TNT300(BN302)

Service Manual

ZHEJIANG QIANJIANG MOTORCYCLE CO., LTD.

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 Content

Preface ......................................................................................................................................... - 6 -

Service Data ................................................................................................................................. - 7 -

General Safety .......................................................................................................................... - 7 -

Maintenance Regulations ......................................................................................................... - 8 -

Specifications ......................................................................................................................... - 19 -

Fault diagnosis ....................................................................................................................... - 21 -

Inspection/Adjustment ........................................................................................................... - 27 -

Inspection and Maintenance of Electrical System ..................................................................... - 50 -

Ⅰ Battery/Charging System ...................................................................................................... - 51 -

1.1 Service Data ..................................................................................................................... - 51 -

1.2 Fault Diagnosis ................................................................................................................ - 52 -

1.3 Battery .............................................................................................................................. - 53 -

1.4 Charging System .............................................................................................................. - 54 -

1.5 Voltage-current Regulator ................................................................................................ - 55 -

1.6 Magneto Charging Coil .................................................................................................... - 56 -

1.7 Magneto Removal ............................................................................................................ - 57 -

Ⅱ Ignition System ..................................................................................................................... - 60 -

2.1 Service Data ..................................................................................................................... - 60 -

2.2 Fault Diagnosis ................................................................................................................ - 62 -

2.3 Ignition System inspection ............................................................................................... - 63 -

2.4 ECU Group ...................................................................................................................... - 64 -

2.5 Ignition Coil ..................................................................................................................... - 65 -

2.6 Sensor of the crankshaft position ..................................................................................... - 65 -

Ⅲ Starting System ..................................................................................................................... - 67 -

3.1 Service Data ..................................................................................................................... - 67 -

3.2 Fault Diagnosis ................................................................................................................ - 68 -

3.3 Starter Motor .................................................................................................................... - 68 -

3.4 Starter Relay ..................................................................................................................... - 70 -

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IV Bulbs/Switches/Instruments .................................................................................................. - 72 -

4.1 Service Data ..................................................................................................................... - 72 -

4.2 Fault Diagnosis ................................................................................................................ - 73 -

4.3 Headlamp bulb replacement............................................................................................. - 73 -

4.4 Front clearance lamp bulb replacement ........................................................................... - 74 -

4.5 Tail Lamp Bulb Replacement ........................................................................................... - 74 -

4.6 Rear License Plate Lamp Bulb Replacement ................................................................... - 76 -

4.7 Replacement of Front Turn Light ..................................................................................... - 77 -

4.8 Replacement of Rear Turn Light ...................................................................................... - 77 -

4.9 Instrument ........................................................................................................................ - 78 -

4.10 Main switch .................................................................................................................... - 78 -

4.11 Electric Horn .................................................................................................................. - 78 -

4.12 Handle Switch ................................................................................................................ - 79 -

Vehicle Body Inspection and Maintenance ................................................................................ - 80 -

V Braking System ...................................................................................................................... - 83 -

5.1 Maintenance Instructions ................................................................................................. - 83 -

5.2 Fault Diagnosis ................................................................................................................ - 84 -

5.3 Front Hydraulic Brake ..................................................................................................... - 85 -

5.4 Rear Hydraulic Brake....................................................................................................... - 89 -

VI. Motorcycle Exterior ............................................................................................................. - 94 -

6.1 Disassembly ..................................................................................................................... - 94 -

6.2 Assembly .......................................................................................................................... - 95 -

VII. Front Wheel/Steering Handlebar/Front Suspension ........................................................... - 99 -

7.1 Service Data ..................................................................................................................... - 99 -

7.2 Fault Diagnosis .............................................................................................................. - 100 -

7.3 Front wheel .................................................................................................................... - 101 -

7.4 Steering handlebar.......................................................................................................... - 106 -

7.5 Front fork ....................................................................................................................... - 107 -

VIII. Rear Wheel/Rear Suspension .......................................................................................... - 111 -

8.1 Service Data ................................................................................................................... - 111 -

8.2 Fault Diagnosis .............................................................................................................. - 112 -

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 8.3 Rear Wheel ..................................................................................................................... - 113 -

8.4 Rear Shock Absorber ..................................................................................................... - 115 -

8.5 Chain Drive .................................................................................................................... - 117 -

8.6 Rear Swinging Arm ........................................................................................................ - 120 -

IX. Fuel tank ............................................................................................................................ - 123 -

9.1 Service Data ................................................................................................................... - 123 -

9.2 Fault Diagnosis .............................................................................................................. - 123 -

9.3 Fuel tank......................................................................................................................... - 124 -

X Removal and Installation of Engine ..................................................................................... - 126 -

10.1 Service Data ................................................................................................................. - 126 -

10.2 Removal of Engine....................................................................................................... - 126 -

10.3 Installation of engine .................................................................................................... - 132 -

Check and maintenance of engine............................................................................................ - 133 -

XI. Lubricating System ............................................................................................................ - 138 -

11.1 Service Data ................................................................................................................. - 138 -

11.2 Fault Diagnosis............................................................................................................. - 139 -

11.3 Engine Oil Pump .......................................................................................................... - 139 -

XII Cylinder Head.................................................................................................................... - 144 -

12.1 Service Data ................................................................................................................. - 144 -

12.2 Fault Diagnosis ............................................................................................................ - 145 -

12.3 Cylinder Head .............................................................................................................. - 146 -

XIII. Crankcase ........................................................................................................................ - 155 -

13.1 Service Data ................................................................................................................. - 155 -

13.2 Fault Diagnosis ............................................................................................................ - 157 -

13.3 Upper Box .................................................................................................................... - 159 -

13.4. Piston........................................................................................................................... - 159 -

13.5 Lower Box ................................................................................................................... - 165 -

13.6 Clutch ........................................................................................................................... - 167 -

13.7 Gear Shifting Mechanism ............................................................................................ - 170 -

13.8 Assembly Room and Speed-variable Room of Crankshaft & Connecting Rod ........... - 174 -

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XIV. Cooling System ............................................................................................................... - 180 -

14.1 Preparation of Data ...................................................................................................... - 180 -

14.2 Fault Diagnosis ............................................................................................................ - 180 -

14.3. Water Pump ................................................................................................................. - 181 -

Check and maintenance of exhaust gas emission system......................................................... - 183 -

XV. Control System of Exhaust Gas Emission ........................................................................ - 184 -

15.1 Letter of Guarantee of Exhaust Gas Emission Control System ................................... - 184 -

15.2 Notice of Periodic Maintenance ................................................................................... - 186 -

15.3 Mechanical Function of Exhaust Gas Control System ................................................. - 187 -

15.4 Catalytic Converting System........................................................................................ - 187 -

15.5 Solutions in Case of Idling Emission Value Exceeding Specified Value ..................... - 189 -

Inspection and maintenance of electronic fuel injection system .............................................. - 190 -

XVI. Electrical Fuel Injection System ..................................................................................... - 191 -

16.1 Introduction of Electrical Fuel Injection System ......................................................... - 191 -

16.2 Parts of Electrical Fuel Injection System ..................................................................... - 191 -

16.3 Fault Maintenance and Diagnosis Methods ................................................................. - 204 -

16.4. Elimination Methods of Common Faults .................................................................... - 213 -

BJ300GS Circuit Diagram………………………………………………………….…………- 218 -

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 Preface

The service manual contains descriptions of maintenance essentials on

BJ300GS motorcycle.

Service data include attentions that shall be paid on all the maintenance

operations in the service manual. Please read the manual carefully before

operation.

Check and adjustment contains statements on the main points of

inspection and adjustment, safety of the vehicle, maintenance means of

each component’s performance. This shall be implemented from the time

of periodical inspection.

The parts after Part 1 demonstrate breakdown, assembly and main points

of inspection of electrics, finished motorcycle, engine and other

components.

System diagrams, breakdown drawings, maintenance, fault diagnosis and

explanations are presented before each part when compiled.

Notes：

If patterns or structures of the motorcycles change, or differences exist

between pictures, drawings, instructions or others and physical products,

please take the later as the standard. The product is subject to change

without further notice.

ZHEJIANG QIANJIANG MOTORCYCLE CO., LTD.

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Service Data

General Safety Maintenance Regulation

Specification Sheet Fault Diagnosis

General Safety

Carbon monoxide (CO)

When it is necessary to start the engine, please make sure the workplace is well ventilated. You
shall never run the engine in an enclosed place.

Attention

Gas exhausted from the motorcycle contains toxic carbon monoxide, which may lead to loss
of consciousness and even death.

It is necessary to run the engine in an open area. If the engine is run in an enclosed site, ventilation
system shall be used.

Gasoline

Work in well-ventilated site. Fire and smoking are strictly forbidden in working sites or gasoline
storage places.

Battery

Battery shall be away from spark, open fire and smoking places since it may emit explosive gases.
Keep it in well-ventilated condition while charging.

Battery contains sulphuric acid (electrolyte), which will cause burns when contacting with skin or
eyes. Please put on protection clothing and helmet while handling battery.

——If electrolyte splashes on the skin, flush immediately with water.

——If electrolyte splashes into eyes, flush immediately with water for at least 15mintues and
get a medical examine.

Electrolyte is poisonous. If swallow it by mistake, please immediately drink plenty of water, milk
and milk of magnesia (a kind of laxative antacid) or vegetable oil and get a medical examine.
Keep it out of reach of children.

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Engine Oil

The repeat of exposing the engine oil to air after contact may cause cancer. Although it may be
unlikely to contact with the engine oil in your daily life, please wash your hand thoroughly with
soap after contact. Keep it out of reach of children.

Thermal Energy Part

The engine starts after the lasting of heat generated by engine and the heat-removal system for a
while. Please handle these parts with your hand putting on insulated gloves or after the engine and
the heat-removal system are cooled down.

Maintenance Regulations

While repairing and servicing, try to use tools of metric

system as possible as you can. Incorrect tools may
damage the motorcycle.

Before take down or open protecting plate for

maintenance work, please clean the dirt on external
surface of the component or the assembly to prevent the
dirt from falling into the engine, chassis or braking system.

After disassembly and before measuring friction, please clean the components and purge with air
compressor.

Plastic parts may deteriorate due to aging, which are apt

to be damaged by solvent or oil. Check before
re-installation and replace if necessary.

While removing a component with many assemblies, do from

outside to inside. Loosen firstly smaller assemblies; for the
complicated assemblies, such as gearbox, keep them in a
proper assembling order for the sake of easy assembly later.

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Pay special attention to the key fitting position before
disassembly. The components that are not used any more
shall be replaced on time before disassembly.

Length of bolts and screws are different for assemblies and

protecting plates. They shall be installed at correct
positions. If confused, just put the bolt inside the hole and
see if it matches.

Fill lubricating grease into the groove during oil seal

installation. Check if the oil seal is smooth and if it is
possible to be damaged when installed.

Installation of rubber hose (fuel, vacuum, or coolant): insert

its end into bottom of connector so that there is enough room
for the hose clamp to grip the connector. Install the rubber or
plastic dustproof boot back to its originally designed
position.

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Disassembly of ball bearing: use a tool to push
against one or two (inner and external) bearing
races. If the force works only on one bearing
race (whatever inner or external), the bearing
may be damaged when disassembled and it must
be replaced.

Slack cable implies potential safety hazard on electrics.

Check the next cable when the cable is clamped to ensure

electric safety;

Cable clamp shall not be bent towards solder joint;

Tie the cable at appointed position;

Don’t lay the cable at the end of frame or at the closed angle;

Don’t lay the cable at the tip of a bolt or screw;

Wiring of cable shall be away from heat source or places

where cable may be clipped while moving;

Prevent the cable from being pulled too tightly or slacking

too much when the cable is wired along the handlebar pipe.

The cable shall not be affected by any adjacent components

at any turning place;

The cable shall be wired smoothly and shall not be knotted or

twisted;

Check if sheath of connector is damaged and if connector is

over stretched before butt connection;

If cable runs around the closed angle or the corner, please

protect it with tape or hose;

Tie the cable with adhesive tape reliably after repair;

Controlling cable shall not be bent or twisted. Broken

controlling cable may result in non-flexible control.

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Identification of motorcycle
1．VIN is labeled at Position ①, as shown in Figure 1-1,
labeled as: * LBBGHP00?????????*. The tenth number of
the VIN represents the year of production and the eleventh
represents the code of the manufacturing factory. “*” is
marked respectively at the beginning and the ending of the
frame number. Frame nameplate is riveted at Position ②.

2. The frame and nameplate is shown in

the figure.

3. The serial number of the engine ① is marked on the shell of the crankcase. Refer to the figure
below.

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Important Notes
1．Please use spare parts manufactured by Zhejiang Qianjiang Motorcycle Co., Ltd. Components
that cannot comply with designed specifications of Zhejiang Qianjiang Motorcycle Co., Ltd. may
result in damage on the engine.
2．Only metric tools can be used for maintenance work. Metric bolts, nuts and screws cannot be
exchanged with inch fasteners.
3．While re-assembling, new washers, O rings, cotter pins and locking plates shall be used.
4．While tightening bolt or nut, please first fasten the ones with great-diameter or internal bolts;
and then tighten gradually to specified torque in diagonal order. Those with special requirements
are not included.
5．Clean removed components with cleaning liquid. Lubricate all the sliding surfaces before
assembly.
6．After assembly, check if all the components are correctly installed and can work properly.
7. Remove dirt and oil before measurement; apply recommended lubricant at lubricating positions
at assembly.
8. When the engine and transmission system are disassembled/assembled and needed to be stored
for a long time, please apply lubricant on the surface of the components to avoid rust and dust
deposition.

Special Tools
Special tools mean specially designed tools used at particular places for assembly or disassembly
of certain components on motorcycle. Appropriate special tools are essential for complete and
accurate adjusting and assembling work. Use of special tools can realize safe, reliable and quick
assembly/disassembly of components, working efficiency improvement and labour saving.
1．Tools for engine overhaul
Specially designed tools are required for smooth assembly and disassembly of some components
on the engine.
Special tools and product pictures for engine component assembly and disassembly are listed in
Table1-1 and Table 1-2.

Table 1-1

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 Name Remarks
Special socket wrench Used for dismounting/mounting of flywheel bolt, Figure
Clutch holder 1-3
Flywheel extractor Figure 1-4
Feeler gauge Figure1-5
Bearing puller Figure1-6
Bearing installer Figure1-7
Oil seal remover Figure1-8
Puller handle Figure1-9
Piston pin puller Figure1-10
Piston ring pliers Figure1-11
Spark plug socket wrench Figure1-12
Clutch thickness measurement Figure1-13
Cylinder bore tester Figure1-14
Dial gauge Figure1-15
Dial gauge, V-block Measuring inner diameter of piston pin, Figure 1-16
Valve shaft guide dismounting/mounting tool Measuring the tortuosity valve rod, Figure 1-17
Valve shaft guide mounting tool Measuring outer diameter of valve rod, Figure 1-18
Valve clearance adjusting tool Figure1-19
Value-spring dismounting/mounting tool Figure1-20
Valve shaft guide reamer Figure1-21
Crankcase dismounting tool Figure1-22
Figure1-23
Figure1-24
Continued Table 1-2

Figure 1-3 Figure 1-4

Figure 1-5 Figure 1-6

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 Figure 1-7 Figure 1-8

Figure 1-9 Figure 1-10

① Handle

Figure 1-11 Figure 1-12 ① Pliers ② Piston

Figure 1-13 Figure 1-14

- 14 -
Figure 1-15 Figure 1-16

Figure 1-17 Figure 1-18

Figure 1-19 Figure 1-20

Figure 1-21 Figure 1-22

Figure 1-23 Figure 1-24

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2．Tools for chassis overhaul
Common and special tools, as well as their pictures for chassis component assembly and
disassembly are listed in Table1-25 and 1-26.
Table 1-25
Name Remarks
Torque wrench Figure1-27
Allen wrench Figure1-28
Socket wrench Figure1-29
Micrometer Figure1-30
Magnetic stand, V-block Figure1-31
Dial gauge Figure1-32
Vernier caliper Figure1-33
Spring circlip pliers Figure1-34
Hammer screwdriver Figure1-35
Front fork oil seal installer Figure1-36
Front fork seal driver Figure1-37
Steering nut wrench Figure1-38
(1) General tools used for chassis overhaul
Continued Table 1-26

Figure 1-27 Figure 1-28

Figure 1-29 Figure 1-30

Figure 1-31 Figure 1-32

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 Figure 1-33 Figure 1-34

Figure 1-35 Figure 1-36

(2) Special tools for chassis overhaul: front fork seal driver

Figure 1-37
（3）Steering nut wrench

Figure 1-38
3．Tools for electrical components
Special tools and their pictures for electrical component test are listed in Table 1-39, 1-40.
Table 1-39
Name Remarks
Multimeter Figure1-41
Ignition tester Figure1-42
Continued Table 1-40

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 Figure 1-41

Figure 1-42

- 18 -
Specifications

Engine
Model BJ300GS BJ265MN-A
Model
unleaded gasoline
Overall length(mm) 2130 Fuel
(93/97)
Number of
Overall width(mm) 775 2
cylinders
(Overall
1120 Bore*stroke 65.0×45.2
height(mm)

Engine
Total
Wheelbase(mm) 1410 300cc
Displacement
Gasoline tank Starting
16L Electric
capacity mode
Front
98 Cooling mode Liquid cooling
shaft
Weight (kg) Rear Lubricating Pressure splash
98
（Curb weight） shaft mode lubrication
Total 196 Clutch type Wet, Multiple-disc
Gearshift
Front tire 120/70-17 Six gears
Tire method
Rear tire 160/60-17 Drive method Chain drive
Primary
Battery 1.864
12V-9AH drive ratio
capacity
Drive ratio of
2.846
Permanent magnet Gear 1
Magneto
flywheel
Electrical unit

Drive ratio of
1.947
Gear 2
Spark plug CR9EP
Arranger

Drive ratio of
1.556
Gear 3
Spark plug
0.6-0.7mm
clearance Drive ratio of
1.333
Gear 4
Ignition type TLI Drive ratio of
1.190
Gear 5
Maximum Drive ratio of
26.0 kW/12000rpm 1.083
power Gear 6
Maximum
27.0N.m/9000rpm
torque Final drive
Performance

3.286
Compression ratio
12：1
ratio
Diameter of
front
Brake

Maximum
140km/h hydraulic φ260mm
speed
brake disc
(mm)

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 Diameter of
Fuel rear
consumption ≤5.2L/100km hydraulic φ240mm
limit brake disc
(mm)

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 Fault diagnosis

Start-up difficulty or fail to start

Fault diagnosis Adjustment and inspection Fault reason
Check whether the fuel
pump is able to work
properly There has no gasoline in the tank
Oil pipeline of the oil injector for gasoline tank is
blocked
Sufficient and smooth No gasoline is fed
Oil pipeline of the gasoline pump is blocked
fuel is fed for oil injector for the oil injector
Pipeline for evaporation control system of the
fuel tank is blocked
Remove the sparking plug, put it
Gasoline filter is blocked
into sparking plug cover and
Insufficient pressure of the gasoline pump
connect with engine bond strap
Sparking plug has fault
to check whether it jumps spark
Sparking plug is contaminated
Fault of CPU set
It has It has slight spark
The trigger has fault
jump-spark or it has no spark
Open circuit or short circuit of ignition coil lead
Open circuit or short circuit of ignition coil lead
Compression pressure
Fault of main switch
determination
Fault of charge coil
Fault of starter clutch
Normal Compression pressure is too low or
Faults of cylinder piston and piston ring
compression there is no compression pressure
Air leakage of cylinder gasket

Fault of automatic choke action

The engine fails to
ignite and bursts out
The engine bursts
out but can not be Air suction into intake manifold
started
Wrong ignition time
Adjustment fault of adjusting screw of throttle
Remove the sparking
valve
plug again to check

Excessive injection quantity of oil injector

The sparking The sparking Fault of automatic choke action
plug is wet plug is dry
Throttle opens too much

- 21 -
Unsmooth rotation (acceleration failure and inability)
Fault diagnosis Adjustment and inspection Fault reason
Start engine and
feed oil slightly to Air cleaner is blocked.
check
Defective gasoline
Potation speed Engine speed Pipeline of evaporation control system of
cannot rise
of engine rises fully the fuel tank is blocked
Blocked exhaust pipeline
Use ignition timing Fault of automatic choke
light when adjusting Fault of throttle valve
Correct Wrong ignition time
ignition time
Fault of CPU set
Compression pressure The trigger has fault
determination

Faults of cylinder piston and piston ring

Compression Compression
pressure is normal pressure is too low
Air leakage of cylinder gasket

Check the blockage

of carburetor
Clearance of dirt
No blockage is Blockage is
found found
Remove the sparking Clearance of dirt
plug to check
Heat value of the sparking plug is
No contamination and Contamination and unsuited
color change are found color change are found

Check whether there is excessive

engine oil or whether the oil is Too much engine oil
contaminated in the crankcase
Too little engine oil
The engine oil Too much
quantity is normal engine oil Fail to replace engine oil
Check the oil lubrication of Piston cylinder is worn
cylinder head
Gas mixture is rarefied
Normal Abnormal Defective gasoline
Overheating
engine Too much carbon deposit in the
combustor
Without With
overheating overheating Too early of ignition
Too much carbon deposit in the
Accelerate running or
operating combustor
Defective gasoline
Without engine With engine
knocking knocking Clutch slipping
Weak gas mixture
Too early of ignition

- 22 -
Unsmooth rotation (low speed in particular)
Fault diagnosis Adjustment and inspection Fault reason

Adjustment of ignition time

Fault of CPU set

Normal Abnormal
The trigger has fault

Adjust the adjusting bolts

for of throttle valve

Gas mixture is too rarefied (loose

Good Poor bolts)
adjustment adjustment Gas mixture is too thick (tighten
bolts)
There is air suction
in the gasket Fault of gasket of heat resisting sheet
The fixed nut of throttle valve is loose
Air suction Air suction Heat resisting gasket is broken
does not
occur occurs Negative pressure pipe is broken
Remove the sparking
plug, put into sparking
plug cover and connect
with engine bond strap to
the engine to check
whether it jumps spark Fault of sparking plug or sparking
The sparking plug contaminated
The sparking plug
plug unfavorably unfavorably Fault of CPU
jumps spark jumps spark
Fault of ignition coil
Open circuit or short circuit of
sparking plug lead
Fault of main switch

Negative pressure pipe is damaged

Favorable Poor

Air through-hole is blocked

- 23 -
Unsmooth rotation (high speed)
Fault diagnosis Adjustment and inspection Fault reason
Adjustment of
ignition time

Fault of CUP set

Normal Abnormal

The trigger has fault

Little gasoline in the tank

Gasoline filter of gasoline pipe is
blocked
Normal Abnormal
Pipeline of evaporation control
system of the fuel tank is blocked
Fault of automatic oil ring
Oil injector is blocked

Blockage
No blockage Removed

Favorable The spring is broken

or is lack of elastic Spring fault
force

- 24 -
Bad charging (storage battery over-discharging or overcharging)
Fault diagnosis Adjustment and inspection Fault reason
Measure the voltage
between the both ends of
the storage battery and start
the engine
Storage battery life expires

Storage battery Storage battery voltage rises

voltage does to normal value, but restores
not rise to previous voltage after
Storage battery fault
switching off

Check whether the plug of

voltage adjuster is loose

Poor connection of plug

Normal Abnormal
Open circuit of red wire in
wiring

Check the voltage of the vehicle by

connecting the red wire of voltage
adjuster’s socket to the cathode and
anode wires of multimeter
Voltage adjuster
With voltage No voltage
The white wire in wiring is
broken

Measure coil impedance value of AC

generator

Coil fault
Normal Abnormal
Poor connection of joint
The white wire in wiring of AC
generator is broken
Storage battery fault
Charging fault or over-charging
Start the engine and check the voltage of the
vehicle by connecting the red wire of
voltage adjuster’s socket to the cathode and
anode wires of multimeter
The voltage is
higher than The voltage is normal
normal value

Check whether the wiring of voltage

adjuster connects badly
Loose and bad
Normal connection Poor connection of joints and
Impedance test of single
voltage adjuster poor grounding of wires
Fault of voltage adjuster

- 25 -
 No flashover in spark plug
Fault diagnosis Adjustment and inspection Fault reason
Replace sparking plug
and re-check

There is slight or no Strong spark

jump spark of sparking Original sparking plug fault
plug

Check sparking plug and

re-check

Not loose Loose Sparking plug cover is loose

Check whether the plugs of

CDI set are loose

Normal Abnormal Poor connection of plug

Check the connection of various
terminals of the lead plug of CDI set
and measure the resistance value
Fault of main switch
Fault of charge coil
Normal Abnormal The trigger has fault
Fault of ignition coil
Check of relevant
parts

Normal Abnormal Main wire is broken

Connection of joint plug is
unfavorable
Check the CDI set using CDI tester

Normal Abnormal Fault of CPU set

Check the ignition coil using CDI tester

Abnormal Fault of ignition coil

- 26 -
Inspection/Adjustment

Basic data Periodic maintenance schedule chart

Engine oil/filter Coolant liquid

Assembly and disassembly Fuel injector and oil circuit

of radiator pipe clamp

Throttle cable adjustment Air cleaner

Spark plug Battery

Fuse replacement Cylinder pressure

Drive chain slackness Front brake clearance

Rear brake clearance Headlamp

Clutch Front/rear suspension system

Bolt/nut/fasteners Wheel rim/tire

Steering stem bearing Throttle valve

and handlebar retaining

Lubrication of spare parts

Basic Data

General
Warning!
•Before running the engine, please make sure if the workplace in is well ventilated. You shall
never run the engine in an enclosed site. Gas exhausted from the motorcycle contains carbon
monoxide, which may lead to loss of consciousness and even death.
•Under certain conditions, gasoline is highly volatile. Work in well-ventilated site. Fire and
smoking are strictly forbidden in working sites or gasoline storage places.

