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.