Generic Trigger X 50ccm Owner's Manual
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Generic Trigger X 50ccm Owner's Manual

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Contents ···················································································································································-1-
Preface ·····················································································································································-4-
Documents to be prepared ················································································································-5-
Inspection/adjustment ······················································································································-19-
1 Brake····················································································································································-32-
1.1 Maintenance instruction·············································································································-32-
1.2 Fault diagnosis···························································································································-32-
1.3 Front hydraulic brake·················································································································-33-
1.4 Rear hydraulic brake ··················································································································-35-
2 Body cover ···········································································································································-38-
3 Front wheel/ front suspension ···············································································································-42-
3.1 Preparation data ·························································································································-42-
3.2 Fault diagnosis···························································································································-42-
3.3 Front wheel································································································································-43-
3.4 Steering handle ··························································································································-45-
3.5 Front fork···································································································································-45-
4 Rear wheel/rear suspension ··················································································································-50-
4.1 Preparation data ·························································································································-50-
4.2 Fault diagnosis···························································································································-50-
4.3 Rear wheel·································································································································-51-
4.4 Rear shock absorber/rear rocker·································································································-52-
4.5 Driving chain ·····························································································································-53-
5 Battery/charging system ·······················································································································-56-
5.1 Preparation data ·························································································································-56-
5.2 Fault diagnosis···························································································································-57-
5.3 Battery ·······································································································································-58-
5.4 Charging system ························································································································-59-
5.5 Voltage and current regulator ·····································································································-60-
5.6 Charge coil of the alternator·······································································································-60-
5.7 Illuminating coil of alternator·····································································································-61-
5.8 Disassembly of alternator···········································································································-61-
6 Ignition system ·····································································································································-64-
6.1 Preparation data ·························································································································-64-
6.2 Fault diagnosis···························································································································-65-
6.3 Ignition system inspection··········································································································-66-
6.4 CDI group··································································································································-68-
6.5 Ignition coil ·······························································································································-68-
6.6 Trigger ·······································································································································-69-
7 Startup system ······································································································································-71-
7.1 Preparation data ·························································································································-71-
7.2 Fault diagnosis···························································································································-72-
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  • Page 1: Table Of Contents

    Contents Contents ···················································································································································-1- Preface ·····················································································································································-4- Documents to be prepared ················································································································-5- Inspection/adjustment ······················································································································-19- 1 Brake····················································································································································-32- 1.1 Maintenance instruction·············································································································-32- 1.2 Fault diagnosis···························································································································-32- 1.3 Front hydraulic brake·················································································································-33- 1.4 Rear hydraulic brake ··················································································································-35- 2 Body cover ···········································································································································-38- 3 Front wheel/ front suspension ···············································································································-42- 3.1 Preparation data ·························································································································-42- 3.2 Fault diagnosis···························································································································-42- 3.3 Front wheel································································································································-43- 3.4 Steering handle ··························································································································-45-...
  • Page 2 7.3 Start electric machinery··············································································································-72- 7.4 Start relay···································································································································-74- 8 Bulbs/ switch/instrument ······················································································································-75- 8.1 Preparation data ·························································································································-75- 8.2 Fault diagnosis···························································································································-75- 8.3 Replace the head light bulb ········································································································-75- 8.4 Replace bulb of the front turning light ·······················································································-76- 8.5 Replace the bulb of the taillight / license light / rear turning light ··············································-76- 8.6 Instrument··································································································································-77- 8.7 Main switch ·······························································································································-77- 8.8 Horn ··········································································································································-77-...
  • Page 3 14 Cooling system ··································································································································-112- 14.1 Preparation data ······················································································································-112- 14.2 Fault diagnosis ························································································································-112- 14.3 Water pump/water tank ···········································································································-112- 15 Exhaust emission and control system·································································································-118- 15.1 Warranty of Exhaust emission and control system ··································································-118- 15.2 Regular maintenance guideline ·······························································································-119- 15.3 Mechanical function of the exhaust control system ·································································-120- 15.4 Catalyst converter system ·······································································································-121- 15.5 Countermeasure of idle speed emission exceeding specified value（two-stroke)····················-122- - 2 -...