Specifications

- 27 -
Engine
Bore*stroke 65.0×45.2
Total displacement 300cc
Ignition method TLI
Spark plug clearance 0.6-0.7mm
Spark plug type CR9EP
Combustor model Sphere

Frame

Clearance of front brake handle 10-20mm

Clearance of rear brake pedal 20-30mm
Specification Tire Pressure
Pneumatic pressure unit of tire：
Front tire 120/70-17 190 to 250kPa
Kpa BJ300GS
Rear tire 160/60-17 190 to 250kPa
Front axle fastening 130-140N·m
Torque
Rear axle fastening nut 130-140N·m

Frame

Clearance of front brake handle 10-20mm

Clearance of rear brake pedal 20-30mm
Specification Tire Pressure
Pneumatic pressure unit of tire：
Front tire 110/70-17 190 to 250kPa
Kpa BJ300GS
Rear tire 140/70-17 190 to 250kPa
Front axle fastening 130-140N·m
Torque
Rear axle fastening nut 130-140N·m

- 28 -
 Periodic maintenance schedule chart

Mileage and Every Every Every Every Every

Every
interval 1000K 3000 6000K 12000 14500
300 KM
M KM M KM KM Tools

New One three Six Twelve Fifteen

Items
Vehicle month months months months months
* Air cleaner I C C R C Common tool
* Gasoline filter I I R Common tool
* Engine oil filter C C C Common tool
Engine oil Replacement R Replace every 3000KM. Common tool
Tire pressure I I I I I I Tire gauge, air inflator
Battery inspection I I I I I I Densimeter, multimeter
Actuating clearance
I I I I I I Common tool
inspection
Inspection of steering
I I I Common tool
handle bar looseness
Shock absorber actuating
I I I Common tool
inspection
Inspection of looseness of
I I I I I I Torque wrench
bolts at all positions
Check if gearbox leaks oil I I I I I I Common tool
Spark plug inspection and
* I I R R I Common tool
replacement
Lubrication of all the
L L Lubricant injector
places on the vehicle
Muffler I I I I I I Common tool
* Ignition timing I I I I I I Timing light
* Carburetor A I A A A A Tachometer,
* Idle exhaust gas inspection A I A A A A CO HC analyzer
* Throttle inspection I I I I I Common tool
Fuel hose inspection I I I I I Common tool
Lamps, instrument and
I I I I I I Visual multimeter
electric apparatus
Main stand and side stand I I I Common tool
Shock absorber I I I I Common tool
* Torque of engine bolt I I I I I Torque wrench

Front/rear brake I I I I Common tool

Drive chain I I I I A Common tool
Clutch I I I I Common tool

- 29 -
* Valve I I I I I Feeler gauge

- 30 -
Expected Inspection
1 Ignition system—-perform maintenance inspection on obvious and continuous ignition
malfunctions, engine on fire, overheated back burning and others.
2 Carbon deposit removal—-obvious underpower, get rid of carbon deposited at cylinder head,
piston head and air exhaust system.
3 Piston and cylinder—-When cylinder is over worn or stuck, please replace it.

Please go to your local Qianjing Motorcycle dealer periodically for inspection and adjustment to
keep your vehicle in best conditions.
In above table, monthly 1000km travel is employed as reference.
I— Inspect A—Adjust R—Replace C—Clean L—Lubricate

Note：1. “*” for items involved in exhaust gas, which meets regulations of China Environmental
Protection Agency. Normal maintenance shall be performed according to specifications on the
user’s manual; unauthorized repair and adjustment are forbidden. We will not be responsible for
the results.
2. You shall clean more frequently the air cleaner to extend its service life when your motorcycle
is used on sand-gravel roads or in severely polluted environment.
3. More frequent servicing may be required when the motorcycle is often driven at a high speed or
travels a long distance.

Engine oil/Oil filter

Engine oil level

*Attention
•Motorcycle shall stand on the flat ground while
checking engine oil level.
•Inspect engine oil level when the engine has run for
2~3 minutes and stopped for 2~3 minutes.

Check engine oil level.

When the engine oil level sensor alarms, refill engine
oil to its upper limit.

Engine oil replacement

*Attention
When the engine is warm, replace engine oil. The oil
can flow out easily.
Shut down the engine.
Screw off the drain plug (1) at the bottom of crankcase to drain engine oil.
When the engine oil is completely drained, put back cleaned drain plug and sealing ring.

Refill engine oil to specified level.

- 31 -
Check if there is engine oil leakage. Start the engine and run the engine on idle for a few minutes.
Check engine oil level again.

Replacement of engine oil filter

* Attention

Replacement in the process of engine heating, it will easily

result in engine oil over flowing.

Turn off the engine.

When using special tools to disassemble engine oil filter,

the filter is stuck. Rotate the engine oil filter② required for Engine Oil Filter
replacement in anticlockwise to remove;

Replace with new engine oil filter and coat a layer of lubricating oil on O-rings.

Notes:

Please do not disassemble the O-ring on the engine oil filter, since it will make the seal ring out of
place, thus resulting in oil leakage, engine damage, etc.

Manually install the new engine oil filter to the engine,

screw it by hand till it is tightly fixed and use torque wrench
to fasten engine oil filter, with the torque as 15-20Nm.

Check whether there is leakage in engine oil and start the

engine in idle running for several minutes.

- 32 -
Cooling liquid
During maintenance, it is necessary to check the level of
cooling liquid in the expansion tank.

When cooling liquid turns turbid or it is time for

maintenance, please replace the cooling liquid in time.

Recommended model of cooling liquid: FD-2

The total capacity of cooling liquid in the cooling system is

about 1.9L.

Take out the protection plate on the front right side. Find out
the filling opening① for cooling liquid in the radiator tank.

Uncover the filling opening for cooling liquid and fill in

cooling liquid in proper quantity.

After the completion of filling, re-install the filling opening

cover (2) on the radiator.

After the engine is switched off and cooled down, re-check

the cooling liquid for expansion tank. In check, it is
necessary to ensure that the motorcycle is placed in a
horizontal plane and maintain the vehicle body vertical.
Observe the capacity of cooling liquid in the expansion tank
through the through-hole on the right flame of the vehicle and maintain it between mark H and L.
If the level of cooling liquid is below mark L, please uncover the expansion tank and fill in
cooling liquid.

Warning:
It is not allowed to fill in cooling liquid until the engine
is switched off and cooled down. In order to prevent
scald, please do not uncover the filling opening for
cooling liquid before the engine is cooled down. The
cooling system is under pressure. In some cases,
substances in it might be flammable, which will
generate invisible flame when ignited. Since leaked
cooling liquid will result in serious scald if burning, it
is necessary to prevent it from leaking on spare parts of
the motorcycle in high temperature.
Since cooling liquid is highly toxic, please do not
contact and inhale and place it away from children and
livestock. In case of accidentally inhalation, please seek
medical advice immediately. If cooling liquid is in
contact with skin or eyes carelessly, please wash with
clean water immediately.

Assembly and disassembly of radiator pipe clamp

- 33 -
 Clamp

Radiator pipe clamp is disposable. When it is

disassembled, the old clamp shall not be in repeated use.
Special clamp pincers① are required for re-assembling
the clamp ②. Otherwise, it will result in clamp out of
place and vehicle breakdown.

Fuel injector and oil-way

There are 2 interfaces on fuel pump①. Fuel enters fuel
injector③ from one interface through engine oil filter②.
In the end, oil gas is injected to the engine’s intake tube.
When the fuel oil is of too much pressure, it will return to
the fuel pump from the other interface of fuel pump①.

Refer to the connection as shown in the right figure for

connection of oil inlet and return pipes.

- 34 -
Adjustment of throttle cable
* Attention

It is necessary to correctly adjust engine idling before

adjustment of throttle cable stroke.

Check the free stroke of throttle cable, which shall be 3-5mm.

It needs of adjustment in case of failing to complying with the specified value.

Adjust the free stroke of throttle cable.

The vehicle is equipped with throttle cables in doublet

structure: i.e. A
○ as throttle oil filling cable and B
○ as
throttle oil return cable. Please adjust throttle grip to
control free stroke by the following steps:
(1) Withdraw throttle cable’s dust cover.
(2) Loosen locknut③.
(3) Completely screw to adjusting nut④.
(4) Loosen locknut①.
(5) Rotate adjusting nut②, making free stroke by throttle
grip as 10°-15°.
(6) Screw locknut①.
(7) Adjust adjusting nut④ to make throttle grip rotate in a flexible way.
(8) Screw locknut③.

After free stroke adjustment, it is necessary to screw handle in a horizontal way so as to confirm
that no change has occurred to engine idling.

Air cleaner
Replacement of air cleaner
Open seat cushion by key and take it out.

Disassemble fuel tank’s protection plate and

fixed bolt (1) and take out the fuel tank.

- 35 -
Disassemble the cover of air cleaner.

Take down the filter element.

Check whether the filter element is contaminated

or damaged.

Please replace it by new product if necessary.

Use detergent to softly and thoroughly rinse the

filter element.

It is prohibited to use gasoline so as to prevent

fire.

It is prohibited to warp or wring filter element so

as to prevent damage on foamed materials.

Afterwards coat the filter element with engine oil, extrude residual engine oil and make it moist
without oil drip.

Replacement time
If the vehicle is often driven on poor road surface or driven in rainy days, it is necessary to make
replacement as early as possible.

* Notes

Please do not rotate the engine in the process of filter element replacement to prevent unfiltered air
entering into engine, resulting abrupt wearing of other parts.

Besides, the engine may be damaged accordingly.

In addition, running without filter element will affect carburetor, lead to bad operation or result in
overheating of the engine.

In installation, make operation in a reverse order compared with disassembly.

- 36 -
Spark plug
Spark plug disassembly:
(1) Lift the fuel tank.
(2) Remove the intake air temperature sensors ① on
both sides of the air filter respectively and then remove
the air filter.
(3) Remove the stators on both sides of the spark plug
clap ② respectively.
(4) Remove four spark plug claps ③ respectively, then
the spark plug ④ will be seen.
(5) Using the disassembly sleeve to remove the spark
plug.

Inspection
 If the insulator is cracked or damaged.
 If the electrode is worn
 The combustion conditions and color
 Light grey color means good combustion
conditions.
 Pale color indicates that ignition system fails or
lean air mixture.
 Wet appearing or dark carbon deposition means
higher air mixture.
If the above situations happen, clean the electrode of
spark plug with wire brush or spark plug cleaner and
replace it if necessary.
Visually inspect the spark plug.
Replace a new one if the insulator is cracked or worn.
Replace the spark plug after driving every 8,000 Km.
Clearance: 0.6-0.7mm
Spark plug model: CR9E(NGK)
* Attention
Reinstall the spark plug into the cylinder head and tighten it with the specified torque.
Torque value: 20-25N.m
Install the spark plug by hand at first and then fasten it with the spark plug sleeve.
Do not fasten the spark plug too tightly or stagger the thread in case of damaging the thread of the
cylinder head.
Ensure no foreign matters get into the engine through the spark plug while removing the spark
plug.

- 37 -
Battery

Disassembly of battery

Remove seat cushion.

Remove the mounting plate for battery.

Battery location

Remove cathode wire before removing anode

wire.

Remove storage battery from storage battery box.

Take out the battery.

Warning!

In the process of anode disassembly, it is not allowed to make tools in contact with frame;
otherwise, it will result in short-circuit spark, gasoline ignition and storage battery damage, which
will be rather dangerous.

In installation, make operation in a reverse order compared with disassembly.

Warning!

In order to prevent short-circuit, connect the anode before connecting the cathode.

Please do not to trip off the storage battery during commissioning of the whole vehicle; otherwise,
it will result in internal damage on spare parts of the entire vehicle.

- 38 -
Battery charging (circuit voltage)

inspection
Open the seat cushion and take down the right
protecting plate.
Take out the battery from the battery case.
Disconnect the battery negative (-) lead wire first
and then the positive (+) lead wire.
Remove the battery.

Measure the battery voltage between terminals.

Fully charged: 13.1V
Undercharge: 12.3V（battery not work for one hour）

* Attention
Voltmeter shall be used for charging-state inspection.

Charging
Connection method: Positive pole of battery charger is connected to battery positive lead
wire; Negative pole of battery charger is connected to battery negative lead wire.

Warning!
• Battery shall be away from fire source.
• Shut off charger switch first before or after charging in case
sparks may be generated at connection parts, which may
result in explosion.
• During charging, please take the current time labeled on the
battery as the basic time.

* Attention
• Battery quick charging is not recommended except in case
of emergency.
• After charging, wait at least 30minutes and then measure the battery voltage.

Charging current: Standard: 0.3A

Quick charging: 3.0A
Charging time: Standard: 10-15hours
Quick charging: 30minutes
After completion of charging: open circuit voltage: higher than 12.8V

- 39 -
Replacement of fuse
Fuse is located at the bottom of seat cushion of driver and beside the storage battery.
Main fuse is set on the starter relay and fuse box is
beside main fuse. As shown in the figure, ① refers to
the main fuse whose specification is 40A, ② is the
backup fuse of the main fuse whose specification is
40A and ③ is the fuse box, where fuse configuration is
as shown in the figure:

In case of frequent blowout, it indicates short circuit or overload

on circuit.
Notes:
Before checking or replacing fuse, the ignition switch shall be set
in “off （ ）” in order to prevent short circuit or damage of other
electrical components.
Do not use fuse beyond specification; otherwise, it will result in
seriously adverse impact and even burning vehicle light or fire,
leading to loss of engine traction, which is rather dangerous.

- 40 -
Compression pressure of cylinder
Warm up engine.
Insert the pressure gauge.
Turn choke valve to its full open position.
Set throttle handle to its full open position and kick start the
engine.
Compression pressure of cylinder：1～1.2mpa
* Attention
Start the engine till reading of pressure gauge does not rise.
Causes for low pressure:
 Valve improperly adjusted
 Valve leaks air
 Worn piston ring or cylinder
Causes for high pressure:
 Carbon deposition in combustion chamber or on piston.
 Stop engine and remove spark plug/ spark plug cap.

Looseness of drive chain

The service life of drive chain is dependent upon appropriate
lubrication and adjustment. Improper maintenance is likely
to result in premature wear on drive chain and sprocket. It is
necessary to make frequent maintenance in severe
conditions.

Place the motorcycle in a flat place and maintain it upright.

Check of looseness of drive chain ○

a。

Looseness of drive chain: 10-20mm.

Adjustment on drive chain:

Make adjustment on drive chain per 1000km of traveling so
as to ensure chain sag of 10-20mm. Based on your driving
conditions, chains are likely required of frequent adjustment.
Warning:
These suggestions are the maximum interval for
adjustment. In fact, it is necessary to check and
adjust chains before each drive. Over-loosened
chains are bound to result in off-chain accident or
serious damage on engine.
+
Please adjust chains in the following method:
(1) Use support frame to put up the motorcycle.

- 41 -
 (2) Loosen rear shaft nut①.
(3) Loosen locknut②.
(4) Rotate adjusting bolt ③ rightwards or leftwards to adjust the looseness of chains. In the
meanwhile, it is also necessary to make sure that front and rear sprockets are centering in
alignment. In order to help you in the adjustment, benchmark marks are set on the
swinging arm and each chain adjuster, which are able to be in mutual alignment as
reference from one end to the other. After alignment and adjustment on the looseness of
chains to be 10-20mm, please re-fasten rear-shaft nut and make final check.
Notes:
When new chains are installed, it is necessary
to check whether there is wear on two sprockets
and make replacement if necessary.

In regular check, it is necessary to check the following conditions on chains:

(1) Loosened dowel

(2) Damaged idler wheel
(3) Dry and rusted chain link
(4) Twisted or seized chain link
(5) Excessive injury
(6) Adjust loosened chains
In case of the above faults on the chains, sprockets are bound to encounter damage as well. It is
advised to check the following contents against sprockets:
(1) Severely wearing wheel teeth
(2) Broken or damaged wheel teeth
(3) Loosened fixed nut of sprocket

Lubrication on drive chain

It is necessary to prioritize using drive chain lubricating grease for lubrication. It is allowed to
purchase drive chain lubricating grease or replace it by engine oil or other lubricating oil. Steep
chain link joints, making lubricating grease permeate into link joint, pin, lining and roller.

* Notes

Do not install new drive chain on worn sprocket or install worn chain on new sprocket.

Sprocket and chain shall be in sound condition,

Otherwise, it will result in fast wearing on chain or sprocket replaced.

- 42 -
Free stroke of front brake

Free stroke of front brake

Measure free stroke of front brake at the tip of front
brake handle.
Clearance: 10-20mm

Front brake handle adjuster

Out of demands for operation comfort, it is able to adjust

Front
the location of front brake handle through circular nut’s
adjustment knob. It is able to select one out of the 4
locations for adjustment, which only needs to gently
move forward the front brake handle horizontally and
rotate circular nut adjuster to be in alignment with arrow
A
○ , to adjust it to the required location. Location 1 front
brake handle is the farthest from throttle control grip and location 4 front brake handle is the
nearest from throttle control grip.

Free stroke of rear brake

Free stroke of brake pedal

Measure free stroke of brake pedal
Clearance: 20-30mm.

If the clearance measured does not meet the specified

value, adjust it.
Adjust clearance of brake pedal.
Loosen the nut A first.

- 43 -
Screw in or out B to adjust the clearance of brake pedal.
If 2 is screwed in, clearance is decreased; if screwed out, clearance is increased.
Adjust till the clearance is up to the specification, tighten 1.
After adjustment, the brake shall not drag.

Headlamp
Remove the stand bolt of the headlamp (1).

Turn over the headlamp and the wind deflector

components.
Remove the self-tapping screw (2)
Take down the decoration panel behind the wind
deflector.

Remove the self-tapping screw (3)

Take down the dust shell of the headlamp.

Pull out the headlamp connector (4), take down the lamp holder, loosen the circlip and remove the
bulb.

- 44 -
* Attention
When the bulb is lit, keep you hands and inflammable materials some distance away from it.
Lighting bulb is hot, touch it when it cools down.

Install a new headlamp bulb, lamp holder and

screw tightly the new bulbs into the lamp
holder.
Avoid touching bulb glass with your bare
hands during installation and avoid staining
them with oil, which may affect transparency,
service life and luminous flux of bulbs.
If oil is adhered to the bulb, clean it with a
cloth moistened with alcohol or highly
volatile rubber solution.

Clutch
Check the free stroke for clutch cable.

Free stroke: 10-15mm.

Adjust the free stroke of clutch cable.

Unscrew retaining nut (1).

Screw in or out adjusting device (2),

Till free stroke meets specified value.

Finally, screw retaining nut.

If the handle side of clutch cable is adjusted to the limit location, but it remains
failing to meet the requirements for free stroke, it is necessary to adjust through
the locknut ○A and the adjusting nut ○ B between cable and engine side.

- 45 -
Front/Rear suspension system

Front shock absorber

Grasp the front brake handle and compress upward and
downward the front shock absorber to check its
actuation.
Check if the front shock absorber leaks oil and if the
components are loosened.

Rear shock absorber

Compress upward and downward the rear shock
absorber to check its actuation.
Check if components on the rear shock absorber
are loosened or injured.
Lift and support the rear wheel and swing the
wheel to check if engine suspension bushing is
loosened.

Bolt/nut/fasteners
Inspect if bolts, nuts and fasteners at every part of the motorcycle are loosened.
If it is loosened, tighten it to specified torque.
…

- 46 -
Rim/ tire
Check whether there is crack, iron nail clip or any other
damage on tire.

