Zhejiang Qianjiang Motorcycle RKV 200 Service Manual

1 RKV 200 Motorcycle Service Manual

10 Identification of motorcycle 1 ． Frame number ① labeled as ：LBBPEM2A********* (Just for reference. Labeling method may differ due to

100 Front fork 1 Steering shaft rod nut 2 Dust shield 3 Upper steel bowel, upper bearing 4 Steel ball 3/16’’ 5 Lower steel

101 VII. Front wheel/Front suspension Service Data-----------------------------7. 1 Fault Diagnosis-------------------------7. 2 Front Wheel------

102 The handlebar bearing is faculty. The handlebar bearing is damaged. Pressure within the tyre is too low. Air leaks from the tyre. 7. 2.

103 QJ200-2A front wheel. 7. 3. 2 Check 7. 3. 2. 1Check of wheel shaft bending Place the wheel shaft onto a V-shaped base, and the measure eccentri

104 7. 3. 4 Installation Installation must be initiated in the reverse sequence of disassembly. Attention: Lubricate the front wheel shaft,

105 *Note: See P96 of this manual for disassembly of QJ200-2A steering handlebar. It should be installed by reversing the sequence of disassembl

106 Clean the opening on the body opening with dust rag. The steel bowels of the upper and lower bearings are removed by means of special tool.

107 Rear wheel 1 Self-locking nut M14×1.5 2 Right oil seal assembly of front wheel 3 Rolling bearing 6202-2RS 4 Mounting bolt

108 Rear shock absorber 1 Domed nut M10×1. 25 2 Mounting gasket, rear shock absorber 3 Rear shock absorber component 4 Washer 12 Bolt

109 Rear swing arm 1 Self-locking nut M14×1.5 2 Mounting washer, rear swingarm 3 Intermediate bearing sleeve 4 Mounting shaft, re

11 6．After assembly, check if all the components are correctly installed and can work properly. 7. Remove dirt and oil before measurement; apply reco

110 Chain drive assembly 1 Mounting bolt M10×1. 25×38, sprocket 2 Sprocket hub 3 Chain driving sleeve 4 Rolling bearing 6204-2RS 5 Dust

111 VIII. Rear wheel/Rear suspension Service Data---------------------------------------8. 1 Fault Diagnosis------------------------------------8.

112 Motorcycle frame or swingarm is bent. 8. 2. 2 Wheel rotating without flexibility Brake regulates incorrectly. Rear wheel bearing is worn. D

113 8. 3. 2 Check 8. 3. 2. 1 Check of wheel disk wobbling Turn the rear wheel manually and measure eccentricity with a micrometer gauge.

114 8. 4 Rear shock absorber/rear swingarm 8. 4. 1 Dismantling rear shock absorber Remove the sealing cover. Remove the upper and lower fixing bolt

115 Note: See P101 for details of removal and installation. 8. 4. 5 Check of rear swingarm Check the mounting shaft of rear swingarm and turn t

116 8. 5. 2． Check Measure length of 10 links , and if it does not meet specified value, replace the driving chain. Limit length of the 10 links

117 Check rear hydraulic brake, and if any crack or wearing is found, replace it. Check rear wheel damping sleeve, and if it is worn or damaged, r

118 Seat cushion A Notes: To dismantle gasoline tank, turn the fuel switch to OFF. B Torque force value of bolt 2 in the figure

119 Fuel tank A Gasoline capacity: 17±0. 5L B Torque force value of screw 13 in the figure: 5-9 N·m D Torque force value of nut 6 in the fi

12 Figure 1-3 Figure 1-4 Figure 1-5

120 IX. Fuel tank/Seat cushion Service Data-----------------------9. 1 Fault Diagnosis--------------------9. 2 Fuel Tank/Seat Cushion----------9.

121 9. 3 Fuel tank/Seat cushion 9. 3. 1 Disassembly Dismantle the right and left guards. Insert the ignition key into the seat lock, turn th

122 Maintenance and check of engine Fastener Torque Force Value Table Fastening position and fastener description Fastening torque (Nm) Cylinder head

123 X. Lubricating system Service Data------------------10. 1 Fault Diagnosis---------------10. 2 Engine Oil Pump-------------10. 3 10. 1 Service

124 10. 2Fault Diagnosis Gasoline volume decreases Engine damaged Gasoline is consumed naturall

125 10. 3 Engine oil pump 10. 3. 1 Disassembly Remove the right cover, unscrew the pump fixing screw after engine oil filter is removed, and then

