Baotian BT49QT-7 User manual

BT49QT-7&BT49QT-8
SERVICE MANUAL
JIANGMEN SINO-HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO., LTD

CONTENTS
CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE
. ITEMS OF MAINTENANCE 1
. PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS 1
. MAINTENANCE SPECIFICATIONS 4
. THROTTLE ACTUATION INSPECTION 5
. AIR FILTER INSPECTION AND CLEANING 6
. REAR BRAKE FRICITION LINING INSPECTION 6
.
BRAKE SYSTEM INSPECTION, ADJUSTMENTAND REPLACEMENT 7
.
FRONTAND REAR SHOCKABSORBER INSPECTION 8
. FRONT WHEELAND REAR WHEEL INSPECTION 9
. STEERING STEM INSPECTION 10
CHAPTER TWO MAINTENANCE INFORMATION
. FRAME NUMBER AND ENGINE NUMBER LOCATION 11
. PRECAUTIONS IN OPERATION 11
. SPECIFIED TORQUES 12
CHAPTER THREE BODY TROUBLESHOOTING
41NOITCETEDELBUORTDNASELBUORTNOMMOCYDOBENONOITCES
SECTION TWO DETAILED DESCRIPTIONS OF BODY PARTS TROUBLES
. FRONT WHEEL SERVICE 17
91)EKARBKSID(ECIVRESEKARBTNORF.
. FRONT SHOCK ABSORBER SERVICE 12
. FRONT FORK SERVICE 22
42ECIVRESRABELDNAH.
. REAR WHEEL SERVICE 25
62ECIVRESEKARBRAER.
. REAR SHOCK ABSORBER SERVICE 28
CHAPTER FOUR ELECTRIC PART TROUBLESHOOTING
SECTION ONE ELECTRIC PART COMMON TROUBLES AND TROUBLE DETECTION 29
SECTION TWO DETAILED DESCRIPTIONS OF ELECTRIC ASSEMBLIES AND PARTS SERVICE
. PRECAUTIONS IN ELECTRIC CIRCUIT SERVICE 32
. POWER CHARGING SYSTEM SERVICE 32
. IGNITION SYSTEM SERVICE 38
. ELECTRIC STARTING SYSTEM SERVICE 44
. LIGHTING AND SIGNAL SYSTEM SERVICE 45

1
CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE
. 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. Anewly-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:
Restrict the speed in speed range specified in the instruction manual.
Restrict the load to 2/3 of the maximum load and ride in fairlygood road conditions.
Restrict the length of riding time to avoid long-time running of the engine.
Replace 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.
. 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.
1. Maintenance Schedule

2
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,
4I R R
yrassecennehwecalper,mk0003yrevenaelCgulpkrapS
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, modifyor replace;
A: adjust; C: clean; R: replace; T: tighten.
2. Effect periodic maintenanceaccording to the instructionsin the user’s manual.
3. When the mileage exceeds the rangespecified 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.
2. Maintenance locations

3
Throttle grip
actuation,play
£¨ £©
Oil tank
brake oil level
£¨ £©
Front shock absorber
damage,loosening
£¨ £©
Rear tire
wear,damage,tire pressure
£¨ £©
Rear rim
damage,oscillation
£¨ £©
Front rim
damage,oscillation
£¨ £©
Front tire
wear,damage,tire pressure
£¨
£©
Headlight
beam adjustment
£¨ £©
Rear brake rod
free play
£¨ £©
Rear shock absorber
damage,loosening
£¨ £©
Air filter
contamination
£¨ £©
Front brake disc
damage,wear
£¨ £©
Front brake caliper
wear of friction lining
£¨ £©
Rear brake
wear of brake drum,
damage,wear of friction lining
£¨ £©
gearcase
engine oil quantity,
oil replacement
£¨ £©
Spark plug
damage,contamination
£¨ £©

4
. 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.

