139QMA ENGINE 1390MB MAINTENANCE MANUALFOREWORD This manual is compiled for your use, maintenance and inspection of your motorcycle. For detailed information about structure and appearance of your motorcyle and parts, please refer to BT4960) motorcycle parts catalog and illustration book. Disassembling and assembling of motorcycle parts can be effected by removing the coverture and interference fittings. This manual is based on the structures of the present types Baotian 139QMA and139QMB. We beg our customers to be flexible in using the manual if there is any alteration in structure as a result of technical advancement, ‘Your opinions about this manual will be valued.I. CONTENTS GENERAL INFORMATION 1. ENGINE NUMBERLOCATION 2, BASIC TECHNICAL SPECIFICATIONS 3. DISASSEMBLING AND ASSEMBLING 4. TIGHTENING TORQUE 5, UNIVERSAL AND SPECIAL TOOLS a . ENGINE FUEL SUPPLY LOCATION 7. TROUBLESHOOTING 8, MAINTENANCE INTERVAL ENGINE DISASSEMBLING, ASSEMBLING, INSPECTIONAND ADJUSTMENT LAIR INLET HOUSING, AIR FOIL 2, CYLINDER HEAD HOOD . CYLINDER HEAD AND VALVE . CYLINDER AND PISTON . KICK STARTER (INCLUDING LEFT COVER) . STEPLESS TRANSMISSION SYSTEM are a 7. ELETRIC STARTER 8. MAGNETOAND ELECTRIC FITTINGS (INCLUDING RIGHT CASE COVER) 9. CRANKCASEAND CRANKSHAFT 10. TIMING CHAINAND TENSIONER IL. LUBRICATION SYSTEM (INCLUDING RIGHT CASE), ENGINE OIL PUMP, FILTERAND FILTER COVER 12. REAR TRANSMISSION SYSTEM 13. CARBURETOR 14. AIR FILTER ATTACHED PAGES whe eee a 1B 13 13 16 18 19 21 23 27 29CHAPTER ONE GENERALINFORMATION 1 ENGINE NUMBER LOCATION Engine number location is at the lower left front of left crankcase as illustrated in Figure 1 (Figutel) IL. BASIC TECHNICAL SPECIFICATIONS ( See Table 1) Table 1 Starting mode Kick starting and electric starting Type Four strokes Number of cylinders Single Type of combustion chamber Hemispheric valve stricture O.HC chain transmission Cylinder bore x travel (mm) 39x414 Total displacement (mL) 49 Compression ratio 10.5 Maximum power (Kw/s/min) 2.017500 Maximum ter qiie Nim/r/min 2.9/7000open 0° BTDC Intake (1mm) vertical Valve closed 25) ABDC on-off ao 33' ABDC HERE, Exhatist (limi) vertical closed 2° BTDC Valve gap intake 0.06 (Cold state) mm exhaust 0.08 Idle speed (cimn) 1900 Lubrication mode Both pressure and splash Lubrication | Cilpump Internal external rotors device Oil filter strainer Lubricant volume 0.9L Cooling mode Forced air cooling Air filter Sponge strainer type Diaphragm carburetor plunger diameter (mm) O16 carburetor ventuni (mm) 16.5 throttle Butterfly valve type CDImagneto ignition ignition time 13° (1700r/min) ~28" (3800r/min) Ignition device | breaker Contactless Spark plug ATRTC. ATRC CR7HSA(NGK) CROHSA(NGK) Spark plug gap 0.6~0.7 (nm) clutchtype | type Multiblock dry type type Stepless transmission ; SS — operation utomatic centrifugal ‘transmission type ‘Two-stage reduction Speed reducer | 5 sanction |Fitststage [3.25 ratio Secondstage | 3.4IIL PRECAUTIONS IN DISASSEMBLING AND ASSEMBLING L Paper pad, rubber seals such as O-ring, ring clip and clasticretainer must bereplaced after disassembling 2 When tightening bolts and nuts, tighten those of larger outside diameter before tightening those of smaller outside diameter; lock theminthe order of diagonal lines at specifiedtorques 3.Use parts and greases produced by regular factories 4 Special to ols or universal to ols must beused in disassembling or assembling 5 After disassembling, parts must beinspected and cleaned and their friction faces lubricated before assembling 6. The specified lubrication locations must belubricated with sp ecified lubricants 7 After assembling parts, confirm the state oflocking or movement 8. When two peopleare at work, make sure that both are in safety im repair work 9. When dismounting and mounting battery, the (-) terminal mustbe disconnected first 10 When using an open end wrench, prevent slippage so as to preventinyury 11.At the completion of work, con firm contacting points, fixing points and passages 12. When connecting battery wires, connect the (+) terminal first. 13.Atthe completion of battery terminal connection, apply grease to both terminals 14 When dismounting connectors, press down lock before pulling wire 15 When pulling connectors, hold connectors in hand instead of pulling wires only 16 Repair connectors when their terminals are bent, protruding or disconnected 17 When connector terminals arerusty, rub offrust before connecting them IIL TIGHTENING TORQUE VALUE STANDARD TORQUE VALUE REFER TO STANDARD TORQUE VALUE. See Table? Table 2 Designation Tightening torque Nm 5mm bolt aut 4,506 6mm bolt nut 8~12 8mm bolt aut 13~2 10mm boltaut 30-40 12mm boltaut 40~S0 5mm screw 5,898 6mm screw SH bolt ide 6mm flange boltaut li~14 Smm flange boltaut 10mm flange bot nutTorque Values of Important Parts of Engine See Table 3 Table 3 Serval Tightening part Quantity | Screwdiameter | Tightening numb er (mm) torque Nm 1 Cylinder head bolt A 7 9 2 Cylinder head bolt B a 7 9 2 Engine oil strainer cover 1 30 15 4 Exhaust pipe connector fixingbolt | 2 6 9 = Camshaft seat flange nut A 7 16~18 6 Valve adjusting screw 2 5 9 T Cham stretching plate bolt 1 6 10 (8 Oil drain b olt Z 8 in~13 3 Clutch outer disc setscrewnut 1 10 40 10 Magneto rotor setacrew nut L 10 40 1 Left crankshaftnut 1 12 55 2 Spark plug 1 10 12 13 Engine oil pump driven gear nut 1 6 10 14 Chain tensioner bolt M3*8 L 8 6 15 Rear transmisssion assembly bolt ai 8 hoods 16 Brake shoe fitting shaft nut 1 8 10 17 Cylinder head cover vent chamber | 4 4 cover screw V TOOLS (See attached pages for figures) Tabled Designation of special tools | Teol aumber Flywheel remover | Zoa Valve adjusting fixed wrench | z02 Spark plug special socket | 203Universal Tools Tables Senal Designation of universal tools ‘Tool numer number 1 fixing bracket yot Tesleeye “TS? "10%. 