Benelli TNT600S

Service Manual
KEEWAY Motorcycle Corporation Ltd.
0
Contents
Preface .............................................................................................................................................................. - 1 -
Preparing Documents ....................................................................................................................................... - 2 -
General Safety .......................................................................................................................................... - 2 -
Maintenance Rules ................................................................................................................................... - 3 -
Specification ........................................................................................................................................... - 13 -
Failure Diagnosis.................................................................................................................................... - 15 -
Inspection/Adjustment ........................................................................................................................... - 22 -
Inspection and Maintenance of the Electrical System .................................................................................... - 43 -
1. Battery/Charging System ........................................................................................................................... - 44 -
1.1 Preparing Documents ....................................................................................................................... - 44 -
1.2 Failure Diagnosis.............................................................................................................................. - 45 -
1.3 Battery .............................................................................................................................................. - 46 -
1.4 Charging System .............................................................................................................................. - 47 -
1.5 Voltage/Current Regulator ................................................................................................................ - 48 -
1.6 Magnetor Charging Coil ................................................................................................................... - 48 -
1.7 Magnetor Disassembly ..................................................................................................................... - 49 -
2. Ignition System .......................................................................................................................................... - 52 -
2.3 Ignition System Check ..................................................................................................................... - 54 -
2.4 ECU Group....................................................................................................................................... - 55 -
2.5 Ignition Coil ..................................................................................................................................... - 56 -
2.6 Sensor of the Crankshaft .................................................................................................................. - 56 -
3. Startup System............................................................................................................................................ - 58 -
3.3 Startup Motor ................................................................................................................................... - 59 -
3.4 Starter Relay ..................................................................................................................................... - 61 -
4. Bulbs/ Switches / Meters ............................................................................................................................ - 63 -
4.3 Replacement of Headlamp Bulbs ..................................................................................................... - 64 -
4.4 Replacement of Front Position Lamp Bulbs .................................................................................... - 65 -
4.5 Replacement of Tail Lamp ............................................................................................................... - 66 -
4.6 Replacement of Rear Registration Plate Lamp Bulbs ...................................................................... - 67 -
4.7 Replacement of Front Steering Lamp Bulbs .................................................................................... - 68 -
4.8 Replacement of Rear Steering Lamp Bulbs ..................................................................................... - 68 -
4.9 Meters............................................................................................................................................... - 68 -
4.10 Main Switch ................................................................................................................................... - 69 -
4.11 Horn ................................................................................................................................................ - 69 -
4.12 Handlebar Switch ........................................................................................................................... - 70 -
Inspection and Maintenance of the Motorcycle Body .................................................................................... - 71 -
5. Brake .......................................................................................................................................................... - 74 -
1
5.1 Maintenance Instruction ................................................................................................................... - 74 -
5.3 Front Disc Brake .............................................................................................................................. - 76 -
5.4 Rear Disc Brake ............................................................................................................................... - 80 -
6. Body ........................................................................................................................................................... - 84 -
6.1 Disassembly ..................................................................................................................................... - 84 -
6.2 Assembly .......................................................................................................................................... - 84 -
7. Front Wheel/Handlebar/Front Suspension ................................................................................................. - 88 -
7.3 Front Wheel ...................................................................................................................................... - 90 -
7.4 Steering Handlebar ........................................................................................................................... - 95 -
7.5 Front Fork ......................................................................................................................................... - 97 -
8. Rear Wheel/Rear Suspension ................................................................................................................... - 101 -
8.1 Preparing Documents ..................................................................................................................... - 101 -
8.2 Failure Diagnosis............................................................................................................................ - 101 -
8.3 Rear Wheel ..................................................................................................................................... - 102 -
8.4 Rear Absorber................................................................................................................................. - 106 -
8.5 Chain Drive .................................................................................................................................... - 108 -
8.6 Rear Swinging Arm ........................................................................................................................ - 110 -
9. Fuel Tank .................................................................................................................................................. - 113 -
9.1 Preparing Documents ..................................................................................................................... - 113 -
9.2 Failure Diagnosis............................................................................................................................ - 113 -
9.3 Fuel Tank ........................................................................................................................................ - 114 -
10. Disassembly and Installation of Engine ................................................................................................. - 116 -
10.1 Preparing Documents ................................................................................................................... - 116 -
10.2 Disassembly of Engine ................................................................................................................. - 116 -
10.3 Installation of the Engine ............................................................................................................. - 122 -
Inspection and Maintenance of Engine ........................................................................................................ - 123 -
11. Lubricating System................................................................................................................................. - 124 -
11.2 Failure Diagnosis .......................................................................................................................... - 124 -
11.3 Fuel Pump..................................................................................................................................... - 125 -
12. Cylinder Head ........................................................................................................................................ - 130 -
12.2 Failure Diagnosis.......................................................................................................................... - 130 -
12.3 Cylinder Head .............................................................................................................................. - 132 -
13. Crankcase ............................................................................................................................................... - 140 -
13.3 Upper Box .................................................................................................................................... - 144 -
13.4 Piston ............................................................................................................................................ - 145 -
13.5 Lower Box .................................................................................................................................... - 150 -
13.5 Lower Box .................................................................................................................................... - 151 -
13.6 Clutch ........................................................................................................................................... - 154 -
2
13.7 Gearshift Mechanism ................................................................................................................... - 157 -
13.8 Crankshaft Connecting Rod Assembly Chamber and Variable Speed Chamber .......................... - 161 -
14. Cooling System ...................................................................................................................................... - 167 -
14.3 Water Pump .................................................................................................................................. - 168 -
Inspection and Maintenance of Exhaust Emission System .......................................................................... - 171 -
15. Exhaust Emission & Control System ..................................................................................................... - 172 -
15.1 Warranty on the Exhaust Emission & Control System ................................................................. - 172 -
15.2 Instructions on Periodic Maintenance .......................................................................................... - 173 -
15.3 Mechanical Function of the Exhaust Control System .................................................................. - 173 -
15.4 Catalytic Transfer System ............................................................................................................ - 174 -
15.5 Measures When the Idle Speed Emission Value Exceeds the Standard ....................................... - 176 -
Inspection and Maintenance of Electronic Fuel Injection (EFI) System ...................................................... - 177 -
16. Electronic Fuel Injection System ........................................................................................................... - 178 -
16.1 Introduction of Electronic Fuel Injection System......................................................................... - 178 -
16.2 Components of Electronic Fuel Injection System ........................................................................ - 178 -
16.3 Methods for Fault Diagnosis and Maintenance ............................................................................ - 192 -
16.4 Common Fault Removal Techniques ........................................................................................... - 202 -
BN600 Circuit Diagram ............................................................................................................ .
3
Preface
This maintenance manual is used for operating and maintaining Motorcycle
RK6.
Preparing Documents include all necessary instructions and statements.
Please carefully read this manual before operation.
Inspection & Adjustment states how to check and adjust your motorcycle. All
safety rules and maintenance regulations shall be carried out from the beginning of
periodic inspection.
Except for Chapter I, the rest chapters explain the disassembly/ assembly/
inspection of Electronic Fuel Injection System, engine, entire motorcycle and
electrical equipment.
Breakdown drawing, systematic drawing, failure analysis and statements are
contained at the first part of each chapter.
Please note that photos, pictures or instructions are for your reference only.
The actual object may differ from what is mentioned here. We will not make
notification for any discrepancy.
Qianjiang Motorcycle Corporation Ltd.
- 1 -
Preparing Documents
General Safety Maintenance Rules
Specification Table Inspection/Adjustment
General Safety
Carbon monoxide
Engine must be started up in a well-ventilated place, not in a closed area.
Note
Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human.
Start up engine in an open place. The exhaust cleaning system shall be adopted if engine is started up in a
closed area.
Petrol
Ventilation is required for working places. Fire is strictly forbidden in any working place or where petroleum is
stored.
Battery
Battery emits explosive gas. Therefore, it shall be far away from fire sources, naked flame or smoking places.
Make sure good ventilation during charging.
Battery contains sulfuric acid (electrolyte). It will burn your skin or eyes when contacted. Therefore, wear
protective clothing and mask.
—— Clean with fresh water immediately if electrolyte splashes on the skin.
—— Clean with fresh water at least for 15 minutes immediately and then go to the doctor if electrolyte
splashes on eyes.
Electrolyte is poisonous. Drink a large quantity of fresh water, milk, milk of magnesia (laxative antacid) or
mineral oil if electrolyte is swollen accidentally. Then go to the doctor. It shall be unreachable for children.
Machine Oil
It may trigger cancer if repeatedly expose the hands in the air after contacting with oil. Although there is little
possibility for you to contact with oil in the daily life, wash hands thoroughly with water and soap if you have
contacted. And it shall be unreachable for children.
Thermal Energy
Parts of the engine and cooling system produce heat, which can last for some time before the engine gets
started. Deal with these parts with gloves or after the engine and cooling system cools down.
- 2 -
Maintenance Rules
Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage.
Clean up the surface of components or assembly parts before removing or opening the shield for maintenance,
which can prevent dirt from falling into the engine, the chassis or the braking system.
Wash and dry parts with air compressor after disassembly and
before measurement of attrition value.
Solvent or oil can easily damage aging rubber articles. Check

rubber before reassembly and replace rubber if necessary.
套：boot
When loosening assembly parts, please start form outside to

inside. Small assembly parts shall be loosened first.
Complex assembly parts, such as gearbox, shall be stored in
proper order for facilitating installation in the future.
Please specially note important connections before disassembly.

Replace parts which will not be in use before disassembly.
- 3 -
Bolts and screws with different length shall be separately used for
different assembly parts and shields, and they shall be correctly
mounted. Insert a bolt into a hole to check whether it is proper if
you are confused.
Fill the groove with grease before mounting an oil seal. Check
whether the oil seal is smooth or damaged during assembly.
When installing a rubber hose (fuel, vacuum or cooling agent),

insert its end into the bottom of the connector so that the hose clip
can properly fix the connector. Rubber or plastic dirt-proof boot
shall be mounted at the original design position.
槽：groove 夹子：clip 接头：connector
During dismantling ball bearings, one or two (inside & outside)

bearing rollers shall be supported by tools. Ball bearings may be
damaged during disassembly and have to be replaced if only one
roller (either inside or outside) is imposed with force.
以上两例都会使轴承破裂：Bearings will be broken under either

occasion as mentioned.
- 4 -
Loose cables threaten electrical safety. Check each cable
after it is clamped to another for electrical safety;
Wire clamps are not allowed to bend towards welding
point;
Bind cables at the designated place;
Do not deploy cables at the end of frame or at sharp point;
Do not deploy cables at the end of bolts or screws;
Cable deployment shall be far from heat source and where
cables may be clamped during moving;
Cables along the handlebar shall be neither too tight nor
too loose, and do not interface with any neighboring parts
at steering positions;
Cables shall be properly deployed without twist or knot;
Check whether the connector jacket is damaged and
whether the connector is over-stretched before mounting
connectors;
Adopt adhesive tape or hose to protect cables if they are
positioned at sharp point or corner;
Bind cables with tape after repairing;
Control cables shall not be bent or twisted. Clumsy
operation may be caused in light of damaged control
cables.
- 5 -
Identification
1．The frame number, see figure
Frame Number
Frame
2．Rivets of the frame sign and the frame, see figure
Frame Number Rivets
3．The serial number of the engine, see figure

Engine Number
Significant Notes
1. Please apply valid Qianjiang parts and accessories. Any part or accessory not in accordance with the design
specification of Qianjiang Company may cause damage to engine.
2. Only metric tools are valid for maintenance and repair. Metric screws, bolts and nuts can not be exchanged
with imperial fasteners.
3. New gaskets, O-rings, cotter pins and locking pieces shall be applied for re-assembly.
4. Bolts with large diameter or positioned inside shall be fastened first and then diagonally screw down until
reaching required torque, otherwise there is special instruction.
5. Wash disassembled parts with cleanser. Lubricate all sliding surface before assembly.
6. Check whether all the parts and accessories are correctly mounted and operated after assembly.
7. Clean and remove oil before measurement. Add recommended lubricant to the lubricating areas during
assembly.
8. Apply lubricant to the surface of engine and driving system if they are dismantled for long-term storage,
which can prevent rust and dirt.
- 6 -
Special Tools
Special tools refer to tools which are specially designed for assembling or disassembling some
motorcycle parts on special positions. Applicable special tools are necessary for precise adjustment and
installation. With them, parts and accessories can be mounted safely, reliably and rapidly, which improves
efficiency and saves energy.
1．Tools for repairing the engine
Special tools are required for properly disassembling/assembling some engine parts.
Table and drawing (1-1, 1-2) of special tools for disassembling/assembling engine parts are as follows:
Table 1-1
Name Remark
Special socket spanner Used for assembling/disassembling bolts for flywheels, Fig. 1-3
Clutch clamp holder Fig.1-4
Flywheel puller Fig. 1-4
Feeler gauge Fig. 1-5
Bearing disassembly tools Fig. 1-6
Bearing assembly tools Fig. 1-7
Oil seal remover Fig. 1-8
Handle for dismantling tools Fig. 1-9
Piston pin pulling device Fig. 1-10
Piston pin pliers Fig. 1-11
Socket spanner for spark plug Fig. 1-12
Clutch thickness measuring device Fig. 1-13
Cylinder diameter measuring device Fig. 1-14
Dial indicator Fig. 1-15
Dial indicator, V-block Measuring the inner diameter of the piston pin, Fig. 1-16
Dial indicator For measuring the bending of the valve rod，Fig. 1-17
Assembly/disassembly tool for valve catheter For measuring the external diameter of the valve rod，Fig. 1-18
Assembly tool for valve catheter Fig. 1-19
Adjustment tool for valve space Fig. 1-20
Assembly/disassembly tool for valve spring Fig. 1-21
Valve catheter reamer Fig. 1-22
Disassembly tool for crankcase Fig. 1-23
Fig. 1-24
Table 1-2 (continued)
Fig. 1-3 Fig. 1-4
- 7 -
Fig. 1-5 Fig. 1-6 厚度规（塞尺）
：feeler gauge
Fig. 1-7 Fig. 1-8
Fig. 1-9 Fig. 1-10

①handle
Fig. 1-11 Fig. 1-12 ①pliers ②piston
- 8 -
Fig.1-13 Fig.1-14
Fig. 1-15 Fig. 1-16
Fig. 1-17 Fig. 1-18
Fig. 1-19 Fig. 1-20
Fig. 1-21 Fig. 1-22
- 9 -
Fig. 1-23 Fig. 1-24
2．Tools for repairing the chassis
Table and drawing (1-25, 1-26) of ordinary tools and special tools for disassembling/assembling chassis
parts are as follows:
Fig. 1-25
Name Remark
Torque spanner Fig. 1-27
Inner hexagon spanner Fig. 1-28
Socket spanner Fig. 1-29
Micrometer Fig. 1-30
Magnetic rack, V-block Fig. 1-31
Dial indicator Fig. 1-32
Vernier calipers Fig. 1-33
Circlip pliers Fig. 1-34
Screwdriver with striking cap Fig. 1-35
Tool for assembling oil seal of front fork Fig. 1-36
Tool for hammering seal of front fork Fig. 1-37
Steering nut spanner Fig. 1-38
(1) Ordinary tools for repairing the chassis
Table 1-26 (continued)
Fig. 1-27 Fig. 1-28
Fig. 1-29 Fig. 1-30
- 10 -
Fig. 1-31 Fig. 1-32
Fig. 1-33 Fig. 1-34
Fig. 1-35 Fig. 1-36

(2) Special tools for repairing the chassis: tool for hammering seal of front fork
Fig. 1-37
(3) Steering nut spanner
Fig. 1-38
3．Tools for electric parts
- 11 -
Table and drawings (1-39, 1-40) of special tools for testing electric parts are as follows:
Fig. 1-39
Name Remark
Multimeter Fig. 1-41
Ignition tester Fig. 1-42
Fig. 1-40 (continued)
Fig. 1-41
Fig. 1-42
- 12 -
Specification
Motorcycle Model RK6 Engine Type BJ465MS-A
Length mm 2120 Fuel type Unleaded petrol（93/97）
Width mm 800 No. of 4

cylinder
Height mm 1100 ID × stroke 65.0×45.2
Total
Wheelbase mm 1480 Engine 600cc
displacement
Petrol tank capacity 15L Startup Electric
Forward 115 Cooling Liquid cooling
shaft
Weight kg Back- 105 Lubrication Pressure splash
(Curb weight) shaft lubrication
Total 220 Clutch type Wet multi-chip
Front 120/70 Variable

Six variable speed
tire ZR 17 speed
Tire Size
180/55
Rear tire Transmission Chain
ZR 17
Primary
Battery
12V-9AH transmission 1.864
capacity
ratio
Flywheel permanent Transmisson
Magnetor 2.846
magnet ratio of gear 1
Electric Transmission
devices Spark plug CR9E(NGK) Transmi- 1.947
ratio of gear 2
ssion
Spark plug devices Transmission
0.6-0.7mm 1.556
gap ratio of gear 3
Transmission
Ignition TLI 1.333
ratio of gear 4
Transmission
Max. Hp 60.0kW/11000rpm 1.190
ratio of gear 5
Transmission
Max. torque 55N.m/8000rpm 1.083
ratio of gear 6
Final
Compression
11.5：1 Transmission 3.286
ratio
ratio
Perfor
mance Dia. of front
Max. speed 185km/h liquid brake 320mm
disc（mm）
Brake
Fuel Dia. of rear
consumption ≤5.2L/100km liquid brake 240mm
limit disc（mm）
- 13 -
RK6
- 14 -
Failure Diagnosis
Diagnosis on difficulty or failure in starting up

Failure Diagnosis Adjustment & Inspection Causes of Failure
- 15 -
Check if petrol
pump is working No petrol in the tank
properly Oil tube of fuel injector blocked
Oil tube of petrol pump blocked
Tube of combustion chamber’s
Oil provided to fuel No petrol Evaporation Control System
injector is sufficient provided to blocked
and smooth fuel injector Petrol air filter blocked
Low oil pressure of petrol pump
Disassemble spark Abnormal spark plug
plug into its cap, Polluted spark plug
ground it with engine Abnormal CPU group
to check if it can spark Abnormal trigger
Open circuit or short circuit of
ignition coil’s wire
Spark-over Weak sparks
No Open circuit or short circuit of
ignition coil
Abnormal main switch
Test compression pressure Abnormal charging coil
Abnormal clutch for startup
Abnormal piston of cylinder and

Normal Too low piston ring
No
Leakage of cylinder gasket
Abnormal automatic choke

actuation
No ignition Ignition outbreak
outbreak of of the engine but
Intake manifold with air
the engine no sign of startup
Incorrect ignition time
Disassemble once again the Abnormal adjustment to throttle

spark plug to check valve and bolt
Excessive oil injected to fuel

Dry spark plug Wet spark plug injector
Abnormal automatic choke
actuation
Throttle opens too large
- 16 -
Unsmooth gyration (No speed or weak speed)
Failure diagnosis Adjustment specification Causes of failure
Start engine with
soft refueling Air filter blocked
Abnormal petrol
accelerated Engine can not Tube of combustion chamber’s
gyration speed fully speed up Evaporation Control System
of engine blocked
Exhaust pipe blocked
Adjust ignition timing and Abnormal automatic choke
use ignition timing light Abnormal throttle valve
Correct
Incorrect ignition Abnormal CPU group
ignition time
time
Abnormal trigger
Test compression pressure
Abnormal piston of cylinder and

piston ring
Normal Too low
Leakage of cylinder gasket
Blocking check to Carburetor
No Yes Contaminant removal
Disassemble the spark plug to

check
Contaminant removal
No pollution nor Polluted and
discoloration discolored Heat value of spark plug does
Check oil level in crankcase not conform
if it is high or polluted
Excessive oil
Normal High oil level Insufficient oil
No replacement of oil
Check the lubrication of
cylinder head
Normal Abnormal Abrasion in piston cylinder
Overheated engine Mixed gas too thin
Abnormal petrol
Too much carbon fouling in the
Yes No combustion chamber
Earlier ignition time
Accelerated driving or Too much carbon fouling in the
running combustion chamber
Abnormal petrol
Engine knock No engine knock Clutch slipping
Thin mixed gas
Earlier ignition time
- 17 -
Unsmooth gyration（especially in low speed）
Adjust ignition time
Abnormal CPU group
Normal Abnormal
Abnormal trigger
Adjustment to throttle valve and

bolt
Mixed gas too thin (loosen bolt)

Good Bad
Mixed gas too dense (tighten
bolt)
Spacer inhaled air or not
Abnormal spacer of heat

insulation piece
Throttle valve fixed, bolt
Yes No loosened
Heat insulation piece ruptured
Negative pressure pipe ruptured
Disassemble spark plug

into its cap and ground it
with engine to check if it
Spark plug abnormal or polluted
can spark
Abnormal CPU
Bad spark-over Abnormal ignition coil
Good
spark-over Open circuit or short circuit of
spark plug’s wire
Negative pressure pipe damaged

Good Bad
Air pass-hole blocked
- 18 -
Unsmooth gyration (high speed)
Adjust ignition time
Abnormal CUP group
Normal Abnormal
Abnormal trigger
Little oil in petrol tank

