Service Manual - ZNEN - CRUZER 50 EU4 - GER - Vers 05 2018

Service and Maintenance
Motorcycle CRUZER50 Maintenance Manual
1
`
Precautions ......................................................................... 5
Operating Instructions ................................................................. 6
1-1 Motorcycle Vehicle Identification Number (VIN) and Engine Number ................ 7
1-2 Brief Introduction to the Whole Motorcycle ...................................... 8
1-3 Brief Introduction to the Whole Motorcycle ...................................... 9
1-4 Brief Introduction to the Whole Motorcycle ..................................... 10
1-5 Instrument combination ......................................................... 11
1-6 Left combination switch ....................................................... 12
1-7 Right combination switch ..................................................... 13
1-8 Ignition lock switch ........................................................... 14
1-9 Fuel tank ...................................................................... 15
1-10 Operation of Left Combination Switch .......................................... 16
1-11 Operation of Right Combination Switch ......................................... 16
1-12 Operation of Electric Startup/Operation of foot-stepped startups .............. 17
1-13 SIDE STAND FLAMEOUT SWITCH .................................................... 18
1-14 USB ........................................................................... 18
1-15 Installation of storage battery ............................................... 19
1-16 STARTING OFF/ACCELERATION / DECELERATION/BRAKING .............................. 20
Periodic Maintenance .................................................................. 21
2-1 Specification .................................................................. 22
2-2 Periodic Maintenance & Inspection List ......................................... 24
2-3 Part Function Description and Maintenance of
2-4 Check and Replacement of Lubricating Oil ....................................... 37
2-5 Gear oil ....................................................................... 38
2-6 Service and Maintenance of the Spark Plug ...................................... 39
2-7 Service and Maintenance for the Air Filter ..................................... 40
2
`
2-8 Electronic carburetor .......................................................... 41

2-9 Brake system ................................................................... 46
2-10 Brake panel free play (rear brake) ............................................ 49
2-11 Throttle cable free play ...................................................... 50
2-12 Fuel hose ..................................................................... 51
2-13 Fuel filter .................................................................. 51
2-14 Muffler mounting Bolts & nuts ................................................ 52
2-15 Steering ...................................................................... 52
2-16 Front fork .................................................................... 53
2-17 Rear shock absorber ........................................................... 53
2-18 Tire .......................................................................... 54
2-19 Tappet clearance .............................................................. 57
2-20 Drive belt .................................................................... 59
2-21 Cylinder pressure ............................................................. 60
2-22 Clutch ........................................................................ 61
2-23 Battery ....................................................................... 61
2-24 Bolts and nuts on frame body .................................................. 63
ENGINE ................................................................................ 66
3-1 Engine removal ................................................................. 67
3-2 Engine Reinstallation .......................................................... 68
3-3 Cylinder &cylinder head Disassembly ............................................ 69
3-4 Inspection of Cylinder & Cylinder Head ......................................... 70
3-5 Reassembly of Cylinder & Cylinder head ......................................... 81
3-6 Crankcase Disassembly .......................................................... 82
3-8 Crankcase Parts Reinstallation ................................................. 99
FRAME BODY ........................................................................... 108
3
`
4-1 Outer Parts ................................................................... 109

4-2 Disassembly ................................................................... 113
4-3 Front Wheel .................................................................. 116
4-4 Front Brake System ........................................................... 119
4-5 Steering handle ............................................................... 125
4-6 Front fork .................................................................... 126
4-7 Rear Wheel /Brake/Suspension .................................................. 127
4-8 Tire and Rim .................................................................. 130
ELECTRIC SYSTEM ...................................................................... 133
5-1 General ....................................................................... 134
5-2 Main Switch/Horn ............................................................. 135
5-3 Speedometer ASSY .............................................................. 135
5-4 Fuel level gauge & sensor ..................................................... 137
5-5 Switch& Flasher Relay ......................................................... 138
5-6 Battery ....................................................................... 139
5-7 Charging System ............................................................... 140
5-8 Starting System ............................................................... 142
5-9 Starting System ............................................................... 145
Failure Diagnosis .................................................................... 148
DIMENSIONS ........................................................................... 168
Wiring diagram ....................................................................... 171
Specified Torque ..................................................................... 172
Specified Torque ..................................................................... 173
4
`
Precautions
Please read this User’s Manual carefully before operating this production
Warning
* Please observe traffic laws and regulations carefully and drive safely.
* Make sure not to lend this motorcycle to be driven by a person not holding a driver’s license.
* Make sure not to hang anything on the direction handgrip, otherwise the driving safety may be affected.
* Please wear your protective articles such as helmet, dust goggles, gloves for the sake of your safety.
* Make sure not to use this model to participate in any kind of competition. Otherwise, any mechanical breakdown, injury or death arising wherefrom
shall be on your own account.
* The temperature of exhaust silencer is high when the motorcycle is running. Drivers shall be careful not to touch it to burn them.
* Don’t wear loose clothes or slippers when driving it. Otherwise, it may hook the control grip and accessories, and thus cause potential safety hazards.
Caution
* After opening the packaging box, please check the accessories and various documents delivered with the motorcycle according to the packing list.
* The motorcycle accommodates two persons, and the maximum payload is 150kg. The moped accommodates 1 person, and the maximum payload
is 75kg.
* It is not allowed to modify any part of the motorcycle. Otherwise, the reliability, stability and comfortableness of the motorcycle may be affected.
* Only the fuel with a grade specified on the fuel tank or above can be used. Otherwise, the dynamic performance, economy, and safety of the
motorcycle may be damaged, and the service life of the motorcycle will be shortened. If any mechanical breakdown occurs due to this, you shall be solely
responsible for it.
Suggestion
* This Manual is a necessity for the use of the motorcycle. If the motorcycle is transferred to any other person, this Manual should be transferred
together with the motorcycle.
* When it is necessary to adjust the air valve clearance of the motorcycle, please do it in a professional motorcycle maintenance shop or in a
designated after-sales service center.
5
`
1、Operating Instructions
6
`
1-1 Motorcycle Vehicle Identification Number (VIN) and Engine Number

Motorcycle Vehicle Identification Number (VIN), Engine Number and Quality Certificate, used for obtaining the
motorcycle driving license and motorcycle registry
① The motorcycle Vehicle Identification Number (VIN) is ②The product nameplate is ③The Engine Number is printed on the left lower part of
printed on the vertical tube of the frame. riveted on the right lower part of the crankcase.
the frame.
7
`
1-2 Brief Introduction to the Whole Motorcycle

①. Head Light
②. Left front turn light
③. Disc brake
④. SIDE STAND FLAMEOUT SWITCH
⑤. Side support
⑥. Main support
⑦. Starting arm
⑧. Air filter
⑨. SIDE REFLECTOR
⑩. Rear carrier
⑪. Seat cushion
⑫. Front storage box
⑬. Left Pedal
8
`
Brief Introduction to the Whole Motorcycle ①. Front braking handgrip

②. Right front turn light
③. Front wheel
④. Speed Counter
⑤. Disc brake
⑥. Silencer
⑦. Rear wheel
⑧. Helmet hook
⑨. Right Pedal
⑩. Tail light
9
`

①. Rearview mirror
②. Left handgrip
③. Left combination switch
④. Instrument combination
⑤. Ignition lock switch
⑥. Right combination switch
⑦. Accelerator handgrip
1-5 Instrument combination

10
`
①. Left turning indicator lamp: When the turning indicator lamp “ ” flashes, it
indicates that “Turning signal light” is open.
②. Right turning indicator lamp: When the right turning indicator lamp “ ” flashes,
it indicates that the “Right turning signal light” is on.

③. Trouble light.
When you turn on the ignition，the lamp lights up. After starting the engine，it disappears. If
your vehicle detects a failure in the system，the check engine lamp lights up. Contact a dealer to
check with a diagnosis tool.
④. High beam indicator lamp: When the high beam indicator lamp “ ” is on, it
indicates that the “High beam lamp” is on.

⑤. Fuel gauge:
It indicates how much fuel is left in the fuel tank of the motorcycle.
⑥. Odometer: It records the accumulative travel miles of the motorcycle.
⑦. Maintenance prompt：
for this light, when the first 1000km it will turn on, and every 3000km it will turn on. After
maintenance Start the scooter, push the High beam lamp light conversion button three times in 5
seconds. Then the maintenance symbol will be disappearing.
⑧. Speedometer：It indicates the current driving speed of the motorcycle.
1-6 Left combination switch

11
`
① High beam lamp switch:

When the motorcycle needs to use the “High beam lamp”,
turn the lighting switch to the status “ ”.
② low beam lamp switch:
When the motorcycle needs to use the “Low beam lamp”,
turn the lighting switch to the position “ ”.
③ Horn button:
When the motorcycle needs to horn, press the button “ ”.
④ Turning signal light switch:
When the motorcycle needs to change its travelling direction,
switch to “ ” or “ ” to turn left or right. When the
motorcycle needs to stop turning, simply switch the turning
button to the middle.
1-7 Right combination switch
12
`
① Double flash switch:
② Electric start button:

When the motorcycle needs electric start, press the button
“ ”.
③ Engine is on “ ”
Engine is off “ ”
④ Accelerator handgrip:
It is mainly using to control the fuel flow rate of the carburetor.
1-8 Ignition lock switch
13
`
Caution
* When the motorcycle is parked, please turn the Ignition lock switch to “ ” to lock the direction lock, to prevent the motorcycle from
being stolen.
①Ignition Lock Off：When the key turns to the signal ,the scooter was turned off.
②Ignition lock On:When the key turns to the signal ,the scooter was opened up.
③-④shut gear: The lock of this car has anti-lock function. The lockhole was closed when you pushed the 'shut' button. You can
insert the key after you turn the key to④.
⑤Push the key and turn it to ⑤,then you can open the seat.
1-9 Fuel tank

⑥
`
Turn the hadlebar to the laft, push the key and turn it to ⑥ ,you14can lock the handlebar and the scooter is now in burglarproof statio
n.
1-10 Operation of Left Combination Switch
① When the motorcycle runs at night and needs to see clearly a target in the distance, turn the lighting
switch to the position “ ”, and the High beam lamp begins to work.
② When the motorcycle runs at night and meets another vehicle, in order to ensure the safety of both
parties, turn the lighting switch to the position “ ” and the low beam lamp begins to work.
③ When the motorcycle needs to overtake another vehicle or warn pedestrians, push down the Horn
button“ ” to warn them.
④ When the motorcycle needs to turn left, turn the turning light switch to the position “ ”, and the left
turning light begins to work.
When the motorcycle needs to turn right, turn the turning light switch to the position “ ”, and the
right turning light begins to work.
1-11 Operation of Right Combination Switch

① Double flash switch:
② Electric start button:
When the motorcycle needs electric start, press the button “ ”.

③Engine is on“ ”
Engine is off“ ”
1-12 Operation
④ Accelerator handgrip:of Electric Startup/Operation of foot-stepped startup
It is mainly use to control the fuel flow rate of the carburetor.
15
`
Operation of Electric Startup

1、First, insert the key into the ignition switch lock, and turn it to the position
“ ”.
2、Engine is on“ .
3、Hold the front braking handgripOr hold the rear braking, turn on the
electric startup switch and perform electric startup. Push the electric startup
button ② with your right thumb, and meanwhile turn the acceleration
handgrip slightly with your right hand to add an appropriate amount of fuel.
The foot-stepped startup of the motorcycle is done in the following steps：

1、Start the ignition lock to check whether indicator lamps of instruments of the motorcycle work properly . Open ①
Engine is on“ .
2、Hold the front braking handgrip to prevent the slipping of the motorcycle.
3、Step down the starting arm to its limit, and then reset the starting arm in time. The starting arm must be reset in time after
the startup of the motorcycle.
4、Turn the acceleration handgrip slightly with your right hand to add an appropriate amount of fuel to start up the
motorcycle. The motorcycle can be run only after it is pre-heated.
* Note
The duration of each electric startup should not exceed 5s, and each interval between two electric startups should not be shorter than 10s. If 3 startup attempts
fail consecutively, the motorcycle must be checked.
1-13 SIDE STAND FLAMEOUT SWITCH