1 oe TS, TIO, T12, TM. TI? 3 Box-end wrench ‘yo? 4 Inner-hexagon wrench 8” ¥O3 5 Shovel vod 6 “4” screwdriver vos a Rubber mallet yo 8 Sharp -nose pliers yo7 9 Clip ning caliper YOs 10 Ratehetwheel wrench yoo i sleeves 14%, 17* ¥T14. YTIT 12 Internal thread head M61; M7 1.25 YM6, YM7 13 Button-head screw driver Y10 ENGINE OILSUPPLY LOCATIONS See Table 6 Table 6 | Oil supply location Designation ‘Valve guide, valve rod Hexible part SAEIS-40 Camshaft cam ‘Valve swing arm friction face Camshaft drive chain Cylinder Bing bolt aut Piston ambience and ring slot Piston pin ambience Cylinder face Connecting rod, piston pin hole Connecting rod big end Crankshaft R side oil seal Engine oil pump sprocket All the bearin gs' running positions O-nng face Oil seal lip Oil seal lip Starting wheel gear Grease Starting wheel intermediate gear Starting shaft dleever Starting shaft flexible part Starting one-way clutchTROUBLE FINDING 1 Difficult Starting or Refusal to Starting State of troubles le ‘Balequate and anooth supply of Fuel to the catbsuretor Nofvelsupplyto | cab wre tor [iain Spank plog sparks. [ovnosperk plug spark [Compession pressme| foo baw eran conpxession pressure Norinal compression jpressue No engine ignition eruption { Engine erupts but does | gine up ee Drysperk plug | Inspection and adjustment inspectit theres | fislincabustrby | Toosening caiburetor | oll drain screw. ‘Remove spark plug, ft spark pug between spark plug cover and engine | ‘earth seteor and inepect if! spa pug spas, i Compression pressure; ‘messimenent 1 Causes of troubles [—*No gasoline ingasoline tank ~eClogging of piping between fue! enktand carbeeton == altuna —abiepe ag at gusslcan antes Clogging fuel tank cover vent | —*Clogging of oileup steiner (—#Clogging of oilpiring —#Clogging of carburetor atino- spheric balance tube -#Poor spark plug | —eContamination of spark plug [—*Poor CDI unit }—*Poor impulse coil —*Poor excitation coil | —*Poormain switch \sHigh voltage coil breskiage or shortcirewt [Poot valve timing Valve too tight with no gap |—*Air leakage of valve — Wear of piston sing andl eydinder + Restartas instructed | | Remove sparkplug. | againand inspect at. | |e Air leakage at cylinder gasket “Poor automatic tattle function far leakage at Infake mamfold Inconect ingition timing Poot adjustnent of carburetor air adjustment sciew —# Carburetor oil level too high Wetsperk plug att opening too lange ‘—*Clageing of airfilterIt Rotation (Poor Acceleration or Feeble Rotation) State oftroubles Inspectionandadjustment — Causesof troubles ‘Filleemall amount | ~-loffuel and tryeugane! ‘starting "| -#Clogeing of ait filter hem am [Poor fuel pravage (not ftiooth) Engine speed ‘Engine speed does not] re ‘Passags increases, completely inciease, ‘Clogg ing of fuel tank cover yent hole oe nee Po Clogging of exhaust pipe Sia eho ang’ «Catt acts digging eslnge ~-jbyneens ofagmbon’ | [poor automatic throtle function 1 | mung fg i } Goniectignition Thconectignition p-*PoorCDI mit ‘min ‘tim {Poor impulse ail -| Poon valve adjutinent | Conectvalve gep Tnconect valve gap} _—___y-~#lmomrsctralve playadjushnent LaExcessive wear of valve (valve rod. =) excessive protrusion) ——,_ _______[Goimpeain earn | al a - | eemcey Fomelconpesion| (Comysemion wesmuel PAitearotcytinderand piston presmute ito low ro T-eAir leakage at cylinder head gasket . - —, ePoor timing of cylinder head __! Carburetor clogging | “inspection i ——— Clogged ean I haa ie | andinspectit | ‘No contamination or ‘With contamination) yeRemove dirt idecoloration anddécoloration —[——# mproper spark plug heatvalue a 1 le -lctenkease wexeessive| ogee | _ =! gE xcessive amountofeng ine oil alamo’ —elnacequate amount of engine oil engine oil Mo engine oilexchange Roe ~~tneydinder head ' i Le ine Seine Clogging of engine oil Ties asl ape oa Crattnating of git | epee cisaio nae ! -epilute gaz mixture Nooverheating Ovetheated }-*Poorgazoline +98 sive cabondepositin coubustion hamber No ignition shock fa —sPiemature igaition ceeleaated viding or | —-lhigh-speed successive | p—#Bxcessie carbon dpositincom bution camber (running | }*Poor gasoline }-*Slippage ofclutch With ignition shock| }*Dilute gas mixture Premature ignitionDifficult Rotation (High Speed) State of houbles Inspection and adjustment Causes of toubles _| Ignitiontiming | | adjustment ! Normal Abnomel Normal Abnomnal ftPoor adjustient “LePoorvalve seat Normal Abnomel nadeqnate oil i gasoline tank F crogginy of getnee [ration ofgasalinetankccover hale Poor automatic oileup ~-lClogaing ofeeabinetoa| No clogging Clogged. }——-eemove _Valve timing adjustment! ‘andinspection 1 IComect valve timing lIncouect valve timing, }—— +P oot alignment ofcam timing gearmaik { im = -!Valve spring inspection! {Spring fracture elastic lratigne | __________+Poor spingImproper Charging of Battery (Overchargingor Over-discharging) State of troubles Inspectionandadjustment Causes of troubles | Stat engine to'me asure | Uimitingvoliege | he Withao increase in Normel-oltage of Endofbattery service life Detteryvoliage battery — Poor battery A.C G coilresistence.