Qianjiang QJ150T-10 User manual
User's operation and maintenance manual for
double-wheel motorcycle QJ150T-10
Zhejiang Qianjiang Motorcycle Co., Ltd
- 1 -
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 -
- 2 -
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 -
- 3 -
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 -
- 4 -
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
- 5 -
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.
- 6 -
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
- 7 -
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
- 8 -
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
- 9 -
Figure1-7 Figure1-8
Figure1-9 Figure1-10
①手柄
Figure1-11 Figure1-12
①opening pincer ②piston
Figure1-13 Figure1-14
- 10 -
Figure1-15 Figure1-16
2．Tools used for the underpan-overhaul
The list of general tolls and specific tools for the dismounting of underpan components as well as the figure of
real objects can be seen in table 1-17 and table 1-18.
Figure 1-17
name remarks
rest wrench
inner hexagon wrench
circular wrench
micrometer
magnetic stand, V-shape block
dial indicator
square caliper
spring clip-ring clipper
whack-type screw drive
front fork oil seal dismounting tools
front part seal element driving-in tools
steering nut wrench
Figure 1-19
Figure 1-20
Figure 1-21
Figure 1-22
Figure 1-23
Figure 1-24
Figure 1-25
Figure 1-26
Figure 1-27
Figure 1-28
Figure 1-29
Figure 1-30
（1）General tools for the underpan-overhaul
Successive table 1-18
Figure1-19 Figure1-20
Figure1-21 Figure1-22
1. Bush-head 2.Shake-handle
3.Ratchet type wrench 4.Connecting-rod
- 11 -
Figure1-23 Figure1-24
Figure1-25 Figure1-26
Figure1-27 Figure1-28
（2）Specific tools for underpan-overhaul: front fork seal element driving-in tools
Figure 1-29
（3）Steering nut wrench
Figure 1-30
- 12 -
3．Tools used for electric apparatus components
The list of specific tools for the testing of electric apparatus components, as well as the figure of real objects
can be seen in table 1-31 and table 1-32.
Table 1-31
name remarks
universal meter
ignition tester
Figure 1-33
Figure 1-34
Successive table 1-32
Figure 1-33
Figure 1-34
- 13 -
Specififcation Sheet (QJ150T-10 )
Model QJ150T-10 En
g
ine T
y
pe 158MJ-2
Full length mm 2070 Fuel type Unleaded gasoline
（92/95）
Full width mm 715 Number of
cylinders 1
Full height mm 1260
Inside
measure *
stroke
φ57.5*57.8
Wheelbase mm 1360 Total flow
rate 150ml
Front
axle 50 Start mode Start by electricity
Rear
axle 80 Cooling
mode Water-cooling
Vehicle weight kg
(serving quality)
Total 130 Lubrication servicing quality
Front-wheel
100/80-16
Rear-wheel
Tyre specification
120/80-16
Air cleaner paper characteristic
Engine
Petrol
capacity 7.4±0.2L
Clutch type Automatism Maximum
speed 94km/h
Climbing
capability ≥20°
Transmission CVT
Idling speed
- rpm 1500±100rpm/min
Gearing
Driving mode belt drive Maximum
torque 13.3N.m/6000rpm
Battery
capacity/type 12V-6Ah/dry-charged type Maximum
horsepower 9.6kW/7500 rpm
Generator type QJ（153-2）12V
200W/8500 rpm
Compression
ratio 11：1
Spark plug C5HSA(NGK)
Performance
Cylinder
pressure 1.25MPa/1500rpm
Spark plug gap 0.6-0.7mm
Front liquid
braking disc
unit（mm）
φ240mm
Electrical installation
Ignition mode electric spark ignition
direct current capacitance
Brake
Rear liquid
braking disc
unit（mm）
φ240mm
- 14 -
QJ150-10
- 15 -
Troubleshooting
Difficult to start or unable to start
Troubleshooting Tune-upinspection Failurecause
Enough oil to
carburator
No gasoline
to
carburator
Loosen the oil drain
bolt of carburator to
check whether there
is oil within the
carburator
Spark plug
has flashover
Weak spark or no
spark of spark
plug
Dismantle the spark
plug and put it into
spark plug cover to
connect engine and
check whether the
spark plug has
flashover
Compression
pressure
measurement
Compression
pressure too low,
no compression
p
ressure
Normal compression
pressure
No ignition
burst
phenomenon of
engine
With burst
phenomenon but
the engine failed
to start
Spark plug is
damp
Spark plug is
dry
Dismantle the spark plug
again to re-inspect
No gasoline in gasoline tank
Oil tube clog of gasoline tank carburator
Oil tube clog of float chamber
Conduit clog of evaporation control system of fuel tank
Gasoline filter clog
Auto oil ring is broken
Spark plug is broken
Spark plug is polluted
CDI group is broken
Trigger is broken
The lead of sparking coil is open circuit or short circuit
Sparking coil is open circuit or short circuit
Main switch is broken
Charge coil is broken