16
`
In order to safely use the motorcycle, the side braces are fitted
with SIDE STAND FLAMEOUT SWITCH1, which will be
turned off at 2. Please take back the side support to start the
car when it is used again.
1-14 USB
This motorcycle is equipped with USB interface USB output voltage for DC5V can charge your mobile device.
Use the key to open the front box lock 1. After the lock is opened, the USB interface 2 can be seen on the right side
1-15 Installation of storage battery
of the box. The USB can only be used after the car power lock is opened.
17
`
1、Take out the battery and open the battery package. 2、The electrolyte 3 is stuck into the tank of battery 2 to add liquid to the battery.
18
`
3. Insert the sealing cover of the battery jar ① into the battery jar.
4. Put the mounting nuts 4 into the battery terminals, and fix the positive and negative wires with the bolts ④. (Note that the red positive electrode
line is to be installed first, and then the black negative electrode wire is installed ) ..
5. Screw the lid of battery box after installation of positive and negative electrode wire.
19
`
1-16 STARTING OFF/ACCELERATION / DECELERATION/BRAKING
1. While pulling the rear brake lever with your left hand and holding
1.Close the throttle completely.
the carrier with your right hand, push the vehicle off the main stand.
2.Apply both front and rear brakes simultaneously while gradually
2. Sit astride the seat, and then adjust the rear-view mirrors.
increasing the pressure.
3. Switch the turn signal on to the direction you wish to turn.
4. Check for oncoming traffic, and then slowly turn the throttle grip
(on the right) in order to take off. ENGINE BREAK IN
Since the engine is brand new, do not put an excessive load on it for the
first 1000 km. The various parts in the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full throttle operation or any condition that
might result in engine overheating must be avoided.
The speed can be adjusted by opening and closing the throttle. To

increase the speed, turn the throttle grip in direction (a). To reduce 20
` the speed, turn the throttle grip in direction (b).
2、Periodic Maintenance
21
`
2-1 Specification
Model CRUZER 4T Type of engine BN139QMB
Full length mm 1900 Type of fuel lead-free gasoline（92/95）
Number of
Full width mm 690 1
cylinders
Inside
Full height mm 1135 Ø39.0*41.5
diameter*stroke
Wheelbase mm 1330 Total displacement 49.6ml
fro
nt
37 Initiate mode Electric/foot initiate
Engine
axl
e
Rea
Weight of vehicle kg
（Curb weight） r
59 Cooling system Wind cooling
axl
e
Tot
96
al Lubrication type Pressure splash lubrication
Fro
nt
Wheel specification wh 110/70-12
Air cleaner Dry
eel
22
`
Rea
r
wh 120/70-12
eel Fuel tank capacity 7L±0.2
Type of clutch Dry centrifugal type

Driving mechanism
Carburetor model E-Carburetor

Variable speed
Automatic CVT
mechanism
Idling speed 1800±100rpm/min
Driving type belt transmission
Performance
Maximum torque 2.8N.m/6500 rpm
Storage battery
12V-6AH
capacity /Type
Maximum
2.10 KW/ 7500 rpm
horsepower
Electrical installation
Magneto capacity 95W/4000rpm

Compression ratio 10.5：1
Spark plug NGK/ CR7HSA
Maximum speed 45km/h
Spark plug gap 0.6-0.7mm
Front brake disc
φ190mm
apparatus
Diameter（mm）
Brake
Ignition type ECU Rear brake drum

inside diameter φ110mm
（mm）
23
`
2-2 Periodic Maintenance & Inspection List
The inspection intervals are required, these will void the warranty. 1000 km 4000 km or 1. year 7000 km or 2. year 10000 km or 3. year 13000 km or 4. year
COMPONENT PERFORM
Airfilter Clean/ Exchange   Exchange  
Wheels, Rims Control     
Tire Control of tread depth / Pressure    
Wheel bearing Control/ Exchange    
Tax bearing Control/ Clean / Lubricate    Lubricate 
Glands cover Control/ Retighten    
Brake system Control/ Clean / Exchange    
Side stand Control/ Clean / Lubricate    
Telescopic fork Control    
Shock absorber rear Control    
Oil strainer / Spin filter Clean   
Engine oil / Oil filter Exchange / Control Exchange  Exchange  Exchange
Transmission oil Exchange   
Valves Control / Adjust     
Variomatic belt Control/ Exchange  Exchange 
Variomatic rolls Control/ Exchange  Exchange 
Drive chain / Pinion Control / Clean / Exchange     
Clutch Control     
Cables / Bowden Control / Clean / Lubricate     
Throttle Control / Adjust / Lubricate    
Lights / switch Control / Adjust     
24
`
Fuel line / Filter Control / Exchange  Exchange  
Idle speed Control / Adjust     
Exhaust system Control / Retighten    
25
`
2-3 Part Function Description and Maintenance of

Electronic Carburettor System (ECS)
Function and troubleshooting of components of ECS
Electronic carburetor system, by acquisiting of engine speed signal and feedback signal of the oxygen sensor, engine cylinder head temperature signal, battery voltage
signal, through the ECU control strategy, output PWM control signal and the ignition signal, realize real-time solenoid valve for air supply to the main fuel circuit and
carburetor idle fuel circuit, precise control of the air-fuel ratio and digital ignition system. The feedback signal to realize the closed-loop control of the air-fuel ratio of
the oxygen sensor, so that the air fuel ratio back to the theory of state. By controlling the air-fuel ratio and the ignition advance, we can use different control strategies to
reduce emissions and improve driving performance.
In the ECS system, the special parts involved are electronic control unit (ECU), solenoid air supply valve and its air filter, carburetor, TPS, oxygen sensor and cylinder
head temperature sensor. The following is an introduction to each component function and troubleshooting.
ECU
ECU function introduction
ECU is the electronic control unit. Its maximum operating voltage is 18V. The ECU, through a 16-bit chip, conduct the internal control logic of the speed signal, oxygen
sensor signal and the cylinder head temperature sensor signal and the pick-up signal, to realize the control of the ignition coil, solenoid valve, malfunction lamp, etc.
26
`
ECU test procedure
1.To connect the computer installed with ECS diagnostic software to the diagnostic connector on the vehicle through a communication line;
2.Key-on, but do not start the engine. Verify that the ECU and diagnostics software can be connected
3.Diagnostic software will automatically show prompts after connecting successfully;
4.Verify that the version of ECU and the MAP program ID are correct;
5.Verify if there is an error code in the diagnostic software;
6.Check the ECS parts according to the error code to ensure the error code in the diagnosis software is eliminated
7.Start the engine and check the parameter values in the diagnostic software
ECU test determination
1.Diagnostic software can communicate with the vehicle.

2.The ECU version, the MAP program, the ID correct are correct
3.No error codes or error codes can be eliminated by maintenance of parts.
ECU abnormal phenomena and treatment methods
1.cannot online: firstly, check whether the communication line connection is correct, the vehicle battery power supply is normal, and then check
whether the ECU is abnormal, replace the new parts and confirm.
2.unable to start: to confirm if ignition coil ignition is normal, carburetor fuel supply is normal, the relevant parts or ECU is normal, after replacement
of new parts, to confirm again.
27
`
3.the error codes appear: the corresponding parts or the ECU is abnormal, eliminate the errors according to error codes and to confirm again.
Solenoid air supply valve and its air filter
Introduction of function of solenoid air supply valve and its air filter
The solenoid valve is driven through ECU PWM duty cycle signal, providing air supply to different carburetor main and idle circuit through different PWM signal, so as
to realize the stoichiometric air/fuel ratio of 14.7 of the carburetion.
The air filter is connected with the intake end of the solenoid valve to prevent dust in the air from entering the carburetor with the air and causing the blockage of the
carburetor passage.
Solenoid air supply valve and its air filter inspection procedure
1.check the connection between the solenoid valve and the carburetor, whether the solenoid air supply valve and the main wiring connector are in good condition
2.Check the air filter for obstruction
3.Use "multimeter" to test the value of the resistance between the two lines of the solenoid valve
Solenoid valve and its air filter test determination
1.the connecting pipe between the solenoid air valve and the carburettor must be firmly connected, and the solenoid valve is connected with the main wiring
connector in good condition
2.Its air filters cannot clog up
3.The value of the resistance between the two lines of the Solenoid valve is 70 Ω~85Ω
28
`
Abnormal phenomena and treatment methods of solenoid valve and its air filter
1.The connection pipe between the solenoid valve and the carburetor is loosened → connect them again to ensure the connection is firm
2.The connection between the solenoid valve and the main wiring connector is wrong →
Re-connect the solenoid valve connector and the main wiring connector to ensure the good connection
3.Air filter clogging → maintenance or replacement of a new air filter to the blocked air filter, make air flow through it smoothly
4.There is no resistance between the two lines of the solenoid valve or the resistance is greater than 85Ω → replace with a new solenoid valve
5.No idle, idle instability, bad acceleration → to ensure that connection between the solenoid valve and the carburetor is solid, the carburetor itself is not blocked, to
check if the problem can be resolves by replacing with a new solenoid valve.
Carburetor
Introduction to carburetor function
The carburetor is the fuel supply device of ECS. The rotating shaft is provided with a throttle position sensor. In the main fuel circuit and the idle fuel circuit are
respectively added on a channel and the air supply pipe is connected with a solenoid valve. The ECU, through the acquisition of TPS, engine speed, oxygen sensor,
cylinder temperature sensor, drive the solenoid valve with the output of a real-time PWM air signal, thus to realize the real-time correction for the carburetor air quantity,
and to make the carburetor fuel ratio reach the ideal state
Carburetor inspection procedure
According to the routine procedure of carburetor checking, to confirm if the jets of the carburetor is blocked and if the plunger diaphragm is damaged, if the ASD
(Auto start device) is normal, whether there is fuel leakage from float, whether the sealing ring is damaged. Especially to check the following state of an electronic
29
`
controlled carburetor:
1.Whether the main and idle air supply pipes on the carburetor are firmly connected with the solenoid valve.
2.Is the TPS firmly installed on the carburetor?
Carburetor test determination
The main and idle air supply pipes on the carburetor are firmly connected with the solenoid valve.
The TPS is firmly mounted on the carburetor
Abnormal phenomena of carburetor and its treatment
If the relevant component of all electronic carburetor system confirmed no adverse, and other traditional engine components are normal, while the engine performance
still is not smooth, please confirm if the rubber pipe of the solenoid valve and the carburetor is off and if the air filter of the solenoid valve is blocked.
If there is above phenomenon, please re-connect the rubber pipe between the carburetor and solenoid valve, or replace with a new solenoid valve and its air filter
TPS
TPS function introduction
The throttle position sensor (TPS) is mainly made up of a variable resistance chip. It is installed on the throttle shaft of the carburetor, when the throttle shaft rotates, it
generates different resistance, and then output the linear variation voltage signal to provide ECU with real-time judgment of the throttle position (opening), and the ECU
will calculate the appropriate amount of air supply and ignition timing control according to the signals. The TPS consists of 3 pins, 1 for 5V power supply, 1 for voltage
30
`
output pin, and 1 for GND pin
TPS Inspection procedure
1.The sensor joint is connected (using a probe tool), or it can be removed to measure the working voltage (direct measurement).
2.Turn on the main switch, but do not start the engine
3.Use the "multi meter" dc gear (DCV) to check the voltage value of the sensor
4.working voltage confirmation
The negative pole - of the meter is connected to the “ground” line
The positive pole + of meter is connected to the "input" line
5.throttle output signal confirmation (using probe tool)
The negative pole - of the meter is connected to the “ground” line
The positive pole + of meter is connected to the "output" line
Measure the output voltage of the positions of throttle fully closed and throttle fully open respectively
TPS test determination
● Operating voltage value：5.0±0.1V

● Fully closed throttle output voltage value：0.2~1.0 V
● Fully open throttle output voltage：3.2~4.8V
31
`
TPS abnormal phenomena and treatment methods
● The working voltage of TPS is not in the correct range, or the output voltage when throttle fully open or fully closed is not in the correct range → to check the main
wiring or replacement of TPS. In the process of installation, ensure that the TPS voltage at fully closed throttle is 0.6~0.8V, after installation, measure again the
working voltage and TPS output voltage at fully closed and fully open throttle.
Oxygen sensor
Oxygen sensor function introduction
The oxygen sensor is to measure the concentration of oxygen (O2) in the exhaust gas from the cylinder, and to return the signal back to the ECU to change the air supply
of the solenoid valve, and to adjust the air fuel mixture ratio of the carburetor. If the oxygen content is too low that the mixture too thick, it will increase the
concentration of HC and CO in the exhaust gas; if the oxygen content is too high that the mixture too thin, it will increase combustion temperature and increase the
concentration of the exhaust gas NOx. The feedback signal of the oxygen sensor enables the ECU to conduct a closed loop control of the air fuel ration at 14.5~14.7 to
control the CO/HC/Nox in the exhaust gas with highest conversion efficiency and ultimately reduces the exhaust emissions.
Oxygen sensor inspection procedure
1. Start vehicle
2.Keep the throttle fully open for more than 3 minutes
3.Observe if the malfunction light is flashing
32
`
Detection and determination of oxygen sensor
If the frequency of the malfunction lamp is 4 times flashing, it is judged to be a malfunction
Abnormal phenomena of oxygen sensors and treatment methods
The connection is bad → Check whether the main wiring and connector is abnormal or not
The oxygen sensor is damaged → It is recommended to replace with a new oxygen sensor and measured again
Cylinder head temperature sensor
Introduction of cylinder head temperature sensor function
The cylinder head temperature sensor is composed of a thermistor with a negative temperature coefficient (temperature rising and resistance decreasing). The utility
model has 2pin, 1 voltage output pin, and 1 grounding pin. The cylinder head temperature sensor device on the cylinder head, the resistance changes with the
temperature sensed, and converted into a voltage signal which is sent to the ECU to calculate the cylinder head temperature in real time, the ECU according to the
real-time temperature value conduct the correction of the solenoid valve air supply and ignition angle correction.
Test procedure for cylinder head temperature sensor
Remove the connector of the cylinder head temperature sensor.
33
`
Use "multi meter" om gear, check the resistance between the sensor two pins
Cylinder head temperature sensor inspection and determination
The relationship between the resistance and temperature is as follows
Temperature Resistance Value

-20 955± 48.5
20 124.8 ± 6.375
40 53.4±2.745
80 12.5 ± 0.65
Abnormal phenomena and processing methods of cylinder head temperature sensor
● The connection is bad → Check whether the main wiring line is abnormal or not.
●The sensor is damaged → Change the temperature sensor and replace the new temperature sensor
Malfunction diagnosis method description
When an error signal has occurred in the vehicle ECS, it may cause the engine to operate abnormally or un able to start, the
malfunction light on the instrument panel is lit, informing the driver of the need for maintenance testing.
When troubleshooting, you can diagnose errors by using the PC-based diagnostic software on the computer, or the malfunction lamp on the instrument panel shows the
34
`
fault codes for maintenance.

