RK6 Service Manual

 

Service manual of RK6

KEEWA KEEW AY Motorcycle Motorcyc le Corporatio Corpo ration n Ltd. Lt d. 0

 

Contents Preface.............................................................................................................................................................. - 1 Preparing Documents ....................................................................................................................................... - 2 General Safety ..........................................................................................................................................- 2 Maintenance Rules ................................................................................................................................... - 3 Specification........................................................................................................................................... - 13 Failure Diagnosis.................................................................................................................................... - 15 Inspection/Adjustment ........................................................................................................................... - 22 Inspection and Maintenance of the Electrical System .................................................................................... - 43 1. Battery/Charging System ........................................................................................................................... - 44 1.1 Preparing P reparing Documents .......................................................................................................................- 44 1.2 Failure Diagnosis .............................................................................................................................. - 45 1.3 Battery .............................................................................................................................................. - 46 1.4 Charging System ..............................................................................................................................- 47 1.5 Voltage/Current Regulator ................................................................................................................ - 48 1.6 Magnetor Charging Coil ................................................................................................................... - 48 1.7 Magnetor Disassembly .....................................................................................................................- 49 2. Ignition System .......................................................................................................................................... - 52 2.1 Preparing P reparing Documents .......................................................................................................................- 52 2.2 Failure Diagnosis .............................................................................................................................. - 53 2.3 Ignition System Check ..................................................................................................................... - 54 2.4 ECU Group ....................................................................................................................................... - 55 2.5 Ignition Coil ..................................................................................................................................... - 56 2.6 Sensor of the Crankshaft .................................................................................................................. - 56 3. Startup System............................................................................................................................................ - 58 3.1 Preparing P reparing Documents .......................................................................................................................- 58 3.2 Failure Diagnosis .............................................................................................................................. - 59 3.3 Startup Motor ................................................................................................................................... - 59 3.4 Starter Relay ..................................................................................................................................... - 61 4. Bulbs/ Switches / Meters ............................................................................................................................ - 63 4.1 Preparing P reparing Documents .......................................................................................................................- 63 4.2 Failure Diagnosis .............................................................................................................................. - 64 4.3 Replacement of Headlamp Bulbs .....................................................................................................- 64 4.4 Replacement of Front Position Lamp Bulbs .................................................................................... - 65 4.5 Replacement of Tail Lamp ............................................................................................................... - 66 4.6 Replacement of Rear Registration Plate Lamp Bulbs ...................................................................... - 67 4.7 Replacement of Front Steering Lamp Bulbs .................................................................................... - 68 4.8 Replacement of Rear Steering Lamp Bulbs ..................................................................................... - 68 4.9 Meters............................................................................................................................................... - 68 4.10 Main Switch ................................................................................................................................... - 69 4.11 Horn ................................................................................................................................................- 69 4.12 Handlebar Switch ...........................................................................................................................- 70 Inspection and Maintenance of the Motorcycle Body .................................................................................... - 71 5. Brake ..........................................................................................................................................................- 74 1

 

5.1 Maintenance Instruction ................................................................................................................... - 74 5.2 Failure Diagnosis .............................................................................................................................. - 75 5.3 Front Disc Brake .............................................................................................................................. - 76 5.4 Rear Disc Brake ............................................................................................................................... - 80 6. Body ...........................................................................................................................................................- 84 6.1 Disassembly ..................................................................................................................................... - 84 6.2 Assembly ..........................................................................................................................................- 84 7. Front Wheel/Handlebar/Front Suspension ................................................................................................. - 88 7.1 Preparing P reparing Documents .......................................................................................................................- 88 7.2 Failure Diagnosis .............................................................................................................................. - 89 7.3 Front Wheel ...................................................................................................................................... - 90 7.4 Steering Handlebar ........................................................................................................................... - 95 7.5 Front Fork ......................................................................................................................................... - 97 8. Rear Wheel/Rear Suspension ...................................................................................................................- 101 8.1 Preparing P reparing Documents ..................................................................................................................... - 101 8.2 Failure Diagnosis ............................................................................................................................ - 101 8.3 Rear Wheel ..................................................................................................................................... - 102 8.4 Rear Absorber................................................................................................................................. - 106 8.5 Chain Drive ....................................................................................................................................- 108 8.6 Rear Swinging Arm ........................................................................................................................ - 110 9. Fuel Tank.................................................................................................................................................. - 113 9.1 Preparing P reparing Documents ..................................................................................................................... - 113 9.2 Failure Diagnosis ............................................................................................................................ - 113 9.3 Fuel Tank ........................................................................................................................................ - 114 10. Disassembly and Installation of Engine ................................................................................................. - 116 10.1 Preparing P reparing Documents ................................................................................................................... - 116 10.2 Disassembly of Engine ................................................................................................................. - 116 10.3 Installation of the Engine ............................................................................................................. - 122 Inspection and Maintenance of Engine ........................................................................................................ - 123 11. Lubricating System................................................................................................................................. - 124 11.1 Preparing Documents ................................................................................................................... - 124 11.2 Failure Diagnosis .......................................................................................................................... - 124 11.3 Fuel Pump..................................................................................................................................... - 125 12. Cylinder Head ........................................................................................................................................ - 130 12.1 Preparing P reparing Documents ................................................................................................................... - 130 12.2 Failure Diagnosis .......................................................................................................................... - 130 12.3 Cylinder Head .............................................................................................................................. - 132 13. Crankcase ............................................................................................................................................... - 140 13.1 Preparing P reparing Documents ................................................................................................................... - 140 13.2 Failure Diagnosis .......................................................................................................................... - 143 13.3 Upper Box .................................................................................................................................... - 144 13.4 Piston ............................................................................................................................................ - 145 13.5 Lower Box .................................................................................................................................... - 150 13.5 Lower Box .................................................................................................................................... - 151 13.6 Clutch C lutch ...........................................................................................................................................- 154 2

 

13.7 Gearshift Mechanism ................................................................................................................... - 157 13.8 Crankshaft Connecting Rod Assembly Chamber and V Variable ariable Speed Chamber C hamber .......................... - 161 14. Cooling System ......................................................................................................................................- 167 14.1 Preparing P reparing Documents ................................................................................................................... - 167 14.2 Failure Diagnosis .......................................................................................................................... - 168 14.3 Water Pump .................................................................................................................................. - 168 Inspection and Maintenance of Exhaust Emission System .......................................................................... - 171 15. Exhaust Emission & Control System .....................................................................................................- 172 15.1 Warranty Warranty on the Exhaust Emission & Control System ................................................................. - 172 15.2 Instructions on Periodic Maintenance ..........................................................................................- 173 15.3 Mechanical Function of the Exhaust Control System .................................................................. - 173 15.4 Catalytic Transfer System ............................................................................................................ - 174 15.5 Measures When the Idle Speed Emission Value Value Exceeds the Standard .......................................- 176 Inspection and Maintenance of Electronic Fuel Injection (EFI) System...................................................... - 177 16. Electronic Fuel Injection System ........................................................................................................... - 178 16.1 Introduction of Electronic Fuel Injection System......................................................................... - 178 16.2 Components of Electronic Fuel Injection System ........................................................................ - 178 16.3 Methods for Fault Diagnosis and Maintenance ............................................................................ - 192 16.4 Common Fault Removal Techniques ........................................................................................... - 202 RK6 Circuit Diagram ........................................................................................................................................... 0

3

 

Preface This maintenance manual is used for operating and maintaining Motorcycle RK6. 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 Electronic Fuel Injection System, engine, entire motorcycle and electrical equipment. 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 what is mentioned here. We will not make notification for any discrepancy.

Qianjiang Motorcycle Corporation Ltd.

- 1 -

 

Preparing Documents General Safety Specification Table

Maintenance Rules Inspection/Adjustment

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.

Battery Battery emits explosive gas. Therefore, it shall be far away from fire sources, naked flame or smoking places. Make sure good ventilation during charging.  Battery contains sulfuric acid (electrolyte). It will burn your skin or eyes when contacted. Therefore, wear  protective clothing and mask. mask.  ——  Clean  Clean with fresh water immediately if electrolyte splashes on the skin.  ——   Clean with fresh water at least for 15 minutes immediately and then go to the doctor if electrolyte splashes on eyes. Electrolyte is poisonous. Drink a large quantity of fresh water, milk, milk of magnesia (laxative antacid) or mineral oil if electrolyte is swollen accidentally. accidentally. Then go to the doctor. It shall be unreachable for children.

Machine Oil It may trigger cancer if repeatedly expose the hands in the air after contacting with oil. Although there is little  possibility for you to contact with oil in the daily life, wash hands tthoroughly horoughly with water and soap if you have contacted. And it shall be unreachable for children.

Thermal Energy  Parts of the engine and cooling system produce heat, which can last for some time before the engine gets started. Deal with these parts with gloves or after the engine and cooling system cools down.

- 2 -

 

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, the chassis or the braking system. Wash and dry parts with air compressor after disassembly and  before measurement measurement of attrition value.

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 form outside to inside. Small assembly parts shall be loosened first. Complex assembly parts, such as gearbox, shall be stored in  proper order for facilitating facilitating installation in the future. future.

Please specially note important connections before disassembly. Replace parts which will not be in use before disassembly. disassembly.

- 3 -

 

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. assembly.

When installing a rubber 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 B all 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.

- 4 -

 

Loose cables threaten electrical safety. Check each cable after it is clamped to another for electrical safety; Wire clamps are not allowed to bend towards welding  point; Bind cables at the designated place; Do not deploy cables at the end of frame or at sharp point; Do not deploy cables at the end of bolts or screws; Cable deployment shall be far from heat source and where cables may be clamped during moving; Cables along the handlebar shall be neither too tight nor too loose, and do not interface with any neighboring parts at steering positions; Cables shall be properly deployed without twist or knot; Check whether the connector jacket is damaged and whether the connector is over-stretched before mounting connectors; Adopt adhesive tape or hose to protect cables if they are  positioned at sharp point or corner; corner; Bind cables with tape after repairing; Control cables shall not be bent or twisted. Clumsy operation may be caused in light of damaged control cables.

- 5 -

 

Identification 1．The frame number, see figure

Frame Number

Frame

2．Rivets of the frame sign and the frame, see figure

Frame Number

Rivets

3．The serial number of the engine, see figure Engine Number

Significant Notes 1. Please apply valid Qianjiang parts and accessories. Any part or accessory not in accordance with the design specification of Qianjiang Company may cause damage to engine. 2. Only metric tools are valid for maintenance and repair. Metric screws, bolts and nuts can not be exchanged with imperial fasteners. 3. New gaskets, O-rings, cotter pins and locking pieces shall be applied for re-assembly re-assembly.. 4. Bolts with large diameter or positioned inside shall be fastened first and then diagonally screw down until reaching required torque, otherwise there is special instruction. 5. Wash disassembled parts with cleanser. Lubricate all sliding surface before assembly. 6. Check whether all the parts and accessories are correctly mounted and operated after assembly. assembly. 7. Clean and remove oil before measurement. Add recommended lubricant to the lubricating areas during assembly. 8. Apply lubricant to the surface of engine and driving system if they are dismantled for long-term storage, which can prevent rust and dirt.

- 6 -

 

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. Ta Table ble 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. 1-4

Feeler gauge

Fig. 1-5

Bearing disassembly tools

Fig. 1-6

Bearing assembly tools

Fig. 1-7

Oil seal remover

Fig. 1-8

Handle for dismantling tools

Fig. 1-9

Piston pin pulling device

Fig. 1-10

Piston pin pliers

Fig. 1-11

Socket spanner for spark plug

Fig. 1-12

Clutch thickness measuring device

Fig. 1-13

Cylinder diameter measuring device

Fig. 1-14

Dial indicator

Fig. 1-15

Dial indicator, V-block

Measuring the inner diameter of the piston pin, Fig. 1-16

Dial indicator

For measuring the bending of the valve rod ，Fig. 1-17

Assembly/disassembly tool for valve catheter

For measuring the external diameter of the valve rod ，Fig. 1-18

Assembly tool for valve catheter

Fig. 1-19

Adjustment tool for valve space

Fig. 1-20

Assembly/disassembly tool for valve spring

Fig. 1-21

Valve catheter reamer

Fig. 1-22

Disassembly tool for crankcase

Fig. 1-23 Fig. 1-24

Table 1-2 (continued)

Fig. 1-3

Fig. 1-4

- 7 -

 

Fig. 1-5

Fig. 1-6 厚度 厚度规（ 规（塞尺 塞尺） ） ：feeler gauge 

Fig. 1-7

Fig. 1-8

Fig. 1-9

Fig. 1-10

①handle

Fig. 1-11

Fig. 1-12

① pliers ② piston - 8 -

 

Fig.1-13

Fig.1-14

Fig. 1-15

Fig. 1-16

Fig. 1-17

Fig. 1-18

Fig. 1-19

Fig. 1-20

Fig. 1-21

Fig. 1-22

- 9 -

 

Fig. 1-23

Fig. 1-24

2．Tools for repairing the chassis Table and drawing (1-25, 1-26) of ordinary tools and special tools for disassembling/assembling chassis  parts are as follows: Fig. 1-25  Name

Remark

Torque spanner

Fig. 1-27

Inner hexagon spanner

Fig. 1-28

Socket spanner

Fig. 1-29

Micrometer

Fig. 1-30

Magnetic rack, V-block

Fig. 1-31

Dial indicator

Fig. 1-32

Vernier calipers

Fig. 1-33

Circlip pliers

Fig. 1-34

Screwdriver with striking cap

Fig. 1-35

Tool for assembling oil seal of front fork

Fig. 1-36

Tool for hammering seal of front fork

Fig. 1-37

Steering nut spanner

Fig. 1-38

(1) Ordinary tools for repairing the chassis Table 1-26 (continued)

Fig. 1-27

Fig. 1-28

Fig. 1-29

Fig. 1-30 - 10 -

 

Fig. 1-31

Fig. 1-32

Fig. 1-33

Fig. 1-34

Fig. 1-35

Fig. 1-36

(2) Special tools for repairing the chassis: tool for hammering seal of front fork

Fig. 1-37

(3) Steering nut spanner

Fig. 1-38

3．Tools for electric parts - 11 -

 

Ta Table ble and drawings (1-39, 1-40) 1 -40) of special tools for testing electric parts are as follows: Fig. 1-39  Name

Remark

Multimeter

Fig. 1-41

Ignition tester

Fig. 1-42

Fig. 1-40 (continued) (continued)

Fig. 1-41

Fig. 1-42

- 12 -

 

Specification Motorcycle Model

RK6

Engine Type

BJ465MS-A

Length mm

2120

Fuel type

Unleaded petrol（93/97） 

Width mm

800

No. of

4

Height mm

1100

Wheelbase mm

1480

Petrol tank capacity

15L

Weight kg (Curb weight)

Tire Size

Electric devices

65.0×45.2

Total displacement

600cc

Startup

Electric

115

Cooling

Liquid cooling

105

Lubrication

Pressure splash lubrication

Total

220

Clutch type

Wet multi-chip

Front tire

120/70 ZR 17

Variable speed

Six variable speed

Rear tire

180/55 ZR 17

Transmission

Chain

Engine

Forward shaft Backshaft

Battery capacity

12V-9AH

Primary transmission ratio

1.864

Magnetor

Flywheel permanent magnet

Transmisson ratio of gear 1

2.846

Spark plug

CR9E(NGK)

Transmission ratio of gear 2

1.947

Spark plug gap

0.6-0.7mm

Transmission ratio of gear 3

1.556

Ignition

TLI

Transmission ratio of gear 4

1.333

Transmission devices

Transmission ratio of gear 5

Max. Hp

60.0kW/11000rpm

Max. torque

55N.m/8000rpm

Transmission ratio of gear 6

1.083

11.5：1

Final Transmission ratio

3.286

185km/h

Dia. of front liquid brake disc（mm） 

320mm

Compression ratio Perfor mance

c lind inder ID × stroke

Max. speed

1.190

Brake Fuel consumption limit

≤5.2L/100km   ≤5.2L/100km

Dia. of rear liquid brake

240mm

disc（mm） 

- 13 -

 

RK6

- 14 -

 

Failure Diagnosis Diagnosis on difficulty or failure in starting up Failure Diagnosis

Adjustment Adjustment & Inspection

Causes of Failure

- 15 -

 

Check if petrol  pump is working  properly

Oil provided to fuel injector is sufficient and smooth

 No petrol  provided to fuel injector Disassemble spark  plug into its cap, ground it with engine to check check if it can s ark

Spark-over

Weak sparks  No 

Test compression pressure

 Normal

Open circuit or short circuit of ignition coil Abnormal main switch Abnormal charging coil Abnormal clutch for startup Abnormal piston of cylinder and  piston ring

Too low  No

 No ignition outbreak of the engine

 No petrol in the tank Oil tube of fuel injector blocked Oil tube of petrol pump blocked Tube of combustion chamber ’s Evaporation Control System  blocked Petrol air filter blocked Low oil pressure of petrol pump Abnormal spark plug Polluted spark plug Abnormal CPU group Abnormal trigger Open circuit or short circuit of ignition coil’ coil’s wire

Leakage of cylinder gasket

Ignition outbreak of the engine but no sign of startup

Abnormal actuation

automatic

choke

Intake manifold with air Incorrect ignition time

Disassemble once agian the spark plug to check

Dry spark plug

Wet spark plug

Abnormal adjustment to throttle valve and bolt

Excessive oil injected to fuel injector Abnormal automatic choke actuation Throttle opens too large

- 16 -

   

Unsmooth gyration (No speed or weak speed) Failure diagnosis

Adjustment Adjustment specification

Causes of failure

Start engine with soft refueling

accelerated gyration speed of engine

Air filter blocked Abnormal petrol Tube of combustion chamber ’s Evaporation Control System  blocked Exhaust pipe blocked Abnormal automatic choke Abnormal throttle valve

Engine can not fully speed up

Adjust ignition timing and use ignition timing light Correct ignition time

Abnormal CPU group

Incorrect ignition time

Abnormal trigger Test compression pressure Abnormal piston of cylinder and  piston ring  Normal

Too low Leakage of cylinder gasket

Blocking check to Carburetor  No

Yes

Contaminant removal Disassemble the spark plug to check

 No pollution nor discoloration

Contaminant removal

Polluted and discolored

Heat value of spark plug does not conform

Check oil level in crankcase if it is hi h or ollu olluted ted  Normal

Excessive oil Insufficient oil  No replacement replacement of oil

High oil level Check the lubrication c lin linde derr hea head d

 Normal

Abnorm Abnormal al Overheated engine

Yes 

 No

Accelerated driving or runni unnin n Engine knock

 No engine knock knock

of Abrasion in piston cylinder Mixed gas too thin Abnormal petrol Too much carbon fouling in the combustion chamber Earlier ignition time Too much carbon fouling in the combustion chamber Abnormal petrol Clutch slipping Thin mixed gas Earlier ignition time 

- 17 -

 

Unsmooth gyration（especially in low speed）  Failure Diagnosis

Adjustment Adjustment & Inspection

Causes of Failure

Adjust ignition time Abnormal CPU group

 Normal

Abnorm Abnormal al Abnormal trigger

Adjustment to throttle valve and  bolt

Mixed gas too thin (loosen bolt) Good

Bad Mixed gas too dense (tighten  bolt) Spacer inhaled air or not

Yes

Abnormal spacer of heat insulation piece Throttle valve fixed, bolt loosened Heat insulation piece ruptured  Negative pressure pressure pipe ruptured

No

Disassemble spark plug into its cap and ground it with engine to check if it can spark Good spark-over

Bad spark-over

Spark plug abnormal or polluted Abnormal CPU Abnormal ignition coil Open circuit or short circuit of spark plug’ plug’s wire Abnormal main switch

 Negative pressure pressure pipe damag damaged ed Good

Bad Air pass-hole blocked

- 18 -

 

Unsmooth gyration (high speed) Failure Diagnosis

Adjustment Adjustment & Inspection

Causes of Failure

Adjust ignition time

Abnormal CUP group  Normal

Abnormal Abnormal trigger

Little oil in petrol tank  Normal

Petrol filter of the pipe blocked

Abnormal

Tube of combustion chamber ’s Evaporation Control System  blocked Blocked oil injector

 No

Good

Blocked

Spring broken Weak elasticity

Abnormal automatic oil ring

Remove

Abnormal spring

- 19 -

 

Poor battery charging (over discharge or over charge) Failure Diagnosis

Adjustment Adjustment & Inspection

Causes of Failure

Test the voltage of  battery’s two ends, and  battery’ stat stat en ine ine Battery used up  No voltage rise

Voltage rises to normal value, and back to original voltage value after flameout

Check the plug of regulator if it is loose

 Normal

Poor battery

voltage

Poor connection of the plug

Abnorm Abnormal al

Open circuit of the red wire of the charging wire Check if the red wire of voltage regulator ’s socket connects thewire multimeter, while anode and cathode to the voltage  between  betwee n arts of the bo bod d Voltage available

 No voltage voltage

Voltage regulator Open circuit of the white wire of the charging wire

Test the resistance alternator ’’s coil alternator 

 Normal

value

of

Abnormal coil Poor connection of the joint Open circuit of alternator ’s white wire

Abnorm Abnormal al

Poor battery Poor battery charging Overcharging

Voltage above normal value

Start the engine, connect the red wire of the voltage regulator ’s socket to the multimeter, while anode and cathode wire to the voltage  between parts parts of the bo body dy  Normal voltage voltage

Check if charging wire of the voltage regulator connects well  Normal

Loose Bad connection

Use monomer of the voltage regulator

Poor connection of the joint and charging wire to the ground Abnormal voltage regulator

- 20 -

 

No spark-over of the spark plug Failure Diagnosis

Adjustment Adjustment & Inspection

Causes of Failure

Replace on new spark  plug and check check ag again ain

Weak spark-over or no spark-over

Strong spark

Original spark plug abnormal

Check again after checking spark plug

Loose 

 No sign of loose loose

Spark plug cap loose

Check plugs of CDI group if they are loose  Normal

Abnorma Abnormall

Bad connection of the plug Check conduction between terminals of CDI group’ group’s plugs, and test resistance value

Abnormal main switch Abnormal charging coil

 Normal

Abnorm Abnormal al

Abnormal trigger Abnormal ignition coil Check relevant parts

 Normal

Abnormal

Breakage of main wire Bad connection of the plug and socket Use CDI tester to check CDI group  

 Normal

Abnormal CPU group

Abnorm Abnormal al

Use CDI tester to check ignition coil Abnormal

Abnormal ignition coil

- 21 -

 

Inspection/Adjustment Preparing information Engine oil/ Oil filter

Periodic Maintenance & Inspection Table Liquid coolant

Assembly/disassembly of radiator radiator pipe’s clamp

Fuel injector & Oil-way Oil -way

Adjustment of throttle cable

Air filter

Spark plug

Battery

Fuse replacement

Cylinder pressure

The slackness of the drive chain

Free stroke of front brake

Free stroke of rear brake

Headlamp

Clutch

Front/rear suspension system

Bolt/nut/fastener

Rim/tire

Fixing steering stem bearing & handlebar

Throttle valve

Components lubrication

Preparing Prepari ng 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 exploded under certain condition. Ventilation Ventilation is required and no any fire exists in working places. Fire is strictly forbidden in working areas or where oil is stored.

