OUTLOOK(DIERRE) 125 EFI Service Manual
KEEWAY Motorcycle Co., Ltd.
Contents Contents ................................................................................................................................................................. - 1 Preface ................................................................................................................................................................... - 5 Preparing documents ..................................................................................................................................... - 6 Inspection/Adjustment ................................................................................................................................. - 15 I. Battery/Charging System.................................................................................................................................. - 27 1.1 Preparing documents ............................................................................................................................. - 27 1.2 Failure diagnosis .................................................................................................................................... - 28 1.3 Battery ................................................................................................................................................... - 29 1.4 Charging system .................................................................................................................................... - 30 1.5 Voltage/current regulator ....................................................................................................................... - 31 1.6 Magnetor charging coil .......................................................................................................................... - 32 1.7 Magnetor disassembly ........................................................................................................................... - 32 II. Ignition System ............................................................................................................................................... - 35 2.1 Preparing documents ............................................................................................................................. - 35 2.2 Failure diagnosis .................................................................................................................................... - 36 2.3 Ignition system check ............................................................................................................................ - 37 2.4 CDI Group ............................................................................................................................................. - 40 2.5 Ignition coil (picture to be updated) ...................................................................................................... - 40 2.6 Trigger ................................................................................................................................................... - 41 III. Startup System ............................................................................................................................................... - 44 3.1 Preparing documents ............................................................................................................................. - 44 3.2 Failure diagnosis .................................................................................................................................... - 45 3.3 Startup motor ......................................................................................................................................... - 45 3.4 Starter relay............................................................................................................................................ - 47 IV. Bulbs/Switches/Meters .................................................................................................................................. - 49 4.1 Preparing documents ............................................................................................................................. - 49 4.2 Failure diagnosis .................................................................................................................................... - 49 4.3 Replacement of headlamp bulbs ............................................................................................................ - 49 4.4 Replacement of front steering lamp bulbs ............................................................................................. - 50 4.5 Replacement of tail lamp bulbs ............................................................................................................. - 50 4.6 Meter (picture to be updated)................................................................................................................. - 51 4.7 Main switch ........................................................................................................................................... - 51 4.8 Horn ....................................................................................................................................................... - 52 4.9 Handlebar switch ................................................................................................................................... - 52 V. Brake ............................................................................................................................................................... - 55 5.1 Maintenance instruction......................................................................................................................... - 55 5.2 Failure diagnosis .................................................................................................................................... - 55 5.3 Front disc brake ..................................................................................................................................... - 56 5.4 Rear disc brake ...................................................................................................................................... - 58 VI. Body .............................................................................................................................................................. - 61 - 1 -
VII. Front Wheel/Front Suspension ..................................................................................................................... - 63 7.1 Preparing documents ............................................................................................................................. - 63 7.2 Failure diagnosis .................................................................................................................................... - 63 7.3 Front wheel ............................................................................................................................................ - 64 7.4 Steering handle ...................................................................................................................................... - 66 7.5 Front fork ............................................................................................................................................... - 67 7.6 Radiator/expansion tank assembly......................................................................................................... - 68 VIII. Rear Wheel/Rear Suspension ...................................................................................................................... - 70 8.1 Preparing documents ............................................................................................................................. - 71 8.2 Failure diagnosis .................................................................................................................................... - 71 8.3 Rear wheel ............................................................................................................................................. - 71 8.4 Rear absorber/rear swing arm ................................................................................................................ - 72 IX. Lubricating System........................................................................................................................................ - 76 9.1 Preparing documents ............................................................................................................................. - 76 9.2 Failure diagnosis .................................................................................................................................... - 76 9.3 Fuel pump .............................................................................................................................................. - 77 X. Cylinder Head/Valve ....................................................................................................................................... - 81 10.1 Preparing documents ........................................................................................................................... - 81 10.2 Failure diagnosis .................................................................................................................................. - 82 10.3 Cylinder head ....................................................................................................................................... - 82 10.4 Cylinder head check ............................................................................................................................ - 84 10.5 Valve .................................................................................................................................................... - 85 10.6 Valve check .......................................................................................................................................... - 86 10.7 Replacement of valve guide................................................................................................................. - 87 10.8 Adjustment of the valve retainer .......................................................................................................... - 89 10.9 Installation ........................................................................................................................................... - 90 XI. Cylinder Block and Piston ............................................................................................................................. - 92 11.1 Preparing documents............................................................................................................................ - 92 11.2 Failure diagnosis .................................................................................................................................. - 93 11.3 Cylinder block...................................................................................................................................... - 93 11.4 Piston ................................................................................................................................................... - 94 11.5 Piston installation ................................................................................................................................. - 98 11.6 Cylinder installation ............................................................................................................................. - 98 XII. Drive Face/Clutch/Driven Wheel ............................................................................................................... - 101 12.1 Preparing documents ......................................................................................................................... - 101 12.2 Failure diagnosis ................................................................................................................................ - 101 12.3 Left crankcase cover .......................................................................................................................... - 102 12.4 Drive face .......................................................................................................................................... - 102 12.5 Clutch/driven wheel ........................................................................................................................... - 105 12.6 Breakdown of clutch and driven wheel ............................................................................................. - 106 12.7 Installation ......................................................................................................................................... - 110 XIII. Decelerator ................................................................................................................................................ - 112 13.1 Preparing documents ......................................................................................................................... - 112 - 2 -
13.2 Failure diagnosis ................................................................................................................................ - 112 13.3 Gearbox ............................................................................................................................................. - 112 13.4 Installation ......................................................................................................................................... - 114 XIV. Crankcase .................................................................................................................................................. - 115 14.1Preparing documents .......................................................................................................................... - 115 14.2 Failure diagnosis ................................................................................................................................ - 116 14.3 Crankcase........................................................................................................................................... - 116 14.4 Installation ......................................................................................................................................... - 118 XV. Cooling System .......................................................................................................................................... - 120 15.1 Preparing documents ......................................................................................................................... - 120 15.2 Failure diagnosis ................................................................................................................................ - 120 15.3 Thermostat ......................................................................................................................................... - 121 XVI. Exhaust Emission & Control System ....................................................................................................... - 125 16.1 Warranty on the exhaust emission & control system ......................................................................... - 125 16.2 Instructions on the periodic maintenance .......................................................................................... - 126 16.3 Mechanical function of the exhaust control system ........................................................................... - 127 16.4 Catalytic conversion system .............................................................................................................. - 127 XVII. EFI System .................................................................................................................................................. 129 17.1. Connection of the EFI system ............................................................................................................... 129 17.2. Engine controller (MC21)..................................................................................................................... 130 17.3. Power supply requirements ................................................................................................................... 135 17.4. Work temperature.................................................................................................................................. 135 17.5 Maintenance and repair.......................................................................................................................... 135 XVIII. M3 and M3.5 Fuel Injector ........................................................................................................................ 137 18.1. List of spare parts.................................................................................................................................. 137 18.2. General work principle ......................................................................................................................... 137 18.3. Appearance ........................................................................................................................................... 138 18.4. O-ring.................................................................................................................................................... 139 18.5. O-ring replacement ............................................................................................................................... 139 18.6. Suggested lubricant............................................................................................................................... 139 18.8. Temperature range ................................................................................................................................ 140 18.9. Fuel contaminants ................................................................................................................................. 141 18.10. Cable arrangement .............................................................................................................................. 141 18.11. Instructions.......................................................................................................................................... 141 18.13. Replacement ....................................................................................................................................... 143 18.14. Replaceability ..................................................................................................................................... 144 18.15. Fuel injector blocked .......................................................................................................................... 144 18.16. Cleaning .............................................................................................................................................. 145 XIX. Throttle Valve Assembly............................................................................................................................... 145 19.1. List of spare parts.................................................................................................................................. 145 19.2General work principle ........................................................................................................................... 146 19.3. Appearance ........................................................................................................................................... 146 19.4. Technical parameters ............................................................................................................................ 146 - 3 -
19.5. Work environment ................................................................................................................................ 147 19.6. Disassembly of the throttle valve.......................................................................................................... 147 19.7. Cleaning ................................................................................................................................................ 147 19.8. Installation of the throttle valve ............................................................................................................ 148 19.9. Precautions............................................................................................................................................ 148 19.10. Instruction ........................................................................................................................................... 148 XX. Water Temperature Sensor for the Engine ..................................................................................................... 150 20.1 List of spare parts................................................................................................................................... 150 20.2. General work principle ......................................................................................................................... 150 20.3. Appearance ........................................................................................................................................... 150 20.4. Installation requirements....................................................................................................................... 150 20.5. Work environment ................................................................................................................................ 151 20.6. Storage environment ............................................................................................................................. 151 20.7. Electric environment ............................................................................................................................. 151 20.8. Cleaning samples .................................................................................................................................. 151 XXI. Intake Air Temperature Sensor ..................................................................................................................... 152 21.1. List of spare parts.................................................................................................................................. 152 21.2. General work principle ......................................................................................................................... 152 21.3. Appearance ........................................................................................................................................... 152 21.4. Technical parameters ............................................................................................................................ 152 21.5. Installation requirements: ..................................................................................................................... 152 21.6. Cleaning samples .................................................................................................................................. 152 XXII. Oxygen Sensor ............................................................................................................................................ 153 22.1. List of spare parts.................................................................................................................................. 153 22.2. General work principle ......................................................................................................................... 153 22.3. Appearance ........................................................................................................................................... 153 22.4. Technical parameters ............................................................................................................................ 153 22.5. Installation requirements....................................................................................................................... 154 22.6. Fuel quality requirements ..................................................................................................................... 154 XXIII. Fuel Pump Assembly ................................................................................................................................. 154 224. List of spare parts................................................................................................................................... 154 23.2. General work principle ......................................................................................................................... 155 23.3. Appearance and structure ...................................................................................................................... 155 23.4. Dimension ............................................................................................................................................. 156 23.5. Label and mark ..................................................................................................................................... 156 23.6. Work environment ................................................................................................................................ 156 23.8. Maintenance procedures ....................................................................................................................... 157 XXIV. Failure Diagnosis ....................................................................................................................................... 163 24.1. Diagnostic tools .................................................................................................................................... 163 24.2. Pin definition for the diagnosis interface: ............................................................................................. 163 24.3. Software instruction .............................................................................................................................. 164 24.4 Cross reference table for malfunction code ........................................................................................... 168 Circuit Diagram ................................................................................................................................................. 172 - 4 -
Preface This maintenance manual is used for operating and maintaining EFI Motorcycle OUTLOOK (DIERRE) 125. Preparing Documents include all necessary instructions and statements. Please carefully read this manual before operation. Inspection & Adjustment states how to check and adjust your motorcycle. All safety rules and maintenance regulations shall be carried out from the beginning of periodic inspection. Except for Chapter I, the rest chapters explain the disassembly/ assembly/ inspection of engine, entire motorcycle and electrical parts. Breakdown drawing, systematic drawing, failure analysis and statements are contained at the first part of each chapter.
Please note that photos, pictures or instructions are for your reference only. The actual object may differ from this mentioned here. We will not make notification for any discrepancy.
KEEWAY Motorcycle Co., Ltd. - 5 -
Preparing documents General safety
Maintenance rules
Specification table
Failure diagnosis
General Safety Carbon monoxide Engine must be started up in a well-ventilated place, not in a closed area. Note Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human. Start up engine in an open place. The exhaust cleaning system shall be adopted if engine is started up in a closed area.
Petrol Ventilation is required for working places. Fire is strictly forbidden in any working place or where petroleum is stored.
- 6 -
Maintenance Rules Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage. Clean up the surface of components or assembly parts before removing or opening the shield for maintenance, which can prevent dirt from falling into the engine, chassis or braking system. Wash and dry parts with air compressor after disassembly and before measurement of attrition value.
Do not bend or twist it. Otherwise it will cause difficulty in operation or early damage.
错误：error
Solvent or oil can easily damage aging rubber articles. Check rubber before reassembly and replace rubber if necessary.
套：boot
When loosening assembly parts, please start from outside to inside. Small assembly parts shall be loosened first.
Complex assembly parts, such as gearbox, shall be stored in proper order for facilitating installation in the future.
- 7 -
Please specially note important connections before disassembly. Replace parts which will not be in use before disassembly.
Bolts and screws with different length shall be separately used for different assembly parts and shields, and they shall be correctly mounted. Insert a bolt into a hole to check whether it is proper if you are confused.
Fill the groove with grease before mounting an oil seal. Check whether the oil seal is smooth or damaged during assembly.
When installing a hose (fuel, vacuum or cooling agent), insert its end into the bottom of the connector so that the hose clip can properly fix the connector. Rubber or plastic dirt-proof boot shall be mounted at the original design position.
槽：groove 夹子：clip 接头：connector During dismantling ball bearings, one or two (inside & outside) bearing rollers shall be supported by tools. Ball bearings may be damaged during disassembly and have to be replaced if only one roller (either inside or outside) is imposed with force. 以上两例都会使轴承破裂：Bearings will be broken under either occasion as mentioned.
- 8 -
Special Tools Special tools refer to tools which are specially designed for assembling or disassembling some motorcycle parts on special positions. Applicable special tools are necessary for precise adjustment and installation. With them, parts and accessories can be mounted safely, reliably and rapidly, which improves efficiency and saves energy.
1．Tools for repairing the engine Special tools are required for properly disassembling/assembling some engine parts. Table and drawing (1-1, 1-2) of special tools for disassembling/assembling engine parts are as follows: Table 1-1 Name
Remark
Special socket spanner
Used for assembling/disassembling bolts for flywheels, Fig. 1-3
Clutch clamp holder
Fig. 1-4
Flywheel puller
Fig. 1-5
Feeler gauge
Fig. 1-6
Bearing disassembly tools
Fig. 1-7
Bearing assembly tools
Fig. 1-8
Oil seal remover
Fig. 1-9
Handle for dismantling tools
Fig. 1-10
Piston pin pulling device
Fig. 1-11
Piston pin pliers
Fig. 1-12
Socket spanner for spark plug
Fig. 1-13
Clutch thickness measuring device
Fig. 1-14
Cylinder diameter measuring device
Fig. 1-15
Dial indicator
Measuring the inner diameter of piston pin, Fig. 1-16
Table 1-2 (continued)
Fig. 1-3
Fig. 1-4
- 9 -
Fig. 1-5
Fig. 1-6
Fig. 1-7
Fig. 1-8
Fig. 1-9
Fig. 1-10 ① handle
- 10 -
Fig. 1-11
Fig. 1-12 ① pliers ② piston
Fig. 1-13
Fig. 1-14
Fig. 1-15
Fig. 1-16
2．Tools for repairing the chassis Table and drawing (1-17, 1-18) of ordinary tools and special tools for disassembling/assembling chassis parts are as follows: Table 1-17 Name
Remark
Torque spanner
Fig. 1-19
Inner hexagon spanner
Fig. 1-20
Socket spanner
Fig. 1-21
Micrometer
Fig. 1-22
Magnetic rack, V-block
Fig. 1-23
Dial indicator
Fig. 1-24
Vernier calipers
Fig. 1-25
Circlip pliers
Fig. 1-26
Screwdriver with striking cap
Fig. 1-27
Tool for assembling oil seal of front fork
Fig. 1-28
Tool for hammering seal of front fork
Fig. 1-29
Steering nut spanner
Fig. 1-30
(1) Ordinary tools for repairing the chassis Table 1-18 (continued)
- 11 -
Fig. 1-19
Fig. 1-20
1. socket head 2. crank handle 3. ratchet spanner 4. connecting rod Fig. 1-21
Fig. 1-22
Fig. 1-23
Fig. 1-24
Fig. 1-25
Fig. 1-26
Fig. 1-27
Fig. 1-28 - 12 -
(2) Special tools for repairing the chassis: tool for hammering seal of front fork
Fig. 1-29
(3) Steering nut spanner
Fig. 1-30
3．Tools for electric parts Table and drawings (1-31, 1-32) of special tools for testing electric parts are as follows: Table 1-31 Name
Remark
Multimeter
Fig. 1-33
Ignition tester
Fig. 1-34
Table 1-32 (continued)
Fig. 1-33
Fig. 1-34 - 13 -
Specification (EFI Motorcycle QJ125T-30)
Model
EFI Motorcycle QJ125T-30
Engine type
QJ153MI-2A
Length mm
2070
Fuel type
Unleaded petrol
Width mm
715
No. of cylinder
1
Height mm
1260
ID × stroke
φ52.4*57.8
Wheelbase mm
1360
Total displacement
125ml
Weight kg (Curb weight)
Engine
Forward shaft
50
Startup
Electric
Backshaft
80
Cooling
Water cooling
Total
130 Lubrication
Force-feed and splash
Air filter
Paper-made
Capacity of gasoline tank
7.4±0.2L
Max. speed
90km/h
Gradeability
≥20 degree
Idle speed -rpm
1500±100rpm/min
Front wheel 100/80-16 Rear wheel 120/80-16
Tyre Size
Clutch
Automatic
Transmission gear Transmission
Drive
Electric devices
CVT
Belt drive
Performance Max. torque
Battery 12V-6Ah/ capacity/type dry-charged Magnetor QJ（153-2）12V type 200W/8500 rpm Spark plug
CR8EH (NGK)
- 14 -
Max. Hp Compression ratio Cylinder pressure
12.5N.m/7500rpm 8.9kW/8250 rpm 10.4：1 1.25MPa/1500rpm
Spark plug gap
0.6-0.7mm
Ignition
Electric spark lighter DC capacitance
Braking system
Unit of front fluid brake disc (mm)
φ240mm
Unit of rear fluid brake disc (mm)
φ240mm
Inspection/Adjustment Preparing information
Cylinder pressure
Periodic Maintenance & Inspection Table
Gear oil
Engine oil/ Oil filter
Replacement of gear oil
Fixing steering stem bearing & handlebar
Driving belt
Inspection & adjustment of throttle cable
Free stroke of front/rear brake
Air filter
Inspection of brake fluid level
Spark plug
Headlamp
Battery
Clutch
Ignition timing
Front/rear suspension system
Rim/tyre
Bolt/nut/fastener
Tyre specification
Preparing Principles General Warning! • Make sure that it is well ventilated before starting the engine. It is forbidden to start it in a closed area. Exhaust gas, which contains monoxide, may cause unconsciousness or even death of human being. • Petrol is liable to volatile or explode under certain condition. Ventilation is required and no any fire exists in working places. Fire is strictly forbidden in working areas or where oil is stored. - 15 -
Specification Engine Idle speed
1500±100rpm/min
Spark plug gap
0.6-0.7mm
Spec. of spark plug
C5HSA(NGK)
Cylinder compression pressure
1.25Mpa/1500rpm
Ignition time
BTDC12 degree ±1 degree, 1500±100rpm
Frame Free stroke of front brake lever
10-20mm
Free stroke of rear brake lever
10-20mm Specification
Tyre pressure unit: Kpa
Torque value
EFI Motorcycle QJ125T-30
Tyre pressure
Front wheel
100/80-16
225kpa
Rear wheel
120/80-16
225kpa
Locking nut for front wheel spindle
55-62
Fixing nut for rear wheel
N·m
100-113 N·m
- 16 -
Periodic Maintenance & Inspection Table
Service cycle and time
Per 300 KM
Per 1000 KM
Per 3000 KM
Per 6000 KM
Per 12000 KM
Per 14500 KM
New
One Three Six month months months
Twelve months
Fifteen months
C
C
R
C
Tools
Inspection item
*
Air filter
I
*
Petrol filter
I
I
R
Ordinary tools
*
Fuel filter
C
C
C
Ordinary tools
Replacement of engine fuel
R
Tyre pressure
I
I
I
I
I
I
Tyre pressure gauge, inflator
Battery inspection
I
I
I
I
I
I
Densimeter, multimeter
Actuation gap inspection
I
I
I
I
I
I
Ordinary tools
Inspection of steering handle fastening
I
I
I
Ordinary tools
Absorber working inspection
I
I
I
Ordinary tools
Screw fastening inspection
I
I
I
I
I
I
Torque spanner
Oil leakage inspection for gearbox
I
I
I
I
I
I
Ordinary tools
*
Inspection or replacement of spark plug
I
I
R
R
I
Ordinary tools
*
Replacement of gearbox oil
I
Replacement every 1000KM
Ordinary tools
Replacement every 5000KM
Lubrication of each part
L
L
Ordinary tools
Ordinary tools Lubricator
Exhaust pipe
I
I
I
I
I
I
Ordinary tools
*
Ignition timing
I
I
I
I
I
I
Timing lamp
*
Exhaust gas inspection at idle speed
A
I
A
A
A
A
Tachometer, CO HC analyzer
*
Throttle inspection
I
I
I
I
I
Ordinary tools
Fuel pipeline inspection
I
I
I
I
I
Ordinary tools
Lighting/metering/electric devices
I
I
I
I
I
Visual multimeter
I
- 17 -
Main stand bracket
I
Absorber Torque force of engine bolts
*
I
I
I
Ordinary tools
I
I
I
I
Ordinary tools
I
I
I
I
Torque spanner
Anticipated Inspection 1
Ignition system—obviously continuous ignition abnormality, engine fire or overheating, which requires inspection and maintenance.
