KEEWAY F-ACT EVO Instruction & Maintenance Manual

Two-wheeled Motorcycle F-ACT EVO

User’s Instruction and Maintenance Manual

KEEWAY Motorcycle Co., Ltd

- 1 -

Content ................................................................. 错误！未定义书签。

Preface .............................................................................. - 3 -

Preparation Data ................................................................. - 4 -

Inspection/Adjustment ........................................................... - 36 -

Inspection and maintenance of electrical system ..................................... - 50 -

1. Battery/charging system .......................................................... - 52 -

1.1 Preparing documents ......................................................... - 52 -

1.2 Failure diagnosis ........................................................... - 53 -

1.3 Battery ..................................................................... - 54 -

1.4 Charging System ............................................................. - 55 -

1.5 Rectifier ................................................................... - 56 -

1.6 Magnetor Charging Coil ...................................................... - 56 -

1.7 Magnetor Lighting Coil ...................................................... - 57 -

2. Ignition System .................................................................. - 60 -

2.1 Material Preparation ........................................................ - 60 -

2.2 Failure Diagnosis ........................................................... - 61 -

2.3 Ignition System Inspection .................................................. - 62 -

2.4 CDI Group ................................................................... - 64 -

2.5 Ignition Coil ............................................................... - 64 -

2.6 Trigger ..................................................................... - 65 -

3. Activation System ................................................................ - 67 -

3.1 Material Preparation ........................................................ - 67 -

3.2 Failure Diagnosis ........................................................... - 68 -

3.3 Starting Motor .............................................................. - 68 -

3.4 Starting Relay .............................................................. - 70 -

4. Bulbs/Switches/Meters ............................................................ - 73 -

4.1 Material Preparation ........................................................ - 73 -

4.2 Failure Diagnosis ........................................................... - 73 -

4.3 Headlight Bulb Replacement .................................................. - 73 -

4.4 Front Turn Signal Lamp Bulb Replacement ..................................... - 74 -

4.5 Taillight Bulb Replacement .................................................. - 74 -

4.6 Meters ...................................................................... - 75 -

4.7 Power Lock .................................................................. - 75 -

4.8 Speaker .......................................................................... 76

4.9 Handle switch ..................................................................... 76

The check and maintenance of the chassis ...................................................... 77

5. Brake ................................................................................. 80

5.1 Maintenance instructions ............................................................. 80

5.3 Front hydraulic brake ............................................................ - 82 -

5.4 Rear hub brake ................................................................. - 83 -

6. Body cover ......................................................................... - 87 -

7. Front wheel/front suspension ........................................................... - 92 -

7.1 Preparation data ................................................................ - 92 -

7.2 Fault diagnosis ................................................................. - 92 -

- 2 -

7.3 Front wheel ................................................................... - 93 -

7.4 Direction handle................................................................ - 96 -

7.5 Front fork ..................................................................... - 96 -

8. Rear wheel/rear suspension ........................................................... - 100 -

8.1 Preparation data ............................................................... - 100 -

8.2 Fault diagnosis ................................................................ - 100 -

8.3 The rear wheel ............................................................. - 101 -

8.4 Rear muffler .................................................................. - 102 -

9. Tank/seat cushion ................................................................... - 106 -

9.1 Preparation data ............................................................... - 106 -

9.2 Fault diagnosis ................................................................ - 106 -

9.3 Tank/seat cushion .............................................................. - 107 -

Check and maintenance of the engine ..................................................... - 108 -

10. Lubricating system................................................................. - 111 -

10.1 Preparation data .............................................................. - 111 -

10.2 Fault diagnosis ............................................................... - 111 -

10.3 Machine oil pump ............................................................ - 112 -

11.1 Preparation data .............................................................. - 115 -

Operation precautions ............................................................. - 115 -

11.2 Fault diagnosis ............................................................... - 115 -

11.3 Disassembly of carburetor ...................................................... - 116 -

11.4 Assembly and adjustment ...................................................... - 118 -

12. Cylinder cover .................................................................... - 121 -

12.1 Preparation materials .......................................................... - 121 -

12.2 Failure diagnosis ............................................................. - 121 -

12.3 Cylinder cover ............................................................... - 121 -

12.4 Checking of cylinder cover ..................................................... - 122 -

12.5 Assembly of cylinder cover ..................................................... - 122 -

Thirteenth, Cylinder block and piston ..................................................... - 124 -