| 1 aessuring Poorcoil Nonna Very lange measured _______Rerrneng, short cireuit value Poor contact of connectors | Tnopect voltage adgusting | | aechfie socket Waiaed_ | | Sess comsectal tone | ~ | Gand © corm thoy | | face mlaaeie velags | | teen as \ Battery withvolmge Seg |} ——-eReawite breakage iispectifvoltage adjusting rectifier plug is Loose 1 I La 4 _ — Poorwoltage adjusting rectifier Nomel Bbmormed | ~$$1 crcont of comectos eo Prorat Improper chaiging (overcharging) (MinguacGesaaet {blackenize coxnected fo! De ~- === | temmal@anl@ comected | | tobody frameant meas | {rellgetctvem tere | Battenyis wntvolige Tip Rey a eae luchen main switch is at taithicaton |-—-—————* Blac kite breakage (ON position sires mpgs | ? Rca | | ingeodconiact, | Nontal | Peorsndloose | __¢ poorcontactof contactor (__". Bear valtage adjusting rectifierSpark Plug Does Not Spark Wealrepankiig o:nasperking MMpectionand adjustment Gene | Replace spark plug | | andinupect ' Weak sparking or eee Stong sparking | —_______ Poor dpeik plug ‘Inepectif wirebe te en | {spat plug and high- | \vroltage wire isloose. | No loosening | —____-» Loose spark plug cap a | Inspect ff CDI wnat | | plugs.aze loose. | Normal Abnormal = | Poor plg contact il inspect conductivity | ‘between CDI unit wine | Normal Abnormal a ~ ~~~ {Inspect related parts. -# Poor main switeh Poor excitation coil Nomal Abnomel + Poor impulse call Poor high-voltage coil Breakage of main wite Poor contactof connectorsocket _| RepleceCDIend | [ampectegan | Nonnel | Abnomal —§ |} Poor CDI unit 10Difficult Rotation (Low Speed and Idle Speed) State of toubles ~~~ 1Adjustingition timing! [Adjustcarbuetoroil | \wokuue adjushng sere! [Airinteke ateaburetor) "gesket ' Nommel ‘Abnormal Good adjustment Pooradjustment Nosirintale Airintelke Safe E S| app and engine ear ‘covutor satu etd inspect sparking of | spark plug Inspectionand adjustment Causes of troubles otFeerent Poor imprilse coil [-® Dilute mixed gas (loose screw) Mixed ges too thick (tight screw) Poor heat-insulating gasket Loos: setnut of carbmetor |-@ Breakage of heat-insulation plate Breakage of negative pressure tube [Poor end contaminated spark plug, |-#Poor CDI unit [—#Poor high-voltage coil \_ePoor main switeh (—#PoorA CG Good sparking of (Cecasional poor satling spark plug lf apanleplng jePoor ACG | AG G inspection Good Poor 1 |——-# Danmge of negative pressure tube ‘Clogging of vent holeMAINTEN ANCEINTERVALS Engine maintenance intervals are recorded in terms of mileage asi sillustrated in table 7 I Inspection: Effect cleaning, lubrication, replenishment, modi fication orreplacement when necessary. A Adjustment; C: Cleaning; R: Replacement, T Tightening Table 7 iz “ \ Ties Mileage Kim Ko | Note | Items. 000 | 2000 | so00 } ono | sooo | soa0 | 7000 | 8000 | e000 }io000 11000 12000) Engine oil New | R R R R R R Hyehicle R300 Engine oil a g stininer Gearoil, [Note 3 [New R R ehicle| [R300 Valve gap A A A A Carburetor 1 1 & Aivfilte |Notes| 1 eR) ce 33 Spark plg cR) cR CR) CR) Dnvebelt I Boltsand I nuts Notes: | 1, Please repeat maintenance in case mileage exceeds the specified ranges in the table 2 Inspection andreplacem ent should be effected in advance in dusty of rainy conditions 3, Please shoiten replacement intervals in heavy-load, long siding or sainy conditionsIL ENGINE DISASSEMBLING, ASSEMBLING, INSPECTING AND ADJUSTING aa L Air Inlet Housing and Airfoil Disassembling, Assembling and Inspecting and Adjusting Remove 2 nuts M6 of carburetor, remove carburetor seat; remove 4 air inlet s crews, remove air inlethousing, remove 3 screws M6 ofairfoil and clamp, remove airfoil and finally remove airfoil sealring from cylinder head Inspect the parts and in case of dirty parts, clean them to facilitate flow of cooling air If any part is damaged, replace it. Froceed assemblingin areversed order IL Disassembling, Assembling and Inspecting Cylinder Head Hood Removed bolts Mé of cylinder head hood and clamp, remove cylinder head hood, removeinner and outer oil stains, inspect for easy venting of vent chamber; letin compressed air (Figure 2-1) through evhaust pipe Quick exhaust a fair from vent chamber shows that venting is eary, otherwise it shows that vent chamberis clogged. In case ofvent chanber clagging,remove4 screws M4, dismauntparts, clean vent chamber and remove oil stains and clogging matters. After cleaning, mountremoved vent chamber partsin their origina positions. When mounting replace vent chamber seal zing and apply sealing adhesavetoit, Cylander hood seal should be replaced when mounting cylinder head hood on engine sivimtake v cylinder hood seal ting (Figure 2-1) Il Cylinder Head and Valve L Turn plastic fan beside magneto ta position acamshaft sprocket holeoverit, (Figure3-1) 7 Loosentensioner bolt, remove ? bolts M6x16 oftensioner and remove tensioner and its ‘bolt MGx16 gasket 3 Loosen valve gap adjusting sorew, removed nuts M7 ofcylindérbead, remove camshaft mounting seat, remove positioning pin and camshaft walters (Figire3-1) 134 Remove 2 bolts M6x85 ofcylinderhead, remove cylinder head and cylinder gasket and remove positioning pin from cylinderhead 5.Remove spark plug and carburetor seat ineulation gasket. Remove carbon deposit on cylinder head, remove the covering material of cylinder head gasket (Figure 3-2) without harming cylinder heat. Remove valve trip by means ofvalve spring compressor, take out valve spring, spring seat, valverod oil seal and valve 6 Inspecting cylinder head: Inspectif there isa fissure near sparkplug hole or valve hole (Figure 3-2) and, in case-of fissure, replace cylinder head. Inspectwalve bushing inner hole, standard value; 5.0~5.012, limitofuse: replace when itis 5.03. Inspectifwearofcamshaftbeaingmounting holeas sertous (Figure3-3) and, ifyes, repair or replaceit T Inspecting valve spring: Inspect valve inner and outer spring free length (Figure3-4): Inner spring standard value. 30. 540.2,if L<28. 