  • Page 4: Preface

    Preface This Manual explains the maintenance of Generic Trigger 50ccm 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 5: Documents To Be Prepared

    Documents to be prepared General safety Maintenance regulation Specififcation sheet Troubleshooting General safety Carbon monoxide The engine should be started in ventilated area other than closed area. Attention The exhaust contains toxic gas, carbon monoxide, which can numb people and may result in death. The engine should be started in an open area and the exhaust scavenging system should be applied if the engine has to be started in a closed area.
  • Page 6 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 the 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 7 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 8 Specififcation Sheet Trigger X 50ccm Model Trigger 50ccm Engine Type 40-2 2-stroke engine Unleaded gasoline of 95 Full length mm 2060 Fuel type Octane above Number of Full width mm cylinders Inside measure Full height mm 1230 40.25*39mm * stroke...
  • Page 9 Maximum horsepower 1.39KW/5500 rpm capacity/type Generator type 1E40MB-2 Compression ratio 7.0：1 Spark plug BR8ES/F10KC Cylinder pressure 1.1-1.3Mpa/1400rpm Front liquid braking disc Spark plug gap 0.5-0.7mm φ280mm unit（mm） Rear liquid braking disc Ignition mode φ220mm unit（mm） TRIGGER X 50ccm - 8 -...
  • Page 10 - 9 -...
  • Page 11 TRIGGER SM 50ccm - 10 -...

  • Page 12: Troubleshooting

    Troubleshooting Difficult to start or unable to start Troubleshooting Tune-up inspection Failure cause Loosen the oil drain bolt of carburator to No gasoline in gasoline tank check whether there is oil within the Oil tube clog of gasoline tank carburator carburator Oil tube clog of float chamber No gasoline...
  • Page 13 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 14 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 adjustment Too thick gas mixture （locking screw）...
  • Page 15 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 16 Improper charging (overdischarge or over charge of battery) Troubleshooting Tune-up inspection Failure cause Measure the voltages of the both ends of battery, start Expired battery engine Battery voltage No increase of rised normal battery voltage Bad battery value and restore its original voltage after killing engine...
  • Page 17 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 18: Inspection/Adjustment

    Inspection/adjustment Preparation of documents Cylinder pressure Check list of constant maintenance Gear mobile oil Engine mobile oil/oil strainer Changing gear oil Gasoline filter Driving chain Inspection/adjustment of accelerator's pull wire Clearance of front/rear brake Air cleaner Front shoe block abrasion Spark plug Head lighting Battery...
  • Page 19 Specification Engine Gyration speed at idle 1400±100rpm/min speed Spark plug gap 0.5-0.7mm Engine oil 0.8L capacity BR8ES/F10KC Spark plug specification Compression pressure of 1.1-1.3Mpa/1400rpm air cylinder Firing time BTDC12 degree（+/-）1degree 1400±100rpm Carriage Free stroke of front brake 20-30mm drawbar Free stroke of rear brake 20-30mm drawbar Specification...
  • Page 20 Check list of constant maintenance Mileage time Every Every Every 3000 Every 6000 Every Every maintenance 1000 300 KM 12000 KM 14500 KM Tools Inspection items motorcy 3 months 6 months A year 15 months month Air cleaner General purpose tool Gasoline filter General purpose tool Oil cleaner...
  • Page 21 Piston, air cylinder - excessive wear of air cylinder and cylinder smoothness, please replace. Please be inspected at the dealer in Generic regularly in order to keep motorcycle under its optimized condition. The said table is based on that the motorcycle runs 1000km per month.

  • Page 22: Air Cleaner

    replaced with new product. Warning! Smoking or lighting fires are strictly forbidened. Inspection/adjustmentof accelerator's pull wire Check the smoothness of accelerator pull wire. Check the clearance of accelerator pull wire. Clearance：2 - 6mm The main adjusting position is on the carburator side. Loosen the fixing nut and adjust by turning adjusting nut.

  • Page 23: Cylinder Head

    Spark plug Spark plug Dismantle spark plug. Check the overburning, pollution and carbon laydown of spark plug. If there is the said problem, please purge it with cleaner of spark plug or steel brush. Cylinder head Inspection of spark plug gap Clearance：0.5-0.7mm spark plug gap *Attention...
  • Page 24 Inspection of charging state (CCU) Open cushion. Unclose the top cover of air filter and disconnect the lead of 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 voltage meter.
  • Page 25 Carburator Idle adjustment *Attention The idle adjustment should be made when the engine is 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 26: Changing Gear Oil