13.1 Preparation materials .......................................................... - 124 -

13.2 Failure diagnosis ............................................................. - 125 -

13.3 Cylinder block ............................................................... - 125 -

13.4 Piston ...................................................................... - 126 -

13.5 Assembly of piston ........................................................... - 128 -

14.1 Preparation of materials ........................................................ - 131 -

14.2 Failure diagnosis ............................................................. - 131 -

14.3 Left crankcase cover .......................................................... - 132 -

14.4 Driving plate ................................................................ - 132 -

14.5 Clutch/Driven wheel .......................................................... - 134 -

14.6 Disassembly of clutch and driven wheel ........................................... - 136 -

14.7 Assembly ................................................................... - 139 -

14.8 Feet start mechanism .......................................................... - 139 -

- 3 -

Preface

This maintainence manual mainly describes the maintainence essentials of the

Qiangjiang QJ50T-21T.

The Preparation Data include all the operation precautions, please read this

maintainence manual carefully before any operation.

Check & Adjustment mainly describes the essentials of check and adjustment,

vehicle safety and the performance maintenance method of various components.

Check & Adjustment should be implemented from the time of periodic check.

The content after Chapter I mainly describe the assembly, disassembly and

check essentials of motor, complete vehicle and electric fittings.

Every Chapter is accompanied by an exploded view, system diagram, and failure

diagonosis and instructions during the editing.

Notice:

Actual product may differ from the photo or illustration on the manual. The style

or structure of the vehicle shall be subject to other changes without further notices.

KEEWAY Motorcycle Co., Ltd

- 4 -

Preparation Data

General Safety Maintenance Regulations

Specification Sheet Failure Diagonosis

General Safety

Carbon Monoxide (CO)

If the motor has to been started, make sure the working space is well ventilated, the motor can not be run in closed

space.

Caution

The exhaust gas contains toxic gas carbon monoxide (CO), which may render people unconscious or even cause

death.

The motor should be run in the open space, if in closed space, the gas scavenging system shall be used.

Gasoline

The vehicle shall be worked in a well ventilated place, no smoking or naked lights in working place or

gasolince-stored place.

Storage Battery

Storage battery may emit explosive gas, which should be far away from sparkles, naked fire and smoking areas.

The space shall be well ventilated when charging the battery.

Storage battery containes sulphuric acid (electrolyte). It will cause serious burns if it gets on the skin or eys.

Therefore, protective clothing and face mask should be worn in operation.

——Please flush with water immediately if the electrolyte gets on the skin.

——Immediately flush with large amounts of water for at least 15 minutes and seek medical attention

immediately if the electrolyte gets on the eyes.

The electrolyte is tocix. If swallow any of such electrolyte by mistake, immediately drink large amounts of water,

milk and milk of magnesia (a kind of laxative antacid) or vegetable oil and seek medical attention. Keep it out of

reach of children.

Users shall not disconnect the storage battery during the adjustment of complete vehicle, otherwise may cause

internal damage to the components of the whole vehicle.

- 5 -

Maintenance Regulations

During the maintence of the motorcycle, please use the metric instruments whenever possible, improper

instruments may cause damage to the motorcycle.

Before the maintainence operation of disconnecting or opening the protecting plate, please eliminate the pollution

outside the parts or assembly parts to prevent the pollution fall into the motor, bottom plate or brake system.

After disconnecting and before measuring the wear value, please

purge the components and blow through with the air compressor.

The rubber parts may deteriorate because of aging, which is

extremely damaged by solvents or oil. Therefore it should be

checked before reassembly and replaced when necessary.

When loosing the components which have many assembly parts,

the loosing sequence should be from exterior to interior, and the

samll assembly part should be loosed first.

The complex assembly part such as speed gear box shall be

stored in proper sequence for the easy assemble in the future.

Special attention should be paid to the important attachment

postions before disassembly. The non-used components should

be replaced in time before disassembly.

- 6 -

The length of bolt or screw is different in terms of assembly parts

and protective plate. It should be installed in the right position, if

confused, place the bolt into the hole to check whether it fits or

not.

