Zhejiang Qianjiang Motorcycle RKV 200 User manual

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RKV 200 Motorcycle
Service Manual

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ZHEJIANG QIANJIANG MOTORCYCLE CO.LTD.
Content
Content.........................................................................................................錯誤! 尚未定義書籤。
Preface................................................................................................. 錯誤! 尚未定義書籤。
Service Data............................................................................................................................. 6
Inspection/Adjustment ........................................................................................................... 47
Inspection and maintenance of electrical system............................................................................61
ⅠBattery/Charging System...........................................................................................................63
1.1 Service Data..................................................................................................................... 63
1.2 Fault Diagnosis ................................................................................................................ 64
1.3 Battery.............................................................................................................................. 65
1.4 Charging system............................................................................................................... 66
1.5 Voltage-current regulator.................................................................................................. 66
1.6 Magneto charging coil...................................................................................................... 67
1.7 Magneto Removal............................................................................................................ 68
ⅡIgnition System..........................................................................................................................71
2.1 Service Data..................................................................................................................... 71
2.2 Fault diagnosis ................................................................................................................. 72
2.3 Ignition system inspection................................................................................................ 73
2.4 CDIAssembly.................................................................................................................. 74
2.5 Ignition coil...................................................................................................................... 75
2.6 Trigger.............................................................................................................................. 76
ⅢStarting System..........................................................................................................................78
3.1 Service Data..................................................................................................................... 78
3.2 Fault Diagnosis ................................................................................................................ 79
3.3 Starter Motor.................................................................................................................... 79
3.4 Starter Relay..................................................................................................................... 81
Bulbs/Switches/Instruments............................................................................................................83
4.1 Serivce Data..................................................................................................................... 83
4.2 Fault Diagnosis ................................................................................................................ 84
4.3 Headlamp bulb replacement............................................................................................. 84
4.4 Front turn signal lamp bulb replacement.......................................................................... 85
4.5 Tail lamp bulb replacement.............................................................................................. 85
4.6 Instrument ........................................................................................................................ 86
4.7 Main switch...................................................................................................................... 86
4.8 Electric horn..................................................................................................................... 87
4.9 Handle switch................................................................................................................... 87
Chassis Inspection and Maintenance..............................................................................................88
ⅤBraking System..........................................................................................................................91
5.1 Maintenance Instructions................................................................................................. 91
5.2 Fault Diagnosis ................................................................................................................ 92