2
Carbon fouling elimination—obviously insufficient horsepower, which requires carbon fouling removal from cylinder head, piston head and exhaust system.
3
Piston & cylinder—excessive abrasion; replace cylinder if it is blocked.
Please have your motorcycle inspected and adjusted periodically at KEEWAY distributors for being in best condition. The above table is established under the presupposition of 1000 km/month. I—Inspection A—Adjustment R—Replacement C—Cleaning L—Lubrication Note: 1. ―*‖ Regulations on exhaust emission made by the State Environmental Protection Agency shall be complied with. Maintenance must be carried out in accordance with the instruction manual supplied by the company. We are not responsible for any loss rising from private adjustment or maintenance. 2. Increase frequency of washing air filter if your motorcycle runs on the sandy/gravel road or under heavily polluted environment so as to extend its service life. 3. Motorcycles which often run at high speed or with high mileage shall be maintained frequently.
Engine oil/filter Oil level *Note • The motorcycle should be parked on a flat ground when checking its oil level • After the engine runs for 2-3 minutes or stops running for about 2-3 minutes, check the oil level. Check the oil level. Add oil to the upper limit when it is below the lower limit. （机油量尺：dipstick 上限：upper limit 下限：lower limit 机油 滤网：filter） - 18 -
Oil replacement *Note* It will be easier to change oil when the engine is warming up. Turn off the engine. Remove the bolt at the bottom of the crankcase and discharge oil. When oil is discharged completely, you can install the bolt and packing washer after they are cleaned. Add oil to the required level. Check oil leakage when the engine operates at its idle speed for minutes. Check the oil level again.
Throttle cable inspection/adjustment Check whether the throttle cable works smoothly. Check the free stroke of the throttle cable. Free stroke: 5-10mm Loosen the fixing nut and then rotate the adjusting nut for adjustment. （固定螺母：fixing nut 调整螺母：adjusting nut）
Air
filter
(picture
to
be
updated) Filter replacement. Remove the fixing screws of air filter. Remove the top cap of air filter. Remove the cartridge from the filter. （卡簧组件：clamp assembly） Check whether the cartridge is stained or damaged. - 19 -
Replace it if necessary. Remove the clamp assembly. Remove the filter. Check whether the filter is stained or damaged. Replace it if necessary.
Replacement time Replace it as early as possible if the motorcycle is always running on rainy days or on rugged road. *Note* •Make sure the air filter cap is well installed before installing the filter. （空滤器上盖：top cap of the air filter 安装螺钉：mounting screw 振谐箱：resonance box 箱体：body 滤 芯：cartridge）
Spark plug Remove the spark plug. Check whether the spark plug is damaged or stained or has carbon fouling. If yes, please clean it with spark plug cleaner or steel brush. Check spark plug gap. Gap: 0.6-0.7mm *Note For the installation of spark plug, it shall be installed with hand first and then fastened with spark plug sleeve. （火花塞间隙：spark plug gap）
- 20 -
Igition timing (picture to be updated) *Note Check the ignition system if ignition timing is incorrect. Remove the fastening bolt. Remove the magneto end cap. Check ignition timing with ignition timing lamp. （紧固螺栓：fastening bolt 磁电机端盖：magnetor end cap）
Cylinder pressure Operate it when the engine warms up. Remove the seat and body guard. Remove the spark plug. Install the cylinder pressure gauge. At full throttle, measure the cylinder pressure by starting the engine. Compression pressure: 1.25Mpa/1500rpm Following items shall be checked in case of extra-low pressure: （测气缸压力：measure cylinder pressure） —whether the spacer of cylinder head is damaged; —whether piston ring is damaged; —whether piston ring is worn; —whether the piston, cylinder or valve is worn. When compression pressure is too high, please check whether there is too much carbon fouling inside the combustion chamber and at piston head.
- 21 -
Gear oil Inspection *Note Set the middle kickstand on the flat ground and keep the motorcycle upright for checking the oil level. Remove the oil-check bolt after the engine is stopped. It is good if the oil level is at the lower limit of the oil-check bolt hole. Add gear oil when the oil level is too low. Install the oil-check bolt.
（放油螺栓：drain bolt 右盖：right cover）
*Note Make sure whether the bolt is well sealed, slippery or damaged.
Gear oil replacement Remove the oil-check bolt. Remove the drain bolt and gear oil is drained. Install the drain bolt. *Note Make sure whether the bolt is well sealed, slippery or damaged. （放油螺栓：drain bolt 右盖：right cover）
Add gear oil. Check whether there is oil leakage in any part. Install the oil-check bolt.
Drive belt Remove the cover of left crankcase. Check whether the drive belt is ruptured or abraded. Periodically maintenance shall be guaranteed, and replace the drive belt if necessary. （驱动皮带：drive belt） - 22 -
Free stroke of front/rear brake Free stroke of front brake Measure the free stroke of front brake at the tip of the brake lever. Free stroke: 10-20mm
Free stroke of rear brake Measure the free stroke of rear brake at the tip of the rear brake lever. Free stroke: 10-20mm
Inspection of brake fluid level Brake to the maximum and check the oil level through the oil sight glass. In case the brake fluid level is at or below the arrow in the picture, certain brake fluid shall be added until it reaches the upper limit. Note: The fuel pump assembly shall be parallel with the ground during inspection. （油泵体：fuel pump body 油镜：oil sight glass）
- 23 -
Headlamp Remove the front shield. Disconnect the connector of the headlamp. Remove the headlamp.
Clutch Start the engine and increase its speed gradually to check the work condition of the clutch. If the motorcycle fails to run or the engine flames out, you should check the clutch block. Replace it if necessary.
Front/rear suspension system
Compress upwards or downwards
Front Pull the front brake tight; compress the front absorber upwards or downwards for check. Check whether there is oil leakage in the front absorber and whether any component is damaged or loosened. （上下压缩：compress upwards or downwards）
Rear Compress the rear absorber upwards or downwards for check. Check whether each part of the rear absorber is damaged or loosened. Suspend the rear wheel and check shimmy. Check whether the suspension bushing of the engine is loose or not. （上下压缩：compress upwards or downwards）
- 24 -
Rim/tyre Check whether tyres or rims have any crack, nail or any other damage. Check tyre pressure.
*Note Check tyre pressure when it is cold.
Required pressure
Unit: Kpa
Specification EFI Motorcycle QJ125T-30
Tyre pressure
Front wheel
100/80-16
225
Rear wheel
120/80-16
225
Check whether the locking nut of the front wheel spindle is loose. Check whether the fixing nut of the rear wheel is loose. Tighten it to the required torque value if it is loose. Torque value: locking nut of the front wheel spindle fixing nut of the rear wheel
（测量轮胎压力：measure tyre pressure） 55-62 N·m 100-113 N·m
Fixing steering stem bearing and handlebar (picture to be updated) Move the handlebar to confirm there is no wire interference. Rotate the front wheel and move the handlebar freely for check. If the handlebar is not moved freely or loosened, check the steering stem bearing. （左右摆动：move from side to side）
- 25 -
高压包 FBT 电源锁组件 switch lock assembly 启动电机 startup motor
稳压器 stabilizer
Charging System - 26 -
蓄电池 battery
I. Battery/Charging System Preparing documents -------------1.1
Failure diagnosis --------------1.2
Battery -----------------------------1.3
Charging system ---------------1.4
Voltage/current regulator --------1.5
Charging coil of magnetor----1.6
Disassembly of magnetor--------1.7
1.1 Preparing documents Work Instructions *Note 1. Battery can be charged or discharged repeatedly. If it is placed after discharge, its service life will be shortened and performance is undermined. Normally, the battery performance will be degraded after two or three years. For battery with performance degradation (reduced capacity), voltage will recover temporarily after charging but decrease sharply when loading. 2. Battery overcharge: normally, overcharge can be judged upon the battery. In the case of short circuit inside the battery, its terminal is unable to detect voltage or the detected voltage is very low. Regulator failure: overvoltage inside the battery will shorten its service life. 3. The battery will be self-discharged if being stored for a long time, which reduces its capacity. It shall be charged about every three months. 4. Check the charging system following the sequence listed on the failure diagnosis table. 5. Do not remove the connector when there is current through electrical parts, otherwise it will cause overvoltage and damage to electrical parts inside the voltage regulator. Please operate it after the main switch turns off. 6. It is unnecessary to check the maintenance-free battery and add electrolyte and distilled water. 7. Check all the electric load. 8. Emergency charging can only be used under emergency situation. 9. Remove the battery from the motorcycle for emergency charging. 10. Do not use electrolyte-added batteries when interchanging batteries. 11. Use a voltmeter to check charging condition of the battery.
Preparing principles Item Battery
Specifications Capacity/Type
Voltage
12V-6AH/ dry-charged
Fully charged
13.1V - 27 -
（20℃）
Magnetor
Necessary charging
12.3V (not working for 1h)
Charging current
Standard: 0.6A, quick: 6A
Charging time
Standard: 10-15 hours, quick: 30 mins
Capacity
200W/8500rpm
Coil impedance (20℃)
Voltage regulator
Between white-black
3.3-3.5Ω
Type
Three-phase full-wave
Charging voltage
14.5±0.5V/5.000rpm
Tightening torque force Rectifier bolt High-voltage coil fixing bolt Flywheel fixing nut Body guard bolt
Tools 5.0 N·m 9.0 N·m 5.0 N·m 9.0 N·m
Universal fixing spanner Flywheel remover Test instrument Multimeter
1.2 Failure diagnosis Power supply dead
Interrupted current
Battery overdischarge Unconnected battery wiring Fuse blow Poor switch
Poor contact of the charging wire Poor contact of the charging system Poor contact or short circuit of the lighting system
Low voltage
Poor charging system
Poor battery charging Poor contact Poor charging system Poor voltage/current regulator
Poor contact, short circuit or open circuit of wire terminals Poor voltage/current regulator Poor magnetor
- 28 -
1.3 Battery 1.3.1 Battery disassembly Remove the battery cover. Remove the fixing plate. Remove the negative lead and then positive lead. Remove the battery. Warning! During the removal of the positive terminal, the tool should not be contacted with the frame. It is dangerous that spark caused by short circuit will ignite petrol and destroy the battery. Install the battery in a reversal order.
（电瓶盖：battery cover 电瓶压板组件：fixing plate assembly 电瓶：battery 电瓶盒：battery box 脚踏板：pedal）
*Note First positive terminal and then negative terminal to prevent short circuit. Check the charging situation (open circuit voltage). Open the battery cover and remove the fixing plate assembly of the battery. Remove the lead of the battery connector. Measure voltage between terminals. Fully charged: 13.1V Insufficiently charged: 12.3V (not working for 1h) *Note Use a voltmeter to check the charging situation.
1.3.2 Charging Connection method: connect the positive terminal of the charger with the positive terminal of the battery; connect the negative terminal of the charger with the negative terminal of the battery. - 29 -
Warning! • The battery should be far away from fire source. • Turn off the charger before or after charging to avoid explosive danger caused by spark which may exist in any connection. • Comply with the current and time requirements for charging as stated on the battery. *Note • Except emergencies, you should not use emergency charging. • Measure voltage in 30 minutes after the battery is charged. Charging current: standard: 0.6A quick: 6.0A Charging time: standard: 10-15 hours quick: 30 minutes Charging completed: open circuit voltage: above 12.8V
1.4 Charging system 1.4.1 Short-circuit test Remove the earth lead from the battery. Install a voltmeter between the negative terminal and the earth lead. Turn off the switch. Check short-circuit. *Note Connect the positive terminal of the multimeter with the negative terminal of the battery. Check whether there is short-circuit in the main switch or in the main wire in the case of any abnormality.
- 30 -
1.4.2 Charging check Use a multimeter to check the charging status of the battery when it is being fully charged. Install the fully charged battery after the engine warms up. Connect a voltmeter between terminals. Remove the main fuse and connect an ammeter between terminals. Start the engine and increase its speed gradually to measure the limiting voltage and current. Limiting voltage/speed: 14-15V (5.000rpm) Check the voltage regulator if the limiting voltage is not within its required range. Check the limiting voltage of the lighting system. *Note Set the multimeter to the AC voltage position. （万用电表：multimeter） Limiting voltage: 13.1±0.5V/5.000rpm Check the voltage/current regulator if the limiting voltage is not within its required range.
1.5 Voltage/current regulator 1.5.1 Main wiring check Remove 4p plug of the voltage/current regulator. Check conductivity between main wiring terminals. Item (wire color)
Judgment
Between Battery(red) and GND of the body
With battery voltage
Between GND wire (black) and GND of the body Between charging coil (white) and the GND of the body
With lead
黑 白3 红
Resistance in the coil of the magnetor.
白2 白1
（黑：black 红：red 白：white）
1.5.2 Voltage-current regulator check - 31 -
1. Select ―diode‖ in the multimeter; 2. The black probe connects the red terminal of the stabilizer, and the red probe respectively connects white terminals of the stabilizer (white1, white 2 and white3). Pointers indicate values. If not, the stabilizer is damaged and needs replacement. 3. The red probe connects the black terminal of the stabilizer and the black probe connects white terminals of the stabilizer (white1, white2, white3). Pointers indicate values. If not, the stabilizer is damaged and needs replacement. *Note • Do not touch any metal part of the test rod of the multimeter with your finger for check. • Check with multimeter. Different multimeters show different impedance and different results. Replace the voltage-current regulator when the impedance between terminals is abnormal.
1.6 Magnetor charging coil *Note Check the magnetor charging coil on the engine.
Check Remove the 6p connector of the magnetor. Measure impedance between the white coil of the magnetor and the body with multimeter. Standard: 0.6-1Ω（20℃） Replace the magnetor coil when the measured value exceeds the standard value.
1.7 Magnetor disassembly 1.7.1 Disassembly Remove the body guard.
螺栓
Fix the flywheel using the universal spanner. Remove fixing bolts of the flywheel. Remove the flywheel using the flywheel remover. Remove the solid key. Remove the conductor joint. Remove the stator.
（螺栓：bolt） - 32 -
1.7.2 Installation Install the stator on the body of the engine. Connect the magnetor joint.
Clean up the crankshaft and the taper part of the flywheel. Install the solid key into the groove above the upper crankshaft key and confirm it. Aim the groove in the flywheel at the solid key on the shaft. *Note
螺栓
Ensure there is no any bolt in the inner magnetic side of the flywheel. Fix the flywheel with the universal spanner and tighten fixing nuts. Torque force: 9.0 N·m
（螺栓：bolt） Install the left body guard.
- 33 -
电源锁组件 power lock assembly 继电器 relay
点火器 igniter
SPARK PLUG
电喇叭 electric horn
MAIN SW B/W B B/R BL/W W/G
W/G W W W BL/W IGNITION COIL MAGNETO
Ignition System 点火系统 - 34 -
BATTERY
蓄电池 battery
II. Ignition System Preparing documents--------------2.1
CDI Group ----------------2.4
Failure diagnosis ------------------2.2
Ignition coil --------------2.5
Ignition system check-------------2.3
Trigger --------------------2.6
2.1 Preparing documents Work Instructions 1. Check the ignition system following the sequence listed in the table of failure diagnosis. 2. This ignition system is an electronically and automatically angling device. It is solidified in the CDI group and you don’t have to adjust the ignition time. 3. Check the ignition system following the sequence listed in the table of failure diagnosis. 4. Do not make CDI of the ignition system fall down or hang down or hammer it with strong force (primary causes for failure). Pay special attention during disassembly. 5. Failure of the ignition system is mostly caused by poor contact of the socket. Check whether each connector is in good condition. 6. Check whether the heat value used for the spark plug is proper. If not, the engine may work abnormally or the spark plug may be burnt. 7. Check in this chapter is based on the maximum voltage. It also refers to check on the impedance of the ignition coil. 8. Check the main switch according to the conduction table. 9. Remove the magnetor and the stator according to instructions.
