Qianjiang QJ150T-10 User manual

User's operation and maintenance manual for
double-wheel motorcycle QJ150T-10
Zhejiang Qianjiang Motorcycle Co., Ltd

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Contents
Contents.................................................................................................................................................................- 1 -
Preface ...................................................................................................................................................................- 4 -
Documents to be prepared .............................................................................................................................- 5 -
Inspection/adjustment ..................................................................................................................................- 21 -
1 Battery/charging system ...................................................................................................................................- 34 -
1.1 Preparation data .....................................................................................................................................- 34 -
1.2 Fault diagnosis.......................................................................................................................................- 35 -
1.3 Battery ...................................................................................................................................................- 36 -
1.4 Charging system ....................................................................................................................................- 37 -
5.5 Voltage and current regulator.................................................................................................................- 38 -
1.6 Charge coil of the alternator ..................................................................................................................- 39 -
1.7 Disassembly of alternator ......................................................................................................................- 39 -
2 Ignition system .................................................................................................................................................- 41 -
2.1 Preparation data .....................................................................................................................................- 41 -
2.2 Fault diagnosis.......................................................................................................................................- 42 -
2.3 Ignition system inspection .....................................................................................................................- 43 -
2.4 CDI group ..............................................................................................................................................- 45 -
2.5 Ignition coil............................................................................................................................................- 45 -
2.6 Trigger ...................................................................................................................................................- 46 -
3 Startup system...................................................................................................................................................- 48 -
3.1 Preparation data .....................................................................................................................................- 48 -
3.2 Fault diagnosis.......................................................................................................................................- 49 -
3.3 Start electric machinery .........................................................................................................................- 49 -
3.4 Start relay...............................................................................................................................................- 51 -
4 Bulbs/ switch/instrument ..................................................................................................................................- 52 -
4.1 Preparation data .....................................................................................................................................- 52 -
4.2 Fault diagnosis.......................................................................................................................................- 52 -
4.3 Replace the head light bulb....................................................................................................................- 52 -
4.4 Replace bulb of the front turning light...................................................................................................- 53 -
4.5 Replace the bulb of the taillight.............................................................................................................- 53 -
4.6 Instrument..............................................................................................................................................- 54 -
4.7 Main switch ...........................................................................................................................................- 54 -
4.8 Horn.......................................................................................................................................................- 54 -
4.9 Handle switch ........................................................................................................................................- 55 -
5 Brake.................................................................................................................................................................- 58 -
5.1 Maintenance instruction.........................................................................................................................- 58 -
5.2 Fault diagnosis.......................................................................................................................................- 58 -
5.3 Front hydraulic brake.............................................................................................................................- 59 -
5.4 Rear hydraulic brake..............................................................................................................................- 60 -
6 Body cover........................................................................................................................................................- 64 -
7 Front wheel/ front suspension...........................................................................................................................- 66 -