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5.3 Front Hydraulic Brake...................................................................................................... 92
5.4 Rear Hydraulic Brake....................................................................................................... 94
ⅥMotorcycle Exterior................................................................................錯誤! 尚未定義書籤。
7.1 Service data................................................................................... 錯誤! 尚未定義書籤。
7.2 Fault Diagnosis ............................................................................. 錯誤! 尚未定義書籤。
7.3 Front Wheel................................................................................... 錯誤! 尚未定義書籤。
7.4Steering Handlebar......................................................................... 錯誤! 尚未定義書籤。
7.5 Front Fork ..................................................................................... 錯誤! 尚未定義書籤。
ⅧRear Wheel/Rear Suspension..................................................................錯誤! 尚未定義書籤。
8.1 Service Data.................................................................................. 錯誤! 尚未定義書籤。
8.2 Fault Diagnosis ............................................................................. 錯誤! 尚未定義書籤。
8.3 Rear Wheel.................................................................................... 錯誤! 尚未定義書籤。
8.4 Rear ShockAbsorber/Rear Swingarm........................................... 錯誤! 尚未定義書籤。
8.5 Chain Drive Assembly .................................................................. 錯誤! 尚未定義書籤。
ⅨFuel Tank/Seat Cushion..........................................................................錯誤! 尚未定義書籤。
9.1 Service Data.................................................................................. 錯誤! 尚未定義書籤。
9.2 Fault Diagnosis ............................................................................. 錯誤! 尚未定義書籤。
9.3 Fuel Tank/Seat Cushion ................................................................ 錯誤! 尚未定義書籤。
Engine Inspection and Maintenance............................................................錯誤! 尚未定義書籤。
ⅩLubricating System.................................................................................錯誤! 尚未定義書籤。
10.1 Service Data................................................................................ 錯誤! 尚未定義書籤。
10.2 Fault Diagnosis ........................................................................... 錯誤! 尚未定義書籤。
10.3 Engine Oil Pump......................................................................... 錯誤! 尚未定義書籤。
ⅨCarburetor...............................................................................................錯誤! 尚未定義書籤。
11.1 Service Data ................................................................................ 錯誤! 尚未定義書籤。
11.2 Fault Diagnosis............................................................................ 錯誤! 尚未定義書籤。
11.3 Removal of Carburetor................................................................ 錯誤! 尚未定義書籤。
ⅫCylinder Head/Valve................................................................................錯誤! 尚未定義書籤。
12.1 Service Data................................................................................ 錯誤! 尚未定義書籤。
12.2 Fault Diagnosis ........................................................................... 錯誤! 尚未定義書籤。
12.3 Cylinder Head ............................................................................. 錯誤! 尚未定義書籤。
12.4 Inspection.................................................................................... 錯誤! 尚未定義書籤。
12.5 Valve Guide Replacement........................................................... 錯誤! 尚未定義書籤。
12.6 Vavle Race Fixing and Adjustment............................................. 錯誤! 尚未定義書籤。
12.7 Installation................................................................................... 錯誤! 尚未定義書籤。
ⅩⅢ Cylinder Block and Piston..................................................................錯誤! 尚未定義書籤。
ⅩⅢ Cylinder Block and Piston..................................................................錯誤! 尚未定義書籤。
13.1 Service Data................................................................................ 錯誤! 尚未定義書籤。
13.2 Fault Diagnosis ........................................................................... 錯誤! 尚未定義書籤。
13.3 Cylinder Block............................................................................ 錯誤! 尚未定義書籤。
13.4 Piston........................................................................................... 錯誤! 尚未定義書籤。
13.5 Cylinder Installation.................................................................... 錯誤! 尚未定義書籤。
ⅩⅣ Crankcase............................................................................................錯誤! 尚未定義書籤。
14.1 Service Data................................................................................ 錯誤! 尚未定義書籤。

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14.2 Fault Diagnosis ........................................................................... 錯誤! 尚未定義書籤。
14.3 Crankcase.................................................................................... 錯誤! 尚未定義書籤。
14.4 Gearshift Mechanism.................................................................. 錯誤! 尚未定義書籤。
14.5 Crankshaft Connecting RodAssembly ....................................... 錯誤! 尚未定義書籤。
14.6 Gearbox Assembly...................................................................... 錯誤! 尚未定義書籤。
Exhaust System Inspection and Maintenance..................................... 錯誤! 尚未定義書籤。
ⅩⅦ Emission Control System....................................................................錯誤! 尚未定義書籤。
15.1 Emission Control System Guarantee........................................... 錯誤! 尚未定義書籤。
15.2 Periodical Maintenance Instructions........................................... 錯誤! 尚未定義書籤。
15.3 Mechanical Functions of Emission Control System ................... 錯誤! 尚未定義書籤。
15.4 Solutions to the problem of idle exhaust exceeding specified value (four-stroke)錯誤!
尚未定義書籤。
Complete 150-19A Schematic Circuit Diagram…………………………………………- 170-

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Preface
The service manual contains descriptions of maintenance essentials on QJ
200-2A motorcycle.
Service data include attentions that shall be paid on all the maintenance
operations in the service manual. Please read the manual carefully before
operation.
Check and adjustment contains statements on the main points of
inspection and adjustment, safety of the vehicle, maintenance means of
each component’s performance. This shall be implemented from the time
of periodical inspection.
The parts after Part 1 demonstrate breakdown, assembly and main points
of inspection of electrics, finished motorcycle, engine and other
components.
System diagrams, breakdown drawings, maintenance, fault diagnosis and
explanation are presented before each part when compiled.
Notes：
If patterns or structures of the motorcycles change, or differences exist
between pictures, drawings, instructions or others and physical products,
please take the later as the standard. The product is subject to change
without further notice.
ZHEJIANG QIANJIANG MOTORCYCLE CO.LTD