    Gear mobile oil 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. Please supplement gear oil when the oil level is too low.
  • Page 27 Clearance of front/rear brake Front brake clearance Measure the clearance of the front brake drawbar at the top point of brake drawbar. Clearance：20-30mm Rear brake clearance Measure the clearance of the rear brake drawbar at the top point of brake drawbar. Clearance：20-30mm Abrasion of front brake shoe Check the oil level via oil immersion lens when the brake is...
  • Page 28 Front/rear suspension system Compress up and down Front Strain the front brake and compress the front shock absorber up and down to check the actuation. Check whether the front shock absorber is leak and each part is loosen. Rear Actuation inspection up and down Rear shock absorption Compress the rear shock absorber up and down to check the actuation.
  • Page 29 Specified pressure unit：Kpa Specification Tire pressure Front 3.00-21 wheel QJ50-23 Rear 4.10-18 wheel Front 100/80-17 wheel QJ50-23A Rear 130/80-17 wheel Tyre specification Front wheel 3.00-21 of inside Front wheel 3.00-21 of outside QJ50-23 Rear wheel 4.10-18 of inside Rear wheel 4.10-18 of outside Front wheel...
  • Page 30 Front liquid brake Rear liquid brake brake shoe - 29 -...

  • Page 31: Brake

    1 Brake Maintenance instruction ------------------------ 1.1 Fault diagnosis ----------------------------------- 1.2 Front hydraulic brake ----------------------------1.3 Rear hydraulic brake ---------------------------- 1.4 1.1 Maintenance instruction Matters needing attention in operation * Note •The braking components can not be spoiled by oil stain in installation or disassembly. •Rinse with stipulated cleaning agent in order to avoid reduction of braking quality.

  • Page 32: 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 polluted Strange sound in braking 1. Brake pad worn out 2. Brake pad polluted 1.3 Front hydraulic brake * Note •The braking components can not be spoiled by oil stain in installation or disassembly.

  • Page 33: Brake Pad

    1.3.2 Inspection Inspect whether the brake pad is worn out and replace it if necessary. Measure the brake pad and brake disc and put down the maximal value. Specification diameter of front hydraulic brake QJ50-23 φ230mm diameter of front hydraulic brake QJ50-23A φ280mm *Note...

  • Page 34: Rear Hydraulic Brake

    * Note Grease on the brake pad may reduce brake ability and invalidate the brake. Brake pad 1.4 Rear hydraulic brake 1.4.1 Disassembly Disassemble the rear brake cylinder set. Disassemble the rear wheel. * Note •Always replace the brake pad in pairs. •If a brake pad is reused, mark a signal on its side before disassembly so that it can be installed to the original position.
  • Page 35 *Note Grease on the brake pad may reduce brake ability and invalidate the brake. Screw the bolt and nut to the stipulated torque force value. Torque value mounting bolt of brake caliper ： 22-29 N·m Keep the brake pad and brake disc free of oil stain. If the brake pad and brake disc are polluted with oil, rinse them with brake cleaning fluid.
  • Page 36 - 35 -...

  • Page 37: Body Cover

    2 Body cover Disassemble the motorcycle body according to the following order: Rearview mirror → Air guide sleeve → Instrument support → Instrument → Front mudguard →Front top guards ↓ Front bottom guards →cushion→left, right guard strip → Rear left and right guard→...
  • Page 38 Front wheel/ front suspension （QJ50-23） - 37 -...
  • Page 39 Front wheel/ front suspension（QJ50-23A） - 38 -...
  • Page 40 QJ50-23 Front wheel front rim mounting bolt of brake disc front wheel spindle left shaft sleeve of front wheel oil seal of front wheel rolling bearing rolling bearing odometer gear stand middle shaft sleeve of oil seal of front wheel front wheel front brake disc front rim set...

  • Page 41: Front Wheel/ Front Suspension

    3 Front wheel/ front suspension -------------------------3.1 Preparation data Fault diagnosis -------------------------3.2 Front wheel -------------------------3.3 Steering handle -------------------------3.4 Front fork -------------------------3.5 3.1 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.

  • Page 42: Front Wheel

    3.2.2 Deviation of steering lever The left and right shock absorbers are not balanced. The front fork is bent. The front tire is bent and the tyre deviates. 3.2.3 Front wheel yawing The tyre is distorted. The front wheel bearing is loosened. The tyre is not good.
  • Page 43 3.3.2.3 Inspect the front wheel bearing Middle sleeve of front wheel Disassemble the middle sleeve of front wheel and remove the oil seal. oil seall clearance Inspect rolling condition of the inner race of swivel bearing clearance If it does not roll or is loosely contacted with the outer race or it is damaged, please replace with a new one.