5
IV. THROTTLE ACTUATION INSPECTION
Inspect throttle grip for easy and smooth movement.
Inspect throttle freetravel.
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 theside of the throttle grip.
Effected adjustment is by removing the dust cover,
loosening the tightening nut and turning the adjusting nut.
. 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
free travel:2-6mm
adjusting nut
tightening nut
adjusting nut
dust cover
tightening nut

6
2000-3000kmand 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
dustand 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 bereplaced with new ones.
VII. BRAKE SYSTEM INSPECTION, ADJUSTMENTAND REPLACEMENT
1. Front brake (disk brake)
Remove the bolts linking brake caliper and frontshock
absorber.
Remove brakecaliper.
cleaning gripping gasoline soaking gripping
arrow scotch
brake caliper
bolt
front shock
bolt
absorber
air filter
bolt

7
* Do not pull brakelever when brake caliper is removed so
as to prevent jamming of brake block.
If brake block isjammed, pryit 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 necessarytoremove brake oil pipe when
replacing brake block.
* Brake block must be replacedas aset.
Remove two pieces of brake block pins by means of a
hexagon wrench.
Effect mounting in an order reversedto that of dismounting.
*After effecting, first tighten the brake caliper and put its
hole right to the hole of brake caliper and then put the brake
block pin in and tighten it.
Brake Disc Inspection:
Inspect brake disc thickness.
Limit of use: 3.0mm
Inspect brake disc angularity.
Limit of use: 0.3mm
2. Rear Brake
brake block
brake caliper
brake block pin
brake block pin
press brake block
rear brake lever

8
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 brakelever, press front shock absorber up
and down and inspect actuation.
Inspect front shock absorber to see if there is leakage of oil
andif there is damage or loosening.
2. Rear ShockAbsorber
Press rear shock absorber to inspect actuation. Inspect rear
shock absorber to see if there is oil leakage and if there is
damage or loosening in machine parts.
Lift rear wheel, press rear wheel right and left to inspect if
engine suspensionlug buffer bushis loose.
IX. FRONT WHEEL AND REAR WHEEL INSPECTION
Wheel Rim Inspection:
adjusting nut
front brake lever

9
Inspect wheel rim, remove rust stains and rubber chips.
Deformation and fissures are causes of air leakage. Do not use wheel rims in the following
cases:
Bruise of wheel rim face contacting tire bead ring exceeds 0.5mm in depth and 1.0mm in
width.
Tire Inspection:
Inspect if there is fissure or iron nail in the tire.
In one of the following conditions,tires must be replaced instead of repair.
Puncture of tire bya foreigner matter 6mm in diameter or tirefissure.
Layered tire.
Chunking of tread
Damaged tire bead
Broken tire bead or other tire bead damages
Broken tire cord
Damage due to forced dismounting
Fissure extending to frame
Abnormal inner lining
Tire groove wear: front wheel <0.8mm, rear wheel <0.8mm.
Puncturedor otherwise damaged tire flank
Inspect tire pressure by means of atire pressure gauge
* Tire pressure should be inspected when the motorcycle is in a cold state.
Specified pressure Unit: kPa
Front wheel 250
Rear wheel 250
Tire Specifications:
Front wheel 120/70 -56J
Rear wheel 3.50-10 -51J
Inspect if frontwheel nutis loose.
Inspect if rear wheel nut is loose.
If loose, tighten them to specifiedtorques.
front axle nut

01
Torques: front wheel nut 60N·m
rear wheel nut 120N·m
X. STEERING STEM INSPECTION
Swing handlebar right and left to see if there is
interference such as wire or other things.
Turn front wheel to see that handlebar is easy in operation.
In case of any difficulty in operation, inspect steering stem
bearing assembly.
CHAPTER TWO MAINTENANCE INFORMATION
I. FRAME NUMBER AND ENGINE NUMBER LOCATION
engine number
frame number

