Baotian BT49QT-28 Service Manual

Text of Baotian BT49QT-28 User Guide:

• Baotian BT49QT-28, 34 3. Voltage Adjusting Rectifier Troubles Causes Inspection method troubleshooting parameter Burnt bulb in lighting system Damaged voltage adjusting part of voltage adjusting rectifier Start engine and measure lighting coil voltage. In case voltage rises with the rise of engine speed, trouble exists. Replace voltage adjusting rectifier Voltage: 8- 12V Storage battery overcharging or overdischarging Damaged voltage adjusting part of voltage adjusting rectifier Start engine, measure charging voltage and charging current Voltage: 11.1～16.8V Current: 0.5�

• Baotian BT49QT-28, 18 Axle Bending Inspection Place axle on a V-seat and measure with a dial gauge. The dial gauge indicates a 1/2 bending value. Limit of use: Replace if >0.2mm. Wheel Rim Oscillation Inspection Measure oscillation value on a correcting bench. Limit of use: Replace if >2.0mm. Traverse direction: Replace if >2.0mm. Front Wheel Bearing Inspection Remove front wheel bearing and dust cover. Turn bearing inner race to inspect sliding. Replace it with a new on

• Baotian BT49QT-28, 1 CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE Ⅰ ⅠⅠ Ⅰ. ITEMS OF MAINTENANCE When the motorcycle is used, parts loose and mechanical wear inevitably occur to varied extents. Neglecting of timely maintenance not only reduces its mechanical function, economic performance, stability and durability, but also threatens the safety of the motorcycle and the rider. Correct and timely maintenance of the motorcycle is necessary. Items of maintenance refer to the parts and positions for maintenance. Different items of maintenance are affected in

• Baotian BT49QT-28, CONTENTS CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE Ⅰ. ITEMS OF MAINTENANCE 1 Ⅱ. PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS 1 Ⅲ. MAINTENANCE SPECIFICATIONS 4 Ⅳ. THROTTLE ACTUATION INSPECTION 5 Ⅴ. AIR FILTER INSPECTION AND CLEANING 6 Ⅵ. BRAKE BLOCKS INSPECTION

• Baotian BT49QT-28, 21 Inspection Inspect for wear or ageing of main and auxiliary cups on pistons. Inspect for scratches and other damages on main cylinder and piston. Measure main cylinder bore. Measure the outside diameter of piston at the end of auxiliary cup. Mounting Apply pure brake oil to piston, main cup and auxiliary cup. Mount spring, piston, retaining ring and piston cap. ·Piston cup cannot be used inside out. Apply grease to brake lever axis pin. Mount brake lever and brake switch. Mount main cyl

• 17 SECTION TWO DETAILED DESCRIPTION OF BODY PARTS MALFUNCTION Precautions in Operation:  Forced mounting or dismounting of body cover parts will cause damage to claws and slots of corresponding hoods.  When mounting body cover parts, be sure to align the corresponding parts of hoods.  When mounting body cover parts, avoid pressin

• 20 Connect a transparent hose to exhaust valve. Grip brake lever fast and open exhaust valve 1/2 turn to let out air and lock exhaust valve. Repeat this operation till no bubbles are exhausted from brake oil passage. ·Do not release brake lever before exhaust valve is closed. At the completion of adjustment, replenish brake oil till o

• Baotian BT49QT-28, 27 Inspection Inspect rear shock absorber oil seal for oil leakage, inspect buffer bar and spring for deformation and other parts for damage and loosening. Mounting Mount rear shock absorber. Torque: upper mounting bolt: 40N·m lower mounting bolt: 25N·m Mount motorcycle body covering parts.

• Baotian BT49QT-28, Ⅲ. FRONT SHOCK ABSORBER SERVICE 48 Ⅳ. FRONT FORK SERVICE 48 Ⅴ. HANDLEBAR SERVICE 50 Ⅵ. REAR WHEEL SERVICE 51 Ⅶ. REAR BRAKE SERVICE (DISK BRAKE) 52 Ⅷ. REAR SHOCK ABSORBER SERVICE 53 Ⅸ. COOLAN

• Baotian BT49QT-28, 16 Chart continued Troubles Causes Details (reference) Deviation of motorcycle direction (inclining to roadside) Steering stem rotation not easy Refer to “Front Fork Service” Bent shock absorber Refer to “Front Shock Absorber Service” Shock absorber oil leakage Bent front axle, incorrect wheel mounting Refer to “Front Wheel Service” Roundness error of wheel rim Deformation of wheel rim Inadequate tire pressure Front wheel oscillation Deformed wheel rim Refer to “Front Wheel Service” Loose front wh

• Baotian BT49QT-28, 46 6.Handlebar Switch Remove handlebar switch connector. Inspect conductivity between connector terminals. Headlight Switch Starting Switch Horn Switch

