt for the front brake cylinder components 22-29 N·m...
Page 60: Front Hydraulic Brake
2. Brake pad worn out 2. Brake pad worn out 3. Improper installation of brake pad 3. Improper installation of brake pad 4. Brake pad, hydraulic brake polluted Strange sound in braking 1. Brake pad worn out 2. Brake pad, hydraulic brakepolluted 5.3 Front hydraulic brake 5.3.1 Disassembly *Note...
Page 61: Rear Hydraulic Brake
Measure the thickness of brake pad. If the thickness of brake pad is less than the maintenance value or it is polluted by grease, just replace it. Allowable limit: brake pad 3.0mm brake disc 3.0mm Note: the brake clutch should be replaced in pairs. brake pad 5.3.3 Installation Install the brake disk and front wheel.
Page 62 Brake hose * Note assembly •Always replace the brake pad in pairs. •If a brake pad is reused, mark a signal Brake hose on its side before disassembly so that it assembly can be installed to the original position. Remove the following components from the rear wheel.
Page 63 Keep the brake pad and brake disc free of oil stain. Oil pump body If the brake pad and brake disc are polluted with oil, component rinse them with brake cleaning fluid. Brake hose * Note assembly Oil stain on the brake clutch will reduce its performance.
Page 64 - 63 -...
Page 65: Body Cover
6 Body cover Disassemble the motorcycle body according to the following order: Front cover of handle→wind shield→rear cover of handle→instrument→front cover→板 anterior-interior mudguard→foot guard plate→ ↓ battery package box lid→left and right foot pedal cover plate→left and right foot pedal rubber→foot pedal left-and right guard plate→rear handrail→cushion→...
Page 66 Front wheel/ front suspension Front wheel Left-separating sleeve Liquid-brake Split pin Gear seat component Front wheel ring Oil seal of front wheel Front wheel axle Rolling bearing Installing bolt of liquid-brake pan Grooved nut Rolling bearing Front tyre Middle axial sleeve of front wheel - 65 -...
Page 67: Front Wheel/ Front Suspension
7 Front wheel/ front suspension Preparation data -------------------------7.1 Fault diagnosis --------------------------7.2 Front wheel ------------------------------7.3 -------------------------------7.4 Direction handle Front fork --------------------------------7.5 7.1 Preparation data Matters needing attention in operation Support the body bottom with a jack before disassembly so that the front wheel is suspended but couldn't rotate. Keep the brake pad, brake disc free of grease in operation.
Page 68: Front Wheel
Dismantle the brake hose of the front brake. Dismantle the oil seal and bearings by oil-seal puller and bearings puller respectively. *Note: the QJ150T-10 forward-mounting assemble and dissemble map can be seen on P65 of this manual. 7.3.2 Inspection 7.3.2.1 Inspect bending of the wheel spindle Put the wheel axle on a V-shape seat and use dial indicator to measure its excentricity.
Page 69 Install and tighten the front wheel axle. *Note: the QJ150T-10 forward-mounting assemble and dissemble map can be seen on P65 of this manual. Torque force Front wheel-axle clamping nut 55-62 N·m...
Page 70: Direction Handle
7.4 Direction handle rearview mirror components 7.4.1Dissemble left-direction grip cover Dismantle the front guard shield, rear guard shield well rearview mirror Right Handle Components components. Right-direction grip cover bolt Dismantle the front brake handle and the rear brake handle. welding component of direction handle Throttle line...
Page 71: Radiator/Expansion Kettle Components
7.6 Radiator/expansion kettle components 7.6.1 Dismantle Dismantle the car body guard plate Radiator fan Dismantle the front headlamp. Loosen the fixed bolts of the radiator components.(four units) Loosen the water-in/water-out hose fixed bolts of the radiator. Dismantle the power lead of the cooling fan. Dismantle radiator components,...
Page 72 Compression test of radiator Dismantle the radiator cover after the cooling liquid is sufficiently cooled. Apply the required pressure (lower than the valve opening pressure of the cover) to the cooling system through the Radiator cover tester radiator cover tester, and make sure that the required pressure is lasted for 6 seconds;...
Page 73 Rear wheel/rear suspension - 72 -...
Page 74: Rear Wheel/Rear Suspension
8 Rear wheel/rear suspension Preparation data -----------------------------8.1 Fault diagnosis ------------------------------8.2 Rear wheel -----------------------------------8.3 Rear shock absorber/rear rocker ----------8.4 8.1 Preparation data Matters needing attention in operation There cannot be any oil stain stuck to the surface of the brake disc or brake pad. Preparation reference Item Standard value （mm）...
Page 75: Rear Wheel