- 22 -

 

Specification Engine ID × stroke

65.0×45.2

Total displacement displace ment

600cc

Ignition

TLI

Spark plug gap

0.6-0.7mm

Spec. of spark plug

CR9E(NGK)  

Ty Type pe of combustion chamber

spherical

Frame Free stroke of front brake lever

10-20mm

Free stroke of rear brake pedal

20-30mm Specification

Tyre pressure unit：Kpa Fixing front wheel Torque

spindle

value

Fixing nut of rear

RK6

Tire pressure

Front tire

120/70 ZR 17

250±10kpa

Rear tire

180/55 ZR 17

290±10kpa

100-140N·m 130-150N·m

wheel spindle

- 23 -

 

Periodic Maintenance & Inspection Table Service cycle and time Inspection item

Per 300 Km

 New * * *

*

Per 14500 Km

One months Three months Six month

Twelve months

Fifteen months

C

R R C

C

Per 3000 Km

Per 6000 Km

I I C

Replacement of engine fuel

R

Tire pressure pressur e

I

I

I

I

I

I

Battery inspection

I

I

I

I

I

I

Actuation gap inspection

I

I

I

I

I

I

I

I

I

Ordinary tools

I

I

I

Ordinary tools

handle fastening Absorber working inspection Screw fastening inspection Oil leakage inspection for gearbox Inspection or replacement of spark plug Replacement of gearbox oil

C I C

Tools

Air filter Petrol filter Fuel filter

Inspection of steering

*

Per 12000 Km

Per 1000 Km

Replacement every 1000KM

Ordinary tools Ordinary tools Ordinary tools Ordinary tools Tire pressure gauge, inflator Densimeter, multimeter Ordinary tools

I

I

I

I

I

I

Torque spanner

I

I

I

I

I

I

Ordinary tools

I

R

R

I

Ordinary tools

I I

Replacement every 5000KM

Lubrication of each part

L

L

Ordinary tools Lubricator

Muffler

I

I

I

I

I

I

Ordinary tools

*

Ignition timing

I

I

I

I

I

I

Timing lamp

*

Carburetor

A

I

A

A

A

A

A

I

A

A

A

A

Tachometer, CO HC analyzer

I

I

I

I

I

Ordinary tools

I

I

I

I

I

Ordinary tools

I

I

I

I

Visual multimeter

I

I I

I I

I

Ordinary tools Ordinary tools

I

I

I

I

Torque spanner

I

I

I

I

Ordinary

* *

*

Exhaust gas inspection at idle speed Throttle inspection Fuel pipeline inspection Lighting/metering/electric devices Main stand bracket Absorber Torque force of engine  bolts

I

I

I I

Front/rear brake

*

Drive chain

I

I

I

I

A

Ordinary

Clutch Valve

I

I I

I I

I I

I I

Ordinary Feeler

- 24 -

 

Anticipated Inspection 1 2 3

Ignition system — obviously obviously continuous ignition abnormality, engine fire or overheating, which requires inspection and maintenance. Carbon fouling elimination — obviously obviously insufficient horsepower, which requires carbon fouling removal from cylinder head, piston head and exhaust system. Piston & cylinder   — excessive excessive abrasion; replace cylinder cylinder if it is blocked.

Please have your motorcycle inspected and adjusted periodically at Qianjiang distributors for being in best condition. The above table is established under the presupposition of 1000 km/month. I — Inspection Inspection A — Adjustment Adjustment R   — Replacement Replacement C — Cleaning Cleaning L — Lubrication Lubrication Note: 1. “*” Regulations on 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. company 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. 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 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 there is an alarm from the oil level sensor.

Check oil level *Note

Do not tighten dipstick when check.  Check the oil level, and lay down the single shoring on the flat ground so that the body is vertical. Oil level must be checked regularly when oil is constantly  being consumed, and refuel refuel to a right level. level. Oil capacity: capacity : 3.0L change oil

3.2L disassemble disassembl e

The working of engine and clutch will be affected if the oil level is too high;

(上限：maximum 下限：minimum)

And if it is too low that will lead to overheated engine and earlier abrasion of the components. If refuel with inferior oil or oil of other brand or class will reduce the effect of lubrication. Disassemble the dipstick after the engine stops, and dry it with a clean cloth. Put the dipstick into the measurement hole with the engine on the flat ground, but do not tighten it up. Ta Take ke out the dipstick and check the oil level. - 25 -

 

If it is below or near the minimum level, Refuel with the recommended oil to the maximum level. *Note

Check the O-ring. Assemble the dipstick.

Oil Replacement * Note

It will be easier to change oil when the engine is warming up. Preheat the engine. Place a drip pan under the engine, and disassemble the drain  bolt ① and the dipstick. Repeatedly start the engine for several times until the oil is discharged completed. When the oil is discharged completely, install back the drain  bolt and the packing washer washer after cleaning. cleaning. Refuel recommended oil to the crankcase to a required capacity. capacity. Assemble the dipstick. Start the engine to run in an idle speed for 2-3 minutes. Stop the engine, and check if the dipstick is at the maximum level several minutes later. The engine should be upright while checking. Make sure that there is no leakage.

Replacement of the Oil Filter *Note

It will be easier to change oil when the engine is warming up. Turn off the engine. Make the oil filter stuck with special removal tool, spin anticlockwise and disassemble the oil filter that needs replacement② . Replace on new oil filter and coat a layer of lubricant on the O-ring.

Oil filter

Note:

Do not disassemble the O-ring, otherwise it will make the O-ring out of position while installing, which can lead to oil leakage or the damage of the engine. Install the new oil filter to the engine with hands, spin until it can not be screwed any further, then tighten it with Torque Tor que spanner (torque: 12-20Nm). Check oil leakage when the engine operates at its idle speed for minutes.

- 26 -

 

Cooling Liquid Check the height of the cooling liquid in the expansion kettle during maintenance. Replace in time the cooling liquid when it becomes turbid or it is time for maintenance. Recommended model of the cooling liquid: FD-2 Total Tot al liquid capacity of the cooling system: about 2.0L Remove the front shield on the right side. Find the filler mouth of radiator water tank ①.

Open the filler cap and inject a right amount of cooling liquid. Re-install the cap after injection. Check the cooling liquid of the expansion kettle after the engine has been turned off and cooled down. While checking, make sure the motorcycle is on the flat ground and its body upright. Observe the capacity of the cooling liquid in the expansion kettle through the frame hole from the right side of the motorcycle. Keep the capacity between the mark of H and L. If the liquid is below H, remove the cap of the expansion kettle② and then add cooling liquid. Warning: Add the cooling liquid after the engine is turned off

and cooled down. In case of burns, do not open the filler cap before the engine has cooled down. The cooling system is under pressure. In some cases, the cooling liquid contains substances that are combustible, and there will be visible flame when ignited. Avoid the leakage of cooling liquid on hot motorcycle parts,  because it can cause cause serious burns if combust. combust. Avoid contact to and inhalation of the cooling liquid, because it is highly toxic. And keep it away from the children and domestic animals. If inhaled, seek medical advises immediately, and if the skin or eyes have accidentally contacted the cooling liquid, they must be cleaned with water instantly. instantly.

- 27 -

 

Assembly Asse mbly and Disassembly of the Clamp of the Radiator’s Conduit  Conduit   The clamp of the radiator’s conduit is disposable component, so the old clamp can not be reused when disassembled. And the clamp② can only be assembled by special clamp pliers①, or it may not in place, which will lead to the breakdown of the vehicle.

卡箍：clamp

Fuel Injector and Oil-way

The fuel pump①  has two connectors, oil passes through the fuel filter ②  from one of the two connector into the fuel injector ③, and finally inject oil into the intake manifold of the engine. When the oil is under too high  pressure, it will pass through another connector back to the fuel pump①. Please connect the inlet and outlet oil tubes as shown in the figure at right.

- 28 -

 

Adjustment to the Steel Rope of the Throttle *Note

Adjust the idle speed of the engine right before adjusting the stroke of the steel rope of the throttle. Check the free stroke of the steel rope of the throttle, and it should be 3-5mm. Adjust if it does not conform to the specified value. Adjust the free stroke of the steel rope of the throttle. The motorcycle is configured with two-lane steel rope of the throttle, among the two ropes, A for throttle forward (1)Remove the dustproof boot of the steel rope of the throttle. (2)Loosen the locking nut③. (3)Screw in completely the adjusting nut④. (4)Loosen the locking nut①. (5)Rotate the adjusting nut②  to make the free stroke of controlling handlebar of the throttle to 10°～15°. (6)Tighten up the locking nut ①. (7)Adjust nut④ to make the controlling handlebar of the throttle flexible. (8)Tighten up the locking nut ③. After adjusting the free stroke, the handle should be twisted left and right to make sure that there is no change of the idle speed of the engine.

Air Filter Filter Replacement Open the rear seat cushion with the key, and remove it.

钥匙：key

Pull the seat steel rope, open the front seat and take it off. - 29 -

 

座垫钢索：seat steel rope

Disassemble the shield of the fuel tank and its front fixing  bolt, and open the fuel tank. tank.

油箱前固定螺栓：front fixing bolt of the fuel tank

Disassemble the cover of the air filter. Take off its cartridge. Check whether the cartridge is stained or damaged. Replace it if necessary. Clean thoroughly but gently the cartridge with the cleanser. cleanser. Do not use petrol, in case of fire. Do not distort or wring the cartridge so as not to damage the foam. Then apply the engine oil to it, and squeeze out the excess oil to make the cartridge seem moist, but make sure there is no oil dripping.

空气滤清器盖罩：  cover of the air filter 油箱：  fuel tank

Cartridge

Replacement Time Replace it as early as possible if the motorcycle is always running on rainy days or on rugged road.

*Note - 30 -

 

Do not start engine when disassemble the cartridge of the air filter, otherwise, the engine will intake unfiltered air, which may lead to rapid abrasion of other components, and the damage of the engine too. In addition, rotation without cartridge will cause sequential malfunctions of the carburetor, and it may lead to overheat of the engine. Install in reverse order. order.

Spark Plug Remove the spark plug: (1)Lift up the fuel tank. (2)Disassemble the intake air temperature sensors①  on both side of the air filter, and then remove the air filter. (3)Remove the stators② of the spark plug caps on both sides. (4)Remove four spark plug③, and you can see the spark plug④. (5)Remove the spark plug with the spark plug demolition sleeve.

Check   Whether the insulator is cracked or damaged   Whether the electrodes are abrasive   The combustion condition and color  The condition is good in light grey  Combustion color of pale indicates that the ignition system

gets a breakdown or the mixed air is too thin.  The condition of wet or there is black carbon deposition

indicates that the mixed air is too thick. If there occur any cases mentioned above, please remove with spark  plug cleaner or steel brush, brush, and replace if if necessary. necessary. Check the spark plug visually visually.. Replace the cracked or abrasive insulator if necessary. Replace the spark plug after 8000 kilometers of each driving. Check the spark plug gap. Gap: 0.6-0.7mm

Model: CR9E(NGK)  

火花塞间隙：spark plug gap

*Note

Re-install the spark plug to the cylinder head, and screw tight with a specified torque. Torque value: 20-25N.m Manually install the spark plug first, and then tighten with the spark plug sleeve. Do not make the spark plug too tight or the threads staggered, so as not to damage the threads of the cylinder head. When remove the spark plug, avoid impurities from entering into the engine through it.

- 31 -

 

Battery Battery Disassembly Disassemble the front seat. Remove the mounting plate of the battery.

Remove the negative wire and then the positive wire. Remove the battery from the battery box.  Take out the battery.   Warning!

When the positive wire is disassembled, do not make the tool contact with the frame. Otherwise, it may cause short-circuit spark, which may ignite gasoline and damage the battery. It is dangerous.

Install it in reverse order. order. Warning!

To prevent short circuit, connect the positive wire first and then the negative wire.  Do not remove the battery during commissioning. Otherwise, it may cause damage to inner parts of the vehicle.

Check the Charging Condition (closed circuit voltage) Open the front seat. Remove the battery from the battery box.  Remove the negative wire and then the positive wire. Take out the battery. Te Test st the voltage between battery terminals. Fully charged: 13.1V Insufficient charging: 12.3V（1 hour off work ）  *Note

Use a voltmeter to check the charging condition.

Charging Connection: Connect the positive pole of the charger to the positive pole of the battery. Connect the negative pole of the charger to the negative pole of the battery.

- 32 -

 

Warning!

• The battery should be far away from fire source.  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. charging.   • Measure voltage in 30 minutes after the battery is charged. charged.  

伏特表：voltmeter   Charging current: standard: 0.3A quick: 3.0A Charging time: standard: 10-15 hours quick: 30 minutes open-circuit cuit voltage: above 12.8V charging accomplished：open-cir

Fuse Replacement The fuse is under the driver’s seat, and a nd near the battery. The main fuse is set on the starter relay, and the fuse box is near the fuse. As shown in the figure ①  refers to the fuse, model: 40A, ② refers to the spare fuse of the main fuse, model: 40A, ③ refers to the fuse box, the configuration of the fuse is shown in the figure: Frequent fuse blowout indicates that there is short circuit or circuit overload. Note: Before check or replace the fuse, set the ignition switch to “off ”, in case of short circuit or damage to other electrical components. Use the specified fuse only, or it will cause serious affect to the electric system, and it can even burn the lamps of the motorcycle or cause a fire or loss of engine traction, which is very dangerous.

灯光: light; 燃油泵：fuel pump; 风扇：fan; 电源锁： power lock; 备用保险丝：spare fuse

- 33 -

 

Cylinder Pressure Warm up the engine. Insert the pressure gauge. Turn the choke lever to the fully open position. Start up the engine repeatedly, The pressure of the cylinder: 1～1.2mpa *Note

Start the engine until the reading does not rise. Reasons for low pressure:  

Incorrect valve adjustment

 

Leakage of the valve

 

Abrasive piston ring or cylinder

Reasons for high pressure:  

Carbon deposition in the combustion chamber or piston

Turn off the engine, and remove the spark plug/spark plug cap

Looseness of the Drive Chain The life of the drive chain depends on appropriate lubrication and adjustment. Improper maintenance could lead to earlier abrasion of the dive chain and the sprocket. It must be maintained frequently if harshly used.

Looseness: 10-20mm  Adjustment to the drive chain: Adjust the drive chain to the sag of 10-20mm in every 1000 kilometers’ drive. Regular adjustment may need which depends on your driving. Warning: It is the maximum interval for adjustment as recommended; in fact, you should adjust the chain  before every drive. Over loosened chain may cause the accessory chain off the drive chain or serious damages to the engine.

Adjust the chain according the following methods mentioned：  - 34 -

 

(1)Put up the motorcycle with the support frame. (2)Loosen the rear axle nut①. (3)Loosen the locking nut②. (4)Turn right or left the adjustment bolt③ to adjust the looseness of the chain, and keep the centers of the rear and back sprockets into a straight line. There are benchmarks on the swinging arm and each chain adjuster to facilitate your adjustment, and they can be aligned with each other and the reference from one side to the other. Align and adjust the looseness of the chain to 10 — 20mm, 20mm, and then fix again the rear axle nut for the final check. Note:

The two sprockets of the newly replaced chain should be checked to make sure whether they are abrasive or not, replace if necessary. Inspect periodically the following condition of the chain: (1)Loose pin (2)Damaged idler wheel (3)Dry and rusty chain (4)Twisted (4)T wisted or blocked chain link (5)Excessive damage (6)Adjust loose chain If the chain has defects as mentioned above, then there is a high possibility that the sprocket will damage the chain. So the following items should be check to the sprocket: (1)Excessively abraded gear tooth (2)Broken or damaged gear tooth (3)Loose fixing nut of the sprocket Lubrication of the drive chain

Priority should be given to lubricate by the lubrication grease for the drive chain, and you may buy it or use engine oil or other lubrication oil instead. Dip every chain joint to make the lubrication grease penetrate to the space between the chain plates, pins, bushings and rollers. *Note

Do not assemble new drive chain to abraded sprocket or vice versa. The sprocket and the chain should all be in good conditions, or it will cause quick abrasion of the newly replaced chain or sprocket.

- 35 -

 

Free Stroke of the Front Brake Free stroke of front brake  Measure the free stroke of front brake at the tip of the  brake lever. lever. Free stroke: 10-20mm

Regulator of Lever Grip of the Front Brake Depending on the operating needs for the comfort, the  position of the lever grip of the front brake can be adjusted by adjusting the knob with the ring nut. There are four positions for adjustment, and you can adjust to a desired position just by moving gently forward the lever of the brake, and then rotating the adjuster of the ring nut at the arrow A. ○ And position 1 of the front brake lever is most remote to the controlling handlebar of the throttle, while the position 4 nearest to it.

前：  front

Free Stroke of the Rear Brake Free stroke of the brake pedal  Measure the free stroke of the brake pedal. Free stroke: 20-30mm

- 36 -

 

If specified value has not been met, it should be adjusted. Adjust the free stroke of the brake pedal. First open the nut 1. Screw in or out nut 2 to adjust the free stroke of the brake pedal. Screw in 2 to reduce the free stroke; Screw out 2 to increase the free stroke. Tighten the fixture 1 until the specified value is met. After being adjusted, dragging should not occur to the brake.

Headlamp Disassemble the fixing bolt① of the headlamp support.

Disassemble the fixing bolt② of the headlamp support.

- 37 -

 

Unplug the lamp holder connector ③  of the headlamp, remove the lamp holder, disentwine the snap ring, and take out the bulb.

*Note

Keep combustible materials and your hands a distance away from the bulb when it is light. Because the bulb is very hot at that moment, you should let it cool down before touching it. Install new headlamp bulb, lamp holder, and screw in the  bulb to the socket. During the installation, avoid direct touch with the glass of the bulb, an do not make it oil-stained. Or it will affect the transparency,, life and luminous flux of the bulb. transparency Once stained with oil, wipe thoroughly with a damp cloth of alcohol or rubber solution of strong volatility.

Clutch Check the free stroke of steel rope of the clutch. Free stroke: 10-15mm 

Adjust the free stroke of the steel rope of the clutch. First open the clamp nut（1）. Then screw in or back to the adjusting device（2）. Until the specified value of the free stroke is met. Finally,, tighten the clamp nut. Finally

If adjusting the handle of the inhaul cable of the clutch to its ultimate position can not meet the requirement of the free A stroke, then adjust the locking nut nut○ ○   of the engine and the adjusting nut○ nutB ○  with the inhaul cable. cable.

- 38 -

 

Front/Rear Suspension System Front Absorber 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  （上下压缩：compress upwards or downwards） 

Rear Absorber 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 

Bolt/ Nut/Fastener Check whether each bolt, nut and fastener is loose. If yes, tighten it to required torque.

- 39 -

 

Rim/Tyre Check whether tires or rims have any crack, nail or any other damage. Check tyre pressure. *Note

Check tyre pressure when it is cold. Tyre

Specification

RK6

pressure

Front tyre

120/70 ZR 17

250±10kpa

Rear tyre 

180/55 ZR 17

290±10kpa

When the non-skid depth on the central thread of the tyre reaches to the figure in the table, the tyre should be replaced. Minimum non-skid depth

Front tyre Rear tyre

1.6mm 2.0mm

Warning: Do not attempt to repair the damaged tyre.

The balance and reliability of the tyre is likely to worsen. Improper tyre inflation will lead to abnormal abrasion of the tyre and threat the safety. And insufficient inflation will cause tyre slip, or disengage the tyre, or lead to the deflation of tyre which is out of control. It is dangerous to drive with excessively abraded tires, and it is adverse to the adhesion or driving.

