Baotian BT50QT-9 Manuale utente
BT50QT-9&BT49QT-3
SERVICE MANUAL
JIANGMEN SINO-HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO., LTD
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CONTENTS
CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE
Ⅰ. ITEMSOFMAINTENANCE 1
Ⅱ. PERIODIC MAINTENANCE SCHEDULEAND MAINTENANCE LOCATIONS 1
Ⅲ. MAINTENANCE SPECIFICATIONS 4
Ⅳ. THROTTLE ACTUATION INSPECTION 5
Ⅴ. AIRFILTERINSPECTIONANDCLEANING 6
Ⅵ. REARBRAKEFRICITIONLININGINSPECTION 6
Ⅶ. BRAKE SYSTEM INSPECTION, ADJUSTMENTAND REPLACEMENT 7
Ⅷ. FRONTAND REAR SHOCK ABSORBER INSPECTION 8
Ⅸ. FRONTWHEELANDREARWHEELINSPECTION 9
Ⅹ. STEERING STEM INSPECTION 10
CHAPTER TWO MAINTENANCE INFORMATION
Ⅰ. FRAMENUMBERANDENGINENUMBERLOCATION 11
Ⅱ. PRECAUTIONSINOPERATION 11
Ⅲ. SPECIFIEDTORQUES 12
CHAPTER THREE BODY TROUBLESHOOTING
SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION 14
SECTION TWO DETAILED DESCRIPTIONS OF BODY PARTS TROUBLES
Ⅰ. FRONTWHEELSERVICE 17
Ⅱ. FRONTBRAKESERVICE(DISKBRAKE) 19
Ⅲ. FRONTSHOCKABSORBERSERVICE 21
Ⅳ. FRONTFORKSERVICE 22
Ⅴ. HANDLEBARSERVICE 24
Ⅵ. REARWHEELSERVICE 25
Ⅶ. REARBRAKESERVICE 26
Ⅷ. REARSHOCKABSORBERSERVICE 28
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CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE
Ⅰ. ITEMS OF MAINTENANCE
When the motorcycle is used, loosening of parts and mechanical wear inevitably occur to
varied extents. Neglect of timely maintenance not only reduces its mechanical function,
economic performance, stability and durability, but also threatens the safety of the motorcycle
and the rider. Correct and timely maintenance of the motorcycle is a must. Items of maintenance
refer to the parts and positions for maintenance. Different items of maintenance are effected at
different intervals and in different manners.
1. Running-in Maintenance
This is the maintenance at the end of the first 1000km and is an all-round inspection of the
motorcycle. A newly-bought motorcycle or a motorcycle fresh from an overhaul might be
severely overheated as a result of severe friction between the moving parts which might be
imperfect in finishing or fitting. Neglect in use might lead to damage of the friction surfaces and
might threaten the performance, and the service life, of the motorcycle. Please observe the
following points:
zRestrict the speed in speed range specified in the instruction manual.
zRestrict the load to 2/3 of the maximum load and ride in fairly good road conditions.
zRestrict the length of riding time to avoid long-time running of the engine.
zReplace engine oil at short intervals so that metal chips caused in the running-in period
can be discharged. It is recommended to replace engine oil for 3 times during the
running-in period.
2. Routine Maintenance
Routine maintenance is the basis of all kinds of maintenances. It refers to the daily
maintenance, including cleaning, inspection and common troubleshooting.
3. Periodic Maintenance
This maintenance is to restore normal performance of the motorcycle. The maintenance is
classified into first-grade periodic technical maintenance and second-grade periodic technical
maintenance (also known as items of maintenance) according to different mileages. Generally
speaking, a first-grade maintenance is effected after the initial 4000km and a second-grade
maintenance is effected every 8000km. As the service time extends, maintenance intervals
should be shortened accordingly.
Ⅱ. PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS
After a period of use (one day, one month or half a year, for example) or a certain mileage
(1000km, 4000km, 8000km, for example), an all-round maintenance operation should be
effected, including comprehensive inspection, adjustment, tightening, lubrication, cleaning or
replacement. The specific regulation made according to time intervals or mileages is known as
maintenance interval. The motorcycle maintenance schedule is as follows.
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1. Maintenance Schedule
Maintenance Schedule
time
item Mileage 1000km
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000
Engine oil New R
300km R R R R R R R R R R R
Engine oil
strainer C C
Gasoline
strainer R
Gear oil Note 4 New R
300km R R
Throttle play A A A A
Carburetor I I C
Air filter Note 3,
4 I R R
Spark plug Clean every 3000km, replace when necessary
Brake system I I I I I I I I I I I I
Drive belt I
Suspension I I I
Tire I I I
Steering rod
bearing I I I
Screws and
bolts of parts I I
Rear brake
cam C
Notes:
1. I: Inspect and when necessary, clean, lubricate, supplement, modify or replace;
A: adjust; C: clean; R: replace; T: tighten.