  • Page 44: Steering Handle

    3.3.4 Installation Spread grease on the oil seal at the brake disc. Spread grease on the gearing mesh and the active parts of speed indicator. Install the brake disc after meshing between gears of speed indicator and the bearing claws. Note •If the bearing claws do not mesh, the claws may be distorted when screwing up the nuts.
  • Page 45 Tools： Fixing spanner of steering lever upper weld assembly connecting Fixing nut spanner instrument board support bearing *Note： lower •Clean the opening part of the body guard board with rags. connecting board Specification of the front shock absorber front shock absorber Length：862.5mm Angle：64°...
  • Page 46 Rear wheel/rear suspension（QJ50-23） - 45 -...
  • Page 47 Rear wheel/rear suspension（QJ50-23A） - 46 -...
  • Page 48 Rear shock absorber/rear rocker 1. Mounting shaft of rear rocker 2. Cover of rear rocker 3.O-shape sealing washer 4. Distance sleeve 5. Inner spindle sleeve 6. Weld assembly of rear rocker 7. Chain sleeve 8. Chain guard 9. Wire clamp of hydraulic brake 10. Connecting rod set of rear shock absorber 11. Rocker set of rear rocker 12.

  • Page 49: Rear Wheel/Rear Suspension

    4 Rear wheel/rear suspension Preparation data -----------------4.1 Fault diagnosis -----------------4.2 Rear wheel -----------------4.3 Rear shock absorber/rear rocker ----------4.4 Driving chain -----------------4.5 4.1 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 50: Rear Wheel

    4.3 Rear wheel 4.3.1 Disassembly rear rocker Loosen the nuts on rear-wheel spindle. Remove the nuts on the rear-wheel spindle and the chain. Unload the rear-wheel spindle. Unload the rear-wheel. rear-wheel 4.3.2 Inspection spindle Inspect the run-out of rear wheel. Allowable limit ：...

  • Page 51: Rear Shock Absorber/Rear Rocker

    QJ50-23A rear wheel vacuum tyre rear rim fixing bolt on chain wheel chain wheel rear brake disc bearing sleeve fixing bolt of hydraulic brake press plate of rear wheel press plate of rear wheel spindle rear wheel rolling bearing rolling bearing oil seal of front wheel left rear sleeve chain...

  • Page 52: Driving Chain

    4.4.3 Disassemble the rear rocker Disassemble the chain adjuster, rear-wheel spindle, rear wheel and rear shock absorber. Remove nuts and rear rocker. Disassemble the chain guard. Disassemble the rear rocker set and the sleeve of middle shaft. 4.4.4 Inspect the rear rocker Inspect the rear swing shaft by rotating it on flat surface and t is bent，please replace it.
  • Page 53 stores. Inspect rigidity of the driving chain. If it is hard, please rinse, lubricate or replace it. Inspect the driving wheel, driven wheel and if 1/4 of the gear teeth are worn out, replace the chain ○ wheels. And if gear teeth are bent, replace chain wheels too.
  • Page 54 - 53 -...

  • Page 55: Battery/Charging System

    5 Battery/charging system Preparation data -------------5.1 Fault diagnosis -------------5.2 Battery ---------------5.3 Charging system -------------5.4 Voltage and current regulator -------5.5 Charge coil of the alternator ---5.6 Illuminating coil of alternator ---5.7 Disassembly of alternator -----5.8 5.1 Preparation data Matters needing attention in operation * Note 1.

  • Page 56: Fault Diagnosis

    Preparation reference Item Specification capacity/ type 12V-3AH/Dry charge type Battery Voltage Fully charged 13.1V （20 ） Must be 12.3V(not work for an hour) charge Charging current Standard：0.4A，Fast：4A Charging time Standard：10-15h，Fast：30m Capacity 80W/5.000rpm Alternator Coil impedance value Between white and black 3.3-3.5Ω （20 ）...

  • Page 57: Battery

    5.3 Battery 电瓶的安 mounting 5.3.1 Disassembly of the battery position 装位置 of the battery Unclose the pad. Disassemble the left guard strip and then the air filter cover. Disassemble the negative wire and then the positive wire. Take out the battery. Warning! In the disassembly of positive pole the tools mustn't contact the frame because the short-circuit spark will...