Petrol filter of the pipe blocked
Normal Abnormal
Tube of combustion chamber’s
Evaporation Control System
blocked
Blocked oil injector Abnormal automatic oil ring
No Blocked Remove
Good Spring broken

Weak elasticity Abnormal spring
- 19 -
Poor battery charging (over discharge or over charge)
Test the voltage of
battery’s two ends, and
stat engine
Battery used up
No voltage rise Voltage rises to normal

value, and back to
original voltage value Poor battery
after flameout
Check the plug of voltage

regulator if it is loose
Poor connection of the plug

Normal Abnormal
Open circuit of the red wire of
the charging wire
Check if the red wire of voltage regulator’s

socket connects the multimeter, while
anode and cathode wire to the voltage
between parts of the body
Voltage regulator
Voltage No voltage
available Open circuit of the white wire of
the charging wire
Test the resistance value of

alternator’s coil
Abnormal coil
Normal Abnormal Poor connection of the joint
Open circuit of alternator’s
white wire
Poor battery
Poor battery charging
Overcharging Start the engine, connect the red wire of the
voltage regulator’s socket to the multimeter,
while anode and cathode wire to the voltage
between parts of the body
Voltage above Normal voltage

normal value
Check if charging wire of the voltage

regulator connects well
Loose
Normal Poor connection of the joint and
Bad connection
Use monomer of the voltage regulator
to test impedance charging wire to the ground
Abnormal voltage regulator
- 20 -
No spark-over of the spark plug
Replace on new spark

plug and check again
Weak spark-over or Strong spark Original spark plug abnormal

no spark-over
Check again after

checking spark plug
No sign of loose Loose

Spark plug cap loose
Check plugs of CDI group if they

are loose
Normal Abnormal
Bad connection of the plug
Check conduction between terminals
of CDI group’s plugs, and test
resistance value
Abnormal charging coil
Normal Abnormal
Abnormal trigger
Abnormal ignition coil
Check relevant parts
Normal Abnormal
Breakage of main wire
Bad connection of the plug and
socket
Use CDI tester to check CDI group
Normal Abnormal Abnormal CPU group
Use CDI tester to check ignition coil
Abnormal
Abnormal ignition coil
- 21 -
Inspection/Adjustment
Preparing information Periodic Maintenance & Inspection Table
Engine oil/ Oil filter Liquid coolant
Assembly/disassembly of radiator pipe’s clamp Fuel injector & Oil-way
Adjustment of throttle cable Air filter
Spark plug Battery
Fuse replacement Cylinder pressure
The slackness of the drive chain Free stroke of front brake
Free stroke of rear brake Headlamp
Clutch Front/rear suspension system
Bolt/nut/fastener Rim/tire
Fixing steering stem bearing & handlebar Throttle valve
Components lubrication
Preparing Principles
General
Warning!
• Make sure that it is well ventilated before starting the engine. It is forbidden to start it in a closed area.
Exhaust gas, which contains monoxide, may cause unconsciousness or even death of human being.
• Petrol is liable to volatile or exploded under certain condition. Ventilation is required and no any fire exists in
working places. Fire is strictly forbidden in working areas or where oil is stored.
- 22 -
Specification
Engine
ID × stroke 65.0×45.2
Total displacement 600cc
Ignition TLI
Spark plug gap 0.6-0.7mm
Spec. of spark plug CR9E(NGK)
Type of combustion chamber Spherical
Frame
Free stroke of front brake lever 10-20mm

Free stroke of rear brake pedal 20-30mm
Specification Tire pressure
Tyre pressure unit：Kpa Front tire 120/70 ZR 17 250±10kpa
RK6
Rear tire 180/55 ZR 17 290±10kpa
Fixing front wheel 100-140N·m
Torque spindle
value Fixing nut of rear 130-150N·m
wheel spindle
- 23 -
Periodic Maintenance & Inspection Table
Service cycle and time Per Per Per Per Per Per
300 1000 4000 7000 11000 14000
Inspection item Km Km Km Km Km Km Tools
One Three Six Twelve Fifteen
New month months months months months
* Air filter I C C R C Ordinary tools
* Petrol filter I I R Ordinary tools
* Fuel filter C C C Ordinary tools
Replacement of engine
R Replacement every 1000KM Ordinary tools
fuel
Tire pressure
Tire pressure I I I I I I
gauge, inflator
Densimeter,
Battery inspection I I I I I I
multimeter
Actuation gap inspection I I I I I I Ordinary tools
Inspection of steering
I I I Ordinary tools
handle fastening
Absorber working
I I I Ordinary tools
inspection
Screw fastening
I I I I I I Torque spanner
inspection
Oil leakage inspection for
I I I I I I Ordinary tools
gearbox
Inspection or replacement
* I I R R I Ordinary tools
of spark plug
Replacement of gearbox
* I Replacement every 6000KM Ordinary tools
oil
Lubrication of each part L L Lubricator
Muffler I I I I I I Ordinary tools
* Ignition timing I I I I I I Timing lamp
* Carburetor A I A A A A
Tachometer, CO
Exhaust gas inspection at HC analyzer
* A I A A A A
idle speed
* Throttle inspection I I I I I Ordinary tools
Fuel pipeline inspection I I I I I Ordinary tools
Lighting/metering/electric
I I I I I I Visual multimeter
devices
Main stand bracket I I I Ordinary tools
Absorber I I I I Ordinary tools
Torque force of engine
* I I I I I Torque spanner
bolts
Front/rear brake I I I I Ordinary
Drive chain I I I I A Ordinary
Clutch I I I I Ordinary
* Valve I I I I I Feeler
- 24 -
Anticipated Inspection
1 Ignition system—obviously continuous ignition abnormality, engine fire or overheating, which requires
inspection and maintenance.
2 Carbon fouling elimination—obviously insufficient horsepower, which requires carbon fouling removal
from cylinder head, piston head and exhaust system.
3 Piston & cylinder—excessive abrasion; replace cylinder if it is blocked.
Please have your motorcycle inspected and adjusted periodically at Qianjiang distributors for being in best
condition.
The above table is established under the presupposition of 1000 km/month.
I—Inspection A—Adjustment R—Replacement C—Cleaning L—Lubrication
Note: 1. “*” Regulations on exhaust emission made by the State Environmental Protection Agency shall be
complied with. Maintenance must be carried out in accordance with the instruction manual supplied by the
company. We are not responsible for any loss rising from private adjustment or maintenance.
2. Increase frequency of washing air filter if your motorcycle runs on the sandy/gravel road or under
heavily polluted environment so as to extend its service life.
3. Motorcycles which often run at high speed or with high mileage shall be maintained frequently.
Engine Oil/Filter
Oil level
* Note
• The motorcycle should be parked on a flat ground when
checking its oil level.
• After the engine runs for 2-3 minutes or stops running for
about 2-3 minutes, check the oil level.
Check the oil level.

Add oil to the upper limit when there is an alarm from the oil level sensor.
Check oil level

*Note
Do not tighten dipstick when check.
Check the oil level, and lay down the single shoring on the flat
ground so that the body is vertical.
Oil level must be checked regularly when oil is constantly
being consumed, and refuel to a right level.
Oil capacity: 3.0L change oil 3.2L disassemble
The working of engine and clutch will be affected if the oil
level is too high; (上限：maximum 下限：minimum)
And if it is too low that will lead to overheated engine and earlier abrasion of the components.
If refuel with inferior oil or oil of other brand or class will reduce the effect of lubrication.
Disassemble the dipstick after the engine stops, and dry it with a clean cloth.
Put the dipstick into the measurement hole with the engine on the flat ground, but do not tighten it up.
Take out the dipstick and check the oil level.
- 25 -
If it is below or near the minimum level,
Refuel with the recommended oil to the maximum level.
*Note
Check the O-ring.
Assemble the dipstick.
Oil Replacement
* Note
It will be easier to change oil when the engine is warming up.
Preheat the engine.

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

*Note
It will be easier to change oil when the engine is warming up.
Turn off the engine.

Make the oil filter stuck with special removal tool, spin
anticlockwise and disassemble the oil filter that needs
replacement② .
Replace on new oil filter and coat a layer of lubricant on the
O-ring. Oil filter
Note:
Do not disassemble the O-ring, otherwise it will make the
O-ring out of position while installing, which can lead to
oil leakage or the damage of the engine.
Install the new oil filter to the engine with hands, spin until
it can not be screwed any further, then tighten it with
Torque spanner (torque: 12-20Nm).
Check oil leakage when the engine operates at its idle
speed for minutes.
- 26 -
Cooling Liquid
Check the height of the cooling liquid in the expansion kettle

during maintenance.
Replace in time the cooling liquid when it becomes turbid or it
is time for maintenance.
Recommended model of the cooling liquid: FD-2

Total liquid capacity of the cooling system: about 2.0L
Remove the front shield on the right side. Find the filler mouth
of radiator water tank①.
Open the filler cap and inject a right amount of cooling liquid.
Re-install the cap after injection.
Check the cooling liquid of the expansion kettle after the
engine has been turned off and cooled down.
While checking, make sure the motorcycle is on the flat ground
and its body upright.
Observe the capacity of the cooling liquid in the expansion
kettle through the frame hole from the right side of the
motorcycle.
Keep the capacity between the mark of H and L. If the liquid is below H, remove the cap of the expansion
kettle② and then add cooling liquid.
Warning:
Add the cooling liquid after the engine is turned off
and cooled down. In case of burns, do not open the filler
cap before the engine has cooled down. The cooling
system is under pressure. In some cases, the cooling
liquid contains substances that are combustible, and
there will be visible flame when ignited. Avoid the
leakage of cooling liquid on hot motorcycle parts,
because it can cause serious burns if combust.
Avoid contact to and inhalation of the cooling
liquid, because it is highly toxic. And keep it away from
the children and domestic animals. If inhaled, seek
medical advises immediately, and if the skin or eyes
have accidentally contacted the cooling liquid, they
must be cleaned with water instantly.
- 27 -
Assembly and Disassembly of the Clamp of the Radiator’s Conduit
The clamp of the radiator’s conduit is disposable component, so

the old clamp can not be reused when disassembled. And the
clamp② can only be assembled by special clamp pliers①, or it
may not in place, which will lead to the breakdown of the
vehicle.
卡箍：clamp
Fuel Injector and Oil-way
The fuel pump① has two connectors, oil passes through

the fuel filter② from one of the two connector into the
fuel injector③, and finally injects oil into the intake
manifold of the engine. When the oil is under too high
pressure, it will pass through another connector back to
the fuel pump①.
Please connect the inlet and outlet oil tubes as shown in
the figure at right.
- 28 -
Adjustment to the Steel Rope of the Throttle
*Note
Adjust the idle speed of the engine right before adjusting
the stroke of the steel rope of the throttle.
Check the free stroke of the steel rope of the throttle, and it
should be 3-5mm.
Adjust if it does not conform to the specified value.
Adjust the free stroke of the steel rope of the throttle.
The motorcycle is configured with two-lane steel rope of

the throttle, among the two ropes, A for throttle forward
(1)Remove the dustproof boot of the steel rope of the
throttle.
(2)Loosen the locking nut③.
(3)Screw in completely the adjusting nut④.
(4)Loosen the locking nut①.
(5)Rotate the adjusting nut② to make the free stroke of
controlling handlebar of the throttle to 10°～15°.
(6)Tighten up the locking nut①.
(7)Adjust nut④ to make the controlling handlebar of the
throttle flexible.
(8)Tighten up the locking nut③.
After adjusting the free stroke, the handle should be
twisted left and right to make sure that there is no change
of the idle speed of the engine.
Air Filter
Filter Replacement
Open the rear seat cushion with the key, and remove it.
钥匙：key
Pull the seat steel rope, open the front seat and take it off.
- 29 -
坐垫钢索：seat steel rope
Disassemble the shield of the fuel tank and its front fixing
bolt, and open the fuel tank.
油箱前固定螺栓：front fixing bolt of the fuel tank
Disassemble the cover of the air filter.

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

油箱： fuel tank Cartridge
Replacement Time
Replace it as early as possible if the motorcycle is always running on rainy days or on rugged road.
*Note
- 30 -
Do not start engine when disassemble the cartridge of the air filter, otherwise, the engine will intake unfiltered
air, which may lead to rapid abrasion of other components, and the damage of the engine too.
In addition, rotation without cartridge will cause sequential malfunctions of the carburetor, and it may lead to
overheat of the engine.
Install in reverse order.
Spark Plug
Remove the spark plug:

(1)Lift up the fuel tank.
(2)Disassemble the intake air temperature sensors① on both side
of the air filter, and then remove the air filter.
(3)Remove the stators② of the spark plug caps on both sides.
(4)Remove four spark plug③, and you can see the spark plug④.
(5)Remove the spark plug with the spark plug demolition sleeve.
Check
 Whether the insulator is cracked or damaged
 Whether the electrodes are abrasive
 The combustion condition and color
 The condition is good in light grey
 Combustion color of pale indicates that the ignition system
gets a breakdown or the mixed air is too thin.
 The condition of wet or there is black carbon deposition
indicates that the mixed air is too thick.
If there occur any cases mentioned above, please remove with spark
plug cleaner or steel brush, and replace if necessary.
Check the spark plug visually.
Replace the cracked or abrasive insulator if necessary.
Replace the spark plug after 8000 kilometers of each driving.
Check the spark plug gap.
Gap: 0.6-0.7mm
Model: CR9E(NGK) 火花塞间隙：spark plug gap
*Note
Re-install the spark plug to the cylinder head, and screw tight with a specified torque.
Torque value: 20-25N.m
Manually install the spark plug first, and then tighten with the spark plug sleeve.
Do not make the spark plug too tight or the threads staggered, so as not to damage the threads of the cylinder
head.
When remove the spark plug, avoid impurities from entering into the engine through it.
- 31 -
Battery
Battery Disassembly
Disassemble the front seat.
Remove the mounting plate of the battery.
Remove the negative wire and then the positive wire.

Remove the battery from the battery box.
Take out the battery.
Warning!
When the positive wire is disassembled, do not make the
tool contact with the frame. Otherwise, it may cause
short-circuit spark, which may ignite gasoline and damage
the battery. It is dangerous.
Install it in reverse order.

Warning!
To prevent short circuit, connect the positive wire first and then the negative wire.
Do not remove the battery during commissioning. Otherwise, it may cause damage to inner parts of the
vehicle.
Check the Charging Condition (closed circuit voltage)

Open the front seat.
Remove the battery from the battery box.
Remove the negative wire and then the positive wire.
Take out the battery.
Test the voltage between battery terminals.

Fully charged: 13.1V
Insufficient charging: 12.3V（1 hour off work）
*Note
Use a voltmeter to check the charging condition.
Charging
Connection: Connect the positive pole of the charger to the positive pole of the battery.
Connect the negative pole of the charger to the negative pole of the battery.
- 32 -
Warning!
• The battery should be far away from fire source.
• Turn off the charger before or after charging to avoid
explosive danger caused by spark which may exist in any
connection.
• Comply with the current and time requirements for charging
as stated on the battery.
* Note
• Except emergencies, you should not use emergency charging.
• Measure voltage in 30 minutes after the battery is charged.
伏特表：voltmeter
Charging current: standard: 0.3A
quick: 3.0A
Charging time: standard: 10-15 hours
quick: 30 minutes
charging accomplished：open-circuit voltage: above 12.8V
Fuse Replacement
The fuse is under the driver’s seat, and near the battery.
The main fuse is set on the starter relay, and the fuse box is
near the fuse. As shown in the figure ① refers to the fuse,
model: 40A, ② refers to the spare fuse of the main fuse, model:
40A, ③ refers to the fuse box, the configuration of the fuse is
shown in the figure:
Frequent fuse blowout indicates that there is short circuit or
circuit overload.
Note:
Before check or replace the fuse, set the ignition switch to “off
”, in case of short circuit or damage to other electrical
components.
Use the specified fuse only, or it will cause serious affect to the
electric system, and it can even burn the lamps of the
motorcycle or cause a fire or loss of engine traction, which is
very dangerous.
灯光: light; 燃油泵：fuel pump; 风扇：fan;

电源锁：power lock; 备用保险丝：spare fuse
- 33 -
Cylinder Pressure
Warm up the engine.

Insert the pressure gauge.
Turn the choke lever to the fully open position.
Start up the engine repeatedly,
The pressure of the cylinder: 1～1.2mpa
*Note
Start the engine until the reading does not rise.
Reasons for low pressure:
 Incorrect valve adjustment
 Leakage of the valve
 Abrasive piston ring or cylinder
Reasons for high pressure:
 Carbon deposition in the combustion chamber or piston
Turn off the engine, and remove the spark plug/spark plug cap
Looseness of the Drive Chain
The life of the drive chain depends on appropriate

lubrication and adjustment. Improper maintenance could
lead to earlier abrasion of the dive chain and the sprocket.
It must be maintained frequently if harshly used.
Looseness: 10-20mm
Adjustment to the drive chain:

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

mentioned：
- 34 -
(1)Put up the motorcycle with the support frame.
(2)Loosen the rear axle nut①.
(3)Loosen the locking nut②.
(4)Turn right or left the adjustment bolt③ to adjust the looseness of the chain, and keep the centers of the
rear and back sprockets into a straight line. There are benchmarks on the swinging arm and each chain
adjuster to facilitate your adjustment, and they can be aligned with each other and the reference from
one side to the other. Align and adjust the looseness of the chain to 10—20mm, and then fix again the
rear axle nut for the final check.
Note:
The two sprockets of the newly replaced
chain should be checked to make sure whether
they are abrasive or not, replace if necessary.
Inspect periodically the following condition of the chain:

(1)Loose pin
(2)Damaged idler wheel
(3)Dry and rusty chain
(4)Twisted or blocked chain link
(5)Excessive damage
(6)Adjust loose chain
If the chain has defects as mentioned above, then there is a high possibility that the sprocket will damage the
chain. So the following items should be check to the sprocket:
(1)Excessively abraded gear tooth
(2)Broken or damaged gear tooth
(3)Loose fixing nut of the sprocket
Lubrication of the drive chain

Priority should be given to lubricate by the lubrication grease for the drive chain, and you may buy it or use
engine oil or other lubrication oil instead. Dip every chain joint to make the lubrication grease penetrate to the
space between the chain plates, pins, bushings and rollers.
*Note
Do not assemble new drive chain to abraded sprocket or vice versa.
The sprocket and the chain should all be in good conditions, or it will cause quick abrasion of the newly
replaced chain or sprocket.
- 35 -
Free Stroke of the Front Brake
Free stroke of front brake

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

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

- 36 -
If specified value has not been met, it should be adjusted.
Adjust the free stroke of the brake pedal.
First open the nut 1.
Screw in or out nut 2 to adjust the free stroke of the brake pedal.
Screw in 2 to reduce the free stroke;
Screw out 2 to increase the free stroke.
Tighten the fixture 1 until the specified value is met.
After being adjusted, dragging should not occur to the brake.
Headlamp
Disassemble the fixing bolt① of the headlamp support.
Disassemble the fixing bolt② of the headlamp support.
- 37 -
Unplug the lamp holder connector③ of the headlamp,
remove the lamp holder, disentwine the snap ring, and take
out the bulb.
*Note
Keep combustible materials and your hands a distance away
from the bulb when it is light. Because the bulb is very hot at
that moment, you should let it cool down before touching it.
Install new headlamp bulb, lamp holder, and screw in the
bulb to the socket.
During the installation, avoid direct touch with the glass of
the bulb, and do not make it oil-stained. Or it will affect the
transparency, life and luminous flux of the bulb.
Once stained with oil, wipe thoroughly with a damp cloth of
alcohol or rubber solution of strong volatility.
Clutch
Check the free stroke of steel rope of the clutch.

Adjust the free stroke of the steel rope of the clutch.

First open the clamp nut（1）.
Then screw in or back to the adjusting device（2）.
Until the specified value of the free stroke is met.
Finally, tighten the clamp nut.
If adjusting the handle of the inhaul cable of the clutch to its

ultimate position can not meet the requirement of the free
stroke, then adjust the locking nut○A of the engine and the
adjusting nut○B with the inhaul cable.
- 38 -
Front/Rear Suspension System
Front Absorber
Pull the front brake tight; compress the front absorber upwards or downwards for check.
Check whether there is oil leakage in the front absorber and whether any component is damaged or loosened
上下压缩
（上下压缩：compress upwards or downwards）
Rear Absorber
Compress the rear absorber upwards or downwards for check.
Check whether each part of the rear absorber is damaged or loosened.
Suspend the rear wheel and check shimmy.
Check whether the suspension bushing of the engine is loose or not.
上下压缩
Bolt/ Nut/Fastener
Check whether each bolt, nut and fastener is loose.