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Service Data
General Safety Maintenance Regulation
Specification Sheet Fault Diagnosis
General Safety
Carbon monoxide (CO)
When it is necessary to start the engine, please make sure the workplace is well ventilated. You
shall never run the engine in an enclosed place.
Attention
Gas exhausted from the motorcycle contains toxic carbon monoxide, which may lead to loss of consciousness
and even death.
It is necessary to run the engine in an open area. If the engine is run in an enclosed site, ventilation
system shall be used.
Gasoline
Work in well-ventilated site. Fire and smoking are strictly forbidden in working sites or gasoline
storage places.
Battery
Battery shall be away from spark, open fire and smoking places since it may emit explosive gases.
Keep it in well-ventilated condition while charging.
Battery contains sulphuric acid (electrolyte), which will cause burns when contacting with skin or
eyes. Please put on protection clothing and helmet while handling battery.
——if electrolyte splashes on the skin, flush immediately with water.
——If electrolyte splashes into eyes, flush immediately with water for at least 15mintues and
get a medical examine.
Electrolyte is poisonous. If swallow it by mistake, please immediately drink plenty of water, milk
and milk of magnesia (a kind of laxative antacid) or vegetable oil and get a medical examine.
Keep it out of reach of Children.

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Maintenance Regulations
While repairing and servicing, try to use tools of metric system as possible as you can. Incorrect
tools may damage the motorcycle.
Before take down or open protecting plate for maintenance work,
please clean the dirt on external surface of the component or the
assembly to prevent the dirt from falling into the engine, chassis or
braking system.
After disassembly and before measuring friction, please clean the
components and purge with air compressor.
Plastic parts may deteriorate due to aging, which are apt to be
damaged by solvent or oil. Check before re-installation and replace
if necessary.
While removing a component with many assemblies, do from outside
to inside. Loosen firstly smaller assemblies; for the complicated
assemblies, such as gearbox, keep them in a proper assembling order
for the sake of easy assembly later.
Pay special attention to the key fitting position before disassembly.
The components that are not used any more shall be replaced on time
before disassembly.

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Length of bolts and screws are different for assemblies and protecting
plates. They shall be installed at correct positions. If confused, just
put the bolt inside the hole and see if it matches.
Fill lubricating grease into the groove during oil seal installation.
Check if the oil seal is smooth and if it is possible to be damaged
when installed.
Installation of rubber hose (fuel, vacuum, or coolant): insert its
end into bottom of connector so that there is enough room for
the hose clamp to grip the connector. Install the rubber or plastic
dustproof boot back to its originally designed position.
Disassembly of ball bearing: use a tool to push against one or
two (inner and external) bearing races. If the force works only
on one bearing race (whatever inner or external), the bearing
may be damaged when disassembled and it must be replaced.

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Slack cable implies potential safety hazard on electrics.
Check the next cable when the cable is clamped to ensure
electric safety;
Cable clamp shall not be bent towards solder joint;
Tie the cable at appointed position;
Don’t lay the cable at the end of frame or at the closed angle;
Don’t lay the cable at the tip of a bolt or screw;
Wiring of cable shall be away from heat source or places
where cable may be clipped while moving;
Prevent the cable from being pulled too tightly or slacking
too much when the cable is wired along the handlebar pipe.
The cable shall not be affected by any adjacent components
at any turning place;
The cable shall be wired smoothly and shall not be knotted or
twisted;
Check if sheath of connector is damaged and if connector is
over stretched before butt connection;
If cable runs around the closed angle or the corner, please
protect it with tape or hose;
Tie the cable with adhersive tape reliably after repair;
Controlling cable shall not be bent or twisted. Broken
Controlling cable may result in non-flexible control.

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Identification of motorcycle
1．Frame number ①labeled as ：
LBBPEM2A********* (Just for reference.
Labeling method may differ due to various
conditions),as shown in Figure 1-1.
2．Frame nameplate is riveted at Position ②, as
shown in Figure 1-1.
Frame nameplate adopts non-European
KEEWAY09 Version. Contents needed to be
filled in the blank on the nameplate are
described as follows:
Model：RKV 200S
Displacement：200ML
Production date：such as 09/2010
Figure 1-1
3. Serial number of engine ①is marked on
the housing of crankcase, as shown in Figure
1-3．
Figure 1-3
Important Notes
1．Please use spare parts manufactured by Zhejiang Qianjiang Motorcycle Co., Ltd. Components
that cannot comply with designed specifications of Zhejiang Qianjiang Motorcycle Co., Ltd. may
result in damage on the engine.
2．Only metric tools can be used for maintenance work. Metric bolts, nuts and screws cannot be
exchanged with inch fasteners.
3．While re-assembling, new washers, O rings, cotter pins and locking plates shall be used.
4．While tightening bolt or nut, please first fasten the ones with great-diameter or internal bolts;
and then tighten gradually to specified torque in diagonal order. Those with special requirements
are not included.
5．Clean removed components with cleaning liquid. Lubricate all the sliding surfaces before
assembly.