  • Page 58: 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：0.4A Fast：4.0A Charging time ：Standard：10-15h Fast：30m Charge completed：open-circuit voltage：12.8V or above 5.4 Charging system 5.4.1Short 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...

  • Page 59: Voltage And Current Regulator

    5.5 Voltage and current regulator 5.5.1 Inspect the main wire circuit Unload the body guard, pad and oil tank. Disassemble the 4P plug of the voltage and current regulator, inspect the conduction between main wire terminals with the following methods. Item（wire color）...

  • Page 60: Illuminating Coil Of Alternator

    Standard value ：0.6-1Ω（20 ） If the measured value exceeds the standard value, replace the alternator coil. 5.7 Illuminating coil of alternator *Note Inspection of the illuminating coil of alternator can be conducted on the engine. Inspection Disassemble the 4P joint of alternator. Measure the resistance value between the white coil of alternator and the body ground with an avometer.
  • Page 61 5.8.2 Installation Install the alternator stator to the engine case. Connect the lead connector of the alternator. Clean the tapered part of the crankshaft and flywheel. Install the retaining key of flywheel in the key groove on the crankshaft and confirm. Align the flywheel groove with the retaining key of the Fixing 固定...

  • Page 62: Ignition System

    MAIN SW SPARK PLUG FUSE BL/W R/W BL/W IGNITION COIL MAGNETO BATTERY 点火系统 Ignition system - 61 -...

  • Page 63: Preparation Data

    6 Ignition system Preparation data ---------------------- 6.1 Ignition coil -------------------- 6.5 Fault diagnosis ----------------------- 6.2 Trigger -------------------------- 6.6 Ignition system inspection --------- 6.3 Charge coil --------------------- 6.7 CDI group ---------------------------- 6.4 6.1 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 64: Fault Diagnosis

    6.2 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 designated tester. The cranking speed is too low. ignition high voltage too low The tester is disturbed（if the voltage coil measured for several times is above...

  • Page 65: Ignition System Inspection

    6.3 Ignition system inspection avometer *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 66 Minimum voltage：95V or above. *Note black The metal area of the avometer prod mustn't be touched 黑 by fingers to prevent electroshock. red / white 红/白 If the peak voltage of the CDI terminal has an abnormal value, disassemble the alternator connector. Connect the charge coil（red / white）...

  • Page 67: Cdi Group

    6.4 CDI group 黑 black 红/黑 Red/black 蓝/白 blue/white 6.4.1 System inspection 黑/白 Black/white System inspection. Disassemble the CDI group and inspect the parts related with the ignition system at the wire terminal. 6.4.2 Inspection Disassemble the CDI group and inspect whether the joint is loosen or eroded.

  • Page 68: Trigger

    6.5.3 Secondary coil Measure the resistance value between the wire of spark plug ignition line figure 点火线图 cover (with the spark plug) and the terminal. Standard value ：8-11KΩ（20 ） If the resistance value is within standard value range, the Ω primary coil is good.
  • Page 69 BRAKE SWITCH BRAKE SWITCH BATTERY RELAY STARTOR MOTOR STARTER SWITCH startup diagram 启动示意图 - 68 -...

  • Page 70: Startup System

    7 Startup system Preparation data --------------------------7.1 Fault diagnosis ---------------------------7.2 Start electrical machinery ---------------7.3 Start relay ----------------------------------7.4 7.1 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 71: Fault Diagnosis

    7.2 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 72 Inspect conduction of contact surfaces between other assemblies. Confirm the armature shafts between each surface of the electric brush 电刷 commutator cannot be connected. Inspect conduction of the housing of startup Confirm the terminal and housing of the startup electric machinery cannot be connected.

  • Page 73: Start Relay

    7.4 Start relay 7.4.1 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 74: Bulbs/ Switch/Instrument

    8 Bulbs/ switch/instrument Preparation data -------------------------------8.1 Instrument-----------------8.6 Fault diagnosis --------------------------------8.2 Main switch --------------8.7 Replace the head light bulb -----------------8.3 Horn------------------------8.8 Replace bulb of the front turning light-----8.4 Handle switch ------------8.9 Replace the bulb of the taillight / licence light / rear turning light ----------8.5 8.1 Preparation data Matters needing attention in operation The conduction of switches may be measured after...