5,replace it;outer spring standard value: 34.1 +02, 1fL=<32, replace it 8 Inspecting valve: Inspect if thereis any deformation, burn, or damage an intake valve or exhaust valve and ifthereis accentnic wear invalverod, In any of the above-mentioned cases, correction orreplacement mustbe effected. Place valve inta valve bushing andinspectifitis smoathinmovement. Measure arintake valve rod and exhaust-valve rad chameters (Figure 3-5), standard walue- air intake valve 94.975 ~4 99. exhaust valveg4 955 ~4 97, limitofuse replaceifairintake valved<4.92, replace ifexhaust valved <4.9 (Figure 3.2) (Figwe 3-3) (Figue 3-4) autake valve o exhaustvalve (Figure 3-5) (Figue 3-6) 149.Inspecting spark plug: Remove spark plug carbon deposit and inspect electrode gap. Play should be 0.6~0.7mm, 10 Inspecting camshaft mounting seat: Remove camshaft and swingamn, inspect if wear of bearing mounting holeis serious. Ifyes, effect correction or replacement. (Figure 3-6) 11 Jngpecting airintake and exhaust valves swing arm: Inspect standard value of outside diameter of intake and exhaust swingarm shaft; 09.937~99.972, limit ofuse:Ifd < replacement and inspect for free oil passage of intake swing am. (Figure 3-7) 7 (Figure 3-7) 12. Swing arm inspecting: Inspect wear of swing arm face which contacts cam,inspect wear of swing arm shaft hole, standard value: 910.022. limit ofuse: if > 010.1, effect replacement (Figure 3-8) 13 Valvecamshaftassembly Inspectmaneuverability ofvalve camshaft bearing inspect wear of timing chain sprocketwheel and inspect heights ofintake cam and exhaust cam. Intake cam height standard value 25 745mm, exhaust cam height standard value:25.5Smmj limit ofuse: ifthat of intake cam < 25. 345mm, effectreplacement and if that ofexhaust cam— 25,15mm, effect replacement Assemble inspected or comected parts inan order reversed to that of disassembling as specified, paying attention to the following points 1 Apply seal adhesive tothe two sides of tensioner paper gasket, torque bolt M8x8: 6N.m; 2 Mount camshaft on cylinder head with camshaft intake and exit cam downward, make the two small hole reticles parallel to cylinder head face with the larger hole perpendicular to cylinder (Figure 3-10); align mark reticle “T” an fly wheel with aligning mark on right crankcase cover (Figure 3-11) 15 (Figure 3-8) ‘Cylinder head face (Figure $10) 9.91, effect3 Tighten cylinder head aut M7 in 2~3 steps at a torque of 16-18N m, 4Valwe gap adjusting: Intake valve 0.6mm, exhaust valve: 0.08mm, valve adjusting screw Lock aut torque: 9N.m (Figure 3-10) 1¥ Disassembling And Inspecting Cylinder Block and Piston L Take out guide board, remove cylinder block and positioning pin 2 Remove piston pia retaining ring with butten-head serew driver, remove piston pin and piston (Figure4-1) piston pin Tetaining ring (Figuie 3-11) 3 Remove gasket material on cylinder block with a shovel, remove carbon depositin cylinder sleeve (Figure4-2) and inspect wear in cylinder sleeve, 4 Remove carbon deposit ontop of piston, inspect and measure wear of piston skirt (Figure 4-3), standard value; 38.99~-38.97, limit ofuse: if 39,93, effect replacement. (Figwe 4-2) 4 Measure cylinder bore diameter at 3 positions in arectangular direction (X-Y), standard value 939. 0~839. 01mm (Figure 4-4) (Figure 4-5), Limit ofcylinderuse if039 Imm, effect replacement Ifplaybetween cylinder and piston exceeds 0.10, effect correction or replacement (Figure 43) ie(Figme 4-5) 6 Inspectand measure outside diameter of piston pan (Figure 4-6), standardvalue: 912.998 ~ 612.992mm, limit ofuse:if <012 97mm, effect replaceme TAnspect and measure inside diameter of piston pin hole (Figure4-7), standardvalue: 813 002 ~ 13,008, limit of use: if> 913.04, effect replacement 8 Inspectmating gap between piston pinhole and pin, limit ofuse: if =0.04mm, effect replacement, 9 Inspect wear of piston ring and groove (Figure 4-8), Thickness of first piston ng 0.77~0.79mm, of second piston ring 0,795 ~0.775mm, width of piston groove 082mm; limit ofuse: if first and second ring width >0.72mm, effectreplacement 10 Remove piston ring (Figure 4-9), mount piston rings to the lower part of cylinder and measure pistonsingend gap (Figure4-10), Firstpiston tingassembly gap 0.03~0.20mm, second piston tingassembly gap 0.05~0.20mm, Limit ofuse if 0.5mm for firstand second, effect replacement. 17 (Figwe 46) b , Ay (Figued.7)11, Mount inspected or corrected parts in an orderreversed to thataf disammbling as specified. In mounting, piston rings should be 90" or 120" in relative positions (Figure 4-11). Mount pistons, the sidemarked “IN” should face intake side. clearance gage pastonaing (Figure 4-8) (Fignze +10) Kickstarter Disassemblingand Inspecting (Figme 411) 1 Remove 8 bolts M6x35 ofl eft camshaft cover, wire clip assembly, rear bralce wire assembly, leicle rod screw Méx2S andleft cover 2.Press kaickcstarting rod, remove fo ot-operated intermediate gear, removekick startingrod, remove setaining ring by means of clip ring calipers (Figure 5-1) and remove starting shaftassemblyand return spring (Figure 5-2) (Figure 5-1) (Figure 5-2) 183. Remove rust on starting shaft gear and foot-operated intermediate gear, inspectifthereisany damage dueto impact , wear or other damage and correct it in case there is 4 Inspect returning elasticity ofretum spring: Replace it if elasticity is weale. 5 Mountinspected or corrected partsin an order reversed to that of disassembling Note: A. Apply a small amount of grease or mol ybdic sul fide toinsi de and outside of starting shaft and gear, B. lnspect thatkick starting rodactuates starting shaft smoothlyand thatintermediate gear moves upand down, C. Axial jerky mation gap <1mmwhen starting shaft assembly is mounted mmeft cover: VI, Disassemblingand Inspecting Stepless Transmission System 1 Fizmain drive gear by means of fixing clamp, remove nut M12 washer, drivegeareft part, fan, foot-operated driven claw(Figureé-1) (Figue 6-1) 2. Fimdriven gear outer disc by means of fizing damp, remove nutM10, dnven gear and V-belt(Figure 6-2) 3. Remove right partof drive gear and shaft sleeve (Figure 6-3). 