Preparing principles Item Spark plug recommended
Standard value Standard
C5HSA(NGK)
Hot type
C6HSA(NGK)
Cold type
C7HSA(NGK)
Spark plug gap
(20℃)
0.4Ω±10％
Primary coil
Ignition coil impedance
0.6-0.7mm
Secondary coil
With plug cap
8-11KΩ
Without plug cap
4.5-5.5KΩ
Impedance of trigger（20℃）
100-200Ω
Measure the maximum primary voltage of the ignition
95-400V
coil
Above 1.7V
Trigger voltage - 35 -
Tools Attachments to the Maximum Voltage Table Multimeter
2.2 Failure diagnosis Non-sparking of spark plug
Ignition coil
Abnormality
Cause (confirm it sequentially as follows)
Too low high-voltage
①The inner resistance is too small and it should be tested by required tester. ②Low speed of the crankshaft. ③Interfered tester (It is normal that voltage is always beyond the required value upon several measurements.) ④Poor wiring contact of the ignition system. ⑤Poor ignition coil. ⑥Poor charging coil (measured at the maximum voltage).
No or interrupted high voltage
①Incorrect connection of the tester. ②Poor main switch. ③Poor contact of CDI terminal. ④Short circuit or poor contact of the GND of CDI. ⑤Poor contact of charging coil (measured at the maximum voltage). ⑥Poor trigger (measured at the maximum voltage). ⑦Poor terminal of high-voltage wires. ⑧Poor CDI group (when item ①-⑦ is checked to be abnormal or there is no spark for spark plug.)
Normal high voltage, but no spark
①Poor spark plug or secondary leakage of the ignition coil. ②Poor ignition coil.
No high voltage
①The inner resistance is too small and it should be tested by required tester. ②Low speed of the crankshaft. ③Interfered tester (It is normal that voltage is always beyond the required value upon several measurements.) ④Poor charging coil (Item ①-③ is checked to be normal.)
Side voltage
Charging coil
- 36 -
①Poor ignition coil. ②Poor charging coil.
No or interrupted high voltage
①The inner resistance is too small and it should be tested by required tester. ②Low speed of the crankshaft. ③Interfered tester (It is normal that voltage is always beyond the required value upon several measurements.) ④Poor trigger (Item ①-③ is checked to be normal.)
Too low high-voltage Trigger
①Poor ignition coil. ②Poor trigger.
No or interrupted high voltage
万用表
2.3 Ignition system check *Note • When there is no spark, check whether there is loose wiring or poor contact, and make sure all voltage values are normal. • There are kinds of multimeters with different impedances and different test values. Connect a high-pressure shunt or an ammeter with an input impedance above 10MΩ10CV to the multimeter.
（万用表：multimeter）
19.1 Primary voltage of the ignition coil If you replace the original spark plug with a better one, make ground connection with the engine. *Note Make sure all wiring is correct before test. Cylinder compression pressure normally refers to the test value when the spark plug is installed on the cylinder head. Connect the lead of the ignition coil and also the shunt - 37 -
between the primary coil terminal (black/white) and the GND. Press the startup motor or step the actuating lever to measure the maximum primary voltage of the ignition coil. Minimum voltage: above 95V. *Note Never touch any metal part of the test rod with your finger to avoid electric shock.
19.2 Charging coil *Note
蓝/白 黑/白
Install the spark plug on the cylinder head and carry out measurement when the compression pressure is normal.
黑/红
白/绿 黑 Remove 4P connector and 2P connector from CDI group. Install a high-pressure shunt between the charging coil with 2P connector (red/white terminal) and 4P connector (black terminal). Press the startup motor or step the actuating lever to measure the maximum voltage of the charging coil. Connection: positive pole to red/white; negative pole to black. （黑：black 红：red 白：white 绿：green 蓝：blue） Minimum voltage: above 95V. *Note
Never touch any metal part of the test rod with your finger to avoid electric shock. 蓝/白 黑/白
When the maximum voltage measured at the terminal of CDI Group is abnormal, dismantle the body guard and the magnetor terminal. Connect the charging coil (black/red) to the shunt. • If the voltage of CDI is measured to be abnormal while the voltage at the magnetor terminal is normal, it is caused by poor contact or disconnected wiring. • If the voltage at both CDI and magnetor terminal appears to be abnormal, it is caused by poor charging coil. Please refer to charging coil check.
黑/红 白/绿 黑
（黑：black 红：red 白：white 绿：green 蓝：blue）
19.3 Trigger - 38 -
*Note Install the spark plug on the cylinder head and carry out measurement when the compression pressure is normal. Remove 6P connector of CDI group. Connect the peak-voltage shunt between the trigger with 6P connector (blue/white terminal) and 6P connector (black terminal). Press the startup motor or step the actuating lever to measure the maximum voltage of the trigger.
Ω 蓝/白
Connection: positive pole to blue/white; negative pole to black. Minimum voltage: above 1.7V. *Note Never touch any metal part of the test rod with your finger to avoid electric shock. （白：white 蓝：blue） When the maximum voltage measured at the terminal of CDI Group is abnormal, dismantle the right body guard and the magnetor connector. Connect the trigger (blue/white) to the shunt. • If the voltage of CDI is measured to be abnormal while the voltage at the magnetor terminal is normal, it is caused by poor contact or disconnected wiring. • If the voltage at both CDI and magnetor terminal appears to be abnormal, it is caused by poor trigger. Please refer to the table of failure diagnosis.
- 39 -
Check the system. Remove the CDI Group, and check components of the ignition system at the terminal.
白/绿 黑
20.1 System check
黑/红 蓝/白 黑/白
2.4 CDI Group
20.2 Check Remove CDI Group and check whether the terminal is loose or corrosive. （黑：black 红：red 白：white 绿：green 蓝：blue） Item
Test terminal
Standard (20℃)
Main switch
Red--red/white
Conduction when the main switch is ―OFF‖
Trigger
Blue/white – white/green
100-200Ω
Primary coil of the ignition coil
Black/white--black
0.4Ω±10％
Secondary coil of the ignition coil
Black--spark plug cap（excluding the spark plug）
4.5-5.5KΩ±10％
2.5 Ignition coil (picture to be updated) 21.1 Disassembly Remove the body guard. Remove the spark plug cap. Remove the primary lead of the ignition coil. Remove the fixing bolts and then the ignition coil. Install the ignition coil in reverse order. *Note
点火线图
Install the primary coil with black/white terminal.
(点火线圈：ignition coil)
Ω
21.2 Check the primary coil - 40 -
Measure impedance between terminals of the primary coil. Standard: 0.4Ω±10％（20℃） It shows good if the impedance is within the range of standard values. Replace the primary coil if the impedance shows ∞ which indicates that the coil breaks.
21.3 Secondary coil Attached with spark plug. Measure the impedance between the wiring side of the spark plug cap and the terminals. Standard: 8-11KΩ（20℃） It shows good if the impedance is within the range of standard values. The impedance ∞ indicates that the coil breaks. Remove the spark plug cap. Measure the impedance between the primary side wire of the ignition coil and the negative terminal. Standard: 4.5-5.5KΩ±10％（20℃）
点火线图
Ω
(点火线圈：ignition coil)
2.6 Trigger *Note Check the trigger on the engine.
Check Remove the body guard. Remove the trigger terminal. Measure the impedance between the blue/white terminal of the side wire of the engine and the body GND. Standard: 100-200Ω（20℃） Replace the magnetor if the measured value exceeds the standard value.
Ω 蓝/白
（白：white 蓝：blue）
- 41 -
白/绿 蓝/白
白
白
白
插件：DJ7061Y-2.3-21总成 铜件：DJ621-2.3A 防水栓：MFD004-2 （白/绿 white/green 蓝/白 blue/white 白 white 插件 connector 总成 assembly 铜件 copper pieces 防水栓 waterproof bolt）
- 42 -
高压包 FBT 电源锁组件 switch lock assembly 启动电机 startup motor
BRAKE SWITCH BRAKE SWITCH STARTER SWITCH
BATTERY
Startup Diagram 启动示意图 - 43 -
稳压器 stabilizer
RELAY
蓄电池 battery
STARTOR MOTOR
III. Startup System Preparing documents---------------3.1 Failure diagnosis -------------------3.2 Startup motor------------------------3.3 Starter relay--------------------------3.4
3.1 Preparing documents Work Instructions Disassemble the startup motor on the engine. For the disassembly of the startup clutch, please comply with related regulations.
Preparing principles Item
Standard
Limit for use
Length of the brush of the startup motor
12.5mm
8.5mm
Bushing of the startup idler shaft
8.3mm
Outer diameter of the startup idler shaft
7.94mm
Tightening torque force Bolts for the clutch cover of the startup motor Fixing bolts for the clutch of the startup motor
12 N·m 95 N·m
Tools Spanner for fixing nuts Universal fixing spanner
- 44 -
3.2 Failure diagnosis Startup failure
• Fuse blow • Low battery • Poor main switch • Poor startup clutch • Poor brake switch • Poor starter relay • Poor wiring contact • Poor startup motor
Weak in rotation
No rotation of RE rotary engine
of the startup motor
of the startup motor
• Low battery • Poor wiring contact • Gear seized
• Poor startup clutch • Reversal rotation of the startup motor • Low battery
3.3 Startup motor 3.3.1 Disassembly *Note Before the startup motor is disassembled, turn off the main switch, remove the GND wire of the battery, and then power on to check whether the startup motor works for ensuring safety. Remove the wire clip of the startup motor. Remove the fixing bolts, separate the front and rear end caps, and dismantle the startup motor. Roll the waterproof rubber case and dismantle the terminal （换向器：commutator） of the startup motor.
3.3.2 Breakdown Remove screws in the shell, front cover, motor housing and other parts.
3.3.3 Check Check other components. - 45 -
碳刷
Replace any part with abraded, damaged or burnt surface. （碳刷：carbon brush） Clean the commutator surface if there is metal power attached to it. Check conduction between the surface of other components. Ensure non-conduction between armature shafts of the commutator. Check the conduction of the shell of the startup motor. Ensure non-conduction between the conduction terminal and the startup motor shell. Check conduction between the conduction terminal and the brush. Replace any abnormal part. Check conduction of the brush bracket. Replace it when there is conduction. Measure the length of the brush. Limit for use: replace it if lower than 8.5mm Check smooth rotation of the needle bearing inside the front cover and whether it is loose when press-in. Replace it if there is any abnormality. Check whether the oil seal is abraded or damaged.
3.3.4 Assembly Lubricate the oil seal inside the front cover with grease. Install the brush on the bracket. Lubricate moving parts at two ends of the brush shaft with grease. Press each brush into the bracket. *Note • Pay special attention that the surface of the brush and the armature shall not be damaged. • Pay attention that the armature shaft shall not damage lips of the oil seal. Install the rear cover of the motor. Aim the screw hole of the motor shell at the screw hole of the front cover for installation. Lock screws in the shell. *Note When the shell and the front cover are assembled, it is easy to pull the front cover with magnet to attract the armature. Press it gently for assembly.
3.3.5 Installation Install the lead of the startup motor and the dustproof boot. - 46 -
Then install the startup motor. Install the wire clip for rear brake.
3.4 Starter relay 3.4.1 Check Remove the body guard When the main switch is ―on‖, check there is ―click‖ sound at the time of pressing the startup motor. With click sound, it is normal. Without click sound: • check voltage of the starter relay; • check the GND loop of the starter relay; • check the movement of the starter relay. 启动 继电器
3.4.2 Check voltage of the starter relay Set up the main stand, and measure voltage between the negative pole of the green/yellow wire of the starter relay terminal and the body ground connection. When the main switch is ―on‖, hold the brake lever. The （启动继电器：starter relay） battery voltage shall comply with regulations. When there is no voltage at the starter relay terminal, check the conduction of the brake switch and leads.
3.4.3 Check GND loop of the starter relay Remove the starter relay connector. Check conduction between the black wire of the lead terminal and the body ground connection. When the startup button is pressed, it shall show good conduction between the black wire of the terminal and the body ground connection. Check conduction of the startup button and leads when it is not conducted.
绿/黄 黑
Ω
启动 继电器
（启动继电器：starter relay 绿：green 黄：yellow 黑：black）
- 47 -
3.4.4 Check Connect the starter relay to the battery, and the terminal of the startup motor to the multimeter. Connect fully charged battery between the black wire and the green/yellow wire of the relay. The relay shall sound ―click‖ and the multimeter shall indicate resistance of ―zero‖.
- 48 -
Ω
IV. Bulbs/Switches/Meters Preparing documents --------------4.1
Meters ----------------4.6
Failure diagnosis--------------4.2
Main switch --------------4.7
Replacement of headlamp bulbs --------4.3
Horn ----------------4.8
Replacement of front steering lamp bulbs------4.4 Handlebar switch -------4.9 Replacement of tail lamp bulbs-------4.5
4.1 Preparing documents Work Instructions Remove the switch from the vehicle to measure its conduction.
4.2 Failure diagnosis When the main switch ―ON‖ is not light, it is due to • Poor bulbs. • Poor switch. • Bad contact or broken wires.
4.3 Replacement of headlamp bulbs 4.3.1 Disassembly Remove the front shield. Remove fixing screws for dismantling the headlamp. Disconnect the headlamp connector. Remove the headlamp. Remove the glass of the headlamp. Fix the headlamp and rotate the socket clockwise to remove the bulb. （前照灯：headlamp） - 49 -
4.3.2 Installation Install the bulb in reverse order.
4.4 Replacement of front steering lamp bulbs 4.4.1 Disassembly Remove the handlebar shade. Loosen fixing screws of steering lamps. Remove the bulb socket from the lamps.
4.4.2 Installation Install the bulb in reverse order.
（左右转向灯：left/right steering lamp）
4.5 Replacement of tail lamp bulbs 4.5.1 Disassembly Remove the body guard. Remove fixing screws to dismantle the tail lamp shield. Disconnect the tail lamp connector. Remove the tail lamp. (尾灯：tail lamp)
4.5.2 Installation Install the tail lamp in reverse order.
4.5.3 Replacement of tail lamp bulbs 4.5.3.1 Disassembly Remove screws to dismantle the tail lamp shield. Remove the bulb from the socket. （尾灯：tail lamp 灯泡：bulb） - 50 -
4.5.3.2 Installation Install the bulb in reverse order.
4.6 Meter (picture to be updated) Remove the rearview mirror. Remove the handlebar shade and waterproof connector. Remove screws. Remove the odometer assembly to dismantle the odometer. Install the odometer in reverse order. （仪表盘：odometer）
4.7 Main switch 4.7.1 Check Remove the front guard. Remove the main switch lead terminal. Check conduction of the terminal.
电源开关
红 红/白 黄 橙/蓝
P （红：red 红/白：red/white 黄：yellow 橙/蓝：orange/blue） （电源开关：power switch）
4.7.2 Replacement of main switch Remove the front guard. Remove fixing bolts and the fixing seat for the main switch. Remove fixing bolts and replace the main switch.
- 51 -
4.8 Horn Check Remove horn wires. It shows good when the horn wire is connected to the battery.
4.9 Handlebar switch ①
1. Dipswitch 2. Steering lamp switch 3. Horn switch 4. Lamp switch 5. Startup switch
PASSING
②
④
③ ⑤
- 52 -
Front disc brake
1. front disc brake assembly 2. handle 3. handle screw 4. hexagon flange locking nut 5. hexagon flange bolt 6. packing washer 7. fuel pump assembly 8. bolt 9. fixing cover 10. brake switch assembly 11. screw 12. brake hose assembly 13. brake cylinder assembly 14. connecting bracket of the front disc brake 15. brake shoe assembly 16. bolt
- 53 -
Rear disc brake
1. rear disc brake assembly 2. fuel pump assembly 3. brake cylinder assembly 4. brake hose assembly 5. handle 6. packing washer 7. hexagon flange locking nut 8. hexagon flange screw 9. fixing cover 10. brake switch assembly 11. cross recessed countersunk screw 12. hexagon flange locking nut 13. handle screw 14. connecting bracket of the rear disc brake 15. brake shoe assembly 16. mounting bolts for rear disc brake 17. rear disc brake clamp
- 54 -
V. Brake Maintenance instruction ------------------------5.1 Failure diagnosis---------------------------------5.2 Front disc brake ---------------------------------5.3 Rear disc brake ----------------------------------5.4
5.1 Maintenance instruction Work Instructions *Note • Do not stain the brake assembly with oil spots during installation or disassembly. • Clean it with required cleaning agent to maintain the brake performance. *Check brake before riding.*
5.1.1 Specification Item
Standard (mm)
Limit for use (mm)
Thickness of front brake disc
4.0
3.0
Thickness of front brake shoe
6.0
3.0
Thickness of rear brake disc
4.0
3.0
Thickness of rear brake shoe
6.0
3.0
EFI Motorcycle QJ125T-30 φ240mm
Diameter of front disc brake: φ240mm
5.1.2 Torque force Fixing bolts for front/rear brake disc Mounting bolts for front brake cylinder assembly Mounting bolts for rear brake cylinder assembly
22-29 N·m 22-29 N·m 22-29 N·m
5.2 Failure diagnosis Brake - 55 -
Diameter of rear disc brake:
Poor brake performance
Slow reaction or tight lever
1. Improper adjustment of the brake 2. Abraded brake shoe 3. Improper installation of the brake shoe 4. Stained brake shoe or brake disc
1. Improper adjustment of the brake 2. Abraded brake shoe 3. Improper installation of the brake shoe
Abnormal noise 1. Abraded brake shoe 2. Stained brake shoe or brake disc
5.3 Front disc brake 5.3.1 Disassembly *Note • Replace the brake shoe assembly. • If the brake shoe will be used again, mark it before disassembly so as to reinstall it at the original place. Remove following assemblies from the front absorber. Front brake: 1. brake cylinder assembly 2. front brake hose assembly 3. brake shoe assembly 4. connecting bracket of the front brake （油泵体组件：fuel pump assembly 制动缸组件：brake cylinder assembly） *Note • Do not stain the brake assembly with oil spots during installation or disassembly. • Clean it with required cleaning agent to maintain the brake performance. Loosen fixing bolts for the brake cylinder assembly. Remove the brake cylinder assembly from the front absorber. Remove the front wheel spindle. Remove the front wheel. Remove the brake disc from the front wheel.