When installing the oil seal, please fill the grease lubricant into

the oil seal groove, and check the oil seal is smooth or not,

otherwise it may damage the oil seal.

When installing the rubber hose (fuel oil, vacuum or coolant), the

end of the rubber hose shall be inserted into the connection

bottom, so that the hose clamp has enough space to grip the

connection. The rubber of plastic dust cover shall be put into the

original design position.

Disassembly of ball bearing: use the instrument to withstand one

or two (inside and outside) bearing race ring. If the strength is

only used on one race ring (no matter inside or outside), it may

cause damage to bearing when disassembling and the bearing has

to be replaced.

- 7 -

The loose cable is the potential electric safety hazard. After

clamping the cable, please check the following one to ensure

the electric safety;

The wire clip is not allowed to bend towards the welding spot

direction;

Please bind the cables at the specified position；

The cable can not be routed on the end or closed angle of the

frame;

The cable can not be routed on the end of bolt or screw;

The cable routing shall be kept away from a heat source or

the place which may clip the cable when moving;

Over tightening or over loosening shall be avoided when the

cable is routed along the cocket handle, and no contacting

with the adjacent components in any steering position;

The cable routing shall be smooth without twisting or

knotting;

Please confirm if there is any damage to the connector

assembly sheath or any excessive expansion of the connector

assembly before the butt joint of the onnector assembly;

If the cable is placed on the closed angle or corner, please use

tape or hose to protect;

Please use the tape to wrap the cable after repairing;

The control wire shall be free from twisting or knotting. Any

damage to the control wire may cause inadequate control;

- 8 -

Motorcycle Identification

1．The motorcycle indentification number is printed on the

frame ① , please see Figure 1-1. Indentification number:

LBB11B05?????????. The ninth number of the vehicle

indentification number is the chek code, the tenth one year code

and the eleventh one assembly factory code. The frame

nameplate is riveted on the left side ② of the frame.

Figure 1-1

2．The engine series number ① is printed on the outer shell

of crankcase, please see Figure 1-2.

Figure 1-2

Important Notices:

1．Please use the pure components manufactured by Qiangjiang. Use the components not complying with the

design specifications of Qiangjiang Company may cause damage to the engine.

2．Use only the metric instruments to do the maintainence operation. The metric bolt, nut and screw are not

interchangeable with the British fastener.

3．When reassembling, new washer, O ring, split pin and locking plate should be replaced.

4．When tightening bolt or nut, unless otherwise specified, bolt with larger diameter or near the inner side should

be tightened first, then along the diagonal line, gradually tighten the bolt to stated torque.

5．Wash the disassembled parts with cleaning solution. Lubricate all the sliding surfaces before assembling.

6．After assembling, please check all the components are assembled and operated in a proper way.

7. Eliminate the pollution and oil before measuring, and add the recommended lubricant onto the oil site when

assembling.

8. If the engine and drive system need to be stored for a long time after disassembling, please spread lubricant

onto the surface of the parts to prevent rusting and dust.

- 9 -

Special Tools

Special tools are the specially designed tools used for special positions in order to assemble or disassemble

certain parts of the motorcycle. Proper special tools are essential in terms of the complete and proper adjustment

and assembling. The special tools can assemble and disassemble parts safely, dependably and quickly, which can

improve working efficiency by saving labor and energy.

1 Tools used for the overhaul of engine

When assembling and disassembling the engine, specially designed tools are needed to properly assemble and

disassemble some parts.

The special tools list to assemble and disassemble the engine parts and the corresponding physical figure,

please see Table 1-1 and 1-2.

Table 1-1

Name

Note

special socket wrench

clutch clamper

flywheel extractor

proof stick

bearing disassembling tool

bearing assembling tool

oil seal assembler/disassembler

dismantling tool handle

piston pin pulling off device

piston ring opening pliers

spark plug socket wrench

measuring the thickness of clutch

cylinder diameter determinator

dial gauge

Used for assembling and disassembling Flywheel Bolt, Figure 1-3

Figure 1-4

Figure 1-5

Figure 1-6

Figure 1-7

Figure 1-8

Figure 1-9

Figure 1-10

Figure 1-11

Figure 1-12

Figure 1-13

Figure 1-14

Figure 1-15

Measuring the inside diameter of piston pin hole，Figure 1-16

Continuation Table 1-2

Figure 1-3 Figure 1-4

- 10 -

Figure 1-5 Figure 1-6

Figure 1-7 Figure 1-8

Figure 1-9 Figure 1-10

① Handle

Figure 1-11 Figure 1-12

- 11 -

①Opening pliers ②Piston

Figure 1-13 Figure 1-14

Figure 1-15 Figure 1-16

2．Tools used for the overhaul of chassis

The special tools list to assemble and disassemble the chassis parts and the corresponding physical figure,

please see Table 1-11 and 1-18.