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6．After assembly, check if all the components are correctly installed and can work properly.
7. Remove dirt and oil before measurement; apply recommended lubricant at lubricating positions
at assembly.
8. When the engine and transmission system are disassembled/assembled and needed to be stored
for a long time, please apply lubricant on the surface of the components to avoid rust and dust
deposition.
Special Tools
Special tools mean specially designed tools used at particular places for assembly or disassembly
of certain components on motorcycle. Appropriate special tools are essential for complete and
accurate adjusting and assembling work. Use of special tools can realize safe, reliable and quick
assembly/disassembly of components, working efficiency improvement and labour saving.
1．Tools for engine overhaul
Specially designed tools are required for smooth assembly and disassembly of some components
on the engine.
Special tools and product pictures for engine component assembly and disassembly are listed in
Table1-1 and Table 1-2.
Table 1-1
Name
Remarks
Special socket wrench
Clutch holder
Flywheel extractor
Feeler gauge
Bearing puller
Bearing installer
Oil seal remover
Puller handle
Piston pin puller
Piston ring pliers
Spark plug socket wrench
Clutch thickness measurement
Cylinder bore tester
Dial gauge
Dial gauge, V-block
Micrometer
Valve guide remover
Valve guide installer
Valve clearance adjuster
Valve spring remover
Valve guide reamer
Crankcase remover
Used for disassembly/assembly of flywheel bolt, Figure
1-3
Figure 1-4
Figure1-5
Figure1-6
Figure1-7
Figure1-8
Figure1-9
Figure1-10
Figure1-11
Figure1-12
Figure1-13
Figure1-14
Figure1-15
Measuring inner diameter of piston pin, Figure 1-16
Measuring valve stem deflection, Figure1-17
Measuring OD of valve stem, Figure1-18
Figure1-19
Figure1-20
Figure1-21
Figure1-22
Figure1-23
Figure1-24
Continued Table 1-2

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Figure 1-3 Figure 1-4
Figure 1-5 Figure 1-6
Figure 1-7 Figure 1-8
Figure 1-9 Figure 1-10
①Handle

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Figure 1-11 Figure 1-12 ①Pliers ②
Piston
Figure 1-13 Figure 1-14
Figure 1-15 Figure 1-16
Figure 1-17 Figure 1-18

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Figure 1-19 Figure 1-20
Figure 1-21 Figure 1-22
Figure 1-23 Figure 1-24
2．Toes for chassis overhaul
Common and special tools, as well as their pictures for chassis component assembly and
disassembly are listed in Table1-25 and 1-26.
Table1-25
Name
Remarks
Torque wrench
Allen wrench
Socket wrench
Micrometer
Magnetic stand, V-block
Dial gauge
Venier caliper
Spring criclip pliers
Hammer screwdriver
Front fork oil seal installer
Front fork seal driver
Steering nut wrench
Figure1-27
Figure1-28
Figure1-29
Figure1-30
Figure1-31
Figure1-32
Figure1-33
Figure1-34
Figure1-35
Figure1-36
Figure1-37
Figure1-38
(1) General tools used for chassis overhaul
Continued Table 1-26

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Figure 1-27 Figure 1-28
Figure 1-29 Figure 1-30
Figure 1-31 Figure 1-32
Figure 1-33 Figure 1-34
Figure 1-35 Figure 1-36
（2）Special tools for chassis overhaul：front fork seal driver

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Figure 1-37
（3）Steering nut wrench
Figure 1-38
3．Tools for electrical components
Special tools and their pictures for electrical component test are listed in Table1-39 and Table
1-40.
Table 1-39
Name
Remarks
Multimeter
Ignition tester
Figure1-41
Figure1-42
Continued Table 1-40
Figure 1-41
Figure 1-42