11
II. PRECAUTIONS IN OPERATION
Removed washers, 0-rings, elastic retaining rings and split pins must be replaced with new
ones.
When mounting bolts, nuts andscrews, proceed fromtrial tightening, from larger
diameters to smaller diameters and inner ones to outer ones in a diagonallyorder. Tighten
themto specific torques.
Parts and greases must be those made by our factoryor recommended by our factory.
Special operations must be effected with specialtools or specified universal tools.
Removedparts must be rubbed or cleaned before they are inspected or measured. They
must be coated on the sliding facesbefore mounting.
They must be greased at the specified positions with designated or equivalentgreases.
Parts must be tightened and their performances inspected at their positions when mounted.
The battery’s negative terminal must be disconnected before operation.
Make surethat tools such as wrenchesare not in contact with theframe.
At the completion of operations, reconfirmcorrect connections and fastenings.
The positive terminal must be connected first in case of a removed battery.
Connected terminals must be coated with lubricant.
The terminals must be completely covered with caps.
When a fuse is burnt, inspect the cause and replace the fuse with a fuse of equivalent
capacity.
At the completion of operation,completelycover terminals with caps.
When removing connectors with locks, they must be unlocked before operation.
When removing connectors,the connectors proper must be held instead of pulling their
wires.
Before connecting connectors, confirmthat they are free from breakage, bending, over
length or loosening.
Connectors must be inserted home.
When connecting connectors with locks, confirmthat their locks are fastened.
Confirm that the wires are not loose.
Confirmthat connectors’plastic sleeves completely cover the connectors without fail.
Before connecting the connectors, confirmthat their sleeves are free from breakage and
their terminals are not oversized.
Connector plugs must be fully inserted.
Confirmthat plastic sleevescompletely cover the terminals.
Plasticsleevesshould not be placed with the open side up.
Wire bunch bands should be fixedat the specified positionof motorcycle frame.
Wire clamps must correctly keep wires in place.
Avoid welding stains of welded clamps when clamping wires.

21
Wire bunches must be fixed away from turning or moving parts.
Do not damage the covering of wire bunches.
In caseof wire bunch defects, remedyit withinsulating bands.
Wire bunches must notbe covered with mounted parts.
Do not twist or bend cables by force. Deformed or damagedcables wouldresult in poor
rotation or damage.
III. SPECIFIED TORQUES
Torques at important positions and standard torques of other positions are as follows:
SPECIFIED TORQUES
Frame:
Designations of tightening positions Number Threadspecification Torques: N·m
Engine suspension lug mounting nut 1 M10 45
Engine mounting nut 1 M10 45
Front axle nut 1 M12 60
Rear axle nut 1 M16 120
Rear shock absorber upper mounting bolt 1 M10 40
Rear shock absorber lower mounting bolt 1 M10 25
Front shock absorber upper lock bolt 4 M8 35
Steering stem lock nut 1 M25 70

31
Handlebar mounting nut 1 M10 45
Upper bearing top 1 M252.5
Exhaust muffler connector nut 2 M6 12
Exhaust muffler mounting bolt 2 M8 35
Standard Torques:
N:seuqroTsnoitangiseD ·m
Bolt, nut M5 5
Bolt, nut M6 10
Bolt, nutM8 21.5
Bolt, nut M10 35
Bolt, nut M12 55
Screw M5 4
Screw M6 9
Flange bolt, nut M6 12
Flange bolt, nut M8 27
Flange bolt, nut M10 40
CHAPTER THREE BODY TROUBLESHOOTING
SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION
Body part common troubles and possible causes are as follows:
)ecnerefer(sliateDsesuaCselbuorT
Over tightening of handlebar adjusting nutHandlebar rotation not
easy (strenuous turning
or unstabletightness) Steering stem over worn Refer to “Front Fork
Service”
Incorrect mounting of brakecable or
tachometer cable
Refer to “Handlebar
Service”, “Front Fork
Service”
Heavy steering stem
turning
Remarkable deformation of steering stem
due to outside impact Refer to “Front Fork
Service”

41
Over tightening of steering stemtop ball
bearing retainer
Damaged or broken ball bearing
Reduced tire air Refer to “Front Wheel
Service”, “Rear Wheel
Service”
Imbalanceof right and left shock absorbers Refer to “Front Shock
Absorber Service”
Bent front fork Refer to “Front Fork
Service”
Deflected steering stem
Bent front tire, deflected tire Refer to “Front Wheel
Service”
Normal wear of brake lining
Hardened brake block or dustyblock
Excessive front brake and rear brake
Damaged brake cable
Brake camrotation not easy
Worn brake block
Drum brake failure
Worn or slotted brake drum bore
Refer to “Brake System
Inspection, Adjustment
and Replacement”,
“Rear BrakeService”
Bentbrake lever
Air in hydraulic device
Leakage in hydraulic
device
Disk brake failure Feeble brake
lever
Clogged hydraulic
passage
Refer to “Brake System
Inspection, Adjustment
and Replacement”,
“Front Brake Service”
Chart continued
)ecnerefer(sliateDsesuaCselbuorT
Inadequate liquid
Contaminated brake
block and brake disc
Bent or deformed brake
disc
Contaminated brake
caliper
Worn seal ring of brake
caliper piston
Disk brake failure Feeble brake
lever
Viscous or worn brake
caliper piston
Refer to “Brake System
Inspection, Adjustment
and Replacement”,
“Front Brake Service”

