Instruction and Maintenance Manual

 

 

ZHEJIANG QIANJIANG MOTORCYCLE CO., LTD.

Contents

PrefaceЎ¤ - 1 -

Preparatory DataЎ¤ - 2 -

Inspection/Adjustment - 15 -

Check and Maintenance of Body Ў¤ - 32 -

I Braking System Ў¤Ў¤ - 34 -

1.1 Maintenance InstructionЎ¤ - 34 -

1.2 Fault diagnosis - 35 -

1.3 Front Hydraulic BrakeЎ¤ - 36 -

1.4 Back liquid brakeЎ¤ - 38 -

II Vehicle Housing Ў¤ - 42 -

III Front Wheel/Front Suspension Ў¤ - 45 -

3.1 Preparatory DataЎ¤ - 45 -

3.2 Fault diagnosis - 45 -

3.3 Front wheel - 47 -

3.4 Direction handleЎ¤ - 49 -

3.5 Front forkЎ¤ - 49 -

IV Rear Wheel/Rear Suspension Ў¤ - 54 -

4.1 Preparatory DataЎ¤ - 54 -

4.2 Fault Diagnosis - 55 -

4.3 Rear wheel - 56 -

4.4 Rear Shock Absorber - 57 -

4.5 Rear Swing ArmЎ¤Ў¤ - 58 -

4.6 Drive ChainЎ¤ - 59 -

V Storage Battery/Charging System Ў¤Ў¤ - 62 -

5.1 Preparatory DataЎ¤ - 62 -

5.2 Fault Diagnosis - 63 -

5.3 Storage BatteryЎ¤ - 64 -

5.4 Charging SystemЎ¤Ў¤ - 65 -

5.5 Voltage-current Regulator - 66 -

5.6 Alternator Charging Coil - 67 -

5.7 alternator light coil - 67 -

5.8 disassembly of alternator - 68 -

VI Ignition System Ў¤Ў¤ - 71 -

6.1 Preparatory DataЎ¤ - 71 -

6.2 Fault Diagnosis - 72 -

6.3 Ignition System InspectionЎ¤ - 73 -

6.4 CDI AssemblyЎ¤ - 75 -

6.5 Ignition Coil - 75 -

6.6 Trigger - 76 -

VIIStarting System Ў¤Ў¤ - 78 -

7.1 Preparatory DataЎ¤ - 78 -

7.2 Fault Diagnosis - 79 -

7.3 Starting Motor - 79 -

7.4 Starting RelayЎ¤ - 81 -

VIIIBulbs/Switches/Instruments - 82 -

8.1 Preparatory DataЎ¤ - 82 -

8.2 Fault Diagnosis - 82 -

8.3 Headlamp Bulb Replacement - 83 -

8.4 Front Turn Signal Lamp Bulb Replacement - 84 -

8.5 Taillight/license plate lamp/rear turn-lamp bulb replacement - 84 -

8.6 Instrument - 85 -

8.7 Main SwitchЎ¤ - 85 -

8.8 HornЎ¤ - 86 -

8.9 Handle switchЎ¤ - 86 -

Engine Inspection and Maintenance Ў¤ - 87 -

IX Lubricating System Ў¤Ў¤ - 89 -

9.1 Preparatory DataЎ¤ - 89 -

9.2 Fault Diagnosis - 89 -

9.3 Oil PumpЎ¤ - 90 -

X Cooling system Ў¤Ў¤ - 93 -

10.1 Preparatory dataЎ¤ - 93 -

10.2 Fault diagnosis - 93 -

10.3 Water pumpЎ¤ - 94 -

XI Cylinder Head Ў¤ - 97 -

11.1 Preparatory DataЎ¤ - 97 -

11.2 Fault Diagnosis - 98 -

11.3 Cylinder HeadЎ¤ - 98 -

XII Cylinder Block and Piston Ў¤ - 107 -

12.1 Preparatory DataЎ¤ - 107 -

12.2 Fault Diagnosis - 108 -

12.3 Cylinder HeadЎ¤ - 108 -

XIII Crankcase Ў¤ - 113 -

13.1 Preparatory DataЎ¤ - 113 -

13.2 Fault Diagnosis - 114 -

13.3 CrankcaseЎ¤ - 115 -

13.4 ClutchЎ¤ - 116 -

13.5 Gearshift mechanismЎ¤Ў¤ - 121 -

13.6 Crankcase connecting rod combinationЎ¤ - 122 -

13.7 Variable speed chamber - 125 -

Exhaust System Inspection and Maintenance Ў¤ - 128 -

XV Emission Control System Ў¤Ў¤ - 129 -

15.1 Emission Control System GuaranteeЎ¤ - 129 -

15.2 Regular maintenance guidelines - 129 -

15.3 Emission Control System Mechanical Functions - 130 -

15.4 Catalyst conversion systemЎ¤Ў¤ - 131 -

15.5 Solutions to Idle Exhaust Exceeding Specified ValueЎ¤ - 132 -

Inspection and Maintenance of EFI System Ў¤Ў¤ - 133 -

XVIEFI System Description Ў¤ - 134 -

16.1 Introduction to EFI System of finished enginecycleЎ¤ - 134 -

16.2 EFI system parts - 134 -

16.3 Troubleshooting diagnosis - 146 -

16.4 Common troubleshootingЎ¤ - 153 -

16.4.3 Concise troubleshootingЎ¤ - 154 -

QJ125GY-16A circuit diagram Ў¤Ў¤ i

 

Preface

 

The Instruction and Maintenance Manual contains an introductory description of maintenance on QJ125GY-16A motorcycle.