  • Page 75: Replace Bulb Of The Front Turning Light

    8.3.2 Installation Install the bulb back to the original position in the reverse order of disassembly. 8.4 Replace bulb of the front turning light 8.4.1Disassembly Unscrew the setscrew on the turning light. Remove the bulb socket from the light. position bulb 8.4.2Installation headlamp bulb Install the bulb back to the original position in the reverse order...

  • Page 76: Instrument

    8.6 Instrument Disassemble the rearview mirror； instrument panel Disassemble the faucet shield and unplug the waterproof connector. Disassemble the bolts. Disassemble the instrument case so that the instrument could be disassembled. Install the speed indicator back to the original position in the reverse order of disassembly.
  • Page 77 orange black 黑 橙 粉红 pink green/white 绿/白 white/red 白\红 Baby blue 淡蓝 green / black 绿/黑 棕 brown 蓝 blue violet green/ yellow - 76 -...

  • Page 78: Table Of Torque Value Of Engine Fastener

    Table of torque value of engine fastener Fastening area and fastener name Tightening torque （N·m） 18～22 Cylinder cover nut Fixing nut in the power gear of the clutch 50～60 Stud bolt of air cylinder 18～22 Clutch locknut 50～60 Lock bolt of flywheel 35～40 Spark plug 10～15...
  • Page 79 piston crankcase carburetor oil tank oil pump - 78 -...

  • Page 80: 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 The operation of engine in this chapter can be conducted on the motorcycle body. When disassembling the oil pump, see to it that no foreign objects could enter into the engine. After installation of oil pump, inspect whether machine oil leaks in each part.
  • Page 81 Take down the elastic collar and flat gasket. elastic collar Take down the drive gear set of the oil pump. flat gasket drive gear set Unscrew the bolts and take down the oil pump cover. oil pump cover bolt oil tube sleeve Disassemble the tight wire of the oil pump and unload oil pump...
  • Page 82 9.3.3 Inspection outer diameter Inspect wear and tear of the worm wheel and worm gear. 外径 Severe wear and replace. Inspect wear and tear of the camshaft. Severe wear and replace. Measure the outer diameter of the piston. Allowable limit ：2.45mm. 9.3.4 Assembly Assembly of the oil pump is conducted in the reverse order of disassembly.

  • Page 83: Carburetor

    10 Carburetor Preparation data-------------10.1 Float chamber -------------10.5 Fault diagnosis-------------10.2 Installation of carburetor -------10.6 Disassembly of carburetor-----------10.3 Carburetor cover -------10.4 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.

  • Page 84: Disassembly Of Carburetor

    ·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 · Bad adjustment of oil volume Too much fuel in the engine Too sparse gas mixture -Air filter blocked...

  • Page 85: Carburetor Cover

    Do not pull the enrichment valve wire, insert the nylon tube enrichment valve wire into the extender oil pipe and blow air into the pipe with mouth. There should be no air in the extender oil pipe, otherwise, the pipe should be replaced. extender oil pipe-hole 10.3.2.1 Disassembly bolt...

  • Page 86: Float Chamber

    10.5 Float chamber 10.5.1 Dismantling bolt Dismantle the four fixing bolts and unload the float chamber. Dismantle the float pin and unload the float and needle valve set. Dismantle the main jet, main bubble tube and float chamber idle jet. Dismantle the idle adjustment bolts.
  • Page 87 At this point the engine will stall（if not，inspect whether air escapes at the interface of air filter , whether the bolt is tightened and whether the intake of the air filter is blocked). Withdraw the mixture adjustment bolt for 1 circle. Restart and adjust the idle adjustment screw so that the rotation speed reaches 2000-2500rpm.
  • Page 88 constant temperature set gasket spark plug cylinder cover temperature controller - 87 -...

  • Page 89: Cylinder Cover/Air Cylinder/Piston

    11 Cylinder cover/air cylinder/piston Preparation data ---------------11.1 Fault diagnosis ---------------11.2 Disassembly of air cylinder -------------11.3 Disassembly and installation of the piston -------11.4 Installation of air cylinder -------------11.5 Disassembly of cylinder cover -----------11.6 Installation of cylinder cover - ---------11.7 11.1 Preparation data Matters needing attention in operation ·The operation of air cylinder/piston can be conducted on the frame.

  • Page 90: Fault Diagnosis

    Allowable Item Standard value limit Bore diameter 40.27-40.28 40.3 Bent 0.05 cylinder Cylindricity 0.05 Roundness 0.05 Top ring 0.015-0.05 0.09 clearance between the piston Second ring and piston ring groove 0.015-0.05 0.09 ring Top ring 0.1-0.25 Piston and Interface clearance Second piston 0.1-0.25...