126 Check radial clearance between inner and outer rotors Allowable limit: 0. 25mm. Check clearance between outer rotor and pu

127 10. 3. 2 Assembly of engine oil pump As shown in the following figure. Attention: After these parts are combined into the pump, the inner and

128 Swingarm Cam mechanism Piston Oil filter Engine oil pump Engine oil filtration net Crankshaft

129 XI. Carburetor Service Data--------------------------11. 1 Fault Diagnosis----------------------11. 2 Disassembly of carbureto

13 Figure 1-11 Figure 1-12 ① Pliers ② Piston Figu

130 Needle valve locked Bad idle adjustment Bad oil surface adjustment Bad oil

131 11. 3. 2 Decomposition of carburetor Remove the fixing plate of throttle cable. Take down the throttle valve bonnet, spring and throttle valve.

132 Remove the idling adjusting screws and their springs. Dismantle mixture screw and its spring. 11. 3. 4 Assembly and installation Assembly a

133 XII Cylinder head/Valve Service Data-----------------------------------12. 1 Fault Diagnosis--------------------------------12. 2 Cylinder Hea

134 Installation-----------------------------------------12. 7 Adjustment of Valve Clearance-----------------12. 8 12. 1 Service Data Function of cyl

135 Air leakage from cylinder head gasket Too much accumulated carbon in combustion chamber Poor installation of spark p

136 Measure outer diameter of swingarm shaft. Allowable limit: 11. 93mm Measure inner diameter of swingarm hole. Allowable limit: 12.

137 12. 3. 2 Decomposition of valve 12. 4 Inspection Clear carbon accumulated on the cylinder cover. Measure flatness of the interfacing

138 Measure outer diameter of valve rod. Allowable limit: 4. 92mm for discharge and 4. 935 for intake Check the valve guide. Prior to

139 12. 5 Valve guide replacement Attention: If clearance between the valve and its guide, replace the guide. After the guide is r

14 Figure 1-19 Figure 1-20 Figure 1-21

140 Clear carbon accumulated within the combustion chamber and valve, and thoroughly clean the intake and discharge valves. Check width

141 Use a 32° cutter to clear 1/4 of external end of race. Use a 60° cutter to clear 1/4 of bottom of race. Remove the cut

142 If the contact is higher part in the valve, use a 32° cutter to lower the race to its minimum height. If the contact is lower

143

144

145 XIII Cylinder block and piston Service Data--------------------13. 1 Piston----------------------------13. 4 Fault Diagnosis-----------------13.

146 13. 2Fault Diagnosis Low compression pressure White smoke from discharge duct Piston worn, burnt or broken

147 13. 4 Piston 13. 4. 1 Disassembly Remove the piston retaining ring. Attention: During removal, do not fall the retaining ring into crankcase.

148 Measure piston pin hole ID. Allowable limit: 16. 04mm. Measure piston pin hole OD. Allowable limit: 15. 96mm Clearance bet

149 Measure the roundness of cylinder inner wall (difference between X ID and Y ID). Allowable limit: 0. 05mm Measure the cylindricality

15 Figure 1-27 Figure 1-28 Figure 1-29

150 Clear all of gaskets attached on the crankcase. Attention: any foreign matter shall not fall into the crankcase. Install piston, piston pin

151 14. 1 Service Data Function of crankcase: It is a bearing component in the engine. It is provided to support the crankshaft, cl

152 14. 2Fault Diagnosis Low compression pressure Abnormal noise in the crankcase Crankcase air leakage

153 Use the electrical or pneumatic tool to loosen flywheel locking nut. Take out the flywheel component (including sprocket), and remove the idl

154 14.4 Clutch 14.4.1 Dismounting Unscrew the five bolts in the pressure plate with the diagonal cross method. Dismount the clutch spring

155 14.4.2 Clutch disassembly 1 nut; 2 Phillips adjusting screw; 3 thrust washer; 4 plane needle roller bearing; 5 lock nut; 6 bearing sup

156 Measure the free length of the pressure spring. Replace it if the limit is below 29.7 mm. Measure the thickness of the friction

157 Measure the thickness of the plane needle roller bearing. Replace it if the limit is below 1.8mm. Crank connecting rod combination and

158 Gearshift drum Shifting fork Shift rail Principal shaft assembly Vice shaft assembly

159 14.4 Gearshift Mechanism 14.4.1 Dismounting Dismount the gearshift combination. Dismount the upper baffle bolt, the upper baffle and gearshift ra