5.3.2 Check Check whether brake shoes are abraded. Replace it if necessary. Measure the brake shoe and the brake disc. Record maximum values. - 56 -
Specification Diameter of the front brake disc Thickness of the front brake disc
φ240mm 4.0mm
*Note • Measurement with micrometer. Measure the thickness of the brake shoe. If the thickness of the brake disc or the brake shoe is below the required value for maintenance or it is stained with grease, please replace it. Limit for use: brake shoe 3.0mm brake disc 3.0mm Note: replace brake shoes in pair.
（制动蹄块：brake shoe）
5.3.3 Installation Install the brake disc and the front wheel. Install the front brake hose assembly and the brake cylinder assembly. Do not stain the brake shoes and the brake disc with grease. *Note Any grease on brake shoes will reduce the brake performance and even lead to failure. Tighten bolts and nuts to the required torque force. Torque force: Fixing bolts for the brake disc 22-29 N·m Mounting bolts for the front brake shoe assembly 22-29 N·m Do not stain brake shoes with oil spots. Use brake cleaning agent to clean brake shoes with oil spots. （制动蹄块：brake shoe 制动缸：brake cylinder） *Note Any oil spot on brake shoes will reduce brake performance. - 57 -
5.4 Rear disc brake 5.4.1 Disassembly Remove the body guard. Remove the rear brake cylinder assembly. Remove the rear wheel. Remove the brake disc from the rim of the rear wheel.
（油泵体组件：fuel pump assembly 制动缸组件：brake cylinder assembly 制动软管总成：brake hose assembly） *Note • Replace the brake shoe assembly. • If the brake shoe will be used again, mark it before disassembly so as to reinstall it at the original place. Remove following assemblies from the rear wheel. Rear brake: 1. brake shoe assembly 2. rear brake hose assembly 3. brake cylinder 4. connecting bracket of the rear disc brake 5. rear disc brake clamp （油泵体组件：fuel pump assembly 制动缸组件：brake cylinder assembly 制动软管总成：brake hose assembly） Note: for details, see P60
5.4.2 Check Check whether the brake disc and the brake shoes are abraded. Replace it if necessary. Measure the brake shoe and the brake disc. Record maximum values. *Note • Scrub the rusty brake disc with sandpaper #120. • Measurement with micrometer. Measure the thickness of the brake disc and the brake shoes. If the thickness of the brake disc or the brake shoe is below - 58 -
the required value for maintenance or it is stained with grease, please replace it. Note: replace brake shoes in pair. Diameter of the rear brake disc φ240mm Thickness of the rear brake disc 4.0mm Limit for use: brake shoes 3.0 mm brake disc 3.0mm
5.4.3 Installation Install the rear brake disc. Install the rear wheel. Install the rear brake cylinder assembly. *Note Any grease on brake shoes will reduce the brake performance and even lead to failure. Tighten bolts and nuts to the required torque force.
（制动蹄块：brake shoe 制动缸：brake cylinder） Torque force: Fixing bolts for rear brake shoe assembly: 22-29 N·m Do not stain brake shoes and brake disc with oil spots. Use brake cleaning agent to clean brake shoes and brake disc with oil spots. *Note Any oil spot on brake shoes will reduce the brake performance. Note: for details, see P60.
（油泵体组件：fuel pump assembly 制动缸组件：brake cylinder assembly 制动软管总成：brake hose assembly）
- 59 -
前大罩栅格 front shield lattic 前大罩 front shield 前挡泥板 front fender 挡风玻璃 windshield 把手前 罩 handlebar front shield 前大罩饰框 decorating frame of the front shield 散热器前导风板 front wind board of the radiator 散热器后导风板 rear wind board of the radiator 前内挡泥板 front inner fender 把手后罩 rear handlebar shield 电瓶盖 battery cover 车架号码盖 frame number cover 脚踏板 pedal 下挡泥板 lower fender 脚防护板左右侧面栅格 left/right lattice of the foot guard 置物箱盖组件 tail box cover assembly 电瓶 battery 左前护板 front left guard 脚蹬左右护板 left/right pedal guard 右前护板 front right - 60 -
guard 座垫组件 seat assembly 右前护板 front right guard 右左脚蹬盖板 right cover of the left pedal 左右脚蹬盖板 left cover of the right pedal 后下挡泥 rear lower fender 后内挡泥板 rear inner fender 后内 泥板挡水橡胶 rear inner fender rubber 右后护板 rear right guard 左后护板 rear left guard 护条左侧装饰 板 left decorating board for the guard 护条右侧装饰板 right decorating board for the guard 后扶手 rear handrail 后挡泥板 rear fender 后反射体 rear reflector
VI. Body Dismantle the body in following order.
Handlebar front shield →windshield →handlebar rear shield →meter →front shield →front inner fender →foot guard→ ↓ battery box cover →left/right pedal cover →left/right pedal rubber →left/right pedal guard →rear handrail →seat→ ↓ helmet box →left/right rear guard →left/right front guard →rear fender →rear inner fender→ ↓ rear inner fender rubber →rear lower fender →pedal →front fender *Note Do not damage any body part during disassembly. Do not damage any hook or claw in the body during disassembly. Aim panels in the body at each corresponding groove. Ensure correct installation of each hook or claw part during assembly. Do no damage any part during assembly.
- 61 -
Front wheel/front suspension
Front wheel
开口销 cotter pin 齿轮座组件 gear housing assembly 前轮圈 front rim 油封 oil seal 液刹盘 brake disc 前轮左隔套 left bushing of the front wheel 前轮轴 front wheel spindle 开槽螺母 slotted nut 滚动轴承 rolling bearing 前轮胎 front tyre 前轮中间轴套 middle spindle sleeve of the front wheel 滚动轴承 rolling bearing 液刹盘安装螺栓 mounting bolts for the brake disc
- 62 -
VII. Front Wheel/Front Suspension Preparing documents-------------------------7.1 Failure diagnosis -----------------------------7.2 Front wheel -----------------------------------7.3 Steering handle -------------------------------7.4 Front fork -------------------------------------7.5
7.1 Preparing documents Work Instructions Before removing the front wheel, you should use jack to support the body bottom and suspend the front wheel which shall not be reversely rotated. Pay attention that brake shoes and brake discs shall not be stained with grease during operation.
Motorcycle Standards Standard (mm)
Measurement points
Item
Front wheel spindle
Bending
Front wheel
Rim shimmy
0.2
Vertically Horizontally
2.0 Within 1.0
Torque force Fixing bolts for the steering handle Locking nut for the front wheel spindle
Limit for use (mm)
2.0
Tools 40-60 55-62
7.2 Failure diagnosis 7.2.1 Difficulty in steering Failure of the steering handle bearing. Damaged steering handle bearing. Low tyre pressure. - 63 -
N·m N·m
Bearing puller Locking nut spanner
Flat tyre.
7.2.2 Unsteady steering Damaged steering handle bearing. Low tyre pressure. Bending of the front fork or the front wheel spindle. Deformed or unbalanced front tyre.
7.2.3 Front tyre shimmy Deformed rim. Loose front wheel bearing. Poor tyre.
7.2.4 Difficulty in wheel rolling Failure of wheel bearing or gear housing.
7.2.5 Abnormal noise of the front absorber Fricative sound of the absorber guard. Loose bolts in the absorber.
7.3 Front wheel 7.3.1 Disassembly Support the body bottom to suspend the front wheel. Remove the cotter pin and locking nuts for the front wheel spindle. Remove the front wheel spindle, gear housing assembly and front wheel. Remove screws, front fender and odometer cable. Remove the front brake hose. Remove the oil seal and the bearings respectively with oil seal remover and bearing puller.
7.3.2 Check 7.3.2.1 Check the bending of the wheel spindle - 64 -
（车轴：wheel spindle）
Place the wheel spindle on the V-base and measure the eccentricity ratio with a dial indicator. Limit for use: replacement when beyond 0.2mm
7.3.2.2 Check the rim shimmy Place the rim on a precision bracket and check the rim shimmy. Rotate the wheel by manual and read indication. Limit for use: Vertically: replacement when beyond 2.0mm. Horizontally: replacement when beyond 2.0mm.
7.3.2.3 Check the front wheel bearing Remove the left bushing and the oil seal of the front wheel. （前轮圈 front rim 滚动轴承 rolling bearing 液刹盘 brake disc 前轮左隔套 left bushing of the front wheel 前轮中间轴套 middle spindle sleeve of the front wheel 油封 oil seal 液刹盘安装螺栓 mounting bolts for the brake disc 前轮轴 front wheel spindle）
Check rolling of the bearings. The bearings will not roll if abraded or loosened. Replace it.
（游隙 clearance
轴向 axially
径向 radially）
7.3.3 Bearing replacement Remove the front wheel spindle, front wheel, middle spindle sleeve and left spindle sleeve; then remove the oil seal and the bearing respectively with oil seal remover and bearing puller. Note: replace dismantled bearings with new ones. - 65 -
Lubricate the bearings with grease during installation. Then press the bearings in with bearing installation tools. *Note • Bearings must be pressed in horizontally. • The oil seal side of the bearings shall be pressed in from outside.
7.3.4 Installation Lubricate the oil seal of the front wheel with grease. Lubricate gear engagement parts and moving parts with grease. Install the middle spindle sleeve, bearings and oil seal. Align the gear housing assembly and then install the front wheel. Note • If the gear housing assembly of the odometer is not aimed at and locked with the front wheel spindle, the gear housing assembly will be deformed. • After the rim is installed, rotate the rim to ensure that the drive shaft of the odometer works normally. Install and tighten the front wheel spindle. * Note: for the disassembly and assembly of the front suspension of EFI Motorcycle QJ125T-30, please see P65. Torque force Locking nuts for the front wheel spindle 55-62 N·m
7.4 Steering handle 7.4.1 Disassembly Remove the front and rear shield and the rearview mirror assembly. Remove the front brake handle and the rear brake handle. Remove the decorating cover of the grip, the throttle cable assembly and the right grip assembly. Remove the left steering handle sleeve. Remove fixing bolts for the steering handle. Remove the steering handle. （左方向把套 left steering handle sleeve 后视镜组件 rearview mirror assembly - 66 -
方向把焊接组件 weld
assembly of the steering handle 螺栓 bolt 自锁螺母 locking nut 方向柱紧固套 fixing sleeve of the steering stem 油门线组件 throttle cable assembly 握把装饰盖 decorating cover of the grip 右握把组件 right grip assembly 螺钉 screw 右把手套 right handle sleeve）
7.4.2 Installation Install it in reverse order. Fixing bolts Torque force: 40-60 N·m
7.5 Front fork 7.5.1 Disassembly Remove the front wheel. Remove the front shield, front inner fender and front fender. Remove the brake hose and the odometer cable. Loosen the gland nut and the lock washer. Remove the upper and the lower bearing cups. Remove the front fork. Tools: Fixing bolt spanner for the steering handle. Fixing nut spanner. Special disassembly tool for bearing cups. *Note: •The opening of the body guard shall be cleaned with cloth.
7.5.3 Installation Tools: Fixing nut spanner. Ensure the front fork is not loose by left and right movement. Steps: Install the steering handle. Install the absorber. Install the front wheel. （下联板焊接组件 weld assembly of the lower connecting bracket 前左减震器组件 front left absorber assembly 压紧螺母 gland nut 止动垫圈 lock washer 上轴承上钢碗 upper cup of the upper bearing 钢球 steel ball 上轴承下钢碗 lower cup of the upper bearing 轴承 bearing 垫圈 washer 弹簧垫圈 spring washer 螺栓 bolt 前右减震器组件 front right absorber assembly）
- 67 -
7.6 Radiator/expansion tank assembly 7.6.1 Disassembly Remove the body guard. Remove the headlamp. Loosen four fixing bolts for the radiator assembly. Loosen fixing bolts for inlet/outlet hoses of the radiator. Remove the power cord of the cooling fan. Remove the radiator assembly and the expansion tank assembly. heat sink
7.6.2 Check Open the water tank cover and check the coolant level inside. Add coolant when it approaches the limit. Broken or twisted heat sink will reduce the cooling （散热片：heat sink） capability of the radiator. Repair the radiator with a small club when over 1/3 of heat sink is damaged or twisted. Check the liquid level of the radiator. Remove the radiator cover after the liquid is fully cooled; Completely discharge the coolant; Add the prepared coolant slowly through the filling hole (mounting hole of the radiator) until it reaches the edge of the hole; Install the radiator cover. Note: please use KEEWAY coolant; The minimum temperature for using KEEWAY coolant is -35℃.
（口沿：edge
- 68 -
散热片：heat sink
冷却液：coolant）
Check the switch of the fan. Replace it when the switch can not work normally.
（冷却风扇：cooling fan
风扇电机开关：fan switch）
Pressure test for the radiator. Remove the radiator cover after coolant is fully cooled; Apply required pressure to the cooling system with the radiator cover tester (lower than pressure for opening the valve of the cover) and ensure that it can keep for at least 6s under the required pressure; In the case of pressure leakage, check the hose, all connections, pump position and inspection hole.
7.6.3 Installation Install it in reverse order. （散热器盖测定器：radiator cover tester）
- 69 -
Rear wheel/rear suspension (picture to be updated)
VIII. Rear Wheel/Rear Suspension Preparing documents -----------------8.1 Failure diagnosis ----------------------8.2 Rear wheel -----------------------------8.3 Rear absorber/rear swing arm -------8.4 - 70 -
8.1 Preparing documents Work Instructions The surface of brake discs and brake shoes shall not be stained with oil spots.
Preparing Principles Item Rear wheel shimmy
Standard (mm)
Limit for use (mm)
Vertically
2.0
Horizontally
2.0
Locking torque force Fixing nuts for the rear wheel Top nuts for the rear absorber Bottom nuts for the rear absorber
100-113 N·m 37 - 44 N·m 22 - 29 N·m
8.2 Failure diagnosis 8.2.1 Rear wheel shimmy Deformed rim. Tyre failure. Rear wheel not fixed. Low tyre pressure.
8.2.2 Too soft absorber Elastic fatigue of spring
8.3 Rear wheel 8.3.1 Disassembly Remove the body guard and the muffler. Remove the rear brake cylinder assembly. Remove the nuts of the rear wheel spindle and the fixing bolts of the rear right absorber. Remove the rear absorber bracket assembly. Remove the rear wheel. （后轮轴螺母：rear wheel spindle nut） - 71 -
8.3.2 Check 8.3.2.1 Check the rim shimmy Rotate the wheel by manual and measure the eccentricity ratio with a dial indicator. Limit for use: Vertically: replacement when beyond 2.0mm. Horizontally: replacement when beyond 2.0mm. When the rear wheel shimmy exceeds the limit, the rear wheel bearing is loose, which causes shimmy. Check and replace the rear wheel bearings.
8.3.3 Installation Install the rear wheel in reverse order and lock nuts. Fixing nuts for the rear wheel Torque force: 100-113 N·m
Rear wheel of EFI Motorcycle QJ125T-30
（液刹盘安装螺栓 mounting bolts for brake discs 液刹盘 brake disc 轮胎 tyre 后轮右隔套 right bushing of the rear wheel 密封圈 seal ring 后减震器挂板 rear absorber bracket 后轮左隔套 left bushing of the rear wheel 油封 oil seal 开口销 cotter pin 挡圈 retainer ring 轴承 bearing 挡圈 retainer ring 开槽螺母 slotted nut 固定座固定套组件 fixing sleeve assembly of the fixing bracket 后减震器固定衬套 组件 stationary bushing assembly of the rear absorber 后轮圈 rear rim 后减震器挂板组件 rear absorber bracket assembly）
8.4 Rear absorber/rear swing arm - 72 -
8.4.1 Disassembly of the rear absorber Remove the seat and the left/right rear guard. Remove the rear handrail and the rear fender. Remove the muffler. Remove the air cleaner assembly. Remove the fixing bolts for the rear absorber. Remove the rear absorber.
8.4.2 Installation Install the rear absorber. Torque force: Upper fixing nut: 37-44 N·m Lower fixing nut: 22-29 N·m Install the rear absorber. Install the air cleaner. Install the muffler. Install the rear handrail and the rear fender. Install the seat and the rear left/right guard.
（螺栓：bolt
- 73 -
后减震器组件：rear absorber assembly）
Table of Torque Force of Engine Fasteners
Name of fastening parts and fasteners
Tightening torque（N·m）
Cylinder cover bolts
25～28
Drain bolts
22～25
Spark plug
10～15
Closing bolts
10～12
Blots for the transmission chamber cover
10～12
Fixing bolts for the motor
10～12
Fixing bolts for the fuel pump
10～12
Fixing bolts for the fuel pump sprocket
10～12
Locking nuts for the flywheel
50～60
Right cover stud
10～12
Double-end stud
18～22
Fixing bolts for the chain adjuster
10～12
Fixing screws for the electrical cable clamp
4～7
- 74 -
Lubricating system diagram
camshaft
piston
crankshaft
Fuel pump
Fuel pump filter
- 75 -
IX. Lubricating System Preparing documents -----------9.1 Failure diagnosis-----------9.2 Fuel pump-------------9.3 9.1 Preparing documents Work Instructions After the fuel pump is disassembled, carefully clean each part and its surface with high-pressure gas. When the fuel pump is disassembled, do not make any impurity fall into the crankcase.
Function of the lubricating system: the lubricating system of the engine is to provide lubricating oil to the frictional surface of each part, which transforms dry friction into liquid friction between lubricating oil particles and also reduces abrasion of parts. It also cools components with high thermal load, absorbs shock from bearings and other parts, reduces noise, increases sealing between piston ring and cylinder wall, and cleans and removes particles in the surface.
Preparing Principles Item Fuel capacity
Fuel pump rotor
Standard
Limit for use
0.9L
/
1L
/
radial clearance between inner and outer rotors
0.04－0.15
0.20
clearance between outer rotor and pump body
0.15－0.21
0.21
0.07-0.12
0.18
when replacing fuel when disassembly
clearance between rotor surface
9.2 Failure diagnosis Decreasing fuel
Burnt engine
Natural consumption of fuel Fuel leakage Abrasive or incorrectly installed piston ring
No fuel or low fuel pressure Blocked fuel pipes No fuel used - 76 -
9.3 Fuel pump 9.3.1 Disassembly Remove the right cover and one-way clutch assembly. Loosen the fixing bolts for the fuel pump chain cover and then remove the chain cover.
（链条罩：chain cover
螺钉：screw）
Remove the fixing nuts for the sprocket. Remove the sprocket and the chain.
（链条：chain
链轮：sprocket
Remove screws and fuel pump assembly.
（机油泵：fuel pump 螺钉：screw） - 77 -
螺母：nut）
Remove screws and fuel pump cover.