If yes, tighten it to required torque.
- 39 -
Rim/Tyre
Check whether tires or rims have any crack, nail or any

other damage.
Check tyre pressure.
*Note
Check tyre pressure when it is cold.
Tyre
Specification
pressure
Front tyre 120/70 ZR 17 250±10kpa
RK6
Rear tyre 180/55 ZR 17 290±10kpa
When the non-skid depth on the central thread of the tyre

reaches to the figure in the table, the tyre should be
replaced.
Minimum non-skid depth
Front tyre 1.6mm
Rear tyre 2.0mm
Warning:
Do not attempt to repair the damaged tyre.
The balance and reliability of the tyre is likely to
worsen.
Improper tyre inflation will lead to abnormal
abrasion of the tyre and threat the safety. And
insufficient inflation will cause tyre slip, or
disengage the tyre, or lead to the deflation of tyre
which is out of control. It is dangerous to drive
with excessively abraded tires, and it is adverse to
the adhesion or driving.
轮胎气压表：barometer of the tyre

Check whether the locking nut of the front wheel spindle is loose.
Check whether the fixing nut of the rear wheel is loose.
Tighten it to the required torque value if it is loose.
Torque value: fixing the front wheel spindle 55-62 N·m

fixing nut of the rear wheel spindle 85-108 N·m
- 40 -
Fixing Steering Stem Bearing and Handlebar
Move the handlebar to confirm there is no wire interference.

Rotate the front wheel and move the handlebar freely for check.
If the handlebar moves difficultly, release it and then check the bearing of the fixing steering stem.
Throttle Body
The idle speed of the motorcycle will be reduced to some

extent due to the pollution of the throttle body. It is better to
clean it after every 5000 kilometer’s drive.
When cleaning, disconnect the negative pole of the battery,
connectors of the sensor installed on the throttle; and
remove the throttle cable, hose connected to the air filter
and the intake manifold, and the throttle body.
Open the lid on the bottom of the throttle body, spray
cleanser to its in-wall and brush the dust and carbon
deposition, etc.
After cleaning, operate in reverse order, install the throttle
and make sure that all parts are in place, and try to start the
engine successfully.
Note:
Do not let impurities block the parichnos nearby.
- 41 -
Components Lubrication
Appropriate lubrication is of great importance to the normal operation of each part of the motorcycle, to an
extended life and to the safety drive. Lubricate the motorcycle after a long time running or exposure in the rain
or after cleaning. As for detailed points for lubrication and maintenance, see the following figure:
□
Ｙmotorcycle lubrication □ grease
Ｚ
○
1 axis of the rear brake pedal Ｚ
□ ○
2 single bracket joint and spring hookＺ
□ ○
3 pin of the
gearshift riding rod Ｚ□
○
4 throttle cableＹ□ ○
5 pin of the front brake handle Ｚ□ ○
6 clutch handle（pin）Ｙ □
- 42 -
Inspection and Maintenance of the Electrical System
充电系统
充电系统： charging system
- 43 -
1. Battery/Charging System
Preparing Documents-----------------------1.1
Failure Diagnosis----------------------------1.2
Battery-----------------------------------------1.3
Charging System-----------------------------1.4
Voltage/Current Regulator -------------------1.5
Charging Coil of Magnetor ------------------1.6
Disassembly of Magnetor -------------------1.7
1.1 Preparing Documents
Work Instructions
*Note
1. Battery can be charged or discharged repeatedly. If it is placed after discharge, its service life will be
shortened and performance is undermined. Normally, the battery performance will be degraded after two or
three years. As for battery of degraded performance (reduced capacity), whose voltage will recover temporarily
after charging but decrease sharply when loading.
2. Battery overcharge: normally, overcharge can be judged upon the battery. In the case of short circuit inside
the battery, its terminal is unable to detect voltage or the detected voltage is very low. Regulator failure: over
voltage inside the battery will shorten its service life.
3. The battery will be self-discharged if being stored for a long time, which reduces its capacity. It shall be
charged about every three months.
4. Check the charging system following the sequence listed on the failure diagnosis table.
5. Do not remove the connector when there is current through electrical parts, otherwise it will cause over
voltage and damage to electrical parts inside the voltage regulator. Please operate it after the main switch turns
off.
6. It is unnecessary to check the maintenance-free battery and add electrolyte and distilled water.
7. Check all electric loads.
8. Emergency charging can only be used under emergency situation.
9. Remove the battery from the motorcycle for emergency charging.
10. Do not use electrolyte-added batteries when interchanging batteries.
11. Use a voltmeter to check charging condition of the battery.
- 44 -
Item Specifications
Capacity/Type 12V-9AH/ dry-charged
Fully charged 13.1V
Battery Voltage
Necessary
（20℃） 12.3V(not working for 1h)
charging
Charging current Standard: 0.8A, quick:8A
Charging time Standard: 10-15 hours, quick: 30 mins
Impedance of the coil
Magnetor Between white-white 1.5-3.5Ω
（20℃）
Type Three-phase full wave
Voltage
Charging voltage of the
regulator 14.5±0.5V/5.000rpm
battery
Tightening Torque Force Tools

Rectifier bolt 5.0 N·m Universal fixing spanner
High-voltage coil fixing bolt 9.0 N·m Flywheel remover
Flywheel fixing nut 5.0 N·m Test instrument
Body guard bolt 9.0 N·m Multimeter
1.2 Failure Diagnosis
Power Supply Dead Interrupted Current

Battery over-discharge Poor contact of the charging wire
Unconnected battery wiring Poor contact of the charging system
Fuse blow Poor contact or short circuit of the lighting system
Poor switch
Low Voltage Poor Charging System

Poor battery charging Poor contact, short circuit or open circuit of wire terminals
Poor contact Poor voltage/current regulator
Poor charging system Poor magnetor
Poor voltage/current regulator
- 45 -
1.3 Battery
1.3.1 Battery Disassembly

As for details, please see page 31.
电瓶位置：battery position
Warning!
When the positive wire is disassembled, do not

make the tool contact with the frame. Otherwise, it
may cause short-circuit spark, which may ignite
gasoline and damage the battery. It is dangerous.
*Note
To prevent short circuit, connect the positive wire
first and then the negative wire.
Check the charging condition (closed circuit voltage).

Remove the seat.
Remove cables of the battery.
Test the voltage between battery terminals.
Fully charged: 13.1V
Insufficient charging: 12.3V (not working for 1
hour)
* Note
Use a voltmeter to check the charging condition.
1.3.2 Charging
Connection method: connect the positive pole of the charger with the positive pole of the battery;
connect the negative pole of the charger with the negative pole of the battery.
Warning!
• The battery should be far away from fire source.
• Turn off the charger before or after charging to
avoid explosive danger caused by spark which
may exist in any connection.
• Comply with the current and time requirements
for charging as stated on the battery.
- 46 -
*Note
• Except emergencies, you should not use
emergency charging.
• Measure voltage in 30 minutes after the battery
is charged.
Charging current: standard: 0.8A

quick: 8.0A
Charging time: standard: 10-15 hours
quick: 30 mins
Charging completed: open circuit voltage: above 12.8V
1.4 Charging System
1.4.1 Short-circuit Test

Remove the earth lead from the battery. Install a voltmeter between the negative terminal and the earth lead.
Turn off the switch. Check the short-circuit.
*Note
Connect the positive terminal of the multimeter
with the negative terminal of the battery.
Check whether there is short-circuit in the main switch or in the main wire in the case of any abnormality.
1.4.2 Charging Check

Use a multimeter to check the charging status of the battery when it is being fully charged.
Install the fully charged battery after the engine warms up.
Connect a voltmeter between terminals.
Remove the main fuse and connect an ammeter between terminals.
Start the engine and increase its speed gradually to measure the limiting voltage and current.
Limiting voltage/speed: 14-15V （5.000rpm）
Check the voltage regulator if the limiting voltage is not within its required range.
Check the limiting voltage of the lighting system.
Remove the seat.
*Note
Set the multimeter to the AC voltage position.
Limiting voltage: 13.1（+/-）0.5V/5.000rpm

Check the voltage/current regulator if the limiting voltage is not within its required range.
- 47 -
1.5 Voltage/Current Regulator
1.5.1 Main Wiring Check

Remove the shield of the body.
Remove 4p plug of the voltage/current regulator.
Check conductivity between main wiring terminals.
Item (wire color) Judgment
Between Battery(red) and With battery
GND of the body voltage
Between GND wire (black)
With lead
and GND of the body
Resistance in the
Between charging coil (white) coil of the
and the GND of the body magnetor.
1.5.2 Voltage-current Regulator Check

1. Choose diode file with multimeter.
2. The black probe connects to the red wire terminal of the voltage regulator, and the red probe connects
respectively with the white wire terminal (white 1, white 2, white 3). The pointer gauge shows a certain value,
otherwise it indicates the damage of the voltage regulator and replacement is needed.
3. The red probe connects to the black wire terminal of the voltage regulator, and the black probe connects
respectively with the white wire terminal (white 1, white 2, white 3). The pointer gauge shows a certain value,
otherwise it indicates the damage of the voltage regulator and replacement is needed.
*Note
• Do not touch any metal part of the test rod of the
multimeter with your finger for check.
• Check with multimeter. Different multimeters
show different impedance and different results.
Replace the voltage-current regulator when the impedance between terminals is abnormal.
1.6 Magnetor Charging Coil

Ω
*Note 白
白
白
Check the magnetor charging coil on the engine.
Check
Remove the 6p connector of the magnetor.
Measure the impedance between the three white terminals of the magnetor with the multimeter.
Standard: 1.5-3.5Ω（20℃）
Replace the magnetor coil when the measured value exceeds the standard value.
- 48 -
1.7 Magnetor Disassembly
Left cover and
the magnetic coil
1.7.1 Disassembly
Loosen the fixing nuts on the left cover, and
remove the left cover and the magnetic coil.
Bolt
Fix the flywheel with the universal fixing

spanner.
Bolt
Remove fixing bolts of the flywheel.
Remove the flywheel with the flywheel remover.
Remove the solid key.
Remove the conductor joint.
Remove the stator.
Loosen the four fixing bolts of the magnetic coil,

and remove the magnetic coil.
Bolt
- 49 -
Loosen the locking nuts of the flywheel with
electric, pneumatic tools or torque spanner. Locking nut of
Remove the flywheel assembly. the flywheel
1.7.2 Installation
Install the stator on the body of the engine.

Connect the magnetor joint.
Clean up the crankshaft and the taper part of the flywheel.

Install the solid key into the groove above the upper crankshaft key and confirm it.
Aim the groove in the flywheel at the solid key on the shaft.
* Note
Ensure there is no any bolt in the inner magnetic
side of the flywheel.
Fix the flywheel with the universal spanner and tighten fixing nuts.
Torque force: 9.0 N·m
- 50 -
电源
黑/红2
黑
黑/白2
ECU2
黑/红2
黑
橙/绿2
黑/红1
黑
黑/白1
白蓝
/ /
ECU1 黑/红1
绿白
黑
橙/绿1
触发头
电源
电源：power, 触发头：trigger, 点火系统：ignition system

黑：black, 白：white, 红：red, 橙：orange, 绿：green, 蓝：blue
- 51 -
2. Ignition System
Preparing Documents -----------------2.1
Failure Diagnosis ---------------------2.2
Ignition System Check ---------------2.3
ECU Group----------------------------2.4
Ignition Coil ---------------------------2.5
Trigger ---------------------------------2.6
Work Instructions
1. Check the ignition system following the sequence listed in the table of failure diagnosis.
2. This ignition system is an electronically and automatically angling device. It is solidified in the ECU group
and you don’t have to adjust the ignition time.
3. Check the ignition system following the sequence listed in the table of failure diagnosis.
4. Do not make ECU of the ignition system fall down or hang down or hammer it with strong force (primary
causes for failure). Pay special attention during disassembly.
5. Failure of the ignition system is mostly caused by poor contact of the socket. Check whether each connector
is in good condition.
6. Check whether the heat value used for the spark plug is proper. If not, the engine may work abnormally or
the spark plug may be burnt.
7. Check in this chapter is based on the maximum voltage. It also refers to check on the impedance of the
ignition coil.
8. Check the main switch according to the conduction table.
9. Remove the magnetor and the stator according to instructions.
Item Standard value
Spark plug
Standard CR9E(NGK)
recommended
Spark plug gap 0.6-0.7mm
Ignition coil
Primary coil 650±50mΩ
impedance（20℃）
Impedance of trigger（20℃） 100-300Ω
Measure the maximum primary voltage of the ignition coil 14V
Trigger voltage Above 1.7V
Tools
Attachments to the Maximum Voltage Table
Multimeter
- 52 -
No spark-over of the spark plug

Abnormality Cause (confirm it sequentially as follows)
①The inner resistance is too small and it should be
tested by required tester.
②Low speed of the crankshaft.
③Interfered tester (It is normal that voltage is
Ignition
always beyond the required value upon several
coil Too low high-voltage
measurements.)
④Poor wiring contact of the ignition system.
⑤Poor ignition coil.
⑥Poor charging coil (measured at the maximum
voltage).
①Incorrect connection of the tester.
②Poor main switch.
③Poor contact of ECU terminal.
④Short circuit or poor contact of the GND of ECU.
⑤Poor contact of charging coil (measured at the
No or interrupted high voltage
maximum voltage).
Side
⑥Poor trigger (measured at the maximum voltage).
voltage
⑦Poor terminal of high-voltage wires.
⑧Poor ECU group (when item ①-⑦ is checked to
be abnormal or there is no spark for spark plug.)
①Poor spark plug or secondary leakage of the
Normal high voltage, but no spark ignition coil.
②Poor ignition coil.
No high voltage
Charging always beyond the required value upon several
coil measurements.)
④Poor charging coil (Item ①-③ is checked to be
normal.)
①Poor ignition coil.
②Poor charging coil.
Too low high-voltage
always beyond the required value upon several
Trigger
measurements.)
④Poor trigger (Item ①-③ is checked to be
normal.)
①Poor ignition coil.
②Poor trigger.
- 53 -
2.3 Ignition System Check
*Note
• When there is no spark, check whether there is
loose wiring 万用表
or poor contact, and make sure all voltage values
are normal.
• There are kinds of multimeters with different
impedances and different test values.
Connect a high-pressure shunt or an ammeter with

an input impedance above 10MΩ10CV to the multimeter. （万用表：multimeter）高压分流器
2.3.1 Primary Voltage of the Ignition Coil (高压分流器：high-pressure shunt)
If you replace the original spark plug with a better one, make ground connection with the engine.
*Note
Make sure all wiring is correct before test.
Cylinder compression pressure normally refers to
the test value when the spark plug is installed on
the cylinder head.
Connect the lead of the ignition coil and also the shunt
between the primary coil terminal (black/red) and the GND.
Press the startup motor or step the actuating lever to
measure the maximum primary voltage of the ignition coil.
Minimum voltage: above 95V
*Note
Never touch any metal part of the test rod with
your finger to avoid electric shock.
- 54 -
2.3.2 Sensor of the Crankshaft
*Note
Install the spark plug on the cylinder head and
carry out measurement when the compression
pressure is normal.
Remove 18 connectors of ECU group. Connect the

peak-voltage shunt between the charging coils
(blue/white terminal) with 18 connector and
the 18 connector (white/green terminal).
Press the startup motor or step the actuating lever to measure
the maximum voltage of the charging coil.
Connection: positive pole to blue/white; negative pole to white/green.

Minimum voltage: above 95V
*Note
Never touch any metal part of the test rod with
your finger to avoid electric shock.
When the maximum voltage measured at the terminal of ECU Group is abnormal; dismantle the shield of the
body and the magnetor terminal.
• If the voltage of ECU is measured to be abnormal while the voltage at the magnetor terminal is normal, it is
caused by poor contact or disconnected wiring.
• If the voltage at both ECU and magnetor terminal appears to be abnormal, it is caused by poor charging coil.
Please refer to charging coil check.
2.4 ECU Group
2.4.1 System Check

Check the system.
Remove the ECU Group, and check components
of the ignition system at the terminal.
- 55 -
2.5 Ignition Coil
2.5.1 Disassembly
Remove the body.
Remove the spark plug cap.
Remove the primary lead of the ignition coil.
Remove the fixing bolts and then the ignition coil.
Install the ignition coil in reverse order.
*Note
Install the primary coil with black/red
terminal.
2.5.2 Check the Primary Coil

Measure the impedance between terminals of the primary coil.
Standard: (4±0.2)Ω (20℃)
It shows good if the impedance is within the range of standard values.
Replace the primary coil if the impedance shows ∞ which indicates that the coil breaks.
2.6 Sensor of the Crankshaft
*Note
Check the trigger on the engine.
Check
Remove the shield of the body.
Remove the trigger terminal.
Measure the impedance between the blue/white terminal of
the side wire of the engine and the body GND.
Standard: 100-300Ω（20℃）
Replace the magnetor if the measured value exceeds the
standard value.
- 56 -
BATTERY
G/Y
G/Y M
启动示意图
启动示意图：Startup Schematic Diagram
- 57 -
3. Startup System
Preparing Documents ----------------3.1
Failure Diagnosis ---------------------3.2
Startup Motor -------------------------3.3
Starter Relay --------------------------3.4
Starter Clutch--------------------------3.5
Work Instructions
Disassemble the startup motor on the engine.
For the disassembly of the startup clutch, please comply with related regulations
Item Standard Limit for use
Length of the brush of the
12.5mm 8.5mm
startup motor
Bushing of the startup idler
8.3mm
shaft
Outer diameter of the startup
7.94mm
idler shaft
Tightening torque force

Bolts for the clutch cover of the startup motor 12 N·m
Retaining nut for the clutch of the startup motor 95 N·m
Tools
Spanner for retaining nuts
Universal fixing spanner
- 58 -
Startup failure Weak in rotation No rotation of RE rotary engine
of the startup motor of the startup motor

• Fuse blow • Low battery • Poor startup clutch
• Low battery • Poor wiring contact • Reversal rotation of the startup motor
• Poor main switch • Gear seized • Low battery
• Poor startup clutch
• Poor brake switch
• Poor starter relay
• Poor wiring contact
• Poor startup motor
3.3 Startup Motor
3.3.1 Disassembly
Loosen the two fixing bolts of the startup motor,
and remove the motor.
Bolt
Startup motor
* Note
Before the startup motor is disassembled, turn off the
main switch, remove the GND wire of the battery, and
then power on to check whether the startup motor
works for ensuring safety.
- 59 -
Remove the wire clip of the startup motor.
Remove the fixing bolts of the startup motor, separate
the front cover and the back cover, and dismantle the
startup motor.
Roll the waterproof rubber case and dismantle the
connector of the startup motor.
换向器：commutator
3.3.2 Breakdown
Remove screws in the shell, front cover, motor housing and other parts.
3.3.3 Check
碳刷
Check other components.
Replace any part with abraded, damaged or burnt surface.
Clean the commutator surface if there is metal power attached to it.
Check conduction between the surfaces of other components.
Ensure non-conduction between armature shafts of the commutator.
Check the conduction of the shell of the startup motor.
Ensure non-conduction between the conduction terminal and the startup motor shell.
Check conduction between the conduction terminal and the brush.
Replace any abnormal part.
Check conduction of the brush bracket. Replace it when there is conduction.
Measure the length of the brush.
Limit for use: replace it if lower than 8.5mm
Check smooth rotation of the needle bearing inside the front cover and whether it is loose when press-in.
Replace it if there is any abnormality.
Check whether the oil seal is abraded or damaged.
碳刷：carbon brush
- 60 -
3.3.4 Assembly
Lubricate the oil seal inside the front cover with grease.
Install the brush on the bracket.
Lubricate moving parts at two ends of the brush shaft
with grease.
Press each brush into the bracket,
* Note
• Pay special attention that the contact surface between
the brush and the armature shall not be damaged.
• Pay attention that the armature shaft shall not damage
lips of the oil seal.
and install the back cover of the electric machine.

