Download 50cc QMB139 Based Scooters Service Manual

GY6 50cc
SERVICE AND REPAIR MANUAL
4 STROKE ENGINE
Model Numbers: JL50QT-18 - JL50QT-X1/8 - JL50QT-14
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A. Electric Scooter Assembly
A. Electric Scooter Assembly
Topic
Important points
Torque Settings
Scheduled Maintenance
Specifications
Troubleshooting
Rear Wheel Dismantling
Page
A-2
A-2
A-3
A-4
A-4
A-5
Topic
Rear Wheel Removal
Electric Motor Removal
Motor Dissasembly
Motor Inspection
Battery Access and Power
Recharging Batteries
Page
A-5
A-8
A-10
A-12
A-13
A-16
Important Points
The electrolyte (diluted sulfuric acid) is very toxic. DO NOT allow acid to splash onto clothes, the skin
or eyes to protect them from burning. Eye contact with acid may cause blindness. In case of contact
with the acid, use a large amount of clean water to flush and rinse the areas in which the acid came
into contact. See a Physician immediately. If the electrolyte acid gets into clothes, it will permeate to
the skin. Remove tainted clothes immediately and then put them in water to rinse.
•The batteries can withstand numerous cycles of charging and discharging as long as it is not left in a
discharged condition for a long period of time.
•If one of the batteries are overcharged, it can be detected by close inspection of the battery itself.
If the battery is exposed to an extreme overcharged condition, it can break down and short circuit
internally. In this condition, the battery will produce zero voltage under all load and charge conditions.
An overcharged battery can “boil off” the electrolyte solution. This problem can be due to excessive
time on a battery charger or a failed voltage regulator.
•If the scooter is left to sit for a long time or is stored, the battery will slowly discharge. It is
advisable to recharge the battery before attempting to start the scooter after a period of storage.
•When filling a new battery with acid, allow it to sit and “breath” for fifteen minutes before installing it
into the scooter or charging it. It is advisable to charge a new battery after filling with acid even
though it may appear to have sufficient charge.
•When working on the scooter’s electrical system, make sure that the main switch is turned off
and/or the battery is disconnected. Disconnecting and reconnecting of live circuits can cause high
instantaneous currents that can damage the battery and cause injury.
•Any short-circuiting of the wiring can cause damage to the battery.
Torque
The nut of the rear wheel axle
The top of the rear buffer
The bottom bolt of the rear buffer
The connection nut of the silencer
The fix bolt of the silencer
10.0kg•m
4.5kg•m
3.0kg•m
1.2kg•m
3.5kg•m
75ft lbs
30ft lbs
20ft lbs
10ft lbs
25ft lbs
A. Electric Scooter Assembly
Scheduled Maintenance
�
Perform regular maintenance on the following parts as the chart indicates.
C = Clean
L = Lubricate
I = Inspect, check, fix, replace when necessary
Frequency
Item
Controller
Charger
Front/rear detent
Wheel bearing
Front/rear suspension
Front fork bearing
T ire
Major side kickstand
A ll other body parts
A ll screws & nuts
Motor bearing
Mileage (km)
124
(200)
621
(1000)
1864
(3000)
3107
(5000)
I
C
I
I
4972
(8000)
6215
(10000)
7458
(12000)
L
L
C
I
I
I
I
I
I
I
I
I
I
L
I
I
I
I
I
L
L
I
I
I
I
I f riding the vehicle in dusty or rainy areas, perform maintenance more frequently.
A. Electric Scooter Assembly
Specifications
�
No.
1
2
3
Description
Product Si ze
T read
Description
Speedchanging
Motor type
R ated power
Specifi cations
Automatic
1180 mm
110 mm
No.
13
14
15
4
5
6
7
N. W
L oad weight
Maximum speed
Mileage per
charge
90 kg
<80 kg
>40 kg
<40 kg
16
17
18
19
R ated current
R ated voltage
22A
48V
>72%
B attery
S ealed, free
protective, leadacid battery
8
9
10
11
B rake distance
B rake ways
Climbing ability
Max torque
<4.5 m
M/M
>8°
20 N. M
20
21
22
23
B attery capacity
Charger
T ire
12V 17Ahx4
A merican
3.0-10-4PR
175/225 (kpa)
12
Max noise
64dB(A )
M inimum clearance
from ground
Specifi cations
1700x760x1180mm
W orking efficiency
W heel Pr essure
(FR /R R )
B lushless mo tor
750W
Troubleshooting
Problem
Scooter does not start.
Cause
No power
B attery connection poor
Scooter runs weak.
Weak battery
Scooter starts but does not
move.
Motor inoperative
Solution
Charge or replace
battery/batteries.
R econnect battery
terminals.
R echarge or replace
batteries.
R eplace 750W motor.
A. Electric Scooter Assembly
Dismantling and Removing Rear Wheel Assembly
�
1. Loosen and remove brake cable
mount from Brake Arm.
