Generic Onyx 50 User manual

Service Manual
Holtvej 8-10, Høruphav, 6470 Sydals
Telefon: [phone]
Fax: [phone]
[email protected] · www.scanmi.dk
CVR: 27 73 31 07
www.genericmotor.dk
Juli 2011
ONYX
50

ONYX
Service Manual
Generic Motor GmbH

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Contents
Contents................................................................................................................................................ - 1 -
Preface.................................................................................................................................................. - 7 -
Preparing documents....................................................................................................................... - 8 -
Inspection/Adjustment................................................................................................................... - 38 -
Inspection and maintenance of electrical system...................................................................................... - 53 -
1. Battery/charging system.................................................................................................................... - 55 -
1.1 Preparing documents ............................................................................................................... - 55 -
1.2 Failure diagnosis ..................................................................................................................... - 56 -
1.3 Battery ................................................................................................................................... - 57 -
1.4 Charging system...................................................................................................................... - 58 -
1.5 Rectifier ................................................................................................................................. - 59 -
1.6 Magnetor charging coil ............................................................................................................ - 60 -
1.7 Replacement of magnetor......................................................................................................... - 61 -
2. Ignition system................................................................................................................................. - 64 -
2.1 Preparing documents ............................................................................................................... - 64 -
2.2 Failure diagnosis ..................................................................................................................... - 65 -
2.3 Checking the ignition system.................................................................................................... - 66 -
2.4 CDI Group.............................................................................................................................. - 68 -
2.5 Ignition coil ............................................................................................................................ - 69 -
2.6 Trigger ................................................................................................................................... - 70 -

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3. Activation system............................................................................................................................. - 72 -
3.1 Preparing documents ............................................................................................................... - 72 -
3.2 Failure diagnosis ..................................................................................................................... - 73 -
3.3 Starting motor ......................................................................................................................... - 73 -
3.4 Starting relay .......................................................................................................................... - 75 -
4. Bulbs/Switches/Meters...................................................................................................................... - 79 -
4.1 Preparing documents ............................................................................................................... - 79 -
4.2 Failure diagnosis ..................................................................................................................... - 79 -
4.3 Headlight bulb replacement ...................................................................................................... - 79 -
4.4 Front turn signal lamp bulb replacement .................................................................................... - 80 -
4.5 Taillight/Rear turn signal lamp replacement................................................................................ - 80 -
4.6 Meters.................................................................................................................................... - 81 -
4.7 Main switches ......................................................................................................................... - 81 -
4.8 Speakers................................................................................................................................. - 81 -
4.9 Combined switch..................................................................................................................... - 82 -
Examination and maintenance of chassis ................................................................................................ - 83 -
5. Brake .............................................................................................................................................. - 86 -
5.1 Maintenance instruction ........................................................................................................... - 86 -
5.2 Failure Diagnosis .................................................................................................................... - 87 -
5.3 Front fluid brake...................................................................................................................... - 87 -
5. 4 Rear drum brake..................................................................................................................... - 89 -
6. Body panel ...................................................................................................................................... - 93 -

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7.Front wheel/front suspension.............................................................................................................. - 97 -
7.1 Preparation documents............................................................................................................. - 97 -
7.2 Failure diagnosis ..................................................................................................................... - 98 -
7.3 Front wheel............................................................................................................................. - 98 -
7.4 Steering handle ..................................................................................................................... - 100 -
7.5 Front fork ............................................................................................................................. - 101 -
8.Rearwheel/rear suspension ............................................................................................................... - 106 -
8.1 Preparing documents ............................................................................................................. - 106 -
8.2 Failure diagnosis ................................................................................................................... - 106 -
8.3 Rear wheel............................................................................................................................ - 107 -
8.4 Rear shock absorber............................................................................................................... - 108 -
9.Fuel tank/seat.................................................................................................................................. - 114 -
9.1 Preparation documents........................................................................................................... - 114 -
9.2 Failure diagnosis ................................................................................................................... - 114 -
9.3 Fuel tank/seat........................................................................................................................ - 115 -
10.Removal / installation of motor....................................................................................................... - 117 -
10.1 Preparation documents ......................................................................................................... - 117 -
10.2 Failure diagnosis ................................................................................................................. - 117 -
10.3 Removal of motor................................................................................................................ - 118 -
10.4 Installation of motor............................................................................................................. - 119 -
Inspection and maintenance of motor ................................................................................................... - 120 -
11.Lubricaiton system ........................................................................................................................ - 122 -