Inspect tire pressure.

* Attention

Measure air pressure in tire when it is in cold state.

Tire specifications Tire pressure

Front
tire 120/70-17 190±10kPa
BJ300GS
Rear tire 160/60-17 210±10kPa

When the depth of tread pattern on the central tread of tire reaches the degree in the table,

the tire shall be replaced.

Minimum depth of tread pattern

Front tire 1.6mm
Rear tire 2.0mm

Warning:
Please do not attempt to repair damaged tire.
Wheel balance and tire reliability are likely to
deteriorate.
Improper air inflation in tire will result in
abnormal tread wear and endanger safety.
Improper air inflation in tire is likely to result in
tire slipping or tire off, triggering tire deflation
due to out of control.
Driving a motorcycle when the tire is severely
worn is very dangerous, which is not convenient
to ground adhesion and driving.

Check whether the retaining nut for front wheel shaft is loose.

Check whether the retaining nut for front wheel shaft is loose.

In case of looseness, it is necessary to tighten to specified

torque force value.

Torque force value:

fixation on front shaft 130-140 N·m

Retaining nut for rear shaft 130-140 N·m

- 47 -
Steering stem bearing and handlebar retaining
Move left and right the handlebar and check if lead
wires disturb it.
Rotate front wheel and confirm the handlebar can
move smoothly.
If the handlebar does not move smoothly and is
loosened,
check steering stem bearing.

Throttle valve
Motorcycle idling will be reduced due to pollution on
throttle valve; therefore, it is advised to clean throttle
valve for every 5000km of traveling.

When cleaning throttle valve, it is necessary to

disconnect storage battery cathode and sensor
connector installed on throttle valve; dismantle throttle
wire and hose between air filter and intake manifold
and disassemble throttle valve.

Uncover the bottom of the throttle valve, spray

detergent inside throttle valve and wipe off dust,
carbon deposit etc. by brush.

After cleaning, make reverse operation, install throttle valve, ensure that all the parts have been
installed in place and pilot starting the engine.

Notes:

Do not make impurities block the bypass air tubes.

- 48 -
Lubrication on spare parts
Proper lubrication is of vital importance to maintain normal operation of each component of the
motorcycle and prolong its service life and safe driving. After the motorcycle is driven for a long
time or is soaked or cleaned in rain, it requires of lubrication maintenance on the motorcycle.
Refer to the following figure for key points in specific lubrication maintenance:

ＹMotorcycle
□ lubricating oil □ Lubricating grease
Ｚ

1 Rear brake pedal shaftＺ

□ 2 Kick stand joint and spring hookＺ
□ 3 Gear shifting treadle pin Ｚ
□

4 Throttle cable Ｙ
□ 5 Front brake handle pinＺ
□ 6 Clutch handle (pin) Ｙ
□

- 49 -
Inspection and Maintenance of Electrical System

充电系统
Charging System

- 50 -
Ⅰ Battery/Charging System

Service Data-------------------------1.1

Fault Diagnosis---------------------1.2

Battery-------------------------------1.3

Charging System-------------------1.4

Voltage/Current Regulator--------1.5

Magneto Charging Coil-----------1.6

Removal of Magneto--------------1.7

1.1 Service Data

Precautions on operation
* Attentions
1. The battery can be charged and discharged, and used repeatedly. If a battery is laid aside after
discharging, its service life will be shortened and its performance is degraded. Performance of a
battery is usually reduced after about 2-3 years’ use. Voltage of the performance-reduced (capacity
drops) battery can be resumed, but the voltage will run down quickly while loading.
2. Overcharging of battery: Usually overcharging is demonstrated by the battery itself. If short
circuit occurs inside the battery, voltage or very low voltage on the terminals of the battery cannot
be inspected. If the regulator fails, it will have too high voltage on the battery and the life-span
of the battery will be shortened.
3. When the battery is laid aside for a long period, it will self-discharge and its capacitance will
drop. The battery should be recharged every three months.
4. Charging system inspection: please perform inspection in accordance with the sequence listed
in the fault diagnosis table.
5. If there is current going through the electric parts, the connector shall not be removed, or the
voltage will be very high and electronic components inside the voltage regulator will be damaged.
Set ignition switch at “Off” position and then begin your work.
6. It is not necessary to inspect maintenance-free (dry-charged type) battery. Electrolyte and
distilled water are not required to be added.
7. Inspect the entire electric load.
8. Quick charging is forbidden except in emergency.

- 51 -
9. During quick charging, the battery must be removed from the motorcycle first and then be
charged.
10. While battery is exchanged, please do not use liquid-feeding battery.
11. A voltmeter shall be employed to check the state of charged battery.

Service Data
Item Specification
Capacity/type 12V-9AH/ dry-charged type
Voltage Fully charged 13.1V
Battery (20℃) Must be charged 12.3V(stop working for one hour)
Charging current Standard：0.8A，Quick：8A
Charging time Standard：10-15hours; Quick：30minutes
Capacity 160W/4000rpm
Magneto
Coiling impedance value (20℃) White-white 1.5-3.5Ω
Type Full wave of three-phase
Voltage
regulator Battery charging voltage 14.5V±0.5V/5.000rpm

Tightening torque Tools

Rectifier bolt 5.0 N·m Universal non-adjustable spanner
High-voltage coil pinch bolt 9.0 N·m Flywheel remover
Flywheel locknut 5.0 N·m Testing device
Vehicle block protecting plate bolt 9.0 N·m Multimeter

1.2 Fault Diagnosis

No power Unstable power

Battery over discharged Wiring of battery is poorly contacted
Wiring of battery is not connected Discharging system is of poor contact
Fuse fails Lighting system is of poor contact or short circuit
Power switch is poorly contacted

Low voltage Poor charging system

Battery is poorly charged Wire connector is of poor contact, short circuit or short line
Poor contact Defective voltage and current regulator
Poor charging system Magneto does not work well.
Poor voltage and current regulator

- 52 -
1.3 Battery

1.3.1 Battery Removal

Refer to page 36 for disassembly of battery.

Warning!
During positive lead wire disconnection, be sure to
prevent the tools being used from touching the
frame; or it will result in short circuit sparks, which
may ignite gasoline and damage battery. It is
dangerous!

Install the battery in the reverse order of removal.

* Attention

To avoid short circuit, please connect positive

lead wire first and then the negative lead wire.

Battery charging (circuit voltage) inspection

Open the battery cover and remove battery pressure
plate assembly.
Disconnect lead wire of the battery connector.

Measure voltage between terminals of the battery.

Fully charged: 13.1V

Undercharged: 12.3V （battery stop working for 1 hour）

* Attention

A voltmeter shall be employed to check the state of charged

battery.

1.3.2 Charging
Connection method: Positive pole of battery charger is connected to battery positive pole;
Negative pole of battery charger is connected to battery negative pole.

- 53 -
 Warning!
• Battery shall be away from fire sources.
• Shut off charger first before or after charging in case that sparks may be generated at connection
parts, which may result in explosion.
• During charging, please take the current time labeled on the battery as the basic time.

* Attention
• Battery quick charging is not recommended except in case of emergency.
• After charging, measure the battery voltage in 30minutes’ time.

Charging current: Standard: 0.8A

Quick charging: 8.0A
Charging time: Standard: 10-15 hours
Quick charging: 30 minutes
Charging completed: open circuit voltage: higher than 12.8V

1.4 Charging System

1.4.1 Short circuit test

Disconnect the grounding wire from the battery and use a voltmeter to connect battery negative
lead wire with grounding wire. Set the switch at OFF position and check if it is shorted.

* Attention
Positive lead wire of multimeter is connected to
negative lead wire of battery.
If abnormality is found, check if there is short circuit on ignition switch and main wiring.

1.4.2 Charging State Inspection

While in inspection, if the battery is fully charged, a multimeter
shall be used for the test.
Warm up the engine and then install the fully charged battery onto
the motorcycle.
Connect voltmeter between terminals of the battery.
Remove the main fuse and connect an ammeter between the two
terminals.
Start engine and slowly raise RPM. Measure limited voltage and
current.
Limited voltage/rpm：14-15V （5.000rpm）
If limited voltage is beyond the specified range, check the voltage
regulator.
Inspecting the limited voltage of the illuminating system.

- 54 -
Remove the seat cushion.
*Attention
The multimeter is set at the alternation voltage gear.

Limited voltage: 13.1 (+/-) 0.5V/5.000rpm

Please inspect the voltage-current regulator if the limited voltage is not in the specified range.

1.5 Voltage-current Regulator

1.5.1 Loop inspection on main wiring terminals

Remove the fender of the vehicle. Disconnect the 4P plug on the voltage-current regulator.
Check between main wiring terminals in the following
way:

Item （wire color） Judgment

Between battery (red) and There is battery
ground of vehicle block voltage.
Between ground wire (black)
There is a lead wire.
and ground of vehicle block
Between charging coil
The magneto coil has
(white) and ground of
resistance
vehicle block

1.5.2 Voltage-current regulator inspection

1. Diode is used in multimeter;

2. Black probe is connected to the red end of the voltage regulator, the red probes are connected to
the white ends (white 1, white 2, white 3) respectively. The pointer tables all reveal certain
numbers, otherwise the voltage regulator will be deemed to be damaged or replaced.
3. Red probe is connected to the black end of the voltage regulator, the black probes are connected
to the white ends (white 1, white 2, white 3) respectively. The pointer tables all reveal certain
numbers, otherwise the voltage regulator will be deemed to be damaged or replaced.
* Attention
• Do not touch the metal part of multimeter probe with your finger.
• Check with a multimeter. If impedance values measured by different multimeters are not the same,
it indicates incorrect inspection.
When impedance value between terminals is abnormal, voltage regulator shall be replaced.

- 55 -
1.6 Magneto Charging Coil

* Attention
Inspection of magneto charging coil can be performed on the engine.

Inspection
Ω
Disconnect the 6P connector on the magneto. 白
白 白

Use a multimeter to measure impedance value

between three white terminals of the magneto.
Standard value：1.5-3.5Ω（20℃）
If measured value exceeds the standard, the
magneto coiling shall be replaced.

- 56 -
1.7 Magneto Removal

1.7.1 Disassembly
Loosen retaining bolt on the left cover and take the left cover and magnetic coil.

Left cover and

magnetic coil

Bolt

Use universal non-adjustable spanner Bolt

to fasten flywheel.
Dismantle the retaining bolt for flywheel.
Use flywheel unplugging equipment to dismantle
flywheel.
Dismantle solid key.
Dismantle magneto wire joint.
Dismantle magneto stator.

Loosen four magnetic coil retaining bolts and dismantle magnetic coil.

Bolt

- 57 -
Use electrical or pneumatic tool or torque spanner to loosen flywheel locknut.
Unplug flywheel components.

Flywheel locknut

1.7.2 Installation

Install the magneto stator onto the engine case.

Connect connector of magneto lead wire.

Clean crankshaft and conical part of flywheel.

Align the groove on the flywheel to the retaining key on the crankshaft.
Make sure the retaining key is installed into the key slot on the crankshaft.

*Attention
There is magnetism on the inner surface of flywheel, and make sure there is no bolt.

Fix the flywheel using a universal non-adjustable spanner and then tighten the locknut.

Torque force value: 9.0 N·m

- 58 -
- 59 -
Ⅱ Ignition System

Service Data-------------------------2.1

Fault Diagnosis---------------------2.2

Ignition System Inspection-------2.3

ECU Assembly----------------------2.4

Ignition Coil------------------------2.5

Trigger------------------------------2.6

2.1 Service Data

Precautions on operation
1. Ignition system inspection: please perform inspection in accordance with the sequence listed in
the fault diagnosis table.
2. Ignition system uses electronic-type automatic timing device, which is solidified in the ECU
assembly, so ignition time adjustment is unnecessary.
3. Ignition system inspection: please perform inspection in accordance with the sequence listed in
the fault diagnosis table.
4. Ignition system ECU shall not be dropped and hung, or heavily knocked (this is also the main
reason for its failure). Pay special attention to this while removing it.
5. Most of the ignition system problems are due to poor contact of sockets. Please check first if
parts of the connector are well contacted.
6. Check if heat value of spark plug is proper. Improper spark plug may result in unsmooth engine
running or burnt of spark plug.
7. The maximum voltage is taken to introduce inspection items in this Part. Inspection methods for
impedance value of ignition coil are also recorded and judged.
8. Check ignition switch according to the continuity test table.
9. Remove magneto and stator on operation instructions.

- 60 -
Service data
Item Standard Value
Recommended Spark plug Standard CR9E(NGK)
Spark plug clearance 0.6-0.7mm
Ignition coil impedance value (20℃) Primary coil 650±50mΩ
Impedance value of trigger (20℃) 100-300Ω
Ignition coil primary peak voltage 14V
Trigger voltage Higher than 1.7V

Tools
Accessories for the voltage with maximum range
Multimeter

- 61 -
 2.2 Fault Diagnosis

Spark plug not sparking

Symptom Possible causes（Determine the cause from 1 in sequence）
①When inner impedance is too small, use the appointed
tester to test.
②Crankshaft rpm is too low.
Ignition coil When the high voltage power is ③Tester is disturbed (it is normal when several times’
too low. measured voltages are above the basic）.
④Wiring of ignition system is poorly contacted.
⑤Ignition coil is no good.
⑥Charging coil is bad. (Peak voltage measurement)
①Tester is wrongly connected.
②Poor ignition switch.
③Connector of ECU assembly is poorly contacted.
④Ground wire for ECU assembly is shorted or poorly
While no high-voltage power
contacted.
supply, high voltage power is
⑤ Poor charging coil (Peak voltage measurement）.
Secondary sporadic.
⑥ Defective trigger （Peak voltage measurement）.
side voltage
⑦ Poor connector of high voltage wire.
⑧ Inferior ECU assembly.（after items ①-⑦ are tested and
proved abnormal or spark plug no sparking.）
①Inferior spark plug or secondary leakage of the ignition
High-voltage power is normal,
coil.
spark plug no sparking.
② Poor ignition coil.
①Inner impedance is too low. Use appointed tester to test.
②Crankshaft rpm is too low.
③Tester is disturbed (it is normal when more than one
No high-voltage power supply
time’s measured voltage is above the basic）.
Charging
④Poor charging coil (when items （ ①-③ are proved
coil
normal）
No high-voltage power supply ①Poor ignition coil.
or high voltage power is ②Poor charging coil.
sporadic.
①Inner impedance is too low. Use appointed tester to test.
②Crankshaft rpm is too low.
High-voltage power supply is
③Tester is disturbed (it is normal when more than one
Crankshaft too low.
time’s measured voltage is above the basic）.
position
④Poor trigger (when items （①-③ are proved normal）
sensor
No high-voltage power supply ①Poor ignition coil.
or high voltage power is ②Poor trigger.
sporadic.

- 62 -
2.3 Ignition System inspection

* Attention
• When the spark plug is not sparking,
check if components of wiring are
loosened or badly contacted and make
sure all the voltage values are normal.
• There are many brands of multimeters
with different interior impedance. The
values they measured are not the same.

Connect a high-voltage shunt or an ammeter

with input impedance higher than 10MΩ
10CV to the multimeter.

2.3.1 Primary voltage of ignition coil

If an old spark plug is removed and replaced with
a good one, ground it with engine.

* Attention
Test when wirings of all the circuits are
correct.
Normal cylinder compression pressure means
to test with spark plug installed on the
cylinder head.

Connect lead wire of ignition coil and a shunt is

connected between terminal (black/red) of primary coil and grounding wire of vehicle block.
Press starter motor button or kick starter pedal to measure primary peak voltage of ignition coil.
Min. voltage: higher than 95V.

*Attention
Please do not touch the metal parts of testing probe with your fingers while
measuring voltage, or you will be shocked. Please take care.

- 63 -
2.3.2 Crankshaft position sensor

* Attention

Sparking plug is installed on the cylinder head. It

is necessary to check when compression pressure
is normal.

Dismantle 18 joints in ECU group and install the

maximum voltage shunt between the 18 joints
(white/green terminal) for triggers (blue/white
terminal) at the 18 joints in wiring side.

Press starting motor or trample starting lever to

measure the maximum voltage of trigger.

Means of connection: anode is connected to blue/white terminal and cathode is connected to

white/green terminal.

Minimum voltage: over 1.7V.

* Attention

In the process of metering voltage, do not touch

the test bar metal with fingers to avoid electric
shock, which is necessary to pay special attention
to.

When the maximum voltage at the ECU group joint side is measured abnormally, please dismantle
the protection plate on the right and magneto joint.

• When voltage in the ECU group side is measured as abnormal, while that at the magneto side is
normal, it means poor contact on joint or broken wiring.

• When it is abnormal in measurement on both sides, it means poor condition on the trigger. Please
refer to the fault diagnose table to check each item.

2.4 ECU Group

2.4.1 System inspection

System check

Dismantle ECU group and check spare parts on wiring side pertinent to the ignition system.

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2.5 Ignition Coil

2.5.1 Removal
Remove protecting plate of vehicle block.
Remove spark plug cap.
Remove primary lead wire of ignition coil.
Unscrew locknut of ignition coil and take out the ignition coil.
Install it in the reverse order of removal.
*Attention
The primary coil is installed with black/red wire connector.

2.5.2 Primary coil inspection

Measure impedance between terminals of primary coil.
Standard value: (4±0.2)Ω (20℃)
Impedance value within the range is good.
Impedance value “∞” indicates broken wire inside the coil. The coil shall be replaced.

2.6 Sensor of the crankshaft position

** Attention
Trigger inspection can be performed on the engine.

Inspection
Remove protecting plate of vehicle block.
Remove lead-wire connector of trigger.
Measure impedance between blue/white
terminal
of lead wire on the engine side and ground
wire
of vehicle block.
Standard value:100-300Ω（20℃）
If measured impedance value is beyond the
range,
please replace the magneto.

- 65 -
 BATTERY

G/Y

G/Y M

Schematic启动示意图
diagram of for starting

- 66 -
Ⅲ Starting System

Service Data--------------3.1

Fault Diagnosis----------3.2

Starter Motor-------------3.3

Starter Relay-------------3.4

Starter Clutch------------3.5

3.1 Service Data

Precautions on operation
Starter motor removal can be performed on the engine.
Starter clutch removal refers to removal instruction.

Basic data
Item Standard Allowable limit
Length of starter motor 12.5mm 8.5mm
electric carbon brush
Starter idler shaft bushing 8.3mm
Starter idler shaft OD 7.94mm

Tightening torque
Starter motor clutch cap bolt 12 N·m
Starter motor clutch locknut 95 N·m

Tools

Locknut spanner
Universal un-adjustable spanner

- 67 -
3.2 Fault Diagnosis

Stator motor cannot run Stator motor runs weakly Starter motor rotates but the engine does not
•Broken Fuse •Low battery •Defective starter clutch
•Low battery •Poor connecting wire contact •Starter motor counter-rotate
•Defective ignition switch •Stator motor gear stuck by •Low battery
•Defective starter clutch foreign substances
•Defective braking switch
•Defective starter relay
•Defective connecting wire contact
•Defective starter motor

3.3 Starter Motor

3.3.1 Removal
Loosen two retaining bolts of the
Bolt
starter motor and remove the motor.

Starter motor

* Attention
Before removing starter motor, the ignition
switch must be set at “OFF” position.
Disconnect battery grounding wire and then turn
on the power supply to check if the starter motor
runs to confirm safety.
First remove the lead-wire clip of starter engine.
Remove starter motor retaining bolt, separate the front

- 68 -
and rear end cap and take down the starter motor.
Roll up the rubber waterproof jacket and remove starter motor connector.

3.3.2 Disassembly

Disassemble housing screw, front cover, motor housing and other parts.

3.3.3 Inspection
Inspect other component assemblies.
Replace with a new one when there is surface partial friction, injuries or burning loss.
Commutator shall be cleaned when there is metal particles adhered to its surface.
Inspect for continuity between contact surfaces of
other assemblies.
Confirm uncontinuity of armature shaft among
surfaces of commutator.
Inspect for continuity of starter motor housing.
Confirm incontinuity between conducting terminal
and starter motor housing.
Inspect continuity between conducting terminal
and brush.
Replace it with a new one if abnormality exits.
Inspect carbon brush holder for continuity. If there
is continuity, replace it.
Measure carbon brush length.
Allowable limit: replace it when it is shorter than 8.5mm
Check rotation smoothness of the needle bearing in the front cover and whether it is loosened
when it is pressed in.
If there is abnormality, replace it with a new one.
Check if the oil seal is worn or damaged.

3.3.4 Assembly
Apply lubricating grease on the oil seal in the front
cover.
Install brush onto the carbon brush holder.
Apply lubricating grease on movable parts at both ends
of brush shaft.
Press carbon brush into its holder and install front cover
of electrodes.

- 69 -
* Attention
• There should be no hurt on the contact surface of carbon
brush and armature. Take care.
• Installation shaft of armature cannot hurt lip of oil seal.
Take care.
Then install the rear cover of the dynomo.
Align and install the bolt hole of the motor housing to the bolt hole of front cover.
Tighten housing screws.

* Attention
When assembling housing and front cover, armature can
work as a magnet to easily pull the front cover up; and then
gently press it down with hands to complete the assembly.

3.3.5 Installation
Install lead wire of starter motor and be sure to install the dust seal.
Then install the starter motor.
Install rear brake wire clip.

3.4 Starter Relay

3.4.1 Actuation Inspection

When the ignition switch is set at “ON” position,
press starter motor and a “Click” sound can be
heard.
“Click” sound indicates normal.
No sound: • Check starter relay voltage.
• Check starter relay ground wire loop.
• Inspect starter relay actuation.

- 70 -
3.4.2 Starter relay voltage inspection
Lift and support the main stand. Measure the
voltage between negative pole (green/yellow)
of starter relay connector and vehicle ground
wire.
Set ignition switch at “ON” position and catch
the brake lever. Battery voltage shall meet the
specified.
When there is no voltage at wire terminal of
starter relay, inspect braking switch continuity
and lead wire.

3.4.3 Starter relay ground loop inspection

Remove starter relay connector.
Inspect continuity between black wire of connector
terminal and vehicle ground wire.
When the starter button is pressed, continuity between
black wire of connector and vehicle ground wire
shall be fine.
If there is no continuity, inspect starter button
continuity and lead wire.