  • Page 91: Disassembly And Installation Of The Piston

    11.4 Disassembly and installation of the piston piston Disassemble the retaining ring for piston pin. Note： When disassembling， do not drop the retaining ring into the crankcase. Withdraw the piston pin and unload the piston. retaining ring for piston pin piston pin Unload the piston ring.
  • Page 92 Measure the bore diameter of the piston pin hole. Allowable limit：12.04mm。 Measure the outer diameter of the piston pin. Allowable limit：11.96mm。 Measure the outer diameter of the piston. Note： The measuring position and the piston pin form an angle of 90 degree, some 15.5mm below the skirt of piston.

  • Page 93: Installation Of Piston

    Measure the roundness of inner wall（bore diameter difference between X and Y direction ）. Allowable limit：0.04mm。 upper Measure the cylindricity of inner wall（bore diameter difference at the upper , middle and lower part in X or Y middle direction）. middle Allowable limit：0.05mm。...

  • Page 94: Installation Of The Air Cylinder

    crankcase. Scrape the adhesive gasket off the Note： No foreign objects should fall into the crankcase. arrow mark Install the piston, piston ring and retaining ring. Note： Install according to the arrow mark on the piston top. The retaining ring should not fall into the crankcase. 11.5 Installation of the air cylinder Install the gasket on the crankcase.

  • Page 95: Installation Of The Cylinder Cover

    gasket Unload the gasket. constant Unscrew the bolts and unload the constant temperature set temperature set from the cylinder cover. bolt 11.6.2 Inspection ruler Inspect whether the cylinder cover is broken. Inspect the flatness of the bottom surface of the cylinder. Allowable limit：0.05mm.
  • Page 96 Crankshaft-connecting rod set right crankcase bolt balancing shift chamber left crankcase Housing set internal gear gasket center wearing plate iron friction plate flat gasket fixing gasket dish gasket Locknut bearing ball inward release lever outward release lever adjustment bolt clamp nut pressure cover pressure spring Bolt and gasket...

  • Page 97: Crankcase/Clutch/Actuating Lever

    12 Crankcase/clutch/actuating lever Preparation data ----------------12.1 Fault diagnosis -----------------12.2 Crankcase -----------------------12.3 Clutch ---------------------------12.4 Actuating lever -----------------12.5 12.1 Preparation data 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.

  • Page 98: Fault Diagnosis

    12.2 Fault diagnosis Low compression pressure Strange noises in crankcase Air escape in crankcase Parts shattered or broken in crankcase Overheat of engine Engine stalling Slipping of clutch Clutch depressed Lubricant starvation Unable to put the shift Difficulty in gearshift Gearshift fork broken or distorted Half disengagement Fork pin broken...

  • Page 99: Clutch

    Unload the release lever set. Unload the electric starter set. release lever electric starter set 12.3.2 Disassembly of right crankcase right cover cover Unscrew the binding bolts and unload the right crankcase binding bolts cover（ called as right cover for short in the diagram）. Note：...
  • Page 100 Unscrew the four bolts，and unload the pressure spring, clutch pressure plate. bolt Unload the adjustment bolt and clamp nut on the press plate. adjustment bolt/ bolt pressure spring clutch pressure plate Remove the gasket lock by unscrewing the locknut with a special tool.
  • Page 101 Housing set Dismantling internal gear gasket center wearing plate iron friction plate flat gasket fixing gasket dish gasket Locknut bearing ball inward release lever outward release lever adjustment bolt clamp nut pressure cover pressure spring Bolt and gasket 12.4.2 Inspection gear shape Inspect whether the housing groove of clutch is burred or broken.

  • Page 102: Actuating Lever

    Measure the thickness of the wearing plate with a vernier caliper. thickthick Allowable limit ：2.6mm。 12.5 Actuating lever 12.5.1 Disassembly After unclosing the right cover, unload the actuating lever set. actuating lever set 12.5.2 Dismantling ratchet elastic collar ratchet spring return spring actuating gear actuating shaft...
  • Page 103 Crankshaft-connecting rod set right crankcase bolt balancing shaft shift chamber left crankcase main shaft set sub shaft set pin of return spring middle fork shaft middle fork shift shaft set fixer set shift drum left and right fork shaft left and right fork shaft - 102 -...