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7.1 Preparation data .....................................................................................................................................- 66 -
7.2 Fault diagnosis.......................................................................................................................................- 66 -
7.3 Front wheel ............................................................................................................................................- 67 -
7.4 Direction handle.....................................................................................................................................- 69 -
7.5 Front fork...............................................................................................................................................- 69 -
7.6 Radiator/expansion kettle components ..................................................................................................- 70 -
8 Rear wheel/rear suspension ..............................................................................................................................- 73 -
8.1 Preparation data .....................................................................................................................................- 73 -
8.2 Fault diagnosis.......................................................................................................................................- 73 -
8.3 Rear wheel .............................................................................................................................................- 74 -
8.4 Rear shock absorber/rear rocker ............................................................................................................- 75 -
9 Lubrication system ...........................................................................................................................................- 78 -
9.1 Preparation data .....................................................................................................................................- 78 -
9.2 Fault diagnosis.......................................................................................................................................- 78 -
9.3 Oil pump ................................................................................................................................................- 79 -
10 Carburetor.......................................................................................................................................................- 82 -
10.1 Preparation data ...................................................................................................................................- 82 -
10.2 Fault diagnosis.....................................................................................................................................- 82 -
10.3 Disassembly of carburetor ...................................................................................................................- 83 -
10.4 Installation of carburetor......................................................................................................................- 85 -
10.5Adjustment of carburetor......................................................................................................................- 85 -
11 Cylinder cover/air cylinder/piston ..................................................................................................................- 87 -
11.1 Preparation data ...................................................................................................................................- 87 -
11.2 Fault diagnosis .....................................................................................................................................- 88 -
11.3 Cylinder head.......................................................................................................................................- 88 -
11.4 Examination on cylinder head .............................................................................................................- 90 -
11.5 Valve ....................................................................................................................................................- 91 -
11.6 Examination on valve ..........................................................................................................................- 91 -
11.7 Replace the valve guide .......................................................................................................................- 92 -
11.8 Shaping of Valve Seat ..........................................................................................................................- 93 -
11.9 Installation ...........................................................................................................................................- 95 -
12 Crankcase/clutch/actuating lever ....................................................................................................................- 97 -
12.1 Preparation data ...................................................................................................................................- 97 -
12.2 Fault diagnosis.....................................................................................................................................- 98 -
12.3 Cylinder body ......................................................................................................................................- 98 -
12.4 Piston ...................................................................................................................................................- 99 -
12.5 Installation of piston ..........................................................................................................................- 101 -
12.6 Installation of the air cylinder............................................................................................................- 102 -
13 Drive disk/Clutch/Driven Wheel ..................................................................................................................- 104 -
13.1 Preparation data .................................................................................................................................- 104 -
13.2 Fault diagnosis...................................................................................................................................- 104 -
13.3 Left crankcase cover ..........................................................................................................................- 105 -
13.4 Drive disk ..........................................................................................................................................- 105 -

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13.5 Clutch/driven wheel...........................................................................................................................- 107 -
13.6 Disassemble the clutch and the driven wheel ....................................................................................- 108 -
13.7 Installation ......................................................................................................................................... - 111 -
14 Decelerator....................................................................................................................................................- 113 -
14.1 Preparation data .................................................................................................................................- 113 -
14.2 Fault diagnosis...................................................................................................................................- 113 -
14.3 Gear Case...........................................................................................................................................- 113 -
14.4 Installation .........................................................................................................................................- 114 -
15 Crankcase .....................................................................................................................................................- 116 -
15.1 Preparation data .................................................................................................................................- 116 -
15.2 Fault diagnosis...................................................................................................................................- 116 -
15.3 Crankcase...........................................................................................................................................- 117 -
15.4 Installation .........................................................................................................................................- 119 -
16 Cooling system .............................................................................................................................................- 121 -
16.1 Cooling system ..................................................................................................................................- 121 -
14.2 Fault diagnosis...................................................................................................................................- 121 -
16.3 Thermostat .........................................................................................................................................- 122 -
17 Exhaust emission and control system ...........................................................................................................- 125 -
17.1 Warranty of Exhaust emission and control system............................................................................- 125 -
17.2 Regular maintenance guideline..........................................................................................................- 126 -
17.3 Mechanical function of the exhaust control system...........................................................................- 127 -
17.4 Catalyst converter system..................................................................................................................- 128 -
17.5 Countermeasure of idle speed emission exceeding specified value（four-stroke)............................- 129 -

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Preface
This Manual explains the maintenance of Qianjiang QJ150T-10.
The documents to be prepared are the maintenance manual and all the operations
are included in, please read the manual prior to operation.
Inspection and Adjustment explains the gist of inspection and adjustment; the
maintenance of safety of vehicle and the performance of each part should come into
force since regular inspection.
After Chapter I is the explanation of the gist of disassembly, assembly and
inspection of engine, entire vehicle and electric fittings.
There are exploded view, system diagram, maintenance, fault diagnosis and
explanation before each chapter.
Notice：
For the universal parts of both types of motorcycle, this manual does not
seperate the explanation.
There is no prior individual notification on the alteration of mode or structure of
motorcycle and the actual product shall prevail if there is discrepancy between the
photos, pictures or explanation contained in this Manual and the actual product.
Zhejiang Qianjiang Motorcycle Co., Ltd

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Documents to be prepared
Generalsafety Maintenanceregulation
Specififcation sheet Troubleshooting
General safety
Carbon monoxide
If the engine must be activated, make sure that the workplace is well ventilated. The engine can not be running in
a confined place.
Attention
The exhaust contains toxic gas, carbon monoxide, which can numb people and may result in death.
The engine should be started in an open area and the exhaust scavenging system should be applied if the engine
has to be started in a closed area.
Gasoline
The operation should be made in a ventilated area and smoking or lighting fires should be strictly forbidden in
working space or the place stored gasoline.