3.4.4 Actuation inspection

Connect starter relay with battery and connect
terminal of starter motor with multimeter.
Connect fully charged battery between black wire
and green/yellow wire of relay. A “tap” sound of
operation can be heard on the relay and resistance
displayed by multimeter is “zero”.
Ω

- 71 -
IV Bulbs/Switches/Instruments

Service Data--------------------------------------------------------4.1

Fault Diagnosis----------------------------------------------------4.2

Headlamp Bulb Replacement-------------------------------4.3

Front Clearance Lamp Bulb Replacement----------------4.4

Tail Lamp Bulb Replacement ------------------------------4.5

Rear License Plate Lamp Bulb Replacement-------------4.6

Front Turn Light Bulb Replacement-----------------------4.7

Rear Turn Light Bulb Replacement------------------------4.8

Instrument-----------------------------------------------------4.9

Main Switch---------------------------------------------------4.10

Electric Horn--------------------------------------------------4.11

Handle Switch------------------------------------------------4.12

4.1 Service Data

Precautions on operation
 Remove switches from the motorcycle and perform continuity test.
 All the plastic connectors have pawls on them.
 Release clamping of the pawl before removal.
 Align pawl to its hole when it is reinstalled.
 While diagnosing electric faults, please check the circuit.
 Check continuity of electric component.
 Confirm state of battery before any inspection.
 Including checking the state of battery voltage.

- 72 -
4.2 Fault Diagnosis

“ON” lamp of ignition switch is not lit.

• Defective bulb.
• Defective switch.
• Poor contact of connector or broken wire.
• Low battery power or no voltage.

4.3 Headlamp bulb replacement

Remove two headlamp retaining bolts on the left

and right under the instrument ①.

Turn over the headlamp and the wind deflector

components.
Remove the self-tapping screw (2) and take down the
decoration board behind the wind deflector.

Remove the self-tapping screw (3) and take down

dust shell of the headlamp.

- 73 -
As shown in the following figures, 4 is the low beam light bulb and 5 is the high beam light bulb.
Remove the power line socket, bulb joint retaining screw and the bulb joint of the low/high beam
light respectively and finally take out the
damaged bulb.

Align to the joint of the bulb and replace a new

bulb of the same type.

* Attention
When the bulb is lit, keep you hands and
inflammable materials some distance away from
it. Lighting bulb is hot; touch it when it cools
down.

4.4 Front clearance lamp bulb replacement

The front clearance lamp and the headlamp are placed in

the same lamp body. As shown in the figure, both the left
and right side have a front clearance lamp bulb ①
respectively.
(1) Operate according to the above descriptions in the
foresaid “Headlamp bulb replacement”
(2) Take out the damaged bulb and replace a new one of
the same type.
(3) Install the bulb reversely.

4.5 Tail Lamp Bulb

Replacement

The illuminant of the tail lamp is LED. Replace

the whole tamp while replacing the bulb.
(1) Remove the seat cushion.
(2) Unscrew the retaining screw of the rear
armrest (1) and take down the armrest.

- 74 -
(3) Unscrew the retaining screw (2).

(4) Unscrew the retaining nut (3).

(5) Remove the rear combination lamp cable, take down the damaged lamps and replace the rear
combination lamp of the same type.
(6) Install the lamp reversely.

- 75 -
4.6 Rear License Plate Lamp Bulb

Replacement

(1) Unscrew the retaining screw (1) of the rear license

plate lamp, then the lamp shall be able to be removed.

(2) Take out the damaged bulb and replace a new

one of the same type.

(3) Install the bulb reversely.

- 76 -
4.7 Replacement of Front Turn

Light

The light source for front turn light is LED, which is

required of replacing the entire light.

(1) Make operations in line with the above mentioned

“replacement of headlamp bulb”.

(2) Dismantle fixed bolt ① for left or right turn light.

(3) Dismantle cables for front turn light, take out

damaged light and replace it with product of the same model.

(4) Install the light in the reverse order.

4.8 Replacement of Rear Turn Light

Light source for rear turn light is LED, which is required

of replacing the entire light.

(1) Dismantle fixed bolt (1) for left or right turn light
from the back of rear license plate support.

(2) Dismantle cables for rear turn light, take out

damaged light and replace it with product of the
same model.

(3) Install the light in the reverse order.

- 77 -
4.9 Instrument

Remove the rearview mirror;

Remove the handle cover and pull out the
connector, unscrew the screw for the removal of
the instrument.
Install the instrument orderly in the reverse order
of removal.

4.10 Main switch

4.10.1 Inspection
Remove the front protecting plate.
Disconnect connector of main switch lead wire.
Check the connector terminal for continuity.

POWER LOCK
ON
OFF
LOCK

R R/W

4.10.2 Replacement of main switch

Remove the front protecting plate.

Unscrew the retaining bolt and take down the main switch holder.
Remove the retaining bolt and replace the main switch.

4.11 Electric Horn

Inspection
Disconnect wire to the electric horn.
Connect lead wire of horn with the battery. When the
electric horn sounds, it indicates the horn is in good

- 78 -
condition.

4.12 Handle Switch

The switches are:

1. Dimmer switch
2. Starting switch
3. Directional signal switch
4. Horn switch
5. Stop switch
6. Attention switch

/black

- 79 -
Vehicle Body Inspection and Maintenance

Tightening Torque of Fasteners on Vehicle Body

Fastening positions and names of fasteners Tightening Torque（N·m）
Retaining bolt of front shock absorber M8 22-34

Lock screw of front wheel shaft M6 5-10

Front retaining bolt of fuel tank M6 5-10

Retaining bolt of oil pump block components M6 5-10

Upper fixed seat retaining bolt of the handlebar M8 22-34

Retaining bolt of upper plate M8 22-34

Rear retaining bolt of fuel tank M6 5-10

Mounting bolt of front brake cylinder components M10 37-55

Retaining bolt of rear hydraulic brake M8 22-34

Retaining bolt of chain wheel M10 37-55

Retaining bolt of prop 50-70

Top bolt of rear shock absorber M10 37-55

Bottom bolt of rear shock absorber M10 37-55

Retaining bolt of engine M10 37-55

Retaining bolt of rear swing arm shaft M20 130-140

Front wheel shaft M20 130-140

Retaining nut of rear wheel shaft M20 130-140

- 80 -
Front Hydraulic Brake

A Front left/right hydraulic brake disc diameter: 260mm

Front left/right hydraulic brake disc thickness: 4.0mm

B
Service limit: 3.6mm

Thickness of brake shoe block: 7.8mm

C
Service limit: 3.8mm

D Mounting torque for Bolt 8 in the diagram: 5-9 N·m

E Mounting torque for Bolt 5 in the diagram: 22-29N·m

1 Front hydraulic brake assembly 2 Front hydraulic brake hose assembly 3 Front right brake
cylinder assembly 4 Front left brake cylinder assembly 5 Washer 6 Deflating valve 7 Dust
shell of deflating valve 8 Bolt M6×23 9 Hexagon flange bolt 10 Handle screw 11 Oil pump
block assembly 12 Nut M6 13 Half-round head screw M4×`12 14 Washer 15 Front
hydraulic brake handle assembly 16 Brake switch assembly 17 Retaining cover 18 Friction
lining assembly (including 2 linings) 19 Oil hose mounting bolt 20 Square-ring seal A 21
Square-ring seal B 22 Front brake disc/disc chuck ф260×4 23 Bolt M8×16

- 81 -
Rear Hydraulic Brake

A Front left/right hydraulic brake disc diameter: 260mm

Front left/right hydraulic brake disc thickness: 4.0mm

B
Service limit: 3.6mm

Thickness of brake shoe block: 7.8mm

C
Service limit: 3.8mm

D Mounting torque for Bolt 8 in the diagram: 5-9 N·m

E Mounting torque for Bolt 5 in the diagram: 22-29N·m

1 Rear brake disc 2 Bolt M8×26 3 Screw M6×25-8.8-ZG 4 Screw M6×14 5 Screw
M6×20-10.9-ZG

- 82 -
 Ⅴ Braking System

Maintenance Instruction---------------------5.1

Fault Diagnosis-------------------------------5.2

Front Hydraulic brake------------------------5.3

Rear Hydraulic brake-------------------------5.4

5.1 Maintenance Instructions

Precautions on operation
* Attention
 A dirty brake block or protection pad will reduce the braking force; therefore it is necessary to
discard dirty gasket and clean the dirty brake block by quality brake degreasant.
 Use brake control rod and pedal to check the brake system.
 Overflown brake fluid is harmful to instrument concentration and coating surface as well as
rubber. It is necessary to be careful whenever requiring of disassembling the cover. Firstly,
confirm that brake fluid in the oil cup is level.
 It is prohibited to place dirt (soil, water etc.) in open oil cup.
 In repair, it is necessary to take out DOT4 brake fluid from sealed container. Do not mix it
with liquid in other types since they are not allowed to coexist.

*Check brake before driving*

5.1.1 Specification
Available Available
Items Standard value Items Standard value
limit limit
Special brake fluid for
Special brake fluid DOT4 - DOT4 -
hydraulic brake
Thickness of left/right Thickness of hydraulic
4.0mm 3.6mm 5.0mm 4.5mm
hydraulic brake disc brake disc
Thickness of left/right brake Thickness of brake shoe
7.8mm 3.8mm 7.0mm 3.7mm
shoe pads pads
Diameter of left/right Diameter of hydraulic
Φ320mm - Φ240mm -
hydraulic brake disc brake disc
Bounce of brake surface on
Bounce of brake surface
Front left/right hydraulic brake 0.1mm - Rear 0.1mm -
on hydraulic brake disc
disc
Inner diameter in oil pump Inner diameter in oil
Φ16+0.043 mm - Φ11+0.027 mm -
cylinder 0
pump cylinder 0

Outer diameter of oil pump Outer diameter of oil

Φ16-0.032
-0.059 mm - Φ11-0.032
-0.059 mm -
piston pump piston
Inner diameter of caliper Inner diameter of caliper
Φ34+0.08
+0.03 mm - Φ32+0.08
+0.03 mm -
cylinder cylinder
Outer diameter of caliper Outer diameter of caliper
32-0.032
-0.065 mm - Φ32-0.032
-0.065 mm -
piston piston

- 83 -
5.1.2 Torque force value
Front wheel shaft retaining 100-140 N·m
Front left brake cylinder assembly mounting screw 37-55 N·m
Front right brake cylinder assembly mounting screw 37-55 N·m
Rear wheel shaft retaining nut 130-150 N·m
Rear brake cylinder assembly mounting screw 22-34 N·m

5.2 Fault Diagnosis

5.2.1 Poor braking performance

1. Improper brake adjustment
2. Worn brake shoe pad and hydraulic brake disc
3. Improper installation of brake shoe pad
4. Contaminated hydraulic brake disc of the brake shoe pad

5.2.2 Brake drags or tight handle

1. Improper brake adjustment
2. Worn brake shoe pad and hydraulic brake disc
3. Improper installation of brake shoe pad

5.2.3 Noisy Braking

1. Worn brake shoe pad and hydraulic brake disc
2. Contaminated hydraulic brake disc of the brake shoe pad

5.2.4 Brake handle/ pedal softness or lightness

1. Air presences in the hydraulic system
2. Leakage in hydraulic system
3. Brake pedal/plate is dirty
4. Caliper piston is sealed and worn
5. Brake pedal/plate is worn

6. Calipers are dirty

7. Calipers are unable to be in normal slipping

8. Braking liquid is short

9. Braking liquid channel is blocked

- 84 -
10. Caliper piston is bent/incomplete

11. Piston of main cylinder is bent/incomplete

12. Main cylinder piston is dirty

13. Brake handle/pedal is bent

5.2.5 Brake is jammed or pulled to the other side

1． Brake pedal/plate is dirty

2． Wheel deflects

3． Brake hose joint is blocked or limited

4． Brake disc is bent/incomplete

5． Abnormal slipping on calipers

5.2.6 Brake drag

1． Brake pedal/plate is dirty

2． Wheel deflects

3． Brake pedal/plate is worn

4． Brake disc is bent/incomplete

5． Calipers are unable to be in normal slipping

5.2.7 Brake handle/pedal is hard

1． Brake system is blocked or limited

2． Caliper piston is clingy/worn

3． Calipers are unable to be in normal slipping

4． Braking liquid pipeline is blocked/limited

5． Caliper piston is sealed and worn

6． Piston of main cylinder is clingy/worn

7． Brake handle/pedal is bent

5.3 Front Hydraulic Brake

5.3.1 Removal

- 85 -
* Attention
 Replace brake shoe pad assembly.
 If a brake shoe pad assembly will be used again, please mark it on the side before removal so
as to re-install it to its original place.

Remove the following assembly respectively from the right handlebar and the front shock
absorber
Front hydraulic brake:
Rearview mirror nut
1. Hydraulic brake handle
2. Oil pump block
assembly
3. Brake hose assembly Retaining screw of oil pump
4. Left/right brake cylinder block
assembly
5. Left/right hydraulic
brake disc

* Attention
 Please do not contaminate braking shoe pad with oil while assembly or disassembly
 Please use specified detergent to clean the braking assembly, or it may reduce braking
performance.

Retaining screw of handle

Retaining bolt of brake hose

Brake hose

- 86 -
Loosen the retaining screw of brake cylinder assembly.
Remove the brake cylinder assembly from the front shock absorber.

Deflating valve

Retaining bolt of brake hose

Right brake cylinder assembly

Retaining bolt of brake cylinder

Deflating valve

Retaining bolt of brake hose

Retaining bolt of brake cylinder

Left brake cylinder assembly

Remove the front wheel shaft.

Remove the front wheel.
Remove the hydraulic brake disc from the
front wheel rim.

- 87 -
5.3.2 Inspection
Check if the brake shoe pad assembly and the hydraulic brake disc are worn out.
Replace the brake shoe pad if necessary.

Measure brake shoe pad and hydraulic brake disc and record the maximum values.

Specifications
Front hydraulic brake disc diameter
φ320mm
Front hydraulic brake disc thickness
4.0mm

* Attention
A micrometer shall be used for the measurement.

Measure the thickness of the brake shoe pad.

If hydraulic brake disc and brake shoe pad are
contaminated by grease or their thickness is smaller than
Allowable limit, replace them.

Allowable limit: Brake shoe pad 3.8mm

Hydraulic brake disc: 3.6mm
Note:
The left and right brake shoe pads shall be replaced in
pairs.

5.3.3 Installation
Install hydraulic brake discs and front wheel.
Install front brake hose assembly and brake cylinder assembly.
Please do not contaminate brake shop pad and hydraulic brake discs with oil.

* Attention
A greasing brake shoe pad will reduce braking performance and result in brake failure.

- 88 -
Tighten bolt and nut to their specified torque force value.

Torque force value:

Front wheel shaft retaining 120 N·m
Front hydraulic brake disc bolt 28 N·m
Retaining bolt of oil pump block 8 N·m
Front brake cylinder assembly mounting bolt 50N·m

Do not contaminate brake shoe pad with oil.

If a brake shoe pad is polluted by oil, clean it with brake cleaner.
*Attention
A greasing brake shoe pad will weaken braking performance.

*Attention
• Do not contaminate brake shoe pad with oil while assembling or disassembling.
• Clean it with specified cleaner in case of reducing the braking performance.

5.4 Rear Hydraulic Brake

5.4.1 Removal
*Attention
 Replace brake shoe pad assembly.
 If a brake shoe pad assembly will be used again, please mark it on the side before removal so
as to re-install it to its original place.

Remove the following assembly from the frame and rear swing arm
Rear hydraulic brake:
(1) Oil pump block assembly
(2) Brake hose assembly
(3) Brake cylinder assembly
(4) Hydraulic brake disc

Loosen two retaining screws of the oil pump block.

Oil pump block assembly

Retaining screw

- 89 -
Remove the oil pump block assembly.

Oil pump assembly

Loosen the retaining screw of the brake cylinder assembly.

Remove the brake cylinder assembly from rear swing arm.

Rear brake hose

Retaining bolt

Brake cylinder assembly

Retaining bolt

Remove the rear wheel shaft.

Remove the rear wheel.
Remove the hydraulic brake disc from the rear
wheel.

- 90 -
5.4.2 Inspection
Check if braking shoe pad assembly and hydraulic brake
disc are worn out. Replace them if necessary.

Replace the brake shoe pad.

Measure brake shoe pad and hydraulic brake disc and
record the maximum values.

Specifications
Rear hydraulic brake disc diameter
Φ240mm
Rear hydraulic brake disc thickness
5.0mm
*Attention
•A micrometer shall be used in measurement.

Measure the thickness of the brake shoe pad.

If the brake shoe pads are contaminated by oil or their
thickness is smaller than the Allowable limit, replace
them.

Allowable limit: Brake shoe pad

3.7mm
Hydraulic brake disc
4.5mm
Note:
The brake shoe pads shall be replaced in pairs.

5.4.3 Installation
Install rear hydraulic brake discs.
Install rear wheel.
Install brake cylinder.

* Attention
A greasing brake shoe pad will decrease braking performance and result in braking failure.

- 91 -
Tighten bolts and nuts to their specified torque force value.

Install rear brake cylinder assembly.

Install engine assembly and air cleaner assembly.
Install muffler assembly, protecting plate assembly and seat cushion assembly.
Torque force value:
Rear wheel shaft retaining 140 N·m
Rear hydraulic brake disc bolt 8 N·m
Retaining bolt of oil pump block assembly 8 N·m
Mounting bolt of rear brake cylinder assembly 28 N·m

Do not contaminate the brake shoe pad with oil.

Clean the brake shoe pad with brake cleaner if it is contaminated with oil.

* Attention
The brake shoe pad shall not be contaminated with oil while assembling or disassembling.
Use the specified cleaner to clean the pad in case of decreasing the braking performance.

- 92 -
Exterior

*Attention
Do not damage the exterior during disassembly.
Do not damage falcula on the exterior during disassembly.
Align insert plates and covers on the exterior with their slots.
Correctly install falculas on each position during assembly.
Do not damage auxiliaries during installation of the exterior.

1. Chain cover 2 Right rear tail cap 3 Down right rear tail cap 4 Right trim board of fuel tank 5 Right trim
board 6 Left trim board of the frame 7 Left trim board of the fuel tank 8 Right guard 9 Right piece of the
rear mud fender 10 Left piece of the rear mud fender 11 Front mud fender 12 Front small mud fender 13
rear reflector 14 Left trim board 15 Left guard 16 Side reflector assembly 17 Right guard board of the fuel
tank 18 Right dynamic bottom cover 19 Connecting plate of dynamic bottom cover 20 Left dynamic bottom
cover 21 Inner damper of the right guard board of the fuel tank 22 Trim board of the right guard board of the
fuel tank 23 Trim board of the left guard board of the fuel tank 24 Inner damper of the left guard board of the
fuel tank 25 Left guard board of the fuel tank 26 Rear trim board of the left wind deflector 27 Wind deflector
28 Rear trim board of the right wind deflector 29 Forepart of the rear mud fender 30 Left rear tail cap 31
Down left rear tail cap 32 Seat cushion assembly 33 Rear armrest 34 Rear down mud fender 35 Sunvisor
of the speed indicator 36 Rear trim board of the wind deflector 37 Lower cover of instrument

- 93 -
VI. Motorcycle Exterior

6.1 Disassembly

Conduct the disassembly in the following sequence.

Rear seat cushion assembly→ Front seat cushion assembly→ Front guard of fuel

tank→ Left guard of fuel tank→ Right guard of fuel tank→ Left front guard→ Right

front guard→ Central guard of fuel tank→ Fuel tank components

Rear connecting board of left and right guards→ Left rear armrest→ Right rear

armrest→ Down left guard→ Left guard→ Down right guard→ Right guard→ Tail

Lamp→ Rear down mud fender→ Right trim cap of silencer→ Right trim cover of

silencer→ Left trim cap of silencer→ Left trim cover of silencer→ Cylinder

component of silencer→ Rear mud fender component→ Battery case

Mounting rack of headlamp component→ Windshield→ Mounting board of left wind

deflector→ Mounting board of right wind deflector→ Headlamp

*Attention
Do not damage the cover of the motorcycle while removing or installing.
Do not break the hooks of the cover while removing or installing.

- 94 -
6.2 Assembly

Assemble reversely according to the disassembly processes.

*Attention
Align the panel of vehicle body cover and cover board to their respective grooves.
Install the hooks of each part correctly while assembling.
Do not damage the mountings while installing the covers.

- 95 -
Front suspension

The mounting torque of the lower connecting plate retaining bolt 19 in the
A
diagram is: 22-29 N·m
The mounting torque of the upper base of steering handlebar mounting bolt
B
3 in the diagram is: 22-29N·m
The mounting torque of the upper connecting plate retaining bolt 3 in the
C
diagram is: 22-29 N·m
The mounting torque of front shock absorber mounting bolt 19 in the
D
diagram is: 22-29N·m

1. Front right shock absorber component 2 Front left shock absorber component 3 Bolt M8×1.25×25 4
Retaining screw of upper connecting plate 5 Upper pressing block 6 Lower base of steering handlebar 7
Silencer plug 8 Handle positioning gasket 9 Handle positioning double end stud 10 Locknut M10×1.25
11 Upper connecting plate 12 Clamp nut of upper connecting plate 13 Compression nut 14 Scraper seal
15 Steering bearing 16 Longitudinalshaft 17 Anti-loosing ring 18 Screw M6×14 19 Bolt M8×1.25×30
20 Lower connecting plate 21 Left hydraulic brake pipe clamp 22 Right hydraulic brake pipe clamp 23
Socket head cap screw M10×1.25×45 24 Hydraulic brake pipe clamp

- 96 -
Steering handlebar

1. Rearview mirror component 2 Accelerator handlebar 3 Rear cover of accelerator cable 4 Front cover of
accelerator cable 5 Right combination switch 6 Counterbalance 7 steering handlebar 8 Left combination
switch 9 Left handlebar 10 Clutch handle component 11 Clutch cable component 12 Accelerator cable
component I 13 Accelerator cable component II 14 Right rearview mirror 15 Left rearview mirror 16
Socket head cap screw M6×35 17 Spring washer 18 Washer 19 Mounting base of counterbalance 20
Counterbalance 21 Cable clamp 22 Check valve flexible wire clamp 23 Steering handlebar flexible wire
clamp 24 Cotter 2×18 25 Axis pin 6×14 26 Clutch handle

- 97 -
Front wheel
A Front tire size: 120/70-17
B Air pressure of front tire: 190±10kpa
C The minimum tread pattern depth: 1.6mm
Limit value of run-out tolerance of rim:
D Vertical: 2.0mm
Horizontal: 2.0mm
The mounting torque of hydraulic brake disc bolt 1 in the
E
diagram is: 22-29N·m

1 Bolt M8×16 2 Front brake disc/disc chuck ф260×4 3 Left lining of front wheel 4 Vacuum tire 120/70-17 5
Front wheel rim 6 Front wheel shaft 7 Cycle valve 8 Right lining of front wheel 9 Central shaft sleeve of
front wheel 10 Scraper seal component 11 Rolling bearing 6204-2RS

- 98 -
VII. Front Wheel/Steering Handlebar/Front Suspension

Service Data-----------------------------------7. 1

Fault Diagnosis-------------------------------7. 2

Front Wheel-----------------------------------7. 3

Steering Handlebar---------------------------7. 4

Front Suspension-----------------------------7. 5

7. 1 Service Data

Precautions
Prior to disassembly of the front wheel, use a jack to support against bottom of the motorcycle, and it is important
that the front wheels must not rotate reversely when they are kept away from the ground.
During operation, it is important that any grease must not be attached on brake shoe pad and hydraulic brake disc.
Abandon the contaminated gasket if the brake fore is decreased by polluted brake disc or brake shoe pad. Clean
the polluted brake disc with high quality brake degreaser.