16 Figure 1-37 （3）Steering nut wrench Figure 1-38 3．Tools

160 Check the abrasion of the locating plate of the gearshift. Replace it if there is too much abrasion. Check if the gearshift shaft is bent. Replac

161 14.5 Crankshaft connecting rod assembly 14.5.1 Dismounting Remove the crankshaft connecting rod assembly from the right crank case. Note: do

162 Check if the crank shaft is noisy or loose while restoring. Replace it if so. Note: both the crank connecting rod and the gearshif

163 14.5.3 Check Measure the external diameter of the shifting fork. Allowable limit: 9.96mm. Measure the inner diameter of the fork hole. All

164 14.6 Gear box assembly Remove the principal shaft assembly. Remove the vice shaft assembly. Dismantling drawing of the principal and vice sh

165 Check Check the abrasion of the wheel gear surface and the drive claw. Replace it if there is too much abrasion or damage. Remove the bear

166 Principal and vice shaft assemblies Note: lubrication oil should be used on the wheel gears and shafts while assembling them. Ensure

167 Exhaust System Inspection and Maintenance Muffler 1 welded components on the muffler; 2 socket head cap screw; 3 liner compon

168 ⅩⅦ Emission Control System Emission Control System Guarantee……………………………………...…...…..15.1 Periodical Maintenance Instructions/Ensuring Emissions

169  This vehicle has passed strict inspection. It completely meets the emissions control standards. Due to the varying concrete conditions of

17 Specifications (QJ200-2A) Model QJ200-2A Engine Engine type QJ168FML-B Overall Length(mm) 2080 Fuel RQ-90 Overall Width(mm) 800 Number o

170 Implement periodic check (maintenance plan) Idling emissions measurement (Note 1) Carburetor adjustment (Note 2) Dismount and clean the carburet

171 Complete QJ200-2A Schematic Circuit Diagram

18

19 Fault Diagnosis Engine will not start or is hard to start. Diagnosis procedures Perform spark-over test Clean deposited carbon Spark is weak be

2 ZHEJIANG QIANJIANG MOTORCYCLE CO.LTD. Content Content ...

20 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 t

21 Yes No Yes No Yes No No Yes Yes No Symptom: Engine Overheats Diagnosis procedures Eng

22 Clutch slips Handle it as Item 1.7. Remove the spark plug and check color of skirt section

23 Symptom: Engine lacks power Diagnosis procedures Yes No Use an ignition timing lamp to check ignition timing of engine Lift it with m

24 Symptom: Poor idle speed of engine Diagnosis procedures Poor idle speed Higher idle speed Engine has no idle speed. Unsteady i

25 Symptom: Too much fuel consumption by the engine Diagnosis procedures Too much fuel consumption Check operation method Lift

26 Symptom: Clutch slips Diagnosis procedures Clutch slips Manually controlled wet multi-plate clutch slips Automatic centrifug

27 Symptom: 4-stroke engine exhaust muffler gives off blue-white smoke Diagnosis procedures Symptom: Incomplete separation of clutch

28 Symptom: Difficult gearshift on transmission Diagnosis procedures Incomplete separation of clutch Check if clearance of clutch handle bar is

29 Yes No Yes Yes No Yes No No Difficult gearshift on transmission Start engine and check if idle is too high. Readjust Check i

3 5.3 Front Hydraulic Brake... 92 5.4 Rear Hydraul

30 Symptom: Jumps of gear on the transmission Diagnosis procedures Jumps of gear on transmission Yes Yes Yes No No No 1.Che

31 No Yes No Yes Yes No Symptom: Drum-type brake fails Diagnosis procedures Symptom: Hydraulic disc brake fails

32 Symptom: Battery can not be charged Diagnosis procedures Yes No Wire from connector to battery is broken. Set multimeter on 0V~20V

33 Symptom: Battery cannot be fully charged Diagnosis procedures Yes

34 Symptom: Starter motor does not run Diagnosis procedures Electric horn does not sound or sound weakly. Turn signal lamp is dim. Electric

35 Coil in starter coil is broken or shorted. Striding Motorcycle Autoscooter Yes Yes No No Check wiring in electrical starter control sy

36 Symptom: Starter motor runs weakly Diagnosis procedures Starter motor runs weakly. Check if the lead wire connector from starter relay

37 Symptom: All the lights are not on Diagnosis procedures Lighting coil of magneto or its output wire is broken or shorted. Test l

38 Replace headlamp bulb and check other bulbs one by one. Check if there is power output from power input wire of light swit

39 Symptom: Light bulb is apt be burnt Diagnosis procedures Light bulb is apt to be burnt. Turn on ignition switch; press horn but

4 14.2 Fault Diagnosis ... 錯誤! 尚未定義書籤。 14.3 Crankcase ...