If the trouble has been removed or repaired, the malfunction light will go out
Error codes and parts fault check list
Code Part name MIL LED Description Note

170 1 blink TPS 0.2V This part is not exited in
TPS TPS signal lower than 0,2V some application
171 TPS 4.8V
TPS signal higher than 4,8V
120 Solenoid valve 2 blinks Air valve in short circuit
121 Air valve in open circuit
104 Engine temperature sensor 3 blinks Engine temperature sensor in short circuit
105 Engine temperature sensor in open circuit
190 Lambda sensor 4 blinks Lambda sensor short circuit
192 Lambda sensor fault
130 ASD 5 blinks Starter in short circuit This part is not
131 Starter in open circuit exited/controlled in some
application
138 Speed sensor 6 blinks Speed sensor in short circuit This part is not exited in
139 Speed sensor in open circuit some application
35
`
electric control diagram
36
`
2-4 Check and Replacement of Lubricating Oil

2-4.1 Check of Lubricating Oil
Inspection steps:
1、First, twist off the oil gauge①and check whether the lubricating oil becomes black
or deteriorated. If the lubricating oil becomes black or deteriorated Please replace it.
2、The motorcycle should be parked on a flat ground when checking its oil
level.minutes after the engine running, stop for aboutminutes and then check the oil
leve.If the oil position is below the horizontal level, please add oil in time.
2-4.2 Oil replacement Explain

* It will be easier to change the oil when the engine is warming up.Turn off the engine.Remove the bolt at the
bottom①of the crankcase and release oil.When the oil leaks completely, you can install the bolt and packing washer
after they are cleaned. Add oil to proper level.
* When the lubricating oil is basically drained off, turn the engine for several times to completely discharge residual
lubricating oil.
* The specification and grade of lubricating oil may be selected from the figure below based on actual local
temperature. SG 10W40 gasoline engine oil is recommended.
* Check whether the filter screen④, , spring③, O-ring②and oil drain plug①are in good conditions. If not, replace
them.
* After replacing the lubricating oil, tighten the oil drain plug ①and oil fill plug⑤, and check whether there is any oil
leakage.
* After replacing the lubricating oil, the idle speed of the engine must be re-adjusted to be within the range of standard
values.
* the engine oil added to this motorcycle is 750 mL and 800mL.
* Drain plug tighten torque： 12N.m.
37
`
2-5 Gear oil
Remove oil level bolt②for checking.Refill oil till overflowing.

Drain gear oil out throttle drain plug③and refill whith fresh one.
Grade: SGL-4 85W-90 110mL~120mL
Drain plug tighten torque： 12N.m
* Note:
Confirm whether the bolts wear or not.
Supplement gear oil,
Check if there is leaking oil
Install gear oil to check bolt
38
`
2-6 Service and Maintenance of the Spark Plug

Remove helmet seat, front connection boards on right and left protection boards, take out the spark plug cap and then the spark plug.
Check the burning, pollution and carbon deposition situation of the spark plug.
If there is the situation above, please clean with the spark plug scavenger or steel brush
Check the electrode gap of the

spark plug with a plug gauge, and Carefully screw spark plug into its
adjust the gap to 0.6mm -0.7mm.
hole by hand to avoid damaging
the thread on cylinder head, then
tighten it to specified torque by
First, soak it with spark plug detergent wrench.
or gasoline for about half an hour and
then use a non-metal blade to remove
the carbon deposit surrounding the
spark plug, and finally clean the spark
plug with gasoline.
Caution
In cleaning the spark plug, make sure not to damage the insulator. It is forbidden to remove the carbon deposit or filth by burning with fire or scrubbing with metal wires.
Specified torque: 11N·m
39
`
2-7 Service and Maintenance for the Air Filter
When the filter element of the air filter is blocked by dust, it may result in increased resistance of the air intake system, over rich gas mixture, reduced power and greater
fuel consumption. Therefore, the filter element of the air filter should be cleaned on a regular basis.
Clean the foam filter element: Take off the foam filter element. First, soak
Take off the fastening screws of the air filter cover, and remove the air
the foam filter element of the air filter in the detergent, and then pinch and
filter cover. Check whether there is too much dust on the sponge foam of
wash it. After the foam filter element is cleaned and dried, soak the foam
the filter element. Take off the sponge foam.
filter element in SAE lubricating oil until it is saturated. Extrude excessive
Wipe off the dust inside the air filter with clean and dry cloth.
lubricating oil and mount it.
Caution
It is forbidden to use the following cleaning agents to clean paper filter elements, such as gasoline, low ignition-point solvent, acid, alkaline or organic volatile oil.
40
`
2-8 Electronic carburetor
Electronic carburetor system, by acquisiting of engine speed signal and feedback signal of the
oxygen sensor, engine cylinder head temperature signal, battery voltage signal, through the
ECU control strategy, output PWM control signal and the ignition signal, realize real-time
solenoid valve for air supply to the main fuel circuit and carburetor idle fuel circuit, precise
control of the air-fuel ratio and digital ignition system. The feedback signal to realize the
closed-loop control of the air-fuel ratio of the oxygen sensor, so that the air fuel ratio back to
the theory of state. By controlling the air-fuel ratio and the ignition advance, we can use
different control strategies to reduce emissions and improve driving performance.
41
`
2-8.1 Construct
Number Parts name Number Parts name

① Vacuum pipe ⑧ Starter valve
② TPS ⑨ Accelerate rocker
air adjusting screw
③ ⑩ Idle adjusting screw
④ drain oil pipe ⑪ Replenish air joint

⑤ Drain oil screw
⑥ Oil pipe joint
⑦ Replenish air joint
42
`
2-8.2 Disassembly
Disconnect the drain pipe① Remove SE starter valve cover, screws, and Remove O-ring④from SE starter valve, check
SE starter valve②andTPS③. the valve⑤and jet⑥for damage and step wear.
TPS 故障排除见 Electronic Hold the top cap⑦ of vacuum chamber and Remove vacuum chamber cap⑦, spring⑧
Carburettor System remove screws. and diaphragm/vacuum piston⑨.
43
`
2-8.3 Disassembly
Remove jet needle

holder①O-ring②and jet
needle③from vacuum piston. Disassembling float chamber
Remove float chamber body, and Remove screw⑤ , float pin⑥ ,
Check needle for step wear. Remove screws
float ⑦ and needle valve ⑧ .
Check vacuum piston for wear and take out sealing ring④ from float
Check float for damage and
damage.Check diaphragm for chamber body. leakage.
pinhole, deform and damage.
Remove the parts in following order: Main jet①/main jet

holder②/pilot jet③
Turn in pilot air adjusting screw slightly tight, and mark down total turns.
Remove pilot air adjusting screw ④ and spring⑤.
Check and replace it if worn.
Check needle jet seat⑨ for scratch,

clog and damage. Check needle jet
for step wear. Replace it if it isworn.
Reinstall in the reverse order of disassembly.
44
`
2-8.4 Cleaning carburetor
Blow compressed air through all jets(main jet①/main jet holder②/ pilot jet③), air passage and fuel passage.
45
`
2-9 Brake system
Inspect brake system after initial 1000km (3 month) and every 4000km (20 month).
Check brake hose and fluid after every 4000km (20 month). Replace the brake hose after every 4 years and replace brake fluid after every 2 years.
2-9.1 Brake fluid level inspection

Stand the vehicle vertically and keep handlebar forward. Compare the level of brake fluid in reservoir with the mark on screen.
Caution
Only glycol based hydraulic brake fluid is equipped in brake system of this vehicle. Don’t use or mix with silicon or fossil oil based fluid when refilling, otherwise
the brake system will be damaged.
Don’t use long-stocking or unsealed brake fluid. Caution
Any brake fluid leakage will be dangerous in running. Ensure hose and sealing not damaged or leaked.
46
`
2-9.2 Caliper pad wearing
Check the wearing terrain on caliper pad, and
replace the pad if friction surface reach the
sign “A” of wear.
2-9.3 Caliper pad replacement
Remove brake caliper①ASSY. Remove brake pad②from caliper
ASSY.
47
`
2-9.4 Brake fluid replacement
Connect the bleed valve and other container by sufficient hose. Loosen the bleed
valve and pump out all previous brake fluid by forcing brake lever. After closing
bleed valve and disconnecting drain hose, refill with fresh brake fluid till its level
reach the upper limit on inspection screen.
Specified torque for bleedingvalve: 7.5N.m
48
`
2-9.5 Bleeding out air from brake system
Stand the vehicle on horizontal ground with Refill brake fluid again to its reservoir to ensure fluid
handlebar in verticality.
level above “UPPER” mark.
Remove handlebar front cover.
Remove the cap and diaphragm of fluid
reservoir. Pump out previous brake fluid
Connect the bleed valve and other container by transparent hose.
Refill with fresh brake fluid.
Rapidly press and release the brake lever several times, then press the lever firmly.
Loosen the bleed valve for 1/4 turn to allow brake fluid drain out. Due to this operation
the brake lever will release and touch with handlebar, then close the bleed valve.
Close bleeding valve and tighten to specified torque, then remove the drain hose.
Specified torque: 7.5N.m
Caution: Take care to deal with brake fluid because it can damage the parts of plastic, paint and rubber due to chemistry.
49
`
2-10 Brake panel free play (rear brake)
Unlike the front brake lever needs Periodically check the brake lever free play Always check and adjust the brake
to have the rear brake a game of and, if necessary, adjust it as follows. To lever before riding. To check the
about 10 mm. The rear brake is increase the brake lever free play, turn the brake, check the position of the
actuated cable. If there is no play, it adjusting nut at the brake shoe plate in adjustable nut if the nut position
may be that the brake linings drag direction (A). To decrease the brake lever reach to the end, have a dealer to
permanently in the brake drum. free play, turn the adjusting nut in direction replace the brake shoes as a set.
(B).
50
`
2-11 Throttle cable free play
The throttle cable free play ①should measure 1.5 ~ 3.5 mm at
the throttle grip.
Periodically check the throttle cable free play and, if necessary,
have a dealer adjust it.
Turn the adjuster③to get the specified free play, then tighten
the lock nut② .
Specified value A: 2.0—4.0mm
51
`
2-12 Fuel hose

Inspect after every 4000km (or 20 month), and
replace after every 4 years.
Check fuel hose for crack or leakage, and replace the
fault one.
2-13 Fuel filter
Clean the filter after every 8000km (or 40 month).
Clean it by compressed air if clogged.
52
`
2-14 Muffler mounting Bolts & nuts

Tighten the exhaust nuts and mounting bolts after initial
1000 km (3 month) and every 4000km (20 month).
Tighten the exhaust nuts and mounting bolts to specified
torque by torque wrench. Specified torque: 24N·m
2-15 Steering
Inspect steering system after initial 1000km (3 month) and every 12000km (24 month).
Steering (3
nspect steering system after initial 1000km system mustand
month) be properly adjusted to(24
every 12000km ensure handlebar turning
month).
smoothly and safety riding. Too tight steering will affect handlebar
balance, and too loose steering will affect riding stability. Stand the
vehicle and keep front wheel forward and away from ground, hold the
lower end of front fork and pull forward to check the clearance between
the parts of front fork. Adjust the steering race if gap is found.
53
`
2-16 Front fork

Check the damper tub for leakage or scratch, replace the damaged parts
if necessary.
2-17 Rear shock absorber
Check rear shock absorber for oil leakage, and check engine mounting
bracket for cushion wear. Replace the damaged parts if necessary.
54
`
2-18 Tire
To maximize the performance, durability, and safe operation of your vehicle, note the following points
regarding the specified tires.
2-18.1 Tire air pressure
Tire air pressure: Maximum load*:
Front: 2.2 bar - 2.3 bar 50 cm³: 150kg
Rear: 2.2 bar - 2.3 bar 125 cm³: 160kg
Total weight of rider, passenger, cargo and *Total weight of rider, passenger, cargo and
accessories! accessories!
WARNING
Caution
The tire air pressure must be checked and adjusted on cold tires (i.e., when the temperature of the tires equals the
ambient temperature). The tire air pressure must be adjusted in accordance with the riding condition. If you are not
familiar to this, please have dealer for help.
55
`
2-18.2 Tire inspection
1.Tire tread depth.

2.Tire sidewall.
3.Tire wear indicator.
Inspect tires for every 4000km (20month).