Reference for motorcycle

Standard
Measuring position Item Allowable limit (mm)
value (mm)
Front wheel shaft Bending 0. 2
Longitudinaldirection 2. 0
Wheel disk
Front wheel Horizontal direction Not less than
shimmy 2. 0
1. 0

Torque force value Tool

Retaining bolt of upper connecting plate component 24-34 N·m Dismantling rod, bearing
Front wheel shaft retaining 130-140 N·m Locknut spanner
Fastening screw of front wheel shaft head 5-10 N·m
Retaining screw of front shock absorber 5-10 N·m
Retaining bolt of steering rod 22-29 N·m
Assembling bolt of front hydraulic brake cylinder 37-44 N·m

- 99 -
7.2 Fault Diagnosis

7.2.1 Steering handlebar rotating without flexibility

 The handlebar bearing is out of order or damaged.
 The handlebar bearing is damaged.
 The adjusting nut of the steering bearing is too tight.
 Pressure within the tire is insufficient.

7.2.2 Direction not steady

 The handlebar bearing is damaged.
 Pressure within the tire is insufficient.
 Front fork is bent and its bearing is bent.
 Front wheel tire is subjected deformation and the tire is not aligned.

7.2.3 Front wheel wobbling

 Wheel rim is deformed.
 Front wheel bearing is worn.
 Tire is in poor condition.
 Tires or wheels are lopsided.

7.2.4 Wheel failing to rotate

 Wheel shaft bearing is out of order.
 The brake is faulted.
 The wheels are faulted.
 The front wheel is bent.

7.2.5 Abnormal noises from front shock absorber

 The liquid in shock absorber is insufficient.
 Noises due to friction against absorber guard.
 Bolts of the absorber are loosened.

7.2.6 Abnormal noises from front shock absorber

 The left and right fork is adjusted unevenly.
 The shock absorber is bent.
 The wheels are bent.
 The installment of wheels is not correct.
 The frame is bent.
 The wheel shafts are damaged.
 The central shaft of swing arm is damaged.

7.2.7 Front shock absorber is soft

 Liquid in the shock absorber is insufficient.
 The spring of shock absorber is unstable.

- 100 -
 The pressure of the tire is too low.

7.2.8 Front shock absorber is hard

 Improper weight of liquid
 The channel of shock absorber is jammed.

7.3 Front wheel

7.3.1 Disassembly
Attention:
The motorcycle must be securely supported.

Support the motorcycle with a stable bracket or crane.

Remove the front mud fender and loosen the retaining screw ①②.

Remove brake caliper of the front hydraulic brake

Unscrew the retaining screw of brake cylinder assembly.
Remove the brake cylinder assembly form the front shock absorber.

Deflating valve

Retaining bolt of brake hose

Right brake cylinder assembly

Retaining bolt of brake cylinder

- 101 -
 Deflating Valve

Retaining bolt of brake hose

Retaining bolt of brake cylinder

Left brake cylinder assembly

Remove the tightening screw (1) of front wheel shaft (front shock absorber on the right side)

Remove the front wheel shaft (2)

- 102 -
Remove the front wheel assembly
Take down the left shaft sleeve of front wheel (3)

Remove the lower shaft bearing with bearing puller.

Note:
Do not operate the brake joystick after the brake caliper is removed.

7.3.2 Check

7.3.2.1Check of wheel shaft bending

Place the wheel shaft onto a V-shaped base, and the
measure eccentricity with a micrometer gauge.
Allowable limit: replacing is required in case of
exceeding 0. 2mm.

- 103 -
7.3.2.2 Check on rim swinging

Place rim on a precise support and check the degree of rim

swinging.

Rotate wheel by hand and read the degree of swinging.

Available limit:

Vertical direction: it is necessary to replace if it is above

2.0mm.

Vertical direction: it is necessary to replace if it is above

2.0mm.

Wheel balance:

Warning:

Wheel balance has direct impact on stability, operation and

motorcycle safety. It is also necessary to check wheel stability when tire is dismantled.

Notes:

For the optimal balance, it is necessary make tire marking close to the valve stem (by drawing a point on the edge).
Install tire if necessary

7.3.2.3 Balance of front tire

Notes:

Paste marking for rotary direction on wheel and tire

Dismantle anti-dust seal ring from wheel;

Install wheel, tire and brake disc components in the inspection station;

Halt rotary wheel and mark the bottom (peak) by chalk.

Repeat twice or three times in this way to verify the heaviest area.

If the wheel is balance, it will not always halt in the same location.

In order to balance wheel, install wheel load on the side where the rim is higher and mark the other side by chalk.
When wheel is rotating, it is necessary to supplement adequate weight so that wheel will not halt in the same
location.

Do not add load that is over 60g on the wheel.

- 104 -
7.3.2.4 Check of front wheel shaft
Remove the bearing ① and the central spacer
sleeve of front wheel.

Check the rotating condition of the bearing.

If it fails to rotate, rotate freely or steadily and if
the bearing is worn out or loosened, then replace a
new one.

7.3.3 Replacing bearing

After removing the front wheel shaft, front wheel, left bearing sleeve and the central bearing sleeve of front wheel,
remove the oil seal and bearing respectively with the oil seal puller and bearing puller.

Note:
The removed bearing must be replaced with a new one.
During installation, apply the lubricating grease onto the
bearing.
Then use the bearing mounting tool to press the bearing.

*Attention
•The bearing must be pressed in a parallel manner.

7.3.4 Installation
Installation must be conducted reversely according to the disassembly.

Note:
Lubricate the front wheel shaft, left bearing sleeve of front wheel, bearing 6005-2RS/1-C3 and central bearing
sleeve.
The recommended lubrication is calcium-base lubricating grease.
Make sure that the hydraulic brake disc is between the brake blocks while tightening the front wheel and hydraulic
caliper.
No free stoke can be adjusted on the front brake handles.

Note:
The retaining torque force value of front wheel shaft is: 100-140 N·m

- 105 -
7.4 Steering handlebar

7.4.1 Disassembly
Remove the left/right rearview mirror component

Remove the oil pump block assembly

Remove the right combination switch
Dismantle the accelerator cable mounting assembly

Oil pump block assembly

Accelerator cable mounting assembly

Retaining screw

Right combination switch

Retaining screw

Remove the left handle assembly

Remove the left combination switch.

Left handle assembly

Retaining screw

Left combination switch

- 106 -
Remove the counterbalance assembly①
Remove the right handle assembly②
Remove the counterbalance③

Loosen the retaining screw of the upper base of the steering handlebar.
Turn over the upper base of the steering handlebar.
Remove the handle tube.

Retaining screw

Combination switch of upper

base of the steering handlebar.

7.4.2 Installation

Install reversely according to the disassembly process.

Note:
Retaining screw of the upper base of steering handlebar
Torque force value: 22-34 N·m

7. 5 Front fork

7.5.1 Disassembly
Support the main stand of the motorcycle.
Remove the front wheel.
Remove the brake caliper and the brake pipe clamp.

- 107 -
Remove the steering handlebar.

Remove the strut bolt Strut bolt

Upper connecting plate

Remove the instrument and its holder

Loosen the retaining bolt of Retaining bolt
the upper connecting plate
Remove the upper connecting plate

Clamping bolt

Remove the headlamp and its lower holder.

Loosen the clamping bolt of the lower connecting plate.
Remove the front shock absorber.

Tool:
The retaining nut spanner
Special disassembling tool for the bearing and steel bowl

*Attention:
Clean the opening on the body opening with dust rag.
The steel bowels of the upper and lower bearings are removed by means of special tool.

7.5.3 Installation
Note:
Make sure that the front wheel shafts are concentric while installing the left and right shock absorbers.

Install reversely according to the disassembly.

Note:
Retaining screw of the lower connecting plate: 28 N.m
Retaining screw of the upper connecting plate: 28 N.m

- 108 -
Rear wheel / Rear suspension
A Rear tire type: 160/60-17
B Rear tire pressure: 210±10kpa
C Minimum tread pattern depth: 2.0mm
Rim run-out tolerance limit:
D Vertical: 2.0mm
Horizontal: 2.0mm
Torque force value of bolt 3 in the diagram:
E
5-10N·m
Torque force value of bolt 18 in the diagram:
F
37-55N·m
G Torque force value of bolt 9 in the diagram: 130-150N·m

1 Rear wheel shaft 2 Right sleeve of rear wheel 3 Screw M6×20-10.9-ZG 4 Rear brake disc 5 Inflating
valve 6 Rear rim 7 Central bearing sleeve of rear wheel 8 Vacuum tire 160/60-17 9 Locknut M20×1.5 10
Cushion collar of the rear wheel 11 Left sleeve of rear wheel 12 O-seal ring 13 Rolling bearing 14 Scraper
seal component 15 Retaining bolt of chain wheel 16 Chain wheel hub 17 Chain wheel hub 18 Locknut
M10×1.25 19 Chain drive shaft sleeve 20 Bearing 21 Check ring 22 Chain 23 Delf-seal packing
component

- 109 -
Rear shock absorber and rear swing arm
A Torque force value of Bolt 8 in the diagram is: 130-140 N·m

B Torque force value of Bolt 19 in the diagram is: 22-29 N·m

C Torque force value of Bolt 11 in the diagram is: 5-9 N·m

1 Welding component of rear swing arm 2 Outer spacer sleeve of rear swing arm 3 Delf-seal component
25×37×7 4 Circlip for holes 5 Rolling needle bearing NA4904 6 Rolling bearing 61904-2RS 7 Central
bearing sleeve of rear swing arm 8 Mounting shaft of rear swing arm 9 Locknut M20×1.5 10 Protecting
blocks of chain 11 Bolt M6×19 12 Supporting sleeve M6×25 14 Mounting board of rear hydraulic brake
15 Screw M6×14 16 Speed sensor 17 Adjusting block of chain 18 Chain adjusting screw M8 19 Nut M8
20 Chain guard 21 Rear lower mud fender 22 Cable clamp of clutch cable 23 Rear shock absorber
component 24 Socket head cap screw M10×50 25 Lower decoration pad of rear shock absorber 26 Bolt M10

- 110 -
VIII. Rear Wheel/Rear Suspension

Service Data---------------------------------------8. 1

Fault Diagnosis------------------------------------8. 2

Rear Wheel-----------------------------------------8. 3

Rear Shock Absorber------------------------------8. 4

Chain Drive ----------------------------------------8. 5

Rear Swing Arm------------------------------------8.6

8. 1 Service Data

Precautions
Any grease spot is not allowed on the hydraulic brake disc and brake shoe pad.

Reference
Item Standard value (mm) Allowable limit (mm)
Verticall
2. 0
Rear wheel direction
wobbling Horizontal
2. 0
direction

Locking torque force

Retaining nut of rear wheel shaft 130-140 N·m
Top bolt of the rear shock absorber 37-44 N·m
Bottom bolt of the rear shock absorber 37-44 N·m
Retaining bolt of rear swing arm 130-140 N·m
Retaining nut of chain wheel 37-4455 N·m
Retaining bolt of rear hydraulic brake disc 5-9 N·m

- 111 -
8. 2Fault Diagnosis

8. 2. 1 Rear wheel wobbling

 Wheel disc is deformed.
 Rear wheel bearing is worn.
 Tire is faulty.
 Swing arm shaft bearing is worn or damaged.
 Driving chain regulator adjusts incorrectly.
 Tires and wheels are lopsided.
 Tire pressure is too low
 Motorcycle frame or swing arm is bent.

8. 2. 2 Wheel rotating without flexibility

 Rear hydraulic brake disc is bent
 Rear wheel bearing is worn
 Driving chain is too tightened

8.2.3 Suspension is too soft

 Damping spring is not fastened with vibration

 Front suspension adjuster is incorrect

 Oil leakage in the damper

 Intensity of pressure on tire is too low

8.2.4 Suspension is too hard

 Assembly shaft on the damper is damaged

 Bending of damper pipe barrel

 Rear swinging arm pivot shaft is damaged

 Rear swinging arm pivot shaft is bent

 Fault occurs to suspension adjuster

 Intensity of pressure in the tire is too high

8.2.5 It is only allowed to operate unilaterally or it fails to stick to straight line

 Rear shaft is bent

 Wheel shaft array/ chain adjuster on both sides is incompetent

- 112 -
8. 3 Rear Wheel

8. 3. 1 Disassembly
The motorcycle should be supported securely so that the rear wheel can keep away from the ground.
Remove the brake caliper of rear hydraulic brake
Loosen the adjusting screw of rear wheel

Brake caliber of rear hydraulic brake

Retaining screw of brake caliber of rear

hydraulic brake

Adjusting screw of rear wheel

Remove the rear wheel shaft nut and the adjusting block of left chain

Adjusting screw of rear wheel

Adjusting block of left chain

Rear wheel shaft nut

Remove the rear wheel shaft and adjusting block of

right chain

Rear wheel shaft

Adjusting block of right chain

- 113 -
Take the chain off the large chain wheel

Chain

Large chain wheel

Take down the rear wheel assembly

Remove the chain wheel assembly

Unscrew the retaining screw of chain wheel

Retaining screw of chain wheel

- 114 -
8.3.2 Check

8.3.2.1 Check of wheel disc wobbling

Turn the rear wheel manually and measure eccentricity with a
micrometer gauge.

Allowable limit:
Longitudinal direction: replacing in case of exceeding 2. 0mm
Horizontal direction: replacing in case of exceeding 2. 0mm

If the rear wheel wobbling exceeds the allowable limit, the rear wheel
bearing is loosened, consequently the rear wheel wobbling. Replace
the rear wheel bearing after check.

8.3.3 Installation
Install the rear wheel in reverse sequence of disassembly and lock the nut.

Retaining nut of rear wheel shaft

Torque force value: 130-150N·m

8. 4 Rear Shock Absorber

8.4.1 Dismantling rear shock absorber

Remove the right trim cover of rear shock absorber

Right trim cover

- 115 -
Remove the upper and lower retaining bolt of rear shock absorber.
Remove the rear shock absorber.

Retaining bolt

Retaining bolt

8.4.2 Check of rear shock absorber

Visually check the shock absorber whether it’s damaged or not.

Check the following items:

-If the shock absorber rod is bent or damaged
-If the shock absorber is deformed or leaking oil.
-If the rubber pad is worn or damaged
-If the spring is damaged

Check other parts whether they are damaged or worn out

Replace the shock absorber if necessary

8.4.3 Installation of rear shock absorber

Installation must be initiated in the reverse sequence of dismantling.
Mount the upper retaining nut and lower retaining bolt on the rear shock absorber.
Lock to the specified torque force.

Retaining nut
Torque force value: 37-55N·m

- 116 -
8. 5 Chain Drive

8.5.1. Disassembly
Stop the motorcycle on the flat ground, and support it securely.
Remove the left rear cover of engine.

Retaining bolt of left rear cover

Left cover of the engine

Remove the rear wheel, rear shock absorber, chain guard and driving chain.

8.5.2．Check

Measure length of 10 links , and if it does not meet specified value, replace the driving chain.
Limit length of the 10 links is 1587.5mm.

- 117 -
*Attention:
Measurement shall be made only after the chain is straightened manually.
Measurement shall cover from link roller (1) to (11).
Measure length of 10 links.
2-3 measurements shall be made for length of 10 links on different positions.

Clean the driving chain and place it into kerosene.

Clear dust as much as possible.
And then, take the chain out of kerosene, and dry it.

Check rotor ① and side panel ②.

If either of them is worn or damaged, replace the driving chain.
Lubricate the driving chain, and the lubricant can be outsourced from a shop.

Check hardness of driving chain.

If the chain is hard, clean, lubricate or replace it.

- 118 -
Check driving sprocket and driven sprocket.
If 1/4 teeth is worn, replace the sprocket.
If the sprocket is bent, replace it.

8.5.4. Installation
Installation must be initiated in the reverse sequence of disassembly.

Retaining nut
Torque force value: 37-55 N·m

Note:
Adjust the looseness of driving chain and free stroke of brake pedal.
If the looseness is too small, the engine and other key parts will be consequently overloaded.
Maintain the chain looseness within the specified limits.

- 119 -
8.6 Rear Swinging Arm

8.6.1 Dismantle rear swinging arm

Place the motorcycle on flat ground, with appropriate
fastening and supporting.

Disassemble rear wheel

Dismantle retaining bolts (24) and (26) below the

damper.

Dismantle bolt (15) and transmission chain cover

(20).

Dismantle clamp nut (9) for swinging arm shaft from

the frame.

Dismantle rear swinging arm shaft (8) and

component (1).

Dismantle rear swinging arm roller pin shafts (5) and (6) and shaft sleeve (7).

8.6.2 Check rear swinging arm

Check installation shaft of rear swinging arm and rotate the
shaft or use dial indicator to make measurement on plat surface.
It is necessary to make replacement if it is bent.

* Attention

Please do not attempt to straighten bent shaft.

Clean spare parts for installation shaft of rear swinging arm in

solvent.

Check rear swinging arm’s shaft sleeve and intermediate shaft sleeve and replace them in case of damage.

- 120 -
Check whether shaft is damaged

Rotate your fingers in inner circle in right pivot shaft.

Shaft shall be in smooth and stable rotation. It is also

necessary to check whether the external ring of shaft is
installed in a fastened way on the wheel hub.

If the ring fails to be in smooth and stable rotation or it is

installed on the pivot shaft in a loose way, please dismantle
and discard the part.

8.6.3 Install rear swinging arm

Please implement in the steps reverse to disassembly.

Coat pivot shaft bush with lubricating grease.

Notes:

Rear swinging arm shaft bolt

Torque force value: 70-105N·m

- 121 -
Fuel tank

Fuel tank capacity:

A
15±0.2L
Torque force value of bolt 3 in
B the diagram is:
5-10N·m
Torque force value of bolt 6 in
D the diagram is:
5-10N·m
Torque force value of bolt 9 in
E
the diagram is: 5-10N·m
Torque force value of bolt 12
F in the diagram is:
5-10N·m
Torque force value of bolt 16
G
in the diagram is: 22-37N·m

1 Socket head cap screw M5×30 2 Socket head cap screw M5×14 3 Fuel tank cover sealing gasket 4 Fuel tank
cover supporting component 5 Fuel tank component 6 Screw M6×35 7 Front mounting base of seat cushion
8 Fuel tank mounting gasket 9 Rubber sleeve 10 Fuel tank mounting shaft sleeve 11 Fuel tank base plate
12 Fuel pump component 13 Oil pump screw M5×16 14 Oil pipe component 15 Filter component 16 Nut
M6 17 Fuel sensor component 18 Rubber pad of sensor 19 Cable clamp component 20 Rubber sleeve 21
Rubber pad C of guard board 22 Rubber pad B of guard board 23 Steel wire hoop Φ10.5 24
Downcomer/molding pipe Φ7×2×880 25 Check valve and fuel tank joint pipe 26 Two-way pipe 27 Piping
cord of rear guard board

- 122 -
IX. Fuel tank

Service Data------------------------9. 1

Fault Diagnosis--------------------9. 2

Fuel Tank---------------------------9. 3

9. 1 Service Data

Precautions
The dismantling site shall keep away from source of spark.
During assembly, tighten the bolt and nut to specified torque force value.
After assembly, check if all parts are installed correctly and operated correctly.

Reference
Item Standard Allowable limit

Fuel tank capacity 16±0.2L /

Locking torque force

Front retaining bolt of fuel tank 22-37 N·m
Rear retaining bolt of fuel tank 5-10 N·m
Retaining bolt of front mounting board of fuel tank 5-10 N·m
Retaining bolt of oil pump 5-10 N·m
Retaining bolt of fuel lever sensor 5-10 N·m

9. 2 Fault Diagnosis

Gasoline volume decreases.

 Gasoline is consumed naturally
 Gasoline leaks.

- 123 -
9. 3 Fuel tank

9.3.1 Disassembly
Open the seat cushion with the key and remove the seat cushion.

Remove the high-pressure oil pipe component.

Remove the oil pump connector.
Remove the fuel lever sensor connector.

Fuel lever sensor

Oil pump

High-pressure oil pipe

Oil pump connector

Fuel lever sensor connector

Remove the rear retaining bolt (1) of the fuel tank.

Remove the fuel tank from the frame.

- 124 -
9.3.1 Installation
Installation must be initiated in the reverse sequence of disassembly.

Mounting torque force:

Front retaining bolt of fuel tank 22-37 N·m
Rear retaining bolt of fuel tank 5-10 N·m
Retaining bolt of front mounting board of fuel tank 5-10 N·m
Retaining bolt of oil pump 5-10 N·m
Retaining bolt of fuel lever sensor 5-10 N·m

- 125 -
X Removal and Installation of Engine

Service Data-------------------------------------10.1

Removal and Installation of Engine----------10.2

10. 1 Service Data

Precautions of operation
The dismantling site shall keep away from source of spark.
During assembly, tighten the bolt and nut to specified torque force value.
After assembly, check if all parts are installed correctly and operated correctly.

Tightening torque
Gearshift lever bolt: 10 N·m

Retaining bolt of engine: 50 N·m

10.2 Removal of Engine

Support the motorcycle securely so that the rear

wheel may keep off the ground.

Screw out the clamps for inlet and outlet of water

pump on engine, dismantle cooling tube and
discharge all cooling liquid.

- 126 -
Dismantle seat cushion

Insert the key into the protection plate lock (1)

to turn it on by clockwise turning;

Lightly press on the back of the seat cushion by

your right hand and upwards and backwards lift
the cushion

Take down the cushion;

Notes:

The seat shall be installed after confirmation of

the positioning of limits on both sides.

- 127 -
Disassemble oil tank assembly

See 9.3.1 for oil tank disassembly

Disassemble air cleaner assembly

Disassemble the retaining bolts of air filter

Disassemble the hoop of air filter

Disassemble the connector assembly of inlet temperature sensor;

Disconnect rubber breather pipe from the air port on cylinder cover;

Take out the air filter.