（机油泵盖：fuel pump cover）
Check the radial clearance between inner and outer rotors. Limit for use: 0.20mm。
Check the clearance between the outer rotor and the fuel pump housing. Limit for use: 0.21mm。 （测试规：gauge）
Check clearance between rotor surface. Limit for use: 0.18mm。
（测试规：gauge - 78 -
平板：panel）
9.3.2 Breakdown Break down the fuel pump according to the following picture.
（内转子 inner rotor 机油泵体 fuel pump 机油泵轴 fuel pump shaft 机油泵链 fuel pump chain 定位销 cotter pin 外转子 outer rotor 机油泵盖 fuel pump cover 螺钉 screw ） Note: After assembly, the inner and outer rotors shall rotate flexibly without being seized.
9.3.3 Installation Install it in reverse order.
- 79 -
- 80 -
X. Cylinder Head/Valve Preparing documents---------------11.1 Failure diagnosis---------------11.2
Valve check---------------11.6
Replacement of valve guide-----------11.7
Cylinder head-----------------11.3
Adjustment of valve retainer ---------11.8
Cylinder head check-------------11.4
Installation-------------------11.9
Valve-------------------11.5 10.1 Preparing documents Work Instructions To ensure sealing between the cylinder head and the cylinder block, the cylinder head shall sustain the bolt pretension of 50Nm. All parts shall be cleaned and blown with high-pressure gas before check.
Function of cylinder head: The cylinder head is used for sealing the cylinder and constitutes the combustion chamber with the piston to sustain high-temperature and high-pressure gas. It achieves gas intake and exhaust with the valve actuating mechanism.
Preparing Principles Item
Standard
Limit for use
Cylinder pressure
1.25MPa
/
Flatness of cylinder cover
0.03
0.03
Intake
0.10
0.12
Exhaust
0.13
0.14
Intake
5.00-5.012
5.03
Exhaust
5.00-5.012
5.03
Intake
0.010-0.035
0.08
Exhaust
0.030-0.05
0.10
Intake
1.2
1.7
Exhaust
1.2
1.7
Intake/exhaust
35.4
34.9
10.00-10.015
10.10
Valve clearance
Valve Valve guide
Unit: mm
Inner diameter of valve guide Clearance between the valve stem and the valve guide Width of valve seat
Valve spring
Free length
Swing arm
Diameter of swing arm hole
Intake/exhaust - 81 -
Diameter of swing arm shaft
Intake/exhaust
Clearance between the swing arm hole and the swing arm shaft
Intake/exhaust
Cam height
9.982-9.988
9.90
0.012-0.033
0.033
Intake
29.78
Exhaust
29.54
29.83 29.59
10.2 Failure diagnosis Low compression pressure
Abnormal noise in the cylinder head
Poor adjustment of the valve clearance Burnt or bent valve Poor sealing of the valve seat Leakage of the cylinder head spacer Poor installation of spark plug
Poor adjustment of the valve clearance Damaged valve spring Abrasive or damaged camshaft Abrasive camshaft or valve swing arm
High compression pressure Too much carbon deposit in the combustion chamber
10.3 Cylinder head 11.3.1 Disassembly Remove fixing bolts.
（固定螺栓：fixing bolt）
- 82 -
Remove bolts, chain tensioner and spacer.
（链条张紧器：chain tensioner 垫片：spacer） Remove the washer and the cotter pin. Loosen bolts and remove the camshaft bracket assembly. Note: when the bolts of the camshaft bracket are removed, apply staggered steps. Otherwise, the bracket will be broken.
（垫圈：washer
定位销：cotter pin
凸轮轴支座：camshaft bracket）
Remove the chain from the timing driven sprocket. Remove the camshaft. Remove the cotter pin. Remove the cylinder head. Note: hang the chain with a section of metal wire to prevent it from falling into the crankcase.
（凸轮轴：camshaft - 83 -
定位销：cotter pin）
Fasten M5 screw into the swing arm shaft and pull the shaft out. Remove the swing arm and the decompressor.
（M5 螺钉： M5 screw）
10.4 Cylinder head check Check the outer ring of the bearing. Replace it if it can not rotate steadily and flexibly. Check the inner ring of the bearing. Replace it if it is not fastened on the camshaft. Check the raised part of the camshaft. Replace it if it has abrasive, scratched or blue spots. Measure the cam height and meanwhile check whether it is abraded or damaged. Replace it if it can not meet requirements. Limit for use: Cam height: intake: 29.83mm。 exhaust: 29.59mm。 Measure the outer diameter of the swing arm shaft. Limit for use: 9.90mm。
（千分尺：micrometer）
- 84 -
Measure the inner diameter of the swing arm hole. Limit for use: 10.10mm。 Clearance between the swing arm hole and the swing arm shaft. Limit for use: 0.033mm。
（测试计：tester）
Compress the valve spring with the valve spring compression tool and remove the valve cotter. Remove the spring plate, valve spring, spring washer for the outer valve and valve in sequence.
（气门锁夹：valve cotter）
10.5 Valve Valve breakdown
- 85 -
（气门 valve 垫片 spacer 门锁夹 valve cotter）
弹簧盘 spring plate
气门油封 valve oil seal
弹簧 spring
10.6 Valve check Eliminate carbon deposit on the cylinder cover. Measure the flatness of the connection surface of the cylinder cover. Limit for use: 0.15mm。 When the flatness of the connection surface of the cylinder cover exceeds the limit, place the emery paper on the plate and contact the connection surface of the cylinder cover with the emery paper. Scrub the surface in the shape of 8.
（直尺：ruler
测试规：gauge）
Measure the free length of the valve spring. Limit for use: spring: 34.9 mm。
（游标卡尺：vernier caliper） Measure the outer diameter of the valve stem. Limit for use: 4.95mm。
- 86 -
气
Check the valve guide and eliminate carbon deposit in the valve guide with reamer before check. Note: rotate the reamer clockwise, but not counterclockwise.
（气门铰刀：valve reamer）
Measure the inner diameter of each valve guide. Limit for use: intake/exhaust: 5.03mm。 Limit for use for the clearance between the valve and the valve guide: Intake valve: 0.08mm。 Exhaust valve: 0.10mm。
（测试计：tester）
10.7 Replacement of valve guide Note: when the clearance between the valve and the valve guide exceeds the limit, replace the valve guide. After replacement, adjust the surface of the valve retainer. Place the valve guide in the freezer for cooling for 1 hour. Heat the cylinder head in the stove or oven to 100-150℃.
（气门导管起子：valve guide screwdriver）
- 87 -
Fix the cylinder head. Remove the valve guide from the cylinder head with the valve guide disassembly tool. Place a new O-ring on the new valve guide. Install the valve guide over the cylinder head. Note: do not damage the cylinder head when the valve guide is installed.
（气门导管起子：valve guide screwdriver）
Insert the valve guide. Adjust it with the valve guide reamer. Note: add some cutting oil when cutting with the reamer which shall rotate clockwise.
（气门铰刀：valve reamer） Eliminate carbon deposit inside the combustion chamber and the valve. Thoroughly clean the intake valve and the exhaust valve. Check the width of the contact surface of the valve seat (width of the valve retainer). Limit for use: intake/exhaust: 1.7mm
（气门座接触面：contact surface of the valve seat）
- 88 -
10.8 Adjustment of the valve retainer
Remove any hackly or uneven part in the surface of the valve retainer with a milling cutter of 45°. Note: add a layer of transparent or Prussian blue coating on the valve retainer so as to see it clearly.
（粗糙不平部位：hackly part） Eliminate 1/4 of the outer edge of the valve retainer with a milling cutter of 20°.
Eliminate 1/4 of the bottom end of the valve retainer with a milling cutter of 60°. Remove the milling cutter and check any milled part.
- 89 -
Mill the valve retainer with a refined milling cutter of 45° to make it have proper width. Any dent or hackly part must be removed. Standard width of the valve retainer: intake: 1.2m exhaust: 1.2m
If the higher part of the valve is contacted, reduce the height of the valve retainer with end mills of 20°. If the lower part of the valve is contacted, increase the height of the valve retainer with an inner milling cutter of 60°. Mill the valve retainer with a refined milling cutter of 45° again to make it meet requirements. After milling, coat the valve surface with brightener and slightly polish the valve. （接触面高：high contact surface 接触面低：low contact surface）
10.9 Installation Install it in reverse order. Note: When the valve spring is installed, point the spring end with smaller pitch to the combustion chamber. When the valve cotter is installed, apply a valve spring compression tool. When the valve is installed, apply some fuel to the surface of the valve stem and then install it into the valve guide.
- 90 -
- 91 -
XI. Cylinder Block and Piston Preparing documents -----------------12.1
Piston-------------------12.4
Failure diagnosis -----------------12.2
Piston installation-------------12.5
Cylinder block -------------------12.3
Cylinder installation-------------12.6
11.1 Preparing documents Work Instructions All parts shall be cleaned and blown with high-pressure gas before check.
Function of the cylinder block: The cylinder block provides space for gas compression, combustion and expansion, and also guides the piston movement. It transfers part of heat inside the cylinder to cooling medium around.
Function of the piston: 1．It is able to sustain pressure caused by combustion of mixed combustible gas in the cylinder and transfer such pressure to the connecting rod which drives the crankshaft to rotate. 2．It forms a combustion chamber with the cylinder cover.
Preparing Principles
Unit: mm Item
Standard
Limit for use
52.40-52.413
52.413
Cylindricity
0.004
0.004
Roundness
0.005
0.005
Flatness
0.05
0.05
―IN‖ opposite the intake valve
/
52.36－52.37 (7mm below the bottom of the piston skirt
52.37
14.002－14.008
14.04
13.994-13.999
13.97
Clearance between the cylinder and the piston
0.03-0.053
0.053
Clearance
0.03－0.07
0.10
Inner diameter Cylinder
Marked direction
Outer diameter measuring point Piston Piston ring Piston pin
Inner diameter of the piston pin hole Outer diameter of the piston pin
Ring 1
- 92 -
between the piston ring and the ring slot Joint gap of the piston ring
Ring 2
0.03－0.07
0.10
Ring 1
0.10-0.25
0.50
Ring 2
0.20-0.35
0.60
Oil ring
0.1－0.6
Clearance between the piston and the piston pin
0.003-0.014
0.03
Inner diameter of the smaller end of the connecting rod
14.010－14.018
14.04
Clearance between the connecting rod and the piston pin
0.011－0.024
0.05
11.2 Failure diagnosis Low compression pressure
White smoke from the exhaust pipe
Abrasive, burnt or ruptured piston Abrasive or damaged cylinder or piston Damaged spacer or crankcase leakage
Abrasive or damaged piston ring Abrasive or damaged cylinder or piston
Over-high compression pressure
Abnormal noise of the piston
Too much carbon deposit in the combustion chamber
Damaged cylinder, piston or piston ring Abrasive piston pin hole and piston pin
11.3 Cylinder block 119.1 Disassembly of the cylinder block Remove the cylinder head, spacer for the cylinder cover and locating pin. Remove the main chain plate. Remove the cylinder.
（气缸：cylinder
定位销：locating pin - 93 -
垫片：spacer
主导链板：main chain plate）
119.2 Cylinder block check Check the abrasion of the inner wall of the cylinder. If it is serious, replace it.
Remove the spacer and the locating pin. Remove any residual spacer attached to the cylinder. （定位销：locating pin
垫片：spacer）
11.4 Piston 120.1 Disassembly Remove the retainer ring of the piston. Note: during assembly, do not make the retainer ring fall into the crankcase. Remove the piston pin and the piston. （活塞销：piston pin 挡圈：retainer ring）
Check the piston, piston pin and piston ring. Remove the piston ring. Note: Do not rupture or damage the piston ring. Eliminate carbon deposit in the groove of the piston ring.
- 94 -
Install the piston ring. Measure the clearance between the piston ring and the piston ring groove. Limit for use: top ring: 0.10mm. Ring 2: 0.10mm.
（活塞：piston 测试规：gauge 推入：push in 活塞环：piston ring）
Remove the piston ring and install each piston ring at the cylinder bottom. Note: Press the piston ring into the cylinder with the piston head. Measure the joint gap of the piston ring. Limit for use: 0.5mm.
（测试规：gauge Measure the inner diameter of the piston pin hole. Limit for use: 14.04mm.
- 95 -
活塞环：piston ring）
Measure the outer diameter of the piston pin. Limit for use: 13.97mm. Clearance between the piston pin hole and the piston pin. Limit for use: 0.03mm.
Measure the outer diameter of the piston. Note: The measuring point shall be at 90 degree with the piston pin, and at 7mm below the piston skirt. Limit for use：52.37mm。
90°
7mm
Check whether the inner wall of the cylinder is scratched or abraded. Note: It is at 90 degree with the piston pin. Measure the inner diameter of the cylinder at the top, middle and bottom points. Limit for use: 52.413mm。 Measure the clearance between the cylinder and the piston. Record the maximum value. Limit for use: 0.053mm。
（测试计：tester）
- 96 -
Measure the roundness of the inner wall of the cylinder (inner diameter difference at X direction and Y direction). Limit for use: 0.005mm。 Measure the cylindricity of the inner wall of the cylinder (inner diameter difference at the top, middle and bottom points of X direction or Y direction). Limit for use: 0.004mm。
Check the flatness of the cylinder surface. Limit for use: 0.05mm。
（直尺：ruler
测试规：gauge）
Measure the inner diameter of the smaller end of the connecting rod. Limit for use: 14.04mm。
（连杆小端：smaller end of the connecting rod）
- 97 -
11.5 Piston installation Install the locating pin. Apply fuel to each piston ring and piston. Install the piston ring with marked side upward. Note: Do not scratch the piston or break the piston ring. After the piston ring is installed, it shall be able to rotate freely in the piston ring groove.
（顶环：top ring 第二环：ring 2 油环：oil ring）
Open the right cover and remove the starting lever assembly. Remove any residual spacer attached to the crankcase. Note: Do not make any object fall into the crankcase. Install the piston, piston pin and retainer ring. Note: Install the piston with its top mark ―IN‖ towards the intake valve.
（IN 记号： IN mark）
11.6 Cylinder installation Install the spacer and the locating pin on the crankcase.
（定位销：locating pin 垫片：spacer） - 98 -
Evenly apply fuel to the inner wall of the cylinder, piston and piston ring. Carefully install the piston ring into the cylinder. Note: Do not damage the piston ring.
- 99 -
- 100 -
XII. Drive Face/Clutch/Driven Wheel Preparing documents -------------------13.1 Failure diagnosis -------13.2
Clutch/driven wheel ---------13.5
Breakdown of clutch and driven wheel----13.6
Left crankcase cover--------------------13.3
Installation --------------------13.7
Drive face -------------------------------13.4 12.1 Preparing documents Work Instructions During operation, the surface of the triangle belt can not be stained with any grease which must be removed. It helps avoid slipping between the triangle belt and the belt pulley as much as possible. Function: Drive face, clutch and driven wheel constitute stepless transmission. The triangle belt transfers torque between the drive face and the driven wheel.
Preparing Principles
Unit: mm Item
Standard
Limit for use
Inner diameter of right half-driven wheel
28-28.02
28.04
Outer diameter of the sliding sleeve
23.967-23.98
23.98
Width of the triangle belt
21.2－22.8
22.8
Thickness of the clutch facing
1.5
1.5
Inner diameter of the clutch sleeve
125－125.2
125.5
Free length of the clutch spring
69±1
70
Outer diameter of the bushing on the right half driven wheel
42.92-42.98
42.90
Outer diameter of the sliding sleeve on the left half driven wheel
33.95－33.975
34.00
Outer diameter of the ball
20-20.2
19.5
12.2 Failure diagnosis No run after engine startup Insufficient horsepower Abrasive triangle belt
Abrasive triangle belt - 101 -
Vibration during run Ruptured or damaged clutch facing
Damaged driven wheel Broken or damaged clutch facing Ruptured clutch spring
Deformed clutch spring Abrasive ball Stained surface of the driving pulley
12.3 Left crankcase cover Disassembly Remove fixing bolts, spacer and locating pin.
（左盖：left cover
固定螺栓：fixing bolt）
Note: Fixing bolts shall be removed in staggered sequence.
Remove the spacer and locating pin.
（垫片：spacer
定位销：locating pin）
12.4 Drive face Disassembly Remove fixing nuts for the drive face and the left half-drive face. Remove the triangle belt from the drive face.
（固定器：fixer 三角皮带：triangle belt 驱动盘左半: left half drive face 扳手：spanner）
- 102 -
Check whether the triangle belt is cracked and whether rubber or cotton yarn falls down or is abnormally abrasive. Measure the width of the triangle belt. Limit for use: 22.8mm。 Note: apply original parts from our company for replacement.
宽度
（宽度：Width）
Remove the right half drive wheel assembly.
（驱动轮右半组件： right half drive wheel assembly）
Breakdown of right half drive wheel assembly
- 103 -
Check abrasion of the ball. Measure the outer diameter of the ball. Limit for use: 19.5mm。
Measure the inner diameter of the right half drive wheel. Limit for use: 28.04mm。 Measure the outer diameter of the sliding sleeve. Limit for use: 23.98mm。
- 104 -
（滑套：sliding sleeve
驱动轮右半：right half drive wheel）
12.5 Clutch/driven wheel 13.5.1 Disassembly Fix the clutch sleeve with the fixer and remove fixing nuts. Remove the clutch sleeve, clutch and driven wheel.
（从动轮：driven wheel 离合器外套：clutch sleeve 固定器：fixer
13.5.2 Breakdown of clutch Remove the retainer ring and break down the clutch. Note: do not stain the clutch facing with any grease during breakdown.
（挡圈：retainer ring
磨擦片：clutch facing）
- 105 -
套筒扳手：socket spanner）
Check abrasion of the clutch sleeve. Measure the outer diameter of the clutch sleeve. Limit for use: 125.5mm.
Check abrasion of the clutch facing. Measure the thickness of the clutch facing. Limit for use: 1.5mm。
摩擦片
（磨擦片：clutch facing）
12.6 Breakdown of clutch and driven wheel Clutch spring compressor must be used for disassembling the clutch spring. Note: spring compressor must be used for disassembly to avoid damage to spring. Fix the spring compressor to remove fixing nuts of the clutch. Loosen the compressor, and disassemble the clutch and the driven wheel.
（扳手：spanner
- 106 -
离合器弹簧器压缩器：clutch spring compressor）
Remove the spring guard.