Carry out the installation of the rear wheel according to a reversed sequence of dismantle., and then tighten the nuts. rear wheel fixed nut Torque value ：100-113 N·m QJ150T-10 rear wheel Tyre Suspended plate of right shock absorber Right separator of rear wheel Installing bolt of liquid –brake pan...
Page 76: Rear Shock Absorber/Rear Rocker
8.4 Rear shock absorber/rear rocker 8.4.1 Disassemble rear shock absorber Bolt Dismantle the cushion, the left-rear guard plate and the Right shock absorber right-rear guard plate. component Dismantle the rear handrail and the rear mudguard. Dismantle the take-in silencer. Dismantle the air filter assembly. Remove the fixing bolts of rear shock absorber.
Page 77 Table of torque value of engine fastener Fastening area and fastener name Tightening torque （N·m） 25～28 Cylinder cover nut 22～25 Oil-discharge bolt 10～15 Spark plug 10～12 Mould assembling bolt 10～12 Variable-speed chamber bolt 10～12 Motor fixing bolt 10～12 Oil pump fixed bolt 10～12 Oil pump chain wheel bolt 50～60...
Page 78 Lubrication system figure camshaft piston bent axle oil pump engine oil strainer - 77 -...
Page 79: Lubrication System
9 Lubrication system Preparation data -----------9.1 Fault diagnosis ------------9.2 Oil pump -------------------9.3 9.1 Preparation data Matters needing attention in operation After dismantling the oil pump, all the components should be carefully cleaned and their surfaced should be cleared by high-pressure gas. When dismantling the oil pump, pay attention to prevent foreign matters from falling into the crankcase.
Page 80: Oil Pump
9.3 Oil pump 9.3.1 Disassembly Dismantle the right cover, and lift down the unidirectional clutch components, loosen the chain cover fixed bolt of the oil pump, and take off the chain cover. Chain cover Bolt Dismantle the chain wheel fixed nut. Lift down the chain wheel and chain.
Page 81 Oil pump cover Dismantle the bolts and lift down the oil pump cover. Bolt Examine the radical clearance between the inner and outer rotors. Allowable limit ：0.20mm。 Testing ruler Examine the clearance between the outer rotor and the oil pump seat. Allowable limit ：0.21mm。...
Page 82 9.3.2 Dismantling Dismantle the oil pump as shown in the diagram. Oil pump body Inner rotor Oil pump axle Oil pump chain Fitting pin Outer rotor Oil pump cove Bolt Note: After the combination, the inner and outer rotors should rotate flexibly with no jamming. 9.3.3 Installation Carry out the installation according to the reversed sequence of dismantle.
Page 83: Carburetor
10 Carburetor Preparation data------------------------10.1 Fault diagnosis-------------------------10.2 Disassembly of carburetor------------10.3 Installation of carburetor -------------10.4 Adjustment of carburetor ------------10.5 10.1 Preparation data Matters needing attention in operation *Note ·Gasoline is extremely dangerous，so smoking or lighting is strictly forbidden in operational field. ·Pay special attention to flakes. ·No wire should be pulled and bent with rudeness.
Page 84: Disassembly Of Carburetor
·Compression pressure too low · Bad ignition ·Carburetor short of fuel · Too dense or sparse gas mixture -Gasoline filter blocked · Bad fuel -Gasoline pipe blocked · Secondary air inlet of suction system -Needle valve conglutination · Bad idle adjustment -Bad adjustment of oil level ·...
Page 85 Dismantle the throttle pulling-line fixed plate. Air throttle cover Dismantle the air throttle cover, spring and the air throttle. Fixed plate of throttle pulling-line Spring Air throttle Loosen the bolt and dismantle the upper cover. Take out the spring and the plunger components.
Page 86: Installation Of Carburetor
Installation of carburetor 10.4 Bolt Assembly and installatioj is conducted in the reverse order of disassembly. Sealing ring Lower shell body 10.5Adjustment of carburetor Floater Floater pin Needle valve core Switch on and warm up the machine for about 3 minutes, so that the engine will operate in normal running Main nozzle Idle metering hole...
Page 87 - 86 -...
Page 88: Cylinder Cover/Air Cylinder/Piston
11 Cylinder cover/air cylinder/piston Preparation data------------------------11.1 Air valve examination------------11.6 Fault diagnosis-------------------------11.2 Displace the valve guide----------11.7 Cylinder head -------------------------11.3 Shaping of the valve seat----------11.8 Examination of the cylinder head--11.4 Installation---------------------------11.9 Air valve-------------------------------11.5 11.1 Preparation data Matters needing attention in operation In order to ensure the encapsulation of cylinder cover and cylinder body，the cylinder cover bears considerable bolt retightening force.