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Maintenance regulation
As maintaining this vehicle, the instrument of metric system should be applied as possible for the reason that the
application of incorrect instrument may demage this vehicle.
Before dismantling from or frame cover of vehicle to maintain the dirt of parts or external subassembly should be
purged in order to prevent that falling into engine , chasis or braking system.
After dismantling and before measuring attrition value, please
clean parts and purge it with compressor.
The operation should not be bended or distorted; otherwise it will
cause operational difficulties or demage ahead of time.
The rubber parts will be deteriorated due to aging which is prone
to be damaged by solvent or oil and it should be inspected (if
necessary, it should be replaced) before reinstallation.
Loosen the parts with multiple assemblies that should be made
from outside to inside and started from small one.
The complicated assembly, transmission case, for instance, should
be stored according to proper assembly sequence in order to
facilitate the assembly in the future.
error error error
cover

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For the important assembly position, it should be given special attention
before dismantling. The parts out of use should be replaced before
dismantling in time.
The length of bolts to assemblies and frame cover are different which should be installed in correct position and
the bolts may placed in the hole to find out whether they are suitable if
they are mixed.
For the installation of oil seal, the grease should be filled in oil seal groove;
as installing oil seal, it should check the smoothness of oil seal whether it
will likely damage the oil seal.
For the installation of rubber hose (fuel, vacuum or coolant), the ends of
which should plug into the bottom of the joint in order to ensure that there
is enough space for hose clamp to clamp the joint. The rubber or plastic
soldering cup should restore its original design position.
As dismantling ball bearing, please use the tool to withstand
one or two (internal and external) bearing runners. If the
strength is only applied onto a rolling ring (no matter internal
or external), the bearing may be damaged as dismantling and
has to be replaced.
Specific tools In both instances, the bearings
will be broken

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The so-called specific tools refer to those specifically designed for assemble or dismantle of certain
components of the motorcycle. These tools are usually used in specific locations. Appropriate specific tools are
indispensable in the complete and accurate adjustment as well as in the assembly operations. By taking advantage
of specific tools, the components can be safely, reliably and quickly assemble or dismantle, thus enhancing the
work efficiency and saving lots of efforts.
1．tools used for the engine-overhaul
When assembling or dismantling the engine, specifically designed tools should be used for some certain
components to guarantee a smooth dismounting.
The list of specific tools for the assembly and dismantling of engine components and the figure of real objects
can be seen in table 1-1 and table 1-2.
Table 1-1
name remarks
Specialized circular wrench
Clutch holder
Flywheel extractor
Spacer gauge
Dismounting tools for bearing
Assembling tools for bearing
Oil-seal dismounting tool
Handle of dismounting tools
Piston pin exhaustion apparatus
Piston ring opening pincer
Heating plug circular wrench
Measure the thickness of clutch
Cylinder diameter tester
Dial dictator
Used for the assembly and dismantle of flywheel bolt ,figure 1-3
Figure 1-4
Figure 1-5
Figure 1-6
Figure 1-7
Figure 1-8
Figure 1-9
Figure 1-10
Figure 1-11
Figure 1-12
Figure 1-13
Figure 1-14
Figure 1-15
Measure the inner canon of piston pin,Figure 1-16
Successive table 1-2
Figure1-3 Figure1-4
Figure1-5 Figure1-6

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Figure1-7 Figure1-8
Figure1-9 Figure1-10
①手柄
Figure1-11 Figure1-12
①opening pincer ②piston
Figure1-13 Figure1-14