轮胎气压表： barometer of the tyre tyre 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: fixing the front wheel spindle fixing nut of the rear wheel spindle

55-62

N· N·m m

85-108  N·m

- 40 -

 

Fixing Steering Stem Bearing and Handlebar Move the handlebar to confirm there is no wire interference. Rotate the front wheel and move the handlebar freely for check. If the handlebar moves difficultly, release it and then check the bearing of the fixing steering stem.

Throttle Body The idle speed of the motorcycle will be reduced to some extent due to the pollution of the throttle body. body. It is better to clean it after every 5000 kilometer’s drive.  drive.  When cleaning, disconnect the negative pole of the battery, connectors of the sensor installed on the throttle; and remove the throttle cable, hose connected to the air filter and the intake manifold, and the throttle body. body. Open the lid on the bottom of the throttle body, spray cleanser to its in-wall and brush the dust and carbon deposition, etc. After cleaning, operate in reverse order, install the throttle and make sure that all parts are in place, and try to start the engine successfully.  Note: Do not let impurities block the parichnos nearby. nearby.

- 41 -

 

Componentss Lubrication Component Appropriate lubrication is of great importance to the normal operation of each part of the motorcycle, to an extended life and to the safety drive. Lubricate the motorcycle after a long time running or exposure in the rain or after cleaning. As for detailed points for lubrication and maintenance, see the following figure:

Ｙ □ motorcycle lubrication

Ｚ □   grease ○ 1 axis of the rear brake brake pedal Ｚ □  ○ 2 single bracket joint and spring hook □ hook Ｚ □ 

○ 3 pin of the

gearshift riding rod Ｚ □  ○ 4 throttle cableＹ □ 

○ 5 pin of the front brake brake handle Ｚ □ 

○ 6 clutch handle（ pin）Ｙ □ 

- 42 -

 

Inspection and Maintenance of the Electrical System

充电系统  

充电系统：  charging system

- 43 -

 

1. Battery/Charging System Preparing Documents------------Documents------------------------------1.1 --1.1 Failure Diagnosis--------------Diagnosis------------------------------------1.2 ----1.2 Battery-----------------------------------------1.3 Charging System-----------------------------1.4 Voltage/Current Regulator  -------------------1.5   -------------------1.5 Charging Coil of Magnetor  ------------------1.6   ------------------1.6 Disassembly of Magnetor  -------------------1.7   -------------------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. As for battery of degraded performance (reduced capacity), whose 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: over voltage 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 over voltage and damage to electrical parts inside the voltage regulator. 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 electric loads. 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. battery.

- 44 -

 

Preparing Principles Item

Specifications

Capacity/Type Battery

Fully charged

Voltage

 Necessary

（20℃） 

charging Charging current Charging time Magnetor Voltage regulator

12V-9AH/ dry-charged

Impedance of the coil

（20℃）  Type Charging voltage of the  battery

13.1V 12.3V(not working for 1h) Standard: 0.8A, quick:8A Standard: 10-15 hours, quick: 30 mins Between white-white 1.5-3.5Ω 1.5-3.5Ω   Three-phase Three-pha se full wave 14.5±0.5V/5.000rpm

Tightening Torque Force Rectifier bolt

Tools 5.0 N· N·m m

Universal Universa l fixing spanner

High-volt age coil fixing bolt High-voltage Flywheel fixing nut

9.0 N·m N·m 5.0 N· N·m m

Flywheel remover Test instrument

Body guard bolt

9.0 N·m N·m

Multimeter

1.2 Failure Diagnosis

Power Supply Dead

Interrupted Current

Battery over-discharge over-discharge

Poor contact of the charging wire

Unconnected battery wiring

Poor contact of the charging system

Fuse blow

Poor contact or short circuit of the lighting system

Poor switch

Low Voltage

Poor Charging System

Poor battery charging

Poor contact, short circuit or open circuit of wire terminals

Poor contact

Poor voltage/current regulator

Poor charging system

Poor magnetor

Poor voltage/current regulator

- 45 -

 

1.3 Battery 1.3.1 Battery Disassembly  As for details, please see page 31.

电瓶位置： battery position Warning!

When the positive wire is disassembled, do not make the tool contact with the frame. Otherwise, it may cause short-circuit spark, which may ignite gasoline and damage the battery. battery. It is dangerous. Install it in reverse order. order. *Note

To prevent short circuit, connect the positive wire first and then the negative wire. Check the charging condition (closed circuit voltage). Remove the seat. Remove cables of the battery. Te Test st the voltage between battery terminals. Fully charged: 13.1V Insufficient charging: 12.3V (not working for 1 hour) * Note

Use a voltmeter to check the charging condition.

1.3.2 Charging Connection method: connect connect the positive pole of the charger with the positive pole of the battery; connect the negative pole of the charger with the negative pole of the battery. Warning!

• The battery should be far away from 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. battery. - 46 -

 

*Note

• Except emergencies, emergencies, you should not use emergency charging. • Measure voltage in 30 minutes after the battery is charged.

Charging current: standard: 0.8A quick: 8.0A Charging time: standard: 10-15 hours quick: 30 mins 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 the short-circuit. *Note

Connect the positive terminal of the multimeter with the negative terminal of the battery. battery. Check whether there is short-circuit in the main switch or in the main wire in the case of any abnormality. abnormality.

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. Remove the seat. *Note

Set the multimeter to the AC voltage position. Limiting voltage: 13.1（+/-）0.5V/5.000rpm

Check the voltage/current regulator if the limiting voltage is not within its required range.

- 47 -

 

1.5 Voltage/Current Regulator 1.5.1 Main Wiring Check Remove the shield of the body. Remove 4p plug of the voltage/current regulator. Check conductivity between main wiring terminals.   Item (wire color)

Judgment

Between Battery(red) and

With battery

GND of the body

voltage

Between GND wire (black) and GND of the body

With lead Resistance in the

Between charging coil (white)

coil of the

and the GND of the body

magnetor.

1.5.2 Voltage-current Regulator Check   1. Choose diode file with multimeter. 2. The black probe connects to the red wire terminal of the voltage regulator, and the red probe connects respectively with the white wire terminal (white 1, white 2, white 3). The pointer gauge shows a certain value, otherwise it indicates the damage of the voltage regulator and replacement is needed. 3. The red probe connects to the black wire terminal of the voltage regulator, and the black probe connects respectively with the white wire terminal (white 1, white 2, white 3). The pointer gauge shows a certain value, otherwise it indicates the damage of the voltage regulator and replacement is needed. *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 Ω

*Note 白

白  

白

Check the magnetor charging coil on the engine.

Check Remove the 6p connector of the magnetor. Measure the impedance between the three white terminals of the magnetor with the multimeter. Standard: 1.5-3.5Ω 1.5-3.5Ω（20℃）  Replace the magnetor coil when the measured value exceeds the standard value. - 48 -

 

1.7 Magnetor Disassembly Left cover and the magnetic coil

1.7.1 Disassembly Loosen the fixing nuts on the left cover, and remove the left cover and the magnetic coil.

Bolt

Fix the flywheel with the universal fixing spanner.

Bolt

Remove fixing bolts of the flywheel. Remove the flywheel with the flywheel remover remover.. Remove the solid key. Remove the conductor joint. Remove the stator.

Loosen the four fixing bolts of the magnetic coil, and remove the magnetic coil.

Bolt

- 49 -

 

Loosen the locking nuts of the flywheel with electric, pneumatic tools or torque spanner.

Locking nut of

Remove the flywheel assembly. assembly.

the flywheel

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

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 N··m

- 50 -

  

电源

黑/红2 黑 黑/白2 ECU2

黑/红2 黑 橙/绿2

黑/红1 黑 黑/白1

白蓝 / / ECU1

绿白

黑/红1 黑 橙/绿1

触发头 电源

 

电源： power  power,, 触发头：trigger, 点火系统：ignition system 黑： black, 白：white, 红：red, 橙：orange, 绿：green, 蓝： blue

- 51 -

 

2. Ignition System Preparing Documents -----------------2.1 Failure Diagnosis ---------------------2.2 Ignition System Check ---------------2.3 ECU Group--------------------------Grou p----------------------------2.4 -2.4 Ignition Coil ---------------------------2.5 Triggerr ---------------------------------2.6 Trigge

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 ECU group and you don’t have to adjust the ignition time.  time.  3. Check the ignition system following the sequence listed in the table of failure diagnosis. 4. Do not make ECU of the ignition system fall down or hang down or hammer it with strong force (primary causes for failure). Pay special attention during disassembly disassembly.. 5. Failure of the ignition system is mostly caused by poor contact of the socket. Check C heck 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

Standard value

Spark plug recommended

Standard Spark plug gap

Ignition coil impedance（20℃） 

Primary coil

CR9E(NGK)  

0.6-0.7mm 650±50mΩ   650±50mΩ

Impedance of trigger （20℃） 

100-300Ω   100-300Ω

Measure the maximum primary voltage of the ignition coil

14V

Trigger voltage

Above 1.7V

Tools Attachments to the Maximum Voltage Table Multimeter - 52 -

 

2.2 Failure Diagnosis No spark-over of the spark plug

Abnormality

Cause (confirm it sequentially as follows)

①The inner resistance is too small and it should be

Ignition coil

Too low high-voltage

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).

①Incorrect connection of the tester. ②Poor main switch. ③Poor contact of ECU terminal. ④Short circuit or poor contact of the GND of ECU. ⑤Poor contact of charging coil (measured at the Side voltage

 No or interrupted high voltage voltage

maximum voltage). ⑥Poor trigger (measured at the maximum voltage). ⑦Poor terminal of high-voltage wires. ⑧Poor ECU group (when item ①-⑦ is checked to  be abnormal or there there is no spark for spark plug.) plug.)

①Poor spark plug or secondary leakage of the  Normal high voltage, but no spark

Charging

 No high voltage

ignition coil. ②Poor ignition coil. 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.)

coil

 No or interrupted high voltage voltage

Too low high-voltage Trigger

 No or interrupted high voltage voltage

①Poor ignition coil. ②Poor charging coil. 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.)

①Poor ignition coil. ②Poor trigger.

- 53 -

 

2.3 Ignition System Check *Note

• When there is no spark, check whether there is loose wiring

万用表

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 ） 

高压分流器

2.3.1 Primary Voltage of the Ignition Coil ( 高压分流器：high-pressure shunt) 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  between the primary primary coil terminal (black/red) (black/red) 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.

- 54 -

 

2.3.2 Sensor of the Crankshaft *Note

Install the spark plug on the cylinder head and carry out measurement when the compression  pressure is normal. Remove 18 connectors of ECU group. Connect the  peak-voltage shunt between between the charging charging coil (blue/white terminal) with 18 connector and the 18 connector (white/green terminal). Press the startup motor or step the actuating lever to measure the maximum voltage of the charging coil. Connection: positive pole to blue/white; negative pole to white/green. Minimum voltage: above 95V *Note

 Never touch any metal part of the test rod with your finger to avoid electric shock. When the maximum voltage measured at the terminal of ECU Group is abnormal; dismantle the shield of the  body and the magnetor terminal. • If the voltage of ECU 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 ECU and magnetor terminal appears to be abnormal, it is caused by po or charging coil. Please refer to charging coil check.

2.4 ECU Group 2.4.1 System Check   Check the system. Remove the ECU Group, and check components of the ignition system at the terminal.

- 55 -

 

2.5 Ignition Coil 2.5.1 Disassembly Remove the body. 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

Install the primary coil with black/red terminal. 

2.5.2 Check the Primary Coil Measure the impedance between terminals of the primary coil. 

℃ Standard: (4±0.2)Ω (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.

2.6 Sensor of the Crankshaft *Note

Check the trigger on the engine.

Check Remove the shield of the body. Remove the trigger terminal. Measure the impedance between the blue/white terminal of the side wire of the engine and the body GND. Standard: 100-300Ω 100-300Ω（20℃）  Replace the magnetor if the measured value exceeds the standard value.

- 56 -

 

BATTERY

G/Y

M

G/Y

启动示意图 启动示意图：Startup Schematic Diagram 

57

 

3. Startup System Preparing Documents ----------------3.1 Failure Diagnosis ---------------------3.2 Startup Motor -------------------------3.3 Starter Relay --------------------------3.4 Starter Clutch--------------------------3.5 Clutch--------------------------3.5

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 Length of the brush of the startup motor

Standard

Limit for use

12.5mm

8.5mm

Bushing of the startup idler

8.3mm

shaft Outer diameter of the startup idler shaft

7.94mm

Tightening torque force Bolts for the clutch cover of the startup motor Retaining Retainin g nut for the clutch of the startup motor

Tools Spanner for retaining nuts Universal fixing spanner

12 N· N·m m  95 N· N·m m 

58

 

3.2 Failure Diagnosis Startup failure

Weak in rotation of the startup motor

No rotation of RE rotary engine of the startup motor

• Fuse blow

• Low battery

• Poor startup clutch

• Low battery

• Poor wiring contact

• Reversal r otation otation of the startup motor

• Poor main switch

• Gear seized

• Low battery

• Poor startup clutch • Poor brake switch • Poor starter relay • Poor wiring contact • Poor startup motor

3.3 Startup Motor 3.3.1 Disassembly Loosen the two fixing bolts of the startup motor, and remove the motor.  Bolt

Startup motor

* Note

Before the startup motor is disassembled, turn off the main switch, remove the GND wire of the battery, battery, and then power on to check whether the startup motor works for ensuring safety.

59

 

Remove the wire clip of the startup motor. motor. Remove the fixing bolts of the startup motor, separate the front cover and the back cover, and dismantle the startup motor. Roll the waterproof rubber case and dismantle the connector of the startup motor. motor.

换向器：commutator

3.3.2 Breakdown  Remove screws in the shell, front cover, motor housing and other parts.

3.3.3 Check  

碳刷 Check other components. Replace any part with abraded, damaged or burnt surface. Clean the commutator surface if there is metal power attached to it. Check conduction between the surfaces of other components. Ensure non-conduction between armature shafts of the commutator. commutator. Check the conduction of the shell of the startup motor 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.

碳刷：carbon brush

60

 

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 contact surface between between the brush and the armature shall not be damaged. • Pay attention that the armature shaft shall not damage lips of the oil seal. and install the back cover of the electric machine. 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. assembly.

3.3.5 Installation  Install the lead of the startup motor and the dustproof boot. And then install the startup motor. Install the wire clip for rear brake.

3.4 Starter Relay 3.4.1 Check   When the main switch is “on”, check there is “click” sound at the time of pressing the startup motor. 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.  relay.  

启动继电器：starter relay

61

 

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

Ω

terminal and the body ground connection. When the main switch is “on”, hold the brake lever. The  battery voltage shall comply comply with regulations. When there is no voltage at the starter relay terminal, check the conduction of the brake switch and leads.

启动继电器：starter relay

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.

3.4.4 Check Connect the starter relay to the battery, and the terminal of the startup motor to the multimeter. multimeter. Connect the 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”.  “zero”. 

Ω

- 62 -

 

4. Bulbs/ Switches / Meters Preparing Documents ---------------------------------------------------------------------------------------------------------------------4.1 ----4.1 Failure Diagnosis -------------------------------------------------------------------------------------------------------------------------------4.2 ----4.2 Replacement Replaceme nt of Headlamp Bulbs------------------------------------------------4.3 Replacement Replaceme nt of Front Position Lamp Bulbs------------------------------------4.4 Replacement Replaceme nt of Tail Lamp---------------------------Lamp--------------------------------------------------------4.5 ----------------------------4.5 Replacement Replaceme nt of Rear Registration Plate Lamp Bulbs-------------------------4.6 Bulbs -------------------------4.6 Replacement Replaceme nt of Front Steering Lamp Bulbs ------------------------------------------------------------------4.7 ---4.7 Replacement Replaceme nt of Rear Steering Lamp Bulbs ------------------------------------4.8 ------------------------------------4.8 Meters--------------------------------------------------------------------------------4.9 Main Switch -----------------------------------------------------------------------------------------------------4.1 ----------------------------------------4.10 0 Horn ---------------------------------------------------------------------------------------------------------------------------------------------4.1 --------------------4.11 1 Handlebar Switch -------------------------------------------------------------------------------------------------4.12 --------------------------------4.12

4.1 Preparing Documents Work Instructions  

Remove the switch from the vehicle to measure its condition.

 

All plastic connectors have clamping jaws,

 

lift the clamping jaws and clamps before disassembly,

 

and make sure that the clamping holes aim at the clamping jaws when installing.

 

When looking up for electric faults,

 

check the continuity of the circuit passing through the electronic devices.

 

The state of the battery must be confirmed before carrying carrying out any inspection,

 

including the voltage, to confirm that whether it is normal or not.

- 63 -

 

4.2 Failure Diagnosis The ignition switch “ON” is not light, which due to • Poor bulbs. • Poor switch. • Bad contact or broken wires  wires  • Weak battery power or no voltage.  voltage.  

4.3 Replacement of Headlamp Bulbs   Remove the two fixing bolts① of the headlamp at the bottom left and bottom right of the meter.

Lower the headlamp forward, you can see the back of the headlamp, and remove its dustproof cover ②. 

- 64 -

 

The figure below shows the bulb of the dipped headlight③, and the bulb of the headlight on full  beam④, remove the power cord socket, bulb snap, fixing bolts and the bulb snap buckle of the dipped headlight and the headlight on full beam that need to  be replaced, and finally finally remove the damaged damaged bulb. Aim the position of the light snap, and replace on a new one of the same specification. *Note

Keep combustible materials and your hands a distance away from the bulb when it is light. Because the bulb is very hot at that moment, you should let it cool down before touching it. Install the bulb in reverse order. During the installation, avoid direct touch with the glass of the bulb, an do not make it oil-stained. Or it will affect the transparency, life and luminous flux of the bulb. Once stained with oil, wipe thoroughly with a damp cloth of alcohol or rubber solution of strong volatility. volatility. Install headlamp devices.

4.4 Replacement of Front Position Lamp Bulbs   The front position lamp and the headlamp are in one lamp body, as shown in the figure, there is a front  position lamp bulb① on the right and left sides. (1)  Operate according to the prompts of the above chapter   — Replacement Replacement of the Headlamp Bulbs. (2)  Remove the damaged bulb, and replace on a new one of the same specification. (3)  Install the bulb in reverse order.

- 65 -

 

4.5 Replacement of Tail Lamp   The illuminant of the tail lamp is LED, replace the whole lamp if necessary. (1)  Remove the passenger’s seat and the driver’s.  driver’s.  (2)  Remove the tow fixing nuts① of the tail-hood shield, and then move it horizontally backward to take it down.

(3)  Remove the two fixing nuts②  of the rear lamp combination.

(4)  Remove the three fixing bolts③  of the rear lamp combination. (5)  Remove the cable of the rear lamp combination, take off the damaged lamp, and replace on a new one of the same specification. (6)  Install the lamp in reverse order. order.

- 66 -

 

4.6 Replacement of Rear Registration Plate Lamp Bulbs   (1)  Remove the fixing nuts①  of the rear registration  plate lamp to take down the tail-hood② of it. 

(2)  Take off the damaged bulb, and replace on a new one of the same specification.

(3)  Install the lamp in reverse order.

- 67 -

 

Steering ring Lamp Bulbs   4.7 Replacement of Front Stee The illuminant of the front steering lamp is LED, replace the whole lamp if necessary. (1)  Operate according to the prompts of the above chapter   — Replacement Replacement of the Headlamp Bulbs. (2)  Remove the fixing nuts①  of the right or left steering lamp. (3)  Remove the cable of the front steering lamp, take off the damaged lamp, and replace on a new one of the same specification. (4)  Install the lamp in reverse order.

4.8 Replacement of Rear Steering Lamp Bulbs  The illuminant of the rear steering lamp is LED, replace the whole lamp if necessary. (1)  Remove the fixing nuts①  of the right or left steering lamp from the back of bracket of the rear registration plate. (2)  Remove the cable of the rear steering lamp, take off the damaged lamp, and replace on a new one of the same specification. (3)  Install the lamp in reverse order.

4.9 Meters Remove the rearview mirror; Remove the handle cover, and unplug the connectors. Remove the nuts the meter. meter. Install the meter in reverse order. order.

- 68 -

 

4.10 Main Switch 4.10.1 Check Remove the front shield. Remove the main switch lead terminal. Check the conduction of the terminal.

POWER LOCK ON OFF LOCK

R

R/W

4.10.2 Replacement of Main Switch Remove the front shield. Remove the fixing bolts, and take off the fixing socket of the main switch. Remove the fixing bolts, and replace the main switch.