Aim the screw hole of the motor shell at the screw hole of the front cover for installation.
Lock screws in the shell.
* Note
When the shell and the front cover are assembled, it is
easy to pull the front cover with magnet to attract the
armature. Press it gently for assembly.
3.3.5 Installation
Install the lead of the startup motor and the dustproof boot.
And then install the startup motor.
Install the wire clip for rear brake.
3.4 Starter Relay
3.4.1 Check
When the main switch is “on”, check there is “click” sound at
the time of pressing the startup motor.
With click sound, it is normal.
Without click sound: • check voltage of the starter relay;
• check the GND loop of the starter relay;
• check the movement of the starter relay.
启动继电器：starter relay
- 61 -
3.4.2 Check Voltage of the Starter Relay
Set up the main stand, and measure voltage between the
negative pole of the green/yellow wire of the starter relay
terminal and the body ground connection. Ω
When the main switch is “on”, hold the brake lever. The
battery voltage shall comply with regulations.
When there is no voltage at the starter relay terminal,
check the conduction of the brake switch and leads.
启动继电器：starter relay
3.4.3 Check GND Loop of the Starter Relay

Remove the starter relay connector.
Check conduction between the black wire of the lead terminal and the body ground connection.
When the startup button is pressed, it shall show good conduction between the black wire of the terminal and
the body ground connection.
Check conduction of the startup button and leads when it is not conducted.
3.4.4 Check
Connect the starter relay to the battery, and the
terminal of the startup motor to the multimeter.
Connect the fully charged battery between the black
wire and the green/yellow wire of the relay. The relay
shall sound “click” and the multimeter shall indicate
resistance of “zero”.
- 62 -
4. Bulbs/ Switches / Meters
Preparing Documents -------------------------------------------------------------4.1
Failure Diagnosis ------------------------------------------------------------------4.2
Replacement of Headlamp Bulbs------------------------------------------------4.3
Replacement of Front Position Lamp Bulbs------------------------------------4.4
Replacement of Tail Lamp--------------------------------------------------------4.5
Replacement of Rear Registration Plate Lamp Bulbs-------------------------4.6
Replacement of Front Steering Lamp Bulbs -----------------------------------4.7
Replacement of Rear Steering Lamp Bulbs ------------------------------------4.8
Meters--------------------------------------------------------------------------------4.9
Main Switch -----------------------------------------------------------------------4.10
Horn ---------------------------------------------------------------------------------4.11
Handlebar Switch -----------------------------------------------------------------4.12
Work Instructions
 Remove the switch from the vehicle to measure its condition.
 All plastic connectors have clamping jaws,
 lift the clamping jaws and clamps before disassembly,
 and make sure that the clamping holes aim at the clamping jaws when installing.
 When looking up for electric faults,
 check the continuity of the circuit passing through the electronic devices.
 The state of the battery must be confirmed before carrying out any inspection,
 including the voltage, to confirm that whether it is normal or not.
- 63 -
The ignition switch “ON” is not light, which due to

• Poor bulbs.
• Poor switch.
• Bad contact or broken wires
• Weak battery power or no voltage.
4.3 Replacement of Headlamp Bulbs
Remove the two fixing bolts① of the headlamp at

the bottom left and bottom right of the meter.
Lower the headlamp forward, you can see the back

of the headlamp, and remove its dustproof cover②.
- 64 -
The figure below shows the bulb of the dipped
headlight③, and the bulb of the headlight on full
beam④, remove the power cord socket, bulb snap,
fixing bolts and the bulb snap buckle of the dipped
headlight and the headlight on full beam that need to
be replaced, and finally remove the damaged bulb.
Aim the position of the light snap, and replace on a

new one of the same specification.
*Note
Keep combustible materials and your hands a distance
away from the bulb when it is light. Because the bulb
is very hot at that moment, you should let it cool
down before touching it.
Install the bulb in reverse order.
During the installation, avoid direct touch with the
glass of the bulb, and do not make it oil-stained. Or it
will affect the transparency, life and luminous flux of
the bulb.
Once stained with oil, wipe thoroughly with a damp cloth of alcohol or rubber solution of strong volatility.
Install headlamp devices.
4.4 Replacement of Front Position Lamp Bulbs
The front position lamp and the headlamp are in one

lamp body, as shown in the figure, there is a front
position lamp bulb① on the right and left sides.
(1) Operate according to the prompts of the above
chapter—Replacement of the Headlamp Bulbs.
(2) Remove the damaged bulb, and replace on a new
one of the same specification.
(3) Install the bulb in reverse order.
- 65 -
4.5 Replacement of Tail Lamp
The illuminant of the tail lamp is LED, replace the whole

lamp if necessary.
(1) Remove the passenger’s seat and the driver’s.
(2) Remove the tow fixing nuts① of the tail-hood shield,
and then move it horizontally backward to take it
down.
(3) Remove the two fixing nuts② of the rear lamp

combination.
(4) Remove the three fixing bolts③ of the rear lamp

combination.
(5) Remove the cable of the rear lamp combination, take
off the damaged lamp, and replace on a new one of
the same specification.
(6) Install the lamp in reverse order.
- 66 -
4.6 Replacement of Rear Registration Plate Lamp Bulbs
(1) Remove the fixing nuts① of the rear registration

plate lamp to take down the tail-hood② of it.
(2) Take off the damaged bulb, and replace on a new one
of the same specification.
- 67 -
4.7 Replacement of Front Steering Lamp Bulbs
The illuminant of the front steering lamp is LED,

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

the whole lamp if necessary.
(1) Remove the fixing nuts① of the right or left
steering lamp from the back of bracket of the rear
registration plate.
(2) Remove the cable of the rear steering lamp, take off
the damaged lamp, and replace on a new one of the same specification.
4.9 Meters
Remove the rearview mirror;

Remove the handle cover, and unplug the connectors.
Remove the nuts the meter.
Install the meter in reverse order.
- 68 -
4.10 Main Switch
4.10.1 Check
Remove the front shield.
Remove the main switch lead terminal.
Check the conduction of the terminal.
POWER LOCK
ON
OFF
LOCK
R R/W
4.10.2 Replacement of Main Switch

Remove the front shield.
Remove the fixing bolts, and take off the fixing socket of the main switch.
Remove the fixing bolts, and replace the main switch.
4.11 Horn
Check
Remove horn wires.
It shows good when the horn wire is connected to the battery.
- 69 -
4.12 Handlebar Switch
Switch classification:
1. Light changing switch （变光开关）
2. Start switch
3. Steering switch （转向开关）
4. Horn switch （喇叭开关）
5. Turn off switch （熄火开关）
6. Warning switch
接线原理图
变光开关转向开关
兰黄/红浅兰绿/黑橙绿/白
喇叭按钮
黑棕
大灯开关启动按钮熄火开关

红/白棕/白黄黄/红红/白绿黑白
接线原理图：Schematic diagram of wiring

大灯开关：headlamp switch
启动按钮：start button
兰：blue
黄/红：yellow/red
浅兰：light blue
黑：black
棕：grey
红/白：red/white
棕/白：grey/white
绿：green
白：white
- 70 -
Inspection and Maintenance of the Motorcycle Body
Torque Force Table of the Body

Name of fastening parts and fasteners Tightening torque（N·m）
Fixing bolt of the front absorber M6 5-10
Locking screw of the front wheel spindle M6 5-10
Front fixing bolt of the fuel tank M6 5-10
Fixing bolt of the front fuel pump assembly M6 5-10
Fixing bolt of the rear fuel pump assembly M6 5-10
Fixing bolt of the fixing seat on the handlebar M8 22-34
Fixing bolt of the upper connecting bracket M8 22-34
Rear fixing bolt of the fuel tank M6 5-10
Mounting bolt of the front brake cylinder assembly M10 37-55
Mounting bolt of the rear brake cylinder assembly M8 22-34
Fixing bolt of the sprocket M10 37-55
Fixing bolt of the rear frame M10 37-55
Fixing bolt of the pillar 50-70
Top bolt of the rear absorber M10 37-55
Bottom bolt of the rear absorber M10 37-55
Fixing bolt of the engine M10 37-55
Fixing bolt of the rear swinging arm axle M14 70-105
Front wheel spindle M16 100-140
Fixing nut of the rear wheel spindle M24 130-150
- 71 -
Front Disc Brake
Dia. of the front left/right brake
A
disc:320mm
Thickness of the front left/right brake
B disc:4.0mm
Limit for use: 3.6mm
Thickness of the brake shoes:7.8mm
C
Limit for use:3.8mm
Torque for mounting bolt 4 in the
D
figure:5-10N·m
E
figure:30-35N·m
F figure:
5-7N·m
G
figure:30-35N·m
H
figure:37-55N·m
I
figure:22-34N·m
1. handlebar assembly of the front brake disc 2.handlebar screw 3.fixing cover 4.bolt M6×23 5.hexagon
flange screw 6.brake switch 7.screw M4×12 8.nut M6 9.brake hose assembly 10.11. bleed nipple
12.mounting bolt of the oil tube 13.gasket 14.bolt M10×1.25×55 15.front left brake cylinder assembly
16.brake shoes 17.bolt M8×16 18.D.320front brake disc 19.front right brake cylinder assembly
- 72 -
Rear Disc Brake
A Dia of the rear disc brake: 240mm
Thickness of the rear disc brake: 5.0mm
B
Thickness of the brake shoes: 7.0mm
C
D
figure:30-35N·m: 22-34 N·m
E
figure:30-35N·m: 5-10 N·m
F
figure:30-35N·m: 30-35 N·m
G
figure:30-35N·m: 30-35 N·m
1.pin 2.joint M6 3.cotter 4.nut M6 5.pushrod 6.rear fuel pump assembly 7.gasket 8.rear brake
indicator 9.rear brake hose assembly 10.mounting bolt of the oil tube 11.rear brake cylinder assembly
12.brake shoes 13.rear disc brake 14.screw M6×20 15.bolt M8×1.25×20
- 73 -
5. Brake
Maintenance Instruction ------------------------5.1
Failure Diagnosis --------------------------------5.2
Front Disc Brake ---------------------------------5.3
Rear Disc Drake ---------------------------------5.4
5.1 Maintenance Instruction
Work Instructions
*Note
 A stained brake disc or protective gasket will reduce brake force, so discard
stained gasket and clean the brake disc with quality brake degreaser.
 Check the brake system through the brake lever and pedals.
 Spilled brake liquid is harmful to the focusing and paint of the equipment,
and the rubber parts too. So be careful whenever you remove the cap of the
oil cup, and the first thing you should do is to make sure that the liquid in the
cup is aclinic.
 Never let the earth, water or other dirt into an open cup.
 Use the DOT4 brake liquid taken out from a sealed container when doing
maintenance, and do not mix it with other type of liquid, since they can not
coexist.
* Check the brake before riding.*
5.1.1Specification
Item Standard Limit for use Item Standard Limit for use
Special brake liquid DOT4 - Special brake liquid DOT4 -
Thickness of the left/right
4.0mm 3.6mm Thickness of the brake disc 5.0mm 4.5mm
brake disc
Thickness of the left/right
7.8mm 3.8mm Thickness of the brake shoe 7.0mm 3.7mm
brake shoe
Dia. of the left/right brake disc Φ320mm - Dia. of the brake disc Φ240mm -
The jump of the brake surface The jump of the brake
Front 0.1mm - Rear 0.1mm -
of the left/right brake disc surface of the brake disc
I.D. of the pump oil cylinder Φ16+0.043
0 mm - I.D. of the pump oil cylinder Φ11+0.027
0 mm -
O.D. of the oil-pumping O.D. of the oil-pumping
Φ16-0.032
-0.059 mm - Φ11-0.032
-0.059 mm -
piston piston
I.D. of the caliper cylinder Φ34+0.08
+0.03 mm - I.D. of the caliper cylinder Φ32+0.08
+0.03 mm -
O.D. of the caliper piston 32-0.032
-0.065 mm - O.D. of the caliper piston Φ32-0.032
-0.065 mm -
- 74 -
5.1.2 Torque Force
Fixing the front wheel spindle 100-140N·m
Mounting screw of the front left brake cylinder assembly 37-55N·m
Mounting screw of the front right brake cylinder assembly 37-55N·m
Fixing nut of the rear wheel spindle 130-150N·m
Mounting screw of the rear brake cylinder assembly 22-34N·m
5.2.1 Poor Brake Performance

1. Improper adjustment of the brake
2. Abraded brake shoes assembly or disc brake
3. Improper installation of the brake shoes assembly
4. Stained brake shoes assembly or disc brake
5.2.2 Slow Reaction or Tight Lever

1. Improper adjustment of the brake
2. Abraded brake shoes assembly or disc brake
3. Improper installation of the brake shoes assembly
5.2.3 Abnormal Noise

1． Abraded brake shoes assembly or disc brake
2． Stained brake shoes assembly or disc brake
5.2.4 Soft or Flossy Brake Lever/Pedal

1. Air in the hydraulic system
2. Leakage of the hydraulic system
3. Stained brake pedal/disc
4. Abraded seal of the caliper piston
5. Abraded brake pedal/disc
6. Stained caliper
7. Abnormal slip of the caliper
8. Insufficient brake liquid
9. Blocked brake liquid channel
10. Bended/fragmentary caliper piston
11. Bended/fragmentary piston of the main cylinder
12. Stained piston of the main cylinder
13. Bending braking lever/pedal
5.2.5 Brake Stuck or Pulled to One Side

1． Stained brake pedal/disc
2． Wheel deviation
- 75 -
3． Blocked or limited joint of the brake hose
4． Bending/fragmentary brake disc
5． Abnormal slip of the caliper
5.2.6 Brake Resistance

1． Strained brake pedal/disc
2． Wheel deviation
3． Abraded brake pedal/disc
4． Bending/fragmentary brake pedal/disc
5.2.7 Stiff Brake Lever/Pedal

1． Blocked/limited brake system
2． Sticked/abraded caliper piston
4． Blocked/limited brake liquid channel
5． Abraded sealing gasket of the caliper piston
6． Sticked/abraded piston of the main cylinder
7． Bending brake lever/pedal
5.3 Front Disc Brake
5.3.1 Disassembly
*Note
 Replace the brake shoes assembly.
 If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place.
Remove following assemblies from the right grip and the front absorber.
Front brake:
Nut of the rearview
1. brake handle mirror
2. fuel pump assembly
3. brake hose assembly
4. left/right brake cylinder assembly Fixing screw of
5. left/right brake disc the fuel pump
*Note
 Do not stain the brake assembly with oil spots during
installation or disassembly.
 Clean it with required cleaning agent to maintain the brake performance.
- 76 -
Fixing screw of the handle
Fixing bolt of the brake hose
Brake hose
Bleed nipple
Right brake cylinder assembly
Fixing bolt of the brake cylinder
Loosen the fixing screws of the brake cylinder assembly.

Remove the brake cylinder assembly from the front absorber.
Bleed nipple
Left brake cylinder assembly
Fixing bolt of the brake

cylinder
- 77 -
Remove the front wheel spindle.
Remove the front wheel.
Remove the disc brake off the front rim.
前轮：front wheel
前轮轴：front wheel spindle
前左液刹：front left disc brake
固定螺钉：fixing screws
5.3.2 Check
Check whether the brake shoes assembly and the brake
disc are abraded. Replace brake shoes if necessary.
Measure the brake shoes and the brake disc. Record
maximum values.
Specification
Diameter of the front brake disc Φ320mm
Thickness of the front brake disc 4.0mm
*Note
Measure them with micrometer.
- 78 -
Measure the thickness of the brake shoes.
If the thickness of the brake disc or the brake shoe is
below the required value for maintenance or it is stained
with grease, please replace it.
Limit for use: brake shoe 3.8mm

brake disc 3.6mm
Note:
Replace brake shoes in pair.
5.3.3 Installation
Install the brake disc and the front wheel.
Install the front brake hose assembly and the brake cylinder assembly.
Do not stain shoes and the brake disc with grease.
* Note
Any grease on brake shoes will reduce the brake performance and even lead to failure.
Tighten bolts and nuts to the required torque force.
Torque force:
Fixing the front wheel spindle 120N·m
The bolt of the brake disc 28N·m
The fixing bolt of the fuel pump assembly 8N·m
Mounting bolt of the front brake cylinder assembly 50N·m
Do not stain the brake shoes with oil spots.

Use brake cleaning agent to clean brake shoes with oil spots.
*Note
Any grease on brake shoes will reduce the brake performance.
*Note
• Do not stain the brake assembly with oil spots during installation or disassembly.
• Clean it with required cleaning agent to maintain the brake performance.
- 79 -
5.4 Rear Disc Brake
5.4.1 Disassembly
*Note
 Replace the brake shoes assembly.
 If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place.
Remove the following assembly off the frame and the rear swinging arm.
Rear disc brake:
(1) Fuel pump assembly
(2) Brake hose assembly
(3) Brake cylinder assembly
(4) Brake discs
Loosen the fixing screws of the right pedal cover plate.

Right pedal cover
plate
Fixing screws
Loosen the fixing screws of the oil pump assembly.

Remove the oil pump cylinder.
Fuel pump
assembly
Fixing screws
- 80 -
Remove the brake cylinder assembly off the rear
swinging arm.
Rear brake hose
Fixing bolt
Brake cylinder
assembly
Fixing screw
Remove the rear wheel spindle.

Then take off the rear wheel.
Remove the bake disc off the rear rim.
后轮：rear wheel
后液刹盘：rear brake disc
固定螺钉：fixing screw
后轮轴：rear wheel spindle
5.4.2 Check
Check whether the brake shoes assembly and the brake
disc are abraded. Replace brake shoes if necessary.
Measure the brake shoes and the brake disc. Record
maximum values.
Specification
Diameter of the rear brake disc Φ240mm
Thickness of the rear brake disc 5.0mm
*Note
• Measure with micrometer.
- 81 -
Measure the thickness of the brake shoes.
If the thickness of the brake disc or the brake shoe is
below the required value for maintenance or it is
stained with grease, please replace it.
Limit for use: brake shoe 3.7mm

brake disc 4.5mm
Note:
Replace brake shoes in pair.
5.4.3 Installation
Install the rear brake disc.
Install the rear wheel.
Install the brake cylinder.
* Note
Any grease on brake shoes will reduce the brake performance and even lead to failure.
Tighten bolts and nuts to the required torque force.
Torque force:
Fixing the rear wheel spindle 120N·m
The bolt of the brake disc 28N·m
The fixing bolt of the fuel pump assembly 8N·m
Mounting bolt of the rear brake cylinder assembly 50N·m
Do not stain the brake shoes with oil spots.

Use brake cleaning agent to clean brake shoes with oil spots.
*Note
• Do not stain the brake assembly with oil spots during installation or disassembly.
• Clean it with required cleaning agent to maintain the brake performance.
- 82 -
Body
*Note:
Do not damage any body part during disassembly.
Do not damage any hook or claw in the body during
disassembly.
Aim panels in the body at each corresponding
groove.
Ensure correct installation of each hook or claw
part during assembly.
Do not damage any part during assembly.
1. right air deflector mounting plate 2. windshield 3. left air deflector mounting plate 4. 5. right front shield 6.
right shield of the tank 7 bottom right shield 8. right shield 9. trim-cover of the right muffler 10. decorative
cover of the right muffler 11. back seat assembly 12. right rear handrail 13. left rear handrail 14. 16. left
assembly of the rear fender 17. right assembly of the rear fender 18. left shield 19. battery box 20. bottom left
shield 21. front seat assembly 22. middle shield of the tank 23. left shield of the tank 24. left front shield 25.
front shield of the tank 26.connecting board of the left/right shield
- 83 -
6. Body
6.1 Disassembly
Disassemble in the following order:
back seat assembly→ front seat assembly → front shield of the tank→ left shield
of the tank→ right shield of the tank→ left front shield→ right front shield →
middle shield of the tank → tank assembly
rear connecting board of the left/right shield → left rear handrail → right rear
handrail → bottom left shield→ left shield→ bottom right shield → right shield →
taillight → rear bottom fender → decorative cover of the right muffler →
trim-cover of the right muffler → decorative cover of the left muffler → trim-cover
of the left muffler → barrel assembly of the muffler → rear fender assembly →
battery box
mounting frame assembly of the headlamp → windshield → left air deflector
mounting plate → right air deflector mounting plate → headlamp

*Note
Do not damage any body part during disassembly.
Do not damage any hook or claw in the body during disassembly.
6.2 Assembly
Assembly in reverse order.

*Note
Aim panels in the body at each corresponding groove.
Ensure correct installation of each hook or claw part during assembly.
Do no damage any part during assembly.
- 84 -
Front Suspension
Torque for mounting the
fixing bolt 20 of the steering
A
column in the figure:
50-70N·m
fixing bolt 16 of the upper
B
base of the steering handlebar
in the figure: 22-34N·m
fixing bolt 13 of the upper
C
connecting board in the
figure: 22-34N·m
fixing bolt 5 of the front
D
absorber in the figure:
5-10N·m
Torque for mounting the front
E wheel spindle 1 in the figure:
100-140N·m
locking bolt 28 of the head of
F
the front wheel spindle in the
figure: 5-10N·m
1. front wheel spindle 2. bolt M5×0.8×14 3. screw M6×15.2 .4. front right absorber assembly 5. bolt
M6×20 6. screw M5×0.8×12 7. bolt M6×1×14 8. suspension bush 9. mounting base under the
headlamp 10. spacer bush 11. screw M6×1×16 12. mounting base above the headlamp 13. bolt
M8×1.25×25 14. upper connecting board 15. upper base of the steering handlebar 16. bolt M8×1.25×25
17. locking screw of the inner hexagon flat end M4×6 18. pin 19. column 20. fixing screw of the upper
connecting board 21. nut 22. locking nut of the upper connecting board 23. steering bearing 24. screw
M6×8 25. fixing wire clip of the front brake tube 26. bottom connecting board 27 front left absorber
assembly 28. bolt M6×30 29. left spacer bush of the front wheel
- 85 -
Handlebar
1. balance piece assembly 2. throttle lever 3. mounting base of the balance piece 4. front cover of the throttle
cable 5. screw 6. right switch group 7. handlebar 8. left switch group 9. cover of the left handlebar 10.
handle combination of the clutch 11. clutch cable assembly 12. throttle cable assembly I 13. throttle cable
assembly II
- 86 -
Front Wheel
Tyre size: front tyre: 120/70

A
ZR17
Pressure of the front tyre:
B
250±10kpa
Minimum non-skid depth:
C
1.6mm
Rim run-out limit:
D Vertically: 2.0mm
Horizontally: 2.0mm
Torque for mounting the bolt 1
E
of the brake disc: 22-34N·m
1. bolt M8×16 2. front brake disc 3. bearing 6005-2RS/1-C3 4. middle spacer bush of the front wheel 5. front
rim 6. vacuum tyre 120/70 ZR17 7. front brake disc 8. valve
- 87 -
7. Front Wheel/Handlebar/Front Suspension
Preparing Documents--------------------------7.1
Failure Diagnosis-----------------------------7.2
Front Wheel-----------------------------------7.3
Handlebar--------------------------------------7.4
Front Suspension-----------------------------7.5
Work Instructions
Before removing the front wheel, you should use jack to support the body bottom and suspend the front wheel
which shall not be reversely rotated.
Pay attention that the brake shoes and the brake disc shall not be stained with grease during operation.
A stained brake disc or brake shoe will reduce brake force, so discard stained gasket and clean the brake disc
with quality brake degreaser.
Motorcycle Standards
Standard
Measurement points Item Limit for use (mm)
(mm)
Front wheel spindle Bending 0.2
Rim Vertically 2.0
Front wheel
shimmy Horizontally Within 1.0 2.0
Torque Force Tools

Fixing bolt of the upper connecting board assembly 22-34N·m Bearing puller
Fixing the front wheel spindle 100-140N·m Locking nut spanner
Locking screw of the head of the front wheel spindle 5-10N·m
Fixing screw of the front absorber 5-10N·m
Fixing bolt of the steering column 50-70N·m
Assembling bolt of the front brake cylinder 37-55N·m
- 88 -
7.2.1 Difficulty in Steering

 Failure or damage of the steering handlebar.
 Damaged bearing of the handlebar.
 Too tight of the adjusting bolt of the faucet bearing.
 Insufficient tyre pressure.
7.2.2 Unsteady Steering

 Damaged steering handlebar.
 Insufficient tyre pressure.
 Bending of the front fork or the front wheel spindle.
 Deformed or unbalanced front tyre.
7.2.3 Front Tyre Shimmy

 Deformed rim.
 Abraded front wheel bearing.
 Flawed front tyre.
 Unbalanced tyre or wheel.
7.2.4 Difficulty in Wheel Rolling

 Failure in the front wheel spindle bearing.
 Braking fault of the brake.
 Failure in the front wheel spindle.
 Bending of the front wheel.
7.2.5 Abnormal Noise of the Front Absorber

 Insufficient liquid in the absorber.
 Fricative sound of the absorber guard.
 Loose bolts in the absorber.
7.2.6 Operation Only Available in One Side or Move in Curve

 Unbalanced adjustment of the left and right forks
 Bending absorber
 Bending wheel
 Incorrect installation of the wheel
 Bending frame
 Broken wheel bearing
 Broken central axis of the swinging arm
7.2.7 Soft Front Absorber

 Insufficient liquid in the absorber
 The spring of the absorber is not firm.
 Too low of the tyre pressure
- 89 -
7.2.8 Too Stiff of the Front Absorber
 Improper weight of the liquid
 Blocked pathway of the liquid in the absorber
7.3 Front Wheel
7.3.1 Disassembly
Note:
Support the motorcycle firmly.
Support the motorcycle with a safety frame or firm crane.