40 Symptom: Headlamp is dim. Diagnosis procedures Headlamp is dim Separate conductors of lead wire bundle of magnet from cable

41 No Yes

42 Symptom: Turn signal lamp is off. Diagnosis procedures Electric horn does not sound or sounds hoarse. Separate connectors of

43 Separate connectors of turn signal lamp switch and use a piece of wire to short circuit respectively power input line of the switch

44 Symptom: Electric horn mutes. Diagnosis procedures

45 Electric horn mutes. Turn on ignition switch; slide turn signal lamp switch and check. Turn signal lamp is not lit or dim. Turn signal l

46 Symptom: Brake lamp does not work. Diagnosis procedures Brake lamp does not work. Take down cover of brake lamp and check if b

47 Inspection/Adjustment Basic data Compression pressure of cylind

48 Specifications Engine Idle speed 1400±100r/min Spark plug clearance 0.6-0.7mm Spark plug type CR9E Combustion chamber Spherical Ignition time（angl

49 Periodic maintenance schedule chart Mileage and interval Items Every 300 KM Every 1000KM Every 3000 KM Ever

5 Preface The service manual contains descriptions of maintenance essentials on QJ 200-2A motorcycle. Service data include attentions that shall be p

50 * Valve I I I I I Feeler gauge Expected Inspection 1 Ignition system—-perform maintenance inspection on obvious and continuous ignition

51 When the engine oil is completely drained, put back cleaned drain plug and sealing ring. Refill engine oil to specified level. Check if there is

52 * Attention While removing filter element of air cleaner, please do not run the engine, in case unfiltered air comes into the engine, which may r

53 Battery Removal

54 Charging Connection method: Positive pole of battery charger is connected to battery positive lead wire; Negative pole of battery charger is conne

55 Stop the engine and connect the timing lamp to lead wire of spark plug. Remove timing hole cap. Start engine and idle it. Inspect ignition timing.

56 premature component wear. Refilling engine oil of poor quality or different types or brands will reduce lubrication effects. When the engine st

57 Adjust drive chain slackness: Screw off rear shaft nut and locknuts of adjusters on both drive chains. Rotate uniformly both adjusters till the dr

58 Headlamp Remove the locknuts of headlamp . Take down the headlamp. Pull out connector of headlamp holder and remove the reflector. Release

59 Front/rear suspension system Front suspension Grasp the front brake handle and compress upward and downward the front shock absorber to c

6 Service Data General Safety Maintenance Regulation Specification Sheet Fault Diagnosis General Safety Carbon mono

60 Wheel rim/tire Check if there is crack, nails and similar sharp objects, and other injuries on the tyres. * Attention Measure cold inflation tire

61 Inspection and maintenance of electrical system Tightening torque table for fasteners used in electric system Fastening positions and names of fas

62 Charging system Charging System 1.Variable frequency scintillator 2. Ignitor 3. Bat

63 Ⅰ Battery/Charging System Service Data-----------------------1.1 Fault diagnosis----------------------1.2 Battery-------------------------------1

64 8. Quick charging is forbidden except in emergency. 9. During quick charging, the battery must be removed from the motorcycle first an

65 1.3 Battery 1.3.1 Battery Removal Take down the right protecting plate . Disconnect the battery negative lead wire first and then the po

66 * Attention • Battery quick charging is not recommended except in case of emergency. • After charging, measure the battery voltage in 30minutes’ t

67 Disconnect the 6P plug on the voltage-current regulator. Check continuity between main wiring terminals in the following way: Item （wire color）

68 1.7 Magneto Removal 1.7.1 Removal Remove vehicle block protecting plate. Remove protecting plate of engine on the left side. Remove fly

69 ** Attention There is magnetism on the inner surface of flywheel, and make sure there is no bolt. Fix the flywheel using a universal

7 Maintenance Regulations While repairing and servicing, try to use tools of metric system as possible as you can. Incorrect tools may damage the mot

70 Ignition System 1.Variable frequency scintillator 2. Ignitor 3. Battery 4. Voltage regulator 5. High-voltage ignition c