Table 1-17

Name

Note

torque wrench

inner hexagonal wrench

socket wrench

micrometer

magnetic frame, V-block

dial gauge

vernier caliper

spring retaining ring pliers

knocker screwdriver

front fork oil seal assembling tool

front fork seal driver

steering nut wrench

Figure 1-19

Figure 1-20

Figure 1-21

Figure 1-22

Figure 1-23

Figure 1-24

Figure 1-25

Figure 1-26

Figure 1-27

Figure 1-28

Figure 1-29

Figure 1-30

（1）Universal tool for the overhaul of chassis

Continuation Table 1-18

- 12 -

Figure 1-19 Figure 1-20

Figure 1-21 Figure 1-22

Figure 1-23 Figure 1-24

Figure 1-25 Figure 1-26

Figure 1-27 Figure 1-28

（2）Special tool for the overhaul of chassis: front fork seal driver.

- 13 -

Figure 1-29

（3）steering nut wrench.

Figure 1-30

3．Tools used for electrical parts

The special tools list to test the electrical parts and the corresponding physical figure, please see Table 1-31

and 1-32.

Table 1-31

Name

Note

avometer

ignition tester

Figure 1-33

Figure 1-34

Continuation Table 1-32

Figure 1-33

Figure 1-34

- 14 -

Specification Table (QJ50T-21T)