Disassemble the front fender, and loosen the fixing screws①②.
Bleed nipple
Fixing bolt of the bake hose
Fixing bolt of the brake

cylinder
Disassemble the braking caliper of the front disc brake.
Remove the brake cylinder assembly off the front absorber.
- 90 -
Bleed nipple
Fixing bolt of the bake hose
Fixing bolt of the brake cylinder
Remove the clamping screw① of the front wheel spindle

(right front absorber)
Disassemble the front wheel spindle①
- 91 -
Disassemble the front wheel assembly①
Remove the left spindle sleeve of the front wheel②
Disassemble the bearing with the bearing remover.
Note:
Do not operate the brake controlling lever after the removal of the brake caliper.
- 92 -
7.3.2 Check
7.3.2.1 Check the Bending of the Wheel Spindle

Place the wheel spindle on the V-base and measure the
eccentricity ratio with a dial indicator.
Limit for use: replacement when beyond 0.2mm
车轴：axle
7.3.2.2 Check the Rim Shimmy

Place the rim on a precision bracket
and check the rim shimmy.
Rotate the wheel by manual and read indication.
Limit for use:

Vertically: replacement when beyond 2.0mm
Horizontally: replacement when beyond 2.0mm
Balance of the wheel：

Warning：
The balance of the wheel directly affects the stability,
operation and safety of the motorcycle. Check the stability of
the wheel when it is removed.
Note:
In order to keep balance, mark on the tyre near the bleed
nipple by drawing a dot at the rim. Assemble the tyre when
necessary.
7.3.2.3 Balance of the Front Wheel

Note:
Paste marks of the rotating direction on wheels and tires.
Remove the dust-proof sealing ring off wheels;

Install the wheels, tires and brake disc assembly at the Checkpoints;
Stop the rotating wheels, and mark the lowest (highest) point with the chalk.
Verify the most important sector in this way for 2 or 3 times.
If the wheel is in balance, it will not stop at one point.
In order to keep the wheel in balance, put on weight to it at the higher side of the rim, and mark with the chalk
at the other side. Add enough weight to the wheel when it is on rotation until it does not stop at one point.
Do not add weight above 60g to the wheel.
- 93 -
7.3.2.4 Check the front wheel bearing
Remove the bearing①, and the middle sleeve of
the front wheel②.
Check the rolling of the bearings.

Replace it if the bearing does not roll, or the
rolling is unsmooth or unstable, or the it is abraded
or loose.
7.3.3 Bearing Replacement

Remove the front wheel spindle, front wheel, left
spindle sleeve and the middle spindle sleeve. Then
remove the oil seal and the bearing respectively with
the oil seal remover and the bearing puller.
Note:
Replace dismantled bearings with new ones.
Lubricate the bearings with grease during installation.
Then press the bearings in with bearing installation
tools.
*Note
• Bearings must be pressed in horizontally.
游隙 clearance 轴向 axially 径向 radial
7.3.4 Installation
Note:
Lubricate the front wheel spindle, left spindle sleeve of the front wheel, bearing 6005-2RS/1-C3, and the
middle spindle sleeve.
Albany grease is suggested.
When tighten the front wheel and the caliper assembly of the disc brake, make sure that the brake disc is
between the brake pads.
The free stroke of the front brake lever can not be adjusted.
*Note
Torque of fixing the front wheel spindle: 100-140N·m
- 94 -
7.4 Steering Handlebar
7.4.1 Disassembly
Remove the left/right rearview mirror assembly.
Right rearview mirror
Left rearview mirror
Remove the oil pump assembly of the front brake.

Remove the right switch group.
Remove the mounting base assembly of the throttle
cable.
Oil pump assembly
Mounting base assembly of the throttle

cable
Fixing screw
Right switch group
Fixing screw
- 95 -
Remove the left handle assembly.
Remove the left switch group.
Left handle
assembly
Fixing screw
Left switch group
Remove the balance block assembly①.

Remove the right handle assembly②.
Remove the balance block③.
Remove the fixing bolts② of the upper base of the

steering handlebar.
Turn the upper base① of the steering handlebar.
Remove the tube of the handlebar.
7.4.2 Installation
Install in reverse order.
Note:
Fixing screw of the upper base of the steering handlebar
Torque: 22-34N·m
- 96 -
7.5 Front Fork
7.5.1 Disassembly
Support well the middle bracket of the motorcycle.
Disassemble the front wheel.
Disassemble the brake caliper and the brake pipe clamp.
Remove the steering handlebar.
Remove the pillar bolt①.
Remove the meter and the meter bracket.

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

Loosen the clamping bolts① of the upper
connecting board.
Remove the front absorber.
- 97 -
Tools:
Fixing nut spanner.
Special disassembly tool for bearing cup.
*Note:
The opening of the body guard shall be cleaned with cloth.
The upper/lower bearing cup shall be dismantled with a special disassembly tool for bearing cup.
7.5.3 Installation
Note:
Make sure that the hole of the front wheel spindle is concentric when installing the left and right
absorber.
Steps are contrary to the process of disassembly.
Note:
Fixing screws for the bottom connecting board: 10N.m
Fixing screws for the upper connecting board: 28N.m
- 98 -
Rear Wheel/Rear Suspension
Tyre size: rear tyre: 180/55 ZR
A
17
Pressure of the rear tyre:
B
290±10kpa
Minimum non-skid depth:
C
2.0mm
Rim run-out limit:
D Vertically: 2.0mm
Horizontally: 2.0mm
Torque for mounting the bolt 2 in
E
the figure: 5-10N·m
Torque for mounting nut 19 in the
F
figure: 37-55N·m
Torque for mounting nut 20 in the
G
figure: 130-150N·m
1. rear wheel spindle 2. screw M6×20 3. right spacer bush of the rear wheel 4. DIA.240 disc brake 5.
bearing 6006-2RS1-3C 6. spacer bush of the rear wheel 7. valve 8. rear rim 9. vacuum tyre 180/55 ZR17 1.
bearing 6006-2RS1-3C 11. buffer bushing 12. left spindle sleeve of the rear wheel 13. bearing 30×62×23.8
14. spindle sleeve of the sprocket wheel 15. fixing bolt of the sprocket wheel 16. sprocket wheel rim 17.
sprocket wheel 18. retaining ring Φ62 19. self-locking bolt M10×1.25 20. self-locking bolt M24×1.5
- 99 -
Rear Suspension/Rear Absorber
Torque for mounting bolt 1
A
in the figure: 70-105 N·m
Torque for mounting nut
T 10 in the figure: 37-55
N·m
Torque for mounting nut
C 10 in the figure: 37-55
N·m
1. screw 2. mounting sleeve of the rear swinging arm 3. rolling bearing 61905-2RS 4. straight pin 4×8 5.
middle spacer bush 6. mounting sleeve of the rear swinging arm 7. sleeve 8. rear absorber assembly 9.
mounting gasket of the rear absorber 10. fixing spindle of the rear absorber 11. nut M10×1.25 12. supporting
board of the brake clamp 13. rear chain cover 14 bolt M6×8 15. bolt M6×1×14 16. chain protecting block 17
bolt M6×1×14 18 front chain cover 19 bolt M6×1×14 20 fixing spindle of the rear absorber
- 100 -
8. Rear Wheel/Rear Suspension
Preparing Documents --------------------8.1
Failure Diagnosis -------------------------8.2
Rear Wheel --------------------------------8.3
Rear Absorber -----------------------------8.4
Chain Drive--------------------------------8.5
Rear Swinging Arm----------------------8.6
Work Instructions
The surface of the disc brake and the brake shoes shall not be stained with oil spots.
Item Standard (mm) Limit for use (mm)
Rear wheel Vertically 2.0
shimmy Horizontally 2.0
Locking torque force

Fixing nuts for the rear wheel spindle 130-150N·m
Top bolts for the rear absorber 37-55N·m
Bottom bolts for the rear absorber 37-55N·m
Fixing bolts for the rear swinging arm 70-105N·m
Fixing nuts for the sprocket wheel 37-55N·m
Fixing bolts for the rear brake disc 5-10N·m
8.2.1 Rear Wheel Shimmy

 Deformed rim
 Abraded rear wheel spindle
 Tyre failure
- 101 -
 Abraded or damaged bearings of the swinging arm spindle
 Incorrect adjustment of the drive chain
 Unbalanced tires and wheels
 Bending frame or the rear swinging arm
8.2.2 Inflexible Rolling of the Wheel

 Bending rear disc brake
 Abraded bearings of the rear wheel spindle
 Too tight of the drive chain
8.2.3 Too Soft of the Suspension

 Insecure or shaking damping spring
 Incorrect front suspension regulator
 Oil leakage of the absorber
8.2.4 Too Stiff of the Suspension

 Damaged assembly bearing of the absorber
 Bending tube of the absorber
 Damaged bearing of the rear swinging arm axis
 Bending of the rear swinging axis
 Fault in the suspension regulator
 Too high of the tyre pressure
8.2.5 Operation Only Available in One Side or Move in Curve

 Bending rear wheel spindle
 Incompetent of the axle arrangement/chain regulator on both sides
8.3 Rear Wheel
8.3.1 Disassembly
Support the motorcycle firmly with the rear
wheel above the group.
- 102 -
Caliper of the rear disc brake
Fixing screws of the caliper of

the rear disc brake
Adjusting screw of the rear wheel
Remove the caliper of the rear disc brake.

Loosen the adjusting screws of the rear wheel.
Remove the nuts of the rear wheel spindle and left adjusting block of the chain.
Nut of the rear wheel spindle
Left chain adjusting block
Adjusting screw of the rear wheel
Remove the rear wheel spindle and the right adjusting block of the chain.
后轮：rear wheel
后液刹盘：rear disc brake disc
固定螺钉：fixing screws
后轮轴：rear wheel spindle
Take the chain off the big sprocket wheel.
Chain
Big sprocket
wheel
- 103 -
Remove the rear wheel assembly.
Remove the supporting board of the brake clamp.
Supporting board of the brake

clamp
Remove the sprocket wheel assembly.

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

wheel
- 104 -
8.3.2 Check
8.3.2.1 Check the Rim Shimmy

Rotate the wheel by manual and measure the
eccentricity ratio with a dial indicator.
Limit for use:

Vertically: replacement when beyond 2.0mm
Horizontally: replacement when beyond 2.0mm
When the rear wheel indication goes beyond the limit for
use, the rear wheel bearing is loosened leading to the rear
wheel shimmy. Replace the rear wheel bearing after check.
8.3.3 Installation
Install the rear wheel in reverse order, and lock the nuts.
Fixing nuts for the rear wheel spindle

Torque force: 130-150 N·m
- 105 -
8.4 Rear Absorber
8.4.1 Disassemble the Rear Absorber

Remove the upper/lower fixing nut of the rear absorber.
Remove the rear absorber.
8.4.2 Check the Rear Absorber

Visually inspect of the absorber for damage.
Check the following items:

——whether the absorber tube is bent or damaged
——whether the absorber has signs of deformation or oil leakage
——whether the rubber block is abraded or damaged.
——whether the spring is damaged
Check all other parts for damage or abrasion

If necessary, replace the absorber
8.4.3 Install the Rear Absorber

Install the upper fixing nut and lower fixing bolt of the rear absorber.
Lock to the specified torque force.
- 106 -
Fixing bolts
- 107 -
8.5 Chain Drive
8.5.1. Disassembly
Put the motorcycle on level ground, and firmly support it.
Remove the left rear cover.
Fixing bolt of the left rear cover
Engine left rear cover
Disassemble the rear wheel, rear absorber, the drive

chain shade and drive chain.
8.5.2 Check
Measure the length of ten chain links ,

if the length doesn’t meet the specified value, replace
the drive chain.
The limit value of the length of ten chain links is
1587.5mm.
- 108 -
* Note:
• Measure after stretching the chain by hand.
• Range from chain link roller (1) to the inside of roller (11).
• Measure the length of ten chain links.
• Measure the length of ten chain links of different parts 2-3 times.
Clean the drive chain, put it into the kerosene,

and wash off the dust as much as possible,
then take the chain out of kerosene and dry it.
Check the rotor ① and side panels ②,

if damaged or frayed, replace the drive chain.
The lubricant for drive chain can be purchased from the
shop to lubricate the drive chain.
Check the hardness of drive chain,

clean, lubricate or replace it if hard.
- 109 -
Check the drive sprocket and driven sprocket.
If one-fourth of the teeth of a cogwheel is frayed,

replace the sprocket,
the bending of the teeth of a cogwheel also requires
the replacement of sprocket.
8.5.4. Installation
Fixing nuts
Note:
Adjust the laxation degree of the drive chain and the free stroke of the brake pedal.
If the laxation degree of the chain is too small, engine and other vital parts will be overloaded.
The laxation degree of the chain should be kept within the prescribed limit value.
8.6 Rear Swinging Arm
8.6.1 Disassemble the Rear Swinging
Arm
Put the motorcycle on level ground, and firmly support it.
Disassemble the rear wheel.
Disassemble the lower fixing nut of the absorber.
Disassemble the bolt and drive chain shade.
Disassemble the fastening bolt of the swinging arm spindle

from the frame.
Disassemble the rear swinging arm spindle and rear swinging
arm assembly.
- 110 -
Disassemble the rear swinging arm spindle bearing and the
rear swinging arm spindle
8.6.2 Check the Rear Swinging Arm

Check the rear swinging arm mounting spindle, rotate the
spindle on a flat surface or measure with a dial indicator, if
bent, replace it.
*Note
Don’t attempt to straighten the spindle already bent.
Clean the parts of the rear swinging arm mounting spindle Rear swinging arm
in the solvent.
Check the sleeve of the rear swinging arm and the middle
sleeve, if damaged, replace them.
Check the bearing for the damage
Use your finger to rotate in the inner bush of the right-pivot

bearing
The bearing shall rotate smoothly and steadily, and the
installment of the bearing's outer ring on the wheel hub
should be checked for security
If the ring can not rotate smoothly and steadily, or it is Bearing

flexible in installation on the pivot, please disassemble and
discard it
8.6.3 Install the Rear Swinging Arm

Spindle bush of the pivot should be greased,
Note:
Bolts for the rear swinging arm spindle
Torque force: 70-105N·m
- 111 -
Fuel Tank
Gasoline capacity of the
A gasoline tank:
15±0.2L
Torque force of bolt 3:
B
5-10N·m
D
5-10N·m
E
5-10N·m
F
5-10N·m
图中螺栓 16 的扭力值：
G
22-37N·m
1.fuel tank body assembly 2.gasket 6.4×12.5×1.6 3.bolt M6×70 4.fuel pump seal gasket 5.fuel pump
assembly 6.petrol pump screw 7.fuel pipe assembly 8.filter assembly 9.bolt M6 10.gasket 5,3×10×1
11.oil level sensor assembly 12.bolt M6×25 bolt M6×25 13. rubber gasket tube 14.fuel tank front
mounting pad 15.fuel tank front mounting board 16.bolt M8×1.25×20 17.fuel tank cover support
assembly 18.fuel tank lock 19.socket head cap screw M5×30 20.socket head cap screw M5×14 21.fuel
tank cover seal gasket
- 112 -
9. Fuel Tank
Preparing Documents -----------9.1
Failure Diagnosis -----------9.2
Fuel Tank -----------------9.3
Work Instructions:
It shall be dismantled far from fire sources.
Tighten all the bolts and screws to the required torque value for assembly.
After assembly, check whether all the parts are correctly installed and operated.
Gasoline tank capacity 15±0.2L /
Tightening torque force

Front fixing bolts for the gasoline tank 22-37N·m
Rear fixing bolts for the gasoline tank 5-10 N·m
Fixing bolts for the fuel tank front mounting pad 5-10 N·m
Fixing bolts for the fuel pump 5-10N·m
Fixing bolts for the oil level sensor 5-10N·m
9.2.1 Decreasing Gasoline

 Natural consumption of gasoline
 Leakage of gasoline
- 113 -
9.3 Fuel Tank
9.3.1 Disassembly
Remove the rear seat and the front seat
Remove the upper body of the fuel tank.
Remove the front fixing bolt of the fuel tank.
Remove the high-pressure oil pipe assembly.