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Specifications (QJ200-2A)
Model
QJ200-2A
Engine
Engine type
QJ168FML-B
Overall Length(mm)
2080
Fuel
RQ-90
Overall Width(mm)
800
Number of
cylinders
1
Overall height(mm)
1060
Bore*stroke
68×55
Wheelbase(mm)
1350
Total
Displacement
200cc
Weight (kg)
（Curb weight）
Front
axle
67
Starting mode
Electric
Rear
axle
73
Cooling mode
Air cooling and oil
cooling
Total
140
Lubricating
mode
Force-feed and splash
lubrication
Tire
Front
tire
100/80-17
Air cleaner
Paper element
Rear
tire
130/70-17
Drive Train
Clutch type
Wet multi-plate
friction type
Fuel tank
capacity
17±0.5L
Gearshift
pattern
Five-speed
gearshift
Performance
Carburetor
type
PD31
Transmission
Chain drive
Idle
speed-rpm
1400±100r/min
Electricals
Battery
capacity/type
12V dry-charged
type
Max. torque
15N.m/7500rpm
Max. power
12.0kW/9000rpm
Electrical start
100W/8000rpm
Compression
ratio
9.5:1
Spark plug
NGK CR9E
Top speed
100km/h
Spark plug
clearance
0.6-0.7mm
Brake
Diameter of
front brake
disc
φ260mm
Ignition type
ECU-CDI
Diameter of
rear brake
disc
φ240mm

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Fault Diagnosis
Engine will not start or is hard to start.
Diagnosis procedures
Perform spark-over test
Clean deposited carbon
Spark is weak between electrodes or no spark at all.
Strong blue or violet spark leaps between electrodes
Engine will not start or is hard to start
Check ignition system
Remove the spark plug and check if electrodes of the plug are connected by carbon.
Screw off spark plug cap, perform high-voltage wire spark
over test
Use an ignition timing lamp to check ignition timing
ofengine
Strong blue spark leaps
Weak or no spark
Check spark plug and cap
1. Check CDI ignitor 2.
Check magneto flywheel
or trigger coil for
looseness.
Loosen drain screw
of carburetor and
check if overflow
pipe is clogged
Refuel
gasoline
Check compression
pressure in the cylinder
with a pressure gauge.
Check oil in
the fuel tank.
Compression
pressure in
the cylinder
is normal.
Check ignition
power supply.
Check if wires in
the ignition system
are shorted or
broken.
Check if
CDI ignitor
fails.
Non-contact battery ignition system
Non-contact magneto ignition system
1. Check electric quantity
of battery; 2.Check if
low-voltage circuit is
broken or shorted; 3
Check if trigger coil is
shorted or broken.
1. Check if ignition
power supply coils are
shorted or broken; 2.
Check if trigger coil is
shorted or broken.
Compression
pressure in
the cylinder
is low.
No
Yes
No
Yes
Yes
No
Yes
No
Check if
ignition coil
is shorted
or broken.

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Electrodes of spark plug are wet.
Electrodes of spark plug are dry.
Check overflow of carburetor
Drop a little gasoline into the cylinder for a trial start.
1. Check if there is
foreigh substance
between needle valve
and valve seat of
carburetor float so that it
cannot be closed; 2.
Check if the conical
surface of needle valve of
carburetor float is worn
into a step form; 3. Check
if the float is broken; 4.
Check if float is too low.
Check if air filter
is clogged.
Engine stalls when it
runs a very short
time.
Engine can
continue to run
when it is started.
Carburetor is
clogged inside or
float is too high.
Carburetor
starter (i.e
cranking
enrichment
system) fails.
1. Check leakage at
external connection parts
of engine; 2.Check valve
timing; 3. Check if valve
clearance is too small; 4.
Check tightness between
valve and valve seat;
5.Check if piston ring is
stuck inside the ring
groove or of less
elasticity; 6. Check wear
and tear of piston ring
and cylinder.
1. Check if breather on
the fuel tank cap is
clogged; 2. Check if
fuel filter and fuel
switch are clogged; 3.
Check if fuel switch
works normally; 4.
Check if oil intake of
carburetor is clogged;
5. Check if carburetor
float is too high.
Remove
spark plug
and check.
Yes
No