2. Effect periodic maintenance according to the instructions in the user’s manual.
3. When the mileage exceeds the range specified in the schedule, repeat the maintenance.
4. In dusty or rainy conditions, inspection and replacement should be effected earlier.
5. In heavy load, long distance or rainy conditions, replacement should be effected earlier.
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2. Maintenance locations
Throttlegrip
actuation,play
£¨£©
Oiltank
brakeoillevel
£¨£©
Frontshockabsorber
damage,loosening
£¨£©
Rear tire
wear,damage,tirepressure
£¨£©
Rear rim
damage,oscillation
£¨£©
Frontrim
damage,oscillation
£¨£©
Fronttire
wear,damage,tirepressure
£¨
£©
Headlight
beam adjustment
£¨£©
Rear brake rod
free play
£¨£©
Rear shock absorber
damage,loosening
£¨£©
Airfilter
contamination
£¨£©
Frontbrakedisc
damage,wear
£¨£©
Frontbrakecaliper
wear of friction lining
£¨£©
Rear brake
wear of brake drum,
damage,wearoffrictionlining
£¨ £©
gearcase
engine oilquantity,
oilreplacement
£¨ £©
Sparkplug
damage,contamination
£¨£©
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Ⅲ. MAINTENANCE SPECIFICATIONS
The basic methods of motorcycle maintenance include inspection, adjustment, tightening,
lubrication, cleaning, supplementing and replacement, which constitute the main elements of
maintenance.
1. Inspection
Inspection refers to basic inspecting operations in accordance with items and
requirements specified in the user’s manual, including inspection with instruments or
with eyes for abnormalities in machine parts, directly comparing related data and
aligning with tools and gauges.
2. Adjustment
Adjustment refers to inspection-based adjustment and rectification of some specified
machine parts, including adjustment of machine part plays and rectification of
misfittings and deformations so as to restore correct positions, forms and plays.
3. Tightening
Tightening refers tightening of bolts, screws and nuts of machine parts with tools so as
to avoid loosening of machine parts and to obtain specified tightening torques.
4. Cleaning
Cleaning is needed by machine parts and positions which call for cleanliness and
tidiness. Cleaning operations include all the means and measures taken to remove dust,
contamination, metal chips, oily stains and carbon deposits that might lead to pipe
clogging or reduction in motorcycle performance. Cleaning measures are washing,
carbon deposit removing, rubbing, cleaning and clearing.
5. Lubrication
In order to facilitate smooth and easy running of moving machine parts, including
swinging parts, reciprocating parts, sliding parts and vibrating parts, to reduce scuffing,
abrasion, deformation and to reduce friction, it is necessary to coat or spray these parts
with a lubricant. Different lubricants and lubricating methods are required for different
machine parts with different functions. Application of lubricants to machine parts is
known as lubrication.
6. Replenishing, supplement and replacement
These operations refer to addition of oil, lubricants, cooling water, electrolyte, fuel and
replacement of damaged parts with new ones and replacement of denatured oils with
new oils.
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IV. THROTTLE ACTUATION INSPECTION
Inspect throttle grip for easy and smooth
movement.
Inspect throttle free travel.
Free travel: 2-6mm
The main adjusting position is beside the
carburetor.
Remove rear store case cover.
Adjust by loosening the fastening nut and
turning the adjusting nut.
Fine adjustment is effected on the side of
the throttle grip.
Effected adjustment is by removing the dust
cover, loosening the tightening nut and turning
the adjusting nut.
adjustingnut
tighteningnut
free travel:2-6mm
adjusting nut
dust cover tightening nut
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Ⅴ. AIR FILTER INSPECTION AND CLEANING
After a certain mileage, dust and impurities will gather in air filter case and strainer, which
will clog strainer pores and reduce inlet of air and thus lead to excessive concentration of mixed
gas and reduce the performance of engine. That’s why the strainer must be cleaned every
2000-3000km and in dusty or rainy conditions strainer must be cleaned or replaced earlier.
Remove 5 tightening bolts of air filter.
Remove strainer cover.
Take out the foam strainer.
Immerse foam strainer in gasoline and wash
it to remove dust and impurities by gripping and
pressing.
Press gasoline out of the foam.
Soak the cleaned foam with engine oil, press
out or throw out engine oil to leave it moist with
oil.
Mount.
VI. REAR BRAKE FRICTION LINING INSPECTION
If the arrow on brake swing arm is aligned
with the scotch on gear case when brake lever is
drawn to the stopping position, friction linings
must be replaced with new ones.
6
cleaning gripping gasoline soaking gripping
arrow scotch
air filter
bolt
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VII. BRAKE SYSTEM INSPECTION, ADJUSTMENTAND REPLACEMENT
1. Front brake (disk brake)
Remove the bolts linking brake caliper and
front shock absorber;
Remove brake caliper.
* Do not pull brake lever when brake caliper is
removed so as to prevent jamming of brake
block.
If brake block is jammed, pry it with
screwdriver and push piston back into caliper.
Brake Block Replacement:
Brake block must be replaced when it is worn
to the limit of use.
* It is not necessary to remove brake oil pipe
when replacing brake block.
* Brake block must be replaced as a set.
Remove the brake block pin by means of a
hexagon wrench.
Return brake caliper left part counter-clockwise,
remove old brake block and mount new brake
block.
Effect mounting in an order reversed to that of
dismounting.
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brake caliper
bolts
front shock absorber
brake block
brake caliper
brake caliper left part
brake block pin
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Brake Disc Inspection:
Inspect brake disc thickness.
Limit of use: 3.0mm
Inspect brake disc angularity.
Limit of use: 0.3mm
2. Rear Brake
Inspect rear brake lever free travel.
Free travel: 10-20mm
Turn adjusting nut to effect adjustment
when free travel exceeds limit.
VIII. FRONTAND REAR SHOCK ABSORBER INSPECTION
1. Front ShockAbsorber
Tighten front brake lever, press front shock
absorber up and down and inspect actuation.
Inspect front shock absorber to see if there is
leakage of oil and if there is damage or loosening.
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rear brake lever
adjusting nut
front brake lever
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