Remove the fuel pump connector jacket.
Remove oil level sensor connector jacket Front fixing bolt of the fuel tank.
Oil level sensor
Fuel pump
High-pressure oil pipe assembly
Fuel pump connector jacket
Oil level sensor connector jacket
- 114 -
Remove the rear fixing bolt of the fuel tank.
Rear fixing bolt of

the fuel tank
Remove the fuel tank.
9.3.2 Installation
Torque force for mounting:

Front fixing bolts for the gasoline tank 22-37N·m
Rear fixing bolts for the gasoline tank 5-10 N·m
Fixing bolts for the fuel tank front mounting pad 5-10 N·m
Fixing bolts for the fuel pump 5-10N·m
Fixing bolts for the oil level sensor 5-10N·m
- 115 -
10. Disassembly and Installation of Engine
Preparing Documents -------------10.1
Disassembly and Installation of Engine ----------10.2
Work Instructions
It shall be dismantled far from fire sources.
Tighten all the bolts and screws to the required torque value for assembly.
After assembly, check whether all the parts are correctly installed and operated.
Locking torque force

Gearshift rod bolt: 10N.m
Engine fixing bolt: 50N.m
10.2 Disassembly of Engine
Support the motorcycle firmly to make its rear

wheel above the ground.
- 116 -
Unscrew the clamp of the engine water pump
inlet/outlet, remove the cooling water-pipe and
exhaust the coolant
Disassemble the front and rear seats
Disassembly of the rear seat

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

Remove the rear seat;
Hold the front seat cable with hands;
Slightly push the back of the front seat with
your left hand, pull the front seat upwards and
backwards
Remove the front seat;
Note:
Confirm the left and right limits are set at
positions when installing the front seat.
- 117 -
Disassemble the fuel tank assembly
See 9.3.1 Disassembly of the fuel tank
Disassemble the air filter assembly
Disassemble the air filter fixing bolt

Disassemble the air filter hoop
Disassemble the connector jacket of the intake air
temperature sensor;
Disconnect the breather rubber pipe from the vent
of cylinder cover;
Remove the air filter
Note:
The stepper motor of the throttle body should be
set well to position when installing the air filter.
Disassemble the throttle body assembly

Remove the throttle cable assemblyI and throttle
cable assembly II;
Disassemble four throttle body hoops in 1-2-4-3
order;
Remove the connector jacket of the intake air
pressure sensor.
Remove the ejector connector jacket;
Remove the connector jacket of the idle stepper
motor;
Remove the canister desorption rubber pipe;
Remove the intake oil pipe;
Remove the throttle body assembly
Note:
Confirm the throttle cable assemblyI and throttle
cable assemblyII are set at positions;
Confirm the oil pipe is connected well to place
without oil leakage after the correct installation of
the throttle body assembly.
Confirm the electric components are connected at
positions;
- 118 -
Disassemble the canister assembly
Canister assembly
Disassemble the clutch steel rope assembly
Clutch steel rope assembly
Disconnect the battery wire, disassemble the starter motor wire

and the ground wire
Disassemble the FBT connector jacket, rectifier
and outlet water temperature switch connector
jacket
Battery wire
- 119 -
Disassemble the anterior segment of muffler exhaust
pipe
Disassemble the radiator filler, water tank, and

disconnect the fan switch connector jacket
Disconnect the crankshaft position sensor, neutral
switch connector jacket
Disconnect the single-kickstand flameout switch

connector jacket and disassemble the single-kickstand
flameout switch
Single kickstand flameout switch
- 120 -
Disassemble gearshift lever swing arm and the left cover of
the engine
Disassemble the small sprocket and detach the chain from the
sprocket
Release the engine fixing bolt and lift the engine
- 121 -
10.3 Installation of the Engine
Note:
 Place an appropriate holder under the frame in case of rollover when disassembling the engine.
 Engine fuel: 3.2L when assembling.
 Start the engine and check it for abnormal vibration, noise and engine lubrication.
 After the engine works properly at idle speed for a period of time, turn the throttle handle to maximum
level, then completely relax the throttle handle, at this time if the idle speed changes, it shows that the
throttle cable hasn’t been regulated well. Therefore, attention should be given to the regulation in this
regard prior to the testing the engine.
 Checking method of engine fuel

a. Pull out the fuel rod, wipe it off with a clean cloth.
b. Insert the rod into the oil and remove it to check the oil level, if the oil level is lower than the
lowest limit, increase the fuel.
c. Heating up for 5 minutes and cooling for 3 minutes, then check the oil level again, if the oil level
is lower than the lowest position, increase the fuel.
d. The oil level should always be kept between the lowest limit and the toppest limit.
- 122 -
Inspection and Maintenance of Engine
Table of Torque Force of Fasteners

Name of fastening parts and fasteners Tightening torque (N·m)
Magnetic bolt M14 20~25
Oil pan bolt M6 10~12
cylinder double-end bolt 60~62
Flywheel locking bolt 100~110
Gearshift positioner bolt M6 10~12
Crankcase bolt M6 10~12
Connecting rod bolt 23~27
Left/right crankcase cover bolt M6 10~12
Flywheel bolt M8 20~24
Fuel filter 18~22
Fuel filter connecting bolt 40~45
Fuel filter bolt M14 40~45
Round nut M20 95~105
Clutch release plate bolt M6 10~12
Cylinder cover shade bolt M6 10~12
Camshaft sprocket bolt M7 20~25
Fuel pump bolt M6 10~12
Gearshift positioning plate bolt M6 10~12
Spark plug 22~25
- 123 -
11. Lubricating System
Preparing Documents ------------11.1
Failure Diagnosis ------------11.2
Fuel Pump ---------------11.3
Function of the lubricating system:

The lubricating system of the engine is to provide lubricating oil to the frictional surface of each part, which
transforms dry friction into liquid friction between lubricating oil particles and also reduces abrasion of parts.
It also cools components with high thermal load, absorbs shock from bearings and other parts, reduces noise,
increases sealing between piston ring and cylinder wall, and cleans and removes particles in the surface.
Work Instructions:
Clean all parts carefully and blow the parts surface clean with high-pressure gas after disassembly of the fuel
pump.
Foreign matter shall not fall into the crankcase when the carburetor is disassembled
Standard of benchmark items and table of limit for use

When oil change 3.0L ＿
Fuel capacity
When disassembling 3.2L ＿
The radial clearance between
0.04-0.11mm 0.15mm
inner and outer rotors
Fuel pump rotor
The clearance between
0.04-0.11mm 0.15mm
outer rotor and pump body
Decreasing fuel Burnt engine

Natural consumption of fuel No fuel pressure or low fuel pressure
Fuel leakage Blocked fuel pipes
- 124 -
11.3 Fuel Pump
11.3.1 Disassembly
Remove the clutch cover, loosen the fuel pump fixing bolt, take down
the fuel pump drive sprocket and the fuel pump drive chain.
Fuel pump chain
Screw
螺钉
Fuel pump drive sprocket
Remove the screw.

Remove the fuel pump body.
Screw
Fuel pump body
Remove the screw, take down the fuel pump cover, and decompose
the fuel pump. Screw
Fuel pump cover
- 125 -
Check the radial clearance between inner and outer rotors
Limit for use: 0.15mm.
Gauge
Check the clearance between outer rotor and fuel pump cover
Limit for use: 0.15mm. Gauge
- 126 -
11.3.2 Assembly of Fuel Pump
As shown below Fuel pump
drive sprocket
Fuel pump cover Outer rotor Pump body
Inner rotor
Pump shaft
Note: After the combination, the inner and outer rotors should rotate flexibly without stagnation.
Installation
- 127 -
11.3.3 Lubricating Systematic Drawing
Piston cooler
排气凸轮轴--- exhaust camshaft 进气凸轮轴--- intake camshaft 活塞冷却器---piston cooler 曲轴连杆

机构--- crankshaft connecting rod mechanism 主油道--- main oil channel 油冷器--- oil cooler 主轴
---main shaft 机油泵--- fuel pump 机油滤清器--- fuel filter 机油集滤器--- fuel strainer 溢流阀--- relief
valve 副轴---countershaft
- 128 -
- 129 -
12. Cylinder Head
Preparing Documents --------------------12.1
Failure Diagnosis -------------------------12.2
Cylinder Head / Valve--------------------12.3
Function of the cylinder head:

The cylinder head is used to seal the cylinder and form the combustion chamber with the piston. It bears HPHT
gas, and achieves air intake and exhaust through distribution mechanism.
Work Instructions:
The cylinder cover bears large bolt pretension to ensure sealing between the cylinder head and the upper
cylinder block. Pretension: 12 N·m, torque force: 60 N·m. All components must be cleaned and dried with
high-pressure air before check.
Standard of benchmark items and table of limit for use Unit: mm
Flatness of cylinder cover 0.03 0.05
Intake 013-0.19 __
Valve gap
Exhaust 0.19-0.25 __
Intake 3.97-3.98 3.96
Outer diameter of valve stem
Exhaust 3.97-3.98 3.96
Valve Intake 4.03-4.04 4.07
Inner diameter of valve catheter
Valve catheter Exhaust 4.03-4.04 4.07
Clearance between valve stem Intake 0.05-0.07 0.11
and valve catheter Exhaust 0.05-0.07 0.11
Intake 1.0-1.1 1.5
Width of valve seat
Exhaust 1.0-1.1 1.5
Intake 38.8 37.3
Valve spring Free length
Exhaust 41.6 40.1
Fitting clearance between camshaft and
Camshaft 0.041-0.054 0.08
cylinder head
Low compression pressure Noise in Cylinder head

Valve clearance maladjustment Valve clearance maladjustment
- 130 -
Burnt or bent valve Damaged valve spring
Poor air-tightness of valve seat Over high compression pressure
Cylinder head gasket leaks gas Too much carbon fouling in the combustion chamber.
Poor installation of spark plug
- 131 -
12.3 Cylinder Head
12.3.1 Disassembly
Remove the ignition coil.
Loosen six locating bolts, remove the gasket and cylinder cover shade.
Cylinder
cover shade
Locating bolt
Loosen the fastening bolt, and remove the air-distributing

chain regulator.
Fastening bolt
Air-distributing chain regulator
Loosen the four sprocket bolts of the camshaft.
Sprocket bolt of the camshaft
Measure the fitting clearance between camshaft and cylinder

head.
Gauge
- 132 -
Loosen the camshaft holder.
Camshaft holder
Remove the camshaft, camshaft sprocket and chain.
Camshaft
Camshaft chain
Camshaft sprocket
Guide chain
plate
Cylinder
cover
Loosen the cylinder cover locking bolt.
Remove the cylinder cover.
Remove the top stem, compress the valve spring with valve
spring compression tools, and remove the valve block.
Remove the valve adjusting gasket, valve spring, valve spring
upper/lower seat and valve.
- 133 -
12.3.2 Cam Assembly Breakdown
Camshaft
Seal cover D13 Bolt
Camshaft sprocket
12.3.3 Valve Breakdown
Valve Valve spring Valve block Top

lower seat stem
Valve spring
Valve spring upper seat Valve adjusting
gasket
Ruler
Gauge
Check
Eliminate carbon deposit in the cylinder cover.
Measure the flatness of the joint surface of the cylinder cover.
When the flatness of the joint surface of cylinder cover
exceeds the limit for use, place the fine-sand paper on the flat
plate, with the joint surface of cylinder cover fitting the sand
paper, and mill it according to 8-shape.
- 134 -
Vernier calipers
Measure the free length of valve intake/ exhaust spring.

Limit for use: intake spring: 37.3mm.
exhaust spring: 40.1mm.
Measure the outer diameter of the valve stem.

Limit for use: intake valve 3.96mm
exhaust valve 3.96mm Micrometer
Check the valve catheter after eliminating the carbon deposit

in it with a reamer.
Note: The reamer should be rotated clockwise, and mustn’t be
rotated anti-clockwise.
Tester
Measure the inner diameter of each valve catheter.

Limit for use: intake/ exhaust: 4.07mm.
Limit for use of the clearance between valve and valve catheter:
Intake valve: 0.11mm.
Exhaust valve: 0.11mm.
- 135 -
Screwdriver
12.3.4 Replace the Valve Catheter

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

Install the valve catheter from the top of the cylinder head. Valve
Note: The cylinder head shall not be damaged when installing reamer
the valve catheter.
After inserting the valve catheter, trim with a valve catheter

reamer.
Note: Add proper amount of cutting oil when cutting with an
reamer. And the reamer should be rotated clockwise.
Eliminate the carbon deposit in the combustion chamber and

valve, clean thoroughly the intake/exhaust valve. Check the
width of the contact surface of the valve seat (width of the
valve seating).
Limit for use: intake/ exhaust: 1.5mm. Contact surface of the valve seat
- 136 -
12.3.5 Trim of Valve Seating
Remove the rugged or ragged parts of the valve seating Rugged part
surface with a milling cutter at 45°angle.
Note: Coat a transparent or prussian-blue cladding on the
valve seating to get a better view.
Remove 1/4 of the outer end of valve seating with a milling

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

cutter at 60°angle. Take down the milling cutter and check the
parts treated.
60°
Grind the valve seating with a refining milling cutter at

45°angle to achieve the proper width.
All dents and ragged parts must be removed. 1.0mm
Standard width of the valve seating: intake: 1.0mm

exhaust: 1.0mm
45°
- 137 -
If the contact is the part where the valve is too high, please
lower the valve seating with a flat milling cutter at
25°angle. High contact surface
If the contact is the part where the valve is too low, raise
the valve seating with a inner milling cutter at 60°angle. 25°
Refine the valve seating again with a refining milling cutter
at 45°angle to meet the specifications required. Low contact surface
After grinding the valve seating, please coat the polish on
the surface of valve to gently polish the valve.
60°
12.3.6 Installation
Note:
When installing the valve spring, the end with smaller pitch of the spring shall be installed towards the
combustion chamber.
When installing the valve collet, install it by compressing the valve spring with valve spring compression
tools
When installing the valve, the surface of the valve stem shall be coated with proper amount of fuel prior
to installing to the valve catheter.
- 138 -
- 139 -
13. Crankcase
Preparing Documents------------------------------------------------------13.1
Failure Diagnosis-----------------------------------------------------------13.2
Upper Box-------------------------------------------------------------------13.3
Piston------------------------------------------------------------------------13.4
Lower Box------------------------------------------------------------------13.5
Clutch-----------------------------------------------------------------------13.6
Variable Speed Gear Transmission---------------------------------------13.7
Camshaft Connecting Rod Assembly-------------------------------------13.8
Function of the upper box:
The cylinder block in the upper box provides space for gas compression, combustion and expansion, and also
guides piston movement.
It also transfers part of heat energy in the cylinder to cooling medium around.
Function of the piston:
1. It bears pressure arising from mixed gas combustion inside the cylinder and transfers such pressure to the
connecting rod for driving the crankshaft.
2. It forms combustion chamber along with the cylinder cover.
Function of the crankcase:
The crankcase is the load-bearing part of the engine. Its main function is to support the crankshaft, clutch,
gearbox, cylinder block and cylinder cover, sustain combustion shock and inertia force from the movement of
the connecting rod, and form part of closed space (oil sealing, gas sealing).
Suspension holes in the crankcase are linked with suspension holes in the body, which connects the engine to
the frame and other parts.
Work Instructions:
- 140 -
All components must be cleaned and blown with high-pressure gas before test.
The crankcase is thin-section casting thus shall not suffer impact during operation which may cause
deformation or fracture.
Lubricant in the crankcase should be drained out before operation.
- 141 -
Standard of benchmark items and table of limit for use
Limit for
Item Standard
use
Cylinder I 65 (0.025, 0.03) 65.100
Diameter of the cylinder
Cylinder II 65 (0.03, 0.035) 65.110
Cylindricity of the cylinder 0.008 0.050
Roundness of the cylinder 0.006 0.050
Flatness of the cylinder 0.03 0.05
Piston I 65 (-0.03, -0.025) 64.90
Outer diameter of piston (measured in piston skirt)
Piston II 65 (-0.025, -0.02) 64.91
Inner diameter of piston pin hole 16 (0.002, 0.008) 16.04
Outer diameter of piston pin 16（-0.008, 0） 15.96
Clearance between piston pin hole and piston pin 0.002-0.016 0.04
Upper box
Clearance between piston ring Ring 1 0.05-0.09 0.11
and ring groove Ring 2 0.04-0.08 0.11
Ring 1 0.15-0.30 0.5
Joint gap of the piston ring Ring 2 0.25-0.45 0.65
Fuel ring 0.20-0.70 1.0
Inner diameter of the smaller head of connecting rod. 16 (0.016, 0.034) 16.04
Clearance between connecting rod and piston pin 0.016-0.042 —
Thickness 1.5 (0-0.09) 1.48
Connecting-rod Clearance between the
bearing connecting-rod bearing and 0.025-0.05 0.065
crankshaft
Left-right clearance of the larger
0.1-0.25 0.5
end of the connecting rod
Connecting rod
Radial clearance of the larger
0.008-0.016 0.05
Thickness 1.5 (0-0.012) 1.44
Main-shaft
Clearance between main shaft
bearing 0.03-0.05 0.07
and crankshaft
2.8 (-0.05, +0.05) 2.45
Thickness of friction disc
Lower box 3（-0.1, 0） 2.6
Clutch
24.3（-0.15, +0.15） 22.8
Length of pressure spring
23.5（-0.2, +0.2） 22.4
Outer diameter of fork shaft 11.973-11.984 11.96
Diameter of fork inner hole 12-12.018 12.03
Variable
Thickness of fork 5.80-5.90 5.75
speed gear
Outer diameter of gearshift drum 41.9-42.1 41.5
transmission
Width of gearshift drum lock
5.45-5.55 5.65
groove
- 142 -
Low compression pressure White smoke from the exhaust pipe

Abrasive, burnt or ruptured piston Abrasive or damaged piston ring
Abrasive or damaged cylinder or piston Abrasive or damaged cylinder or piston
Damaged spacer or crankcase leakage
Over-high compression pressure Abnormal noise of the piston

Too much carbon deposit in the combustion chamber Damaged cylinder, piston or piston ring
Abrasive piston pin hole and piston pin
Low compression pressure Abnormal noise in the crankcase

Crankcase leakage Loose or broken parts inside the crankcase
Engine overheating Engine automatic stopping
Clutch slipping Seized clutch
Poor lubricating
Not in gear Gear skip shift
Broken or deformed variable speed fork The clutch isn’t completely released
Broken fork guide pin Abnormal transmission return spring
Abrasive gear convex claw Abrasive gearshift drum lock groove
Out of gear automatically
Abrasive joint claw, round edge
Decreasing elasticity of variable speed gear return spring
Abrasive spline gear of spline shaft and spline groove of sliding gear, leading to higher axial force when the
gear works
Abrasive gearshift drum and fork
- 143 -
13.3 Upper Box
BJ465MS/QJ465MS Engine cylinder block

Namely it is part of the upper box.
Upper box
Check
Check the abrasion of the inner wall of the cylinder.
If it is serious, replace it.
Spacer
Remove the spacer and locating pin.
Locating pin
- 144 -
13.4 Piston
13.4.1 Disassembly
Remove the retainer ring of the piston pin.
Note: during assembly, do not make the retainer ring fall
into the crankcase.
Remove the piston pin and the piston.
Retainer ring of the piston
Piston pin
Remove the piston ring.

Check the piston, piston pin and piston ring.
Note:
Do not rupture or damage the piston ring.
Eliminate carbon deposit in the groove of the piston ring.
Install the piston ring.

Measure the clearance between piston ring and piston ring
groove.
Limit for use: ring 1: 0.11mm.
ring 2: 0.11mm. Piston Push into
Piston ring
Gauge
- 145 -
Remove the piston ring, and install each piston ring on the
cylinder bottom.
Note:
Press the piston ring into the cylinder with piston head.
Measure the joint gap of the piston ring.
Limit for use: ring 1: 0.5mm.
ring 2: 0.65mm. Piston ring
Gauge
Measure the inner diameter of the piston pin hole.

Tester
Measure the outer diameter of the piston pin.

Clearance between piston pin hole and piston pin.
Limit for use: 0.04mm. 1
2
3
- 146 -
Measure the outer diameter of the piston I and piston II.
Note:
90°
The measuring point shall be at 90°with the piston pin, and
at the piston skirt.
Limit for use of the piston I: 64.90mm. 11mm
Limit for use of the piston II: 64.91mm.
Check whether cylinder I/II inner wall is scratched or

abraded.
Note:
It is at 90 degree with the piston pin. Measure the inner
diameter of the cylinder at the top, middle and bottom
points.
Limit for use of the cylinder I: 65.100mm.
Limit for use of the cylinder II: 64.110mm.
Tester
Measure the roundness of the inner wall of the cylinder (inner

diameter difference at X direction and Y direction). In Ex
Limit for use: 0.050mm. 排
Measure the cylindricity of the inner wall of the cylinder Top
(inner diameter difference at the top, middle and bottom
points of X direction and Y direction). Middle
Bottom
- 147 -
Check the flatness of the cylinder surface..
Limit for use: 0.05mm. Ruler
Gauge
Upper box
Measure the inner diameter of the smaller end of the

connecting rod.
Inner diameter of the

smaller end of the
connecting rod
Tester
Measure the clearance between connecting-rod bearing and crankshaft.

Connecting-rod bearing
- 148 -
Measure the clearance between main shaft bearing and crankshaft.
Main shaft bearing
Plastic gauge
13.4.2 Piston Installation Top ring

Install the locating pin.
Apply fuel to each piston ring and piston. Install the piston Ring 2
ring in place.
Fuel ring
Note:
Do not scratch the piston or break the piston ring.
After the piston ring is installed, it shall be able to rotate
freely in the piston ring groove.
- 149 -
Remove any residual spacer attached to the crankcase.
Note:
Do not make any object fall into the crankcase.
Install the piston, piston pin and retainer ring.
Note:
The dot mark on the top of the piston shall be installed
towards the intake valve.
Dot mark
- 150 -
13.5 Lower Box
13.5.1 Disassembly of the Crankcase Left Cover

Lossen the fixing bolt of starter motor, remove the starter motor.
Lossen the bolt of the crankcase left cover.
Remove the left cover.
Remove the electric starting bear, needle bearing and spacer.
Motor idle gear
Starter motor
Locating pin hole

定位销孔
Remove the starter motor idle gear.

Remove the spacer and locating pin hole.
Loosen the flywheel locking nut with the electric or pneumatic tool.
Pull the flywheel assembly (including the star wheel )
Flywheel assembly
- 151 -
13.5.2 Disassembly of the Clutch Cover
Loosen the fixing bolt, and remove the clutch cover.
Bolt
Clutch cover
Remove the clutch release stem from the right cover.
Right cover
Release stem assembly
Remove the fixing bolt, clutch, gearshift arm assembly and fuel pump sprocket.
Clutch assembly
Gearshift arm assembly
Fuel pump sprocket
Driven gear
- 152 -
Loosen the locking nut with the electric or pneumatic
tool, and remove the clutch.
Loosen the fuel pump screw, and remove the fuel pump
gear.
Gearshift drum assembly
Fuel pump chain
Fuel pump sprocket
- 153 -
13.6 Clutch
13.6.1 Disassembly
Unscrew the four bolts of the release plate in diagonally staggered sequence.
Loosen the clutch nut.
Remove the sleeve, bearing, release plate
and the clutch spring.
See the breakdown drawing for the disassembly of parts.
.
Release plate bolt
Clutch nut
Unscrew the clutch locking nut with the special tool, and remove the locking nut and gasket.
Remove the center holder of clutch.
Remove the clutch disc and friction disc.
Remove the clutch pressure plate.
See the breakdown drawing for the disassembly of
parts.
Remove the spline gasket.
Remove the shell assembly.
Four-claw socket spanner
Universal holder
Shell assembly
- 154 -
13.6.2 Clutch Breakdown
滚针轴承---needle bearing 轴套---sleeve 垫片---spacer 主动毂组件---drive hub assembly 从动毂---driven

hub 摩擦片---friction disc 离合器片---clutch disc 碟形弹簧---dish-shaped spring 垫圈---gasket 主动毂座
组件---drive hub housing assembly 压力弹簧---pressure spring 压板---pressure plate 螺栓---bolt 滚动轴
承--- rolling bearing
- 155 -
13.6.3 Check
Check the shell groove for burrs and brakeage, if
trimmed excessively by the file, replace it.
Check the pressure plate and the tooth profile of the
center holder for damage, if damaged, replace it.
Drive hub assembly
Driven hub
Measure the free length of the pressure spring.