Page 89 Fault diagnosis 11.2 Low compression pressure Abnormal noise of the cylinder head The valve clearance is not well adjusted The valve clearance is not well adjusted The valve is burned down or bended The valve spring is damaged The gas-tightness of the valve seat is not good Camshaft is worn down or damaged The filling piece of the cylinder head is of air leakage Camshaft and the valve rocker arm are worn down.
Page 90 Dismantle the cushionring, and positioning pin. Washer Loosen the nuts, and lift down the camshaft bearing combination. Note: when dismantling the camshaft bearing nuts, staggered steps should be taken. Otherwise, the camshaft bearing will be broken. Positioning Camshaft bearing Take off the chain form the driven sprocket. Dismantle the camshaft.
Page 91: Examination On Cylinder Head
11.4 Examination on cylinder head Camshaft Examine the outer ring of the bearing. If the rotation of the nearing is not stable and flexible, then the bearing should be replaced. Examine the inner ring of the bearing. If it is not tightly fastened to the camshaft, it should be replaced.
Page 92: Valve
11.5 Valve valve disassemble Spring pan Spacer Valve valve lock clip Spring valve oil seal 11.6 Examination on valve Clear out the carbon deposit on the cylinder cover. Measure the joint surface flatness of the cylinder cover. Allowable limit ：0.15mm。 Ruler When the joint surface flatness of the cylinder cover exceeds its allowable limit, fine sandpaper should be put...
Page 93: Replace The Valve Guide
Measure the outer diameter of the valve bar. Allowable limit ：4.95mm。 Valve reamer Examine the valve guide. Use reamer to clean out the carbon deposit in the valve guide before examination. Note: the reamer should undergo clockwise rotation while anticlockwise rotation should be inhibited. Measure the inner diameter of each valve guide.
Page 94: Shaping Of Valve Seat
Put a new O-typed ring on the new valve guide. Install the valve guide from the top of the cylinder head. Opener for valve Note: when install the valve guide, do not damage the guiding pipe cylinder head. After embedding the valve guide, use the valve guide Valve reamer reamer to repair.
Page 95 Remove 1/4 of the outer end of valve seat by using the milling cutter of 20°. Remove 1/4 of the bottom end of valve seat by using the milling cutter of 60°. Take down the milling cutter and examine the place which is treated.
Page 96: Installation
11.9 Installation The order of installation is opposite to that of the disassembly. Note: when installing the valve spring, put the spring end with a shorter pitch towards the combustor. When install the valve lock, use the compressing tool of valve spring. When install the valve, paint proper engine oil on the surface of the valve stem, and then put it in the valve guide.
Page 97 - 96 -...
Page 98: Crankcase/Clutch/Actuating Lever
12 Crankcase/clutch/actuating lever Preparation data-----------------12.1 Piston-----------------------------12.4 Fault diagnosis------------------12.2 Installation of the piston--------12.5 Cylinder body-------------------12.3 Installation of air cylinder------12.6 12.1 Preparation data Matters needing attention in operation All parts should be cleaned before inspection and test and should be blow dry with high pressure air. Function of the cylinder body：...
Page 99: Fault Diagnosis
12.2 Fault diagnosis Low compression pressure White fume in vent pipe The piston is worn out，burnt out or broken. ·The piston ring is worn out or damaged. ·The air and cylinder piston is worn out or damaged. ·The piston and air cylinder is worn out or damaged. The gasket is damaged;...
Page 100: Piston
Piston 12.4 Disassembly 12.4.1 Disassemble the retaining ring for piston pin. piston Note：When disassembling，do not drop the retaining ring into the crankcase. Withdraw the piston pin and unload the piston. piston pin, retaining ring Inspect the piston, piston pin and piston ring. Unload the piston ring.
Page 101 Measure the bore diameter of the piston pin hole. Allowable limit：14.04mm。 Measure the outer diameter of the piston pin. Allowable limit：13.97mm。 Clearance of piston pin hole and piston pin Allowable limit：0.03mm。 Measure the outer diameter of the piston. Note： The measuring position and the piston pin form an angle of 90 degree, some 7mm below the skirt of piston.
Page 102: Installation Of Piston
Measure the roundness of inner wall （ bore diameter difference between X and Y direction ）. Allowable limit：0.005mm。 Measure the cylindricity of inner wall（bore diameter upper difference at the upper , middle and lower part in X or Y direction）. middle Allowable limit：0.004mm。...
Page 103: Installation Of The Air Cylinder