Notes:

Stepping motor of the throttle valve needs to be in

place when installing the air cleaner.

Disassemble throttle valve components and parts

Remove part I and part II of throttle cable;

Disassemble 4 pieces of throttle valve hoop in the

sequence of 1-2-4-3;

Disassemble intake pressure sensor connector

assembly.

Disassemble injector connector assembly;

Disassemble the connector assembly for throttle

position sensor;

Disassemble the connector assembly of the idle speed stepping motor;

Disassemble rubber tube attached to carbon canister;

Disassemble oil inlet;

Take down the throttle valve components;

- 128 -
Notes:

Confirm whether the installation of part I and part II of

throttle cable are correct;

After the throttle valve components and parts are well

installed, confirm oil tube is well plugged with no
leakage.

Confirm the electrical elements are well positioned;

Disassemble carbon canister components

Carbon canister
components

Disassemble clutch cable components

Clutch cable
components

Disconnect storage battery’s lead; and

- 129 -
disassemble and start up motor line and bond strap

Disassemble connector assembly of high pressure pack, rectifier, horn and exhaust water switch

Storage battery lead

Disassemble the front section of silencer exhaust pipe

- 130 -
Disassemble radiator inlet opening and water tank; and
disconnect switch connector assembly of the fan

Disconnect connector assembly of crankshaft position

sensor and neutral position switch

Disconnect connector assembly of side stand flameout switch hold-off; and disassemble the switch

Side stand flameout switch

Disassemble the rocker of gear shifting lever; and disassemble

the left cover of the engine

Disassemble minor sprocket to disconnect chain from sprocket

Loose engine fixed bolts; and carry off the engine

- 131 -
10.3 Installation of engine

Carry out in line with the reverse order “disassembly”

Notes:

 Place a suitable support at the bottom of frame at the time of engine disassembling to prevent turnover.

 Engine oil: 3.2 L during assembly.

 Start engine to check on abnormal vibration, noise and engine lubrication.

 After a period of normal running under idle speed, turn the throttle handle to the top gear before completely
releasing; and unchanged idle speed means the throttle cable is not suitably adjusted. So pay attention to
adjustment in this aspect before engine testing.

 Check method of engine oil:

a. Take out engine oil dipstick, which shall be cleaned up with net cloth.

b. Insert dipstick inside, take it out and check oil level; if the oil level is lower than the minimum, add
oil.

c. Heat the engine for 5min, cool it down for 3 min and check it again. If the level is still lower than the
minimum value, add oil.

d. Engine oil needs to stay between the minimum and the maximum levels at all time.

- 132 -
Check and maintenance of engine

Table of Fastener Torque Values

Fastening position and fastener name Tightening Torque (N·m)

Magnetic bolt M14 20～25

Oil sump bolt M6 10～12
Cylinder double-end bolt 60～62
Flywheel locknut 100～110
Gear shifting locator’s bolt M6 10～12
Mould assembling bolt M6 10～12
Mould assembling bolt M8 22～24
Mould assembling bolt M10 35～39
Connecting rod bolt 23～27
Left and right crankcase cover bolts M6 10～12
Flywheel bolt M8 20～24
Engine oil filter 18～22
Engine oil filter connecting bolt 40～45
Engine oil filter bolt M14 40～45
Round nut M20 95～105
Clutch separating disc bolt M6 10～12
Cylinder cover bolt M6 10～12
Camshaft sprocket bolt M7 20～25
Oil pump bolt M6 10～12
Gear shifting locator’s bolt M6 10～12
Spark plug 22～25

- 133 -
Special tools
Sprocket locking tools: used for locking sprocket, which is convenient for installation or
disassembly of output sprocket nuts.

Sprocket locking tool

Output sprocket nut

Sprocket locking tool

Special sleeve for oil filter: used for installation or disassembly of oil filter.

Special sleeve for oil filter

- 134 -
Camshaft sprocket adjustment tool: used for tensioning of
adjustment chain.

Camshaft sprocket adjustment

Camshaft sprocket

Camshaft sprocket

Breather pipe installation tools: used for breather pipe installation.

(1) For breather pipes on cylinder cover

Breather pipe installation tools

Breather pipe

Breather pipe installation tools

- 135 -
(2) For breather pipe on cylinder cover

Breather pipe installation tools

Breather pipe installation tools

Clutch locking tools: used for locking clutch, which is convenient for installation or disassembly of
round nuts.

Round nut

Clutch locking tools

Clutch locking tools

Valve oil seal clamp tooling: used for clamping valve oil seal.
Valve oil seal clamp tooling

Valve oil seal clamp tooling

- 136 -
Shaft bush clamp tool: used for shaft bush installation; clamp one end of the shaft bush in groove,
put the tool above and press it into the groove by hand.

Shaft bush clamp tool

Shaft bush

- 137 -
XI. Lubricating System

Service Data------------------11.1

Fault Diagnosis---------------11.2

Engine Oil Pump-------------11. 3

11.1 Service Data

Function of lubricating system:

Engine lubricating system is to supply lubrication oil to friction surface of engine elements, turning
the dry friction on the surface into liquid friction between lubrication oil particles, thus mitigating
part wearing, cooling down parts with high thermal load, absorbing impact from bearing and the
elements and consequently reducing noises, increasing tightness between cylinder ring and wall,
and cleaning and taking away foreign matters from surface of parts.

Precautions:
After engine oil pump is disassembled, carefully clean its parts and purge the surface with
high-pressure gas.
To disassemble engine oil pump, it is important to prevent any foreign matter from falling into
crankcase.

Table for Standard Value and Allowable Limit of Reference Items

Allowable
Item Standard
limit
For changing oil 2.8L ＿
Engine oil capacity
For disassembly 3.0L ＿
Radial clearance
between inner and outer 0.05-0.13 0.15
Pump rotor rotors
Clearance between
0.06-0.15 0.2
outer rotor and pump

- 138 -
11.2 Fault Diagnosis

Gasoline volume decreases Engine damaged

Gasoline is consumed naturally. No or too low oil pressure
Oil leakage Oil circuit clogged.

11.3 Engine Oil Pump

11.3.1 Disassembly
Remove the engine cover, unscrew the pump retaining screw and then remove the oil pump drive
sprocket and oil pump chain.

Oil pump chain

Screw

Oil pump drive

Remove the screw.

Take down the oil pump body.

Screw

Oil pump body

- 139 -
Remove the screw, take down the oil pump cover and disassemble the oil pump.

Screw

Oil pump cover

Check the radial clearance between inner and outer rotors.

Allowable limit: 0.15mm.

Testing gauge

Check the clearance between outer rotors and oil pump cover.
Allowable limit: 0.15mm.

Testing gauge

- 140 -
11.3.2 Assembly of oil pump
As shown in the following figure.

Screw Oil pump

Screw Outer rotor Oil pump

Oil pump sprocket Oil pump shaft

Washer

Note:
After these parts are combined into the pump, the inner and outer rotors must be free to rotate
without jamming.

Installation
These parts are assembled in the reverse sequence of disassembly.

- 141 -
11.3.3 Lubrication diagram

Discharge cam
bearing

Intake cam
bearing

Connecting rod
Connecting rod
bearing
Throttle valve bearing

Main bearing
Main bearing Main bearing

Main oil duct

Throttle valve Oil filter

Relief valve

Main shaft Countershaft

Oil pump

Oil sump

- 142 -
- 143 -
XII Cylinder Head

Service Data-----------------------------------12. 1

Fault Diagnosis--------------------------------12. 2

Cylinder Head/Valve--------------------------12. 3

12. 1 Service Data

Function of cylinder head:

It is used to seal cylinder and form the combustion chamber along with the piston in order to
withstand high-temperature and high-pressure combustible gas. Through the valve system, the
cylinder head intakes and discharges gas.

Precautions of operation:
To ensure seal between the cylinder head and cylinder body, the head withstand large locking force
from bolt. Pre-tension value: 12Nm Locking force value: 60 Nm
All parts must be cleaned before being checked, and purged with high-pressure air.

- 144 -
Table for Standard Value and Allowable Limit of Reference Items (in mm)
Allowable
Item
Standard limit
Flatness of cylinder head 0. 03 0. 05
Intake 0.13-0.19 ＿
Valve clearance
Discharge 0.19-0.25 ＿
Intake 3.97-3.98 3.96
OD, valve rod
Discharge 3.97-3.98 3.96
Valve Intake 4.03-4.04 4.07
ID, valve guide
Valve guide Discharge 4.03-4.04 4.07
Clearance between valve Intake 0.05-0.07 0.11
rod and valve guide Discharge 0.05-0.07 0.11
Intake 1.1-1.3 1.5
Valve base width
Discharge 1.1-1.3 1.5
Intake 38.8 37.3
Valve spring Free length
Discharge 41.6 40.1
Tolerance clearance between the cam
Cam shaft 0.02-0.054 0.08
shaft and cylinder head

12. 2 Fault Diagnosis

Low compression pressure Abnormal noise in cylinder head

Bad valve clearance adjustment
Valve burned or bent
Bad valve base air tightness
Air leakage from cylinder head gasket
Poor installation of spark plug
Bad valve clearance adjustment
Valve spring damaged
Too high compression pressure
Too much accumulated carbon in
combustion chamber

- 145 -
12. 3 Cylinder Head

12.3.1 Disassembly
Disassemble ignition coil.
Loosen four set bolts; taken off the gasket and disassemble cylinder head cover.

Cylinder cover

Fixing bolt

Loosen fixing bolts and disassemble air manifold

chain adjuster.

Fixing bolt

Air manifold
chain adjuster

Loosen four camshaft sprocket bolts.

Camshaft sprocket
bolt

- 146 -
Measure the fit clearance between camshaft and
cylinder head.
Allowed limit: 0.08mm.
Measuring gauge

Loosen camshaft supports.

Camshaft support

Take off the camshaft, camshaft sprocket, chain guiding plate and chains.

Camshaft

Camshaft sprocket

Camshaft sprocket

- 147 -
 Chain guiding plate

Loosen cylinder locking bolts.

Take off cylinder cover.

Cylinder cover

Disassemble support pillar and take off cotter using valve spring compression tool to compress
valve spring.
Take off valve adjusting gaskets, valve spring, valve spring’s up and down seats and valve.

- 148 -
12.3.2 Breakdown of camshaft component

Sealing cover

Camshaft Camshaft sprocket Bolt

12.3.3 Breakdown of valve

Support pillar
Cotter
Valve Lower seat of
valve spring

Valve spring
Upper seat of Valve adjustment

valve spring gasket

- 149 -
 Ruler
Check
Remove carbon deposits on cylinder cover.
Measure the planeness of the cylinder cover’s
combination surface.
Test gauge
Allowed limit: 0.05mm.
When the combination surface planeness of the
cylinder cover is over limit, put fine sand paper on the flat panel to let the surface match with the
paper and grind in 8-shape.
Measure the free length of the inlet and exhaust
springs of the valve.
Allowed limit: inlet spring: 37.3mm.
Exhaust spring: 40.1mm. Vernier caliper

Micrometer
Measure the outer diameter of the valve rod.
Allowed limit: inlet valve: 3.96mm.
Exhaust valve: 3.96mm
Check valve pipeline after removing the carbon
deposits with reamer.
Notes: reamer shall be rotated clockwise, with no
anticlockwise being allowed.

Measure the inner diameter of each valve pipeline.

Allowed limit: inlet/ exhaust: 4.07mm. Testing meter
Allowed limit of clearance between valve and valve
pipeline:

- 150 -
Inlet valve: 0.11mm.
Exhaust valve: 0.11mm.

Screwdriver
12.3.4 Replacement of valve pipeline
Notes: when the clearance between valve and valve
pipeline is over the limit, it needs to change valve
pipeline. After valve pipeline is changed, valve seat ring’s
surface shall be repaired.
Put the valve pipeline into the freezing chamber of the
refrigerator for 1 hour.
Heat up the cylinder head to 100-150℃ with electric
furnace or hot oven.
Screwdriver
Fix cylinder head; disassemble valve pipeline from the
cylinder head side by use of valve pipeline disassembly
tools.

Valve reamer

Put an O-ring on the new valve pipeline.

Install valve pipeline on the top end of the cylinder head.
Notes: the cylinder head shall stay unharmed when
installing valve pipeline.

Inserted valve pipeline shall be fixed with pipeline reamer.

Notes: moderate cutting oil shall be added when doing the cutting with reamer. The rotation shall be
clockwise.

Remove the carbon deposition in the burning chamber and valve and clean out the inlet and exhaust
valves.
Check the width of the contact surface of the valve seat (valve seat ring width).
Allowed limit: inlet / exhaust: 1.5mm.
Contact surface
of valve seat

- 151 -
12.3.5 Finishing of valve seat ring
Rough part
Remove rough or uneven parts on the surface of the
valve seat ring by use of 45° milling cutter.
Notes: coat a layer of transparent or Prussia blue
coating to the valve seat ring, for better identification.

Remove 1/4 of the external of the valve seat ring with 25° milling cutter.

Remove 1/4 of the external of the valve seat ring with 60° milling cutter. Take off the milling cutter
and check on the handled places.

60°

- 152 -
Grind the seat ring with a 45° finishing milling cutter
to reach moderate width. 1.0mm

Be sure to remove all the dents and uneven places.

Standard width of valve seat ring: inlet: 1.0mm

Exhaust: 1.0mm
45°

If the contacted place locates at the higher part of the valve, use a 25° milling cutter to reduce the
valve seat ring. Relatively higher
If the contacted place locates at the lower part of the
valve, use a 60° milling cutter to reduce the valve seat
ring. 25°
Use 45° finishing milling cutters to ensure the refined
valve seat ring meets required specification.
Relatively lower
After valve seat ring is ground, coat a polishing agent
on the valve surface and polish the valve slightly. 60°

- 153 -
12.3.6 Installation
The assembly shall be executed in opposite sequence of disassembly.
Notes: at the time of valve spring assembly, face the end with relatively lower pitch towards the
combustor.
Valve lock clamp shall be installed using valve spring’s compression tools t compress valve spring
for installation.
Moderate engine oil shall be coated to valve rod surface before putting into the valve pipeline when
installing valve.

- 154 -
XIII. Crankcase

Sevice Data--------------------------------------------------------------13.1

Fault Diagnosis---------------------------------------------------------13.2

Upper Box---------------------------------------------------------------13.3

Piston --------------------------------------------------------------------13.4

Lower Box--------------------------------------------------------------13.5

Clutch--------------------------------------------------------------------13.6

Speed Change Mechanism--------------------------------------------13.7

Assembly of Crankshaft & Connecting Rod-----------------------13.8

13.1 Service Data

Function of upper box: the cylinder of the upper box provides space for compression, combustion
and expansion of air and plays a guidance role for piston motion.
It will also transfer part of the heat to the surrounding cooling medium.
Functions of piston:
1. To bear the pressure produced by the combustion of mixed combustible gases and transfer the
pressure to connecting rod to bring the crankshaft into rotation.
2. Jointly form into a combustor with cylinder cover.
Functions of crankcase: it is the bearing part of the engine. Its main function is to support crank,
clutch, gearbox, cylinder and cylinder cover, bear the inertia force generated by burning and
explosion impact and crank connecting rod mechanism motion and compose a part of sealing space
(of oil and air).
There are hanging hole in the crankcase, connecting the engine with the frame and other parts by
connecting with that on oil return mechanism.

- 155 -
Cautions of operation:
All parts shall be cleaned up before inspection and blow them clean by high pressure air.
Crankcase is a thin-wall casting part, so it needs to avoid impacting to prevent deformation or
breaking during operation.
Before operation, emit the lubrication oil in the crankcase.
Table of Baseline Project Standard Value and Allowed Limit

Items Standard value Service life

Cylinder I 65 (0.025, 0.03) 65.100
Cylinder inner diameter
Cylinder II 65 (0.03, 0.035) 65.110
Cylindricity of cylinder 0.008 0.050
Roundness of cylinder 0.006 0.050
Planeness of cylinder 0.03 0.05
Piston outer diameter (piston Piston I 65 (-0.03, -0.025) 64.90
skirt section measuring) Piston II 65 (-0.025, -0.02) 64.91
Piston pin hole inner diameter 16（0.002,0.008） 16.04
Piston pin outer diameter 16（-0.008，0） 15.96
Clearance between piston pin
0.002-0.016 0.04
hole and piston pin
Clearance between Ring 1 0.05-0.09 0.11
Upper box piston ring and
Ring 2 0.04-0.08 0.11
piston groove
Ring 1 0.15-0.30 0.5
Clearance of piston
Ring 2 0.25-0.45 0.65
ring mouth
Oil ring 0.20-0.70 1.0
Inner diameter of small end of
16（0.016,0.034） 16.04
connecting rod
Clearance between connecting
0.016-0.042 —
rod and piston pin
Thickness 1.5（0-0.09） 1.48
Connecting Clearance
rod shaft between
enclosure connecting rod 0.025-0.05 0.065
shaft bush and
crank
Left-right
clearance of
0.1-0.25 0.5
large end of
Connecting connecting rod
Lower box rod Radial
clearance of
0.028-0.052 0.06
large end of
connecting rod
Main shaft Thickness 1.5（0-0.012） 1.44

- 156 -
 bush Clearance
between main
0.022-0.045 0.06
shaft bush and
crank
Friction plate 2.8（-0.05，+0.05） 2.45
thickness 3（0.1,-0.1） 2.6
Clutch
Pressure spring
35（-0.7，+0.7） 34
length
Outer diameter
of shift fork 11.973-11.984 11.96
shaft
Shift fork inter
12-12.018 12.03
pole diameter
Shift fork
Gear shifting 5.80-5.90 5.75
thickness
mechanism
Gear shifting
drum outer 41.9-42.1 41.5
diameter
Gear shifting
drum's locking 5.45-5.55 5.65
groove width

13.2 Fault Diagnosis

Compression pressure is low Exhaust pipe expels white smoke

Piston is worn or burned damage Piston ring is worn and damaged.
Cylinder and piston are worn or damage Piston and cylinder are worn or damaged
Gasket is damaged and crankcase leaks air or oil
Compression pressure is extremely high Piston generates abnormal noise
Combustor has too much carbon deposition Cylinder, piston and piston ring are damaged
Piston pin hole and piston pin are worn
Compression pressure is low Abnormal noise is found within crankcase
Crankcase leaks air Parts fall down or break down in the crankcase
Engine is overheat Engine automatically switch off
Clutch slides Clutch is jammed
Poor lubrication
It fails to gear up It is difficult in changing gear

- 157 -
Speed change shift fork breaks down or deforms Clutch separation is not absolute
Shift fork's guide pin breaks down Speed changer’s pulling back spring is of bad action
Gear block is worn Gear shifting drum's locking groove is worn
Automatic out of gear
Joint claw is worn and its edges turn into circular bead
The elastic force of return spring of speed changing mechanism reduces
Spline tooth of spline shaft and spline groove of sliding gear wear, which leads to larger axial force
being produced when the gear is working.
Gear shifting drum and shift fork are worn

- 158 -
13.3 Upper Box

QJ265MN engine cylinder is a part of the upper box.

Upper box

Check
Check the wear conditions of cylinder inner wall.
Replacement is necessary if serous wear is found.
Take off the gasket and locating pin.

Gasket

Locating pin

13.4. Piston

13.4.1 Disassembly

Remove piston pin’s retainer ring.

Notes: do not drop the retainer ring into the crankcase
during disassembly.
Take out the piston pin and take off the piston.
Retainer ring of seat ring

Piston pin

- 159 -
- 160 -
Take off the piston ring.
Check the piston, piston pin and piston ring.
Notes: do not break off or damage the piston ring.
Clear the carbon deposit in piston ring groove.

Install the piston ring.

Measure the clearance between the piston ring and
piston ring groove.
Allowed limit: Ring 1: 0.11mm. Pushing-in

Ring 2: 0.11mm. Piston

Piston ring

Test gauge

Take off the piston ring and install each piston ring on
the bottom of cylinder.
Notes: press the piston ring into the cylinder by piston
head.
Measure the clearance of piston ring mouth.
Allowed limit: Ring 1: 0.5mm. Piston ring

Ring 2: 0.65mm.

Test gauge

- 161 -
Measure the inner diameter of piston pin hole.
Allowed limit: 16.04mm.

Testing meter

Measurement of outer diameter of piston pin.

Allowed limit: 15.96mm.
1
Clearance between piston pin hole and piston pin.
2
Allowed limit: 0.04mm.
3

Measurement of outer diameter of Piston I and II.

Notes: the measuring position shall form a degree
of 90 with the piston pin at the piston skirt. 90°
Allowed limit of Piston I: 64.90mm.
Allowed limit of Piston II: 64.91mm.

11mm

Inner wall scratch and abrasion inspection of Cylinder

I and II.
Notes: a right angle (90°) shall be formed with the
piston pin, and the inner diameter of cylinder shall be
measured from three positions, namely, the upper,
central and lower positions.
Allowed limit of Cylinder I: 65.100mm.
Testing meter
- 162 -
Allowed limit of Cylinder II: 64.110mm.
Measure the roundness of cylinder inner wall (inner
diameter difference of X-direction and Y-direction)
Allowed limit: 0.050mm. Inlet Outlet
Measure the cylindricity of cylinder inner wall (inner Upper
diameter difference of X-direction and Y-direction at
the upper, central and lower positions). Central
Allowed limit: 0.050mm.
Lower

Check the flatness of cylinder face. Ruler

Allowed limit: 0.05mm.

Upper box

Measure the inner diameter of connecting rod’s small

end. Inner diameter
Allowed limit: 16.04mm.
Testing meter

Measure the clearance between connecting rod shaft bush and crank.
Allowed limit: 0.065mm.

Connecting rod shaft enclosure

- 163 -
Measure the clearance between connecting rod shaft bush and crank.
Allowed limit: 0.07mm.

Main shaft bush

Plastigauge

13.4.2 Installation of piston Apical ring

Install locating pin.

Ring 2
Coat evenly each piston ring and piston with engine
oil and install the piston ring in place.
Oil ring
Notes: the piston shall not be scratched and the piston
ring shall not be broke off.
The piston ring shall be able to rotate freely inside of
piston ring groove after the installation of piston ring.

Scrape the attached gasket on the box thoroughly.

Notes: no foreign matters shall drop inside the box.
Install piston, piston pin and piston ring’s retainer
ring.
Dot mark
Notes: the piston shall be installed with the dot mark
on the top orienting to inlet valve.

- 164 -
13.5 Lower Box

13.5.1 Disassembly of left cover of crankcase

Loosen fixed bolts on starter motor and take off the starter motor.
Loosen bolts on the left cover of crankcase.
Remove the left cover.
Take out the electric starter gear, roller pin shaft and gasket.