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11.1 Preparation documents ......................................................................................................... - 122 -
11.2 Failure diagnosis.................................................................................................................. - 122 -
11.3 Machine oil pump................................................................................................................ - 123 -
12.Carburetor .................................................................................................................................... - 127 -
12.1 Preparation documents ......................................................................................................... - 127 -
12.2 Failure diagnosis ................................................................................................................. - 128 -
12.3 Removal of carburetor.......................................................................................................... - 128 -
12.4 Installation and adjustment ................................................................................................... - 130 -
13.Cylinder cap ................................................................................................................................. - 133 -
13.1 Preparation documents ......................................................................................................... - 133 -
13.2 Failure diagnosis ................................................................................................................. - 133 -
13.3 Cylinder cap........................................................................................................................ - 133 -
13.4 Cylinder cap inspection........................................................................................................ - 134 -
13.5 Installation of cylinder cap.................................................................................................... - 134 -
14.Cylinder body and piston................................................................................................................ - 137 -
14.1 Preparation documents ......................................................................................................... - 137 -
14.2 Failure diagnosis ................................................................................................................. - 138 -
14.3 Cylinder body ..................................................................................................................... - 138 -
14.4 Piston ................................................................................................................................. - 139 -
14.5 Installation of piston ............................................................................................................ - 142 -
15.Driving /clutch/driven wheel/foot driving device .............................................................................. - 146 -
15.1 Preparation documents ......................................................................................................... - 146 -

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15.2 Failure diagnosis ................................................................................................................. - 146 -
15.3 Left crankcase cover ............................................................................................................ - 147 -
15.4 Driving disc ........................................................................................................................ - 147 -
15.5 Clutch/driven wheel............................................................................................................. - 149 -
15.6 Detach clutch and driven wheel............................................................................................. - 151 -
15.7 Install ................................................................................................................................. - 155 -
15.8 Foot starting device.............................................................................................................. - 155 -
16.1 Preparation documents ......................................................................................................... - 158 -
16.2 Failure diagnosis ................................................................................................................. - 158 -
16.3 Gear box............................................................................................................................. - 158 -
16.4 Installation.......................................................................................................................... - 159 -
17．Crankcase .................................................................................................................................. - 161 -
17.1 Preparation documents ......................................................................................................... - 161 -
17.2 Failure diagnosis ................................................................................................................. - 161 -
17.3 Crankcase ........................................................................................................................... - 162 -
17.4 Installation.......................................................................................................................... - 164 -
Inspection and maintenance of exhaust gas discharge control system....................................................... - 164 -
18.Exhaust gas discharge control system .............................................................................................. - 166 -
18.1 Exhaust gas discharge control system reconizance................................................................... - 166 -
18.2 Regular maintenance notes ................................................................................................... - 166 -
18.3 Mechanic function of exhaust gas discharge control system ..................................................... - 167 -
18.4 Catalytic transfer system ...................................................................................................... - 167 -

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18.5 Solution for idle discharge value exceeding defined value (two-stroke) ..................................... - 169 -

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Preface
This is maintenance manual for QJ50QT-22D.
Preparing Documents include all necessary instructions and statements. Please
carefully read this manual before operation.
Inspection & Adjustment states how to check and adjust your motorcycle. All
safety rules and maintenance regulations shall be carried out from the beginning of
periodic inspection.
Except for chapter one, the rest chapters explain the disassembly/ assembly/
inspection of engine, entire motorcycle and electrical parts.
Breakdown drawing, systematic drawing, failure analysis and statement are
contained at the first part of each chapter.
Please note that photos, pictures or instructions are for your reference only. The
actual object may differ from these mentioned here. We will not make notification for
any discrepancy.
Generic Motor GmbH

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Preparing documents
General safety Maintenance rules
Specification table Failure diagnosis
General Safety
Carbon monoxide
Engine shall be started in a ventilated place, not in a closed area.
Note
Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human
being.
Start engine in an open place. The exhaust cleaning system shall be adopted if engine is started in a closed area.
Petrol
Ventilated place is required for working. Fire is strictly forbidden in work place or where petroleum is stored.