（弹簧护套：spring guard） Remove the guide pin. Remove the weldment on the left half driven wheel. Remove the oil seal on the left half driven wheel.
（从动轮左半焊件： weldment on the left half driven wheel 导向销钉：guide pin
Check the free length of the clutch spring. Limit for use: 70mm.
（自由长度：free length）
- 107 -
油封：oil seal）
Check abrasion of the driven wheel. Measure the outer diameter of the bushing on the right half driven wheel. Limit for use: 42.90mm. Measure the inner diameter of the sliding sleeve on the left half driven wheel. Limit for use: 34.00mm. （从动轮右半：right half driven wheel 从动轮左半：left half driven wheel）
13.6.1 Replacement of the bearing on the right half driven wheel Remove the needle bearing from the right half driven wheel. Remove the elastic retainer ring and the outer rolling bearing.
（滚针轴承：needle bearing 弹性挡圈：elastic retainer ring 滚动轴承：rolling bearing） Note: Removed bearings can not be used any more.
Apply grease evenly to the outer rolling bearing and then place it into the sleeve. Note: place the outer rolling bearing into the sleeve with its marked side outwards. Then fill the sleeve with 8-9g grease. Install the elastic retainer ring.
（轴承起子：bearing screwdriver 弹性挡圈：elastic retainer ring 滚动轴承：rolling bearing） - 108 -
Install the needle bearing. Press the needle bearing in as shown in the picture.
（轴承起子：bearing screwdriver）
13.6.2 Combination of clutch and driven wheel Eliminate any grease on the surface of the driven wheel. Install the oil seal in the sliding sleeve of the left half driven wheel. Apply grease evenly on the O-ring and install it on the sliding sleeve of the left half driven wheel.
（润滑油脂：lubricating grease 油封：oil seal
O 型圈：o-ring）
Combine the left half and the right half driven wheel. Apply grease evenly to the guide pin and then install it into the guide groove.
（导向销：guide pin
- 109 -
导向槽：guide groove）
Install the spring guard. Eliminate leaked grease.
（弹簧护套：spring guard）
Install the clutch spring and the clutch on the driven wheel. Use the clutch spring compression combination. Install locking nuts after compression. Note: properly compress the spring to avoid damage to the spring.
（扳手（锁紧螺母） ：spanner (locking nut)
12.7 Installation Install the drive face/ clutch/ driven wheel in reverse order.
- 110 -
离合器弹簧压缩器：clutch spring compressor ）
输入轴：input shaft
中间轴：intermediate shaft
输出轴：output shaft
- 111 -
XIII. Decelerator Preparing documents -----------------14.1 Failure diagnosis ---------------------14.2 Gearbox --------------------------------14.3 Installation ----------------------------14.4 13.1 Preparing documents Function: transfer torque and decide final output torque and rotational speed.
13.2 Failure diagnosis No run after engine startup Broken driving gear Burnt driving gear
Leaked gear oil Too much gear oil Damaged oil seal
13.3 Gearbox 14.3.1 Disassembly Remove bolts and the gearbox cover.
（齿轮箱盖：gearbox cover 螺栓：bolt） - 112 -
Remove the spacer and the locating pin.
（定位销：locating pin
垫片：spacer）
Remove the output shaft assembly. Remove the intermediate shaft assembly. Remove the input shaft.
（输出轴组合：output shaft assembly 中间轴组合：intermediate shaft assembly 输入轴：input shaft）
Check abrasion of the input shaft, output shaft and each gear. It shall be replaced if being abraded seriously. Remove the oil seal from the gearbox cover and hammer out the bearing. Note: Removed bearing can not be used any more. It shall be replaced. Use special tools to dismantle the bearing and the oil seal.
（轴承：bearing - 113 -
轴承油封：oil seal）
13.4 Installation Install it in reverse order. Note: Use special tools to install the bearing and the oil seal to avoid any damage.
- 114 -
XIV. Crankcase Preparing documents-----------------15.1 Failure diagnosis ---------------------15.2 Crankcase -----------------------------15.3 Installation ----------------------------15.4 14.1Preparing documents Work Instructions The crankcase is thin-section casting thus shall not suffer impact during operation which may cause deformation or fracture. All components must be cleaned and blown with high-pressure gas before test. Lubricant in the crankcase should be drained out before operation.
Function of the crankcase： The crankcase is the load-bearing part of the engine. Its main function is to support the crankshaft, clutch, gearbox, cylinder block and cylinder head, sustain combustion shock and inertia force from the movement of the connecting rod, and form part of closed space (oil sealing, gas sealing). Suspension holes in the crankcase are linked with suspension holes in the body, which connects the engine to the frame and other parts.
Preparing Principles
Unit: mm Item
Crankshaft
Standard
Limit for use
Left-right clearance of the larger end of the connecting rod
0.1-0.35
0.55
Radial clearance of the larger end of the connecting rod
0.008-0.016
0.05
Tools Universal holder Screwdriver lever Guide rod
Clutch spring compressor Socket spanner Bearing screwdriver
- 115 -
14.2 Failure diagnosis Noise in the crankcase Loose or broken parts inside the crankcase Loose crankpin bearing
Loose crankshaft bearing Seized clutch
14.3 Crankcase 15.3.1 Crankcase disassembly Loosen bolts and remove the right crankcase cover.
（右曲轴箱盖：right crankcase cover
螺栓：bolt）
Remove the spacer. Loosen locking nuts with a special tool and remove the magneto. Remove the starter idler gear and the shaft.
（电起动惰齿轮：electric starter idler gear 锁紧螺母：locking nut Remove bolts and the end cap of the fuel pump sprocket. Remove the fuel pump.
（链轮盖：sprocket cap 螺栓：bolt）
- 116 -
磁电机：magneto 垫片：spacer）
Remove the bolts of the right crankcase. Put down the left crankcase and remove the right crankcase.
（右曲轴箱：right crankcase）
Remove the spacer and the locating pin. Remove the connecting rod combination. Remove the timing chain.
（定位销：locating pin
垫片：spacer
曲轴连杆组合：connecting rod combination）
15.3.2 Check Measure the left-right clearance of the larger end of the connecting rod. Limit for use: 0.55mm.
（连杆大端测量位置：measuring point at the larger end of the connecting rod）
- 117 -
Measure the clearance of the larger end of the connecting rod (X-Y direction). Limit for use: 0.05mm.
Check whether there is noise when the crankshaft bearing rotates or whether it is loose. If yes, replace the crankshaft assembly.
（曲轴轴承：crankshaft bearing） Remove the oil seal from the left crankcase. Note: Removed oil seal can not be used any more. Remove the oil seal with a special tool.
（油封：oil seal）
14.4 Installation Install the crankcase in reverse order. Note: Install the oil seal with special tools to avoid any damage to it.
- 118 -
Cooling System Diagram (picture to be updated) Filler
Water outlet pipe Water pipe
inlet
Thermostat
Pump
- 119 -
XV. Cooling System Preparing documents -----------------16.1 Failure diagnosis----------------------16.2 Thermostat-----------------------------16.3
15.1 Preparing documents Function of the cooling system: Use water as heat absorption medium to take heat outside through the cylinder block and the cylinder cover in the engine. Then dissipate heat into air with the radiator to ensure the engine works under the best temperature condition.
Work Instructions: 1. Check and maintain the cooling system after the engine is cooled. 2. Do not remove the radiator cover except that the radiator liquid is filled up again or drained out after the cooling system is dismantled. 3. It is feasible to maintain the cooling system on the motorcycle.
15.2 Failure diagnosis Insufficient cooling water
Overheated engine
Evaporation or leakage Cracked or aged hose Loose joint Poor sealing of the cylinder gasket Deformed iron pipe at the outlet of the hose
Poor cooling cycle Leakage of cooling water which causes little working medium Too much impurity inside the radiator pipe Wrinkled water pipe Pump in bad condition Dirty radiator lattice
- 120 -
15.3 Thermostat Disassembly Drain out the coolant and remove the thermostat. Put the thermostat into the water vessel. Raise water temperature and check the temperature when the valve of the thermostat opens. Initial temperature for opening
72～84°C
Full-open temperature
93～96°C
Lift at the time of fully opening
Above 4.27mm Hydrostatic test at 392KPa shall be carried out on the thermostat for 3 minutes. There shall be no leakage.
（传感器组件：sensor assembly 恒温器组件：thermostat assembly 螺栓：bolt 恒温器室本体：thermostat chamber 恒温器室上盖：upper lid of the thermostat chamber 恒温器密封圈：seal ring of the thermostat o 型圈：o-ring）
Radiator Repair the radiator with a small club when over 1/3 of heat sink is damaged or twisted.
（散热片：heat sink）
- 121 -
Water
outlet
temperature
switch
assembly Conductivity temperature: 93°C±2°C Reset temperature: 88°C±2°C
（出水温开关组件：water outlet temperature switch assembly）
Coolant replacement Confirm the coolant is cooled. Remove drain bolts, tilt the body to the right, completely drain out coolant and then install drain bolts.
（排泄螺栓：drain bolt）
Fill the prepared coolant into the filling hole.
（加水口盖分组件：filler cap assembly
进水管：water inlet pipe
- 122 -
出水管：water outlet pipe）
Pump check Check whether the mechanical seal is damaged through the leakage inspection hole. If the coolant is leaked through the hole, it shows there is damage to the mechanical seal. Replace the whole pump. For any pump which can be disassembled, replace the mechanical seal.
（水泵：pump
- 123 -
漏液检查孔：leakage inspection hole）
Muffler (picture to be updated)
- 124 -
XVI. Exhaust Emission & Control System Warranty on the exhaust emission & control system ---------------------------17.1 Instructions on the periodic maintenance/ compliance with standards-------17.2 Mechanical function of the exhaust control system ----------------------------17.3 Catalytic conversion system -------------------------------------------------------17.4 Measures when the idle speed emission value exceeds the standard---------17.5 16.1 Warranty on the exhaust emission & control system 1. The exhaust emission & control system of this motorcycle is in conformity with the revision of EC/97/24/5/I and 2002/81/EC B issued by the EU. We warrant that the exhaust emission & control system works normally during its effective period provided that users completely comply with all operation and maintenance requirements. 2. Warranty range 1〉Function warranty of the exhaust emission & control system We warrant that it satisfies all periodic or non-periodic inspection by the related government authorities within riding of (15000 kilometers). 3. This provision is not applicable under any following condition. However, our distributor or service store would like to provide maintenance or repair services at reasonable prices. 1〉Users fail in periodic maintenance within the required period or kilometers. 2〉Periodic maintenance, adjustment or repair is not carried out at our distributor or service center, or there is no evidence of maintenance record. 3〉Overload or improper operation. 4〉Refit the motorcycle, remove original parts or replace with other devices in private. 5〉Ride the motorcycle on race tracks or on any non-motorized vehicle lane frequently. 6〉Damage to the motorcycle due to extreme weather such as typhoon or flood, or damage or failure due to negligence, crash or impact. 7〉Users fail in periodic maintenance since it is out of service for a long time. 8〉The odometer is not repaired immediately after being damaged, or it is refit, stopped, or replaced in private. 9〉Users fail in periodic exhaust inspection at the station every three months. ·All new motorcycles delivered by our company have satisfied the noise test and comply with EC 97/24/9 implemented by the EU.
- 125 -
16.2 Instructions on periodic maintenance ·It is the national requirement that all motorcycles produced domestically shall comply with exhaust emission standards to lessen environmental pollution. We strictly accord with these exhaust emission standards and also make great effort in purifying air and reducing pollution. ·This motorcycle has been strictly examined before delivery and is in conformity with all exhaust emission standards. We provide the following periodic inspection table for exhaust emission in consideration of different use by customers. Users shall carry out periodic inspection, adjustment or maintenance according to the schedule to ensure normal emission. ·For any problem, please contact KEEWAY distributors or KEEWAY service center. ·Relevant emission provisions are shown as follows: Emission regulation
CO
HC
NOX
Emission standard
≤2.0g/km
≤0.3g/km
0.5 g/km
※The latest national regulation shall prevail if there is any change. ·We are not responsible for any problem due to failure in periodic maintenance at our distributor or service center. Please carry out necessary inspection to ensure its best condition. Note: ①Clean the air filter frequently if the motorcycle runs in sandy road or under seriously polluted condition to extend the service life of the engine. ②Increase maintenance if the motorcycle often runs at high speed or frequently.
Pay attention to following items to ensure compliance with emission standards: 1〉Please use lead-free gasoline. 2〉Please use fuel with stipulated specification. 3〉Please comply with periodic maintenance requirements. 4> For the exhaust control system, it is forbidden to make any adjustment or replacement at random (including use of spark plug, adjustment of idle speed, ignition timing, etc.) 5〉Notes: ·Since any problem in the ignition system, the charging system or the fuel system has significant effect on the catalytic device, please go to our designated distributor or service center for inspection, adjustment or repair immediately when there is any problem found in the engine. 6〉The exhaust control system of this motorcycle is in accordance with the national regulation. For replacement of any component, please use our original parts and have our designated distributor or service center carry out such replacement.
- 126 -
16.3 Mechanical function of the exhaust control system General This system adopts four-stroke single-cylinder engine and air conduction device to maintain qualified exhaust gas. Meanwhile, active carbon canister is used for exhaust gas evaporated from fuel.
※ Engine improvement As the spark plug, combustion chamber, compression ratio, ignition time, exhaust system and other engine components are improved, as well as the intake/exhaust efficiency is enhanced, the combustion efficiency is raised.
※ Air induction device Induce air into the exhaust pipe, which enables incompletely combusted CO and HC to be reacted again and become harmless gas. Division Exhaust system
Device Catalytic device
Constitution
Function
Catalytic converter
Canned oxidized catalyst installed in the center of the exhaust pipe is able to oxidize CO, HC and NOX.
—Adjustable parameters and suggested value setting ·Adjustment of idle speed —rotating speed of engine 1500±100rpm/min CO concentration 0.5-1.2％
16.4 Catalytic conversion system 17.4.1 Structure:
- 127 -
（触媒放置处：where catalyst is placed）
17.4.2 Instruction 1. The function of convertible catalyst is to converse exhaust gas HC, CO and NOX after complete combustion to harmless gas such as H2O, CO2、and、N2 before emission. 2. Convertible catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used. ※Note that lead gasoline may invalidate catalyst. • General instructions for maintaining motorcycles (exhaust pipe) with catalytic converter: 1〉For motorcycles with catalytic converter, when the engine is running or just closes down, it shall not be touched for a while because of high temperature. 2〉Motorcycles with catalytic converter shall not be near flammable material. 3〉There is CO inside the exhaust pipe, which is harmful to health. So do not run the engine in closed space. 4〉Lead gasoline can not be used for motorcycles with catalytic converter (to prevent catalytic poison). 5〉Do not push the motorcycle to run the engine. If it is necessary, you must wait until the temperature of the engine and the catalytic converter lowers down. 6〉Do not make gear up or flame out when descending. 7〉Do not drive the motorcycle with bad ignition. 8〉Do not remove spark plug and run the engine to see whether there is spark when maintaining the ignition system of the engine. If necessary, it shall be finished in a short time.
- 128 -
XVII. EFI System 17.1. Connection of the EFI system The following figure 1 shows the connection diagram of a typical double-cylinder engine EFI system. Full lines in this figure represent input signals of the engine controller, while dotted lines represent input signals obtained from sensors and switches by the engine.
Figure 1 曲轴位置目标轮 Crankshaft position target wheel 曲轴位置传感器 Crankshaft position sensor 加热式氧传感器 Heated oxygen sensor 发电机温度传感器 Magneto temperature sensor 进气温度/压力一体传感器 Air intake temperature/pressure combined sensor 空档开关 Neutral gear switch 倾倒开关 Dump switch 点火开关 Ignition switch 电瓶 Battery 防盗器 Burglar alarm 选装 Selective 发 动 机 控 制 模 块 Engine control module 故 障 诊 断 开 关 串 行 通 讯 接 口 Serial communication interface for the failure diagnosis switch 故障指示灯 Failure indicator 发动机转速信号 Engine rotating speed signal 节气门位置传感器 Throttle position sensor 怠速控制阀 Idle speed control valve 节流阀体 Throttle valve body 点火线圈 Ignition coil 喷嘴 Nozzle 油压调节器 Fuel pressure regulator 油泵 Fuel pump 金属载体催化转换器 Metal carrier catalytic converter - 129 -
17.2. Engine controller (MC21) 17.1.1 Work principle MC21 controller is the last generation of 16-bit digital control device used for some small engines. This controller is able to monitor data related to engine temperature, air intake pressure, crankshaft angle and exhaust oxygen sensing signal for accurate fuel injection and ignition control. Thus, the engine fuel can be used economically and dynamically. The shell of MC21 controller is made of plastic and glass fiber. It is encapsulated and sealed. It is shockproof and waterproof.
17.1.2. Label and mark The following figure 7 is the label on MC21 controller. Information includes ECU type, component code, customer code, hardware code, production code, software revision and bar code. Any erasion from or stain in this label will affect product warranty.
Figure 7
17.1.3. Pin definition for the controller interface The following figure 8 shows the pin definition diagram for the controller interface. It shall be ensured that input/output load is within the range of the table 9. - 130 -
Figure 8
Figure 9
- 131 -
Figure 10
- 132 -
17.20. Instructions MC21 controller instructions
Table: 4
Instruction
Cause
Forbidden: Place ECU beside the engine or The service life of ECU is affected by high the exhaust pipe during transfer.
temperature which also easily damages the plastic shell of ECU.
Forbidden: Place ECU in water, oil or ECU is sensitive to liquid. liquid environment. Forbidden: ECU is covered with mud or Unfavorable for heat dissipation of ECU water drops.
surface.
Forbidden: Power connection to ECU It seriously affects ECU work and definitely randomly.
damages ECU.
Forbidden: Water drops or too much vapor Short-circuit of ECU connector or damaged on the connector.
ECU.
Forbidden: Clean ECU with agent or Damage ECU shell. corrosive liquid. Should: Clean ECU with wet cloth and Prevent ECU from damage. keep it dry. Should: When ECU is reinstalled, check Keep vehicle performance. whether the air intake pipe is blocked. If yes, clean it. Should: When ECU is reinstalled, fix the Keep vehicle performance. air intake pressure pipe and ensure no leakage. Clamps and air intake pressure hoses shall match with the vehicle type. Should: Keep the air intake hose always Prevent dust from entering into the engine connect ECU and intake manifold.
to ensure safety.