Attention:
Exercise caution when loosening
and removing cable tension spring
2. Loosen and remove brake cable
tension spring from Brake Arm.
3. Loosen and remove fasteners
securing anti-rotational bracket onto
frame and rear wheel axle.
A. Electric Scooter Assembly
�
Dismantling the Rear Brake
4. Remove the adjusting nut
of the rear brake.
5. Remove the fix bolt of
the brake arm.
6. Remove the brake arm.
7. Remove the brake cam.
8. Remove anti-rotational brackets.
9. Remove smaller restraining bracket
10. Remove restraining bolt.
When Assembling the Rear Brake
A. Spread grease on the moving
parts of the lining and of the fix pin
(locating pin).
B. Spread grease on the moving
part of the brake cam shaft and
then assemble it.
C. Install the brake lining.
A. Electric Scooter Assembly
11. Assemble the wear indication board
and the brake arm.
12. Assemble the brake arm and the brake
cam.
�
Attention:
Point the “gullet” mark of the brake
arm to the “dot” mark of the brake
cam, and then assemble them.
13. Install and tighten the bolt of the brake
arm.
14. Install and tighten the fix bolt of the set
arm.
15. Install the return spring of the brake
arm.
16. Install the pin of the brake arm.
17. Install the adjusting nut of the brake
cable.
18. Assemble the rear wheel (refer to
13-2).
19. Adjust the clearance of the brake lever
(refer to 13-8).
A. Electric Scooter Assembly
20. Slide rear wheel away from frame
mounting slots.
�
21. Slowly remove rear wheel from
cam.
22.Carefully loosen all four mounting bolts
securing electric motor to rear wheel.
Electric Motor Removal
1. Loosen and remove four mounting
bolts securing 750 watt motor to rear
wheel.
Attention:
The 750 watt electric motor is very
heavy. Exercise caution while
removing motor mounting bolts.
Attention:
Give particular attention to the power
cable, when removing rear wheel.
A. Electric Scooter Assembly
2. Carefully place rear wheel onto ground with
electric motor facing upwards.
�
3. Using a flat-head screwdriver, cautiously pry
the electric motor from the rear wheel rim.
4. Lift and remove electric motor from wheel
assembly.
5. Loosen set screw securing collar to
motor spindle.
6. Remove and place collar set screw in
secure place for reuse.
A. Electric Scooter Assembly
Motor Disassembly
�
1. Using the proper screwdriver or bit type
and size, carefully loosen each screw that is
securing the motor cover, .
2. Remove each screw and set aside for reuse.
Attention:
Removing the screws in a diagonal pattern
is recommended to avoid stripping and
damaging the screws and the threads.
3. Gently lift and remove the collar from the
motor spindle.
Attention:
Exercise caution with the power cable
when removing set collar.
A. Electric Scooter Assembly
Attention:
Always exercise caution
when using any tool to pry
one surface from another.
�
4. Once again, using a flat-head screwdriver,
carefully pry motor cover from the motor assembly.
Attention:
Use very mild and steady force when prying,
to avoid damaging motor housing and coils.
5.Gently lift and remove the motor cover
from the motor assembly.
A. Electric Scooter Assembly
Motor Inspection
�
1. Carefully lift and remove motor coil sub-assembly
from motor housing.
Attention:
Once again, exercise caution when
removing motor sub-assembly to avoid
damaging motor coils.
2. Thoroughly inspect coils and coil wires for damage.
A. Electric Scooter Assembly
Battery Access and Power
Attention:
Exercise caution when
removing body panels and
fasteners to avoid damage.
1. Loosen and remove fasteners securing left and
right side panels.
2. Loosen and remove fasteners securing floor panels
and panel beneath scooter seat.
3. Carefully remove body panels (as shown).
A. Electric Scooter Assembly
�
4. Access battery power switch located in
rear storage compartment of scooter.
5. Remove power to motor by flipping the
power switch to the ‘OFF’ position.
Attention:
Confirm that power is removed
from motor before beginning
work on vehicle
6. Once power has been removed, disconnect
power connection to motor by carefully unclipping
and seperating the wire connectors
Attention:
Be sure not to sperate the ground wire
connections that are seperate for the
connector.
A. Electric Scooter Assembly
Battery Access and Removal
Attention:
Confirm that power is removed from motor
before disconnecting and removing batteries
7. Loosen and remove fasteners securing battery
restraining bracket.
8. Remove bracket.
9 Disconnect battery terminals.
Attention:
Disconnect and reconnect
positive terminal first, followed
by the negative battery terminal.
A. Electric Scooter Assembly
10. Use a volt meter to check
battery voltage (as shown).
Recharging Batteries
1. Access charging input recepticle, located
inside scooter rear storage compartment.
3. Allow batteries to continue charging until
indicator shows that batteries are fully charged.
2. Plug charger into charging recepticle as well
as into wall outlet (standard AC).
B. Retro Model Scooter Panels
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C. Scooter Panels