  • Page 104: Crankshaft-Connecting Rod Set And Shift Chamber

    13 Crankshaft-connecting rod set and shift chamber Preparation data -------------------------------------13.1 Crankshaft and connecting rod set ----------------13.2 Shift chamber ----------------------------------------13.3 Shift shaft set ----------------------------------------13.4 Main shaft --------------------------------------------13.5 13.1 Preparation data 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.
  • Page 105 Remove the crankshaft off the crankcase. Scrape away the adhesive gasket on the joint face of the crankcase. Note ： The joint face of the crankcase should not be damaged. crankshaft 13.2.2 Inspection Clearance measurement of connecting rod big end in right and left direction Allowable limit ：0.55mm.

  • Page 106: Shift Chamber

    Inspect whether there are strange noises or loosening in rotation of the crank shaft bearing. If there is strange noises or loosening，replace the crankshaft set. crank shaft bearing Note： Install the crankshaft connecting rod assembly on the crankcase along with the gear change mechanism.

  • Page 107: Shift Shaft Set

    Unload the bearing and oil seal of the left crankcase. Inspect whether the bearing or oil seal is damaged, and replace if necessary. 13.3.2 Installation Installation is conducted in the reverse order of disassembly. 13.4 Shift shaft set 13.4.1 Dismantling spread plate hift shaft set spring sleeve...

  • Page 108: Main Shaft And Sub Shaft

    Measure the thickness of the shift fork. thickness Allowable limit ：3.90mm。 Measure the outer diameter of the shift drum. Allowable limit ：41.75mm。 Measure the cotterway width of the shift drum. Allowable limit ：6.3mm。 13. 5 Main shaft and sub shaft cotterway width 13.5.1 Dismantling...
  • Page 109 13.5.2 Inspection gear surface Inspect the wear and tear of the gear surface and driving pawl respectively. Severe wear and replace them. driving pawl 13.5.3 Main shaft and sub shaft assembly Note： In the assembly, evenly spread lubricating oil on each gear and shaft to ensure no clamping stagnation after assembly.
  • Page 110 flow back to the water tank connected to the water tank water bump - 109 -...

  • Page 111: Cooling System

    14 Cooling system Preparation data ----------------14.1 Fault diagnosis ------------------14.2 Water pump/water tank --------14.3 14.1 Preparation data Function of cooling system ：this engine adopts water cooling mode. Water cooling means to cool down high temperature parts with water as the heat absorption medium which then transfers the heat to the ambient air in order to maintain the optimal working temperature of the engine.
  • Page 112 Unscrew the bolts and unload the water pump cover (together with the outlet pipe holder). water pump covear outlet pipe holder bolt guide pin Unload the gasket and guide pin. Unload the water pump impellers. inlet Note： Gasket and joint face of case body should not be damaged in operation.
  • Page 113 Gradually inject the formulated cooling liquid through the filling hole （mounting hole of the radiator） till reaching the margin of the filling hole. Mount the radiator cover. Note：Please use the cooling liquid produced by Generic Company，the lowest service temperature of which is - 35 - 112 -...
  • Page 114 centidegree. Inspect the switch of the fans. Replace it when the switch is incapable of normal turn-on or turnoff. cooling fan switch Pressure test of the radiator. Remove the radiator cover when the cooling liquid is adequately cooled down; exert a set pressure （ lower than the open-valve pressure of the cover ）on the cooling system with a radiator cover tester and confirm whether radiator cover tester...
  • Page 115 Muffler - 114 -...
  • Page 116 vent pipe set front shell set rear shell set - 115 -...

  • Page 117: Exhaust Emission And Control System

    15 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 15.1 Warranty of Exhaust emission and control system 1.

  • Page 118: Regular Maintenance Guideline

    6〉The exhaust control system of the product conforms to state regulations , so make sure to use parts from Generic when replacing any part of the system. And the replacement should be carried out by the designated dealers or service centers.

  • Page 119: Mechanical Function Of The Exhaust Control System

    15.3 Mechanical function of the exhaust control system Outline The countermeasure of exhaust gas is taking the two-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 120: Catalyst Converter System

    15.4 Catalyst converter system 15.4.1 Structure： vent pipe catalyst converter 15.4.2 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 121: Countermeasure Of Idle Speed Emission Exceeding Specified Value（Two-Stroke)

    15.5 Countermeasure of idle speed emission exceeding specified value（two-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 122 - 121 -...

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