Should: When the air intake hose is pulled Prevent joints inside ECU from being loose out from ECU, loosen the clamp at the joint and coating from being damaged. and then pull the hose carefully from ECU.
- 133 -
17.21. Installation requirements The installation requirements for MC21 controller are shown in figure 11 (the tightening torque force for fixing bolts (M6) is 5Nm).
图 11
- 134 -
17.3. Power supply requirements ●Power on Under normal condition, the input voltage from battery keeps stable. When the ignition switch closes and the battery voltage exceeds 6.5V, ECU starts normal work. ●Operation: When the EFI system works, the battery voltage shall keep between 9-16V to ensure normal operation of the system. ●Power down: When the ignition switch turns off, the ignition voltage is below 6.2V, ECU enters into power down condition. ECU records values in EEPROM, such as fault code, frozen fault code, closed-loop value, revised air flow value and throttle value. Based on these values, it enables precision calculation on each parameter for next startup. ●Reset mode: When ECU receives reset command or faces serious problem, the system enters into the reset mode. All I/O interface is reset to the predefined state and enters into normal work condition after reset is finished. ●Overvoltage/counter-voltage ECU, which works under overvoltage of 24V for no more than 1 minute, will not be damaged. ECU, which works under counter-voltage of 14V for no more than 1 minute, will not be damaged.
17.4. Work temperature ●Normal
work temperature range: -30℃ to 70℃ ●Maximum work temperature: 80℃ (continuous work for no more than 30 minutes) ●Storage temperature range: -40℃ to 85℃
17.5 Maintenance and repair The controller can not be maintained after sale. When there is any problem, make sure whether it is cause by calibration or software first. If - 135 -
yes, update the calibration software. If any controller hardware fails or is damaged during the warranty period, the controller must be sent back to the factory, attached with detailed controller component number, serial number, vehicle type, date of production, accumulated kilometers, where be used, and date of return. The following table shall be filled up by the distributor and sent to the factory with the controller for finding reasons. Some actions are only valid for products within the warranty period. Otherwise, users shall be responsible for expenses resulting from the replacement of damaged controllers. DELPHI Request on the Repair of ×××Workshop
Damaged Controller Distributor:
Vehicle type:
Date of failure:
Address: Engine displacement: Date of vehicle production: Accumulated kilometers: Details on controller: Telephone:
Part number:
Mobile telephone:
Serial number:
Contact:
Date of controller production:
Detailed description of failure:
Failure under what condition:
- 136 -
Any measures taken by users and the distributor after failure:
Other information and inferred causes:
XVIII. M3 and M3.5 Fuel Injector 18.1. List of spare parts List of spare parts of the fuel injector
Table: 5
Name of spare parts
Remark
M3 fuel injector M3.5 fuel injector
18.2. General work principle M3 fuel injector boasts high performance and excellent durability. It is designed by DELPHI and used for engines. Electromagnetic coil is around the iron core inside. Two electrode from the electromagnetic coil are input control interface of the oil injector. When the coil is connected to power, the electromagnetic attraction suppresses spring force and fuel pressure of the ball valve, and raises the valve. Thus, high-pressure fuel in the fuel pipe (250～400kPa) runs through the valve seat hole and the orifice plate, forms cone-shaped fog and injects to the air intake valve. After the injector is disconnected, the magnetic force of the electromagnetic coil vanishes automatically, and the ball valve of the fuel injector closes automatically under the action of return spring, which stops fuel injection. The work principle of M3.5 fuel injector is similar to that of M3 fuel injector. The difference is that its electromagnetic coil is more - 137 -
efficient and it has better durability and speed of response.
18.3. Appearance The following figure 12 shows the appearance of M3 fuel injector. O-ring for connecting the fuel rail or the fuel injector cap.
O-ring for connecting the end of the air intake pipe.
Figure 12 There are two types of M3.5 fuel injector: long-type and mini-type. M3.5 fuel injector is able to provide better integrated function.
Long-type fuel injector
Mini-type fuel injector
Figure 13 - 138 -
18.4. O-ring O-ring shown in figure 12 is able to ensure that there will no leakage in the fuel injector when working at between -40℃ and 150℃ (-40 and 302℉). It also resists corrosion from kinds of fuel additives (such as ethanol). The current o-ring design is shown below. If any DELPHI fuel injector is not consistent with following data, please contact DELPHI. O-ring for connecting the fuel rail or the fuel injector cap ·Dimension: ·Inner diameter: 6.35mm ·Outer diameter: 14.85mm ·Section thickness: 4.25mm ·Material: ·Viton GLT(blue): application under low temperature ·Viton A(black): application except for low temperature O-ring for connecting the end of the air intake pipe ·Dimension: ·Inner diameter: 9.61mm ·Outer diameter:14.49 mm ·Section thickness: 2.44 mm ·Material: ·Viton A (blue or brown)
18.5. O-ring replacement ●Use
the suggested lubricating oil to lubricate O-ring. Do not contact the orifice plate with lubricating oil, otherwise it affects fuel injection. ●We suggest that o-ring can be used only once. If replacement is impossible, please check whether it is damaged before repeated use. Any minor damage will cause fuel leakage. To avoid any danger, please strictly comply with requirements to install the oil injector. ●When o-ring is installed into the fuel injector, please be careful and do not damage the o-ring.
18.6. Suggested lubricant - 139 -
For the convenience of fuel injector installation, lubricant shall be applied to o-ring. Table 4 lists applicable and proved lubricant. According to test, following lubricant will not affect the performance of fuel injector. Suggested lubricant
Table: 6
Name of lubricant
Manufacturer
Viscosity (cSt) @40℃
Spindura 10
Equilon
10
Spindura 22
Equilon
21
DTE-24
Mobil
32
DTE-25
Mobil
46
DTE-26
Mobil
68
Norpar15
Exxon/Mobil
50sccm air). Forbidden: water enters into the fuel Cause damage to the fuel injector. pipe during leakage rate inspection. Forbidden: Impose force on the fuel During installation on the nylon intake injector head during installation.
pipe, it is allowed to impose force at the angle of 45 degree.
Forbidden: strike the fuel injector Damage the fuel injector and o-ring. when it is installed on the intake pipe. Forbidden: impose tensile force on the Cause interrupted power supply. connector. Forbidden: use the fuel injector which Possible damage. - 141 -
has been thrown. Forbidden: store fuel injector, fuel rail Possible
damage
or engine with fuel injector installed mechanical under non-protective environment.
to
electronic
components
of
the
and fuel
injector by the external environment.
Forbidden: pick up the fuel injector Damage the fuel injector. when lifting the assembly. Forbidden: components contact each Damage the fuel injector. other during storage. Forbidden: components contact each Possible impact, which may cause damage other during transportation.
to the fuel injector.
Forbidden: hammer the oil injector for Damage the fuel injector. troubleshooting in the case of an error. Forbidden: use non-suggested fuel Significantly affects the performance of injector
instead
of
original
fuel the fuel injector.
injectors. Should: note that the o-ring shall not Protect the o-ring. be cut by the installation seat during the installation of the fuel injector. Should: install it into the hole after Protect the o-ring and reduce pollution. being applied with correct lubricant. Should: test the fuel injector adhered Confirm the invalidation of the fuel to the needle valve or whose needle injector. valve fails in seating. (pulse to the fuel injector with the voltage between 9-15V for less than 5 seconds) Should: before the fuel injector is The needle valve of the fuel injector may assembled, carry out no fuel leakage fail in seating during transportation or test to confirm seating of the needle transfer, which causes fuel leakage. valve. Should: avoid liquid pollution to the Cause short-circuit of the electromagnetic fuel injector.
coil.
Should: carefully dismantle the cables. Cause damage to terminals. Should: use suggested lubricant during Cause corrosion to terminals. the installation of the connector. - 142 -
Should: do not use fallen, damaged or Find causes to problems as soon as unqualified components, and label possible. them to indicate problems.
18.12. Installation requirements Please strictly comply with following instructions for installation and disassembly to avoid damage to fuel injectors and electronic components. ●
●
●
●
●
● ●
●
Lubrication: apply a little lubricant to the lower part of the o-ring. Do not use ISO 10 light mineral oil or equivalent product. If it is possible, it is better to apply lubricant to the fuel injector seat other than o-ring. Thus, it can minimize pollution by the fuel injector. Do not make the orifice plate contact with lubricant, which affects the volume of fuel injection. Do not pick up lubricant with the top of the fuel injector. All M3 and M3.5 oil injector o-rings are assembled before delivery. In principle, o-rings are not allowed to be used repeatedly. Please check whether there is any damage to o-rings. Any minor damage will cause leakage. Install the o-ring into the holder carefully. Do not damage the connector when it is installed. The fuel injector connector is properly installed when there is a click sound. Do not install or disassemble unnecessary connectors. Do not tighten cables too much, otherwise it may lead to short circuit. Do not rotate the fuel injector during the installation of the connector, which will lead to deviation from fuel injection targets.
18.13. Replacement The disassembly and replacement of M3 and M3.5 fuel injectors are as follows. - 143 -
Note: high temperature in the fuel injector and its surrounding parts. ● The motorcycle flames out. ● Disconnect the negative pole of the battery to avoid any accidental startup of the engine. ● Remove the fuel injector connector. ● Discharge fuel pressure. ● Remove the fuel pipe from the fuel injector. ● Remove the fuel injector from the air intake pipe. ● Remove the fuel injector retention clamp and the fuel injector from the seating carefully. ● Carefully clean impurities on the contact surface of the fuel injector. Do not damage the contact surface. ● Apply lubricant to o-rings on two ends of the new fuel injector. ● Install the new fuel injector into the air intake pipe carefully and make sure it is towards the same direction as the original one is. ● Install the fuel injector seating and the retention clip. ● Tighten mounting bolts with required torque according to installation manual. ● Install the fuel pipe. ● Insert the fuel injector connector. ● Insert the key for power on. Check fuel leakage from the fuel injector without engine startup. ● Start up the engine to check its work.
18.14. Replaceability Replace the fuel injector with the one of the same part number. Part number may change. Please check the vehicle maintenance manual and the list of spare parts to select correct fuel injector.
18.15. Fuel injector blocked Accumulated impurities in fuel will cause flow deviation and reduction of service life. When the engine stops working, deposits may be generated in fuel as heat from the engine runs through the fuel injector head. Deposits accumulated around the fuel injection hole will - 144 -
lead to flow deviation. ●
●
●
● ●
If the fuel injector is blocked, reduced flow, increased friction and accumulated impurities will take place, which finally affects emission and durability. Fuel and environment factors will cause fuel crystallization or corrosion to the fuel injector, which also leads to flow deviation. Unsteady fuel oxidation will generate deposits. Please use high-quality gasoline. Add a certain amount of fuel injection cleaner to avoid deposits. When the fuel injector is blocked, please clean the fuel injector with following methods.
18.16. Cleaning ●Disconnect
the fuel pump first. ●Discharge fuel pressure and then remove the fuel pipe. After the fuel pipe is removed, stuff it up with some material to avoid fuel drainage. ●Add fuel injection cleaner and gasoline at certain proportion to the fuel injector cleaner tank. ●Connect the fuel injector cleaner tank to the fuel injector. ●Adjust the cleaner fuel pressure to the vehicle system pressure of 2.5bar. ●Start up the engine, and keep it at the idle speed for 15-20 minutes. ●Remove the cleaner tank, and re-install the fuel pipe to the fuel injector. ● Start up the engine and keep it at the idle speed for 2 minutes. Ensure cleaner is completely discharged.
XIX. Throttle Valve Assembly 19.1. List of spare parts List of spare part of the fuel injector Name of spare part
Table: 8 Remark - 145 -
Throttle valve Throttle position sensor Idle adjustment screw
19.2 General work principle The throttle valve assembly mainly consists of following parts: main cast valve body, bearing, shaft and valve block, return spring, throttle cable and throttle position sensor system. All above subsystems work together to achieve following functions: ● control air intake flow ● control air flow at the idle speed ● check the throttle position—provide throttle feedback signals to the engine control system ● provide the throttle with return force
19.3. Appearance
Figure 16
19.4. Technical parameters Throttle valve (inner diameter: 26mm): - 146 -
Maximum flow: 19.29±1.0g/
[email protected] vacuum degree ● Torque for opening the throttle valve: At idle speed: 0.19±0.05Nm When fully open: 0.37±0.10Nm Throttle position sensor ● Reference voltage: 5±0.1VDC ● Resistance between T1 and T2: 3k～12k∩ ●
Figure 17
19.5. Work environment Normal work environment: -40～125℃
19.6. Disassembly of the throttle valve ●Disconnect
the negative pole of the battery ●Disconnect the throttle position sensor ●Remove the throttle cable ●Remove the hose between the air cleaner and the intake manifold
19.7. Cleaning Remove the cover at the bottom of the throttle valve and clean the body with carburetor cleaner (3M product suggested). Spray cleaner on the inner wall of the throttle valve and remove dust and carbon deposit slightly with brush. Do not block the bypass with impurities. If idle screws are removed and cleaned, assemble idle screws in - 147 -
following order: ● Install o-ring 1 on the idle bypass screws ● Install spring, washer, o-ring 2 on the idle bypass screws ● Install above idle bypass screws on the throttle valve. After idle screws are cleaned and assembled, use diagnosis tools and adjust idle speed. Note: new o-rings shall be used every time of installation.
19.8. Installation of the throttle valve Install the throttle valve in reverse order and pay attention to followings: ● Adjust the throttle cable. ● Ensure all removed components are installed in place. ● Re-install all necessary parts.
19.9. Precautions ●Do
not spray any cleaner into TPS throttle position sensor. ●Use the throttle cable to open the throttle valve block. ●Do not insert any tool or stick into the throttle valve hole to keep the valve block open. It will cause deformation of the valve block and damage to the inner wall of the throttle valve. ●Keep carbon deposit around the valve block to maintain air flow required by idle speed setting. ●Do not adjust the position of idle screws. ●Replace o-rings once disassembled.
19.10. Instruction Instructions of the throttle valve assembly Instruction
Table: 10 Cause
Should: be careful when the throttle Avoid damage to the connector. valve connector is used. Should: avoid any liquid pollution to Ensure normal work. the throttle valve. Should: take and install only one piece Possible damage to components. of throttle valve from the component - 148 -
tray. Should: use a label to describe any Accurately analyze causes as soon as problem
related
to
any
fallen, possible.
damaged or unqualified throttle valve (within warranty range). Should: remove and discard protective Protect the system from pollution and cap before installing components.
keep it work normally.
Should: clean bypass when the seating Ensure stable idle speed. is removed. Should: if idle screws are removed, Ensure no air leakage from o-ring. replace o-rings. Forbidden: use any fallen or defective Possible inner damage. component. Forbidden: no protective cap for Possible impact on normal work due to storage parts. Forbidden:
pollution. no
protection
during Possible impact on normal work due to
transportation or transfer around salt corrosion. spray. Forbidden: completely exposed to the Possible impact on normal work due to environment (humid) before assembly.
corrosion.
Forbidden: tested voltage exceeds the Possible damage. system voltage. Forbidden: use excessively tightening Possible damage. torque. Forbidden: hammer the fuel injector Damage to the fuel injector. for troubleshooting when there is an error. Forbidden: components bump into Possible impact on the minimum air each other when being unpacked.
leakage or other damage.
Forbidden: completely release the Possible damage. throttle at any position. Forbidden: block the bypass hole with Possible impact on the stability of idle dirt or sand. Forbidden:
speed. take,
store
or
hold Possible damage. - 149 -
components in a way of possibly touching other parts.
XX. Water Temperature Sensor for the Engine 20.1 List of spare parts List of spare parts of the water temperature sensor Name of spare part
Table: 11
Remark
Water temperature sensor for the Used for all water-cooled engines. engine
20.2. General work principle This water temperature sensor is used for water-cooled engines. Within the temperature range of this sensor, its resistance will vary upon the engine temperature. Its character refers to negative temperature coefficient resistance property. It is not maintainable.
20.3. Appearance
Figure 18
20.4. Installation requirements ●Dynamic
torque requirement: install it by manual and guide into threads correctly. Then tighten it to the required torque with electric - 150 -
spanner at the speed of beyond 400 rounds/minute or with the manual spanner. Suggested assembly torque is as follows: ●Maximum: 20N· m ●Minimum: 25N· m ●Static torque requirement: torque used for dismantling the sensor from the engine shall be no more than 200% of the assembly torque.
20.5. Work environment ●This
sensor is mainly used for water-cooled engine. ●Temperature range under normal work: -40～135℃ (continuous work) ●Relative humidity under work environment: 0～100% ●Typical work pressure: under the minimum assembly torque, the sensor can achieve coolant sealing for the engine under the actual pressure of 206.8kPa (30psi) and the temperature of 135℃. ●Extreme work environment: only for 1 hour under the maximum temperature of 150℃
20.6. Storage environment ●Storage
temperature: -40℃ to 120℃ ●Transportation without time limit below the altitude of 13700m.
20.7. Electric environment ●Typical
work pressure: reference voltage is 5±0.1VDC ●Maximum exciting current: When the properties of the sensor are tested under any temperature, its performance shall not be affected by current of less than 1mA.
20.8. Cleaning samples ●If
necessary, clean the sensor with isopropanol and then dry it. Sink it in isopropanl for no more than 1 minute. Install sealed connections during cleaning to prevent cleaning agent from entering into the sensor.
- 151 -
XXI. Intake Air Temperature Sensor 21.1. List of spare parts List of spare parts of the intake air temperature sensor Name of spare parts
Remark
Intake air temperature sensor
Used for all engines
Table: 12
21.2. General work principle Within the temperature range of this sensor, its resistance will vary upon the engine temperature. Its character refers to negative temperature coefficient resistance property. It is not maintainable. 21.3. Appearance
The appearance of the intake air temperature sensor is shown as in figure 20 above.
21.4. Technical parameters ●Work
voltage: 5DVC ●Response time: ＜15S ●Work temperature: -40～150℃ ●Relative humidity: 0 to 100% RH
21.5. Installation requirements: ●Suggested
diameter of mounting hole: 12mm ●Suggested depth of mounting hole: 12mm to 16mm ●Mounting angle with the horizontal plane: ＞50°
21.6. Cleaning samples - 152 -
If necessary, clean the sensor with isopropanol and then dry it. Sink it in isopropanl for no more than 1 minute. Install sealed connections during cleaning to prevent cleaning agent from entering into the sensor. ●
XXII. Oxygen Sensor 22.1. List of spare parts List of spare parts of the oxygen sensor List of spare part
Table: 15 Remark
Oxygen sensor
22.2. General work principle Oxygen sensor is used for monitoring the content of waste oxygen inside the exhaust pipe of the combustion engine, including wideband oxygen sensor and switch-type oxygen sensor. Normally, we use switch-type oxygen sensors for small engines. It is mainly used for controlling the fuel closed loop of the engine.