Open the right cover and take down the starting rod components. Scrape the adhesive gasket off the crankcase. Note： No foreign objects should fall into the crankcase. Install the piston, piston ring and retaining ring. Note： Install the piston with the “IN” mark on the piston top towards the inlet valve.
Page 104 - 103 -...
Page 105: Drive Disk/Clutch/Driven Wheel
13 Drive disk/Clutch/Driven Wheel Preparation data -------13.1 Clutch/Driven Wheel -----------------------------13.5 Fault diagnosis---------13.2 Disassemble the clutch and the driven wheel -13.6 left crankcase cover --13.3 Installation------------------------------------------13.7 drive disk --------------13.4 Preparation data 13.1 Matters needing attention in operation In the operation, there should be no grease on the surface of the triangle belt. Otherwise remove it to reduce the skidding between the triangle belt and belt wheel to the lowest.
Page 106: Left Crankcase Cover
13.3 Left crankcase cover Disassembly Dismantle the fixing bolt of the case cover and take down the gasket and the guide pin. Note： left cover left cover when dismantling the fixing bolt, loosen and fixing bolt dismantle it in cross way. Take down the gasket and the guide pin.
Page 107 Dismantle the right-half components of the drive wheel. Right-half components of the drive wheel Decompose the right-half components of the drive wheel. Check the abrasion of the ball bearing. Measure the external diameter of the ball bearing. Allowable limit ：19.5mm。 - 106 -...
Page 108: Clutch/Driven Wheel
Measure the right-half internal diameter of the driven wheel. Sliding sleeve Allowable limit ：28.04mm。 Measure the external diameter of the sliding sleeve Allowable limit ：23.98mm。 Right-half components of the drive wheel 13.5 Clutch/driven wheel 13.5.1 Disassembly Driven wheel Fix the outer part of clutch with the fixing tool and Fixer dismantle the fixing nut.
Page 109: Disassemble The Clutch And The Driven Wheel
Check the abrasion of the outer part of clutch. Measure the internal diameter of the outer part of clutch. Allowable limit ：125.5mm。 Check the abrasion of the friction plate of clutch. Measure the thickness of the friction plate. Allowable limit ：1.5mm。 Friction plate 13.6 Disassemble the clutch and Wrench...
Page 110 Dismantle the guide pin. The left-half weldment of the Take down the left-half weldment of the driven wheel. Oil seal driven wheel Dismantle the oil seal from the left-half part of the driven wheel. Guide pin Check the free length of the clutch spring. Allowable limit ：70mm。...
Page 111 Paint grease on the outer rolling bearing and put it into the shaft sleeve. Bearing opener Note: compress the outer rolling bearing into the shaft sleeve with the marked side outward. Then fill the 8-9g grease in the whole shaft cavity. Assemble the elastic check ring.
Page 112: Installation
Install the protective jacket of the spring. Protective jacket of the spring Wipe and clean the leakage grease. Wrench (locknut) Install the clutch-pressing spring and clutch on the driven wheel. Use clutch spring to compress and compose. After compression, install the locking nut. Note: the spring should be compressed properly.
Page 113 Middle axle Input axle Output axle - 112 -...
Page 114: Decelerator
14 Decelerator Preparation data --------------14.1 Fault diagnosis----------------14.2 Gear case ----------------------14.3 Installation---------------------14.3 Preparation data 14.1 Function: convey the torque and determine the torque and rev of the final output. 14.2 Fault diagnosis The motor can not move when the engine is started. The drive gear is broken.
Page 115: Installation
Take down the gasket and the guide pin. Positioning pin Gasket Dismantle the output shaft combination. Dismantle the middle shaft combination. Dismantle the input shaft. Output axle combination Middle axle combination Input axle Check the worn condition of the input shaft, the output shaft and each gear. If the condition is serious, replacement is necessary.
Page 116 The assembly of bearings and oil seal should use special tools to prevent damage. - 115 -...
Page 117: Crankcase
15 Crankcase Preparation data ---------------15.1 Fault diagnosis-----------------15.2 Crankcase --------------------15.3 Installation ---------------------15.4 Preparation data 15.1 Matters needing attention in operation Since the crankcase is a thin-section casting, please avoid impact on it during operation in case there is any distortion or rupture. All parts should be cleaned before inspection and test and should be blow dry with high pressure air.
Page 118: Crankcase
Crankcase 15.3 Right crankcase cover 15.3.1Disassembly of crankcase Loosen the bolt and dismantle the right crankcase cover. Bolt Locking the screw nut and take down the gasket. Starting indolent gears loosen the locking nut with special tool Locknut Take down the magneto. Take down the starting indolent gears and shaft.
