cgen gy6 50cc service manual

8/11/2019 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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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

cgen gy6 50cc service manual

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