4.11 Horn Check Remove horn wires. It shows good when the horn wire is connected to the battery.

- 69 -

     

4.12 Handlebar Switch Switch classification: 1. Light changing switch （变光开关）  2. Start switch

（转向开关） 3. Steering switch 4. Horn switch （喇叭开关） 

 

5. Turn off switch （熄火开关）  6. Warning switch

接线原理图 变光开关

 

  浅兰 兰 黄/红

转向开关  

绿/黑 橙   绿/白

喇叭按钮 黑 棕  

大灯开关

启动按钮

熄火开关

 绿 红/白  红/白

黑  白

  黄 黄/红 红/白棕/白

 

接线原理图：Schematic diagram of wiring 大灯开关：headlamp switch 启动按钮：start button 兰： blue 黄/红：yellow/red 浅兰：light blue 黑： black 棕：grey 红/白：red/white 棕/白：grey/white 绿：green 白：white

- 70 -

 

Inspection and Maintenance of the Motorcycle Body Torque Force Table of the Body   Name of fastening parts parts and fasteners

Tightening torque（ N·  N·m m） 

Fixing bolt of the front absorber M6

5-10

Locking screw of the front wheel spindle M6

5-10

Front fixing bolt of the fuel tank M6

5-10

Fixing bolt of the front fuel pump assembly M6

5-10

Fixing bolt of the rear fuel pump assembly M6

5-10

Fixing bolt of the fixing seat on the handlebar M8

22-34

Fixing bolt of the upper connecting bracket M8

22-34

Rear fixing bolt of the fuel tank M6

5-10

Mounting bolt of the front brake cylinder assembly M10

37-55

Mounting bolt of the rear brake cylinder assem assembly bly M8

22-34

Fixing bolt of the sprocket M10

37-55

Fixing bolt of the rear frame M10

37-55

Fixing bolt of the pillar

50-70

Top bolt of the rear absorber M10

37-55

Bottom bolt of the rear absorber M10

37-55

Fixing bolt of the engine M10

37-55

Fixing bolt of the rear swinging arm axle M14

70-105

Front wheel spindle M16

100-140

Fixing nut of the rear wheel spindle M24

130-150

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Front Disc Brake

1. handlebar assembly of the front brake disc flange screw

6.brake switch

2.handlebar screw

7.screw M4×12

8.nut M6

12.mounting bolt of the oil tube

13.gasket

16.brake shoes

18.D.320front brake disc

17.bolt M8×16

A

Dia. of the front left/right brake disc:320mm

B

Thickness of the front left/right brake disc:4.0mm Limit for use: 3.6mm

C

Thickness of the brake shoes:7.8mm Limit for use:3.8mm

D

Torque for mounting bolt 4 in the figure:5-10N·m

E

Torque for mounting bolt 5 in the figure:30-35N·m

F

Torque for mounting bolt 11 in the figure: 5-7N·m

G

Torque for mounting bolt 12 in the figure:30-35N·m

H

Torque for mounting bolt 14 in the figure:37-55N·m

I

Torque for mounting bolt 17 in the figure:22-34N·m

3.fixing cover

4.bolt M6×23

9.brake hose assembly

14.bolt M10×1.25×55

5.hexagon

10.11. bleed nipple

15.front left brake cylinder assembly

 

19.front right brake cylinder assembly

- 72 -

 

Rear Disc Brake A B C D E F G

1.pin

Dia of the rear disc brake: 240mm Thickness of the rear disc brake: 5.0mm Limit for use: 4.5mm Thickness of the brake shoes: 7.0mm Limit for use: 3.7mm Torque for mounting bolt figure:30-35N·m: 22-34 N·m Torque for mounting bolt figure:30-35N·m: 5-10 N·m Torque for mounting bolt figure:30-35N·m: 30-35 N·m Torque for mounting bolt figure:30-35N·m: 30-35 N·m

2.joint M6

indicator

3.cotter

15 in the 14 in the 10 in the 8 in the

4.nut M6

9.rear brake hose assembly assembly

12.brake shoes

13.rear disc brake

5.pushrod

6.rear fuel pump assembly

7.gasket

8.rear brake

10.mounting bolt of the oil tube 11.rear brake cylinder cylinder assembly

14.screw M6×20

15.bolt M8×1.25×20

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5. Brake Maintenance Instruction ------------------------5.1 Failure Diagnosis ----------------------------------------------------------5.2 -----5.2 Front Disc Brake ---------------------------------5.3 Rear Disc Drake ---------------------------------5.4 -- -------------------------------5.4

5.1 Maintenance Instruction Work Instructions *Note   A stained brake disc or protective gasket will reduce brake force, so discard

stained gasket and clean the brake disc with quality brake degreaser.

  Check the brake system through the brake lever and pedals.   Spilled brake liquid is harmful to the focusing and paint of the equipment,

and the rubber parts too. So be careful whenever you remove the cap of the oil cup, and the first thing you should do is to make sure that the liquid in the cup is aclinic.   Never let the earth, water or other dirt in into to an open cup.   Use the DOT4 brake liquid taken out from a sealed container when doing

maintenance, and do not mix it with other type of liquid, since they can not coexist.

* Check the brake before riding.*

5.1.1Specification Item Special brake liquid Thickness of the left/right Thickness  brake disc Thicknesss of the left/right Thicknes  brake shoe shoe Dia. of the left/right brake disc The jump of the brake surface Front of the left/right brake disc

Standard DOT4

Limit for use -

Item Special brake liquid

Standard DOT4

Limit for use -

4.0mm

3.6mm

Thickness of the brake disc

5.0mm

4.5mm

7.8mm

3.8mm

Thickness of the brake shoe

7.0mm

3.7mm

Φ320mm   Φ320mm

-

Φ240mm   Φ240mm

-

0.1mm

-

Dia. of the brake disc The jump of the brake surface of the brake disc

0.1mm

-

+0.043

mm

-

+0.027

mm

-

Φ16-0.059 mm

-0.032

-

Φ11-0.059 mm 

-0.032

-

+0.08

-

 piston I.D. of the caliper cylinder

Φ32+0.03 mm 

+0.08

-

-

O.D. of the caliper piston

Φ32-0.065 mm 

-0.032

-

I.D. of the pump oil cylinder Φ16 0 O.D. of the oil-pumping  piston I.D. of the caliper cylinder

Φ34+0.03 mm

O.D. of the caliper piston

32-0.065 mm

-0.032

Rear

I.D. of the pump oil cylinder O.D. of the oil-pumping

Φ11 0

- 74 -

 

5.1.2 Torque Force  Fixing the front wheel spindle

100-140N·m 100-140N· m

Mounting screw of the front left brake cylinder assembly

37-55N·m

Mounting screw of the front right brake cylinder assembly

37-55N· 37-55N ·m

Fixing nut of the rear wheel spindle

130130-150N·m 150N·m

Mounting screw of the rear brake cylinder assembly

22-34N· 22-34N ·m

5.2 Failure Diagnosis 5.2.1 Poor Brake Performance 1. 

Improper adjustment of the brake

2. 

Abraded brake shoes assembly or disc brake

3. 

Improper installation of the brake shoes assembly

4. 

Stained brake shoes assembly or disc brake

5.2.2 Slow Reaction or Tight Lever   1.

Improper adjustment of the brake

2.  Abraded brake shoes assembly or disc brake 3.  Improper installation of the brake shoes assembly

5.2.3 Abnormal Noise  1．  Abraded brake shoes assembly or disc brake 2．  Stained brake shoes assembly or disc brake

5.2.4 Soft or Flossy Brake Lever/Pedal  1. 

Air in the hydraulic system

2. 

Leakage of the hydraulic system

3. 

Stained brake pedal/disc

4. 

Abraded seal of the caliper piston

5. 

Abraded brake pedal/disc

6. 

Stained caliper

7. 

Abnormal slip of the caliper

8. 

Insufficient brake liquid

9. 

Blocked brake liquid channel

10.  Bended/fragmenta Bended/fragmentary ry caliper piston 11.  Bended/fragmenta Bended/fragmentary ry piston of the main cylinder 12.  Stained piston of the main cylinder 13.  Bending braking lever/pedal

5.2.5 Brake Stuck or Pulled to One Side 1．  Stained brake pedal/disc 2．  Wheel deviation

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3．  Blocked or limited joint of the brake hose 4．  Bending/fragmentary brake disc 5．  Abnormal slip of the caliper

5.2.6 Brake Resistance 1．  Strained brake pedal/disc 2．  Wheel deviation 3．  Abraded brake pedal/disc 4．  Bending/fragmentary brake pedal/disc 5．  Abnormal slip of the caliper

5.2.7 Stiff Brake Lever/Pedal 1．  Blocked/limited brake system 2．  Sticked/abrade Sticked/abraded d caliper piston 3．  Abnormal slip of the caliper 4．  Blocked/limited brake liquid channel 5．  Abraded sealing gasket of the caliper piston 6．  Sticked/abrade Sticked/abraded d piston of the main cylinder 7．  Bending brake lever/pedal

5.3 Front Disc Brake 5.3.1 Disassembly *Note  

Replace the brake shoes assembly. assembly.

 

If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place.

Remove following assemblies from the right grip and the front absorber. Front brake: 1.   brake handle

 Nut

of

the

rearview

2.  fuel pump assembly 3.   brake hose assembly assembly 4.  left/right brake cylinder assembly Fixing screw of the fuel pump 5.  left/right brake disc *Note   Do not stain the brake assembly with oil spots during

installation or disassembly. disassembly.   Clean it with required cleaning agent to maintain the brake performance performance..

- 76 -

 

Fixing screw of the handle

Fixing bolt of the brake hose Brake hose

Bleed nipple  Fixing bolt of the brake hose Right brake cylinder assembly Fixing bolt of the brake cylinder Loosen the fixing screws of the brake cylinder assembly assembly.. Remove the brake cylinder assembly from the front absorber.

Bleed nipple  Fixing bolt of the brake hose Left brake cylinder assembly  Fixing bolt of

the

brake

- 77 -

 

Remove the front wheel spindle. Remove the front wheel. Remove the disc brake off the front rim.

前轮：front wheel 前轮轴：front wheel spindle 前左液刹：front left disc brake 固定螺钉：fixing screws

5.3.2 Check   Check whether the brake shoes assembly and the brake disc are abraded. Replace brake shoes if necessary. Measure the brake shoes and the brake disc. Record maximum values. Specification Diameter of the front brake disc Thickness of the front brake disc *Note

Measure them with micrometer.

Φ320mm  Φ320mm  4.0mm

- 78 -

 

Measure the thickness of the brake shoes. 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 brake disc

3.8mm 3.6mm

Note:

Replace brake shoes in pair.

5.3.3 Installation Install the brake disc and the front wheel. Install the front brake hose assembly and the brake cylinder assembly. assembly. Do not stain 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 the front wheel spindle

120N·m 120N·m

The bolt of the brake disc

28N·m

The fixing bolt of the fuel pump assembly

8N·m

Mounting bolt of the front brake cylinder assembly

50N·m

Do not stain the brake shoes with oil spots.  Use brake cleaning agent to clean brake shoes with oil spots. *Note

Any grease on brake shoes will reduce the brake performance. *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. performance.  

- 79 -

 

5.4 Rear Disc Brake 5.4.1 Disassembly *Note    

Replace the brake shoes assembly. assembly. If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place.

Remove the following assembly off the frame and the rear swinging arm. Rear disc brake: (1)  Fuel pump assembly (2)  Brake hose assembly (3)  Brake cylinder assembly (4)  Brake discs

Loosen the fixing screws of the right pedal cover plate. Ri ht

edal edal co cove verr

Fi Fixi xin n scre screws ws

Loosen the fixing screws of the oil pump assembly. assembly. Remove the oil pump cylinder. cylinder. Fuel

um

Fi Fixi xin n scre screws ws

- 80 -

 

Loosen the fixing screws of the brake cylinder assembly assembly.. Remove the brake cylinder assembly off the rear swinging arm.

Rear brake hose

Fixi Fixin n bolt bolt Br Brak akee

c lind linder er

Fixi Fixin n scre screw w

Remove the rear wheel spindle. Then take off the rear wheel. Remove the bake disc off the rear rim.

后轮：rear wheel 后液刹盘：rear brake disc 固定螺钉：fixing screw 后轮轴：rear wheel spindle

5.4.2 Check Check whether the brake shoes assembly and the brake disc are abraded. Replace brake shoes if necessary. Measure the brake shoes and the brake disc. Record maximum values. Specification Diameter of the rear brake disc Thickness of the rear brake disc *Note

• Measure with micrometer.  micrometer. 

Φ240mm  Φ240mm  5.0mm

- 81 -

 

Measure the thickness of the brake shoes. 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 brake disc

3.7mm 4.5mm

Note:

Replace brake shoes in pair.

5.4.3 Installation Install the rear brake disc.  Install the rear wheel. Install the brake cylinder. cylinder. * 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 the rear wheel spindle

120N·m

The bolt of the brake disc

28N·m

The fixing bolt of the fuel pump assembly

8N·m

Mounting bolt of the rear brake cylinder assembly

50N·m

Do not stain the brake shoes with oil spots.  Use brake cleaning agent to clean brake shoes with oil spots. *Note

• Do not stain the brake assembly with oil spots during installation or disassembly disassembly..  • Clean it with required cleaning agent to maintain the brake performance. performance.  

- 82 -

 

Body *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 assembly.. Do not damage any part during assembly.  

1. right air deflector mounting mounting plate 2. windshield windshield 3. left air deflector deflector mounting plate

4. 5. right fr front ont shield 6.

right shield of the tank 7 bottom right shield 8. right shield 9. trim-cover of the right muffler 10. decorative cover of the right muffler 11. back seat assembly 12. right rear handrail 13. left rear handrail 14. 16. left assembly of the rear fender 17. right assembly of the rear fender 18. left shield 19. battery box 20. bottom left shield 21. front seat assembly 22. middle shield of the tank 23. left shield of the tank 24. left front shield 25. front shield of the tank 26.connecting board of the left/right shield 

- 83 -

 

6. Body  6.1 Disassembly Disassemble in the following order:

 back seat assembly→ front seat assembly → front shield of the tank→ left shield of the tank→ right shield of the tank→ left front shield→ right front shield → middle shield of the tank → tank assembly  assembly  ↓  rear connecting board of the left/right shield → left rear handrail → right rear handrail → bottom left shield→ left shield→ bottom right shield → right shield → taillight → rear bottom fender → decorative cover of the right muffler → trim-cover trimcover of the right muffler → decorative cover of the left muffler → trim-cover trim -cover of the left muffler → barrel assembly of the muffler → rear fender assembly →  battery box ↓  mounting frame assembly of the headlamp → windshield → left air deflector mounting plate → right air deflector mounting plate → headlamp  headlamp  *Note

Do not damage any body part during disassembly. disassembly. Do not damage any hook or claw in the body during disassembly.

6.2 Assembly Assembly in reverse order. *Note

Aim panels in the body at each corresponding groove. Ensure correct installation of each hook or claw part during assembly. assembly. Do no damage any part during assembly.

- 84 -

 

Front Suspension A

B

C

D

E

F

Torque for mounting the fixing bolt 20 of the steering column in the figure: 50-70N·m Torque for mounting the fixing bolt 16 of the upper  base of the steering handlebar handlebar in the figure: 22-34N·m Torque for mounting the fixing bolt 13 of the upper connecting board in the figure: 22-34N·m Torque for mounting the fixing bolt 5 of the front absorber in the figure: 5-10N·m Torque for mounting the front wheel spindle 1 in the figure: 100-140N ·m Torque for mounting the locking bolt 28 of the head of the front wheel spindle in the figure: 5-10N·m

1. front wheel spindle 2. bolt M5×0.8×14 3. screw M6×15.2 .4. front right absorber assembly 5. bolt M6×20 6. screw M5×0.8×12 7. bolt M6×1×14 8. suspension bush 9. mounting base under the headlamp 10. spacer bush 11. screw M6×1×16 12. mounting base above the headlamp 13. bolt M8×1.25×25 14. upper connecting board 15. upper base of the steering handlebar 16. bolt M8×1.25×25 17. locking screw of the inner inner hexagon flat eend nd M4×6 18. pin 19. column column 20. fixing screw of the upper connecting board 21. nut 22. locking nut of the upper connecting board 23. steering bearing 24. screw M6×8 25. fixing wire clip of the front brake tube 26. bottom connecting board 27 front left absorber assembly 28. bolt M6×30 29. left spacer bush of the front wheel

- 85 -

 

Handlebar

1. balance piece piece assembly 2. throttle throttle lever 3. mounting base base of the balance balance piece cable 5. screw

6. right switch group

handle combination of the clutch assembly II

7. handlebar

8. left switch group

4. front cover cover of the throttle

9. cover of the left handlebar

11. clutch cable assembly 12. throttle throttle cable cable assembly I

10.

13. throttle cable

- 86 -

 

Front Wheel

A

Tyre size: front tyre: 120/70 ZR17

B

Pressure of 250±10kpa

C

Minimum 1.6mm

the

front

non-skid

tyre: depth:

Rim run-out limit: D

Vertically: 2.0mm Horizontally: 2.0mm

E

Torque for mounting the bolt 1 of the brake disc: 22-34N·m

1. bolt M8×16 2. front brake disc 3. bearing 6005-2RS/1-C3 4. middle spacer bush of the front wheel 5. front rim 6. vacuum tyre 120/70 120/70 ZR17 7. front front brake disc

8. valve valve

- 87 -

 

7. Front Wheel/Handlebar/Front Suspension Preparing Documents--------------------------7.1

Failure Diagnosis-----------------------------7.2 Diagnosis-----------------------------7.2 Front Wheel-----------------------------------7.3 Wheel-----------------------------------7.3 Handlebar--------------------------------------7.4 Front Suspension-----------------------------7.5 Suspension-----------------------------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 the brake shoes and the brake disc shall not be stained with grease during operation. A stained brake disc or brake shoe will reduce brake force, so discard stained gasket and clean the brake disc with quality brake degreaser.

Motorcycle Standards Standard

Measurement points

Item

Front wheel spindle

Bending

Front wheel

Limit for use (mm)

(mm)

Rim

Vertically

shimmy

Horizontally

0.2 2.0 Within 1.0

Torque Force

2.0

Tools

Fixing bolt of the upper connecting board assembly

22-34N· 22-34N ·m

Bearing puller

Fixing the front wheel spindle

100-140N·m 100- 140N·m

Locking nut spanner

Locking screw of the head of the front wheel spindle

5-10N·m

Fixing screw of the front absorber

5-10N·m

Fixing bolt of the steering column

50-70N· 50-7 0N·m m

Assembling bolt of the front brake cylinder

37-55N 37-55N··m

- 88 -

 

7.2 Failure Diagnosis 7.2.1 Difficulty in Steering  

Failure or damage of the steering handlebar. handlebar.

   

Damaged bearing of the handlebar. Too tight of the adjusting bolt of the faucet bearing.

 

Insufficient tyre pressure.

7.2.2 Unsteady Steering   

Damaged steering handlebar.

 

Insufficient 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.

   

Abraded front wheel bearing. Flawed front tyre.

 

Unbalanced tyre or wheel.

7.2.4 Difficulty in Wheel Rolling  

Failure in the front wheel spindle bearing.

 

Braking fault of the brake.

 

Failure in the front wheel spindle.

 

Bending of the front wheel.

7.2.5 Abnormal Abnormal Noise of the Front Absorber  

Insufficient liquid in the absorber.

   

Fricative sound of the absorber guard. Loose bolts in the absorber.

7.2.6 Operation Only Available Available in One Side or Move in Curve  

Unbalanced adjustment of the left and right forks

 

Bending absorber

 

Bending wheel

 

Incorrect installation of the wheel

 

Bending frame

 

Broken wheel bearing

 

Broken central axis of the swinging arm

7.2.7 Soft Front Absorber    

Insufficient liquid in the absorber

 

The spring of the absorber is not firm.

 

Too low of the tyre pressure - 89 -

 

7.2.8 Too Too Stiff of the Front Absorber  

Improper weight of the liquid

 

Blocked pathway of the liquid in the absorber

7.3 Front Wheel 7.3.1 Disassembly Note:

Support the motorcycle firmly. firmly. Support the motorcycle with a safety frame or firm crane. Disassemble the front fender, and loosen the fixing screws①②.

Bleed nipple Fixing bolt of the bake hose Right brake cylinder assembly Fixing bolt of the brake Disassemble the braking caliper of the front disc brake. Loosen the fixing screws of the brake cylinder assembly assembly.. Remove the brake cylinder assembly off the front absorber. absorber.

- 90 -

 

Bleed nipple Fixing bolt of the bake hose Right brake cylinder assembly Fixing bolt of the brake cylinder

Remove the clamping screw① of the front wheel spindle (right front absorber)

Disassemble the front wheel spindle① 

- 91 -

 

Disassemble the front wheel assembly①  Remove the left spindle sleeve of the front wheel ② 

Disassemble the bearing with the bearing remover. remover.

Note:

Do not operate the brake controlling lever after the removal of the brake caliper. caliper.

- 92 -

 

7.3.2 Check 7.3.2.1 Check the Bending of the Wheel Spindle Place the wheel spindle on the V-base and measure the eccentricity ratio with a dial indicator. indicator. Limit for use: replacement when beyond 0.2mm 

车轴：axle

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 Balance of the wheel：  Warning： 

The balance of the wheel directly affects the stability stability,, operation and safety of the motorcycle. Check the stability of the wheel when it is removed. Note:

In order to keep balance, mark on the tyre near the bleed nipple by drawing a dot at the rim. Assemble the tyre when necessary.

7.3.2.3 Balance of the Front Wheel  Note:

Paste marks of the rotating direction on wheels and tires. Remove the dust-proof sealing ring off wheels; Install the wheels, tires and brake disc assembly at the Checkpoints; Stop the rotating wheels, and mark the lowest (highest) point with the chalk. Verify the most important sector in this way for 2 or 3 times. If the wheel is in balance, it will not stop at one point. In order to keep the wheel in balance, put on weight to it at the higher side of the rim, and mark with the chalk at the other side. Add enough weight to the wheel when it is on rotation until it does not stop at one point. Do not add weight above 60g to the wheel.