Page 119 Take down the gasket and the guide pin. Gasket Positioning pin Take down the crankcase-connecting rod assembly. Take out the timing chains. Crankcase-connectin g rod assembly nspection 15.3.2 Clearance measurement of connecting rod big end in right and left direction Allowable limit ：0.55mm。...
Page 120: Installation
Dismantle the oil seal of the left crankcase. Note: The dismantled oil seal can not be used again. Oil seal The dismantling of the oil seal should use special tools. 15.4 Installation The order of assembling crankcase is opposite to that of the disassembly. Note: The installation of oil seal should use special tools in order to prevent the damage against the oil seal.
Page 121 Cooling System Diagram water-inlet mouth water-outlet pipe water-inl et mouth thermostat Pump - 120 -...
Page 122: Cooling System
16 Cooling system Preparation data -----------------16.1 Fault diagnosis ------------------16.2 Thermostat -----------------------16.3 Cooling system 16.1 Functions of the cooling system: the water, as the endothermic medium, carries the heat out the motor through the inside of the cylinder body and cylinder cover of the engine. Then the heat is dissolved into the air through the radiator.
Page 123: Thermostat
16.3 Thermostat Dismantling Sensor component Clear away the coolant and dismantle the thermostat. Thermostat component Put the thermostat into the water in test chamber, then increase water-temperature examine valve-on Upper cover of temperature of the thermostat. thermostat room Bolt Initial startup temperature 72～84°C Full-open temperature 93～96°C...
Page 124 Replace coolant After making sure that liquid has been cooled, dismantle Drainage-bolt the bolt and make vehicle body incline toward right to clear away the coolant absolutely, and then re-install the drainage-bolt. Make the coolant having been matched infuse from Cover-part component infusing-hole.
Page 125 Muffler - 124 -...
Page 126: Exhaust Emission And Control System
17 Exhaust emission and control system Warranty of Exhaust emission and control system ---------------------------15.1 Regular maintenance guideline/ensurance of emission standard -----------15.2 Mechanical function of the exhaust control system --------------------------15.3 Catalyst converter system --------------------------------------------------------15.4 Countermeasures to idle speed emission exceeding specified value -------15.5 17.1 Warranty of Exhaust emission and control system 1.
Page 127: Regular Maintenance Guideline
17.2 Regular maintenance guideline ·To prevent further environment pollution, the State requires all automotive vehicles by manufacturers should meet standards of air pollution emission. Our Company does its utmost to purify air and reduce air pollution besides ensuring that production conforms to standards. ·Each of the motorcycles has passed strict inspection before delivered out of the company and meets standards of air pollution emission.
Page 128: Mechanical Function Of The Exhaust Control System
17.3 Mechanical function of the exhaust control system Outline The countermeasure of exhaust gas is taking the four-stroke single-cylinder engine，carburetor mode as the reference and adopts Air induction device to maintain fine exhaust level. In addition, the charcoal Canister Purge is employed in vaporized exhaust.
Page 129: Catalyst Converter System
17.4 Catalyst converter system 17.4.1 Structure： Catalyst placing Catalyst placing 17.4.2 Description 1.The function of the converter catalyst is to convert HC, CO and NO after incomplete combustion into innocuous gas such as H O,CO and N then discharge them out. 2、...
Page 130: Countermeasure Of Idle Speed Emission Exceeding Specified Value（Four-Stroke)
17.5 Countermeasure of idle speed emission exceeding specified value （four-stroke) Qualified Conduct regular inspection （maintenance and service plan） Qualified Measure idle speed emission （Remark 1） Qualified carburetor（Remark 2） Adjust the Qualified Qualified Disassemble and clean the carburetor for delivery （SJ,MJ,SAJ,MAJ and so on） Qualified Change the carburetor...
Page 131 - 130 -...

Qianjiang QJ150T-10 Operation And Maintenance Manual

1 Battery/Charging System

2 Ignition System

3 Startup System

4 Bulbs/ Switch/Instrument

5 Brake

6 Body Cover

7 Front Wheel/ Front Suspension

8 Rear Wheel/Rear Suspension

9 Lubrication System

10 Carburetor

11 Cylinder Cover/Air Cylinder/Piston

12 Crankcase/Clutch/Actuating Lever

13 Drive Disk/Clutch/Driven Wheel

14 Decelerator

15 Crankcase

16 Cooling System

17 Exhaust Emission and Control System

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