• Baotian BT49QT-28, 15 Chart continued Troubles Causes Details (reference) Disk brake failure Feeble brake lever Inadequate liquid Refer to “Brake System Inspection, Adjustment and Replacement, Front brake service or rear brake service” Contaminated brake block and brake disc Bent or deformed brake disc Contaminated brake caliper Worn seal ring of brake caliper piston Viscous or worn brake caliper piston Inability of brake caliper normal sliding Worn main cylinder piston seal ring Viscous or worn main cylinder piston Contaminated main cylinder Stiff brake le

• Baotian BT49QT-28, 4 IV. THROTTLE ACTUATION INSPECTION Inspect throttle grip for easy and smooth movement. Inspect throttle free travel. Free travel: 2-6mm The main adjusting position is beside the carburetor. Remove rear store case inner cover. Adjust by loosening the fastening nut and turning the adjusting nut. Fine adjustment is effected on the side of the throttle grip. Effected adjustment is by removing the dust cover, loosening the tightening nut and turning the adjusting nut.

• Baotian BT49QT-28, 14 CHAPTER FOUR BODY TROUBLESHOOTING SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION Body part common troubles and possible causes are as follows: Troubles Causes Details (reference) Handlebar rotation not easy (strenuous turning or unstable tightness) Over tightening of handlebar adjusting nut Refer to “Front Fork Service” Steering stem over worn Heavy steering stem turning Incorrect mounting of brake cable or tachometer cable Refer to “Handlebar Service”, “Front Fork Service” Remarkable deformation of steering stem due to outside imp

• Baotian BT49QT-28, 41 Primary Coil Inspection Measure resistance between primary terminals. Standard value: 0.21Ω±10% (20℃) Resistance within standard value indicates good state. Resistance “∞” (infinity) indicates open circuit of coil. Replace coil. Secondary Coil Inspection Measure primary coil resistance between terminals. Standard value: 7～12kΩ (20℃) Resistance value: “∞”indicates breakage of wire in coil. Remove spark plug cover, measure resistance between wire at primary ignition coil side and negative terminal. St

• 38 Ignition Primary Coil Voltage Remove spark plug as illustrated and mount a faultless spark plug. Connect spark plug with engine earthling. Note:  Effect correct connection of wires and their measurements。  Cylinder compression pressure measurement is effected in normal condition (measure with spark plug fitted on cylinder head).

• Baotian BT49QT-28, 40 3. 3.3. 3. CDI Check CDI CheckCDI Check CDI Check Troubles Causes 1. Poor contact 2. Absence of high-voltage 3. Occasional misfire 4. Poor acceleration 5. Effective kick starting, elctronic starting failure 1. Damaged terminal, poor connecting or contact 2. punctured or damaged diode 3. punctured or damaged transistor 4. punctured or damaged thyristor 5. integrated circuit 6. damaged capacitor or resistor Open storage battery cover. Remove CDI set, in

• Baotian BT49QT-28, 3 Ⅲ ⅢⅢ Ⅲ. MAINTENANCE SPECIFICATIONS The basic methods of motorcycle maintenance include inspection, adjustment, tightening, lubrication, cleaning, supplementing and replacement, which constitute the main elements of maintenance. 1. Inspection Inspection refers to basic inspecting operations in accordance with items and requirements specified in the user’s manual, including inspection with instruments or with eyes for abnormalities in machine parts, directly

• 35 Main Wire Terminal Loop Inspection Remove front cover. Remove voltage adjusting rectifier plug 4P and measure conductivity between main wire terminals. Item (wire color) judgment Between storage (red) and motorcycle earthing With storage battery voltage Between earthing wire (green) and motorcycle earthing With conductivity Between lighting wire (yellow) and motorcycle earthing

• Baotian BT49QT-28, 37 ignition and charging coils ○, 2 Poor ignition and charging coils Troubles Causes (Inspect and judge from ○ ○○ ○, 1 ) Trigger coil voltage too low ○, 1 Inner resistance too low, measuree with specified circuit tester. ○, 2 Crankshaft speed too low (storage battery voltage too low or starting rod too feeble when tread on). ○, 3 Circuit tester interfered (normal value: repeated measurement readings above reference value). ○, 4 Poor trigger coil (when ○, 1 ～○, 3

• Baotian BT49QT-28, 39 Ignition and Charging Coil Note:  Mount spark plug on cylinder head, inspect at normal compression pressure. Remove CDI set connector 6P, connect distributor between ignition and charging coil at wire terminal (black/red terminal) and green terminal. Actuate starting motor or tread on starting rod, measure ignition and charging coil maximum voltage. Connecting method: Positive terminal connected with black/red wire and negative terminal connected with green wire. Minimum voltage: 9

• Baotian BT49QT-28, 47 Direction Light Switch Lighting Lamps Switching Switch Brake Switch Remove instrument hood. Remove brake switch wire. There should be conductivity between two wires while brake bar is gripped.

• 22 absorber arm and if there is damage or loosening of any part. Mounting Mount front shock absorber on front fork and mount 2 bolts. Torque: upper bolt 40N·m. Mount bodycovering parts. Mount front wheel. Mount front fender and front brake caliper. Ⅳ ⅣⅣ Ⅳ. FRONT FORK SERVICE Dismounting Remove front body covering parts. Remove bolt, bush and n

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