Worn tires will affect ridding stability and cause accident. Check the tire
surface by depth gauge, and replace with new tires if its groove depth is less
than specified value.
Specified depth: Front and rear: > 1.6 mm
56
`
2-18.3 RIMS
To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding
the specified wheels.
1. The wheel rims should be checked for cracks, bends or warpage before each ride. If any damage is found, have a dealer 2.
replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked
The wheel should be balanced whenever either the tire or wheel has been changed or replaced. An un- balanced wheel can 3.
result in poor performance, adverse handling characteristics, and a shortened tire life.
Ride at moderate speeds after changing a tire since the tire surface must first be “broken in” for it to develop its optimal
characteristics.
Dimensions Tires / Rims
Front Rim: 2,75×12 Tire: 110/70-12
Rear Rim: 2,75×12
Tire: 120/70-12
57
` Tyre type: Tubeless
2-19 Tappet clearance

Disassembly
Remove the inspection cap from the bottom of luggage box Remove the lower
shroud of cylinder head Remove cylinder head cover①。
Inspection
It will be necessary to inspect and adjust the tappet clearance, when
1.periodical maintenance
2.replace or repair cam shaft
3.cam shaft was disturbed when replacing other parts Tappet clearance (cold engine)
Intake valve： 0.06~0.09mm
Exhaust valve： 0.07~0.10mm
When inspecting or adjusting tappet clearance, firstly ensure the piston stopped at
TOP DEAD PIONT.
Above limit is specified for cold engine.
To get correct reading of clearance, crankshaft should be turned by hand in working
direction more than 2 circle and spark plug should be removed.
Turn crankshaft till the mark on rotor aligns to the mark on crankcase.
58
`
2-19.1 Tappet clearance
Loosen tappet adjusting nut.

Insert the thickness gauge between the adjusting screw and top end of valve
stem②.
Adjust valve clearance to specification, and fasten the lock nut③④.
Tools:
Thickness gauge Tappet screw driver Wrench
59
`
2-20 Drive belt（Inspect for every 4000km (20 month).
Stand the vehicle vertically. Remove crankcase cover LH ④.
Check the working surface for crack, and replace if damaged.

Note:
Remove oil and grease from working surface of belt.
60
`
2-21 Cylinder pressure
Operate when the engine warm up.

Remove the cushion and body shield.
Remove the spark plug.
Install the cylinder pressure gauge.
At full throttle, measure the cylinder pressure by starting the engine.
The following items shall be check in case of a low pressure:
—Whether the gasket of cylinder cover is damaged;
—whether piston ring is damaged;
—whether the air inlet and piston ring is worn;
—whether the piston and cylinder is worn
When compression pressure is too high, please check the combustion
chamber and carbon distribution at piston head.
Tools：Compression gauge Compression gauge adopter
Caution；
Before checking cylinder compression, ensure that cylinder head nut and bolt has been tightened to specified
toque, valve clearance has been adjusted, engine has been warmed up and battery has been fully charged.
61
`
2-22 Clutch
Start the engine and increase its speed gradually to check the working
condition of the clutch.
If the motorcycle fails to go and the engine stops, you should
Check the clutch block. If necessary, change a new one.
2-23 Battery（Battery removal ）
Remove the cover of the battery box.

First remove the negative wire and then the positive wire. Take out the battery.
Warning！
The tools for removing the positive electrode should not
contact the flame, otherwise it will be very dangerous that the
damaged battery will cause fire.
Install the battery following the opposite sequence.
62
`
2-23.1 Battery (Charging state）
Do not disconnect the battery during the adjustment of motorcycle,

otherwise inner component of the motorcycle may be damaged. Charging
state (closed circuit) inspection
Measure the voltage between battery terminals.
Full charge：13.5V
Under charge：12.3V
* Note
Charge state examination must use a voltmeter operation.
• Except emergencies, you should not use emergency charge.

• Measure the voltage for every other 30 minutes.
Charging current：standard：0.6A
Emergency：6.0A
Charging time: standard：10-15h.
emergency：30 min.
Charging complete: closed circuit voltage: above 12.8V
63
`
2-24 Bolts and nuts on frame body
Tighten the bolts and nuts to specified torque after initial 1000km (3 month) and every 4000km (20
month).
Specified torque
No. Item N·m kg·m Reference
1 55
Front axle nut 5.5 Fig2-24.1
5.34.9
2 49 4.9
Handlebar mounting bolt Fig2-24.2
3.0
3 30 3.0
Steering stem lock nut Fig2-24.3
2.5
4 25 2.5
Handlebar locating bolt Fig2-24.4
4.5
5 45 4.5
Front fork mounting bolt 1.0 Fig2-24.5
6 10 1.0
Master cylinder mounting bolt 2.3 Fig2-24.6
7 23 2.3
2.6
Brake hose union bolt Fig2-24.7
8 26 0.75
2.6
Brake caliper mounting bolt Fig2-24.8
7.5 2.3
0.75
9 Bleeding valve Fig2-24.9
12.0
64 2.9
`
1.1
9.8
10 24 2.4
Front panel bolt Fig2-24.10
11 120 12.0
Rear axle nut Fig2-24.11
12 29 2.9
Rear shock bolt Fig2-24.12
13 Rear brake lever nut 11 1.1 Fig2-24.13
14 Engine bracket mounting bolt/nut 98 9.8 Fig2-24.14
15 Engine mounting bolt/nut 80 8.0 Fig2-24.15
Fig2-24.1 Fig2-24.2 Fig2-24.3 Fig2-24.4 Fig2-24.5
Fig2-24.6 Fig2-24.7 Fig2-24.8
65
`
Fig2-24.9 Fig2-24.10 Fig2-24.11
F ig2-24.12 Fig2-24.13 Fig2-24.1 Fig2-24.15
66
`
3、 ENGINE
67
`
3-1 Engine removal & disassembly
Disconnect carburetor starting Disconnect throttle cable, fuel

Remove luggage box①. Remove frame cover RH
cable and magneto wires from hoseand vacuum pipe Loosen
&LH②.
main wire harness. clamping screw of air cleaner.
Remove the adjusting nut①of Remove air cleaner assy②. Remove rear shock absorber Remove spark plug adopter.
rear brake cable. assy③.
68
`
Remove the engine assy from

frame body by removing the
bolt⑤of engine mounting
bracket set.
Remove rear wheel by loosing
Remove muffler①。 its nut②. Remove center stand ③.
3-2 Reinstallation (Reinstall the engine in the reverse order of removal. ）
Tighten the nut to specified Replace the exhaust gasket① Tighten the exhaust nuts to Tighten the muffler mounting
torque to install the rear wheel. with fresh piece before specified torque.. Specified nut to specified torque.
69
` Specified torque: 118N·m reinstall muffler. torque: 10N·m Specified torque: 24N·m
3-3 Cylinder &cylinder head Disassembly
Remove the drain plug①to drain Remove air cleaner,carburetor, Remove cylinder head cover Remove cylinder head cover
out engine oil from crankcase. intake pipe, fan cover and bolts. bolts.
shroud A and B.
Cover the crankcase opening with

Loosen the nuts over cam shaft Remove cam shaft holder, then Remove cylinder head gasket, clean rags to prevent clip from
holder⑤diagonally and remove the remove timing chain② from cam
timing chain guide③and entering into the crank chamber,
mounting nuts beside timing chain shaft①.
chamber. cylinder. and remove piston pin clip④.
70
`
Screw one M5 bolt⑦into rocker Press the spring by valve spring

Drive out valve and remove valve
arm shaft⑤, then remove it and compressor⑧, then remove cotters
boot.
rocker arm⑥from cam shaft by forceps.Remove spring seats,
holder.. inner and outer springs.
3-4 Inspection of Cylinder & Cylinder Head
Explanation of specification and specification Ⅱ

•This chapter instructs the inspection and maintenance for cylinder head and accessories, cylinder and piston.
•During inspection, the removed parts should be marked and packed properly to ensure reinstallation.
•Cam shafts and rocker arms are lubricated by the oil coming from the oil channel inside the cylinder head.
Take care to clean these oil channel before assemble cylinder head.
•When inspect cylinder head, valves and cylinder, take care not to damage the sealing surface.
•Take care not to damage the combustion chamber of piston and cylinder head.
•All the removed parts should be cleaned by solvent and dried by compressed air before inspection.
•Remove carbon deposits before inspecting piston and cylinder head.
71
`
Specification Unit：mm
Item Standard Service limit
Cylinder compression 1540kPa(15.7kgf/cm2) at 800rpm ---
Cylinder head warpage --- 0.05
Rocker arm I.D. IN/EX 10.008—10.023 10.10
Rocker arm Rocker arm shaft O.D. IN/EX 9.980—9.995 9.91
Shaft-to-arm clearance IN/EX 0.013—0.043 0.08

IN 25.51—25.61 25.50
Cam Cam lobe height
EX 25.11--25.21 25.10
IN 0.06—0.08 ---
Valve clearance
EX 0.06—0.08 ---
IN 4.975—4.990 4.90
Valve stem O.D.
EX 4.955—4.970 4.90
Valve guide I.D. IN/EX 5.000--5.012 5.03
Valve guide
IN 0.010—0.037 0.08
Stem-to-guide clearance
EX 0.030—0.057 0.10
Valve guide length out of
IN/EX 12.85—13.15 ---
cylinder head
Valve seat width IN/EX 0.8 1.5
inner 30 28
Valve spring free length
outer 34.35 32.35
72
`
Specification Unit：mm
I.D. 39.010—39.015 39.019
Out of round --- 0.05
Cylinder
Taper --- 0.05
Warpage --- 0.05
Piston O.D. 38.985—38.990 38.98
Piston O.D. measurement point 10mm above piston skirt ---
Piston pin hole I.D. 13.002—13.008 13.04
Piston pin O.D. 12.994—13.000 12.98
Piston, Piston ring, Piston-to-piston pin clearance 0.002—0.014 0.04
Piston pin Top ring 0.015—0.045 0.08

Ring-to-ring groove
clearance Second ring 0.015—0.050 0.08
Top ring 0.05—0.15 0.40

Ring end gap Second ring 0.05—0.20 0.40
Oil ring 0.20—0.70 0.90
Cylinder-to-piston clearance 0.010—0.040 0.12
73
`
3-4.1 Checking warpage of cylinder head

After removing the seal ring from cylinder head, press it on the flat
surface plate and check its warpage at different point with thickness
gauge①.
Service limit： 0.06mm.
3-4. 2 Rocker arm shafts O.D.
Measure Rocker arm shaft O.D. by micrometer.
Service limit： 9.91mm.
74
`
3-4.3 Rocker arm I.D.
Measure rocker arm I.D. by micrometer.
Service limit 10.10mm.
3-4.4 Shaft-to-arm clearance
Check shaft-to-arm clearance.
Service limit: 0.08mm.
75
`
3-4.5 Cam shaft
If abnormal noise or vibration was found, or engine output was less,
the bearing①&②, cam profile and shaft journal must be inspected.
3-4.6 Wear of cam
Worn cam shaft will cause insufficient valve timing and less
horsepower. Wear of cam shaft can be indicated as cam height of intake
cam③and exhaust cam④and measured by micrometer. Replace if cam
height exceeds the limit.
Service limit:25.50mm(in.)/25.10mm(ex.)
76
`
3-4.7 Cylinder head warpage
Remove carbon deposits in combustion chamber, and check warpage by

flat surface plate and thickness gauge⑤at different position. Replace
with new cylinder head if the reading of any position exceeds the limit.
Service limit: 0.05mm
3-4.8 Valve spring
Check the spring through measuring the free length or spring tension.
Replace the spring set if the free length exceeds the limit.
Service limit 30mm(inner)/34.35mm(outer)
77
`
3-4.9 Valve/valve guide
Ensure valve stem sliding in Remove valves and measure 4.90mm 4.90mm
valve guide smoothly. Check contact width of valve seat. Replace valve or reface valve Reface the valve seat
for bending, burns, scratches Standard: 0.8mm seat, if valve seat contact contact surface if the it is
or over wear. Measure valve Service limit: 1.5mm surface is damaged or not too high or low. 4.90mm
stem O.D. uniform.
Service limit(in./ex.) 4.90mm 4.90mm
3-4.10 Repair valve seat by4.90mm

reamer
Reduce the height of contact
surface by 32º reamer. Increase the
Refer to operation manual of height of contact surface by 60º
reamer. Take care not to over cut reamer. Polish the contact surface
valve seat. to specification by 45º reamer.
78
`
Remove unequal or rough surface Remove top 1/4 length of valve seat Remove bottom 1/4 length of valve Polish the contact surface to
from valve seat by 45º reamer. by 32º reamer. seat by 60º reamer. specified width by 45º reamer.
3-4.11 Cylinder warpage /Cylinder I.D.

Cylinder warpage:
Check warpage of sealing surface by flat surface plate and thickness gauge at different position.
Replace with new cylinder if the reading of any position exceeds the limit.
Service limit：0.05mm
Cylinder I.D:
Measure the cylinder I.D. at 6 difference position.
Repair the cylinder if any reading exceeds the limit, or replace cylinder and piston in set.
Service limit: 39.019mm.
79
`
3-4.12 Piston O.D.
Measure the piston O.D. by micrometer at the position 10mm above piston skirt.
Replace if reading exceeds the limit.
Service limit 38.98mm
3-4.13 Ring end gap
Insert piston ring into cylinder, measure end gap of each ring by thickness
gauge②. Replace defect piece whose gap exceeds the limit.