Model

QJ50T-21T

Engine

Type of engine

QJ1E40QMB-4

Full length mm

1860

Type of fuel

lead-free gasoline

（93/95）

Full width mm

680

Number of

cylinders

1

Full height mm

1198

Inside

diameter*stroke

49.2×39.2

Wheelbase mm

1290

Total

displacement

49.3cc

Weight of vehicle

kg

（Curb weight）

front axle

40

Initiate mode

Electric/foot initiate

Rear axle

59

Cooling system

Wind cooling

Total

99

Lubrication type

Separating lubrication

Wheel

specification

Front

wheel tyre

120/70-12

Front

wheel rim

3.50×12

Air cleaner

3XG

Rear

wheel tyre

130/70-12

Rear

wheel rim

3.50×12

Fuel tank

capacity

5.6L

Driving mechanism

Type of

clutch

Dry centrifugal type

Carburetor model

PZ19JB

Variable

speed

mechanism

infinite variable speed

Performance

Idling speed -rpm

1800±100rpm/min

Driving type

belt transmission

Maximum torque

4.0N.m/6500rpm

Electrical installation

Storage

battery

capacity

/Type

12V-3AH/dry-charged

Maximum

horsepower

2.7kW/6500 rpm

Magneto

capacity

89.6W/5000rpm

Compression

ratio

6.9：1

Spark plug

BR8HSA

Maximum speed

45km/h

Spark plug

gap

0.6-0.7mm

Brake

apparatus

Front brake disc

Diameter（mm）

φ190mm

Ignition type

CDI

Rear brake drum

inside diameter

（mm）

φ175mm

- 15 -

QJ50T-21T

- 16 -

No

Yes

No

Yes

No

Y

trigg

er

windi

ng es

No

Failure Diagnosis

Failure diagnosis procedure when the engine fails to start or start difficultly

Engine fails to start or start difficultly

Check the ignition system

Remove the spark plug, check the electrodes of spark plug are carbon connected

Do the spark plug spark over test

To clean out carbon

Faint or no spark between electrodes

Strong blue or bluish violet spark from the electrodes

Screw off the spark plug cap, do high-voltage wire spark over test

Use ignition timing light to test whether engine ignition is timing

Strong blue spark

Faint or no spark

Check if the spark plug, spark plug cap fails

Check the

supply of

ignition

power

Check if

there is short

circuit or

broken

circuit of

ignition coil

Check if there

is short circuit

or broken

circuit of the

internal system

of ignition

system

Check if the

CDI ignition

apparatus

fails

Use the cylinder

pressure gauge to test

the cylinder

compression pressure

Check if there

is fuel in the

fuel tank

Cylinder

compression

pressure

normal

Cylinder

compression

pressure

insufficient

To

fill

the

fuel

No contact magneto ignition system

1. Check if there is short

circuit or broken circuit of

ignition power winding

2. Check if there is short

circuit or broken circuit of

trigger winding

1. Check if the CDI ignition

apparatus fails

2. Check if the magneto

flywheel and trigger

winding loosen

Loosen carburetor fuel

draining screw, check if

there is fuel draining

from the carburetor

overflow pipe

- 17 -

Yes

No

Spark plug electrode is moist

Spark plug electrode is dry

Check if there is oil leaking from

carburetor

Instill small amount of fuel into the cylinder to

have an experimental starting

1. Check if there is gap

between the carburetor float

needle valve and valve seat

because of other materials

2. Check if the conical

surface of the carburetor

float needle valve is worn

into step shape

3. Check if the carburetor

float breaks

4. Check if the carburetor

float is too low

Check if the air

cleaner blocks

The engine stops after

running a very short time

Work continuously after

starting

The carburetor inside

blocks or the float is

too high

Carburetor starting

device (starting richer

system) fails

1. Check if there is gas leaking

in external connections of the

engine

2. Check if the piston ring sticks

in ring groove or insufficient

elasticity

3. Check the wearability of

piston ring and cylinder

1. Check if the venthole of

fuel tank cover blocks

2. Check if the fuel filter and

fuel cock block

3. Check if the fuel cock

works well

4. Check if the carburetor inlet

port blocks

5. Check if the carburetor

floater is too high

Remove the

spark plug to

test

- 18 -

Yes

No

Yes

No

Yes

No

Yes

No

The engine overheat failure diagonosis procedure

Engine overheat

Check if the operation method is proper

1. Check if the fuel No. is too low

or the fuel is out of date

2. Check if the engine runs at high

speed or overload for a long time

Check the cooling system

Air cooled engine

Check if the cooling fins are stained with silt or too much oil

Wash

Check if the cooling fans and

wind scoop break (compulsive

air cooled engine)

Check and

eliminate

Use ignition timing light to test

whether engine ignition is timing

1. Check if the CDI

ignition apparatus

fails

2. Check if the

magneto flywheel

and trigger winding

loosen

Check if the clutch slips

Clutch slips

To treat the clutch

slip failure

accordingly

- 19 -

Remove the spark plug, watch the color of spark

plug insulator cluster and determine the mixture ratio

of the combustible gas mixture in accordance with

the different abnormal appearances

Spark plug insulator cluster is white, the

exhaust muffler smokes or blast when the

engine is running at medium and low speed, the

accelerating ability is bad, idle speed is unstable

and tends to stop easily, relatively normal when

running at high speed.

spark plug insulator cluster is brown

Spark plug insulator cluster is

white, the engine is intermittent

when accelerating, carburetor

backfires and the engine power is

insufficient etc

combustible gas mixture is too strong

1. Check if the air cleaner blocks

2. Check if the carburetor starting

device (starting richer system)

works well

3. Check if the carburetor float is

too low

the mixture ratio of the

combustible gas mixture is proper

Check if the vent of

cylinder and exhaust

muffler block because

of too much carbon

Check lubricating

system

combustible gas mixture is

too weak

Two-stroke engine

lubricating system

1. Check if the fuel

cock works well

2. Check if the

carburetor float is too

high

3. Check if the orifices

and pore canals on the

carburetor block

1. Check if the fuel in the

crankcase is insufficient

2. Check if the viscosity of fuel

in the crankcase is too low or the

fuel is too dirty

3. Check if the fuel filter blocks

4. Check if the fuel pump works

well

5. Check if the lubricating oil

path blocks

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KEEWAY F-ACT EVO Instruction & Maintenance Manual

KEEWAY F-ACT EVO Instruction & Maintenance Manual

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