22.3. Appearance The appearance of the oxygen sensor is shown as in figure 22 below.
Figure 22
22.4. Technical parameters - 153 -
value for air-fuel ratio (dense): ＞750VDC ●Threshold value for air-fuel ratio (dilute): ＜120Mvdc ●Heater power for the oxygen sensor: 7.0W (above parameters are measured at the engine test bench under the exhaust temperature of 450℃, duty cycle of 70%, 10Hz and voltage of 13.5V. ) ● Heater resistance: 9.6±1.5Ω (measured below 21℃) ● Work temperature range: 260-850℃ ●Threshold
22.5. Installation requirements ●
Installation angle (angled with the horizontal plane) ≥10 degree
Figure 22 ●
Tightening torque force: 40-60Nm
22.6. Fuel quality requirements Pb≤0.005g/L ● P≤0.0002g/L ● S≤0.04%( ● Si≤4ppm ●
XXIII. Fuel Pump Assembly 224. List of spare parts - 154 -
List of spare parts of the fuel pump Name
Table: 19 Remark
Fuel pump assembly Fuel pump device Fuel pressure regulator Sealing device for the fuel pump assembly
23.2. General work principle Fuel pump assembly: provide the engine with fuel which satisfies the requirements of the pressure system. It is installed at the bottom of the fuel pump and supplies fuel to the engine through connected fuel pipes. Fuel pump: this electric pump obtains pressure fuel from the fuel tank by the motor impeller. Pressure regulator: mechanical diaphragm type; it regulates pressure for fuel provided by the fuel pump to make it meet constant fuel pressure requirements.
23.3. Appearance and structure
- 155 -
油管：fuel pipe
油泵线束：fuel pump cable
regulator pump
压力调节器卡箍：pressure regulator clamp
滤网：filter
油管： fuel pipe
垫圈：washer
压力调节器：pressure
泵体固定架：pump body frame 油泵总成：fuel pump assembly
油泵：fuel
管箍：pipe clamp
油泵支架：fuel pump bracket
23.4. Dimension Dimension of the bottom panel: 115mm×70mm. Mounting height: 135mm (reference dimension)
23.5. Label and mark Fuel pump assembly, fuel pump device and pressure regulator are marked with production batch and date. Fuel pump assembly: labeled on the mounting plate of the fuel pump assembly. Fuel pump: engraved on the pump body. Fuel pressure regulator: engraved on the shell.
23.6. Work environment ●The
fuel pump shall be installed at the bottom of the fuel tank according to installation requirements. ●The general design of the fuel tank is only for gasoline. If it contains ethanol, please contact the fuel pump factory to ensure whether it can be used. ●During the first operation of the fuel pump, please ensure there is enough fuel in the tank. Do not operate it under no fuel condition. ●For the connection of fuel pipes, please see the reference diagram 28. Overall Fuel Pipe Arrangement
- 156 -
Figure 28
23.8. Maintenance procedures Safety precautions: Please be careful and keep your safety when maintaining the fuel system. ● Disconnect the negative pole of the battery. ● Smoking is forbidden. Place a sign of ―No Smoking‖ near the operation area. ● Ensure there is fire extinguishing devices. ● Ensure good ventilation and keep away from fire sources. ● Wear protective goggles. ● To release fuel vapour inside the fuel tank, open the fuel tank and then re-install it. ● When the engine stops working, there is still high pressure inside the fuel pipe and fuel shoots up if the fuel pipe is disassembled or loosened. Please make reference to ―fuel pressure release procedures‖ in this chapter. ● A small amount of fuel flows out after the fuel pipe is disassembled. To avoid any danger, please apply proper and clean material to block the pipe. ● After maintenance, please make sure the fuel pipe and the clamp are installed according to the installation manual. ● After maintenance, please check fuel leakage according to the ―fuel leakage inspection procedures‖. ● After maintenance, make sure there is enough fuel in the fuel - 157 -
tank when the fuel pump works.
Failure diagnosis of the fuel pump assembly: Step 1
Operation After startup by the ignition key, the fuel pump works for 3 seconds. Disconnect the fuel pump connector, and check whether the voltage of the fuel pump is within 10-14V. Supply DC of 12V to the fuel pump; ensure there is enough fuel in the fuel tank to avoid dry run; whether the fuel pump works? When the engine works at idle speed, check whether the fuel supply pressure at the front end of the injector mouth is within 220-270kPa. Whether pressure is lower than 220kPa.
2
3
4
5
Yes If you can hear fuel pump working, please go to step 4. Go to step 3.
No If you cannot hear fuel pump working, please go to step 2. Check the power supply circuit of the fuel pump.
1. Check the loop 1. Check the from the fuel throttle cable; pump to ECU; 2. Check the fuel 2. Check ECU. pump. The fuel assembly normally.
pump Go to step 5. works
1. Check whether 1. The fuel filter is there is leakage blocked; in the fuel pipe; 2. The fuel pipe is 2. Check fuel bent and pump device; twisted; 3. Check pressure 3. Check pressure regulator. regulator.
Disassembly of the fuel pump assembly: ●
● ● ●
●
● ●
Please make reference to fuel pressure in the fuel drain pipe in ―fuel pressure release procedures‖. Disconnect the negative pole of the battery. Disconnect the connector of the fuel pump assembly cable. Pump the residual fuel in the fuel tank out and store it in a proper vessel to ensure safety and reduce pollution. Disassemble the fuel pipe connecting to the fuel pump assembly with standard tools. Remove the fuel tank from the vehicle. Place the fuel tank upside down. Protect it from any scratch or - 158 -
●
crash. Do not damage the filter during removal.
Installation of the fuel pump assembly: ●
●
●
● ● ● ●
Replace the sealing washer of the fuel pump assembly (an used washer may lead to fuel leakage). Fold the filter carefully and asymmetrically arrange mounting bolts for the fuel pump assembly which only can be installed towards required direction. The pressure regulator shall face the back of the fuel tank to ensure the surface of the fuel tank is clean and neat. Install screws in the cover plate of the fuel pump assembly and evenly tighten screws in sequence as shown in figure 33. Torque for mounting screws: 3～4Nm. The fuel pump assembly shall be fixed with special screws. Apply required tightening sequence and torque to fix. Over-torque or incorrect tightening sequence will lead to deformation of the washer, which causes leakage. Install the fuel tank in the vehicle. Connect the fuel pipe and clamp it properly. Connect the connector of the fuel pump cables. Check leakage according to ―fuel leakage inspection procedures‖ before the engine works.
Tightening sequence for mounting screws Figure 33
Replacement of the pressure regulator ● ●
Remove the seating of the pressure regulator. Remove the snap spring from the pressure regulator with the snap - 159 -
● ●
●
●
●
●
● ●
spring tool. Avoid any damage caused by popup of the spring. Remove the pressure regulator. Carefully avoid damage to the outer edge of the pressure regulator. Apply lubricant around o-ring of the new pressure regulator to facilitate installation. Make sure two o-rings are installed on the pressure regulator (one with larger diameter, one with smaller diameter). Install the pressure regulator in the bracket of the fuel pump frame. Do not hammer the pressure regulator (damage to the pressure device). Install the snap spring of the fuel pressure regulator. Replace o-rings of the fuel pump.
Fuel pressure release procedures: Note: do not operate when the engine is hot. Make sure the engine is cooled and then carry out following fuel pressure release procedures: ● The transmission is at the status of ―neutral‖. ● Disconnect the connector connecting fuel pump assembly cables and vehicle cables. ● Start up the engine until it automatically flames out. Open and close the ignition key two or three times at an interval of 3 seconds. ● After above operation, connect the connector of the fuel pump assembly cables.
Fuel leakage inspection procedures: After maintenance on any fuel system, please confirm following fuel leakage inspection test is carried out. ● Add enough fuel into the fuel tank. ● Start the ignition key for 3 seconds and then closes it for 15 seconds; repeat it three or four times to set up fuel pressure in the fuel pipe. - 160 -
●
Check whether there is leakage in any component of the fuel system (fuel tank, fuel pipe, joint, etc.).
Instructions for the fuel pump assembly Instruction
Table: 18 Cause
Forbidden: crash the fuel pump.
Damage to the inside of the fuel pump.
Forbidden: ―dry run‖ by the fuel pump Damage to the inside of the fuel pump. (no fuel from the filter at the entry of the fuel pump); make sure enough fuel in the fuel tank. Forbidden: damage the filter during Impurities enter into the damaged filter maintenance.
and then the fuel pump, which destroy the fuel pump.
Forbidden: disassemble inner parts of No ―warranty‖. the pump body and the pressure regulator. Forbidden: regulate the fuel pump and the pressure regulator. Forbidden: pick up the fuel pump Damage the cables and disconnect the fuel assembly cables to lift the fuel pump pump. assembly. Forbidden: lift the fuel pump assembly cables vertically along the fuel pump cover plate. Forbidden: use damaged fuel pipe Pressure leakage/ fuel leakage. clamp. Forbidden: use seriously damaged or Impurities enter into the fuel pump broken
filter
in
the
assembly.
fuel
pump through the damaged filter, and damage the pump body.
Forbidden: draw fuel from the fuel Fuel pump is not designed for such tank with the fuel pump.
purpose.
Forbidden: use mounting screws of the Affect the installation of the fuel pump fuel pump assembly to fix other assembly. components. - 161 -
Forbidden: damage the fuel pump Damaged
terminals
will
cause
bad
cables when the fuel pump assembly contact/ disconnected power supply. is maintained. Forbidden: the manual pump contacts Avoid damage to the fuel pump assembly. the fuel pump assembly when drawing fuel from the fuel tank. Should: ensure no damage to the fuel Avoid fuel leakage. pipe during maintenance. Should: only use ―original‖ sealing Faked ones may lead to fuel leakage. washers for the fuel pump assembly. Should: use designated hose clamps.
Ensure no fuel leakage on joints of the fuel pipe.
Should: the fuel pump cables are fixed Reduce vibration. on the vehicle. Should: use standard fuel.
Unqualified fuel will lead to early damage to the fuel pump.
Should: replace the fuel filter within Blocked filter will reduce fuel supply. the stipulated period. Should: use stipulated and qualified Unqualified filter will damage the injector fuel filter.
mouth, fuel pressure regulator and fuel pump.
Should: ensure the correct direction of Incorrect direction or interference will the fuel pipe deployment and no damage the fuel pipe. interference with other parts. Should: ensure enough fuel in the fuel Avoid ―dry run‖ of the fuel pump. tank (over the fuel pump filter). Should: replace two o-rings when the Ensure the correct pressure regulation pressure regulator is maintained. Should:
carefully
connect
curve. the Avoid damage to the connector terminals.
connector of the fuel pump assembly cables. Should: return any fallen, damaged or Find causes as soon as possible. unqualified parts and describe related problem. - 162 -
XXIV. Failure Diagnosis Failure diagnosis for the EFI system is carried out as follows: I. Connect a special diagnostic apparatus to the failure diagnosis interface in the motorcycle cables to effectively and accurately read failure. II. Connect a computer installed with diagnostic software to the failure diagnosis interface with a special communication cable, and then read failure in the computer. In addition, the fault light in the meter (as shown in 4-1) also provides failure warning. Under normal condition, Keyon, the fault light turns on and it turns off after startup. In the case of failure, it is always light.
24.1. Diagnostic tools Diag Tool software of PC version (for MC21 system) is used for monitoring and recording operation data of the motorcycle. Connect the computer serial port to the diagnosis interface of the motorcycle with K line before use.
24.2. Pin definition for the diagnosis interface: Pin 6 of the diagnosis interface is defined as follows: the pin combination can achieve different diagnostic service functions. The diagnostic tool uses three pins which are 12V, ground and K line.
- 163 -
Pin2：ground Pin4: K line Pin6: 12V
24.3. Software instruction Initial setting: ●
Connect the computer serial port to the motorcycle diagnosis interface with the diagnostic cable.
●
Start Diag Tool software.
- 164 -
Click ―connect‖ for connection.
Click ―Engine Data‖ for displaying and monitoring engine status.
- 165 -
Click ―Engine Data‖ for displaying and monitoring engine status. Set the sampling frequency as 0.1 second and establish document name and path for data saving.
- 166 -
ECU version
- 167 -
Click ―Malf Code‖ to show current malfunction code. 24.4 Cross reference table for malfunction code Malfunction Description Description of code malfunction code P0106 Map Rationality Rationality of air intake pressure P0107 Map Open/GND Open circuit or short circuit grounding of the built-in air intake pressure sensor P0108 Map Short V Short circuit power supply of the built-in air intake pressure sensor P0112 IAT Short GND Short circuit grounding of the air intake temperature sensor P0113 IAT Short V/Open Short circuit power supply or open circuit of the air intake temperature sensor P0117 Toil Short GND Short circuit grounding of the engine temperature sensor P0118 Toil Short V/Open Short circuit power supply or open circuit of the engine temperature sensor P0563 Battery voltage high Overhigh voltage of the battery P0122 TPS Open/GND Short circuit power - 168 -
Flash code 35 34
33
69
71
15
14
49 22
P0123
P0131
P0132
P0231
P0232
P0601 P0261
P0262
P1351
P0351
supply or open circuit of the throttle position sensor TPS Short V Short circuit grounding of the throttle position sensor O2 Short GND Short circuit grounding of the oxygen sensor O2 Short V Short circuit power supply of the oxygen sensor Pump Open/GND Short circuit grounding or power supply of the fuel pump Pump Short V Short circuit power supply of the fuel pump EEPROM Error EEPROM error Cylinder 1 Inj Short circuit Open/GND grounding or open circuit of the injector of cylinder 1 Cylinder 1 Inj Short V Short circuit power supply of the injector of cylinder 1 Cylinder 1 Ign Short circuit Open/GND grounding of the ignition coil of cylinder 1 Cylinder 1 Ign Short V Short circuit power supply of the ignition - 169 -
21
45
44
29
31
51 16
17
64
42
P1650
P0650
P1654
P0654
P0335 P1352
P0352
P0321
P1321
P0264
coil of cylinder 1 MIL Open /GND Short circuit grounding or open circuit of the fault light MIL Short V Short circuit power supply of the fault light TACO Open/GND Short circuit grounding or open circuit of the engine speed output TACO Short V Short circuit power supply of the engine speed output Crank Sensor Crankshaft position Malfunction sensor malfunction Cyl2 Ign Short GND Short circuit grounding of the ignition coil of cylinder 2 Cyl2 Ign Short V Short circuit power supply of the ignition coil of cylinder 2 Cyl1 IGBT over Overcurrent of the current ignition module of cylinder 1 Cyl2 IGBT over Overcurrent of the current ignition module of cylinder 2 Inj_2 Open/GND Short circuit grounding or open circuit of the injector of cylinder 2 - 170 -
0
0
12
11
19 95
96
79
23
4
P0265
Inj_2 Short V
Short circuit power 5 supply of the injector of cylinder 2
- 171 -
Circuit Diagram QJ125T-30 ELECTROJETELECTRICITY PRINCIPLE DIAGRAM FUELMETER SPEEDOMETER
CLOCK B
FAN LIGHT
LIGHT CONTROL SWITCH START SWITCH POWER LOCK
N/G BL/W1 R/W B
W/Y W/BL B
R Y B
B
WATER TEMPERATURE LIGHT
B/G
BATTERY
RELAY
ON
BRAKE SWITCH
DIAGNOSE
RECTIFIER
SKID SENSOR
PUMP RELAY
OFF LOCK
Y/R O/BL R/W
Y B
INSTRUMENT LIGHT
R R/W Y O/BL
15A FUSE 30A
G/Y
G/B R/W BL B
BEAM INDICATOR LIGHT
P
FAILURE
B W/Y
TURN SIGNAL INDICATOR LIGHT
R/W
M
W/BL
G/W
R W W W B
G/Y B
LIGHT
B
DARK GREEN
Dg
BLUE
BL
BLACK/RED
B/R
LIGHT BLUE
B R/W BL/B
R/W N/B
BLACK
B
R Dg
B/R
LBL
RIGHT TURN LIGHT
R/W
B
BL
Y
G/W R/W W/BL G/B B/G R
N/G N/W W/Y
Y/R G/Y P R/W O/BL
R
R/W
Y
O/BL
R
LR B Gr
R W W W B
G/Y B
N/Y
RED/GREEN
R/G
BROWN
N
RED/WHITE
R/W
YELLOW/RED
Y/R GREEN/BLUE
ORANGE
O
GRAY
GREEN/WHITE
G/W
YELLOW
Y
GREEN/BLACK
G/B
RED
R
YELLOW/GREEN N/B
ORANGE/YELLOW PURPLE
Y/G ORANGE/WHITE
P G/BL Gr
O/W
B R/N W/B R/P N/BL R/W
B
B
G/W
G/W
RIGHT TURN LIGHT RIGHT TURN LIGHT
B G/W
HEAD LIGHT
BL B Y
Y B P
TAIL/BRAKE LIGHT HEAD LIGHT
LEFT TURN LIGHT
HORN
Y B LBL
B G/B
LEFT TURN LIGHT
B
B G/B
LEFT TURN LIGHT
G/B
B N
N R/W BL Y/R LBL O
G/B B G/W
P
G/R R/P
R/W
R/N W/B B/BL LR BL/B N/BL R/G Dg Y/G
N/W N/B
B
B/O W/Gr W/O W/N
Gr
B/W W/P
B
BL/W W/G
R/W Dg R/W B G/W G/B R G/Y W W W
W/G BL/W
B/BL B/R B/O B/BL Y/G B/BL B/BL B/G W/N G/R R/G W/Gr B/R W/O
B/R B/W W/P
B/R
N/G B W/G BL/W
R/W N/G
B N/G
N R/W
BL Y/R LBL
G/B
O
G/W
ALARM SYSTEM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
>98℃
FAN
TURN SWITCH LIGHT SWITCH BRAKE SWITCH HORN SWITCH
- 172 MAGNETO
NEUTRAL SWITCH
OXYGEN SENSOR INTAKE AIR FUEL LIFT PUMP IGNITION COIL OIL RTOMIZER SOLAR TERM POSITION TEMPERTURE SENSOR ENGINE COOLANT SPARK PLUG SENSOR TEMPERATURE SENSOR