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Maintenance Rules
Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage.
Clean up the surface of parts or assembly parts before removing or opening the shield for maintenance, which can
prevent dirt from falling into the engine, chassis or braking system.
Wash parts and dry with compressed air machine after
disassembly and before measurement of attrition value.
Solvent or oil can easily damage aging rubber articles. Check
rubber before reassembly and replace rubber if necessary.
When releasing assembly parts, please start from outside to inside.
Small assembly parts shall be loosened first.
Complex assembly parts, such as gear box, shall be stored in
proper order for facilitating installation in the future.
Please specially note the important connections before
disassembly. Replace parts which will not be in use before
disassembly.
Sheath

- 10 -
Bolts and screws with different length will be separately used for
assembly parts and shields, and they shall be correctly mounted.
Insert a bolt into a hole to check whether it is proper if you are
confused.
Fill the groove with grease before mounting an oil seal. Check
whether the oil seal is smooth or damaged during assembly.
When installing a hosepipe (fuel, vacuum or cooling agent),
insert its end into the bottom of the connector so that the hose clip
can properly fix the connector. Rubber or plastic dirt-proof boot
shall be mounted according to the original design.
During dismantling ball bearing, one or two (inside & outside)
bearing rollers shall be supported by tools. Ball bearings may be
damaged and have to be replaced if only one roller (either inside
or outside) is imposed with force.
Groove
Clip
Connector
Bearings will be broken under either occasion as
mentioned.

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Loose cables threaten electrical safety. Check each cable after they are all clamped to ensure the electrical safety;
Wire clamps are not allowed to bend towards welding point;
Bind cables at the designated place;
Do not deploy cables at the end of frame or at sharp point;
Do not deploy cables at the end of bolts or screws;
Cable deployment shall be far from heat source and where
cables may be clamped during moving;
Cables along the handlebar shall be neither too tight nor too
loose, and do not interface with any neighboring parts at
steering positions;
Cables shall be properly deployed without twist or knot;
Check whether the connector jacket is damaged and whether
the connector is over-stretched before mounting connectors;
Adopt adhesive tape or hosepipe to protect cables if they are
positioned at sharp point or corner;
Bind cables with tape after repairing;
Control cables shall not be bent or twisted. Clumsy operation
may be caused in light of damaged control cables.

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Identification of Motorcycle
1. The identification number of motorcycle frame is
marked at : *LBBB4900?8B?????*. The 9th digital,
10 digital and 11th digital respectively indicate
inspection code, year and supplier code. There are
17-digital in total. The frame sign is nailed at . See
Fig. 1-1.
Fig. 1-1
2. The serial number of engine is printed on the shell of
crankcase of engine and shall be in the format of
KW1E40QMB-4*□□□□□□□□*. Please see fig. 1-2.
Fig. 1-2
Significant Notes
1. Please apply valid Generic parts and accessories. Any part or accessory not in accordance with the design
specification of Generic Company may cause damage to engine.
2. Only metric tools are valid for maintenance and repair. Metric screws, bolts and nuts can not be exchanged with
imperial fasteners.
3. New gaskets, O-rings, cotter pins and locking pieces shall be applied for re-assembly.
4. Bolts with large diameter or positioned inside shall be fastened first and then diagonally screw down until
reaching required torque, otherwise there is special instruction.
5. Wash disassembled parts with cleanser. Lubricate all sliding surface before assembly.
6. Check whether all the parts and accessories are correctly mounted and operated after assembly.
7. Clean and remove oil before measurement. Add recommended lubricant to the lubricating areas during
assembly.
8. Apply lubricant to the surface of engine and driving system if they are dismantled for long-term storage, which
can prevent rust and dirt.