71 Ⅱ Ignition System Service data------------------------------2.1 CDI assembly----------------------2.4 Fault diagnosis---------------------------2

72 Ignition coil impedance value（20℃） Primary coil 0.35±15%Ω Secondary coil With spark plug cap 8-11KΩ Without spark plug cap 4.2±15%KΩ Impedance val

73 No high-voltage power supply or high voltage power is sporadic. ①Defective ignition coil. ②Defective charging coil. Trigger High-voltage power sup

74 *Attention Please do not touch the metal parts of testing probe with your fingers while measuring voltage, or you will be shocked. Please take car

75 2.4 CDI Assembly 2.4.1 System Inspection System inspection. Remove CDI assembly and check components related to ignition system at wiring termin

76 Measure impedance between terminals of primary coil. Standard value:0.4Ω±10％（20℃） Impedance value within the range is good. Impedance value “∞

77 Starting System 1.Variable frequency scintillator 2. Ignitor 3. Battery 4. Voltage regulator 5. High-voltage ignition coil

78 Ⅲ Starting System Service Data-----------3.1 Fault diagnosis--------3.2 Starter motor-----------3.3 Starter relay------------3.4 3.1 Service Data

79 3.2 Fault Diagnosis Stator motor cannot run Stator motor runs weakly Starter motor rotates but the engine does not •Broken Fuse

8 Length of bolts and screws are different for assemblies and protecting plates. They shall be installed at correct positions. If confused, just put

80 assemblies. Confirm uncontinuity of armature shaft among surfaces of commutator. Inspect for continuity of starter motor housing. Confirm incontin

81 3.4 Starter Relay 3.4.1 Actuation Inspection Take down the protecting plate of vehicle block. When the ignition switch is set at “ON” posi

82 Bulbs/Switches/Instruments 1 Instrument 2 Headlamp 3 Front right turn signal lam

83 Bulbs/Switches/Instruments Service data----------------------------------------4.1 Instrument----------------4.6 Fault diagnosis-----------------

84 4.2 Fault Diagnosis “ON” lamp of ignition switch is not lit. • Defective bulb. • Defective switch. • Poor contact of connector or broken wire. • L

85 4.4 Front turn signal lamp bulb replacement 4.4.1 Removal Disconnect wire to turn signal lamp. Screw off self-tapping screw on the turn signal lam

86 4.5.3.1 Removal Screw off mounting bolts on the tail lamp hood. Remove tail lamp hood（1）so that tail lamp bulb can be removed. Remove the tail l

87 Remove the front protecting plate. Unscrew the mounting bolt and take down the main switch holder. Remove the mounting bolt and replace the main

88 Chassis Inspection and Maintenance Tightening Torque of Fasteners on Chassis Fastening positions and names of fasteners Tightening Torque（N·m） Oil

89 Front Hydraulic Brake 1 Oil pump block assembly 2 Front brake handle 3 Bolt 4 Nut 5 Fixing cover 6 Bolt M6×23

9 Slack cable implies potential safety hazard on electrics. Check the next cable when the cable is clamped to ensure electric safety; Ca

90 Rear Hydraulic Brake A Mounting torque for Nut 17 in the diagram: 5-9 N·m B Rear brake drum ID:130 Service limit:131 C Thickness of fricti

91 Ⅴ Braking System Maintenance instruction-------------------5.1 Fault diagnosis-------------------------------5.2 Front hydraulic brake------------

92 5.2 Fault Diagnosis Braking System Poor braking performance Brake drags or tight handle 1. Improper brake adjustment

93 5.3.2 Inspection Check if the friction linings are worn out. Replace them if necessary. Measure friction lining and hydraulic brake disc and r

94 Do not contaminate friction linings with oil. If a friction lining is polluted by oil, clean it with brake cleaner. *Attention A contaminated f

95 Measure thickness of braking shoes and hydraulic brake discs. If the braking

96 Exterior 1. Mounting plate, right guiding cover 2. Mounting plate, guiding cover 3. Mounting plate, left guiding cover, 4. Lef

97 VI. Motorcycle exterior Disassemble the motorcycle body in the following sequence. Seat cushion assembly→ Left guard component→ Right guard

98 Front wheel 1 Front wheel shaft 2 Gear housing assembly 3 Rolling bearing 4 Intermediate sleeve, front wheel 5 Gear housing oil seal com

99 Steering handlebar 1 RR mirror assembly 2 LR mirror assembly 3 Handlebar stop 4 Right handlebar component 5 Right combined