4 Inspect i fcentrifngal roller is damaged or worn, outside diameter standard value: 916 +0.08mm (Figure 6-4), limit of use: if D=<15 5mm, effect replacement 5 Inspect bore diameter of central hale on thenght of drive gear, standard value: 920.009~920.027mm, limit of use: if >6 20 06mm, effect replacement 6. Inspect if drive gear sleevei sworn or damagedand measure its outside diameter, Standard value (riguiess) @19.905~ #19.98min, if<19 94mm, effect replacement. 19‘Tenspect if drive face on the right of drive gear is worn or damaged (Figure 6-5). Limit ofuse if >0.4mm, effect replacement. 8 Inspect ifdriven gear outside disc is worn or damaged and measure its diameter. (Figure 6-6) Standard value:@107.0~ 107, 2mm, limit of use: if D>107.5mm, effect replacement, 9 Inspect ifdriven gear centrifugal ffi ction pad is worn or damaged (Figure 6-7). Limit of use iffriction pad <2, Omm, effectreplacement. D \ (Figure 6-4) (Figue 6-5) (Figme 6-6) (Figure 6.7) 10 Inspect wear depth of driven gear driven face and moving driven face (Figure 6-8), limitof use: if >0.4mm, effect replacement. 11.Inspectto ascertain easy rotation, jamming, wear or damage of roller bearing and needle bearing of driven gear, remave ashes and dirts and apply grease to bearings (Figure 6-7) (Figure d-8) ae i (Figs 6.3) needle bearing Figure 6.9)| 2 Inspectif there is any wear of V-belt. Measure ‘belt working face (Figure 6-10), standard value 1840. 3mm, limtofuse 1f11V Pulse coil maximum voltage Excitation coil maximum voltage 3,3 Inspection instrument: circuit tester 3.4 Ignition system trouble finding A. No spark of sparkplug Poor main switch Poor, damaged or disconnected connecting wires Poor spark plug or secondary current leakage Poor magneto stator coil (pul se excitation) Poor C.D.L B. Engine stops after starting Poor sparking of spark plug Improper ignition time Poor C.D.L ©. Difficult rotation of engine after starting Poor ignition coil Poor sparkplug Spark plug cap electric leakage Poor magneto Poor stator coil Poor C,D.L 3.5 Ignition system inspecting A. Measure resistance of high-voltageignition coil with three-in-one meter Primary coil resistance resistance value 0.2 ~0.3K2 Measure secondary coil resistance with plug cap on resistance value 3~12K 0 Measue secondary coil resisstance with plug cap removed resistance value 3B Spark plugand C D1 Ittenot easy to inspect spark plug with simple tool s, Comparison method is easier Compare partsin question with normal parts for evaluation C.hmpulse coil Measure resistance between blue/white wire and earth wire, D Excitatio: al Measure resistance betwe en red/black wire and earth wire, resistanc 4.Charge (lighting) system Charge (ighting) system consists oflighting charge coil of magneto stator coil, rectifier adjustor, battery and wire hamess coil 4.1 Charge (lighting) system cirenit diagram forinspection (Figure 8-6) stance value 140~200 0 value 350 ~450 0 White wire dowize Greenwire @e My rai aie fect ier Battery Green vite (Figue 3-6) Inthe diagram, OXsymbolizesheadlight When headlight is not on during the day, discharge is effected through releasing resistance. V, and V,symbolize circuit tester for measuring voltage 4.2 Precautions in maintenance inspection A When necessary, distilled water should be added to MF battery (Distilled water must be used forthe firsttime) B, Neveruse quick charge €. Remove battery when charging Incase chargingisneeded withbattery onmoto away from source of heat or spark D. When effecting winng, fix wires propei cle; stay to.avoid short circuit due to wire damage 4.3 Charging condition inspecting Inspect battery with battery in safe charging condition A, Warm up engine for 10 minutes after engine starts B. Connect battery p ositive terminal with ammeter negative terminal be fore connecting am meter positive terminal with battery positive terminal C. Connect volimeter positive terminal with battery positive terminal and voltmeter negative terminal to battery negative terminal D. Charging performance Voltage in the following table is white wire voltage measured when connec the currentis the current measured when rectified voltageis 14V. dto2. 30 andBeginning of Charge Lighting wire sclties 3000r/min 8000r/min White <2500 163V,45A | 18 245A ‘Yellow 2500 13.1V [asav E Limiting voltage Start en gine and measure limiting voltage as sp ced increases Limiting voltage 14 5-0. 5V. Note: Battery ism casured when filly charged E Inspect charge (lighting) wire resistance, remsiance value. 1~0.2.0 G. Rectifier adjustor Inspection of rectifier adjuster is to measureresi stance between connectors, whichisnot easyin correct judgment. Comparison between the part in question and confirmed good rectifier adjusteris recommended 4.4 Trouble finding A No power supply + Battery over-discharging «No electrolytein-b attery + Improper wire connection + Poor power supply switch B. Lowvoltage + Inadequate battery charging *Poorterminal connection + Poor charging system + Poor adjustment ofadjusting rectifier C. Interrupted current * Poor contact of battery wires + Poor contact of charging system. * Poor contact of light system D. Poor charging system + Poor contact of wire terminals, breakage of circuit or short circuit * Pooradjusting rectifier + Poormagneto stator coil (Figure9.1) IX Crankcase and Crankshaft 1. Crankcase consists ofleft crankcase, right crankcase and crankshaft connecting rod 2, Crankease and crankshaft disassembling and inspecting 2. [Remove crankcasebolt M6x45. place left crankcae discharger below, remove sight crankcase, set case, seal gasket and remove crankshaft connectingrod assembly from leftcrankcase (Figure 9-1) 2Remove case paper gasket and oil deposit, letin compressed air through oil passagehole and inspectifoil passage holes are open and through, (Figure 9-2) 272 3Inpectif support frame mounting sleeves on =~ left and night crankcases are damaged © oillowtlet a Alnspectifoil geal 619.8 930xSisin good : i condition and if sealinglip is hardened SInspect the condition ofuse ofle# and right crankshaft bearing holes. Limit of use: left olinet 9 crankcase crankshaft borer47. 