51
Inability of brake caliper
normal sliding
Worn main cylinder
piston sealring
Viscous or worn main
cylinder piston
Contaminated main
cylinder
Clogged narrow brake
system
Clogged narrow liquid
passage
Viscous worn brake
caliper
Inability of brake caliper
normal sliding
Worn seal ring of brake
caliper piston
Stiff brake lever
Viscous or worn main
cylinder piston
Contaminated brake
block and brake disc
Bentor deformed brake
disc
Inability of brake caliper
normal sliding
Resisted
braking
Wheelnot adjusted
straight
Chart continued
)ecnerefer(sliateDsesuaCselbuorT
Hardened brake block surface or dusty
block
Uneven or slotted brake block surface
Serious wear of brake blocklining
Abnormal braking sound
Serious slots inside brake drum
Refer to “Rear Brake
Service”
Steering stem rotation not easy Refer to “Front Fork
Service”
Bentshock absorber
Deviation of motorcycle
direction (inclining to
roadside)
Shock absorber oil leakage
Refer to “Front Shock
Absorber Service”

61
Bent front axle, incorrect wheel
mounting
Roundness error of wheel rim
Deformation of wheel rim
Inadequatetire pressure
Refer to “Front Wheel
Service”
Deformed wheel rim
Loosefront wheel bearing
Poor tire
Front wheel oscillation
Poor axle locking
Refer to “Front Wheel
Service”
Soft frontshock absorber Springfatigue Refer to “Front Shock
Absorber Service”
Deformed wheel rim
Rear wheel oscillation Poor wheel
Refer to “Rear Wheel
Service”
Soft rear shock absorber Spring fatigue Refer to “RearShock
Absorber Service”
SECTION TWO DETAILED DESCRIPTION OF BODY PARTS TROUBLES
Precautions in Operation:
Forced mounting or dismounting of body cover parts will cause damage to claws and slots of
corresponding hoods.
When mounting body coverparts,besure to align the corresponding parts of hoods.
When mounting body coverparts,avoid pressing wires, cables or pipes.
-
I. FRONT WHEEL SERVICE
Front Wheel Dismounting:
Support the body bottom to lift front wheel.
front shock
front axle nut
front axle
absorber

71
Remove front axle nut, brake calipers, front absorbers
connecting bolt and remove brakecalipers,front shock
absorber, transmission gear box,frontaxle bushand the small
bush, remove front axle.
Remove front wheel.
Remove brake disc mounting bolts.
Remove brake disc.
Axle Bending Inspection
Place axle on a V-seat and measure with a dial gauge.
The dial gauge indicates a 1/2 bending value.
Limit of use: Replace if >0.2mm.
Wheel Rim Oscillation Inspection
Measure oscillation value on a correcting bench.
Limit of use: Replace if >2.0mm.
Traverse direction: Replace if >2.0mm.
brake disc
brake caliper
bolt
front axle
mounting bolt
front wheel
front shock
absorber
front axle bush
small front axle bush

81
Front Wheel Bearing Inspection
Removefront wheel bearing and dust cover.
Turn bearing inner race to inspectsliding. Replaceitwith a
new one in case of no sliding or damage or loosening of outer
race.
Front Wheel Bearing Replacement
Dismounting: Remove front wheel bearing by means of a
bearing remover, take out spacer.
Mounting: Apply grease to the bearing.
Drive in left bearings.
Mountspacer.
Drive in right bearings.
Bearings must be driven in parallel.
Dust cover must be driven in with the face out.
Applygrease to new dust cover lip.
Mount front axle bush.
Front Wheel Mounting
Mount brake disc, tighten brake disc mounting bolts.
Torque: 27N·m
Spread front axle with a thin film of grease.
Mount front axle from left side.
Mount inorder small bush, left front shock absorber, bush, front wheel, transmission gear box,
rightfront shock absorber, frontaxle nut and fasten it.
dust cover front axle bush