- 93 -

 

7.3.2.4 Check the front wheel bearing  Remove the bearing①, and the middle sleeve of the front wheel②. Check the rolling of the bearings. Replace it if the bearing does not roll, or the rolling is unsmooth or unstable, or the it is abraded or loose.

7.3.3 Bearing Replacement Remove the front wheel spindle, front wheel, left spindle sleeve and the middle spindle sleeve. Then remove the oil seal and the bearing respectively with the oil seal remover and the bearing puller. Note: Replace dismantled bearings with new ones.

Lubricate the bearings with grease during installation. Then press the bearings in with bearing installation tools. *Note

• Bearings must be pressed in horizontally.  horizontally. 

游隙 clearance

轴向 axially

径向 radial

7.3.4 Installation Install it in reverse order. order. Note: 

Lubricate the front wheel spindle, left spindle sleeve of the front wheel, bearing 6005-2RS/1-C3, and the middle spindle sleeve. Albany grease is suggested. When tighten the front wheel and the caliper assembly of the disc brake, make sure that the brake disc is  between the brake pads. The free stroke of the front brake lever can not be adjusted. *Note Torque of fixing the front wheel spindle: 100-140N·m

- 94 -

 

7.4 Steering Handlebar 7.4.1 Disassembly Remove the left/right rearview mirror assembly. assembly. Right rearview mirror

Left rearview mirror

Remove the oil pump assembly of the front brake. Remove the right switch group. Remove the mounting base assembly of the throttle cable. Oil pump assembly Mounting base assembly of the throttle Fixing screw Right switch group

Fixing screw - 95 -

 

Remove the left handle assembly. Remove the left switch group. Left handle

Fixing screw Left switch group

Remove the balance block assembly①. Remove the right handle assembly②. Remove the balance block ③.

Remove the fixing bolts② of the upper base of the steering handlebar. Turn the upper base① of the steering handlebar. Remove the tube of the handlebar handlebar..

7.4.2 Installation Install in reverse order. order. Note: Fixing screw of the upper base of the steering handlebar Torque: 22-34N·m

- 96 -

 

7.5 Front Fork 7.5.1 Disassembly Support well the middle bracket of the motorcycle. Disassemble the front wheel. Disassemble the brake caliper and the brake pipe clamp. Remove the steering handlebar. Remove the pillar bolt①.

Remove the meter and the meter bracket. Loosen the fixing bolts①  of the upper connecting  board. Remove the upper connecting board②.

Remove the headlamp and its bracket. Loosen

the

clamping

bolts①  of

connecting board. Remove the front absorber. absorber.

the

upper

- 97 -

 

Tools: Fixing nut spanner. Special disassembly tool for bearing cup.

*Note: The opening of the body guard shall be cleaned with cloth.

The upper/lower bearing cup shall be dismantled with a special disassembly tool for bearing cup.

7.5.3 Installation Note: Make sure that the hole of the front wheel spindle is concentric when installing the left and right absorber.

Steps are contrary to the process of disassembly. disassembly.

Note: Fixing screws for the bottom connecting board:

10N.m

Fixing screws for the upper connecting board:

28N.m

- 98 -

 

Rear Wheel/Rear Suspension A

Tyre size: rear tyre: 180/55 ZR

B

17  Pressure of 290±10kpa  

C

Minimum 2.0mm 

D

Rim run-out limit: Vertically: 2.0mm  Horizontally: 2.0mm 

E F G

the

rear

non-skid

tyre: depth:

Torque for mounting the bolt 2 in the figure: 5-10N·m  Torque for mounting nut 19 in the figure: 37-55N·m   Torque for mounting nut 20 in the figure: 130-150N·m 

1. rear wheel spindle spindle

2. screw screw M6×20

3. right spacer bush of the rear wheel 4. 4. DIA.240 disc brake 5.

 bearing 6006-2RS1-3C 6. spacer bush of the rear wheel 7. valve 8. rear rim 9. vacuum tyre 180/55 ZR17 1.  bearing 6006-2RS1-3C 11. buffer bushing 12. left spindle sleeve of the rear wheel 13. bearing 30×62×23.8 14. spindle sleeve of the sprocket wheel 15. fixing bolt of the sprocket wheel 16. sprocket wheel rim 17. sprocket wheel 18. retaining ring Φ62

19. self -locking -locking bolt M10×1.25

20. self-locking bolt M24×1.5

- 99 -

 

Rear Suspension/Rear Absorbe Absorberr A

Torque for mounting bolt 1

T

in the figure: 70-105 N·m Torque for mounting nut 10 in the figure: 37-55   N·  N·m m

C

Torque for mounting nut 10 in the figure: 37-55   N·  N·m m

1. screw 2. mounting sleeve of the rear swinging arm 3. rolling bearing 61905-2RS 4. straight pin 4×8 5. middle spacer bush 6. mounting sleeve of the rear swinging arm 7. sleeve 8. rear absorber assembly 9. mounting gasket of the rear absorber 10. fixing spindle of the rear absorber 11. nut M10×1.25 12. supporting  board of the brake clamp 13. rear chain cover 14 bolt M6×8 15. bolt M6×1×14 16. chain protecting block 17  bolt M6×1×14 18 front chain cover 19 bolt M6×1×14 20 fixing fixing spindle of the rear absorber absorber

- 100 -

 

8. Rear Wheel/Rear Suspension Preparing Documents --------------------8.1 Failure Diagnosis -------------------------8.2 Rear Wheel --------------------------------8.3 -- ------------------------------8.3 Rear Absorber -----------------------------8.4 Chain Drive-------------------------Drive--------------------------------8.5 ------8.5 Rear Swinging Arm----------------------8.6

8.1 Preparing Documents Work Instructions The surface of the disc brake and the brake shoes shall not be stained with oil spots.

Preparing Principles Item

Standard (mm)

Limit for use (mm)

Rear wheel

Vertically

2.0

shimmy

Horizontally

2.0

Locking torque force Fixing nuts for the rear wheel spindle

130-150N·m 130-15 0N·m

Top bolts for the rear absorber

37-55N· 37-55N ·m

Bottom bolts for the rear absorber

37-55N· 37-55N ·m

Fixing bolts for the rear swinging arm

70-105N· 70-105N ·m

Fixing nuts for the sprocket wheel

37-55N 37-55N··m

Fixing bolts for the rear brake disc

5-10N· 5-10N ·m

8.2 Failure Diagnosis 8.2.1 Rear Wheel Shimmy  

Deformed rim

 

Abraded rear wheel spindle

 

Tyre failure - 101 -

 

 

Abraded or damaged bearings of the swinging arm spindle

 

Incorrect adjustment of the drive chain

 

Unbalanced tires and wheels

 

Too low of the tyre pressure

 

Bending frame or the rear swinging arm

8.2.2 Inflexible Rolling of the Wheel  

Bending rear disc brake

 

Abraded bearings of the rear wheel spindle

 

Too tight of the drive chain

8.2.3 T  Too oo Soft of the Suspension  

Insecure or shaking damping spring

 

Incorrect front suspension regulator

 

Oil leakage of the absorber

 

Too low of the tyre pressure

8.2.4 Too Stiff of the Suspension    

Damaged assembly bearing of the absorber Bending tube of the absorber

 

Damaged bearing of the rear swinging arm axis

 

Bending of the rear swinging axis

 

Fault in the suspension regulator

 

Too high of the tyre pressure

8.2.5 Operation Only Available Available in One Side or Move in Curve    

Bending rear wheel spindle

 

Incompetent of the axle arrangeme arrangement/chain nt/chain regulator on both sides

8.3 Rear Wheel 8.3.1 Disassembly Support the motorcycle firmly with the rear wheel above the group.

- 102 -

 

Caliper of the rear disc brake Fixing screws of the caliper of the rear disc brake

Adjusting screw of the rear wheel Remove the caliper of the rear disc brake. Loosen the adjusting screws of the rear wheel.

Remove the nuts of the rear wheel spindle and left adjusting block of the chain.

 Nut of the rear wheel wheel spindle

Left chain adjusting block Adjusting screw of the rear wheel

Remove the rear wheel spindle and the right adjusting block of the chain.

后轮：rear wheel 后液刹盒：rear disc brake box 固定螺钉：fixing screws 后轮轴：rear wheel spindle

Take the chain off the big sprocket wheel.

Chain

Big sprocket

- 103 -

 

Remove the rear wheel assembly.

Remove the supporting board of the brake clamp.

Supporting board of the brake

Remove the sprocket wheel assembly assembly.. Remove the fixing bolts of the sprocket wheel.

Fixing bolts of the sprocket

- 104 -

 

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. indicator. Limit for use: Vertically: replacement when beyond 2.0mm Horizontally: replacement when beyond 2.0mm 

When the rear wheel indication goes beyond the limit for use, the rear wheel bearing is loosened leading to the rear wheel shimmy. shimmy. Replace the rear wheel bearing after check.

8.3.3 Installation Install the rear wheel in reverse order, and lock the nuts. Fixing nuts for the rear wheel spindle Torque force: 130-150 N·m

- 105 -

 

8.4 Rear Absorber 8.4.1 Disassemble the Rear Absorber Remove the upper/lower fixing nut of the rear absorber. Remove the rear absorber.

8.4.2 Check the Rear Absorber Visually Visuall y inspect of the absorber for damage. Check the following items:  —— whether whether the absorber tube is bent or damaged  —— w whether hether the absorber has signs of deformation or oil leakage  —— whether whether the rubber block is abraded or damaged.  —— whether whether the spring is damaged Check all other parts for damage or abrasion If necessary, replace the absorber

8.4.3 Install the Rear Absorber Install it in reverse order. order. Install the upper fixing nut and lower fixing bolt of the rear absorber. Lock to the specified torque force.

- 106 -

 

Fixing bolts Torque force: 37-55 N·m

- 107 -

 

8.5 Chain Drive 8.5.1. Disassembly Put the motorcycle on level ground, and firmly support it. Remove the left rear cover. Fixing bolt of the left rear cover

Engine left rear cover

Disassemble the rear wheel, rear absorber, the drive chain shade and drive chain.

8.5.2 Check Meas Me asur uree tthe he le leng ngth th of ten ten cha chain in link linkss

,

if the length doesn’t meet the specified value, replace the drive chain. The limit value of the length of ten chain links is 1587.5mm.

- 108 -

 

* Note:

• Measure after stretching the chain by hand. • Range from chain link roller (1) to the inside of roller  (11).  (11). • Measure the length of ten chain links.  links.   • Measure the length of ten chain links of different parts 2 2-3 -3 times. Clean the drive chain, put it into the kerosene, and wash off the dust as much as possible, then take the chain out of kerosene and dry it.

Check the rotor ① and side panels ②, if damaged or frayed, replace the drive chain. The lubricant for drive chain can be purchased from the shop to lubricate the drive chain.

Check the hardness of drive chain, clean, lubricate or replace it if hard.

- 109 -

 

Check the drive sprocket and driven sprocket. If one-fourth of the teeth of a cogwheel

is frayed,

replace the sprocket, the bending of the teeth of a cogwheel also requires the replacement of sprocket.

8.5.4. Installation Install it in reverse order. order. Fixing nuts Torque force: 37-55 N N··m Note:

Adjust the laxation degree of the drive chain and the free stroke of the brake pedal. If the laxation degree of the chain is too small, engine and other vital parts will be overloaded. The laxation degree of the chain should be kept within the prescribed limit value.

8.6 Rear Swinging Arm 8.6.1 Disassemble the Rear Swinging Arm Put the motorcycle on level ground, and firmly support it. Disassemble the rear wheel. Disassemble the lower fixing nut of the absorber. Disassemble the bolt and drive chain shade.

Disassemble the fastening bolt of the swinging arm spindle from the frame. Disassemble the rear swinging arm spindle and rear swinging arm assembly.

- 110 -

 

Disassemble the rear swinging arm spindle bearing and the rear swinging arm spindle

8.6.2 Check the Rear Swinging Arm Check the rear swinging arm mounting spindle, rotate the spindle on a flat surface or measure with a dial indicator, if  bent, replace it. *Note

Don’t attempt to straighten the spindle already bent. Clean the parts of the rear swinging arm mounting spindle in the solvent.

Rear swinging Rear  swinging arm 

 

Check the sleeve of the rear swinging arm and the middle sleeve, if damaged, replace them.

Check the bearing for the damage Use your finger to rotate in the inner bush of the right-pivot  bearing The bearing shall rotate smoothly and steadily, and the installment of the bearing's outer ring on the wheel hub should be checked for security If the ring can not rotate smoothly and steadily, steadily, or it is flexible in installation on the pivot, please disassemble and discard it

8.6.3 Install the Rear Swinging Arm Install it in reverse order. order. Spindle bush of the pivot should be greased,  Note: Bolts for the rear swinging arm spindle Torque force: fo rce: 70-105N·m 70 -105N·m

Bearing

- 111 -

 

Fuel Tank Gasoline   capacity of the  Gasoline the  A

gasoline tank: 15 0.2L

B

Torque force of bolt 3: 5 10N m

D

E

F

Torque force of bolt 6: 5 10N m

Torque force of bolt 9: 5 10N m

Torque force of bolt 12: 5 10N m

22 37N m

1.fuel tank body assembly assembly

2.gasket 6.4×12.5×1.6

6.petrol pump screw

3.bolt M6×70

7.fuel pipe assembly

4.fuel pump seal gasket

8.filter assembly

9.bolt M6

5.fuel pump

10.gasket 5,3×10×1

11.oil level sensor assembly 12.bolt M6×25 bolt M6×25 13. rubber gasket tube 14.fuel tank front mounting pad 15.fuel tank front mounting board 16.bolt M8×1.25×20 17.fuel tank cover support assembly

18.fuel tank lock

19.socket head cap screw M5×30

20.socket head cap screw M5×14

21.fuel

tank cover seal gasket - 112 -

 

9. Fuel Tank Preparing Documents -----------9.1 Failure Diagnosis -----------9.2 Fuel Tank -----------------9.3 9.1 Preparing Documents

Work Instructions: It shall be dismantled far from fire sources. Tighten all the bolts and screws to the required torque value for assembly. After assembly, assembly, check whether all the parts are correctly installed and operated.

Preparing Principles Item

Standard

Limit for use

Gasoline tank capacity

15±0.2L

/

Tightening Tight ening torque force  Front fixing bolts for the gasoline tank

22-37N·m 22-37N·m

Rear fixing bolts for the gasoline tank

5-10 N·m N·m

Fixing bolts for the fuel tank front mounting pad

5-10 N·m N·m

Fixing bolts for the fuel pump

5-10N· 5-10N·m m

Fixing bolts for the oil level sensor

5-10N· 5-10N·m m

9.2 Failure Diagnosis

9.2.1 Decreasing Gasoline    Natural consumption of gasoline  

Leakage of gasoline

- 113 -

 

9.3 Fuel Tank

9.3.1 Disassembly Remove the rear seat and the front seat Remove the upper body of the fuel tank.

Remove the front fixing bolt of the fuel tank.

Remove the high-pressure oil pipe assembly assembly.. Remove the fuel pump connector jacket. Remove oil level sensor connector jacket

Oil level sensor   Fuel pump High-pressure oil pipe assembly  Fuel pump connector jacket  Oil level sensor connector jacket 

Front fixing bolt of the fuel tank. 

- 114 -

 

Remove the rear fixing bolt of the fuel tank.

Rear fixing bolt of the fuel tank

Remove the fuel tank.

9.3.2 Installation Install it in reverse order. order.

Torque force for mounting: Front fixing bolts for the gasoline tank

22-37N· 22-37N ·m

Rear fixing bolts for the gasoline tank

5-10 N· N·m m

Fixing bolts for the fuel tank front mounting pad

5-10 N·m

Fixing bolts for the fuel pump

5-10N· 5-10N ·m

Fixing bolts for the oil level sensor

5-10N·m

- 115 -

 

10. Disassembly and Installation of Engine Preparing Documents -------------10.1 Disassembly and Installation of Engine ----------10.2

10.1 Preparing Documents Work Instructions It shall be dismantled far from fire sources. Tighten all the bolts and screws to the required torque value for assembly. After assembly, assembly, check whether all the parts are correctly installed and operated. 

Locking torque force Gearshift rod bolt:

10N.m

Engine fixing bolt:

50N.m

10.2 Disassembly of Engine Support the motorcycle firmly to make its rear wheel above the ground.

- 116 -

 

Unscrew the clamp of the engine water pump inlet/outlet, remove the cooling water-pipe and exhaust the coolant

Disassemble the front and rear seats Disassembly of the rear seat

Insert the key into the guard lock, and open it clockwise; Slightly push the back of the rear seat with your right hand, pull the rear seat upwards and  backwards Remove the rear seat;

Disassembly of the front seat

Remove the rear seat; Hold the front seat cable with hands; Slightly push the back of the front seat with your left hand, pull the front seat upwards and  backwards Remove the front seat;

Note:

Confirm the left and right limits are set at  positions when installing the front seat.

- 117 -

 

Disassemble the fuel tank assembly

See 9.3.1 Disassembly of the fuel tank

Disassemble the air filter assembly Disassemble the air filter fixing bolt Disassemble the air filter hoop Disassemble the connector jacket of the intake air temperature sensor; Disconnect the breather rubber pipe from the vent of cylinder cover; Remove the air filter Note:

The stepper motor of the throttle body should be set well to position when installing the air filter. Disassemble the throttle body assembly

Remove the throttle cable assemblyI and throttle cable assembly II; Disassemble four throttle body hoops in 1-2-4-3 order; Remove the connector jacket of the intake air  pressure sensor. sensor. Remove the ejector connector jacket; Remove the connector jacket of the idle stepper motor; Remove the canister desorption rubber pipe; Remove the intake oil pipe;

Remove the throttle body assembly 

Note:

Confirm the throttle cable assemblyI and throttle cable assemblyII are set at positions; Confirm the oil pipe is connected well to place without oil leakage after the correct installation of the throttle body assembly. assembly. Confirm the electric components are connected at

 positions; - 118 -

 

Disassemble the canister assembly

Canister assembly 

Disassemble the clutch steel rope assembly

Clutch steel rope assembly 

Disconnect the battery wire, disassemble the starter motor wire and the ground wire Disassemble the FBT connector jacket, rectifier and  outlet water temperature switch connector  jacket

Battery wire 

- 119 -

 

Disassemble the anterior segment of muffler exhaust  pipe

Disassemble the radiator filler, water tank, and disconnect the fan switch connector jacket Disconnect the crankshaft position sensor, neutral switch connector jacket

Disconnect the single-kickstand flameout switch connector jacket and disassemble the single-kickstand flameout switch

Single kickstand flameout switch flameout switch  

- 120 -

 

Disassemble gearshift lever swing arm and the left cover of the engine Disassemble the small sprocket and detach the chain from the sprocket

Release the engine fixing bolt and lift the engine

- 121 -

 

10.3 Installation of the Engine Install it in reverse order. order.  Note:  

Place an appropriate holder under the frame in case of rollover when disassembling the engine.

 

Engine fuel: 3.2L when assembling.

 

Start the engine and check it for abnormal vibration, noise and engine lubrication.

 

After the engine works properly at idle speed for a period of time, turn the throttle handle to maximum level, then completely relax the throttle handle, at this time if the idle speed changes, it shows that the throttle cable hasn’t been regulated well. Therefore, attention attenti on should be given to the regulation in this regard prior to the testing the engine.

 

Checking method of engine fuel a. 

Pull out the fuel rod, wipe it off with a clean cloth.

 b. 

Insert the rod into the oil and remove it to check the oil level, if the oil level is lower than the lowest limit, increase the fuel.

c. 

Heating up for 5 minutes and cooling for 3 minutes, then check the oil level again, if the oil level is lower than the lowest position, increase the fuel.

d. 

The oil level should always be kept between the lowest limit and the toppest limit.

- 122 -

 

Inspection and Maintenance of Engine Table of Torque Force of Fasteners Name of fastening parts and fasteners 

Tightening torque (N·m) 

Magnetic bolt M14

20~25

Oil pan bolt M6

10~12

cylinder double-end bolt Flywheel locking bolt

 

60~62 100~110

Gearshift  positioner bolt M6

10~12

Crankcase bolt M6

10~12

Crankcase bolt M8

22~24

Crankcase bolt M10

35~39

Connecting rod bolt

23~27

Left/right crankcase cover bolt M6

10~12

Flywheel bolt M8

20~24

Fuel filter

18~22

Fuel filter connecting bolt

40~45

Fuel filter bolt M14

40~45

Round nut M20

95~105

Clutch release plate bolt M6

10~12

Cylinder cover shade bolt M6

10~12

Camshaft sprocket bolt M7

20~25

Fuel pump bolt M6

10~12

Gearshift positioning plate bolt M6

10~12

Spark plug

22~25

- 123 -

 

11. Lubricating System Preparing Documents ------------11.1 ------------11.1 Failure Diagnosis ------------1 ------------11.2 1.2 Fuel Pump ---------------11.3 ---------------11.3

11.1 Preparing Documents 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.

Work Instructions:

Clean all parts carefully and blow the parts surface clean with high-pressure gas after disassembly of the fuel  pump. Foreign matter shall not fall into the crankcase when the carburetor is disassembled Standard of benchmark items and table of limit for use

Item

Standard

Limit for use

When oil change

3.0L

＿ 

When disassembling The radial clearance between

3.2L

＿ 

0.04-0.11mm

0.15mm

0.04-0.11mm

0.15mm

Fuel capacity

Fuel pump rotor

inner and outer rotors The clearance between outer rotor and pump body

11.2 Failure Diagnosis Decreasing fuel

Burnt engine

 Natural consumption of fuel Fuel leakage

No fuel pressure or low low fuel pressure Blocked fuel pipes

- 124 -

 

11.3 Fuel Pump 11.3.1 Disassembly 

Remove the clutch cover, loosen the fuel pump fixing bolt, take down the fuel pump drive sprocket and the fuel pump drive chain.