Service limit
Top ring 0.08 mm
Second ring 0.08 mm
Oil ring 0.04 mm
80
`
3-4.14 Piston hole-to-piston pin clearance
Measure piston pin hole I.D. by telescope caliper, and measure
piston pin O.D. by micrometer. If piston hole-to-piston pin clearance
exceeds the limit, replace piston and piston pin meanwhile.
Piston hole I.D:
Service limit 12.98
81
`
3-5 Reassembly of Cylinder & Cylinder head

3-5.1 Installation of piston
Apply engine oil to small end of connecting rod.

Install piston with “IN” mark on crown toward
Apply engine oil to piston ring and Adjust piston rings to ensure the up. Apply engine oil to piston pin and install it to
piston ring groove, then install piston rings end gap uniformly distributed piston through the small end of connecting rod.
ring to groove with the stamped mark at 120º Note:
upward. Do not make any object fall into the crankcase.
Install the piston, piston pin and retainer ring.
Install new piston pin circlips properly into its groove and
ensure the circlip end gap not aligned with the rabbet②
of piston pin hole.
Mark Top ring
Note:
Do not make any object fall into the crankcase.
When installing oil ring, firstly install
Install the piston, piston pin and retainer ring.
separating ring, then side track.
82
`
3-5.2 Installation of cylinder

Apply a layer of oil around the
inside of the cylinder first and then
place the piston in the cylinder .
3-5.3 Installation of cylinder head Sub Assembly
Blow compressed air through

all oil passages. Apply grease
to the stem of valves
Apply engine oil to new valve
boot. Install valve spring seats①and
Insert valve stem into valve new valve boot②
guide slowly to avoid
damaging valve boot.
83
`
3-5.4 Assembly
Install dowel pin and new

Clean the contact surface gasket to cylinder.
between cylinder and Take out timing chain
cylinder head. through chain chamber of
cylinder head and install
cylinder head to cylinder.
Install timing chain guide⑤

3-5.5 Install cam shaft holder
groove.
Insert bolt M5 ④ into

Apply engine oil to rocker shaft, then install rock
sliding surface of rock arm and shaft to cam shaft
arm①, and rock arm holder by this bolt.
shaft②③.
84
`
Turn crankshaft counterclockwise till “T”

Insert cam shaft⑤to timing Diagonally tighten cam holder mark on flywheel align with indicator
chain⑥. nuts to specified toque. mark on crankcase RH. Apply engine oil
Specified toque: 18N.M to timing chain and sprocket.
Align the mark on sprocket with flat
surface of cylinder head.
Install timing chain tensioner and Apply engine oil to new O-ring②and insert into
gasket with two bolts and tighten tensioner. Insert spring③into tensioner by
to specified toque. screw and tighten the screw to specified toque.
Specified toque: 10N.m Specified toque: 0.8N.m
85
`
3-5.6 Tappet clearance
Ensure cam profile upward and Adjust Tappet clearance to

Turn crankshaft counterclockwise
till the mark on sprocket align to primary circle downward, and keep specification, and tighten the lock
flat surface④of cylinder head. “T mark on flywheel align with nut to specified toque.
indicator mark⑤ on crankcase RH.
Specified toque: 10N.m.
3-5.7 Cylinder head cover sub assembly
Fig 3.5.19
Install plat② and new
keep “T” mark on flywheel align Bend the edge of plate
with indicator mark ⑤ on crankcase
gasket① to cylinder to lock the bolts with
RH.
head cover. long nozzle pliers.
Fig 3.5.19
k
86
` e
e
p
3-5.6 Installing cylinder head cover
Install cylinder head cover to Install cooling fan ② , and Install fan cover ③ ,upper
Install new rubber ring⑤ to
cylinder head, and diagonally tighten the mounting screws to shroud and lower shroud④, and
sealing surface of cylinder
tighten the mounting bolts to specified toque. tighten the mounting screws to
head cover.
specified toque.Connect specified toque.
breath hose. Specified toque:
10N.m
3-6 Crankcase Disassembly
3-6 .1 Magneto ASSY
Remove bolts and cooling

Remove screws and
fan.
fan cover①.
87
`
Hold the flywheel④by special Take out flywheel nut and Loosen stator bolts and pulse
tool③and loosen the nut. washer. Remove flywheel by coil bolts. Remove stator⑥ Remove the woodruff key①
Special tool: flywheel holder special tool ⑤. and pulse coil⑦. from the crankshaft.
Special tool: flywheel remover
3-6.2 Starter motor
Remove bolts and starter motor. Remove O-ring②from starter motor.
88
`
3-6.3 Cover RH /Oil pump
When removing oil pump,

take care to prevent dust
Loosen mounting bolts from entering the
and remove cover RH. crankcase.
Remove mounting nut③
and oil pump gear④
Remove mounting bolts and Disassemble the oil pump

oil pump. in following order: Screws
Take out O-ring○1 from Oil pump plate②Pin ③
sealing surface of oil Inner rotor④ Outer rotor⑤
passage.
89
`
3-6.4 COVER LH / KICK START
Loosen mounting bolts Remove gasket and dowel

and remove cover LH. pin from cover LH.
3-6.5 Kick start
Before removing kick

Drive the kick lever on lever, scribe the
cover LH to remove alignment mark of kick
kick driven gear①and lever and kick shaft as
thrust washer. reference for
reinstallation.
Remove lock bolt and
kick lever.
90
`
Loosen the kick return spring

Remove circlip②and washer③ from rivet on cover LH. Remove kick shaft bush⑤ and
from kick shaft. Remove kick shaft and kick collar⑥.
return spring.
3-6.6 CLUTCH ASSY Pulley drive
Hold the kick starter ratchet by Remove drive belt and clutch
Remove kick starter ratchet2
special tool 1 , and remove nut and assy when removing movable
fixed drive face3 and cooling fan4.
washer.Special tool: ratchet holder drive face.
91
`
3-6.7 Disassembly/Starter gear assy
Remove roller guide

Remove starter gear
plate⑥and rollers⑦ assy⑨after movable
from movable drive drive face assy
face assy. removed.
Take out sliding bush⑧
from roller guide plate.
3-6.8 Clutch ASSY / Driven pulley
Hold the clutch hub by special Remove the driven plate assy②
tool①to loosen the nut. Remove clutch hub. and belt③.
Special tool: clutch hub holder
92
`
3-6.9 GEAR BOX
Loosen the bolts, and remove Remove gasket and dowel pins. Remove oil seal of drive shaft Remove the parts in following
gear box.Remove drive ①. order: Final gear④
shaft④. Final shaft③ Counter shaft②
Remove the parts in following Drive out final shaft bearing,

order: Final gear④ drive shaft bearing and counter
Final shaft③Counter shaft②
shaft bearing by special tools.
Special tool:Bearing puller
93
`
3-6.10 CRANK CASE
Keep crankcase LH downward,

Remove chain tension pivot
Loosen crankcase bolts. and separate crankcase RH
① and chain guide②.
from crankcase LH.
Slide timing chain③from timing

Remove dowel pins, and
sprocket of crankshaft, then remove
clean the sealing surface of
timing chain from crankcase.
crankcase.
Remove riming chain.
94
`
3-7 Crankcase parts inspection

3-7.1 OIL PUMP ASSY
Perform the measurement at Tip clearance:
different position, and take Insert outer rotor①and inner
the Max. reading as the rotor②to oil pump body.
measurement result. Measure the clearance between
Replace the oil pump assy if outer rotor and inner rotor by
its any part exceeds service thickness gauge.
limit. Service limit :0.20mm
Body clearance: End clearance:

Measure the clearance Measure the end clearance
between outer rotor and between body③and
body by thickness gauge. cover④.
Service limit:0.35mm
95
`
3-7.2 COVER LH / KICK STARTER
Check kick starter shaft1 for wear and damage. Check the teeth of
gears for wear and damage.
Check kick return spring 2 for weak tension and damage. Check
collar 3 for wear and damage.
Check bush 4 for wear and damage.
Check kick driven gear5 and washer 6 for wear and damage.
Check the kick starter ratchet⑦ Check the socket on cover

for wear and damage. LH for wear and damage.
96
`
3-7.3 Drive belt/Ratchet
Check belt for scratch,

separation and over wear,
and measure the width of Check the cooling fan 1
belt. for wear and damage.
Check the rollers②for wear and damage, and measure O.D. of

rollers.
Service limit ：15.4mm
97
`
3-7.4 Moveable drive face assy
Check the working surface

Check the inner bush of
of moveable drive face assy
for wear and damage, and moveable drive face assy
measure its I.D. ③. for wear and damage.
Service limit：20.17mm Measure O.D. of inner
bush.
3-7.5 Starter motor clutch
Ensure starter motor clutch

operating smoothly. Check
the gear①of clutch for
wear or other defect. Check
the shaft②③for wear.
98
`
3-7.6 Crankshaft inspection
Set the crankshaft on V block, and Set the crankshaft on V block, and
Measure the axial gap at connecting
measure the face run-out at connecting measure the radial run-out at
rod big end by thickness gauge.
rod small end by diameter-indicator②. journal by diameter-indicator②.
Service limit 0.02mm Service limit: 0.10mm
Check the oil pump driving gear Turn the outer ring of bearings of
on crankshaft for wear and crankshaft by finger to ensure them
damage. working smoothly.
Ensure the inner ring of bearing
firmly fitting on crankshaft.
99
` Replace the bearing if turning
hardly or loose fitted.
3-8 Crankcase Parts Reinstallation

3-8.1 Assembly
Turn the bearing of crankshaft by Apply engine oil to timing chain③

Always take care to avoid
finger to ensure it moving and insert it into crankcase. Apply
damaging the sealing surface of
smoothly and quietly, otherwise engine oil to crankshaft bearing.
crankcase.C l e a n t h e c r a n k c a s e a n d
replace it. c h e c k i t f o r s c r a t c h o r d a ma g e .
Apply engine oil to big end of Clean the sealing surface of crankcase Install crankcase RH to crankcase
connecting rod, and crankcase RH & LH, and install gasket①and LH, and tighten the bolts to specified
bearing. Press crankshaft assy dowel pin②. torque.
into crankcase LH through timing Specified torque: 10N·m
chain till it fitted firmly.
100
`
Insert tentioner movable guide③ Insert tentioner movable guide③to Apply grease to the lip of fresh oil
to crankcase LH. Insert the pin④ crankcase LH. Insert the pin④of seal⑥. Drive the oil seal into
of tentioner movable guide and tentioner movable guide and O-ring⑤ crankcase LH till it equal to crankcase.
O-ring⑤ to crankcase LH and to crankcase LH and tighten to Tool:Oil seal driver
tighten to specified torque. specified torque.
3-8.2 Oil pump
Apply engine oil to inner rotor① Take care to prevent the duct entering
Install dowel pin and plate to oil pump
and outer rotor② of oil pump, engine when installing oil pump.Install
body, and fasten it by tighten the screws to dowel pin④ to oil pump body, and
and insert them into oil pump
body③. specified torque.Specified torque: 3N.m insert O-ring⑤ to oil channel in crankcase.
101
`
Take care to prevent the duct Install dowel pins and gasket to crankcase
entering engine when installing oil RH .Apply engine oil to oil pump gear⑥.Align Apply grease to the lip of fresh oil
APump.
p p l y e Install
n g i n edowel
o i l t opin④
n e wto oil the slot of gear to oil pump shaft, and install seal. replacement
Bearing
O pump
- r i n g,body,
a n d and
i n sinsert
e r t i tO-ring⑤
t o t h e to the gear to oil pump by tightening nut to
Apply grease to bearing socket, and press
e noichannel
d c o v e r ino fcrankcase.
s t a r t e r m o t o r. specified torque.
bearings into their socket. Apply grease to the
lip of oil seal of final shaft, and install it into
gear box by special tool①.
102
`
3-8.3 Starter motor/Gear box
Install starter motor to crankcase

LH, and tighten mounting bolts to
specified torque.
Fasten crankcase cover RH by

Drive the oil seal into crankcase tightening the bolts to specified
cover RH till it equal to torque.
crankcase cover. Specified torque: 10N·m
103
`
Install new gasket and dowel pins.Fasten

Install final gear⑤to final shaft. crankcase cover LH by tightening the bolts to
specified torque.
Specified torque: 10N·M
Assemble gear box

Apply engine oil to gears and Install washer③to countershaft④, Install washerto countershaft④, and
shafts. Install final shaft to its and install them to bearing. install them to bearing.
bearing.
104
`
3-8.4 Starting gear Assy/Pulley drive
Hold clutch hub②specified torque. Put drive belt out of the bush③of
Specified torque: 50N·m drive face assy.
I n s e r t b e l t ⑥i n t o driven plate Specialtool: Clutch holder.
a s s y ⑦.
3-8.5 Driven plate assy
Remove the oil and grease from rollers③,