Preparatory data include attentions that shall be paid on all the maintenance operations in the Instruction and Maintenance Manual. Please read the manual carefully before operation.

Check and adjustment contains main aspects for inspection and adjustment, safety of the vehicle, performance and maintenance of each component. This shall be started from the time of periodical inspection.

The parts following Chapter One demonstrate the main point of disassembly, installation and check of electrics parts, finished vehicle, engine and other components.

System diagrams, breakdown drawings, fault diagnosis, maintenance and other explanatory contents are presented before each part.

Note:

The parts which are not explained separately in the manual apply to both of the motorcycles.

For any pattern and structure change of the motorcycle, or any difference between the product and pictures, drawings and instructions in the manual, the product shall prevail. The product is subject to changes without prior personal notice.

 

ZHEJIANG QIANJIANG MOTORCYCLE CO., LTD.

Finished Automobile Institute

Preparatory Data

General Safety Maintenance Rules

Specification Table Fault Diagnosis

General Safety

Carbon monoxide (CO)

When it is necessary to start the engine, please make sure the operation area is well ventilated. Never run the engine in an enclosed place.

Attention

Gas exhausted from the motorcycle contains harmful carbon monoxide, which may lead to loss of consciousness and death.

It is necessary to run the engine in an open area. To run the engine in an enclosed site, ventilation system shall be used.

Gasoline

Operate in well-ventilated site. No fire or smoking is allowed in operation site and gasoline storage place.

Storage Battery

Electrolyte in the storage battery has sulfuric acid, so leave eyesЎўskin and clothes away from it. Once got electrolyte on our skin or clothes, you will have to wash them by fresh water thoroughly; once into our eyes, to see a doctor immediately is necessary.

Special Tool

When disassembly and installation is in process, general tools and special tools should be selected correctly. When it is time to use the special, the general can not be substitution. Besides, appropriate power is welcomed to avoid the damage of components.

High Temperature Burn

Tips: Do not be burned by engine, exhaust pipe,silencer and other components with high temperature. When operating together with others, youЎЇd better look after each other and keep a way for safety.

Maintenance Rules

While repairing and servicing, use tools of metric system as possible. Incorrect tools may damage the motorcycle.

Before taking down or opening protecting plate for repair work, please clean the dirt on the external surfaces of components or combination parts and prevent the dirt from falling into engine, chassis or braking system

After disassembly and before measuring friction, please clean the components and blow them with compressed air.

 

 

ЎЄBending or Warping are forbidden in operation, otherwise tough operation or advanced damage will be caused.

 

Plastic parts may age and deteriorate, which are apt to be damaged by solvent or oil. Check before re-installation and replace if necessary.

 

To loose component with many assembling units, it shall start from external to internal and loosen smaller assemblies first.

The complicated assemblies such as transmission case shall be put in proper assembling order for easy assembly in the future.

 

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.

 

Length of bolts and screws are different for assembly components and protecting plates. They shall be installed at correct positions. If confused, just put the bolt in 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 there is any damage to it.

 

 

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 dust cover back to its originally designed position

 

 

Disassembly of ball bearing: use a tool to push against one or two (internal and external) bearing races. If the force works only on one bearing race (whatever internal or external), it may be damaged when the bearing is disassembled, in which case, it must be replaced

Specifications (QJ125GY-16A)

Model	QJ125GY-16A	Engine	Engine type	QJ160MI-A
Overall Length (mm)		Fuel type	92# or 95# unleaded gasoline
Overall Width (mm)		Number of cylinders
Overall height (mm)		Bore*stroke	§¶60 mm *44 mm
Wheelbase (mm)		Displacement	124.4
Vehicle Weight (kg)	Front axle	63kg	Starting mode	Electric
Rear axle	76kg	Cooling mode	Water cooled
Total	139kg	Lubricating mode	Force-feed and splash lubrication
Wheel Specification	Front (External)	Fuel tank capacity	1.2L(Oil change1L)
100/80-17
RearЈЁExternalЈ©	Air cleaner	Filter sponge
130/80-17
Drive Train	Clutch type	Wet multi-plate friction type	Fuel tank capacity	7.5L ЎА 0.2L
Performance	Top speed	110 km/h
Gear shift pattern	Manual 6 gear	Slope climbing force	Maximum climbing angle is not less than 20 degrees
Idle speed	1700ЎА 100rpm/min
Drive Train	Clutch type
Max. torque	12.18NЎ¤m/7500r/min
Electrical	Battery capacity/type	12V-6AH/YUASA TT27SL	Max. power	11 Kw/ 9000 r/min
Generator type	Alternating current permanent magnetic motor	Compression ratio	12.0: 1
Spark plug	NGK CR8E	Pressure of cylinder	8.5Mpa
Spark plug clearance	0.7~0.8mm	Braking system	Diameter of front brake disc	¦Х280mm
Ignition type	CDI	Diameter of rear brake disc	¦Х240mm

QJ125GY-16A

Fault Diagnosis