cgen gy6 50cc service manual
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4 STROKE ENGINE
SERVICE AND REPAIR MANUAL
Model Numbers: JL50QT-18 - JL50QT-X1/8 - JL50QT-14
GY6 50cc
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JL50QT-18
JL50QT-X1/8
JL50QT-14
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AIR INLET TUBE
AIR SCREW
2
3
IDLING SPEEDADJUSTMENT SCREW
3
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6 0
4 5
CORSE SURFACE
IN, EX: (30 mm )
IN, EX: (32 mm )
IN: (24.5m m)
EX: (27 .5m m)
3 2
VALVE SEAT SURFACE WIDTH
VALVE SEAT SURFACE WIDTH
3 2
6 0
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A. Electric Scooter Assembly
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A. Electric Scooter Assembly
Topic
Page Topic
Page
Important Points
The electrolyte (diluted sulfuric acid) is very toxic. DO NOT allow acid to splash onto clothes, the skinor 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 cameinto contact. See a Physician immediately. If the electrolyte acid gets into clothes, it will permeate tothe 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 adischarged 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 circuitinternally. 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 excessivetime 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 isadvisable 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 itinto the scooter or charging it. It is advisable to charge a new battery after filling with acid eventhough it may appear to have sufficient charge.
When working on the scooters electrical system, make sure that the main switch is turned offand/or the battery is disconnected. Disconnecting and reconnecting of live circuits can cause highinstantaneous currents that can damage the battery and cause injury.
Any short-circuiting of the wiring can cause damage to the battery.
Important points A-2
Scheduled Maintenance A-3Specifications A-4Troubleshooting A-4
Rear Wheel Dismantling A-5
Rear Wheel Removal A-5
Electric Motor Removal A-8
Motor Dissasembly A-10
Recharging Batteries A-16
TorqueThe nut of the rear wheel axle 10.0kgm 75ft lbsThe top of the rear buffer 4.5kgm 30ft lbsThe bottom bolt of the rear buffer 3.0kgm 20ft lbsThe connection nut of the silencer 1.2kgm 10ft lbsThe fix bolt of the silencer 3.5kgm 25ft lbs
Torque Settings A-2
Motor Inspection A-12
Battery Access and Power A-13
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A. Electric Scooter Assembly
Perform regular maintenance onthe following parts as the chart indicates.
C = CleanL = LubricateI = Inspect, check, f ix , replace when necessary
Mileage (km)FrequencyItem 124
(200)
621
(1000)
1864
(3000)
3107
(5000)
4972
(8000)
6215
(10000)
7458
(12000)
Controller C C
Charger I I
Front/rear detent I I IWheel bearing I IFront/rear suspension I I
Front fork bearing I I
T ire I I
Major side kickstand L L I
All other body parts L L L IAll screws & nuts I I I I I
Motor bearing I I
I f riding the vehicle in dusty or rainy areas, perform maintenance more frequently.
Scheduled Maintenance
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A. Electric Scooter Assembly
No. Description Specifi cations No. Description Specifi cations1 Product Si ze 1700x760x1180mm 13 Speedchanging Automatic
2 T read 1180 mm 14 Motor type B lushless motor
3 M inimum clearancefrom ground
110 mm 15 R ated power 750W
4 N. W 90 kg 16 R ated current 22A
5 L oad weight 40 kg 18 W orking efficiency >72%
7 Mileage percharge
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A. Electric Scooter Assembly
Dismantling and Removing Rear Wheel Assembly
1. Loosen and remove brake cablemount from Brake Arm.
Attention: Exercise caution when loosening
and removing cable tension spring
2. Loosen and remove brake cabletension spring from Brake Arm.
3. Loosen and remove fasteners
securing anti-rotational bracket ontoframe and rear wheel axle.
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A. Electric Scooter Assembly
Dismantling the Rear Brake
4. Remove the adjusting nutof the rear brake.
5. Remove the fix bolt ofthe brake arm.
6. Remove the brake arm.
7. Remove the brake cam.
When Assembling the Rear Brake
A. Spread grease on the movingparts of the lining and of the fix pin(locating pin).
B. Spread grease on the movingpart of the brake cam shaft andthen assemble it.
C. Install the brake lining.
8. Remove anti-rotational brackets.
9. Remove smaller restraining bracket
10. Remove restraining bolt.
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A. Electric Scooter Assembly
11. Assemble the wear indication boardand the brake arm.
12. Assemble the brake arm and the brakecam.
Attention: Point the gullet mark of the brake
arm to the dot mark of the brakecam, and then assemble them.
13. Install and tighten the bolt of the brakearm.
14. Install and tighten the fix bolt of the setarm.
15. Install the return spring of the brakearm.
16. Install the pin of the brake arm.
17. Install the adjusting nut of the brakecable.
18. Assemble the rear wheel (refer to13-2).
19. Adjust the clearance of the brake lever(refer to 13-8).
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A. Electric Scooter Assembly
20. Slide rear wheel away from framemounting slots.
21. Slowly remove rear wheel from
cam.
Attention: Give particular attention to the power
cable, when removing rear wheel.
22.Carefully loosen all four mounting bolts
securing electric motor to rear wheel.
Attention: The 750 watt electric motor is very
heavy. Exercise caution while
removing motor mounting bolts.
1. Loosen and remove four mounting
bolts securing 750 watt motor to rear
wheel.
Electric Motor Removal
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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.
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A. Electric Scooter Assembly
1. Using the proper screwdriver or bit typeand size, carefully loosen each screw that is
securing the motor cover, .
2. Remove each screw and set aside for reuse.
3. Gently lift and remove the collar from the
motor spindle.
Attention: Removing the screws in a diagonal pattern
is recommended to avoid stripping and
damaging the screws and the threads.
Attention: Exercise caution with the power cable
when removing set collar.
Motor Disassembly
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A. Electric Scooter Assembly
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.
Attention: Always exercise caution
when using any tool to pry one surface from another.
5.Gently lift and remove the motor cover
from the motor assembly.
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A. Electric Scooter Assembly
1. Carefully lift and remove motor coil sub-assembly
from motor housing.
Attention: Once again, exercise caution when
removing motor sub-assembly to avoiddamaging motor coils.
2. Thoroughly inspect coils and coil wires for damage.
Motor Inspection
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A. Electric Scooter Assembly
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).
Attention: Exercise caution when
removing body panels and
fasteners to avoid damage.
Battery Access and Power
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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: Be sure not to sperate the ground wire
connections that are seperate for the
connector.
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
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A. Electric Scooter Assembly
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.
Battery Access and Removal
Attention: Disconnect andreconnect
positive terminal first, followed
by the negative battery terminal.
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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).
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C. Scooter Panels