Apply 0.1-0.3g grease to shaft of Remove the oil and grease from the
insert them into movable drive face
starting gear assy, and insert it into surface of movable drive face assy④,
assy④, and install guiding plate⑤to cover
crankcase LH and insert the inner bush⑤into it.
them.
105
`
Insert kick shaft bush①and Apply grease on kick shaft, and In s t a l l k i c k r e t u r n s p r i n g ③ , a n d f i x

collar②into crankcase cover LH. install it into crankcase cover the longer hook to the rivet on
LH. c r a n k c a s e c o v e r LH . In s t a l l k i c k
s h a f t a s s y i n t o c r a n k c a s e c o v e r LH ,
and fix the shorter hook on kick
s h a f t a s s y.
3-8.6 Kick lever
Hold the fixed drive face by special

tool⑦, and tighten nut to specified
torque.
In s t a l l f i x e d d r i v e f a c e ④,
f a n ⑤ a n d s t a r i n g r a t c h e t ⑥.
Special tool: Ratchet holder⑦
106
`
Install crankcase cover LH to Clean the taper area of crankshaft,

Install dowel pins and new gasket on crankcase LH, and tighten the bolts and insert the key④on it.
crankcase LH. diagonally to specified torque.
3-8.7 Crankcase cover LH/ Magneto Assembly
Turn and hold the kick lever some away from

Install washer④and circlip⑤on Reinstall kick lever to previous dead point, install thrust washer② and kick
kick shaft. location according to disassembly ratchet③ into crankcase cover LH, and ensure
mark, and tighten mounting bolt. spring hook① align with the relative groove on
crankcase cover RH.
107
`
Install fan cover④, and tighten bolts to Tighten bolts to specified torque.
Install cooling fan③, and tighten bolts to Specified torque: 8N·m
specified torque.
specified torque.
Specified torque: 0.8N·m
Install pulse coil⑤, and tighten the bolts to Insert washer, hold fly wheel by special
specified torque. Specified torque: 6N·m Install fly wheel①to crankshaft with tool②, and tighten nut to specified
Install stator plate⑥, and tighten the bolts to its bush groove aligned to key. torque.
specified torque. Specified torque: 50N·m
Specified torque: 8N·m Special tool: Universal holder
108
`
4、 FRAME BODY
109
`
4-1 Outer Parts
No. Picture Description No. Picture Description

Rear view
1 6 The front panel
mirror
Before the The front panel

2 7
instrument cover chrome plated
Headlight The front panel

3 8
decorative circle style
BOTTOM
4 Instrument shell 9
COVER
The front panel

5 10 SEAT ASSY
small cap
110
`
11 Glove box 16 BODY COVER
Glove box inside After decorating

12 17
the small cover plate
BATTERY After decorating

13 18
COVER plate rubber sleeve
Glove box cover Tail lights

14 19
before decoration ring
Glove box cover decorative

15 20
before decoration decoration
111
`
HELMET
21 26 FLOOR PANEL
HOOK
22 LEG SHIELD 27 Filler cap
LID INNER
23 28 After the armrest
BOX
VIN NUMBER After the armrest

24 29
COVER clamp
25 Foot strip 30 The battery pack
112
`
The front fender

31 FENDER RR 36
back
FRAME REAR
32 37 The rear fender
FENDER
33 Front fender 38 After the reflector
Chassis SIDE
34 39
backplane REFLECTOR
The front of
35 40 pedal
front fender
113
`
4-2 Disassembly
Remove front instrument cover②. Disconnect head lamp cable and

Remove mirror RH & LH①.
front winker cable③, and remove
speedometer cable④.
Remove instrument cover. Remove The front panel small cap. Remove The front panel.
114
`
Remove bottom BOTTOM COVER. Turn ignition key to unlock seat ASSY,
Remove BOTTOM COVER RH in RemoveAfter the armrest. and remove luggage box and BATTERY
same method. COVER .
Remove battery. RemoveGlove box cover before.

Note: When removing battery, disconnect the Remove BODY COVER.
negative (-) terminal cable first, then remove
positive terminal cable at the battery.
115
`
First remove Foot strip④ Then Remove ignition switch cap and Remove LEG SHIELD⑥.
remove floor panel③ . HELMET HOOK.
Remove Front fender. Remove Chassis backplane. Remove FENDER RR.
Reinstall in the reverse order of disassembly.
116
`
4-3 Front Wheel /4-3.1 Disassembly
Remove nut①from front axle. Remove brake caliper mounting

bolts③. Remove brake disk and bush.
Disconnect speedometer cable②
Front rim：nspect the run-out（Radial &

Axial）of front rim, and ensure it under
service limit. If over run-out was caused by
damaged rim bearing, rim could be utilized
after replacing the bearing. Otherwise
replace with new rim.Service limit;2.0mm.
Turn the gear in speedometer gear
box to ensure gear and pinion
moving smoothly.
117
`
Front axle： Check rolling of the

Inspect front axle run-out by
bearings：
The bearings will not roll if
micrometer, and replace it if it
abraded or loosened. Replace it.
exceeds service limit. （游隙 clearance 轴向 axially
Tools: Micrometer Magnetic basic 径向 radially）
V-block.
4-3.2 Front Wheel(Reassembly)

Lubricate the front wheel spindle, gear seat assembly, oil seal (opening), spindle sleeve, bearing 6201-2RS and distance sleeve of bearing.
1.Brake disk 2.Speedometer gear box

Ensure there is no any oil dirt on Apply grease to gear and oil seal
brake disk. before installation.
Apply thread locking sealant 1360 Align the gear drive piece with the
to brake disk mounting bolts, and groove on rim, and install the
tighten them to specified torque. speedometer gear box to rim.
Specified torque: 23N.m
118
`
Align the stopper edge on 3.Front axle nut

speedometer gear box to the groove Tighten front axle nut to specified
on front fork, and install front Specified torque: 53N.m
wheel to front fork by inserting
front axle.
119
`
4-4 Front Brake System
1. front disc brake assembly 2. PLATE WASHER 3. MASTER CYLINDER BODY 4. PISTON ASSY.
5. RESERVOIR DIAPHRAGM 6. RESERVOIR CAP 7. SCREW 4X10MM 8. MASTER CYLINDER BRACKET 9. BOLT 6X23MM
10. FR. BRAKE HOSE 11. UNION BOLT 12. MASTER CYLINDER ASSY. 15. CALIPER COMP (GOLDEN) 16. BREED SCREW CAP
17. PAD SUPPORT,1 18. BRAKE PAD SET, NON-ASBESTOS 19. TENSION SPRING,LEVER 21. BRAKE LEVER, FR. DISK
Caution
Only Grade DOT4 glycol based hydraulic brake fluid is equipped in brake system of this vehicle.
Don’t use or mix with silicon or fossil oil based fluid when refilling, otherwise the brake system will be damaged.
Keep the container properly sealed and away from reaching of child when stocking brake fluid. Don’t use long-stocking or unsealed brake fluid.
Take care to avoid any dirt or dust interring the brake system when refilling brake fluid. Use fresh brake fluid only to wash the parts of brake
system.
Dirty brake disk and pad will affect brake efficiency. Replace or clean it by neutral cleaning agent
120
`
4-4.1 Disassemble and reassemble brake caliper Disassembly

Remove brake hose from brake
caliper ASSY by removing the
union bolt①, and drain out
brake fluid to other container. Remove brake pad spring③.
Remove caliper ASSY mounting Remove brake pad holder④.
bolts②
Cover brake caliper by rap to

prevent the piston escape Remove dust ring① and
suddenly, push out the piston by piston sealing ring②.
compressed
1.Brake caliperair.
3.Reassemble brake caliper
Check caliper cylinder wall for crack,
Wash the piston and caliper by
scratch or other blemish. Replace with
specified brake fluid, specially the
new one if necessary.
groove for piston ring and dust seal.
2.Brake caliper piston
Reassemble the brake caliper in
Check caliper piston for crack, scratch
the reverse order of disassembly
or other blemish. Replace with new
one if necessary.
121
`
Tighten caliper mounting

Install piston sealing ring and Apply grease to caliper holder bolts① specified torque.
dust ring . A. Specified torque:
Caliper mounting bolts — 26N.m
Hose union bolts—23N.m
122
`
4-4.2 Brake disk inspection

Check the brake disk for Measure brake disk run-out by
scratch, and measure its diameter-indicator, and replace
thickness by micrometer. with fresh one in it exceeds
Replace with fresh one if it is service limit.
scratched or thickness is less Tools: Diameter- indicator
than specified service limit. Magnetic basic
Service limit:2.5mm Service limit:0.3mm
123
`
4-4.3 Master cylinder disassembly and installation

Remove handlebar covers. Disconnect wire①of front brake
Put some cotton under the brake switch.
hose bolt, and then loosen the bolt Remove master cylinder ASSY.
and remove brake hose.
Remove front brake lever②and Remove cap④and diaphragm⑤⑥.

front brake switch③. Drain out brake fluid.
124
`
Master cylinder inspection:

Remove Dust cap⑦, clip⑧, 1.Cylinder
washer⑨and piston⑩along with Check the inner surface of cylinder
spring. for scratch or other damage.
Replace it if necessary.
Note:
Master cylinder inspection:
Immediately rub the brake fluid away from the surface of
2.Piston and rubber ring
Check piston surface and any parts. Brake fluid can damage the parts of plastic,
sealing ring for scratch or
paint and rubber due to chemistry.
wear. Replace it if necessary.
125
`
4-4.4 Master cylinder disassembly and installation (Reassemble master cylinder in the reverse order of
removal). Install the brake switch with its top
Install the clip properly.
Note end aligning with the master
Ensure clip sharp edge facing cylinder hole.
outward when installing it.
Install the master cylinder to handlebar

with its bracket touching area A
aligning with the mark B on handlebar. Tighten the brake hose bolt to
Firstly, tighten the upper bolt, and specified torque.
tighten both bolts to specified torque. Specified torque: 23 N.m
Specified torque: 10N.m
Note: Ensure “UP” mark on master
cylinder upward.
126
`
4-5 Steering handle

4-5.1 Disassembly
Remove the rear-view mirror assembly.

Remove the fixing screws of the handlebar shade.
Remove the front/rear shield the handlebar and
dismantle the meter.
Remove the front shade assembly.
Remove the left/right combination switch assembly.
Remove the fuel pump assembly.
Remove the left grip and the throttle lever assembly.
Loosen the fixing bolt (2) and nut (3) of the handlebar weld assembly.
Remove the handlebar weld assembly (1).
4-5.2 installation
Reassemble Steering handle in the reverse order of removal.
127
`
4-6 Front fork/4-6.1 Disassembly

Remove the front wheel.
Remove the body guard.
Remove the brake hose and the odometer cable.
Remove the handlebar.
Remove the gland nut (6), dust cover (7), packing
steel bowl (8) and steel ball (9) in order.
Remove the front fork.
Remove the upper/lower steel bowl (10,11) of the
lower bearing and steel balls (9).
Loosen the fixing bolt of the front absorber.
Remove the front left/right absorber assembly (1,2).
Tools:
Fixing bolt spanner for the steering handle weld assembly.
Fixing nut spanner.
Special disassembly tool for bearing steel bowl.
4-6.2 installation
128
`
Reassemble Steering handle in the reverse order of removal.