016mm, night 3 2 crankcase crankshaftbore 42. 0Lémm. agate? 2) 6Rotate crankshaft bearing to inspect if there is abnormal sound of looseness Ifthere is, replace crankshaft assembly. (Figure 9-3) Tingpect loo senessan directions X and Y at ‘haft right angle of crankshaft connect shaft right angle of crankshaft connecting ee rod big end, Limit of use: 1fX, Yradial gap > 0 05mm, effect replacement (Figure 9-4); (Figure 9-3) ifassembly play >0 Smm, effect replacement (Figure 9-3) SInspect for easy rotation of connecting rod crank, inspect wear of connecting rod small end bore, standardvalue: @13.024~@13 006mm, Limit ofuseif bore D>13.05mm, effect replacement (Figure 9-4) SInspect if there is wear or damage of timing chain sprocket aadifthereis, effectreplacement, (Figure 9-3) 2.10 Inspect crankshaft oscillation (Figure 9-5), limit of use =0.6mm 3 Mountinspectedand measured partsin an order reversed to that of di smounting When cranlecases are closed, rotate crankshaft connecting rodta ingpectits easy rotation (Figne 9-5)X. Timing Chainand Tensioner 1. It consists of timing chain, tensioner, tensioning plateassembly and guideplateassembly. 2 Taming chain and tensioner disassemtlingand inspecting 2 | Remove tensioner spring set bolt M&x@ spring, remove 2 bolts M61 6 and tensioner, (Figure 10-1) 2.2Place Left crankecase below, remove right craniccase, crankshaft and finally remove timing chain Figure 10-2) 2 3Remove tensioning plate set boltand draw out tensioning plate 2.4 Remove paper gasket material on the joining face between tensioner and cylinder body, inspect for normal extension of tensioner and fastness of trip If not, effect replacement (Figure 10-3) 2 STefisi oner spsing fre elength should be4Smm ~SOmm, Ifnot, effect replacement (Figure 10-4) Slaspectifthete is wear of damage oftiming chain. IPthefeis, effectreplacement Tinspectifthere is wear, damage or serious deformation oftensioning plate [fthere is, effect replacement. (Figure 10-4) 2. Binspectifthere is wear, damage or serious defonnation ofguide plate, (Figure 10-4) tengioning plate guide plate trip 1 moe (Figure 10-3) (Figiie 10:4) Mount inspectedand measured partsinan order reversed to that of disimountingas technically speci fied Note:A Torque oftensioner mounting bolt Méx16 10N.m B Torque of tensioner bolt M8x8: 6N.m C Apply sealing bond to both sides of tensioner sealing gasket XI Lubrication System 1 Lubrication system mainly consists of engine oil filter, engine oi! pump, engine oil passage, oiling plug, oid drain plugand engine oil gage, etc2 Lubrication system, (Figure 11-1) eng ine oil filter caaiae swing armishaft (Figwe 11-1) Engine oil ds filled through engine oil depth gage hole, filtered through strainer, pumped by engine oil pump to main oil passage, one branch flows nto crankshaft connecting rod through right crankcase shaft hole and is thrown to cylinder and piston and another branch flows into camshaft chamber through cylinder body and cylinder head oil passage, lubricates related parts and enters crankecase engine ail pool 3.Precautions + Usually, engine oil pump isnot disassembled. Effect replacement asa wholein ¢: condition, + After engine oil pump is mounted, inspectif oil pumping systemisnormal 4 Trouble finding 4. L Inadequate engine oil + Natural consumption of engine oil + Leakage ofengine oil + Wear of piston ring + Damage of valve rod oil seal 4.2 Engine bum + No oil pressure or low oil pressure * Clogging of engine oil passage + Absence of specified lubricant 5,Use and inspection 5.1 Engine volume inspection + Wheninspecting engine oil quantity, motoreyd e mustbe placed on alevel ground * Inspect engine quantity when engine has run, for 2-3 minutes and har paused for 2-3 minutes, + Measure engine o1] quantity vith oil depth gage, When oil level is below the lower limit position, add specified oil to bring oil level to the upper (Figure 11-2) 5,2Engine oil changing + Engine oil might flow out as engine warms up + Remove oi] drain plug to let out engine oil + Remove and clean oil strainer and related parte + Inspect O-ring and effect replacement an case ofdamage or hardening + Fill 900ml of engine oil when disassembling engine and ill 750ml of engine oil when changing engine oil. 2 ofpoor engine oil upper limit engine oil lower limit (Figme 11-2) 305. 3Correct remounting of parts after oil filling 5 4When dismounted engine oil pump isremounted. in engine, insp ectif engine oil enters camshaft cham) er, XII. Rear Transmission 1. Rear transmission mainly includes rear transmission: ‘box, brake shoe mounting shaft, bearing 6004-2RS, ‘bearing 6201/P6, bearsng 6303x3/-2/P63, output shaft.input shaft, output gear, intermediate gear shaft, oil seal, etc. 2 Rear transmission disassembling and inspecting 2, [Remove drivengear, unscrew ail drain bolt M&x12 and drain gear oil from transmission case (Figure 12-1) 2Place rear transmission case below, unscrew bolts M8x35 (bolts), M&x40 (Sholts), remove rear transmission case, take aut output shaft, output gear, intermedi ate gear and washers, (Figure 12-2 3Remove 2 set pins M10x20, remove paper gasket material of rear transmission case with shovel and cleanthem, (Figure 12-2) 2.4Unscrew nut MS, remove brake shoe mounting shaft (Figure 12-3) SInspectifthereis bum, wear or damage ofinput shaft, intermediate gear shaft output gearshaft and output shaft 2 Onspect ifthere is abnoral noise or loosening ofbearings. If there is, replace bearing with special bearing remover (Figure 12-4) 2. 