Fuel pump chain  Screw Fuel pump drive sprocket 

Remove the screw. Remove the fuel pump body body.. Screw Fuel pump body 

Remove the screw, take down the fuel pump cover, and decompose the fuel pump.

Screw

Fuel pump cover  

- 125 -

 

Check the radial clearance between inner and outer rotors Limit for use: 0.15mm. Gauge

Check the clearance between outer rotor and fuel pump cover Limit for use: 0.15mm.

Gauge

- 126 -

 

11.3.2

Assembly of Fuel Pump Fuel pump

As shown below

drive sprocket

Fuel pump cover

Outer rotor

Inner rotor

Pump body

Pump shaft

 Note: After After the combination, combination, the inner and outer rotors rotors should rotate flexiblely without stagnation. Installation

Install it in reverse order. order.

- 127 -

 

11.3.3 Lubricating Systematic Drawing

Piston cooler

排气凸轮轴--- exhaust camshaft

进气凸轮轴--- intake camshaft

活塞冷却器---piston cooler

机构--- crankshaft connecting rod mechanism 主油道--- main oil channel ---main shaft

机油泵--- fuel pump 机油滤清器--- fuel filter

valve 副轴---countershaft

曲轴连杆

  oil cooler

油冷器---

 

主轴

机油集滤器--- fuel strainer 溢流阀--- relief

- 128 -

 

- 129 -

 

12. Cylinder Head Preparing Documents --------------------12.1 Failure Diagnosis -------------------------12.2 Cylinder Head / Valve--------------------12.3

12.1 Preparing Documents Function of the cylinder head: The cylinder head is used to seal the cylinder and form the combustion chamber with the piston. It bears HPHT gas, and achieves air intake and exhaust through distribution mechanism. Work Instructions:

The cylinder cover bears large bolt pretension to ensure sealing between the cylinder head and the upper cylinder block. Pretension: 12 N·m, torque force: 60 N ·m. All components must be cleaned and dried with high-pressure air before check. Unit: mm 

Standard of benchmark items and table of limit for use Item

Standard

Limit for use

Flatness of cylinder cover  

0.03

0.05

Intake

013-0.19

__

Exhaust

0.19-0.25

__

Intake

3.97-3.98

3.96

Exhaust

3.97-3.98

3.96

Inner diameter of valve catheter  

Intake Exhaust

4.03-4.04 4.03-4.04

4.07 4.07

Clearance between valve stem

Intake

0.05-0.07

0.11

and valve catheter  

Exhaust

0.05-0.07

0.11

Intake

1.0-1.1

1.5

Exhaust

1.0-1.1

1.5

Intake

38.8

37.3

Exhaust

41.6

40.1

0.041-0.054

0.08

Valve gap

Outer diameter of valve stem  Valve Valve catheter

Width of valve seat

Valve spring

Camshaft 

Free length

Fitting clearance between camshaft and

12.2 Failure Diagnosis

cylinder head 

Low compression pressure

Noise in Cylinder head

Valve clearance maladjustment maladjust ment

Valve clearance maladjustment maladjust ment - 130 -

 

Burnt or bent valve

Damaged valve spring

Poor air-tightness of valve seat

Over high compression pressure

Cylinder head gasket leaks gas

Too much carbon fouling in the combustion chamber. chamber.

Poor installation of spark plug

- 131 -

   

12.3 Cylinder Head 12.3.1 Disassembly Remove the ignition coil. Loosen six locating bolts, remove the gasket and cylinder cover shade.

Cylinder

Locating bolt

Loosen the fastening bolt, and remove the air-distributing chain regulator.  Fastening bolt Air-distributing chain regulator

Loosen the four sprocket bolts of the camshaft.

Sprocket bolt of the camshaft

Measure the fitting clearance between camshaft and cylinder head. Limit for use: 0.08mm.

Gauge

- 132 -

 

Loosen the camshaft holder.

Camshaft holder

Remove the camshaft, camshaft sprocket and chain.

Camshaft

Camshaft chain

Camshaft sprocket

Guide chain  plate

Cylinder cover Loosen the cylinder cover locking bolt. Remove the cylinder cover. Remove the top stem, compress the valve spring with valve spring compression tools, and remove the valve block. Remove the valve adjusting gasket, valve spring, valve spring upper/lower seat and valve.

- 133 -

 

12.3.2 Cam Assembly Breakdown

Seal cover D13 

Camshaft

Bolt

Camshaft sprocket

12.3.3 Valve Breakdown

Valve

Valve spring

Valve block  

lower seat

Valve spring 

Valve spring upper seat

Valve adjusting gasket

Ruler

Check

Gauge

Eliminate carbon deposit in the cylinder cover. Measure the flatness of the joint surface of the cylinder cover cover.. Limit for use: 0.05mm. When the flatness of the joint surface of cylinder cover exceeds the limit for use, place the fine-sand paper on the flat  plate, with the joint surface of cylinder cover fitting the sand  paper, and and mill it according to 8-shape. 8-shape.

Top stem

- 134 -

 

Vernier calipers Measure the free length of valve intake/ exhaust spring. Limit for use: intake spring: 37.3mm. exhaust spring: 40.1mm.

Measure the outer diameter of the valve stem. Limit for use: intake valve 3.96mm exhaust valve 3.96mm

Micrometer

Check the valve catheter after eliminating the carbon deposit in it with a reamer.  Note: The reamer reamer should be rotated clockwise, and mustn’t be rotated anti-clockwise.

Tester Measure the inner diameter of each valve catheter catheter.. Limit for use: intake/ exhaust: 4.07mm. Limit for use of the clearance between valve and valve catheter: Intake valve: 0.11mm. Exhaust valve: 0.11mm.

- 135 -

 

Screwdriver 12.3.4 Replace the Valve Catheter  Note: When the clearance between valve and valve catheter exceeds the limit, replace the valve catheter catheter.. After the replacement, replacement, trim the surface of the valve seating. Put the valve catheter in the freezer of the refrigerator to cool for one hour. Heat the cylinder head to 100-150 ℃ with an electric furnace or a hot oven. Fix the cylinder head, disassemble the valve catheter from the upper side of cylinder head with valve catheter disassembly tools.

Put a new o-ring on the new valve catheter. catheter. Install the valve catheter from the top of the cylinder head.  Note: The cylinder head shall not be damaged when installing the valve catheter.

After inserting the valve catheter, trim with a valve catheter reamer.  Note: Add proper amount of cutting oil when cutting with an reamer.. And the reamer should be rotated clockwise. reamer

Eliminate the carbon deposit in the combustion chamber and valve, clean thoroughly the intake/exhaust valve. Check the width of the contact surface of the valve seat (width of the valve seating).

Valve reamer

Limit for use: intake/ exhaust: 1.5mm.

Contact surface of the valve seat 

- 136 -

 

12.3.5 Trim of Valve Seating

Rugged part

Remove the rugged or ragged parts of the valve seating surface with a milling cutter at 45°angle.  Note: Coat a transparent or prussian-blue cladding on the valve seating to get a better view.

Remove 1/4 of the outer end of valve seating with a milling cutter at 25°angle.

25° 

Remove 1/4 of the bottom of valve seating with a milling cutter at 60°angle. Take down the milling cutter and check the  parts treated.

60°

Grind the valve seating with a refining milling cutter at 45°angle to achieve the proper width. All dents and ragged parts must be removed.

1.0mm

Standard width of the valve seating: intake: 1.0mm exhaust: 1.0mm

45°

- 137 -

 

If the contact is the part where the valve is too high, please lower the valve seating with a flat milling cutter at 25°angle.

High contact surface

If the contact is the part where the valve is too low, raise the valve seating with a inner milling cutter at 60°angle.

25°

Refine the valve seating again with a refining milling cutter

 

at 45°angle to meet the specifications required.

Low contact surface

After grinding the valve seating, please coat the polish on the surface of valve to gently polish the valve.

60°

12.3.6 Installation Install it in reverse order. order.  Note: When installing the valve spring, the end with smaller pitch of the spring shall be installed towards the combustion chamber. chamber. When installing the valve collet, install it by compressing the valve spring with valve spring compression tools When installing the valve, the surface of the valve stem shall be coated with proper amount of fuel prior to installing to the valve catheter.

- 138 -

 

- 139 -

 

13. Crankcase Preparing Documents--------------Documents------------------------------------------------------------------------------------13.1 --------13.1 Failure Diagnosis--------------------------------------------------------Diagnosis-----------------------------------------------------------13.2 --13.2 Upper Box-------------------------------Box---------------------------------------------------------------------------------------------------13.3 --13.3 Piston------------------------------------------------------------------------13.4 Lower Box---------------------------------Box------------------------------------------------------------------13.5 --------------------------------13.5 Clutch-----------------------------------------------------------------------13.6 Variable Speed Gear Transmission-----------------------------------Transmission---------------------------------------13.7 ---13.7 Camshaft Connecting Rod Assembly-------------------------------------13. Assembly-------------------------------------13.8 8

13.1 Preparing Documents Function of the upper box: The cylinder block in the upper box provides space for gas compression, combustion and expansion, and also guides piston movement. It also transfers part of heat energy in the cylinder to cooling medium around.

Function of the piston: 1. It bears pressure arising from mixed gas combustion inside the cylinder and transfers such pressure to the connecting rod for driving the crankshaft. 2. It forms combustion chamber along with the cylinder cover.

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 cover, 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.

Work Instructions: - 140 -

 

All components must be cleaned and blown with high-pressure gas before test.  The crankcase is thin-section casting thus shall not suffer impact during operation which may cause deformation or fracture. Lubricant in the crankcase should be drained out before operation.

- 141 -

 

Standard of benchmark items and table of limit for use Item

Standard

Limit for use

Cylinder I 65 (0.025, 0.03)

65.100

Cylindricity of the cylinder

Cylinder II 65 (0.03, 0.035) 0.008

65.110 0.050

Roundness of the cylinder

0.006

0.050

Flatness of the cylinder

0.03

0.05

Diameter of the cylinder

Outer diameter of piston (measured in piston skirt)

Upper box

Piston I 65 (-0.03, -0.025)

64.90

Piston II 65 (-0.025, -0.02)

64.91

Inner diameter of piston pin hole

16 (0.002, 0.008)

16.04

Outer diameter of piston pin

16（-0.008, 0） 

15.96

0.002-0.016

0.04

Ring 1

0.05-0.09

0.11

and ring groove

Ring 2

0.04-0.08

0.11

Joint gap of the piston ring

Ring 1 Ring 2

0.15-0.30 0.25-0.45

0.5 0.65

Fuel ring

0.20-0.70

1.0

16 (0.016, 0.034)

16.04

Clearance between connecting rod and piston pin

0.016-0.042

 —  

Thickness

1.5 (0-0.09)

1.48

0.025-0.05

0.065

0.1-0.25

0.5

end of the connecting rod

0.008-0.016

0.05

Thickness

1.5 (0-0.012)

1.44

0.03-0.05

0.07

2.8 (-0.05, +0.05)

2.45

3（-0.1, 0） 

2.6

24.3（-0.15, +0.15） 

22.8

23.5（-0.2, +0.2） 

22.4

Outer diameter of fork shaft

11.973-11.984 11.973-11.984

11.96

Diameter of fork inner hole

12-12.018

12.03

Thickness of fork

5.80-5.90

5.75

Outer diameter of gearshift drum Width of gearshift drum lock

41.9-42.1

41.5

Clearance between piston pin hole and piston pin Clearance between piston ring

Inner diameter of the smaller head of connecting rod.

Connecting-rod

Clearance

 bearing

connecting-rod

between bearing

the and

crankshaft Left-right clearance of the larger Connecting rod

Main-shaft

Radial clearance of the larger

Clearance between main shaft

 bearing

Lower box

end of the connecting rod

and crankshaft Thickness of friction disc

Clutch Length of pressure spring

Variable speed transmission

gear

5.45 5.55

groove

5.65

- 142 -

 

13.2 Failure Diagnosis Low compression pressure Abrasive, burnt or ruptured piston

White smoke from the exhaust pipe Abrasive or damaged piston ring

Abrasive or damaged cylinder or piston

Abrasive or damaged cylinder or piston

Damaged spacer or crankcase leakage Over-high compression pressure

Abnormal noise of the piston

Too much carbon deposit in the combustion chamber

Damaged cylinder, cylinder, piston or piston ring Abrasive piston pin hole and piston pin

Low compression pressure

Abnormal noise in the crankcase

Crankcase leakage

Loose or broken parts inside the crankcase

Engine overheating

Engine automatic stopping

Clutch slipping Poor lubricating

Seized clutch

Not in gear

Gear skip shift

Broken or deformed variable speed spee d fork

The clutch isn’t completely released  released 

Broken fork guide pin

Abnormal transmission return spring

Abrasive gear convex claw

Abrasive gearshift drum lock groove

Out of gear automatically

Abrasive joint claw, round edge Decreasing elasticity of variable speed gear return spring Abrasive spline gear of spline shaft and spline groove of sliding gear, leading to higher axial force when the gear works Abrasive gearshift drum and fork

- 143 -

 

13.3 Upper Box BJ465MS/QJ465MS Engine cylinder block  Namely it is part of the upper box.

Upper box 

Check

Check the abrasion of the inner wall of the cylinder. If it is serious, replace it.

Spacer Remove the spacer and locating pin.

Locating pin

- 144 -

 

13.4 Piston 13.4.1 Disassembly Remove the retainer ring of the piston pin. Note: during assembly, do not make the retainer ring fall into the crankcase.  Remove the piston pin and the piston.

Retainer ring of the piston  

Piston pin 

Remove the piston ring. Check the piston, piston pin and piston ring. Note:

Do not rupture or damage the piston ring. Eliminate carbon deposit in the groove of the piston ring.

Install the piston ring. Measure the clearance between piston ring and piston ring groove. Limit for use: ring 1: 0.11mm. ring 2: 0.11mm.

Piston

Piston ring

Gauge

Push into

- 145 -

 

Remove the piston ring, and install each piston ring on the cylinder bottom. Note:

Press the piston ring into the cylinder with piston head. Measure the joint gap of the piston ring. Limit for use: ring 1: 0.5mm. ring 2: 0.65mm.

Piston ring

Gauge

Measure the inner diameter of the piston pin hole. Limit for use: 16.04mm.

Tester

Measure the outer diameter of the piston pin. Limit for use: 15.96mm. Clearance between piston pin hole and piston pin. Limit for use: 0.04mm.

1 2 3

- 146 -

 

Measure the outer diameter of the piston I and piston II. Note:

90° 

The measuring point shall be at 90°with the piston pin, and at the piston skirt.

11mm

Limit for use of the piston I: 64.90mm. Limit for use of the piston II: 64.91mm.

Check whether cylinder I/II inner wall 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 of the cylinder c ylinder I: 65.100mm. Limit for use of the cylinder c ylinder II: 64.110mm.

Tester

Measure the roundness of the inner wall of the cylinder (inner

In

diameter difference at X direction and Y direction).

 

Limit for use: 0.050mm. Measure the cylindricity of the inner wall of the cylinder

Top

(inner diameter difference at the top, middle and bottom  points of X direction and Y direction). direction).

Ex

Middle

Limit for use: 0.050mm. Bottom

- 147 -

 

Check the flatness of the cylinder surface.. Limit for use: 0.05mm.

Ruler

Gauge

Upper box

Measure the inner diameter of the smaller end of the connecting rod. Limit for use: 16.04mm.

Inner diameter of smaller end of connecting rod

the the

Tester

Measure the clearance between connecting-rod bearing and crankshaft. Limit for use: 0.065mm.

Connecting-rod bearing 

- 148 -

 

Measure the clearance between main shaft bearing and crankshaft. Limit for use: 0.07mm.

Main shaft bearing 

Plastic gauge

13.4.2 Piston Installation

Top ring

Install the locating pin. Apply fuel to each piston ring and piston. Install the piston

Ring 2

ring in place.

Fuel ring 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.

- 149 -

 

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:

The dot mark on the top of the piston shall be installed towards the intake valve.

Dot mark

- 150 -

 

13.5 Lower Box 13.5.1 Disassembly of the Crankcase Left Cover Lossen the fixing bolt of starter motor, remove the starter motor. Lossen the bolt of the crankcase left cover. Remove the left cover. Remove the electric starting bear bear,, needle bearing and spacer.

Motor idle gear Starter motor  

Locating pin hole  

Remove the starter motor idle gear. gear. Remove the spacer and locating pin hole. Loosen the flywheel locking nut with the electric or pneumatic tool. Pull the flywheel assembly (including the star wheel )

Flywheel assembly

- 151 -

 

13.5.2 Disassembly of the Clutch Cover Loosen the fixing bolt, and remove the clutch cover.

Bolt

Clutch cover

Remove the clutch release stem from the right cover.

Right cover

Release stem assembly

Remove the fixing bolt, clutch, gearshift arm assembly and fuel pump sprocket. Remove the spacer and locating pin.

Clutch assembly

Gearshift arm assembly

Fuel pump sprocket Driven gear

- 152 -

 

Loosen the locking nut with the electric or pneumatic tool, and remove the clutch. Loosen the fuel pump screw, and remove the fuel pump gear.

Gearshift drum assembly Fuel pump chain

Fuel pump sprocket

- 153 -

 

13.6 Clutch 13.6.1 Disassembly Unscrew the four bolts of the release plate in diagonally staggered sequence sequence.. Loosen the clutch nut. Remove the sleeve, bearing, release plate and the clutch spring. See the breakdown drawing for the disassembly of parts. .

Release plate bolt

Clutch nut

Unscrew the clutch locking nut with the special tool, and remove the locking nut and gasket. Remove the center holder of clutch. Remove the clutch disc and friction disc. Remove the clutch pressure plate. See the breakdown drawing for the disassembly of  parts. Remove the spline gasket. Remove the shell assembly. assembly.

Four-claw socket spanner   Universal holder  

Shell assembly 

Install it in reverse order. order.

- 154 -

 

13.6.2 Clutch Breakdown

滚针轴承---needle bearing 轴套---sleeve 垫片---spacer 主动毂组件---drive hub assembly 从动毂---driven hub 摩擦片---friction disc 离合器片---clutch disc 碟形弹簧---dish-shaped spring 垫圈---gasket 主动毂座

组件---drive hub housing assembly 压力弹簧---pressure spring 压板---pressure plate 螺栓---bolt 承--- rolling bearing 

滚动轴

- 155 -

 

13.6.3 Check Check the shell groove for burrs and brakeage, if trimmed excessively by the file, replace it. Check the pressure plate and the tooth profile of the center holder for damage, if damaged, replace it.

Drive hub assembly 

Driven hub 

Measure the free length of the pressure spring. Limit for use I: replace it if lower than 22.8mm. Limit for use II: replace it if lower than 22.4mm.

Free length Measure the thickness of the friction disc with vernier calipers. Limit for use I: replace it if lower than 2.45mm. Limit for use II: replace it if lower than 2.6mm.

Thickness

- 156 -

 

13.7 Gearshift Mechanism 13.7.1 Disassembly Remove the gearshift shaft assembly. Remove the bolt and gearshift locating plate. Remove the bolt, stop arm and spring. Remove the locating pin. See the breakdown drawing for the disassembly of  parts.

Gearshift shaft assembly

13.7.2 Gearshift Shaft Mechanism Breakage

Fork shaft spring 

Fork  

Fork shaft 

Pressure plate  Gearshift drum 

Gearshift arm assembly 

13.7.2.1 Check

Gearshift drum bearing 

Ratchet

Before the breakage, the gearshift plate should flexibly return without being seized. Check the gearshift plate and gearshift shaft assembly for abrasion. If heavily abrasive, replace the assembly. Check the gearshift locating plate for abrasion, If heavily abrasive, replace the assembly. assembly. - 157 -

 

Check whether the gearshift shaft is bent, if excessively bent, replace it. Check the return spring for decreasing elasticity, elasticity, if necessary, necessary, replace it.

- 158 -

 

Loosen the crankcase bolt. 

Upper box

Separate the crankcase.

 Note: Do not damage the the spacer and crankcase crankcase surface. surface. Remove the upper box.

Crankcase bolt

Lower box

Main shaft assembly

Countershaft assembly

Remove the main-/ countershaft.  Loosen the pressure plate bolt, and remove the pressure plate. Pull the fork shaft. Remove the gearshift drum. Remove the gearshift fork.

Gearshift drum  Fork

Fork shaft

- 159 -

 

13.7.2.2 Check

Fork shaft

Measure the outer diameter of the fork shaft. Limit for use: 11.96mm.

Micrometer

Measure the inner diameter of the fork hole. Limit for use: 12.03mm.

Tester

Vernier calipers 

Measure the thickness of the fork. Limit for use: 5.75mm.

Width of the lock groove  Measure the outer diameter of the gearshift drum. Limit for use: 41.5mm. Measure the width of the gearshift drum locking groove. Limit for use: 5.65mm.