4-7 Rear Wheel /Brake/Suspension
1 RR. RIM COMP. 3.5X12 2. TIRE 130/70-12 3. RIM VALVE Z2-01-1 4. BRAKE SHOE KIT 5. SPRING(BLACK) 6. CAM SHAFT 7. CAM
SHAFT LEVER, ASSY 8. BRAKE INDICATOR PLATE 9.TENSION SPRING 10. HEX. BOLT 6X30MM 11. U NUT 16X1.5MM
129
`
4-7.1 Disassembly
1.Rear wheel and brake Remove rear brake shoes①. Remove brake adjusting nut①, brake
Stand the vehicle by center stand. Remove lever bolt and nut②
muffler.
Remove rear wheel.
Inspection：
Rear shock absorber Remove frame cover. 1.Brake hub Inspect I.D. of brake hub, and
Remove brake lever③, indicator④ and Remove air cleaner. Remove rear shock replace the rim if I.D. exceeds service limit.
brake cam⑤. absorber Tool: Caliper
130
`
2.Brake shoe 3.Rear shock absorber Reinstallation:

Removethe
Inspect brake
brakelever③
shoes, for
indicator④
wear andand
damage,
brake Inspect the rear shock absorber for leakage or Reinstall rear wheel, brake and suspension in
cam⑤
and replace
. the completed set of brake shoes if other damage, and replace if necessary. reverse order of removal.
necessary.
Reinstallation:
Reinstallation: Reinstallation:
Install the indicator to the brake cam with its
Apply grease to the brake cam and fixed Install rear wheel to final shaft, and
tooth aligning with the slot on the brake cam, and
pin before install brake shoes to them. tighten the nut to specified toque.
then install brake lever to the brake cam.
Specified toque:120N.m
Tighten the brake lever bolt to specified toque.
Specified toque:11N.m
131
`
4-8 Tire and Rim

4-8.1 Dismantle
Proper sealing between rim and tire is important for tubeless tire. It is recommended to dismantle and
reassemble the tire by tire building machine according to its operation manual.
Inspection Rim: Tire:

Clean and check the rim, and replace with fresh Check and replace the tire if following defect was found.
piece if following defect was found. Scratch and crack on side face of tire Damaged tire cord
Deform, crack Scratch at rim edge; Over wear. Abnormal wear of tread Crack on tire edge
Tire protector disarrangement.
Service limit 2.0mm.
Tool: Tire tread tester
Service limit of tread depth (Front & rear)1.6mm.
132
`
4-8.2 Inflating valve
Check the inflating valve①and sealing Remove the dust and rust surrounding
ring for crack or other damage. Replace inflating valve. Install inflating valve①to rim.
if necessary.
Note:
Apply special lubricant or neutral soap emulsion on inflating valve before installing it.
133
`
4-8.2 Reinstallation
When installing tire to rim, ensure arrow

Don’t damage the lip A of inflating Apply special lubricant on tire edge. mark①on tire aiming to the rotate direction of
Note: Don’t apply grease, oil or wheel and balance mark②aligning with
valve.
petrol.
inflating valve③.
Ensure balance mark aligning with inflating Ensure the tire out of rim is balanced after
Knock the tire on ground when rolling valve before inflating. inflating.
it for the proper sealing between tire Specified cold tire pressure: Otherwise bleed it and reinstall again.
and rim. Front:220kPa Rear:220kPa
134
`
5、ELECTRIC SYSTEM
135
`
5-1 General
Connector: Hold the connectors instead of Lock connector: Clamp the wires at the location shown in
wire to disconnect it. Push the connectors Release the lock firstly before wire diagram.
firmly to connect it. Check the connector disconnecting the connectors. Push the Don’t use wire or another succedaneum
terminal for corrosion, dirt or crack. connectors firmly to connect it. instead of clamp.
Hold the connectors instead of wire to
disconnect it.
Check the connector terminal for
corrosion, dirt or bending.
Fuse Semiconductor device Battery

Check the defect reason before replacing the burned
Take care not to drop down the parts contain of Sealed battery is equipped in this vehicle.
fuse. Don’t install the unspecified fuse or other
material instead of fuse. semiconductor device, such as ECU, rectifier.
136
`
5-2 Main Switch/Horn
Check
Remove the front guard.
Remove the helmet hook.
Remove the foot guard.
Remove the wiring connector for the main switch.
Check conduction of the terminal.

Check
Remove horn wires.
It shows good if making a sound when the horn wire is connected to the battery.
137
`
5-3 Speedometer ASSY

5-3.1 Dismantle
Remove handlebar cover. Remove and disassemble
speedometer.
5-3.2 Inspection
Install the speedometer in reverse order.
138
`
5-4 Fuel level gauge & sensor

5-4.1 Fuel level gauge inspection
If resistor of 6-10Ωwas If resistor of 90-100Ωwas

connected between B/W & connected between B/W &
Y/B wire and ignition Y/B wire and ignition
switch was turned on, fuel switch was turned on, fuel
level gauge will indicate level gauge will indicate
“F”. “E”.
Replace fuel level gauge if defect was found in any inspection.
Reinstall fuel level sensor Reinstall the fuel level sensor in the reverse order of remove.
139
`
5-5 Switch& Flasher Relay
140
`
Flasher Relay
Flasher relay is located behind front leg shield.
Replace flasher relay when bulbs and electric circuit are in working order, but winkers don’t work.
Note:
Ensure battery is fully charged before this inspection.
Note: Ensure the performance of every switch by multi-meter. Replace accordingly if defect was found.
141
`
5-6 Battery
5-6.1 Charging state (closed circuit) inspection
Open the cover of battery container. First remove the negative wire and thenremove the
positive wire. Take out the battery.
Measure the voltage between battery terminals：
Full charge：13.1V
Under charge：12.3V
* Note
Charge state examination must use a voltmeter operation.
Charge
Connection method：Connect the battery charger positive pole and battery positive pole
together.
Connect the battery charger negative pole and battery negative pole together.
Charging current：standard：0.6A Emergency：6.0A
Charging time：standard：10-15h. Emergency：30 min.
Charging complete：closed circuit voltage: above 12.8V
*Note
• Except emergencies, you should not use emergency charge.
• Measure the voltage for every other 30 minutes.
142
`
5-7 Charging System

Inspection Leakage Test:
Turn the ignition switch off. Remove battery case cover
Disconnect the ground (-) cable from battery.
Connect the ammeter (+) probe to the ground cable and the ammeter (-) probe to the
battery (-) terminal, and check for current leakage.
Tool: multi-meter. Ammeter measurement range：DC 20mA
Specified current leakage：1mA max
Note: When measuring, firstly set the meter to a high range, and then bring the range
down to an appropriate level. Current flow larger than the selected range may
damage the meter.
Connect the multi-meter between

the battery terminals to measure DC
voltage. If the reading is less than
Start engine, turn Light switch to specified value, check alternator coil
ON position and dimmer switch and regulator/rectifier.
to HI position, and keep engine Tool: multi-meter
running and keep engine running voltage measurement range：DC 20V
at 5000 rpm.
Specified regulated voltage: 14.0-15.0V
at 5000rpm
143
`
5-7.1 Stator coil resistance& Generator coil open-circuit

Remove front leg shield and lower shield
voltage
Disconnect Remove front leg shield and lower
shield Disconnect regulator/rectifier connector
Measure voltage between terminals according to
following table.regulator/rectifier connector
Measure voltage between terminals according to
following table.
If the reading is out of specified value, replace
rectifier/regulator.
Tool: multi-meter Measurement range: Diode
Disconnect stator coil 3P Remove inspection cap at bottom

connector. of luggage box. Disconnect stator
5-7.2 Regulator/rectifierMeasure the resistance between coil 3P connector.
Start engine and keep engine running
terminals of stator coils.
at 5000 rpm.
If the reading is less than
Measure open-circuit voltage between
specified value, replace stator terminals of stator coils.
coil. Tool: multi-meter If the reading is less than specified
Measurement range: Ω value, replace stator coil. Tool:
Specified resistance: 0.7-0.9Ω multi-meter Measurement range:
(Yellow wire/Ground) AC 50V Specified voltage: 30V at
1.0-1.2Ω（White wire/Ground） 5000rpm
144
`
5-8 Starting System

Starter motor component：
Starter motor case①、Holder②、Carbon brush③、Armature④、Commutator bar⑤.
Specification
Carbon brush length 6.8mm 4.8mm
Inspection：
1.Carbon brush inspection
When carbon brush worn, starter motor cannot generate enough torque, and engine is hard to start.
To avoid this defect, it is necessary to measure length of carbon brush and replace if it is too short or thin.
2.Armature coil inspection
Check armature commutator bar for color changing. Changed color on one couple of commutators bar shows this coil is shorted.
Ensure every couple of commutator bar admittance. Ensure insulation between commutator bar and armature.
145
`
Trouble shooting：
1.Starter motor cannot work.
Fuse is burn.
Battery is not fully charged
Starter motor wire is disconnected or loose.
Check tarter relay performance. When pressing the starting button, contact sound can be heard.
2.When starter motor working, engine turns slowly.
Battery voltage is low.
Battery terminal is not properly connected Starter motor wire is not properly connected Defect in starter motor.
3.When starter motor working, engine cannot turn.
Starter motor turns in wrong direction.
Starter motor terminal is not properly connected. Defect in starter gears.
4.When pressing the starting button, the contact sound can be heard, but engine doesn’t turn. Due to defect in engine, crankshaft doesn’t turn.
Defect in starter motor.
146
`
5-8.1 Starter Relay
Check Voltage check of the starter relay

Remove the body guard Set up the main stand, and measure voltage between the negative
When the main switch is “on”, check there is “click” sound at the time pole of the green/yellow wire of the starter relay terminal and the
of pressing the startup motor. body ground connection.
With click sound, it is normal. When the main switch is “on”, hold the brake lever. The battery
Without click sound: voltage shall comply with regulations.
•check voltage of the starter relay; •check the GND loop of the starter When there is no voltage at the starter relay terminal, check the
relay; conduction of the brake switch and leads.
check the movement of the starter relay.
147
`
5-9 Starting System

5-9.1Component in ignition system
1、Stator ASSY. 2、Ignition coil . 3、Oxygen Sensor. 4、Engine Temperature Sensor. 5、Spark plug. 6、speed converter.
7、ECU.
148
`
5-9.2 Material Preparation

Note of Work:
1. Checking the ignition system following the sequence listed in the table of failure diagnosis.
2. The ignition system is solidified in the ECU group and you don’t have to adjust the ignition time.
3. Checking the ignition system following the sequence listed in the table of failure diagnosis.
4. Check whether the connection is bad or not, because usually the reason for failure is poor contact socket.
5. The heat value of the spark plug should be appropriate. Improper spark plug will cause the engine running unsmooth and even the spark plug will
be burn-out.
6. Inspection in this chapter is based mainly on the maximum voltage，also inspection of the ignition coil impedance is introduced.
7. Check the main switch according to the table.
8. Remove the alternator and stator according to the instructions.
Standards Preparation
Items Standard Value
Standard CR6HSA(NGK)
Recommended
Hot CR5HSA(NGK)
Spark Plug
Cold CR7HSA(NGK)
Spark Gap 0.6-0.7mm
Ignition Coil Primary Coil (4±0.2) Ω
Impedance Secondary With plug cap (19±2) KΩ
（20℃） Coil Without plug cap 10-15KΩ
Resistance of Trigger（20℃） 100-250Ω
Maximum Voltage Measurement of Ignition Coil 95-400V
Trigger Voltage 0.7V Min
149
`
5-9.3 Failure Diagnosis

Spark plug fails to jump.
Error Reason（in compliance with the following order）
① The inner resistance is too small and it should be tested by required tester.
② Low rotation speed of the bent axle.
Ignition
③ Tester is interfered. (It is normal that several measured voltages are above the basic standard.).
Coil Low Voltage
④ Poor contact wire for the ignition system.
⑤ Bad ignition coil.
⑥ Bad charging coils (measure at maximum voltage).
① Wrong connection with the tester.
② Bad main switch.
③ Bad charging coil (measure at maximum voltage).
Secondary No or interrupted high voltage electricity
④ Bad trigger（measure at maximum voltage）.
Side
⑤ Bad high-tension electricity connector.
Voltage
⑥ ECU system failure
① Bad plug or secondary ignition coil leakage.
Normal high voltage electricity/no spark for the plug
② Bad ignition coil.
① The inner resistance is too small and should be tested by required tester.
② Low rotation speed of the bent axle.
No high voltage electricity
Charging ③ Tester is interfered. (It is normal that several measured voltages are above the basic standard.).
Coil ④ Bad charging coil（①-③are normal）.
① Bad ignition coil.
No or interrupted high-tension electricity ② Bad charging coil.
150
`
① The inner resistance is too small and should be tested by required tester.
② Low rotation speed of the bent axle (It is normal that several measured voltages is above the
Low high voltage electricity basic standard.)
Trigger ③ Tester is interfered.
④ Bad trigger（①-③are normal）.
① Bad ignition coil.
No or interrupted high voltage electricity
② Bad trigger
6、Failure Diagnosis
151
`
Table
Fault system Fault Causes Troubleshooting
Fuel cannot enter the carburetor; Dredge each blocked place.
The engine is The fuel negative pressure switch is blocked; Clean the fuel negative pressure switch
difficult or is The T-pipe leaks; Replace the T-pipe
unable to be
The fuel pipe is blocked; Dredge the fuel pipe.
started.
The vacuum pipe is blocked. Dredge the vacuum pipe
The carburetor is blocked; Clean or replace the carburetor
The adjustment of the mixing ratio and
Fuel system The Readjust the mixing ratio and concentration of the carburetor.
concentration of the carburetor is incorrect;
motorcycle is The carburetor leaks; Clean the carburetor or replace the carburetor floater
difficult to be The fuel filter is blocked; Clean the fuel filter
started or the
The throttle of the carburetor is worn; Replace the throttle
fuel is
excessively The fuel goes bad; Replace the fuel.
consumed. The air vent of the fuel tank is blocked; Dredge the air vent of the fuel tank
The fuel in the fuel tank is not enough. Add fuel to the fuel tank
The Air filter element is blocked; Clean the air filter element
The air filter leaks; Replace the air filter
The air filter has too much dust; Clean the air filter element.
The air filter housing leaks; Repair or change the air filter housing.
The Too much carbon is built up at the exhaust
motorcycle is Clean the carbon buildup at the exhaust port.
Air intake/exhaust port;
difficult to be The exhaust port leaks; The exhaust port leaks.
system
started or is
short of power.
The silencer is blocked. The silencer is blocked.
152
`
Continued
Too much carbon is built up at the secondary

Clean the carbon buildup at the secondary air intake port.
air intake port.
Emitted
pollutants The air pump is blocked or damaged. Replace the air pump.
Environmental The air pump filter is blocked or damaged. Replace the air pump filter.
exceed
protection device The intake rubber hose is aged or leaks. Replace the intake rubber hose.
applicable
standards
The clamp is loose or damaged. Replace the clamp.
There is carbon buildup or dirt on the spark