Starter motor

Idle gear of motor

Locking pin hole

Take off the idle gear of starter motor.

Take off the gasket and locating pin.
Loosen flywheel locknut by electric or pneumatic tools.
Pull out flywheel components (including star wheel).

Flywheel component

13.5.2 Disassembly of right cover of crankcase

Loosen the fixing bolt and take off the right cover.

Fixing bolt

Right cover - 165 -

Take off the components of clutch release lever
from the right cover.
Right cover

Release lever component

Remove the fixing bolt, clutch, components of gear shifting arm and sprocket of engine oil pump.

Fixing bolt

Clutch

Gear shifting arm

component

Sprocket of engine
oil pump

Loosen locknut by electric or pneumatic tools and remove the clutch.

Loosen bolts in engine oil pump and take off the sprocket of engine oil pump.

- 166 -
 Locknut

Bolt of engine oil pump

Bolt of separating disc

Sprocket of engine oil pump

13.6 Clutch Clutch nut

13.6.1 Disassembly
Unscrew the four bolts on the separating disc as per the
opposite-angel interleaved mode.
Loosen the nuts of the clutch.
Remove shaft sleeve, shaft, separating disc and
clutch spring.
See Breakdown Drawing for dismantled parts.
Four-jaw socket

Unscrew the locknut of clutch by special tools and

remove locknut and gasket.
Remove the center support of the clutch.
Take out clutch plate and friction
Universal holder plate.
Remove clutch’s pressure plate.
See Breakdown Drawing for dismantled parts.

- 167 -
Remove spline gasket.
Remove enclosure component.

Enclosure component

The assembly of clutch shall be executed in opposite sequence of disassembly.

- 168 -
13.6.2 Breakdown of clutch

Driven hub seat

component
Pressure spring
Roller pin shaft Pressure plate
Shaft sleeve
Friction plate Bolt
Gasket
Clutch plate
Driver shaft
Belleville spring
Driving hub
component Gasket
Driving hub

13.6.3 Check
Check if there is any burr or damaged trace on the
enclosure groove of clutch; trim it with file, if any and
in case of large trimming amount, it shall be replaced.
Check if tooth profiles of pressure plate and center
support are damaged and replacement shall be executed,
if any.

Driven hub component

Driven hub

Measure the free length of pressure spring.

Replacement is necessary under allowed limit I of
22.8mm.
Replacement is necessary under allowed limit II of
22.4mm. Free length

- 169 -
Measure the thickness of friction block by vernier
caliper. Thickness

Replacement is necessary under allowed limit I of

2.45mm.
Replacement is necessary under allowed limit II of
2.6mm.

13.7 Gear Shifting Mechanism

Gear shift
13.7.1 Disassembly shaft assembly
Remove gear shifting shaft.
Remove bolts and gear shifting locking plate.
Remove bolts, stop arm and spring.
Dismantle the locating pin.
See Breakdown Drawing for dismantled parts.

13.7.2 Breakdown of gear shifting shaft mechanism

- 170 -
 Shift fork
shaft spring Shift fork
Shift fork shaft

Gear shifting drum

Strap

Gear shifting arm component

Gear shifting drum shaft Ratchet wheel

13.7.2.1 Check
The gear shifting plate shall be able to return flexibly with no clamping stagnation before
breakdown.
Check the abrasion conditions of gear shifting plate and gear shifting shaft assembly. In case of
severe abrasion, please replace the components.
Check the abrasion conditions of gear shifting locking plate. In case of severe abrasion, please
replace the components.
Check if the gear shifting shaft is excessively bent and please replace it, if any.
Check if the elastic force of the return spring is decreased and replace it if necessary.
Loosen bolts for mould assembling.
Separate the crankcase. Upper box

Notes: do not damage the gasket and mould assembling

face.
Mould assembling
Take off the upper box. bolt

- 171 -
Lower box
 Main shaft component

Auxiliary shaft component

Gear shifting drum

Take off the main and auxiliary shafts.

Loosen follower bolts and take off the pressure plate.
Pull out the shift fork shaft.
Shift fork
Take off the gear shifting drum.
Take off the gear shifting fork.
Shift fork shaft

173.7.2.2 Check
Shift fork shaft
Measure the outer diameter of shift fork shaft.
Allowed limit: 11.96mm.

Shift fork shaft

Micrometer

- 172 -
Measure the inner diameter of shift fork hole.
Allowed limit: 12.03mm.

Testing meter

Measure the thickness of shift fork.

Allowed limit: 5.75mm.

Vernier caliper

Width of locking groove

Measure the outer diameter of gear shifting drum.
Allowed limit: 41.5mm.
Measure the thickness of hinge slot of gear shifting
drum.
Allowed limit: 5.65mm.

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13.8 Assembly Room and Speed-variable Room of Crankshaft &

Connecting Rod

Assembly room of
crankshaft &
connecting rod

Speed-variable
room

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 Auxiliary shaft component

Main shaft component

Gear shifting drum component

Gear shifting arm component

Shift fork shaft

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 13.8.1 Crankshaft & connecting rod assembly

13.8.1.1 Disassembly
Take off the upper box.
Take off the gasket and locating pin.
Take off the crankshaft & connecting rod assembly from the lower box.

Crankshaft &
connecting rod
components

Main shaft
Auxiliary shaft component component
Mould assembling
surface

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Notes: do not damage the gasket and mould assembling face.

Location for clearance measurement

of connecting rod’s large end
13.8.1.2 Check
Measure the left-right clearance of large end of connecting rod.
Allowed limit: 0.5mm.

Measurement location of
Measure the clearance of connecting rod’s large end at X-Y direction. connecting rod’ large end
Allowed limit: 0.06mm.

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13.8.1.3 Assembly
The assembly shall be executed in opposite sequence of breakdown and disassembly.
Take off the component of main shaft.
Take off the component of auxiliary shaft.
13.8.2.1 Breakdown of main and auxiliary shafts

Auxiliary shaft component

Main shaft component

13.8.2.2 Check
Check the abrasion conditions of tooth face and
transmission claw respectively.
Replacement is necessary in case of serious wear or
damage.
Tooth surface

Transmission claw
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Check if the shaft and oil seal are damaged and replacement is necessary, if any.
Notes: rejected shafts shall not be re-used and shall be replaced with new products.
The disassembly of shaft and oil seal shall be executed by special tools.
13.8.2.3 Assembly of main and auxiliary shafts
Notes: coat each gear and shaft with lubricating oil during assembly. Ensure that no jamming
phenomenon occurs in each gear after assembly.
Notes: the assembly of crankcase shall be executed in opposite sequence of disassembly.

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XIV. Cooling System

Service Data--------------------------14.1

Fault Diagnosis-----------------------14.2

Water Pump----------------------------14.3

14.1 Preparation of Data

Function of cooling system:

The cooling mode of the engine is hydrocooling. Hydrocooling refers to cooling high temperature parts by taking
water as the medium of absorbility and transferring the heat to the outside air, to keep the engine working at the
most suitable temperature status.

Specific cooling route:

Cooling water enters from the crankcase into cylinder jacket and then finally into the radiator for heat dissipation
by passing through the water channel of crankcase and cylinder cover respectively, to transfer the heat to the
outside air by its fins.

14.2 Fault Diagnosis

Water leakage

Damage of seal ring

Crack of pump body

Fracture of water pipe

Excess temperature of cylinder body

Damage of impeller of water pump

Blockage of water pipe

Damage of cooling fan

Damage of water temperature switch

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14.3. Water Pump

Disassembly

Loosen the bolts and remove the water pump sub-assembly.

Bolt

Water pump sub-assembly

Bolt

Loosen the bolts and take off water pump cover

Water pump cover

Remove the impeller.

Impell
Check

Check the abrasion conditions of impeller components.

Replacement is necessary in case of serious wear.

Notes: the joint surface of gasket and box shall not be damaged
during operation.

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 Assembly

The assembly shall be executed in opposite sequence of disassembly.

Diagram of the Cooling System

Kettle

Piping Diagram of 265 Cooling System Kettle

Thermostat

Cylinder cover Pressure valve

Radiator
Cylinder body Water pump

Water flow direction

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Check and maintenance of exhaust gas emission system

1. Sealing gasket component of exhaust pipe 2. Bolt M8 3. Exhaust pipe components 4. Graphite lining ring
5. Bolt M8×45 6. Hoop components

7. Barrel components of silencer 8. Oxygen sensor 9. Rubber sleeve II 10. Lining of protection plate 11.
Bolt M8×1.25×25

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XV. Control System of Exhaust Gas Emission

Letter of Guarantee of Exhaust Gas Emission Control System-----------------15.1

Notice of Periodic Maintenance/ Ensured Emission Standard------------------15.2

Mechanical Function of Exhaust Gas Control System---------------------------15.3

Catalytic Converting System---------------------------------------------------------15.4

Solutions in Case of Idling Emission Value Exceeding Specified Value---------15.5

15.1 Letter of Guarantee of Exhaust Gas Emission Control System

15.1.1 The exhaust gas emission control system of the vehicle conforms to the national stipulated standards of
GB14621-2011, GB14622-2007, GB19758-2005 and GB20998-2007, and our company can grant our guarantee
provided that the vehicle is normally used and maintained by users as required within the effective service life of
the exhaust gas control system.

15.1.2 Guarantee scope

Guarantee for functions of exhaust gas emission control system

It is guaranteed that the vehicle conforms to the exhaust gas inspection executed periodically or aperiodically by
the government agency within the using range of 30,000km.

15.1.3 The guarantee clause is not applicable to the following situations; however, if only required of maintenance
and repair, dealers or service departments in each province of our company are still willing to satisfy with
reasonable prices.

(1) Fail to implement periodic maintenance as per the time or traveling distance required by the company.

(2) Fail to perform periodical inspection, adjustment and maintenance at the dealer or service center of the
company, or provide maintenance certification record.

(3) Overload or misuse.

(4) Remold vehicles randomly, disassemble original parts or install other equipment assertively.

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(5) Use the vehicle for motorcycle race or drive frequently at roads applicable for non-motor vehicle.

(6) Damage caused by weather disasters such as typhoon and flood, or damage and failure caused by negligence,
traffic and foreign object striking.

(7) Fail to execute regular maintenance out of long-term disuse.

(8) Fail to repair the odometer immediately after being damaged or alternation, disuse and replacement caused
artificially.

The new vehicle produced by the company has passed the national stipulated standards of GB 4569-2005 and GB
16169-2005 based on the noise inspection results.

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15.2 Notice of Periodic Maintenance

 It is required by the state that motor vehicles produced by all manufactures shall conform to the emission
standard of air pollution, to avoid the pollution level of environment from being increasingly serious. Despite
producing vehicles conforming to the emission standard of air pollution, our company also strives to purify
the air and reduce air pollution.

 The haulage motor has been strictly inspected before ex-factory, and all parts conform to the emission
standard of air pollution. Since using status of users are different, we make the periodic check list of exhaust
gas emission as follows, and users shall inspect, adjust or repair as per the set time, to ensure normal
emission.

 In case of any other questions in using, please inquire Qjiang dealer, or the service center of Qjiang.

 The relevant emission stipulation is as follows:

Emission specification CO HC NOX

Emission standard ≤2.0g/km ≤0.3g/km 0.15g/km

※ The latest national regulation shall prevail in case of any alteration in emission standards.

 The company hold no responsibility in case of failing to perform periodical inspection at the dealer or service
center of the company. Please perform all necessary inspections at any time, to ensure the best vehicle
situations.

Notes: ① The times for air cleaner washing shall be increased as for traveling under gravel pavement or severe air
pollution, to prolong the service life of the engine.

② The maintenance degree shall be enhanced as for driving at high speed constantly or frequently and with more
mileages.

Ensure the emission standard, and attentions shall be paid to the following items.

(1) As for the utilization of fuel, please restrict the use of No. 93 or No. 97 unleaded gasoline.

(2) As for the utilization of engine oil, please be sure to use products of specified model.

(3) Please perform the maintenance as per the periodic maintenance table.

(4) For exhaust gas control system, it is strictly forbidden to adjust or replace (including ignition plug usage, idle
speed adjustment, ignition timing, throttle valve adjustment, etc.).

(5) Precautions:

 Since faults of ignition system, charging system and fuel system would cause great influence to silencer
device, please go to the dealer or service center assigned by the company for inspection, adjustment or
maintenance if finding any engine fault.

 Please restrict the use of No. 93 or 97 unleaded gasoline, otherwise it would damage the silencer device

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 (four-travel system).

(6) Exhaust gas control system of this vehicle complies with national regulations, therefore it is necessary to use
spare parts from the company when changing any system spare part and implement by assigned dealer or
service center.

15.3 Mechanical Function of Exhaust Gas Control System

Summary

Exhaust gas policy is based on four-travel single-cylinder engine and electrical equipment, adopting air
introducing device and maintaining favorable water level. In addition fuel oil evaporation waste is of charcoal
canister method.

※ Engine modification

Optimization of ignition plug and spherical combustor, together with compression rate, ignition time, exhaust
system and other engine elements, is all beneficial to high gas inlet and outlet efficiency, and striving for increase
of combustion efficiency.

15.4 Catalytic Converting System

15.4.1 Structure:

Touch disc

15.4.2 Description:
(1) The function of converting catalyst is to transform fully burned exhaust gas HC, CO and NOX into H2O, CO2,
N2 and other harmless gas before discharging.

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(2) Converting catalyst contains rare metals and restricts the use of unleaded gasoline.

※ Pay attention that leaded gasoline would make catalyst ineffective.

General precautions during overhaul of vehicles with catalytic converter (exhaust pipe):

a) For vehicles with catalytic converter, it is not allowed to touch when the temperature is high in a short time
during engine starting or after stopping.

b) Vehicles installed with catalytic converter can not get close to flammable objects.

c) Exhaust pipe contains CO which is harmful for health; therefore do not operate engines in closed space.

d) Vehicles installed with catalytic converter can not use lead gasoline. (Prevention for catalyst poisoning)

e) The engine shall not be started with the cart. If the engine must be started with the cart, it necessary to wait
until the temperature of the engine and the catalytic converter fall down.

f) It is prohibited to use the neutral position for downhill traveling.

g) Do not drive vehicles with undesirable ignition.

h) The method of removing the sparking plug and starting the engine to check whether there is park or not shall
not be adopted for the repair of the engine ignition system. If it is necessary, the time shall not be too long.

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15.5 Solutions in Case of Idling Emission Value Exceeding Specified Value

Qualified
Conduct regular check (maintenance plan)

Qualified
Measure emission under idle speed (Note
1)

Qualified

Adjust the throttle valve (Note 2)

Qualified
Remove and clean the oil injector
Approved to leave
the factory

Qualified
Change oil injector

Remove and repair the

Qualified
engine
• Valve (leakage)
• Piston (wear)

Notes:

1. Measure with the idle speed measurement procedures.

2. Adjust the engine’s idle speed to the stipulated range and measure the idle speed CO/HC.

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Inspection and maintenance of electronic fuel injection system

- 190 -
XVI. Electrical Fuel Injection System

Electrical Fuel Injection System---------------------------------------16.1

Parts of Electrical Fuel Injection System-----------------------------16.2

Fault Diagnosis ----------------------------------------------------------16.3

Elimination Methods of Common Faults ----------------------------16.4

16.1 Introduction of Electrical Fuel Injection System

The small engine electronic fuel injection system for manufactured by Delphi is adopted for BJ300GS, which is
controlled by 4 oxygen sensors in closed loop. Fuel injection and ignition control of four cylinders are
independent. Three-way catalyst is adopted for the after-treatment of gas generated by combustion of the engine to
translate it into harmless gas before exhaust. Closed-loop control self-learning system is adopted for the system to
effectively eliminate the manufacturing difference of the system and related mechanical parts, and enhance the
comprehensive consistency of the whole machine; besides, it can also eliminate the error caused by wear or other
factors during actual use of the car.

16.2 Parts of Electrical Fuel Injection System

16.2.1 Engine control unit (MT05.2 ECU)

The engine control unit detects the operation state of the engine in real time through various sensors and controls
the output device through reasonable calculation and self-learning, optimizing the driveability of the vehicle under
various working conditions and ensuring the original vehicle emissions and fuel economy. The engine control unit
can conduct self diagnosis in case of system failure. Two sets of ECU are required by this system for working
together.

16.2.1.1 Appearance of ECU

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The installation location of ECU 12 is on the left of the storage battery and that of ECU 34 is on the rear of the
storage battery.

16.2.1.2 Pin assignment of ECU

1) ECU 12:
J1-1 J2-1 Drive pin for 1-cylinder ignition coil
J1-2 Control pin for headlight J2-2 Grounding pin for the system
J1-3 Pin of fault lights J2-3 Communication pin for K line
Heating pin for 2-cylinder oxygen
J1-4 J2-4 High potential pin for crankshaft signals
sensor
Signal pin for 2-cylinder oxygen
J1-5 J2-5 Drive pin for 1-cylinder fuel injector
sensor
J1-6 Pin for tachometer J2-6 Drive pin for 2-cylinder fuel injector
J1-7 Signal low 1 pin for CAN line J2-7 Heating pin for 1-cylinder oxygen sensor
J1-8 Signal high 1 pin for CAN line J2-8 Signal pin for intake temperature sensor
J1-9 Grounding pin for the system J2-9
J1-10 Drive pin for 2-cylinder ignition coil J2-10 Grounding pin of 5V reference voltage in the system
J1-11 J2-11 Signal pin for intake pressure sensor
J1-12 J2-12 Signal pin for throttle valve position sensor
J1-13 J2-13 Low potential pin for crankshaft signal
J1-14 Dumping switch (low effective) J2-14 Signal pin for water temperature sensor
Ignition power supply (12V positive voltage after plugging the
J1-15 J2-15
key)
J1-16 J2-16
J1-17 J2-17 Signal pin for 1-cylinder oxygen sensor
Storage battery power supply (12V positive voltage of storage
J1-18 Pin for neutral gear switch J2-18
battery)

Remarks:
J1 refers to the grey plug-in on ECU, J2 refers to the black plug-in on ECU and J1-1 refers to the No. 1 pin on the grey plug-in.

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2) ECU34:
High A pin of idle speed stepping
J1-1 J2-1 Drive pin for 4-cylinder ignition coil
motor
J1-2 Pin of carbon canister solenoid valve J2-2 Grounding pin for the system
J1-3 Pin of fault lights J2-3 Communication pin for K line
Heating pin for 3-cylinder oxygen
J1-4 J2-4 High potential pin for crankshaft signals
sensor
Signal pin for 3-cylinder oxygen
J1-5 J2-5 Drive pin for 4-cylinder fuel injector
sensor
J1-6 J2-6 Drive pin for 3-cylinder fuel injector
J1-7 Signal low 2 pin for CAN line J2-7 Heating pin for 4-cylinder oxygen sensor
J1-8 Signal high 2 pin CAN line J2-8 Signal pin for intake temperature sensor
J1-9 Grounding pin for the system J2-9 Control signal pin for oil pump
J1-10 Drive pin for 3-cylinder ignition coil J2-10 Grounding pin of 5V reference voltage in the system
Low A pin of idle speed stepping
J1-11 J2-11 Signal pin for intake pressure sensor
motor
High B pin of idle speed stepping
J1-12 J2-12 Signal pin for throttle valve position sensor
motor
Low B pin of idle speed stepping
J1-13 J2-13 Low potential pin for crankshaft signal
motor
J1-14 Dumping switch (low effective) J2-14 Signal pin for water temperature sensor
Ignition power supply (12V positive voltage after plugging the
J1-15 Vehicle speed sensor J2-15
key)
J1-16 J2-16 5A reference voltage
J1-17 J2-17 Signal pin for 4-cylinder oxygen sensor
Storage battery power supply (12V positive voltage of storage
J1-18 Pin for neutral gear switch J2-18
battery)

Remarks:
J1 refers to the grey plug-in on ECU, J2 refers to the black plug-in on ECU and J1-1 refers to the No. 1 pin on the grey plug-in.

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16.2.1.3 Circuit diagram of electronic fuel injection

Precautions:

a) ECU shall not be put on the position of high temperature, such as silencer or engine;

a) ECU shall not be put on the positions near water drops, oil or other liquid;

b) ECU shall not be covered with mud or other contaminant, or the heat dissipation of it will be effected;

c) Connect with M8 bolt and ensure the tightening torque is 3.9Nm or so, and the installation surface shall be
flat to prevent external force on the ECU which may cause bending of the circuit board.

d) The normal DC power supply voltage of ECU is 9-16V, and working for 1 minute under DC voltage below
26V will not cause permanent damage to the ECU, so as well working for 1 minute under DC voltage below
13V.

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16.2.2 Fuel injector
16.2.2.1 Working principle of fuel injector
The fuel injector is designed with solenoid coil encircling the iron core, and the 2 electrodes led from the solenoid
coil are input control interface for the fuel injector; when the solenoid coil is powered on, the electromagnetic
force generated will overcome the spring force of ball valve and fuel pressure to raise the ball valve, and the
high-pressure (250Kpa) fuel in the fuel pipe will be sprinkled to the inlet valve through the valve seat hole of the
fuel injector after passing the orifice plate and forming taper fog; when the fuel injector is powered off, the
electromagnetic force of the solenoid coil will disappear, and the ball valve of the fuel injector will close
automatically under the influence of the return spring and stop the Injection action of the fuel injector.

16.2.2.2 Appearance of fuel injector

Precautions:

 The fuel injector is equipped with filter which is an unrepairable part, for its designed function is only to
filter the accumulated impurities between the fuel filter and the fuel injector in the oil line; impurities can
cause cementation of the fuel injector, flow excursion, leak and other failures, so the fuel filter is very
important.

 The fuel injector shall be changed with the ones with the same part number.

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16.2.3 Throttle valve
16.2.3.1 Working principle of throttle valve
It consists of main cast valve, return spring, cable throttle, throttle valve position sensor and idle-speed adjusting
screw, etc.

Throttle valve position sensor provides throttle opening for ECU; idle-speed adjusting bolt can control idle speed
and its stability, it reduces the idle speed by clockwise reducing by-pass air amount and increases the idle speed by
anticlockwise increasing by-pass air amount; and its position is generally in 2 circles or so.

16.2.3.2 Appearance of throttle valve：

Qualified

- 196 -
16.2.3.3 Cleaning method of throttle valve
The throttle valve shall be cleaned with carburetor cleanser. Spray the cleanser on the inner wall of the throttle
valve and wipe off the dust and carbon deposition with brush.

Precautions:

The by-pass passage shall not be blocked with garbage.