- 160 -

 

13.8 Crankshaft Connecting Rod Assembly Chamber and Variable Speed Chamber

Depository for the main shaft Depository for the crankshaft connecting rod

Gearshift chamber   

Depository for the countershaft

- 161 -

 

Countershaft assembly

Main shaft assembly Gearshift drum assembly

Gearshift arm assembly

Fork shaft

- 162 -

 

13.8.1 Crankshaft Connecting Rod Assembly 13.8.1.1 Disassembly Remove the upper box. Remove the spacer and locating pin. Remove the crankshaft connecting rod assembly from the lower box.

Countershaft assembly 

Main shaft assembly

 Note: Do not damage the the spacer and crankcase crankcase surface. surface.

Drive gear

- 163 -

 

13.8.1.2 Check

Measure the left-right clearance of the larger end of the connecting rod. Limit for use: 0.5mm.

Measuring

point

at

the

clearance between the larger end of the connecting rod 

Measuring point at the larger end of the connecting rod  Measure the clearance of the larger end of the connecting rod (X-Y direction). Limit for use: 0.05mm.

- 164 -

 

13.8.1.3 Assembly Assemble in reverse order of breakdown and disassembly. disassembly. Remove the main shaft assembly Remove the countershaft assembly. assembly.

13.8.2 Main-/Counter Shaft Breakdown 13.8.2.1 Main-/Counter Shaft Breakdown

Main shaft assembly 

- 165 -

 

Countershaft assembly

13.8.2.2 Check Check the abrasion of gear surface and driving-claw point of the gear respectively respectively.. If it is seriously abraded or damaged, replace it.

Gear surface Check whether the bearing and oil seal are damaged, If yes, replace it.

Driving claw Note:

Removed bearing cannot be used any more. It shall be replaced. Use special tools to dismantle the bearing and the oil seal.

13.8.2.3 Main-/Counter Shaft Assembly Note:

Lubricate all gears and shafts with grease when assembling. Ensure all gears without being seized after assembling.

Note:

Install the crankcase in reverse order. - 166 -

 

14. Cooling System Preparing Documents -------------------------14.1 Failure Diagnosis ------------------------------14. ------------------------------14.2 2 Water Pump ------------------------------------14.3

14.1 Preparing Documents Function of the cooling system:

The cooling method of the engine is wa water ter cooling. W Water ater cooling, in which which the water is used as

the heat

conductor, is a method of cooling high-temperature components and then transferring heat to the outside air, thus keeping the engine working under the optimum temperature.

Specific cooling circuit:

The cooling water entering from the crankcase goes to the cylinder water jacket through the water channel of crankcase, then goes upward through the cylinder cover, finally enters into the radiator through the pipe to - 167 -

 

dissipate heat, and transfers heat to the outside air with the help of radiator’s radiator’s fin.  fin.

14.2 Failure Diagnosis Water leakage

Damaged seal ring Broken pump assembly Broken water pipe Over high temperature in cylinder block

Damaged blade of the water pump Blocked water pipe Damaged cooling fan Damaged water temperature switch

14.3 Water Pump Disassembly

Loosen the bolt, and remove the water pump sub assembly. assembly.

Bolt

- 168 -

 

Water pump sub assembly

Bolt Loosen the bolt, and remove the water pump cover. cover.

Water pump cover

Remove the blade. Blade

Check Check the abrasion of the blade assembly.

If it is serious, replace it. Note: Don’t damage the spacer spacer and the joint surface of box

during operation.

Installation

Install it in reverse order. order.

- 169 -

 

Cooling Systematic Drawing

 Reservoir

465 cooling system piping system piping drawing  

Cylinder cover

Thermostat   Pressure valve  Oil

Water pump Cylinder block

Water direction

 Radiator

- 170 -

 

Inspection and Maintenance of Exhaust Emission System

1 exhaust pipe gasket assembly 2 screw M8×30 muffler buffer rubber

7 muffler decorating panel

3 gasket 8

4 spring gasket 8

8 heat-insulating spacer

5 muffler assembly

9 combined screw M6×10

6

- 171 -

 

15. Exhaust Emission & Control System Warranty on the Exhaust Emission & Control System ---------------------------------- -------------------15.1 --15.1 Instructions on the Periodic Maintenance / Compliance with Standards Standards --------15.2 -----15.2 Mechanical Function of the Exhaust Control System -----------------------------15.3 Catalytic Conversion System --------------------------------------------------------15.4 Measures When the Idle Speed Emission V Value alue Exceeds the Standard -----------------15.5 15.5

15.1 Warranty on the Exhaust Emission & Control System 15.1.1 The exhaust emission & control system of this motorcycle is in conformity with the GB 14621-2011, 14621 -2011, GB 14622-2007, GB 19758-2005 and GB 20998-2007 standards prescribed by the state. W Wee warrant that the exhaust emission & control system works normally during its effective period provided that users completely comply with all operation and maintenance requirements. 15.1.2 Warranty Range 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 (30000 kilometers). 15.1.3 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 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. 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.

·All new motorcycles delivered by our company have satisfied the noise test and comply with the GB 4569-2005 and GB 16169-2005 standards prescribed by the state. - 172 -

 

15.2 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 Qianjiang Q ianjiang distributors or Qianjiang service center.

 

Relevant emission provisions are shown as follows: Emission regulation

CO

HC

NOX 

Emission standard

≤2.0g/km   ≤2.0g/km

≤0.3g/km   ≤0.3g/km

0.15g/km

※  The latest national regulation shall prevail if there is any change. c hange.  

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. center

 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. frequently. Pay attention to following items to ensure meeting emission standards:

(1)  Please use lead-free gasoline #93 or #97. (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, throttle adjustment, etc.) (5)   Notes:  

Since any problem in the ignition system, the charging system or the fuel system has significant

effect on the muffler   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.  

Please use lead-free gasoline #93 or #97. Otherwise, the muffler device (four-stroke system) will be

affected. (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.

15.3 Mechanical Function of the Exhaust Control System General

This system adopts four-stroke single-cylinder engine, EFI and air conduction device to maintain - 173 -

 

qualified exhaust gas. Meanwhile, active carbon canister is used for exhaust gas evaporated from fuel.

※ Engine improvement  As the spark plug, spherical 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.

15.4 Catalytic Transfer System 15.4.1 Structure:

触媒：Catalytic 15.4.2 Instruction:

(1)  Function of transfer catalyst is to transfer completely burnt HC, HC , CO and NO X to harmless gas such as H2O, CO2、and、 N2 for discharge. (2)  Transfer catalyst catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used. - 174 -

 

※ Note that lead gasoline may invalidate catalyst. Notes in maintaining motorcycles motorcycles (gas discharge tube) with catalytic transfer:

a) 

For motorcycles with transfer catalyst, when the motor is running or just shut, it shall not be touched

 because of high temperature. temperature.  b)  Motorcycle with transfer catalyst shall not be near flammable material. c) 

There is CO inside gas discharge tyre, which is harmful to health. So do not run the motor in closed

space. d)  Motorcycle with transfer catalyst shall not use lead gasoline. (prevention for catalytic poison）. e) 

Do not push motorcycle to run motor. If it is necessary, you must stop for temperature of motor and

catalyst to lower down. f) 

Do not shut the motor with gear up when running downward.

g)  Do not drive motorcycle with bad ignition. h)  Do not remove spark plug and run motor to see whether there is spark in maintain motor ignition system. If necessary, necessary, the time shall be short.

- 175 -

 

15.5  Measures When the Idle Speed Emission Value Exceeds the Standard  Qualified Periodic inspection (maintenance plan)

Qualified  Measure idle emission (note 1) 

Qualified  Adjust Carburetor (note2) 

Qualified  Remove and clean the

delivery 

carburetor  

Qualified  Replace the carburetor  

Dismantle and repair engine •Valve（leakage）  •Piston（abrasive）    •Combustor  cleanin

Notes: 1. Measure it with the idle speed measurement program. program.

Qualified for

Qualified 

2. Adjust the engine speed with stop screws to live up to requirements and measure CO/HC at the idle speed.

- 176 -

 

Inspection and Maintenance of Electronic Fuel Injection (EFI) System

- 177 -

 

16. Electronic Fuel Injection System Electronic Fuel Injection System ---------------------------------------16.1 Components of Electronic Fuel Injection System---------------------16.2 Failure Diagnosis ----------------------------------------------------------16.3 Common Troubleshooting Methods-------------------------------------16.4

16.1 Introduction of Electronic Fuel Injection System RK6 adopts the small-scale engine electronic fuel injection system manufactured by Delphi Company, which is controlled with four oxygen sensors within a closed loop. Besides, it is equipped with four-cylinder independent fuel injection and ignition control functions. The three-way catalytic converter would go through treatment with the gas after combustion in the engine, turn it into harmless gas and discharge it into the air. This system adopts the closed-loop independent function that can efficiently eliminate the manufacturing differences within the system and the other corresponding components, highly improving the integrity of the motorcycle, which can also reduce the deviations of the motorcycle after a some time of actual using.

16.2 Components of Electronic Fuel Injection System 16.2.1 Engine Controller (MT05.2 ECU) The engine controller can test the operation conditions of the engine with various sensors at any time and guarantee the emission and economy of fuel by proper computing and self-study control output mechanism with the driving performance optimized. Once failures are found within the engine, the control would go through automatic diagnosis. The normal working of the system requires two ECU.

- 178 -

 

16.2.1.1 ECU Appearance

ECU 12 is located located on the the left of battery and and

ECU 34 is behind the battery battery.. 

16.2.1.2 Definition of ECU Connector Pin 1) ECU 12：  J1-1

J2-1

Pin for activating 1-cylind 1-cylinder er ignition coil

J1-2

Headlight control pin

J2-2

Pin for system grounding

J1-3

Pin for trouble light

J2-3

Pin for K line communication

J2-4

Pin for crank signal high potential

Pin for heating 2-cylinder oxygen J1-4 sensor Pin for activating 1-cylind 1-cylinder er fuel injector

Pin for signal 2-cylinder oxygen J1-5

J2-5 sensor

J1-6

Connector pin for tachometer

J2-6

Pin for activating 2-cylind 2-cylinder er fuel injector

J1-7

CAN line low signal 1 pin

J2-7

Pin for heating 1-cylinder oxygen sensor

J1-8

CAN line high signal 1 pin

J2-8

Pin for intake temperature sensor signal

J1-9

Pin for system grounding

J2-9

J1-10

Pin for activating 2-cylinder ignition coil

J2-10

Pin for 5V system reference voltage grounding

Pin for intake pressure sensor signal

J1 11

J2 11

J1-12

J2-12

Pin for throttle position sensor signal

J1-13

J2-13

Pin for crank signal low potential

- 179 -

 

J1-14

J2-14

Signal pin for water temperature sensor

J1-15

J2-15

Ignition power (12V positive voltage after key)

J1-16

J2-16

J1-17

J2-17

Pin for signal 1-cylinder oxygen sensor

J2-18

Battery power supply (battery 12V positive voltage)

J1-18

Dump switch (efficient at low)

Pin for neutral gear switch

Remarks: J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey connector.

- 180 -

 

2) ECU34：  J1-1

Idle speed stepper motor high A pin

J2-1

Pin for activating 4-cylind 4-cylinder er ignition coil

J1-2

Canister solenoid valve pin

J2-2

Pin for system grounding

J1-3

Pin for trouble light

J2-3

Pin for K line communication

J2-4

Pin for crank signal high potential

Pin for heating 3-cylinder oxygen J1-4 sensor Pin for activating 4-cylind 4-cylinder er fuel injector

Pin for signal 3-cylinder oxygen J1-5

J2-5 sensor

J1-6

J2-6

Pin for activating 3-cylind 3-cylinder er fuel injector

J1-7

CAN line low signal 2 pin

J2-7

Pin for heating 4- cylinder oxygen sensor  

J1-8

CAN line high signal 2 pin

J2-8

Pin for intake temperature sensor signal  

J1-9

Pin for system grounding

J2-9

Pin for oil pump control signal 

J2-10

Pin for 5V system reference voltage grounding  

J1-10

Pin for activating 3-cylinder ignition coil

J1-11

Idle speed stepper motor low A pin

J2-11

Pin for intake pressure sensor signal 

J1-12

Idle speed stepper motor high B pin

J2-12

Pin for throttle position sensor signal

J1-13

Idle speed stepper motor low B pin

J2-13

Pin for crank signal low potential

J1-14

Dump switch (efficient at low)

J2-14

Signal pin for water temperature sensor

J1-15

Pin for vehicle speed sensor

J2-15

Ignition power (12V positive voltage after key)

J1-16

J2-16

5V reference voltage

J1-17

J2-17

Pin for signal 4-cylinder oxygen sensor

J2-18

Battery power supply (battery 12V positive voltage)

J1-18

Pin for neutral gear switch 

Remarks: J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey connector.

- 181 -

 

16.2.1.3 Circuit Diagram of Electronic Injection System

Notes:

a) 

Keep ECU away from places of high temperature, like muffler or engine;

a) 

Keep ECU away from water, engine oil or any places of liquid;

 b)  Keep ECU away from mud or other dirt that would affect the heat dissipation function of ECU; c) 

Connect with M8 bolts and make sure the tightening torque is around 3.9Nm, keep the surface neat to

 prevent outside force to ECU in case of circuit circuit board bending; d)  The DC power supply voltage of ECU of normal working is between 9V and 16V. when it's working

under a voltage not over 26V for one minute, permanent damage would not happen to ECU, neither when the  backward voltage is is not over 13V. 13V.

- 182 -

 

16.2.2 Fuel Injector 16.2.2.1 Working Principle of Fuel Injector: The fuel injector is designed with magnet coil surrounding iron core inside. Two electrodes from magnet coil are input control connectors of the fuel injector. When magnet coil is energizing, electromagnetic attraction generated by magnet coil will conquer spring force and fuel oil pressure of ball valve to uplift the  ball valve. Then high pressured fuel oil (250Kpa) in fuel pipes can inject cone-shaped fuel oil to the air inlet through value seat hole and orifice plate. After power of the fuel injector, magnetic force of the magnet coil will automatically disappear. disappear. The ball valve closes by the action of return spring and fuel injection stops.

16.2.2.2 Appearance:

注意事项：   

Fuel injector is designed with a filter which is not a repairable component because it is designed for only filtering impurities between fuel filter to fuel injector. The impurities may cause failures such as injector

 bonding, flow deviation and and leakage. Thus, fuel fuel filter system is very important.  

Replace the fuel injector with parts of the same models.

- 183 -

 

16.2.3 Throttle Body 16.2.3.1 Working Principle: The throttle body assembly is comprised of the main casting valve body, return spring, throttle position sensor system and idle adjusting screws. Throttle position sensor system offers accelerograph opening for ECU; idle adjusting screws controls and idle speed and the stability by clockwise reducing the ventilation to lower the idle speed and anticlockwise increasing the ventilation to higher the idle speed, which is normally required around 2 circles.

16.2.3.2 Appearance:

- 184 -

 

16.2.3.3 Cleaning Clean the throttle body assembly with carburetor cleanser by spraying it on the inner wall of the throttle  body and brush the dusts and and carbons away gently. gently. Notice:

Make sure the side channel is not blocked by the dirty.

16.2.4 Engine Cylinder Head Temperature Sensor 16.2.4.1 Working Principle: This sensor is used on the air cooled engine for measuring the engine cylinder head temperature. Within the temperature scope of the sensor, the electric resistance would vary with different temperature temperature of the engine,

which is a negative temperature coefficient coefficient resister. It is a not a repairable part.

- 185 -

 

16.2.4.2 Appearance

16.2.5 Intake Air Temperature Sensor 16.2.5.1 Working Principle It is used for measuring the temperature of the intake air. Within the temperature scope of the sensor, the electric resistance would vary with different temperatures of the engine, which is a negative temperature coefficient coefficie nt resister. The intake air temperature sensor is not a repairable part.

16.2.5.2 Appearance

- 186 -

 

16.2.6 Intake Pressure Sensor 16.2.6.1 Working Principle This sensor is mainly used for measuring the absolute pressure of the intake bend tube, which, in compliance with the change between the resistance value and the intake pressure, can measure the air input of the engine's combustion chamber indirectly. indirectly.

16.2.6.1 Appearance

16.2.7 Oxygen Sensor 16.2.7.1 Working Principle Oxygen sensor is mainly used for measuring the oxygen content within the exhaust pipe of combustion engine and for the fuel closed loop controlling in the engines, which can make sure the combustion of the engine is maintained at a reasonable air-gasoline ratio (14.7).

- 187 -

 

16.2.7.2 Appearance

16.2.8 Ignition Coil 16.2.8.1 Working Principle The ignition coil can provide energy to the spark plug. The high voltage wire is used to connect the ignition coil and the spark plug.

- 188 -

 

16.2.8.1 Appearance

16.2.9 Idle Speed Stepper Engine

16.2.9.1 Working Principle The idle speed control valve is used to control the ventilation circulation area aside the throttle body so as to adjust the intake air to the engine, realizing controlling of the idle speed of the engine.

- 189 -

 

16.2.9.1 Appearance

16.2.10 Fuel Pump Assembly Assembly 16.2.10.1 Working Principle The electric pump would work together with the pressure regulator to provide 250Kpa fuel pressure for the engine. It is installed under the gasoline tank.

16.2.10.2 Appearance

- 190 -

 

Back side:

Front side:

16.2.10.3 Failure Diagnosis of Fuel Pump Assembly

a) 

Turn on the key and run the fuel pump for about 3 seconds. If the fuel pump starts to run, refer to step d).

 b)  Cut off the connector of the fuel pump and check whether the power supply voltage is 12V or so. c) 

If there is nothing wrong with the second step, supply 12V DC to the fuel pump with an external storage battery. battery. Check whether the fuel pump runs or not. - 191 -

 

d)  If the fuel pump runs normally, check the oil pressure gauge to see whether the front supply pressure of the nozzle is about 250Kpa when the engine is idling. e) 

If the pipe pressure is lower than 220Kpa, check if there is a leakage in the oil pipe, if the fuel pump runs backwards, or if the filter is blocked.

16.2.10.4 Common Problems a) 

The reverse connection of the connector of the fuel pump assembly causes the fuel pump run  backwards, thus leading to inadequate fuel pressure for the engine. As a result, the engine cannot work normally.

 b)  The fuel pump is damaged and cannot run. Note:

1. Since a new motorcycle has no gasoline in its fuel tank at the very beginning, much air remains in the fuel line after the tank is fueled up. Therefore, it is necessary to turn the motor over for several times to discharge all the air in the fuel line so that that the engine can operate normally. normally.

This is a normal process,

which will avoid the engine from taking a long time to start but still in failure in the later startup. 2. The gasoline can cool down the fuel pump, so do no run the pump with little or no fuel, or the fuel  pump will be overheated overheated and damaged.

16.3 Methods for Fault Diagnosis and Maintenan Maintenance ce The trouble light is on the instrument panel, with a sign of FI down blew. In a normal circumstance, when turning on the key, the trouble light will turn on to indicate the electronic control injection system is power-on and is ready to work. If the trouble light is off, it indicates that there is no power supply in the electronic control injection circuit and thus it cannot work. In this case, check the fuse and the connection of both  positive and negative electrodes of the storage battery. After the engine has been started, if the trouble light turns off, it indicates that there is no fault; otherwise, if the trouble light is still on, it indicates that the electronic control injection system is abnormal and it is necessary to remove the faults.

There are three methods for fault detection: 16.3.1 Direct Diagnosis through the Flickering Trouble Light (FI) on the Instrument Panel When any fault is confirmed, by switching the key for three times, i.e., turning the key on-off-on-off-on, the trouble light will flash in corresponding fault code. Then check the fault code list for the breakdown in

correspondence. In case of reading faults with the trouble light, the rules of flash codes are illustrated as below. Take the open circuit of intake pressure sensor or short circuit of signal end pin to the negative electrode of the battery as an example, after the key has been switched for three times, the trouble light will flash 10 times standing for - 192 -

 

0, flash once after 1.2 seconds standing for 1, flash 10 times after another 1.2 seconds standing for 0 and flash 7 times after another 1.2 seconds standing for 7, that is P0107. It shows that, except the number 0 is represented by flashing for 10 times, other numbers from 1 to 9 will flash as the number itself shows. If there are other fault codes, such as fault P0201, a fault in the fuel injector of front cylinder, the light of fault code P0201 will flash in 3.2 seconds after the flashing of P0107. The trouble lights of P0107 and P0201 will flash circularly in case of no other fault. Then faults can be checked according to the fault code list. Decimal number will be adopted to show the fault code in PCHUD software. The decimal number in the fault code list is corresponded to the previous hexadecimal, thus faults can be found out in correspondence. If MULFCURR (current fault) =263, the corresponding fault code in the fault code list is P0107, i.e., a fault of intake pressure sensor. sensor.