Limit for use I: replace it if lower than 22.8mm.
Limit for use II: replace it if lower than 22.4mm.
Free length
Measure the thickness of the friction disc with vernier

Thickness
calipers.
Limit for use I: replace it if lower than 2.45mm.
Limit for use II: replace it if lower than 2.6mm.
- 156 -
13.7 Gearshift Mechanism
13.7.1 Disassembly
Remove the gearshift shaft assembly.
Remove the bolt and gearshift locating plate.
Remove the bolt, stop arm and spring.
Remove the locating pin.
See the breakdown drawing for the disassembly of
parts.
Gearshift shaft assembly
13.7.2 Gearshift Shaft Mechanism Breakage

Fork shaft spring Fork Fork shaft
Pressure plate
Gearshift drum Gearshift drum bearing Ratchet
Gearshift arm assembly
13.7.2.1 Check
Before the breakage, the gearshift plate should flexibly return without being seized.
Check the gearshift plate and gearshift shaft assembly for abrasion. If heavily abrasive, replace the assembly.
Check the gearshift locating plate for abrasion, If heavily abrasive, replace the assembly.
- 157 -
Check whether the gearshift shaft is bent, if excessively bent, replace it.
Check the return spring for decreasing elasticity, if necessary, replace it.
- 158 -
Loosen the crankcase bolt.
Separate the crankcase. Upper box
Note: Do not damage the spacer and crankcase surface.
Remove the upper box.
Crankcase bolt
Lower box
Main shaft assembly
Countershaft assembly
Remove the main-/ countershaft.
Loosen the pressure plate bolt, and remove the pressure plate.
Pull the fork shaft.
Remove the gearshift drum.
Remove the gearshift fork.
Gearshift drum
Fork
Fork shaft
- 159 -
13.7.2.2 Check
Measure the outer diameter of the fork shaft. Fork shaft
Micrometer
Measure the inner diameter of the fork hole.

Tester
Vernier calipers
Measure the thickness of the fork.

Width of the lock groove

Measure the outer diameter of the gearshift drum.
Measure the width of the gearshift drum locking
groove.
- 160 -
13.8 Crankshaft Connecting Rod Assembly Chamber and Variable
Speed Chamber
Depository for
the main shaft
Depository for the
crankshaft connecting rod Depository for
the countershaft
Gearshift chamber
变档室
- 161 -
Main shaft
assembly
Gearshift drum
assembly
Gearshift arm
Fork shaft
assembly
- 162 -
13.8.1 Crankshaft Connecting Rod Assembly
13.8.1.1 Disassembly
Remove the upper box.
Remove the crankshaft connecting rod assembly from the lower box.
Countershaft Main shaft Drive gear

assembly assembly
asseml
副轴组件
Note: Do not damage the spacer and crankcase surface.
- 163 -
13.8.1.2 Check
Measure the left-right clearance of the larger end of the connecting rod.
Measuring point at the

clearance between the larger
Measuring point at the larger

Measure the clearance of the larger end of the connecting rod (X-Y
direction).
- 164 -
13.8.1.3 Assembly
Assemble in reverse order of breakdown and disassembly.
Remove the main shaft assembly
Remove the countershaft assembly.
13.8.2 Main-/Counter Shaft Breakdown

13.8.2.1 Main-/Counter Shaft Breakdown
Main shaft assembly
- 165 -
13.8.2.2 Check
Check the abrasion of gear surface and driving-claw point of the gear respectively.
If it is seriously abraded or damaged, replace it.
Gear surface
Check whether the bearing and oil seal are damaged, If yes,
replace it.
Driving claw
Note:
Removed bearing cannot be used any more. It shall be
replaced.
Use special tools to dismantle the bearing and the oil seal.
13.8.2.3 Main-/Counter Shaft Assembly
Note:
Lubricate all gears and shafts with grease when assembling.
Ensure all gears without being seized after assembling.
Note:
Install the crankcase in reverse order.
- 166 -
14. Cooling System
Preparing Documents -------------------------14.1
Failure Diagnosis ------------------------------14.2
Water Pump ------------------------------------14.3
Function of the cooling system:

The cooling method of the engine is water cooling. Water cooling, in which the water is used as the heat
conductor, is a method of cooling high-temperature components and then transferring heat to the outside air,
thus keeping the engine working under the optimum temperature.
Specific cooling circuit:
The cooling water entering from the crankcase goes to the cylinder water jacket through the water channel
of crankcase, then goes upward through the cylinder cover, finally enters into the radiator through the pipe to
- 167 -
dissipate heat, and transfers heat to the outside air with the help of radiator’s fin.
Water leakage
Damaged seal ring
Broken pump assembly
Broken water pipe
Over high temperature in cylinder block
Damaged blade of the water pump
Blocked water pipe
Damaged cooling fan
Damaged water temperature switch
14.3 Water Pump
Disassembly
Loosen the bolt, and remove the water pump sub assembly.
Bolt
- 168 -
Water pump sub assembly
Bolt
Loosen the bolt, and remove the water pump cover.
Water pump cover
Remove the blade.

Blade
Check
Check the abrasion of the blade assembly.
If it is serious, replace it.
Note: Don’t damage the spacer and the joint surface of box
during operation.
Installation
- 169 -
Cooling Systematic Drawing
Reservoir
465 cooling system piping drawing
thermostat
t
Cylinder cover Thermostat
Pressure valve
Oil
cooler
Water pump Radiator

Cylinder block
Water direction
- 170 -
Inspection and Maintenance of Exhaust Emission System
1 exhaust pipe gasket assembly 2 screw M8×30 3 gasket 8 4 spring gasket 8 5 muffler assembly 6
muffler buffer rubber 7 muffler decorating panel 8 heat-insulating spacer 9 combined screw M6×10
- 171 -
15. Exhaust Emission & Control System
Warranty on the Exhaust Emission & Control System ----------------------------15.1
Instructions on the Periodic Maintenance / Compliance with Standards -------15.2
Mechanical Function of the Exhaust Control System -----------------------------15.3
Catalytic Conversion System --------------------------------------------------------15.4
Measures When the Idle Speed Emission Value Exceeds the Standard ---------15.5
15.1 Warranty on the Exhaust Emission & Control System
15.1.1 The exhaust emission & control system of this motorcycle is in conformity with the GB 14621-2011,
GB 14622-2007, GB 19758-2005 and GB 20998-2007 standards prescribed by the state. We warrant that the
exhaust emission & control system works normally during its effective period provided that users completely
comply with all operation and maintenance requirements.
15.1.2 Warranty Range
Function warranty of the exhaust emission & control system

We warrant that it satisfies all periodic or non-periodic inspection by the related government authorities within
riding of (30000 kilometers).
15.1.3 This provision is not applicable under any following condition. However, our distributor or service store
would like to provide maintenance or repair services at reasonable prices.
(1) Users fail in periodic maintenance within the required period or kilometers.
(2) Periodic maintenance, adjustment or repair is not carried out at our distributor or service center, or there is
no evidence of maintenance record.
(3) Overload or improper operation.
(4) Refit the motorcycle, remove original parts or replace with other devices in private.
(5) Ride the motorcycle on race tracks or on any non-motorized vehicle lane frequently.
(6) Damage to the motorcycle due to extreme weather such as typhoon or flood, or damage or failure due to
negligence, crash or impact.
(7) Users fail in periodic maintenance since it is out of service for a long time.
(8) The odometer is not repaired immediately after being damaged, or it is refit, stopped, or replaced in
private.
·All new motorcycles delivered by our company have satisfied the noise test and comply with the GB
4569-2005 and GB 16169-2005 standards prescribed by the state.
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15.2 Instructions on Periodic Maintenance
 It is the national requirement that all motorcycles produced domestically shall comply with exhaust
emission standards to lessen environmental pollution. We strictly accord with these exhaust emission
standards and also make great effort in purifying air and reducing pollution.
 This motorcycle has been strictly examined before delivery and is in conformity with all exhaust emission
standards. We provide the following periodic inspection table for exhaust emission in consideration of
different use by customers. Users shall carry out periodic inspection, adjustment or maintenance
according to the schedule to ensure normal emission.
 For any problem, please contact Qianjiang distributors or Qianjiang service center.
 Relevant emission provisions are shown as follows:
Emission regulation CO HC NOX
Emission standard ≤2.0g/km ≤0.3g/km 0.15g/km
※ The latest national regulation shall prevail if there is any change.
 We are not responsible for any problem due to failure in periodic maintenance at our distributor or service
center. Please carry out necessary inspection to ensure its best condition.
Note: ①Clean the air filter frequently if the motorcycle runs in sandy road or under seriously polluted
condition to extend the service life of the engine.
②Increase maintenance if the motorcycle often runs at high speed or frequently.
Pay attention to following items to ensure meeting emission standards:

(1) Please use lead-free gasoline #93 or #97.
(2) Please use fuel with stipulated specification.
(3) Please comply with periodic maintenance requirements.
(4) For the exhaust control system, it is forbidden to make any adjustment or replacement at random
(including use of spark plug, adjustment of idle speed, ignition timing, throttle adjustment, etc.)
(5) Notes:
 Since any problem in the ignition system, the charging system or the fuel system has significant
effect on the muffler device, please go to our designated distributor or service center for inspection,
adjustment or repair immediately when there is any problem found in the engine.
 Please use lead-free gasoline #93 or #97. Otherwise, the muffler device (four-stroke system) will be
affected.
(6) The exhaust control system of this motorcycle is in accordance with the national regulation. For
replacement of any component, please use our original parts and have our designated distributor or
service center carry out such replacement.
15.3 Mechanical Function of the Exhaust Control System
General
This system adopts four-stroke single-cylinder engine, EFI and air conduction device to maintain
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qualified exhaust gas. Meanwhile, active carbon canister is used for exhaust gas evaporated from fuel.
※ Engine improvement
As the spark plug, spherical combustion chamber, compression ratio, ignition time, exhaust system and
other engine components are improved, as well as the intake/exhaust efficiency is enhanced, the combustion
efficiency is raised.
15.4 Catalytic Transfer System
15.4.1 Structure:
触媒：Catalytic
15.4.2 Instruction:
(1) Function of transfer catalyst is to transfer completely burnt HC, CO and NOX to harmless gas such as H2O,
CO2、and、N2 for discharge.
(2) Transfer catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used.
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※ Note that lead gasoline may invalidate catalyst.
Notes in maintaining motorcycles (gas discharge tube) with catalytic transfer:

a) For motorcycles with transfer catalyst, when the motor is running or just shut, it shall not be touched
because of high temperature.
b) Motorcycle with transfer catalyst shall not be near flammable material.
c) There is CO inside gas discharge tyre, which is harmful to health. So do not run the motor in closed
space.
d) Motorcycle with transfer catalyst shall not use lead gasoline. (prevention for catalytic poison）.
e) Do not push motorcycle to run motor. If it is necessary, you must stop for temperature of motor and
catalyst to lower down.
f) Do not shut the motor with gear up when running downward.
g) Do not drive motorcycle with bad ignition.
h) Do not remove spark plug and run motor to see whether there is spark in maintain motor ignition system.
If necessary, the time shall be short.
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15.5 Measures When the Idle Speed Emission Value Exceeds the
Standard
Qualified
Periodic inspection (maintenance plan)
Qualified
Measure idle emission (note 1)
Qualified
Adjust Carburetor (note2)
Qualified Qualified for

Remove and clean the
delivery
carburetor
Qualified
Replace the carburetor
Dismantle and repair

engine Qualified
•Valve（leakage）
•Piston（abrasive）
•Combustor（cleaning）
Notes:
1. Measure it with the idle speed measurement program.
2. Adjust the engine speed with stop screws to live up to requirements and measure CO/HC at the idle speed.
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Inspection and Maintenance of Electronic Fuel
Injection (EFI) System
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16. Electronic Fuel Injection System
Electronic Fuel Injection System ---------------------------------------16.1
Components of Electronic Fuel Injection System---------------------16.2
Failure Diagnosis ----------------------------------------------------------16.3
Common Troubleshooting Methods-------------------------------------16.4
16.1 Introduction of Electronic Fuel Injection System
RK6 adopts the small-scale engine electronic fuel injection system manufactured by Delphi Company, which
is controlled with four oxygen sensors within a closed loop. Besides, it is equipped with four-cylinder
independent fuel injection and ignition control functions. The three-way catalytic converter would go through
treatment with the gas after combustion in the engine, turn it into harmless gas and discharge it into the air.
This system adopts the closed-loop independent function that can efficiently eliminate the manufacturing
differences within the system and the other corresponding components, highly improving the integrity of the
motorcycle, which can also reduce the deviations of the motorcycle after a some time of actual using.
16.2 Components of Electronic Fuel Injection System
16.2.1 Engine Controller (MT05.2 ECU)
The engine controller can test the operation conditions of the engine with various sensors at any time and
guarantee the emission and economy of fuel by proper computing and self-study control output mechanism
with the driving performance optimized. Once failures are found within the engine, the control would go
through automatic diagnosis. The normal working of the system requires two ECU.
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16.2.1.1 ECU Appearance
ECU 12 is located on the left of battery and ECU 34 is behind the battery.
16.2.1.2 Definition of ECU Connector Pin
1) ECU 12：
J1-1 J2-1 Pin for activating 1-cylinder ignition coil
J1-2 Headlight control pin J2-2 Pin for system grounding
J1-3 Pin for trouble light J2-3 Pin for K line communication
Pin for heating 2-cylinder oxygen

J1-4 J2-4 Pin for crank signal high potential
sensor
Pin for signal 2-cylinder oxygen Pin for activating 1-cylinder fuel injector
J1-5 J2-5
sensor
J1-6 Connector pin for tachometer J2-6 Pin for activating 2-cylinder fuel injector
J1-7 CAN line low signal 1 pin J2-7 Pin for heating 1-cylinder oxygen sensor
J1-8 CAN line high signal 1 pin J2-8 Pin for intake temperature sensor signal
J1-9 Pin for system grounding J2-9
Pin for activating 2-cylinder ignition Pin for 5V system reference voltage grounding
J1-10 J2-10
coil
J1-11 J2-11 Pin for intake pressure sensor signal
J1-12 J2-12 Pin for throttle position sensor signal
J1-13 J2-13 Pin for crank signal low potential
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J1-14 Dump switch (efficient at low) J2-14 Signal pin for water temperature sensor
J1-15 J2-15 Ignition power (12V positive voltage after key)
J1-16 J2-16
J1-17 J2-17 Pin for signal 1-cylinder oxygen sensor
J1-18 Pin for neutral gear switch J2-18 Battery power supply (battery 12V positive voltage)
Remarks:
J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey
connector.
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2) ECU34：
J1-1 Idle speed stepper motor high A pin J2-1 Pin for activating 4-cylinder ignition coil
J1-2 Canister solenoid valve pin J2-2 Pin for system grounding
J1-3 Pin for trouble light J2-3 Pin for K line communication
Pin for heating 3-cylinder oxygen

J1-4 J2-4 Pin for crank signal high potential
sensor
Pin for signal 3-cylinder oxygen Pin for activating 4-cylinder fuel injector
J1-5 J2-5
sensor
J1-6 J2-6 Pin for activating 3-cylinder fuel injector
J1-7 CAN line low signal 2 pin J2-7 Pin for heating 4- cylinder oxygen sensor
J1-8 CAN line high signal 2 pin J2-8 Pin for intake temperature sensor signal
J1-9 Pin for system grounding J2-9 Pin for oil pump control signal
Pin for activating 3-cylinder ignition
J1-10 J2-10 Pin for 5V system reference voltage grounding
coil
J1-11 Idle speed stepper motor low A pin J2-11 Pin for intake pressure sensor signal
J1-12 Idle speed stepper motor high B pin J2-12 Pin for throttle position sensor signal
J1-13 Idle speed stepper motor low B pin J2-13 Pin for crank signal low potential
J1-14 Dump switch (efficient at low) J2-14 Signal pin for water temperature sensor
J1-15 Pin for vehicle speed sensor J2-15 Ignition power (12V positive voltage after key)
J1-16 J2-16 5V reference voltage
J1-17 J2-17 Pin for signal 4-cylinder oxygen sensor
J1-18 Pin for neutral gear switch J2-18 Battery power supply (battery 12V positive voltage)
Remarks:
J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey
connector.
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16.2.1.3 Circuit Diagram of Electronic Injection System
Notes:
a) Keep ECU away from places of high temperature, like muffler or engine;
a) Keep ECU away from water, engine oil or any places of liquid;
b) Keep ECU away from mud or other dirt that would affect the heat dissipation function of ECU;
c) Connect with M8 bolts and make sure the tightening torque is around 3.9Nm, keep the surface neat to
prevent outside force to ECU in case of circuit board bending;
d) The DC power supply voltage of ECU of normal working is between 9V and 16V. when it's working
under a voltage not over 26V for one minute, permanent damage would not happen to ECU, neither when the
backward voltage is not over 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 magnet coil surrounding iron core inside. Two electrodes from magnet
coil are input control connectors of the fuel injector. When magnet coil is energizing, electromagnetic
attraction generated by magnet coil will conquer spring force and fuel oil pressure of ball valve to uplift the
ball valve. Then high pressured fuel oil (250Kpa) in fuel pipes can inject cone-shaped fuel oil to the air inlet
through value seat hole and orifice plate. After power of the fuel injector, magnetic force of the magnet coil
will automatically disappear. The ball valve closes by the action of return spring and fuel injection stops.
16.2.2.2 Appearance:
注意事项：
 Fuel injector is designed with a filter which is not a repairable component because it is designed for only
filtering impurities between fuel filter to fuel injector. The impurities may cause failures such as injector
bonding, flow deviation and leakage. Thus, fuel filter system is very important.
 Replace the fuel injector with parts of the same models.
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16.2.3 Throttle Body
16.2.3.1 Working Principle:
The throttle body assembly is comprised of the main casting valve body, return spring, throttle position
sensor system and idle adjusting screws.
Throttle position sensor system offers accelerograph opening for ECU; idle adjusting screws controls and
idle speed and the stability by clockwise reducing the ventilation to lower the idle speed and anticlockwise
increasing the ventilation to higher the idle speed, which is normally required around 2 circles.
16.2.3.2 Appearance:
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16.2.3.3 Cleaning
Clean the throttle body assembly with carburetor cleanser by spraying it on the inner wall of the throttle
body and brush the dusts and carbons away gently.
Notice:
Make sure the side channel is not blocked by the dirty.
16.2.4 Engine Cylinder Head Temperature Sensor
16.2.4.1 Working Principle:
This sensor is used on the air cooled engine for measuring the engine cylinder head temperature. Within
the temperature scope of the sensor, the electric resistance would vary with different temperature of the engine,
which is a negative temperature coefficient resister. It is a not a repairable part.
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16.2.4.2 Appearance
16.2.5 Intake Air Temperature Sensor
16.2.5.1 Working Principle
It is used for measuring the temperature of the intake air. Within the temperature scope of the sensor, the
electric resistance would vary with different temperatures of the engine, which is a negative temperature
coefficient resister. The intake air temperature sensor is not a repairable part.
16.2.5.2 Appearance
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16.2.6 Intake Pressure Sensor
This sensor is mainly used for measuring the absolute pressure of the intake bend tube, which, in
compliance with the change between the resistance value and the intake pressure, can measure the air input of
the engine's combustion chamber indirectly.
16.2.6.1 Appearance
16.2.7 Oxygen Sensor
Oxygen sensor is mainly used for measuring the oxygen content within the exhaust pipe of combustion
engine and for the fuel closed loop controlling in the engines, which can make sure the combustion of the
engine is maintained at a reasonable air-gasoline ratio (14.7).
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16.2.7.2 Appearance
16.2.8 Ignition Coil
The ignition coil can provide energy to the spark plug. The high voltage wire is used to connect the
ignition coil and the spark plug.
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16.2.8.1 Appearance
16.2.9 Idle Speed Stepper Engine
The idle speed control valve is used to control the ventilation circulation area aside the throttle body so as
to adjust the intake air to the engine, realizing controlling of the idle speed of the engine.
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16.2.9.1 Appearance
16.2.10 Fuel Pump Assembly
The electric pump would work together with the pressure regulator to provide 250Kpa fuel pressure for
the engine. It is installed under the gasoline tank.
16.2.10.2 Appearance
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Back side:
Front side:
16.2.10.3 Failure Diagnosis of Fuel Pump Assembly
a) Turn on the key and run the fuel pump for about 3 seconds. If the fuel pump starts to run, refer to
step d).
b) Cut off the connector of the fuel pump and check whether the power supply voltage is 12V or so.
c) If there is nothing wrong with the second step, supply 12V DC to the fuel pump with an external
storage battery. Check whether the fuel pump runs or not.
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d) If the fuel pump runs normally, check the oil pressure gauge to see whether the front supply pressure
of the nozzle is about 250Kpa when the engine is idling.
e) If the pipe pressure is lower than 220Kpa, check if there is a leakage in the oil pipe, if the fuel pump
runs backwards, or if the filter is blocked.
16.2.10.4 Common Problems
a) The reverse connection of the connector of the fuel pump assembly causes the fuel pump run
backwards, thus leading to inadequate fuel pressure for the engine. As a result, the engine
cannot work normally.
b) The fuel pump is damaged and cannot run.
Note:
1. Since a new motorcycle has no gasoline in its fuel tank at the very beginning, much air remains in the
fuel line after the tank is fueled up. Therefore, it is necessary to turn the motor over for several times to
discharge all the air in the fuel line so that the engine can operate normally. This is a normal process,
which will avoid the engine from taking a long time to start but still in failure in the later startup.
2. The gasoline can cool down the fuel pump, so do no run the pump with little or no fuel, or the fuel
pump will be overheated and damaged.
16.3 Methods for Fault Diagnosis and Maintenance
The trouble light is on the instrument panel, with a sign of FI down blew. In a normal circumstance, when
turning on the key, the trouble light will turn on to indicate the electronic control injection system is power-on
and is ready to work. If the trouble light is off, it indicates that there is no power supply in the electronic
control injection circuit and thus it cannot work. In this case, check the fuse and the connection of both
positive and negative electrodes of the storage battery. After the engine has been started, if the trouble light
turns off, it indicates that there is no fault; otherwise, if the trouble light is still on, it indicates that the
electronic control injection system is abnormal and it is necessary to remove the faults.
There are three methods for fault detection:
16.3.1 Direct Diagnosis through the Flickering Trouble Light (FI) on