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Special Tools
Special tools refer to tools which are specially designed for assembling or disassembling some motorcycle
parts on special positions. Applicable special tools are necessary for precise adjustment and installation. With
them, parts and accessories can be mounted safely, reliably and rapidly, which improves efficiency and saves
energy.
1．Tools for repairing engine
Special tools are required for properly disassembling/assembling some engine parts.
List and drawing (1-1, 1-2) of special tools for disassembling/assembling engine parts are as follows:
Table 1-1
Name Remark
Special socket spanner
Clutch clamp holder
Flywheel puller
Feeler gauge
Bearing disassembly tools
Bearing assembly tools
Oil seal remover
Handle for dismantling tools
Piston pin pulling device
Piston pin pliers
Socket spanner for spark plug
Clutch thickness measuring device
Cylinder diameter measuring device
Dial indicato
Used for assembling/disassembling bolts for flywheels, Fig. 1-3
Fig. 1-4
Fig. 1-5
Fig. 1-6
Fig. 1-7
Fig. 1-8
Fig. 1-9
Fig. 1-10
Fig. 1-11
Fig. 1-12
Fig. 1-13
Fig. 1-14
Fig. 1-15
Measuring the inner diameter of piston pin, Fig. 1-16
Table 1-2 (continued)
Fig.1-3 Fig.1-4

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Fig.1-5 Fig.1-6
Fig.1-7 Fig.1-8
Fig.1-9 Fig.1-10
 handle
Fig.1-11 Fig.1-12
Thickness gauge
(feeler gauge)

- 15 -
 pliers  piston
Fig.1-13 Fig.1-14
Fig.1-15 Fig.1-16
2．Tools for repairing chassis
List and drawing (1-17, 1-18) of ordinary tools and special tools for disassembling/assembling chassis parts are
as follows:
Table 1 -17
Name Remark
Torque spanner
Inner hexagon spanner
Socket spanner
Dial indicator
Magnetic rack, V-block
Micrometer
Vernier calipers
Circlip pliers
Screwdriver with striking cap
Tool for assembling oil seal of front fork
Tool for hammering seal of front fork
Steering nut spanner
Fig. 1-19
Fig. 1-20
Fig. 1-21
Fig. 1-22
Fig. 1-23
Fig. 1-24
Fig. 1-25
Fig. 1-26
Fig. 1-27
Fig. 1-28
Fig. 1-29
Fig. 1-30
(1) Ordinary tools for repairing chassis
Table 1-18 (continued)

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Fig.1-19 Fig.1-20
Fig.1-21 Fig.1-22
Fig.1-23 Fig.1-24
Fig.1-25 Fig.1-26
Fig.1-27 Fig.1-28
(2) Special tools for repairing chassis: tool for hammering seal of front fork
1. socket head 2. crank handle 3. ratchet spanner
4. connecting rod

- 17 -
Fig. 1-29
(3) Steering nut spanner
Fig. 1-30
3．Tools for electric parts
List and drawings (1-31, 1-32) of special tools for testing electric parts are as follows:
Table 1 -31
Name Remark
Multimeter
Ignition tester
Fig. 1-33
Fig. 1-34
Table 1-32 (continued)
Fig. 1-33
Fig. 1-34

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Specification (QJ50QT-22D)
Model QJ50QT-22D Engine type QJ1E40QMB-4
Length mm 1940 Fuel type Unleaded petrol
(92/95)
Width mm 730 No. of
cylinder 1
Height mm 1110 ID × stroke 40×39.2
Wheelbase mm 1305 Total
displacement 49.2CC
Forward
shaft 39 Startup Electric/kick
Backshaft 62 Cooling Air cooling
Weight kg
(Curb weight)
Total 102
Front outer
tyre 80/80-16
Lubrication Separate
lubrication
Front rim 16 X1.6
Rear outer
tyre 90/80-16 Air filter AF-B45
Tyre
Size
Rear rim 16 X1.85 Capacity of
gasoline
tank
5.5 L±0.2L
Clutch Dry centrifugal
clutch
Variable speed
gear Stepless
Engine
Carburetor
type PZ19JB-2K
T
ransmissio
n
gear
Transmission Belt transmission Idle speed 1900±100rpm/min
Max. torque 4.36N.m/5250rpm
Battery
capacity 12V-4AH
Max. Hp 2.60kW/6500rpm
Electromagnetic
motor capacity 90W/5000rpm
Compression
ratio 6.9：1
Spark plug BR8HSA（NGK）
Performance
Max. speed 45km/h
Clearance of
spark plug 0.6-0.7mm
Electric
devices
Ignition CDI
Braking
Dia. of fluid
brake disc,
front wheel
φ220mm