7When replacing bearing 6004-2RS, remove oil seal 027x042x7 (Figure 12-3) before driving out bearing Mount inspected or replaced parts im an order reversed to that ofdismounting as specified Note ARemember to mount washers in intermediate gear shaft, B. Apply sealing bondto bothsides of rear transmissi on paper gasket: 31 oildiain pig (Figue 12-1) (Figme 12-4)C.Use brand new oil seal @27x042x7 and oil seal 917x0306 for replacement. Avoid tilting af oil seal and bending oflip D.Bearings must be correctly fitted to avoid slanting of flattening with bearing press-in depth and end run-out < 0.04mm. E Brake shoe mounting shaft O-ring should be replaced and coated with sealing bond. O-ring should be free from edge clipping F Torque ofbolts output M8*35 and M8*40; 20~-22N.m G.Atthe completion of rear transmission assembling, rotate input shaft or output shaft to ascertain casy rotation H This motorcycleis not equipped with gear oil chamber vent tube, When engine is slanted or with excessive engine oil, oil dripping might occur at labyrinth seal. The oil canbe wiped away or dripped out 1 After disassembling, 11 Oml gear oil should be added XIII. Carburetor 1. Precautionsin carburetor maintenance and adjustment * Gasoline is flammable, so worksite should be away from flame or clectric spark * Gasoline evap orates, so operations must be p erformed at awell-ventil ated place + When disassembling, loosen oil drain screwto let out gasoline into acontainer, * Clean carburetor with compressed air, + Drain gasoline from float bowl when carburetorisnot to be used for aperiod of time as gasoline kept for along time in float bowl would deteriorate and clog oil nozzle and would affe ct stability of engine performance 2 Basic structure ofcarburetor Diaphragm carburetor in BT] 39 engine maialy consists ofcontrolsystem, oil inlet system, low-speed oil supply system, high-speed oil supply system, startingprimervalve, accel erating priming device, ete 3.Carburetor disassembling, cleanin g and inspecting, Remove from motorcycle seat cushion and store box, loosen carburetor seat bolt, air filter air inlet pipe bolt B, loosenaut toremove oil valve cable and air inlet pipe and then dismount carburetor. (Figure!3-1) 3.1 Disassembling float bowl sump Remove float bowl connecting screw, float bowl sump and rubber seal gasket. (Figure 13-2) + Removeimpurities and residuein float bowl + Inspectif floatb owl seal gasketis hardened or damaged, Ifyes, effectreplacement erat float bow! sump aes (Figure 13-1) igure 13-2)3 2Float disassembling and adjusting F Remove screw. float and needle valve. (Figure 13-3) Remove impurities on float surface; Remove impurities and condensed gel in gasoline on contact face between needle valve and valve seat Inspectif wear of needle and wear of valve seatis senous, sf yes, repl aceneedle valve. In case ofnecessity, adjustaeedle hanger to enable float to keep required oil level 3.3Main nozzle andidler nozzle disassembling and inspecting Use special tools to prevent deformation of parts en Remaye main nozzle and idler nozzle (Figure 13-3) ee ideeitiweae! Clean main nozale andidler nozzle with carburetor (Piguet u gue 13-3) special cleaning solvent or industrial gasoline Clean all jets with compressed air. Do not wipethem with flashing cloth or paper so as to avoid recontamination + Never poke main nozzle oridler nozzle with hard objects such as changesin carburetor performances due to changesin bores 3 4Diaphragm vacuum piston valve disassembling and inspecting Unscrew 2 screws of carburetor top cover, remove diaphragm, remove retum spring. diaphragm vacuum piston valve oil needle (Figure 13-4) + Inspectif free extension of springisnormal and if not, effectreplacement: (Figure 13-5) * Clean diaphragm vacuum pinstan valve with compressed air and inspect if diaphragm isin good state andifnot, effect replacement. (Figure 13-5) + Inspect fail needle is deformed or worn andif 0-ringisin good state, and ifnot, effect replacement, (Figure 13-6) steel wire so as to avoid pamer bolt diaphragm cece cover tok statingprimer vale (Figure 13-4) oil needle \ \ O-shape sealing sing | | Mlauxed gisadjutngsaen (Figme 13-7) 333 SStarting primer valve disassembling and inspecting Remove ? bolts and starting primer valve (Figure 13-4) + Inspect if thereis damage of starting primer valve O-shape seal ring andifthereis, effect replacement: + Clean with compressed air starting pri mer valve and priming pas sage of carburetor: (Figure 13-7) + Inspect primer valve plunger movement minutes after starting primer valve circuitison lfprimer plunger extends as spring extends, primingis normal, 1fnot, heater in primer valve is damaged and priming valve assembly should be replaced 3.6Mount carburetor parts in an orderreversed to that ofdismounting, noting + Never effect one-step tightening of connecting screws of float bowl, tighten them in two or three steps at a tightening torque of 12 ~15N.m. Otherwise deformation of connecting face oroil leakage or air Leakage shall occur Tightening torque ofjet partsis usually 1,5~3 ON m. Excessive torque shall damage thread and lead to deformation ofparts ‘When mounting diaphragm piston valve, note that sting on diaphragmis aligned with drop pit of carburetor soasto allowonly the covering of diaphragm riminstead of the complete covering of diaphragm by covering plate. (Figure 13-8) Ag position ofidlemaxed gas adjusting screwis vital to the performance of motorcycle exhaust, idle speed, transition and oil consumption, idle mixed gas adjusting screw is usually not turned when cleaning carburetor (Figure 13-7). Intime of absolute necessity for dismounting, tum it home while remembering thenumber of tums (accuarate to 1/8 turn) and when mounting, tum it backin the same number of turns, Standard turns o funscrewing 2+1/2 turns. 