- 193 -

 

MT05 Fault Code List Corresponding Fault code

Description

decimal number

open circuit of intake pressure sensor or short circuit of signal end P0107

 pin to the negative electrode electrode of the battery

263

short circuit of signal end pin of the intake pressure sensor to the P0108

 positive electrode of the battery

264

short circuit of signal end pin of the intake temperature sensor to P0112

the negative electrode of the battery

274

open circuit of intake temperature sensor or short circuit of signal P0113

end pin to the positive electrode of the battery

275

short circuit of signal end pin of the cylinder end temperature P0117

sensor to the negative electrode of the battery

279

open circuit of cylinder end temperature sensor or short circuit of P0118

signal end pin to the positive electrode of the battery

280

open circuit of throttle position sensor or short circuit of signal P0122

end pin to the negative electrode of the battery

290

short circuit of signal end pin of the throttle position sensor to the P0123

 positive electrode of the battery

291

short circuit of signal end pin of the front cylinder oxygen sensor P0131

to the negative electrode of the battery

305

short circuit of signal end pin of the front cylinder oxygen sensor P0132

to the positive electrode of the battery

306

short circuit of heating end pin of the front cylinder oxygen sensor P0031

to the negative electrode of the battery

50

short circuit of heating end pin of the front cylinder oxygen sensor P0032 P0201

to the positive electrode of the battery fault of for fuel injector front cylinder

49 513

fault of for fuel injector rear cylinder (plug-in device of the fuel P0202

injector is not plugged)

514

open circuit of oil pump or short circuit to the negative electrode P0230

of the battery

560

P0232

short circuit of oil pump to the positive electrode of the battery

562

P0336

signal interference of crank shaft position sensor

822

P0337

no signal of crank shaft position sensor

823

P0351

fault of ignition coil for front cylinder

849

P0352

fault of ignition coil for rear cylinder

850

P0562

voltage below level of electronic control injection system

1378

P0563

overtension of electronic control injection system

1379

P0560

fault of trouble light (damage of filament or plug-in device)

1616

P1693

short circuit of tachometer line to the negative electrode of the

5779 - 194 -

 

 battery short circuit of tachometer line to the positive electrode of the P1694

 battery

5780

short circuit of signal end pin of the rear cylinder oxygen sensor P0137

to the negative electrode of the battery

311

P0138

short circuit of signal end pin of the rear cylinder oxygen sensor to the positive electrode of the battery

312

short circuit of heating end pin of the rear cylinder oxygen sensor P0038

to the positive electrode of the battery

56

short circuit of heating end pin of the rear cylinder oxygen sensor P0037

to the negative electrode of the battery

55

- 195 -

 

16.3.2 Fault Diagnosis by Diagnostic Apparatus Apparatus

Operation steps：  a)  Find the 6-hole diagnostic port on the motorcycle.  b)  Connect the connecting line to the port on the diagnostic apparatus. c)  Turn on the key to diagnose the faults.

16.3.3 Fault Diagnosis with the Diagnostic Software PCHUD PCHUD software is used to inspect and record the operating data of the engine. Before using the software, connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line. The notebook computer needs to install the K line driver software before using.

- 196 -

 

Instructions of PCHUD Software: （1）Connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line and turn on the key.

（2）Click the icon "HUD.EXE" to start PCHUD software （3）Select "File" on the software interface, click "Open", choose "PCHUD.HAD" and select OK.

（4）Select "Parameter File" within "Setup", click the file MT05COMMON.par, choose "Comm protocol" within "Setup", then select "Keywork2000" and click OK, meanwhile, choose 17 in Device Code.

- 197 -

 

（5）If the real-time communication data fail to display on the soft ware interface when the power is on, check whether the connection setting of COM port in "Setup". Under the normal circumstance, set COM Port: 4 and Baud Rate: 10400, instead of DTR High at startup.

 Normal communication is ready to make then. Current fault code is displayed in the position of MALFCURR and historical fault code displayed on MALFHIST MALFHIST.. - 198 -

 

Then check the corresponding fault according to the fault code list

- 199 -

 

Interpretation of PCHUD Software Parameter VRPM

发动机转速 

engine speed

VTHROT

节气门开度 

throtle position

大气压力 

BARO

进气歧管压力 

manifold air pressure

进气歧管压力估计值 

expect manifold air pressure

蓄电池电压 

ignition key voltage

发动机缸温或者冷却水温 

cylinder temperature or coolant temperature

VIAT

进气温度 

intake air temperature

STATUSBYTE5

状态标志 5

STATUSBYTE5

VAFCMET

空气流量学习条件满足 

airflow correction met

VBAROCMET

大气压力更新条件满足 

Baro update met

顺序点火标志 

sequential spark enable

tip-in 点火角修正条件满足 

tip-in Spark Advance retard trigger

触媒起燃逻辑使能 

catlyst light-off logic enable

发动机正常工作标志位 

engine work in run state

暖机怠速条件满足 

stable warm idle

2 缸氧传感器加热完成标志位 

O2 ready

进气效率长效学习单元 

 block learn memory memory ce cell ll

1 缸长效学习值 

cylinder 1 block learn memory

闭环学习 I 项 

intergral of close loop correction

闭环学习修正量 

close loop correction

IARDRPM

目标怠速转速 

desired idle rpm

IARPMERR

怠速偏差 

idle rpm error

FPWVC1

1 缸喷油脉宽 

 base pulse width width of cylinder cylinder 1

VO2

氧传感器信号 

Oxygen sensor signal

VBARO VMAP VMAPEXP VIGN VCLTS

VCSINSYNSPRK SATITRIG CATLOENB IF ENGSTATE=3  NISTBLIDLE FO2REDY2 FCNO FBLMCOR1 FCLCINT1 FCLCMUL1

状态标志 STATUSBYTE3

3

STATUSBYTE3

FO2STAT1

1 缸氧传感器浓稀标志位 

cylinder 1 oxygen sensor signal rich lean state

FCLREST1

1 缸闭环修正重置标志位 

cylinder 1 close loop correction reset

- 200 -

 

FOSHTREN

氧传感器加热使能 

Oxygen sensor heater enable

FO2REDY1

1 缸氧传感器加热完成标志位 

cylinder 1 Oxygen sensor ready

怠速步进电机闭环学习使能 

idle airflow control valve close loop correction enable

怠速步进电机丢步标志位 

IACV lost

怠速步进电机禁止移动标志位 

IACV move disable

点火状态标志位 

ignition state

1 缸充气效率 

cylinder 1 Volumetric efficiency

进气压力读取角度 

MAP read angle

目标空燃比 

target air fuel ratio

SAESTA

1 缸点火提前角 

cylinder 1 Spark Advance

SAIDLDYN

怠速动态点火角 

idle dynamic Spark Advance

SPDWELL

充磁时间 

dwell time

怠速步进电机气量学习值 

airflow integral of idle air control valve

怠速步进电机目标步数 

desired position of idld air control valve

状态标志 2

STATUSBYTE2

FCLCEN1

1 缸闭环修正使能 

cylinder 1 close loop correction enable

PPDSEBL

预喷禁止标志位 

 prime pulse disable

FPENABL

油泵使能标志位 

fuel pump enable

FTRNSAES

加速加浓使能 

acceleration enrich enter

FTRNSDES

减速减稀使能 

deceleration enlean enter

FTRNSAEDCLOAD

加速加浓退出 

acceleration enrich exit

FTRNSDEINLOAD

减速减稀退出 

deceleration enlean exit

2 缸闭环修正使能 

cylinder 2 close loop correction enable

IF IACV MODE=0

IAMTRLOST IACMVIHB VIGNS FVE1 VMAPRANG AFFNLAFR

IAINTEGOFST IACVDSMP STATUSBYTE2

FCLCEN2

- 201 -

 

16.4 Common Fault Removal Techniques 16.4.1 Repair Tools a) 

Disassembling the parts of the electronic control system- common disassembly tools for auto machinery  parts

 b)  Circuit of the electronic control system and its electrical signal- digital multimeter (with beep) c) 

Diagnosing the faults in the electronic control system and checking the engine's operation  

Fault diagnostic apparatus for electronic control system(recommended)

 

Fault diagnosis software(PCHUD) and port wire( if available)

d)  Fault code list of the electronic control system( for emergency) emergency) e) 

Fuel pressure gauge, range: 0 ~ 300kPa

16.4.2 The Operation Data Flow of the Engine Shown on the Diagnostic Apparatus Analyze and check the faults in engine through the operation data flow of the engine shown on the

diagnostic apparatus.

- 202 -

 

16.4.2.1 Step One a) 

Engine wire harness and vacuum line- may influence the system in controlling air flow and oil supply.

 b)  Assembly of Oxygen sensor- may influence the system in judging the air-fuel ratio. c) 

Engine trouble light- influences the system in fault warning.

d)  Storage battery voltage- judges whether the battery power is adequate. e) 

According to the experience, judge whether the readings of coolant temperature sensor, air intake temperature sensor, sensor, manifold absolute pressure sensor and oxygen sensor are normal.

f) 

Working range of throttle position sensor- Failure in completely turning on or off the sensor may influence the power performance of the engine and part of system function.

16.4.2.2 Step Two Check whether the power supply of ECU is cut off- the communication between the diagnostic apparatus and the system halts after turning off the key switch.

16.4.2.3 Step Three a) 

Coolant temperature and its cycling- indicate whether the thermostat operates normally.

 b)  Storage battery voltage- shows whether the generator works normally. normally. Too high: maybe a fault in the generator regulator. Too low：maybe the inappropriate connection of generator wires or a fault in the generator c) 

Manifold air pressure- may indicate whether there is an intake air leak or an air valve clearance The air valve clearance is too small: the overhigh figure may influence the power performance performance of the engine. Meanwhile, because the exhaust valve opens too early, early, the increased temperature of the exhausted air will significantly reduce the service lives of oxygen sensor and ternary catalytic converter. The air valve clearance is too large: may cause the manifold air pressure become low, thus influencing the system in judging the engine's operation and leading to abnormal idling in the engine's warming-up. Besides, the clogged exhaust system, e.g., foreign materials in the exhaust passage, or the blocked ternary catalytic converter caused by the over-consumption over-consumption of the engine oil, or damaged pieces inside of the ternary catalytic converter, converter, will lead to an overhigh figure.

d)  Cycle number of the oxygen sensor reading- a small cycle number indicates the failure of the oxygen sensor.

16.4.3 Concise Fault Removal Techniques

Please take the following steps to repair the electronic control injection system. If the fault is removed in a certain step, the following steps can be suspended. Then check and remove the fault code by diagnostic apparatus in compliance with the term 14.4.2.

- 203 -

 

When using the diagnostic apparatus, the storage battery voltage cannot be lower than 8.5V 8.5V..

16.4.3.1 Daily Use and Maintenance  

  

Unleaded gasoline #92 or #95 is strongly recommended. Though ECU is damp-proof, it is forbidden to wash its cover with a high-pressure water gun.

 

The fuel filter should be replaced every 7,000-10,000km

 

In common circumstances, the throttle valve should be washed every 10,000km or every 1 year. year.

16.4.3.2 Fault Description- Startup Failure a) 

Turn the ignition lock to "ON" to check whether the trouble light turns on.

If no： 

  Check the fuse and the ground wire.   Check whether ECU's plug is tightly connected.  

Check whether the light and circuit are normal through the inspection function of the diagnostic apparatus's actuator. actuator.

  Check and repair the light and its circuit.   Make the judgment with another ECU.

If yes： 

  Connect the diagnostic apparatus to the system's diagnostic port.

 b)  Whether the diagnostic apparatus can be connected to the system for communication If no:

  Check the fuse and the ground wire   Check whether ECU's plug is tightly connected   Check whether the diagnostic apparatus works normally on another normal motorcycle.   Make the judgment with another ECU.

If yes:

  Remove the fault shown by the diagnostic apparatus.

c)  Check the faults in the ignition system- whether the spark plug can ignite normally If no:   Check whether the high-tension cable and spark plug are connected tightly or are damaged.   Make the judgment with another ignition coil assembly   Make the judgment with another ECU.

If yes:

  Check whether the high-tension cable is connected with the ignition coil and spark plug in a

correct way d)  Check the faults in the oil supply system Whether the fuel pump is working- the working noise of the fuel pump can be heard in its nearby when starting the engine. If no:

  Check whether the fuel pump relay works normally.   Check whether the connection of crankshaft position sensor and its operation are normal.

  Make the judgment with another ECU.   Check the fuel pump circuit

1)  Whether the supplied oil pressure is above 220Kpa

If yes:

2)  Inadequate

  Check whether there is enough gasoline in the fuel tank - 204 -

 

 pressure： 

  Check whether it is necessary to replace the fuel filter (note: the special

fuel filter for the electronic control injector should be replaced every 7,000-10,000km)   Whether the oil supply line and oil return line are damaged

3)   Normal

  Check whether the nozzle control line is abnormal

 pressure：  e) 

  Whether it is necessary to clean the oil nozzle

Check whether the cylinder is flooded with oil

If yes： 

  Press the accelerator pedal to the limit and turn on the starter. After After several seconds, there

will be a sign showing the engine running. f) 

Whether the clearance of crankshaft position sensor is too large

16.4.3.3 Fault Description- Startup Failure Accompanied with Backfire a) 

Check whether the high-tension cable of ignition coil is loose

 b)  Whether the timing gear is loose.

16.4.3.4 Fault Description- Unstable Idle Speed Idle speed control

Check whether the idle speed by-pass bolt is too loose or tight. Usually it is necessary to

system:

screw 2 turns.

Oil supply system

Whether there is an oil pipeline leak

16.4.3.5

Fault

Description-

Too

High/Low

Idle

Speed

(Apparent

Non-conformity to Target Idle Speed) Idle

speed

is too high:

  When the water temperature is lower than 68℃, the system will increase the idle speed to

accelerate the warming up. Besides this normal process, check according to the following steps.   Check whether the idle air bypass hole is too large.   Check whether the air valve clearance, especially the exhaust valve clearance, is too

large. Idle

speed

is too low:

  Check the oil amount in the fuel tank, the fuel filter, the oil line pressure and the oil

nozzle.   Check whether the idle air bypass hole is too tiny.

 

Check whether the air valve clearance is too small.

- 205 -

 

16.4.3.6 Fault Description- Unstable Idle Speed Slowing Down with Flameout a) 

Check the valve clearance

 b)  Check whether the idle air bypass hole and throttle body are too dirty

16.4.3.7 Fault Description-Poor Acceleration a) 

Whether the parameters at idle speed and high idle speed are normal

 b)  Check the oil amount in the fuel tank, and fuel filter. c) 

Check whether the exhaust system is blocked, e.g., whether the ternary catalytic converter is clogged  because of burning engine engine oil or damages.

d)  Check the oil line pressure and the oil nozzle. e) 

Check whether the trouble light turns on and whether it is because only one cylinder can work normally to ignite.

16.4.3.8 Fault Description- Little Misfire Check whether the spark plug gap meets the standard between 0.7-1mm.

16.4.3.9 Fault Description- Non-conformity between Fault Code and Fault When Trouble Trouble Light is On The ground wire of the system may be not connected well. Reconnect the ground wire, turn off the storage battery power line for 3 minutes and turn it on, then start the engine.

16.4.3.10 Fault Description- Abnormally High Oil Consumption a) 

Check the assembly of the oxygen sensor of two cylinders. If it is in a loose state, the oxygen sensor will make a wrong judgment of the slight lean burn in the cylinders, and thus add more fuel, leading to abnormally high oil consumption.

 b)  When the engine's mechanical parts and the oxygen sensor are confirmed to be normal, start the engine to check the reading of the oxygen sensor. If the reading is always above 500 mV in a normal water temperature, check whether there is a leakage in the oil nozzle. Note

 

Most parts of electronic control injection system are non-repairable. Once a part is damaged, usually it needs to be replaced.

 

When starting the engine, do not run any other organs of the engine (including the throttle, do not push the throttle in the startup). - 206 -

 

 

If the engine trouble light turns on when the engine is operating, it is necessary to check the reason and remove the fault as early as possible.

 

Do not use leaded gasoline for lead will do harm to the oxygen sensor and ternary catalytic converte converter. r.

 

When there is an abnormal consumption of the engine oil, the fault should be removed as soon as possible, or some substances in the engine oil will also do harm to the oxygen sensor and ternary catalytic converter.

 

The air valve clearance should not be too small. If the air valve does not tightly shut off in the exhaust  process, the exhaust temperature temperature will be too high so that the service life of ternary catalytic catalytic converter will  be reduced.

 

When the temperature is lower than 10℃, if the motorcycle and the engine run at a low speed for a long time, the exhaust pipe may have carbon deposits and appear to be black. This is a normal phenomenon. It will disappear after the engine operates at a high speed for some time ti me or by adopting appropriate methods to keep the engine coolant temperature in a specified range

- 207 -

     

RK6 Circuit Diagram 怠速控制阀

黄/紫 灰/白 白/黄 白/黑

前刹车开关 保险盒 灯光

 紫    

10A

 红          白 /     

燃油泵  风扇   ECU1 电源锁 10A

15A   10A

15A

 

ECU2

仪表 电瓶正极

启动继电器

 

电门锁

电瓶正极

马 达

绿 红红 红 粉红 粉 红 / 红1 / 红1/ / / 红 红/ 红 红 橙棕 黄 黄 蓝 蓝

边撑熄火

闪光器

后刹车开关

警示灯二极管

右把手

左把手

2# Gr ECU

IN5408

保险丝 30A

15A

J1

2#BLACK ECU J2

1 2 3  4 5  6 7 8 9 1 01 1 1 2 13 14 15 16 17 18 左 左

右

右

粉 红红 / / 黄红

绿

红

黄淡蓝黄绿红 绿棕红 / 蓝 / / / / / 红 红黑白 白 白

/ 红 / 白/ 黄 红 白

右

右

/ /

蓝黄

红

/ 绿

黑 绿 / 棕1

白

绿 橙绿

紫

/ / /

白 蓝黑

绿绿 红橙 橙 / / / 黑 红/白/ 黑1白1 白 白

/

黄

白/黑

 

3缸氧传感器

绿/蓝

粉红 棕 灰 白/蓝 绿/黑1 墨绿 灰/红 黑 红/白 白 绿/白1 蓝 红/紫1 棕/黑 橙/黑 红  /  /         / 浅蓝

棕/白

黑/红2 黑/黄2 黄/蓝2 黑/蓝

白/紫 白/橙黑/蓝 黑/橙 黄/蓝红/绿 红/黄   棕/蓝 黑 灰/白黄/紫 灰/红1  橙/红 棕/黑 黄/蓝   橙/绿 黑 蓝/白 黑/橙1 棕/红 黑/白白/黄 蓝/橙 红/灰白/绿  绿 白/灰 红/紫 白/红 黄/绿

黑/黄 粉红/蓝

灰

空档

节气门传感器

黑/蓝 黑 橙

橙/黄

机油开关

红/绿 黑/橙

8  9 10 11 12 13 14 15 1 6 17 1 8 1 2 3 4 5 6 7  

左

左

橙绿

绿橙

灰

黑/红2 粉红/蓝

碳罐电磁阀

绿/白 橙/白

右转向灯

橙/红 启动二极管 灰

右转向

前大灯

左转向

绿/黑 橙

绿/白 橙/白

黑 淡蓝 黄 蓝

黑 黄 紫

绿/黑

黄

左转向灯

后尾灯

牌照灯灯

橙

黑 红/紫 棕/红

黑

离合器开关

诊断仪

棕/蓝 红/黄 黑

橙/红

黑/红2 黄/绿2 白/灰2 黑/蓝

黑

喇叭

 

4缸氧传感器

 

进气压力传感器

棕

黑/蓝 红/灰2 红/白 风扇继电器

红/绿

棕/浅绿 红/棕 棕/绿 黑/红2 白/紫2

红/白 大灯继电器

蓝/绿 蓝/黄

喷油器

黄/红 绿/蓝

黑 /红2 白/红2

油泵继电器

黑/红2 红/橙 红/黑 黑

电喷控制继电器2

黑/红2 黑

绿 红/黄 黑/红2

黑/白2

黑

黑/红2

点火线圈

电喷控制继电器1

黑

绿 红/蓝 黑/红1

主继电器1

橙/绿2

红/白 橙/黄 红/白

白/橙2 进气温度

黑/蓝

黑/棕1

诊断仪

红/紫1 红/紫 棕/红1 棕/蓝1 墨绿 红/蓝 棕 /黑 黄/蓝1 棕 /蓝 黑   橙/绿 蓝/绿黑/黄 蓝/绿 黑/黄 橙/黑 棕/红

电瓶正极

红 黑蓝

黑黑黄 白

黑 黑 橙

黑白

黑 白

/

/ / /

/

/

/

/

/ /

/

红1

绿1

红1

白1

红1红1

红1 紫1

/ /

白 蓝橙 白3白2 白3 白2白1 白1 棕 / 黑

浅 绿

棕 黑

墨绿 白

/

/

绿

蓝

风扇

油位传感器

黑 黑 黑

黑黑黑黄 / / / /

/

红1黄 蓝 蓝1

  墨灰 红 绿/ / 红 浅蓝

红 红黑 / / /

绿1灰1蓝

黑 白黄 黑

白蓝

/ / /

/ /

/

绿白

橙1蓝

/

蓝 灰1绿1红1

蓝/橙 黑/橙1 橙/红

白/棕红/绿 红/蓝 白/红 白/橙 黑/白 黑 蓝/白 黄/绿 黑/蓝 白/绿 绿 白/灰 红/紫 白/紫 红/灰

白 黑 /

电瓶负极

白1白2 白3 黑

1 2   3 4

5  6 7 8 9 1 01 1 1 2 13 14 15 16 17 18

1#Gr ECU J1 防侧翻传感器

103 ℃ 水温开关

/

蓝蓝蓝 棕

 黑      红          黑 /     

 

水温传感器

2缸氧传感器

速度传感器

燃油泵

进气压力传感器

1缸氧传感器

触发头

8  9 10 11 12 13 14 15 1 6 17 1 8 1 2 3 4 5 6 7  

1#BLACK ECU J2

进气温度

点火线圈 喷油器

  0