Start clutch is broken
Air cylinder piston and piston ring are
broken
Cylinder head leaks
Auto choke actuation is bad
Intaken air in intake manifold
Incorrect ignition time
Bad adjustment of adjustable bolt of
carburetor
Overhigh oil level of carburetor
Auto choke actuation is bad
Too big throttle opening
- 16 -
Improper gyration (impotent velocity)
Troubleshooting Tune-upinspection Failurecause
Winding number
of engine
increases
Engine revolution
unable to increase
completely
Start the engine
and slightly
accelerate
Correct ignition
time
Incorrect ignition
time
Adjust ignition
timing and use
ignition timing light
N
ormal compressio
n
pressure Compression pressure is too low
Bad timing
ad
j
ustment
No clog Clogged
With pollution
and discoloration
No pollution and no
discoloration
Dismantle the spark plug and re-inspect
Clog inspection of carburetor
Normal Abnormal
Without superheat Overheating
No phenomenon
of detonation
With phenomenon
of detonation
Accelerated drive or
operation
Engine overheat
Inspect the lubrication of
air c
y
linder head
Normal mobile
oil level Too much
mobile oil
Check whether the
mobile oil in crankcase is
too much or polluted
Air cleaner clogged
Bad gasoline
Conduit clog of evaporation control
system of firing chamber
Exhaust pipe clogged
Auto choke is bad
Carburetor vacuum module is broken
Auto oil ring is broken
CDI group is broken
Trigger is broken
Air cylinder piston and piston ring are
broken
Cylinder head leaks
Cleaning contamination
Cleaning contamination
Discrepancy of spark-plug heat value
Too much mobile oil
Too little mobile oil
No change of mobile oil
Piston，cylinder wear
Piston，cylinder wear
Bad gasoline
Too much carbon laydown in combustion chamber
Too early ignition time
Too much carbon laydown in combustion chamber
Bad gasoline
Slipping of clutch
Tenuity of gas mixture
Too early ignition time
- 17 -
Improper gyration（especially at low speed）
Troubleshooting Tune-upinspection Failurecause
Normal Abnormal
Ignition time
adjustment
Favorable
adjustment
Maladjusted
Adjust the
adjustable screw of
carburetor oil level
No intake air With intake air
Dismantle the spark plug
and put it into spark plug
cover to connect engine
and check whether the
spark plug has flashover
Favorable
spark plug
flashover
Bad spark plug
flashover
Bad
Favorable
Intake air in
carburetor shim
CDI group is broken
Trigger is broken
Rare gas mixture（loosen the bolt）
Too thick gas mixture （locking
screw）
Bad heat spacer shim
Loosen fixing nut of carburetor
Broken shock insulator
Broken suction line
Bad or polluted spark plug
Bad CDI
Bad sparking coil
The lead of spark plug is open circuit
or short circuit
Main switch is broken
Damaged suction line
Ventilation hole clogged
- 18 -
Improper gyration（high speed）
Troubleshooting Tune-upinspection Failurecause
Normal
Abnormal
Ignition time
adjustment
Normal
Abnormal
No clog Clogged
Spring broken
and slack
elasticity
Favorable
Carburettor clogged
CDI group is broken
Trigger is broken
Too little gasoline in gasoline
tank
Gasoline filter of gasoline pipe
clogged
Conduit clog of evaporation
control system of fuel tank
Auto oil ring is broken
Purged
Bad spring
- 19 -
Improper charging (overdischarge or over charge of battery)
Troubleshooting Tune-upinspection Failurecause
No increase of
battery voltage
Battery voltage
rised to normal
value and restore its
original voltage
after killing engine
Measure the voltages
of the both ends of
battery, start the
engine
Normal Abnormal
Inspect whether the voltage regulator
p
lu
g
is slack
With voltage No voltage
Measuring alternator coil resistance value
Normal Abnormal
Normal voltage
Voltage
higher than
normal value
Start engine, the red line of voltage regulator
socket connects to avometer and positive and
negative line connects the voltage of
motorcycle
Check the voltage regulator socket,
the red line connects universal meter
and positive and negative line connect
the volta
g
e of motorc
y
cle
Improper charging
Normal Slack and improper
connection
Inspect whether the connection of
voltage regulator wiring is correct
Voltage regulator unit test
impedance
Expired battery
Bad battery
Bad contact of plug
Open circuit of red line of wiring
Voltage regulator
Open circuit of white line of
wiring
Bad coil
Bad contact of joint
White line of alternator
disconnected
Bad battery
Improper contact of joint and
imperfect earth of wiring
Bad voltage regulator
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