4 Carburetor idle speed adjustment 4.1Carburetor lower idle speed adjustment Misfire soon after engine starting is duc toinadequate opening ofoil valve. Turn clockwiseidle speed (Figue 13.8) adjusting screw on control system racket (Figure 13-9). When engine speedis too high, turn it out counterclockwise and when engine speedis too lower, adjust engineidle speed to about 1900+ (SSQSLREIER! 100r/min. bracket 4.2Carburetorunstablei dle speed adjustment Instability of idle speed: After a fewminutes running of engine, speed fluctuates between + 100r/min In such case, adjustidle speed mixed gas adjusting screwto optimal position for solution Themethod isas follows First, adjustidle speed adjusting screw on control system racket to an engine speed slightly higherthanusual speed. Turn idl e speeded gas adjusting screw right and leftto find the highest speed at this position, then slightly adjustidle speed adjusting screw to alower engine sp ced and turn idle speed mixed gas adjusting screw to find the highest speed. Repeat this operation till a certain speedis equal to standard idle speed adjusting screw (Figue 13-9) 34,5 Carburetor troubleshooting andmaintenance Carburetor's fonction is to ensure suitable supply of gasaline-ait mixed gas to en gine under different working conditions. As oil gas poresin many carburetor parts are small, they are apt to be deformed or clogged and as aresult, the function of carburetor may change and troubles in motorcysle riding may occur dueta impurities, colloid or impurities in the air. Carburetor troubles and troubleshooting are as follo ws: 5, [Difficult starting Difficult starting means that engine does not keep continuous running after 15 -minute kick starting or electric starting with correct operation of handlebar oil valve. Main causes of troubles and correspanding troubleshooting methods A. Absence of fuelin carburetor float bowl. Cause: Clogged oi! inlet passage Troubleshooting: Remove carburetor float bowl cover, clean allitsparts, inspect all the oil passages and ait passanges, inspect the function of fuel filter andifitis defective, effect replacement. B. Ineffective priming device: Causes: 3-~5 minutes after motoreycle electric switch is tumed on, touclthe plastic outer case ofelectrothermal starter. The circuitis normal ifitis warm and if otherwise, inspect circutt. In vase electric circuit is normal, primer is defective Troubleshooting: The seine as disassembling and inspe above 5,2Poor transition Inthe process ofaccelerating, engine speed remarkably fluctuates or misfires A Cause: Clogging of carburetorjets or foam pipes Troubleshooting: Clean as carburetor is cleaned as stated above B Cause: In the process of transition, oil supply to carburetoris mainly fromidle speed oil system and in caseidle systemisnotin good condition, transition shall be affected. Troubleshooting: Ajust idle spect! adjusting screw to find optimal adjustment p ovition for adjustment, as stated above 5. Inadequate power It finds cxpression in inadequacy in accelerating function and high-speed function + An obvious feeling ofreduced accelerating and dni ving function + Reduced high-speed with “thrust” of motorcycle and abrupt air-bleeding from exhaust pipe A.Cause Clogging of idle speed oil nozzle ormain oil nozzle Troubleshooting, Clean as carburetoris cleaned, as stated above, B.Cause. Clogging ofidle speed oil passage, air passage, main oil passage of air passage Troubleshooting Same as above. C Cause: Clogging of quick priming device or ineffective diaphragin Troubleshooting: Clean accelerating pump oil passage with compressed air, inspect if diaphragm is effective andifnot, effect replacement. 5 Alnregular oil lewel of carburetor leading to irregular oil supply Cause: A. Foreign matter on contact face between needle valve and valve seat, B Wornneedle valve, D.Floatwith mould or fracture leading to oil leakage Troublingshoating A. Cleancarburetor; B. Replace needle-valve; A Clean carburetor and replace float nig of starting primer valve stated XIV. Air Filter Lousen carburetortube clamp screw (Figure 14-1), loosen vent pipe circlip and remove 2 balts Méx 30 (Figure 14-2) which connect air filter and case body Remove air filter, air filter cover screw and parts (Figure 14-1)Inspect all parts andif they are dirty, clean them andin case of damage, effect repair or replacement, Air filter straner (Figure 14-3) maintenance and service intervals: inspector replace every 5000km. After cleaning, apply a small amount of grease to strainer to increaseits absorptivity to dust, Mountinspected and cleaned parts in an orderreversed to thatof dismounting a_i a Son ~ al Se stramer - a < EEE (Figme 14.2) (Figite 14.3) 36ATTACHED PAGES SPECIAL TOOLS Valve adjusting fixed wrench (202) Flywheel remover (Z01) Spark plug special sleeve (203) Universal tools Fixing bracket (Y01) Qe eee(C Closed wrench 9# (Y02) “T" sleeves’, 10". 12. 14°, 17 (Js TIO, TI; Ty TLD 37Hexagon wrench 3# (03) “4” screwdriver (YDS) Sharp-nowe pliers (07) Ratchetwrench (Y09) Internal thread sorew driver head; M6X1 M7X1.25 (YM6, YM7) Spade ¢y04) Rubbermallet (Y06) Clip ring pliers ( Y08) ee Sleeves 144, 17# (YTI4, YTI7) — =) Round head screwdriver (Y10) 38