the Instrument Panel
When any fault is confirmed, by switching the key for three times, i.e., turning the key on-off-on-off-on,
the trouble light will flash in corresponding fault code. Then check the fault code list for the breakdown in
correspondence.
In case of reading faults with the trouble light, the rules of flash codes are illustrated as below. Take the
open circuit of intake pressure sensor or short circuit of signal end pin to the negative electrode of the battery
as an example, after the key has been switched for three times, the trouble light will flash 10 times standing for
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0, flash once after 1.2 seconds standing for 1, flash 10 times after another 1.2 seconds standing for 0 and flash
7 times after another 1.2 seconds standing for 7, that is P0107. It shows that, except the number 0 is
represented by flashing for 10 times, other numbers from 1 to 9 will flash as the number itself shows. If there
are other fault codes, such as fault P0201, a fault in the fuel injector of front cylinder, the light of fault code
P0201 will flash in 3.2 seconds after the flashing of P0107. The trouble lights of P0107 and P0201 will flash
circularly in case of no other fault. Then faults can be checked according to the fault code list.
Decimal number will be adopted to show the fault code in PCHUD software. The decimal number in the fault
code list is corresponded to the previous hexadecimal, thus faults can be found out in correspondence. If
MULFCURR (current fault) =263, the corresponding fault code in the fault code list is P0107, i.e., a fault of
intake pressure sensor.
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MT05 Fault Code List
Corresponding
Fault code Description decimal number
open circuit of intake pressure sensor or short circuit of signal end
P0107 pin to the negative electrode of the battery 263
short circuit of signal end pin of the intake pressure sensor to the
P0108 positive electrode of the battery 264
short circuit of signal end pin of the intake temperature sensor to
P0112 the negative electrode of the battery 274
open circuit of intake temperature sensor or short circuit of signal
P0113 end pin to the positive electrode of the battery 275
short circuit of signal end pin of the cylinder end temperature
P0117 sensor to the negative electrode of the battery 279
open circuit of cylinder end temperature sensor or short circuit of
P0118 signal end pin to the positive electrode of the battery 280
open circuit of throttle position sensor or short circuit of signal
P0122 end pin to the negative electrode of the battery 290
short circuit of signal end pin of the throttle position sensor to the
P0123 positive electrode of the battery 291
short circuit of signal end pin of the front cylinder oxygen sensor
P0131 to the negative electrode of the battery 305
short circuit of signal end pin of the front cylinder oxygen sensor
P0132 to the positive electrode of the battery 306
short circuit of heating end pin of the front cylinder oxygen sensor
short circuit of heating end pin of the front cylinder oxygen sensor
P0201 fault of for fuel injector front cylinder 513
fault of for fuel injector rear cylinder (plug-in device of the fuel
P0202 injector is not plugged) 514
open circuit of oil pump or short circuit to the negative electrode
P0230 of the battery 560
P0232 short circuit of oil pump to the positive electrode of the battery 562
P0336 signal interference of crank shaft position sensor 822
P0337 no signal of crank shaft position sensor 823
P0351 fault of ignition coil for front cylinder 849
P0352 fault of ignition coil for rear cylinder 850
P0562 voltage below level of electronic control injection system 1378
P0563 overtension of electronic control injection system 1379
P0560 fault of trouble light (damage of filament or plug-in device) 1616
P1693 short circuit of tachometer line to the negative electrode of the 5779
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battery
short circuit of tachometer line to the positive electrode of the
P1694 battery 5780
short circuit of signal end pin of the rear cylinder oxygen sensor
short circuit of signal end pin of the rear cylinder oxygen sensor
short circuit of heating end pin of the rear cylinder oxygen sensor
short circuit of heating end pin of the rear cylinder oxygen sensor
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16.3.2 Fault Diagnosis by Diagnostic Apparatus
Operation steps：
a) Find the 6-hole diagnostic port on the motorcycle.
b) Connect the connecting line to the port on the diagnostic apparatus.
c) Turn on the key to diagnose the faults.
16.3.3 Fault Diagnosis with the Diagnostic Software PCHUD
PCHUD software is used to inspect and record the operating data of the engine. Before using the software,
connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line. The notebook
computer needs to install the K line driver software before using.
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Instructions of PCHUD Software:
（1）Connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line and turn on
the key.
（2）Click the icon "HUD.EXE" to start PCHUD software
（3）Select "File" on the software interface, click "Open", choose "PCHUD.HAD" and select OK.
（4）Select "Parameter File" within "Setup", click the file MT05COMMON.par, choose "Comm protocol"
within "Setup", then select "Keywork2000" and click OK, meanwhile, choose 17 in Device Code.
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（5）If the real-time communication data fail to display on the soft ware interface when the power is on, check
whether the connection setting of COM port in "Setup". Under the normal circumstance, set COM Port: 4 and
Baud Rate: 10400, instead of DTR High at startup.
Normal communication is ready to make then. Current fault code is displayed in the position of MALFCURR
and historical fault code displayed on MALFHIST.
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Then check the corresponding fault according to the fault code list
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Interpretation of PCHUD Software Parameter
VRPM 发动机转速 engine speed
VTHROT 节气门开度 throttle position
VBARO 大气压力 BARO
VMAP 进气歧管压力 manifold air pressure
VMAPEXP 进气歧管压力估计值 expect manifold air pressure
VIGN 蓄电池电压 ignition key voltage
VCLTS 发动机缸温或者冷却水温 cylinder temperature or coolant temperature
VIAT 进气温度 intake air temperature
STATUSBYTE5 状态标志 5 STATUSBYTE5
VAFCMET 空气流量学习条件满足 airflow correction met
VBAROCMET 大气压力更新条件满足 Baro update met
VCSINSYNSPRK 顺序点火标志 sequential spark enable
SATITRIG tip-in 点火角修正条件满足 tip-in Spark Advance retard trigger
CATLOENB 触媒起燃逻辑使能 catalyst light-off logic enable
IF ENGSTATE=3 发动机正常工作标志位 engine work in run state
NISTBLIDLE 暖机怠速条件满足 stable warm idle
FO2REDY2 2 缸氧传感器加热完成标志位 O2 ready
FCNO 进气效率长效学习单元 block learn memory cell
FBLMCOR1 1 缸长效学习值 cylinder 1 block learn memory
FCLCINT1 闭环学习 I 项 integral of close loop correction
FCLCMUL1 闭环学习修正量 close loop correction
IARDRPM 目标怠速转速 desired idle rpm
IARPMERR 怠速偏差 idle rpm error
FPWVC1 1 缸喷油脉宽 base pulse width of cylinder 1
VO2 氧传感器信号 Oxygen sensor signal
FO2STAT1 1 缸氧传感器浓稀标志位 cylinder 1 oxygen sensor signal rich lean state
FCLREST1 1 缸闭环修正重置标志位 cylinder 1 close loop correction reset
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FOSHTREN 氧传感器加热使能 Oxygen sensor heater enable
FO2REDY1 1 缸氧传感器加热完成标志位 cylinder 1 Oxygen sensor ready
IF IACV MODE=0 怠速步进电机闭环学习使能 idle airflow control valve close loop correction enable
IAMTRLOST 怠速步进电机丢步标志位 IACV lost
IACMVIHB 怠速步进电机禁止移动标志位 IACV move disable
VIGNS 点火状态标志位 ignition state
FVE1 1 缸充气效率 cylinder 1 Volumetric efficiency
VMAPRANG 进气压力读取角度 MAP read angle
AFFNLAFR 目标空燃比 target air fuel ratio
SAESTA 1 缸点火提前角 cylinder 1 Spark Advance
SAIDLDYN 怠速动态点火角 idle dynamic Spark Advance
SPDWELL 充磁时间 dwell time
IAINTEGOFST 怠速步进电机气量学习值 airflow integral of idle air control valve
IACVDSMP 怠速步进电机目标步数 desired position of idled air control valve
FCLCEN1 1 缸闭环修正使能 cylinder 1 close loop correction enable
PPDSEBL 预喷禁止标志位 prime pulse disable
FPENABL 油泵使能标志位 fuel pump enable
FTRNSAES 加速加浓使能 acceleration enrich enter
FTRNSDES 减速减稀使能 deceleration enlean enter
FTRNSAEDCLOAD 加速加浓退出 acceleration enrich exit
FTRNSDEINLOAD 减速减稀退出 deceleration enlean exit
FCLCEN2 2 缸闭环修正使能 cylinder 2 close loop correction enable
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16.4 Common Fault Removal Techniques
16.4.1 Repair Tools
a) Disassembling the parts of the electronic control system- common disassembly tools for auto machinery
parts
b) Circuit of the electronic control system and its electrical signal- digital multimeter (with beep)
c) Diagnosing the faults in the electronic control system and checking the engine's operation
 Fault diagnostic apparatus for electronic control system(recommended)
 Fault diagnosis software(PCHUD) and port wire( if available)
d) Fault code list of the electronic control system( for emergency)
e) Fuel pressure gauge, range: 0 ~ 300kPa
16.4.2 The Operation Data Flow of the Engine Shown on the

Diagnostic Apparatus
Analyze and check the faults in engine through the operation data flow of the engine shown on the
diagnostic apparatus.
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16.4.2.1 Step One
a) Engine wire harness and vacuum line- may influence the system in controlling air flow and oil supply.
b) Assembly of Oxygen sensor- may influence the system in judging the air-fuel ratio.
c) Engine trouble light- influences the system in fault warning.
d) Storage battery voltage- judges whether the battery power is adequate.
e) According to the experience, judge whether the readings of coolant temperature sensor, air intake
temperature sensor, manifold absolute pressure sensor and oxygen sensor are normal.
f) Working range of throttle position sensor- Failure in completely turning on or off the sensor may
influence the power performance of the engine and part of system function.
16.4.2.2 Step Two
Check whether the power supply of ECU is cut off- the communication between the diagnostic apparatus
and the system halts after turning off the key switch.
16.4.2.3 Step Three
a) Coolant temperature and its cycling- indicate whether the thermostat operates normally.
b) Storage battery voltage- shows whether the generator works normally.
Too high: maybe a fault in the generator regulator.
Too low：maybe the inappropriate connection of generator wires or a fault in the generator
c) Manifold air pressure- may indicate whether there is an intake air leak or an air valve clearance
The air valve clearance is too small: the overhigh figure may influence the power performance of the
engine. Meanwhile, because the exhaust valve opens too early, the increased temperature of the exhausted
air will significantly reduce the service lives of oxygen sensor and ternary catalytic converter.
The air valve clearance is too large: may cause the manifold air pressure become low, thus influencing the
system in judging the engine's operation and leading to abnormal idling in the engine's warming-up.
Besides, the clogged exhaust system, e.g., foreign materials in the exhaust passage, or the blocked ternary
catalytic converter caused by the over-consumption of the engine oil, or damaged pieces inside of the
ternary catalytic converter, will lead to an overhigh figure.
d) Cycle number of the oxygen sensor reading- a small cycle number indicates the failure of the oxygen
sensor.
16.4.3 Concise Fault Removal Techniques
Please take the following steps to repair the electronic control injection system. If the fault is removed in
a certain step, the following steps can be suspended. Then check and remove the fault code by diagnostic
apparatus in compliance with the term 14.4.2.
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When using the diagnostic apparatus, the storage battery voltage cannot be lower than 8.5V.
16.4.3.1 Daily Use and Maintenance
 Unleaded gasoline #92 or #95 is strongly recommended.

 Though ECU is damp-proof, it is forbidden to wash its cover with a high-pressure water gun.
 The fuel filter should be replaced every 7,000-10,000km
 In common circumstances, the throttle valve should be washed every 10,000km or every 1 year.
16.4.3.2 Fault Description- Startup Failure
a) Turn the ignition lock to "ON" to check whether the trouble light turns on.
If no：  Check the fuse and the ground wire.
 Check whether ECU's plug is tightly connected.
 Check whether the light and circuit are normal through the inspection function of the
diagnostic apparatus's actuator.
 Check and repair the light and its circuit.
 Make the judgment with another ECU.
If yes：  Connect the diagnostic apparatus to the system's diagnostic port.
b) Whether the diagnostic apparatus can be connected to the system for communication
If no:  Check the fuse and the ground wire
 Check whether ECU's plug is tightly connected
 Check whether the diagnostic apparatus works normally on another normal motorcycle.
If yes:  Remove the fault shown by the diagnostic apparatus.
c) Check the faults in the ignition system- whether the spark plug can ignite normally
If no:  Check whether the high-tension cable and spark plug are connected tightly or are damaged.
 Make the judgment with another ignition coil assembly
If yes:  Check whether the high-tension cable is connected with the ignition coil and spark plug in a
correct way
d) Check the faults in the oil supply system
Whether the fuel pump is working- the working noise of the fuel pump can be heard in its nearby when
starting the engine.
If no:  Check whether the fuel pump relay works normally.
 Check whether the connection of crankshaft position sensor and its operation are normal.
 Check the fuel pump circuit
If yes: 1) Whether the supplied oil pressure is above 220Kpa
2) Inadequate  Check whether there is enough gasoline in the fuel tank
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pressure：  Check whether it is necessary to replace the fuel filter (note: the special
fuel filter for the electronic control injector should be replaced every
7,000-10,000km)
 Whether the oil supply line and oil return line are damaged
3) Normal  Check whether the nozzle control line is abnormal
pressure：  Whether it is necessary to clean the oil nozzle
e) Check whether the cylinder is flooded with oil
If yes：  Press the accelerator pedal to the limit and turn on the starter. After several seconds, there
will be a sign showing the engine running.
f) Whether the clearance of crankshaft position sensor is too large
16.4.3.3 Fault Description- Startup Failure Accompanied with Backfire
a) Check whether the high-tension cable of ignition coil is loose

b) Whether the timing gear is loose.
16.4.3.4 Fault Description- Unstable Idle Speed
Idle speed control Check whether the idle speed by-pass bolt is too loose or tight. Usually it is necessary to
system: screw 2 turns.
Oil supply system Whether there is an oil pipeline leak
16.4.3.5 Fault Description- Too High/Low Idle Speed (Apparent
Non-conformity to Target Idle Speed)
Idle speed  When the water temperature is lower than 68℃, the system will increase the idle speed to
is too high: accelerate the warming up. Besides this normal process, check according to the following
steps.
 Check whether the idle air bypass hole is too large.
 Check whether the air valve clearance, especially the exhaust valve clearance, is too
large.
Idle speed  Check the oil amount in the fuel tank, the fuel filter, the oil line pressure and the oil
is too low: nozzle.
 Check whether the idle air bypass hole is too tiny.
 Check whether the air valve clearance is too small.
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16.4.3.6 Fault Description- Unstable Idle Speed Slowing Down with Flameout
a) Check the valve clearance

b) Check whether the idle air bypass hole and throttle body are too dirty
16.4.3.7 Fault Description-Poor Acceleration
a) Whether the parameters at idle speed and high idle speed are normal
b) Check the oil amount in the fuel tank, and fuel filter.
c) Check whether the exhaust system is blocked, e.g., whether the ternary catalytic converter is clogged
because of burning engine oil or damages.
d) Check the oil line pressure and the oil nozzle.
e) Check whether the trouble light turns on and whether it is because only one cylinder can work normally
to ignite.
16.4.3.8 Fault Description- Little Misfire
Check whether the spark plug gap meets the standard between 0.7-1mm.
16.4.3.9 Fault Description- Non-conformity between Fault Code and Fault
When Trouble Light is On
The ground wire of the system may be not connected well. Reconnect the ground wire, turn off the
storage battery power line for 3 minutes and turn it on, then start the engine.
16.4.3.10 Fault Description- Abnormally High Oil Consumption
a) Check the assembly of the oxygen sensor of two cylinders. If it is in a loose state, the oxygen sensor will
make a wrong judgment of the slight lean burn in the cylinders, and thus add more fuel, leading to
abnormally high oil consumption.
b) When the engine's mechanical parts and the oxygen sensor are confirmed to be normal, start the engine to
check the reading of the oxygen sensor. If the reading is always above 500 mV in a normal water
temperature, check whether there is a leakage in the oil nozzle.
Note
 Most parts of electronic control injection system are non-repairable. Once a part is damaged, usually it
needs to be replaced.
 When starting the engine, do not run any other organs of the engine (including the throttle, do not push
the throttle in the startup).
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 If the engine trouble light turns on when the engine is operating, it is necessary to check the reason and
remove the fault as early as possible.
 Do not use leaded gasoline for lead will do harm to the oxygen sensor and ternary catalytic converter.
 When there is an abnormal consumption of the engine oil, the fault should be removed as soon as possible,
or some substances in the engine oil will also do harm to the oxygen sensor and ternary catalytic
converter.
 The air valve clearance should not be too small. If the air valve does not tightly shut off in the exhaust
process, the exhaust temperature will be too high so that the service life of ternary catalytic converter will
be reduced.
 When the temperature is lower than 10℃, if the motorcycle and the engine run at a low speed for a long
time, the exhaust pipe may have carbon deposits and appear to be black. This is a normal phenomenon. It
will disappear after the engine operates at a high speed for some time or by adopting appropriate methods
to keep the engine coolant temperature in a specified ran
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Service Manual

KEEWAY Motorcycle Corporation Ltd.

This maintenance manual is used for operating and maintaining Motorcycle

Preparing Documents include all necessary instructions and statements.

Please carefully read this manual before operation.

inspection of Electronic Fuel Injection System, engine, entire motorcycle and

Breakdown drawing, systematic drawing, failure analysis and statements are

contained at the first part of each chapter.

notification for any discrepancy.

Qianjiang Motorcycle Corporation Ltd.

Engine must be started up in a well-ventilated place, not in a closed area.

Solvent or oil can easily damage aging rubber articles. Check

When loosening assembly parts, please start form outside to

Please specially note important connections before disassembly.

When installing a rubber hose (fuel, vacuum or cooling agent),

槽：groove 夹子：clip 接头：connector

During dismantling ball bearings, one or two (inside & outside)

以上两例都会使轴承破裂：Bearings will be broken under either

1．The frame number, see figure

Frame Number Rivets

3．The serial number of the engine, see figure

Fig. 1-3 Fig. 1-4

Fig. 1-7 Fig. 1-8

Fig. 1-9 Fig. 1-10

Fig. 1-11 Fig. 1-12 ①pliers ②piston

Fig. 1-15 Fig. 1-16

Fig. 1-17 Fig. 1-18

Fig. 1-19 Fig. 1-20

Fig. 1-21 Fig. 1-22

Fig. 1-27 Fig. 1-28

Fig. 1-29 Fig. 1-30

Fig. 1-33 Fig. 1-34

Fig. 1-35 Fig. 1-36

Motorcycle Model RK6 Engine Type BJ465MS-A

Length mm 2120 Fuel type Unleaded petrol（93/97）

Width mm 800 No. of 4

Front 120/70 Variable

Diagnosis on difficulty or failure in starting up

Abnormal piston of cylinder and

Abnormal automatic choke

Incorrect ignition time

Disassemble once again the Abnormal adjustment to throttle

Excessive oil injected to fuel

Abnormal piston of cylinder and

Blocking check to Carburetor

No Yes Contaminant removal

Disassemble the spark plug to

Adjust ignition time

Abnormal CPU group

Adjustment to throttle valve and

Mixed gas too thin (loosen bolt)

Abnormal spacer of heat

Disassemble spark plug

Negative pressure pipe damaged

Abnormal CUP group

Little oil in petrol tank

Good Spring broken

No voltage rise Voltage rises to normal

Check the plug of voltage

Poor connection of the plug

Check if the red wire of voltage regulator’s

Test the resistance value of

Voltage above Normal voltage