16.2.4 Engine compartment temperature sensor

16.2.4.1 Working principle of engine cylinder head temperature sensor
The engine cylinder head temperature sensor is used to measure the cylinder head temperature of air cooled
engine, its resistance will change along with the engine temperature within the sensor temperature range with the
feature of negative temperature coefficient resister. It is an unrepairable part.

16.2.4.2 Appearance of engine cylinder head temperature sensor

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16.2.5 Intake temperature sensor
16.2.5.1 Working principle of intake temperature sensor
It is used to measure the intake temperature, its resistance will change along with the intake temperature with the
feature of negative temperature coefficient resister, and it is also an unrepairable part.

16.2.5.2 Appearance of intake temperature sensor

16.2.6 Intake pressure sensor

16.2.6.1 Working principle of intake pressure sensor
The sensor is used to measure the absolute pressure of the inlet elbow, and reflect the intake pressure according to
resistance value, which will be calculated into air inflow into the engine combustor indirectly. It is also an
unrepairable part.

16.2.6.1 Appearance of intake pressure sensor

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16.2.7 Oxygen sensor
16.2.7.1 Working principle of oxygen sensor
The oxygen sensor can detect the oxygen content of the exhaust gas in the engine exhaust pipe for the closed-loop
control of the ECU internal fuel to keep the engine in the state with the most reasonable ratio of air and gasoline
(14.7).

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16.2.7.2 Appearance of oxygen sensor

16.2.8 Ignition coil

16.2.8.1 Working principle of ignition coil
The ignition coil can provide energy for the sparking plug, and the ignition coil and sparking plug are connected
with high-voltage cable.

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16.2.8.1 Appearance of ignition coil

16.2.9 Idle speed stepping motor

16.2.9.1 Working principle of idle speed stepping motor
The function of idle speed control valve is to control the flow area of bypass air passage on the throttle valve, for
the purpose of adjusting the air amount entering the engine and realizing the idling control of the engine.

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16.2.9.1 Appearance of idle speed stepping motor

16.2.10 Fuel oil pump assembly

16.2.10.1 Working principle of fuel oil pump assembly
The electric fuel pump and the pressure adjuster installed at the bottom of the gasoline tank will work together to
provide gasoline pressure of 250Kpa for the engine.

16.2.10.2 Appearance of fuel oil pump assembly

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Rear view:

Front view

16.2.10.3 Fault diagnosis of fuel oil pump assembly

a) The oil pump will operate for about 3 seconds after open with key; please execute Item d if it is able to hear
oil pump rotation.

b) Break off oil pump plug-in, and inspect whether oil pump’s power supply voltage is about 12V.

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c) If there is no Step 2, externally-connected storage battery will supply 12V DC current to oil pump. Please
inspect whether oil pump operates.

d) If oil pump operates normally, use gasoline pressure meter to inspect whether oil pipe pressure is about
250Kpa at the front end of fuel injector during engine idling.

e) If pipeline pressure is lower than 220Kpa, inspect whether the oil pipeline is oil leakage, whether oil pump
operate reversely, and whether the filter is blocked.

16.2.10.4 Common problems

a) Inverse connection of fuel oil assembly causes reverse operation of fuel oil pump, and cause engines fail to
work normally due to insufficient fuel oil pressure provided to engine.

b) Oil pump is damaged and can not rotate normally.

Precautions:

1. Since there is no gasoline in oil tank of new vehicle at the very beginning, after gasoline filling, there will be
much air in fuel oil pipeline. It is necessary to start the motor for many times to eliminate the air in oil pipe, after
which the engine can normally work. This situation is normal, and there will be no starting problem in later
starting.

2. Since gasoline can cool fuel oil pump, do not operate oil pump under conditions where there is no oil or it is
lack of gasoline, which may burn down the fuel oil pump.

16.3 Fault Maintenance and Diagnosis Methods

Fault light locates on the instrument panel, and there is FI mark under it. Normally, the fault light will be always
on after the key is opened, which indicates that there is electricity in the electrical system, and it is able to work
normally. When the fault light is off, it indicates there is no electricity in electrical circuit, and it is necessary to
inspect the fuse wire and plus-and-minus connection of the storage battery. After starting the engine, if the fault
light is off, it indicates that there is no fault; otherwise, if the fault light is on after the engine is started, it indicates
that the electrical system does not work normally, and it is necessary to eliminate faults if any.

There are 3 methods to inspect faults:

16.3.1 Directly use fault light (FI) flicker on the instrument to diagnose.

After confirming that there is fault, there will be flash codes corresponding to the fault after opening and closing
the key for three times, namely the operation of open - close - open - close - open. Afterwards, check the
corresponding faults through fault mode code table.

Among them, when using fault light to indicate faults, examples for flash code rules are as follows: for example, if
the fault involves in short circuit of intake pressure sensor or short circuit of signal pin to the cathode of storage
battery, the fault light will firstly flicker for 10 times after opening and closing the key for three time, which is

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represented by code 0, flickering every 1.2 seconds is represented by code 1, flickering 10 times after another 1.2
seconds is represented by code 0, and flickering 7 times after another 1.2 seconds is represented by code 7,
namely P0107. In this way, it can be seen that except that code 0 is represented by 10 times of flickering, other
figures are identical by the times of flickering. If there is other fault codes, such as fault P0201, namely that when
the there is fault in front-cylinder fuel injector, it will wait for 3.2 seconds to continue to flicker P0201 fault code
after P0107 flickers. If there is not other fault, it will circularly flicker P0107 and P0201. Accordingly, users can
check relevant faults in line with the fault code table.

When the PCHUD software is used, the software will choose decimal system fault code. The decimal system and
the front hexadecimal in the fault code table corresponds to each other one by one, and it is able to find out
corresponding faults based on corresponding relationship. If MULFCURR (current fault) equals to 263 in the
software, it will correspond to P0107 in the fault code table, namely the intake pressure sensor has faults.

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MT05 Fault Code Table

Corresponding
Fault code Description
decimal number
Short circuit of intake pressure sensor or short circuit of signal pin
P0107 263
to the cathode of storage battery
Short circuit of signal pin of the intake pressure sensor to the
P0108 264
anode of storage battery
Short circuit of signal pin of the intake temperature sensor to the
P0112 274
anode of storage battery
Short circuit of intake temperature sensor or short circuit of signal
P0113 275
pin to the anode of storage battery
Short circuit of signal pin of cylinder head temperature sensor to
P0117 279
the cathode of storage battery
Short circuit of cylinder head temperature sensor or short circuit
P0118 280
of signal pin to the anode of storage battery
Short circuit of throttle valve position sensor or short circuit of
P0122 290
signal pin to cathode of storage battery
Short circuit of signal pin of throttle valve position sensor to
P0123 291
anode of storage battery
Short circuit of signal pin of front-cylinder oxygen sensor to the
P0131 305
cathode of storage battery
Short circuit of signal pin of front-cylinder oxygen sensor to the
P0132 306
anode of storage battery
Short circuit of heating pin of front-cylinder oxygen sensor to the
P0031 50
cathode of storage battery
Short circuit of heating pin of front-cylinder oxygen sensor to the
P0032 49
anode of storage battery
P0201 Front-cylinder fuel injector fault 513
Rear-cylinder fuel injector fault (for example, the plug-in of fuel
P0202 514
injector is not suitably inserted)
Open circuit or short circuit of oil pump to cathode of storage
P0230 560
battery
P0232 Short circuit of oil pump to anode of storage battery 562
P0336 Interference of crankshaft position sensor 822
P0337 No signal of crankshaft position sensor 823
P0351 Fault of front-cylinder ignition coil 849
P0352 Fault of rear-cylinder ignition coil 850
P0562 Excessively lower voltage of electrical fuel injection system 1378
P0563 Excessively high voltage of electrical fuel injection system 1379
Fault light fault (light filament is damaged or the plug-in is not
P0560 1616
well not inserted)
P1693 Short circuit of tachometer line to the cathode of storage battery 5779
P1694 Short circuit of tachometer line to anode of storage battery 5780
Short circuit of signal pin of rear-cylinder oxygen sensor to the
P0137 311
cathode of storage battery
Short circuit of signal pin of rear-cylinder oxygen sensor to the
P0138 312
anode of storage battery
Short circuit of heating pin of rear-cylinder oxygen sensor to the
P0038 56
anode of storage battery
Short circuit of heating pin of rear-cylinder oxygen sensor to the
P0037 55
cathode of storage battery

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16.3.2 Use diagnostic unit for fault diagnosis

Operation method:

a) Find out the 6-hole diagnosis interface on the motorcycle;

b) Connect connecting line to the interface of the diagnostic unit,

c) Unscrew the key to diagnose;

16.3.3 Use diagnostic software PCHUD to inspect faults

PCHUD software is used to inspect and record engine operation data, and before using, it is necessary to connect
the PC to motorcycle 6-hole diagnosis interface through K line. Before using, it is necessary to install K line
driving software on the PC.

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Instructions of PCHUD software:

(1) Use K line to connect the PC to the motorcycle’s 6-hole diagnosis interface and open the key

(2) Click the “HUD.EXE” icon to start the PCHUD software

(3) Select the “File” on the software interface, click “Open” to select “PCHUD.HAD”, and select OK to confirm.

(4) Select the “Parameter File” in “Setup”, click MT05common.par file, select “Comm protocol” in “Setup”,
select “Keyword2000” and click OK; meanwhile, select 17 for Device Code.

- 208 -
 (5)
If the software interface can not display real-time communication data under power-on, it needs to continue the
following works: inspect whether there is problem for COM port connecting setting in “Setup”. Usually, it is set
as COM Port: 4. Baud Rate: 10400. Please do not select DTR High at startup.

- 209 -
Afterwards, it is able to normally communicate and the current fault code will be displayed at the position of
MALFCURR and the history fault code will locate at MALFHIST.

Afterwards, check the corresponding fault according to the fault code table.

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Interpretation of PCHUD software parameters:

VRPM Engine rotation speed engine speed

VTHROT Throttle valve opening throttle position
VBARO Atmospheric pressure BARO
VMAP Intake manifold pressure manifold air pressure
Estimated value of intake
VMAPEXP expect manifold air pressure
manifold pressure
VIGN Battery voltage ignition key voltage
Engine cylinder temperature or
VCLTS cylinder temperature or coolant temperature
cooling water temperature
VIAT Intake temperature intake air temperature
STATUSBYTE5 Status mark 5 STATUSBYTE5
Comply with airflow learning
VAFCMET airflow correction met
condition
Comply with air pressure
VBAROCMET Baro update met
updating conditions
VCSINSYNSPRK Sequential ignition mark sequential spark enable
Comply with tip-in ignition angle
SATITRIG tip-in Spark Advance retard trigger
correcting condition
CATLOENB Catalyst light-up logic enable catlyst light-off logic enable
Normal engine working mark
IF ENGSTATE=3 engine work in run state
place
Comply with heating idling
NISTBLIDLE stable warm idle
condition
2-cylinder oxygen sensor heating
FO2REDY2 O2 ready
completion mark place
Intake efficiency long-acting
FCNO block learn memory cell
learning unit
1-cylinder long-acting learning
FBLMCOR1 cylinder 1 block learn memory
value
FCLCINT1 Close loop learning item I intergral of close loop correction
Close loop learning correction
FCLCMUL1 close loop correction
value
IARDRPM Desired idle rpm desired idle rpm
IARPMERR Idle rpm error idle rpm error
Pulse width of 1-cylinder fuel
FPWVC1 base pulse width of cylinder 1
injection
VO2 Oxygen sensor signal Oxygen sensor signal
STATUSBYTE3 Status mark 3 STATUSBYTE3
1-cylinder oxygen sensor
FO2STAT1 cylinder 1 oxygen sensor signal rich lean state
concentration mark place
1-cylinder close loop correction
FCLREST1 cylinder 1 close loop correction reset
reset mark place
FOSHTREN Oxygen sensor heating enable Oxygen sensor heater enable
1-cylinder oxygen sensor heating
FO2REDY1 cylinder 1 Oxygen sensor ready
completion mark place
Idle speed stepping motor close
IF IACV MODE=0 idle airflow control valve close loop correction enable
loop learning enable
Idle speed stepping motor pulse
IAMTRLOST IACV lost
loosing mark place
Idle speed stepping motor
IACMVIHB IACV move disable
forbidding to move mark place
VIGNS Ignition state mark place ignition state
FVE1 1-cylinder volumetric efficiency cylinder 1 Volumetric efficiency

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 VMAPRANG Intake pressure indicating angle MAP read angle
AFFNLAFR Target air fuel ratio target air fuel ratio
SAESTA 1-cylinder ignition advance angle cylinder 1 Spark Advance
SAIDLDYN Idle dynamic ignition angle idle dynamic Spark Advance
SPDWELL Duration of magnetizing dwell time
Idle speed stepping motor air
IAINTEGOFST airflow integral of idle air control valve
volume learning value
Target step quantity of idle speed
IACVDSMP desired position of idld air control valve
stepping motor
STATUSBYTE2 Status mark 2 STATUSBYTE2
1-cylinder close loop correction
FCLCEN1 cylinder 1 close loop correction reset
enable
Pilot injection forbidding mark
PPDSEBL prime pulse disable
place
FPENABL Oil pump enable mark place fuel pump enable
Acceleration and enrichment
FTRNSAES acceleration enrich enter
enable
FTRNSDES Deceleration and enlean enable deceleration enlean enter
FTRNSAEDCLOAD Acceleration and enrichment exit acceleration enrich exit
FTRNSDEINLOAD Deceleration and enlean exit deceleration enlean exit
2-cylinder close loop correction
FCLCEN2 cylinder 2 close loop correction reset
enable

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16.4. Elimination Methods of Common Faults

16.4.1 Maintenance tools

a) Dismounting of spare parts of electric control system - commonly be performed using auto machinery
dismounting tools

b) Electric control circuit and system electric signal - digital multimeter (with buzzing)

c) Electric control system fault diagnosis and engine working condition detection

 Electric control system diagnosis units (recommended)

 Fault diagnosis software (PCHUD) and interface connecting line (can be used if available)

d) Electric system fault code table (for emergency use)

e) Fuel oil pressure meter, with measuring range of 0-300kPa

16.4.2 Engine working data flow displayed by diagnosis units

Use the engine working data flow displayed by diagnosis units to analyze and judge engine faults.

16.4.2.1 Step 1
a) Engine wiring harness and vacuum pipeline - they may influence system control of air flow and oil supply

b) Inspect whether the oxygen sensor is installed in place - it may influence system judgment to air fuel ratio.

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c) Engine fault indicating light - it will influence system warning to faults

d) Storage battery voltage - it could be used to judge whether there is enough power in storage battery

e) Judge whether the values displayed by cooling liquid temperature sensor, intake temperature sensor, intake
manifold absolute pressure sensor and oxygen sensor are normal.

f) Throttle valve position sensor working range - it fails to be fully opened or closed, which may influence
engine power performance and some of system functions

16.4.2.2 Step 2
Confirm whether ECU power supply is on or off -, the communication between diagnosis units and system stops
after closing the key

16.4.2.3 Step 3
a) Cooling liquid temperature and cooling liquid temperature circulation - they could predict whether
thermostat works normally

b) Storage battery voltage - this will display whether the engine works normally

Overhigh: it may result from engine adjuster fault;

Overlow: it may result from incorrect engine connection or engine fault

c) Intake manifold pressure - it may predict whether there is air leakage and valve clearance problems as for air
intake.

Undersized valve clearance: this value is a little higher, which may influence engine dynamic property, and
greatly shorten the service life of oxygen sensor and three-way catalysts due to over early starting of exhaust
valve and increasing of exhaust temperature;

Oversized valve clearance: this may cause relatively lower intake manifold pressure, influence the judgment
of the system to engine working state and cause idle abnormality during vehicle heating.

Besides, if the exhaust system is blocked, this value will be accordingly higher. For example, the three-way
catalysts is blocked because there is foreign objects in the exhaust pipe, there are more engine oil consumed
or there is inner damage of the three-way catalysts.

d) Circulation times of oxygen sensor value - if the times of circulation is too small, it predicts invalid oxygen
sensor.

16.4.3 Simple fault elimination method

When repairing electrical fuel injection system, please conduct according to the steps as follows. In case of
repairing faults in certain step, it is allowed to stop the following steps. Afterwards, use diagnosis units, inspect,
accept and clear out fault codes according to Article 14.4.2.

In case of using diagnosis units, storage battery voltage can not be lower than 8.5V

16.4.3.1 Daily use and maintenance

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 Gasoline shall be No. 92 or 95 qualified unleaded gasoline.

 ECU has damp proof function, but can not use high-pressure water pistol to wash its enclosure.

 Replace gasoline filter for every 7000-10000km.

 Under normal using condition, clean the throttle valve for every 10,000km or every year.

16.4.3.2 Fault phenomenon - fail to start

a) Switch the ignition switch to “ON”, and check whether the engine fault light is on

 Inspect fuse and grounding line

 Inspect whether ECU connector is connected firmly
 It is also allowed to use the execution mechanism of the diagnosis unit to inspect whether
If not:
the light and circuit are normal.
 Inspect and repair the bulb and its circuit
 Use another ECU for judgment
If can:  Connect the diagnosis unit to system diagnosis interface

b) Check whether the diagnosis unit is able to be connected and communicated with the system

If not:  Inspect fuse and grounding line

 Inspect whether ECU connector is connected firmly
 Test whether the diagnosis unit works normally on another normal vehicle
 Use another ECU for judgment
If can:  Remove the fault as indicated by the diagnostic unit

c) Check the ignition system faults – to confirm whether the sparking plug could ignite normally

 Check whether the high voltage cable and sparking plug are interconnected firmly or
damaged
If not:
 Judge using another ignition coil assembly
 Use another ECU for judgment
 Check whether the ignition coil and sparking plug are connected correctly by the high
If can:
voltage cable

d) Check the faults of oil supply system

Whether the fuel pump could work normally – it is able to hear the operation sound of the fuel pump nearby when
the engine is started

 Check whether the relay of the fuel pump could work normally
It is not
 Check whether the crankshaft position sensor is normally connect and smoothly works
able to
 Use another ECU for judgment
work:
 Check the circuit of the fuel pump
1) Check whether the oil supply pressure is more than 220Kpa
2) Insufficient  Check whether there is enough fuel in fuel tank
pressure:  Check whether the gasoline filter shall be replaced (note: gasoline filter
for electronic fuel injection system shall be replaced for per 7000 -
It is able
10000 km)
to work:
 Confirm whether the oil supply pipe and return pipe are damaged
3) Normal  Check whether there is abnormal situations with the nozzle control
pressure: circuit
 Confirm whether the nozzle shall be cleaned

e) Confirm whether fuel in the cylinder is over loaded.

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  Wide open the throttle and connect with the starter; seconds later, the engine shall be able to
If yes:
work

f) Confirm whether the clearance between crankshaft position sensors is excessive

16.4.3.3 Fault phenomenon - fail to start with backfire

a) Check whether the high voltage cable of ignition coil gets loose

b) Confirm whether the timing gear ring looses

16.4.3.4 Fault phenomenon – unstable idle speed

Idle speed control Check whether the by-pass bolts nearby the idling are excessively or insufficiently
system rotated, which in general, should be two circles
Oil supply system Confirm whether oil pipelines leaks
16.4.3.5 Fault phenomenon – the idle speed is too high or too low (the idle speed obviously
does not match with the target)
The idle  In case of water temperature lower than 68℃, the system will raise the idle speed to
speed is too accelerate the warming-up process, which is a normal phenomenon. Besides, check
high: according to the following steps:
 Check whether the by-pass port under idling condition opens too much
 Check whether the valve clearance is excessive, especially that of exhaust valve
The idle  Check the oil volume in oil tank and the condition of fuel filter, oil pipeline pressure and
speed is too nozzle
low:  Check whether the by-pass port under idling condition opens too small
 Check whether the valve clearance is too small
16.4.3.6 Fault phenomenon – unstable idle speed with slowing down to stop
a) Check the valve clearance

b) Check whether the by-pass port and throttle valve are too dirty

16.4.3.7 Fault phenomenon – acceleration powerless

a) Check whether the parameters are normal under idling and high idling conditions

b) Check the oil volume in the tank and the condition of the fuel filter

c) Check whether the exhaust system is blocked, for example: whether the three-way catalytic converter is
blocked due to engine oil burning or converter broken;

d) Check oil circuit pressure and nozzle

e) Check whether the fault light is on, or ignites smoothly because of only having one cylinder

16.4.3.8 Fault phenomenon – slight fire

Check whether the sparking plug clearance meets the specified specifications of 0.7-1mm

16.4.3.9 Fault phenomenon – fault light is on, but the fault code does not correspond to the
fault
It is possibly because that the system’s earthing wire connects unreliably, and it needs to conduct the connection
again and start the engine after disconnecting the power line of the storage battery 3 minutes later.

16.4.3.10 Fault phenomenon – excessive fuel consumption

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a) Check whether oxygen sensors of two cylinders are installed in place; if they are loose, it means that the
oxygen sensors have judged the rarefied gas burn in the cylinder wrongly and added fuel supply accordingly,
which causes excessive fuel consumption.

b) After confirming that the mechanical parts and oxygen sensors of the engine are normal, run the engine and
observe the reading of the oxygen sensor; under normal water temperature, check whether the injection
nozzle leaks when the reading is always more than 500mV.

Precautions

 Most of electrical fuel injection parts can not be repaired. After confirming that the parts are damaged, it
requires of replacement generally.

 When engine is started, do not operate any mechanism thereon (including the throttle; do not pull the throttle
for starting).

 If the fault light of the engine is on during engine operation, please find out and eliminate the causes as soon
as possible.

 Do not use leaded gasoline, for the lead can damage the oxygen sensor and three-way catalytic converter.

 When abnormal engine oil consumption is found, the problem shall be solved soon. Some substances in the
engine oil may also damage the oxygen sensor and three-way catalytic converter.

 The valve clearance shall not be too small, since if the exhaust valve is not closed tightly, it will result in high
temperature of exhaust gas, thus shortening the service life of three-way catalytic converter.

 In case of temperature lower than 10 ℃, the entire vehicle and its engine run under low temperature, and

there may be carbon deposit on the exhaust pipe that may turn black, which is normal phenomenon. The

phenomenon may disappear after running under high temperature for a while, or keep the cooling liquid of

the engine in specified temperature range by appropriate means.

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BJ300GS Circuit Diagram

1
2 3 4 5 6 7 10 9 11 12 13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

14

53 15

52 16

17
51

50 18

49 19

20
48
21
47

22
46
23
45
44
24

54 25

43

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

39 38 37 36 35 34 33 32 31 30 29 28 27 26

42 41 40

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