Clean the carbon buildup and dirt on the spark plug.
plug.
The spark plug gap is improper. Adjust the gap to 0.6mm~0.7mm
The insulation part of the spark plug is
damaged, resulting in Short-circuit of Replace the spark plug
electrodes.
Weak spark or Short-circuit of the ignition coil Replace the ignition coil
Ignition system
no spark
C.D.I igniter is faulty. Replace C.D.I igniter.
The impulse generator is faulty. Replace the impulse generator.
The connection of the ignition system is

Check each connection.
loose.
The sealing washer of the cylinder head
Replace the sealing washer or apply some sealant.
leaks.
The engine is The adjustment of the valve lash is incorrect. Adjust the valve lash to 0.10mm~0.14mm
difficult to be
Air distribution
started up or The air valve stem bends. Replace the air valve.
system
the idling is not
stable
Th elasticity of the air valve spring is
Replace the air valve spring.
reduced.
153
`
Continued
The cylinder There is too much carbon buildup in the

Clean the carbon buildup in the combustion chamber and on the
pressure is too combustion chamber and on the top of the
top of the piston.
high. piston.
The adjustment of the valve lash is improper. Readjust the valve lash
The engine The air valve spring breaks off. Replace the air valve spring.
shows big
noise. The cylinder and piston wear out. Replace the cylinder and piston.
The cylinder
Air distribution The cylinder, piston and piston ring seriously
pressure is too Replace the cylinder, piston and piston ring.
system wear out.
low.
The piston ring wears out. Replace the piston ring.
The silencer The piston ring is improperly mounted. Remount the piston ring.
gives blue
smoke. There is scratch or wear on the piston or
Replace the piston or cylinder.
cylinder wall.
The cylinder The air valve stem or air valve guide pipe
Replace the air valve stem and air valve guide pipe.
head leaks. wears out.
The front shock absorber deforms. Replace the front shock absorber
The front wheel shafts bends. Rectify the front wheel shaft.
The front The front wheel deforms. Rectify the front wheel and replace the front wheel
wheel The front wheel is improperly mounted. Remount it
deviates.
The front wheel bearings are worn out or
Replace the front wheel bearings.
damaged.
Travel system
The front aluminum wheel deforms. Replace the front aluminum wheel.
The nut of the front wheel shaft is loose. Tighten the nut of the front wheel shaft.
The front The tire pressure is too low. Increase the tire pressure.
wheel swings.
The front wheel shaft is loose. Tighten the nut of the front wheel shaft.
154
`
Continued
The rear aluminum wheel deforms. Replace the rear aluminum wheel.
The rear wheel The tire pressure is too low. Increase the tire pressure.
Travel system
swings.
The rear wheel shaft is loose. Tighten the nut of the rear wheel shaft.
The spring of the shock absorber loses

Replace the spring of the shock absorber
elasticity.
The shock absorber
Suspension system
is too soft.
The shock absorber is improperly adjusted. Re-adjust the shock absorber
The brake malfunctions. Adjust and repair the braking system
The braking The brake shoe wears out. Replace the brake shoe
Braking system performance is
poor. The brake disc wears out. Replace the brake disc.
Add brake oil.
The head light bulb burns out. Replace the head light bulb.
The housing assembly switch is faulty. Repair the housing assembly switch.
The connecting plug is loose. Tighten the connecting plug.

The head Light is
Lighting system The fuse burns out. Replace the fuse.
not on.
The accumulator cell is faulty. Replace the accumulator cell
The lighting coil of the magneto is faulty. Replace the lighting coil.
155
`
Failure diagnosis procedure when the storage battery is undercharged
Storage battery is undercharged
Check if the brake lamp is on
Yes No
Put the ignition switch in “OFF” position, remove the negative pole wire from
Adjust or replace the the storage battery, connect the ammeter negative pen to the negative
brake lamp switch ternminal of storage battery and positive pen to the negative pole wire to
check the leakage current
Leakage current is greater than the

Leakage current is less than the specified value specified value (it is generally required
that the leadkage current is no greater
than 1mA)
Check if the charging coil of magnetor is short-circuited
The wire from the commutator
or the commutation regulator or
Yes No the storage battery to the ignition
switch is short-circuited
1. Check if the electrolyte in the storage
Replace the battery is insufficient
charging coil 2. Check if electrolyte concentration in the
storage battery is too low
3. Check if the polar plate in the storage
battery is sulfurized or short-circuited
156
`
Failure diagnosis procedure when the brake lamp does not work
The brake lamp does not work
The brake lamp does not work
Remove the brake lamp cover and check if the circuit

board of brake lamp is burnt out
Yes No
Use a lead to short circuit the two terminals or two leading

Replace the circuit board of wires of the brake lamp switch
brake lamp
The brake lamp still does not work after short-circuiting The brake lamp will work after short-circuiting
Use the screwdriver or heavy gage wire to touch the The brake lamp switch is
power supply lead of brake lamp switch and the ground adjusted improperly or its
internal contact is in bad
earth quickly, and check if there is sparkle contact
Sparkle appears when touching No sparkle when touching
The lead between the brake lamp switch and the The lead between the ignition switch and the brake
brake lamp is broken or short-circuited lamp switch is broken or short-circuited
157
`
Failure diagnosis procedure when the electric horn does not work
The electric horn does not work
Turn on the ignition switch, and

toggle the steering lamp to check
the work of steering lamp
The steering lamp does not work or the The light of the steering lamp is bright
light is pale
The electricity supply of storage battery is The electricity supply of

insufficient or the wire from the storage storage battery is normal
battery to the ignition switch is broken or
short-circuited Remove the power lead from the power terminal of
electric horn, and touch the power lead with ground
earth quickly to check the sparkle
Sparkle appears when touching No sparkle when touching
Connect the power lead of the electric horn, use the

The power lead from the
screwdriver to contact the non-power terminal of electric ignition switch to the
horn (to the terminal of button) with the ground earth electric horn is broken
The electric horn sounds after The electric horn does not
contacting sound after contacting
158
`
The internal contact of horn Adjust the volume and tone of the electric horn
button is in bad contact or the
lead from the electric horn to the
button is broken
The electric horn still does not The sound of the electric horn returns
sound after adjustment to normal after adjustment
The electric horn is The electric horn is

damaged adjusted improperly
159
`
Failure diagnosis procedure when the steering lamp does not work
The steering lamp does not work
Some steering lamps on one

side do not work Steering lamps on one side do not work All the steering lamps do not work
Remove the steering lamp Remove the steering lamp Press the horn button to check the
cover and check if the bulb of cover and check if the bulb of working condition of electric horn
steering lamp is burnt out steering lamp is burnt out
Yes No Yes No
Use the voltmeter Disconnect the The electric horn The electric horn
Replace to measure the Replace steering lamp switch does not sound or
the bulb the bulb sounds loudly
voltage between insert connector, use sounds raucously
of the lamp stand of steering
steering lamp the ohmmeter to test
power line
lamp if the failure side of The electricity The electricity supply
contact and
negative pole steering lamp switch supply in storage in storage battery is
has been solved battery is insufficient
Yes No insufficient
Voltage No voltage Remove the steering lamp cover
The internal and check if the bulb of steering
indicates indicates The output contact of lamp is burnt out
power line steering lamp is
on the in bad contact No Yes
The lamp stand is The power failure side
grounded line of is broken or
improperly or the lamp Toggle the steering lamp switch, Replace the steering
the lamp
connection stand is use one lead or screwdriver to
stand is lamp bulb, at the
between steering broken short-circuit the two lugs of
lamp bulb and grounded same time check if
improperly scintillator the commutation
lamp stand is in
bad contact regulator works well
160
`
The steering lamp still does not work after

The steering lamp will
short-circuiting work after short-circuiting
Disconnect the insert connector of steering lamp switch, use

a lead to short-circuit the power input lead of the steering The scintillator
lamp switch with the power leads connecting to left and is damaged
right steering lamps respectively
The steering lamp will The steering lamp still does not work after
work after short-circuiting
short-circuiting
The internal contact of Use lamp-testing method to check if there is power output
steering lamp switch is in from the power input lead of the steering lamp switch
bad contact
Testing lamp works Testing lamp does not work
The line from ignition switch to

The power lead of the steering scintillator or the line from
lamp is broken or short-circuited scintillator to steering lamp switch
is broken or short-circuited
161
`
Failure diagnosis procedure when the light of lamp is weak

The light of lamp is weak
AC power supply illuminating system DC power supply illuminating system
Disconnect the insert connector between Turn on the ignition switch, press the horn button or toggle the
the magnetor wire bundle and the turn signal
complete vehicle cable, use the ohmmeter
measure that if the resistance between the
output conductor terminals of magnetor
lighting coils is less than standard value
The electric horn sounds raucously,
Yes No and the light of turn signal is pale
Start the engine and limit its

The lighting coils The sound of the
are short-circuited rotation speed, disconnect the The electricity supply in storage
insert connector between the electric horn is battery is insufficient or the
commutation regulator and the loud and the light connection between the storage
complete vehicle cable to check of turn signal is battery to ignition switch is in
bright bad contact
the brightness of lamps
The lamp lights return to The lamp light is still weak

normal after disconnecting after disconnecting
Check if wires in the

The stabilized voltage of magnetor charging coils and
commutation regulator is charging system are
too low short-circuited
Yes No
Check and exclude Disconnect the head lamp assembly,

and check if the bulb glass of head162
` lamp is black or yellowish-green
No Yes
Check if the bulb power used in Replace the bulb of

the illuminating system meets head lamp
the specified requirements
Yes No
1. Check if the internal contacts of Replace the bulb of lamp

lighting switch and dimmer switch
are in bad contact
2. Check if the insert connector in
the system and earth wire are in
bad contact
163
`
Failure diagnosis procedure when the bulb of lamp is easily burnt out
The bulb of lamp is easily burnt out
Turn on the ignition switch, press the horn button or toggle the turn signal
switch
The sound of the electric horn is

The electric horn does not sound or loud and the light of turn signal
sound raucously, and the light of is bright
turn signal is pale
Remove the insert connector between the

1. Check if the terminal connecting the commutation regulator and the complete vehicle
storage battery is on poor contact cable, and use the ohmmeter to measure that if the
2. Check if the electrolyte in the storage wires from magnetor lighting charge coil to
battery is insufficient commutation regulator are broken
3. Check if electrolyte concentration in No Yes
the storage battery is too low
4. Check if the polar plate in the storage
battery is sulfurized or short-circuited Place the multimeter in the 0V~20V DC Connect
voltage, measure the voltage of the insert
connector to the conductor terminal of
storage battery (generally red wire or
red/white wire) and negative pole
No voltage indicates Voltage indicates
The leads from the insert connector to the Check if the commutation regulator fails
storage battery are broken
164
`
Failure diagnosis procedure when all the lamps don’t work

All the lamps don’t work
AC power supply illuminating system DC power supply illuminating system
Press the horn button or

Disconnect the insert connector between the magnetor
wire bundle and the complete vehicle cable, use the toggle the steering lamp
lamp-testing method to check if there is electrical energy switch
output from the output wire of magnetor lighting coil
The electric horn The electric horn does not

sounds loudly and the sound and the steering lamp
Testing lamp does not work Testing lamp works steering lamp works does not work
Start the engine, disconnect

The magnetor lighting the insert connector between The power supply of Use a wire to touch the
coil or its output wire is the commutation regulator and storage battery is positive terminal and
the complete vehicle cable negative terminal of the
broken or short-circuited normal storage battery quickly, and
check if there is sparkle
The lamp still does not

The lamp works work No sparkle when Sparkle appears
touching when touching
The inside of
commutation regulator is No electricity
short-circuited in the storage 1. Check if the fuse is
Disconnect the head lamp battery burnt out
assembly, and check if the bulb 2. Check if the wires
of head lamp is burnt from the storage
battery to ignition
switch are broken or
165 short-circuited
` 3. Check if the ignition
switch is broken or
short-circuited
Yes No
Replace the bulb of head lamp, and Use the lamp-testing method to check if
check if the bulbs of other lamps there is electrical energy output from the
are burnt one by one power input wire of lighting switch
Yes No
Use a wire to short circuit the power lead The wires between the
of lighting switch and the output lead magnetor or ignition switch to
the lighting switch are broken
or short-circuited
The lamp will work after shortcircuiting The lamp still doesn’t work after shortcircuiting
The internal contact of The wires between the

lighting switch is in poor lighting switch to lamps are
contact broken or short-circuited
166
`
Failure diagnosis procedure when the storage battery is undercharged
Storage battery is undercharged
Check if the brake lamp is on
Yes No
Adjust or replace the brake Put the ignition switch in “OFF” position, remove the negative pole wire from the
lamp switch storage battery, connect the ammeter negative pen to the negative ternminal of storage
battery and positive pen to the negative pole wire to check the leakage current
Leakage current is greater than the

Leakage current is less than the specified value specified value (it is generally required
that the leadkage current is no greater
Check if the charging coil of magnetor is than 1mA)
shortcircuited
The wire from the commutator
Yes No or the commutation regulator or
the storage battery to the ignition
Replace the 1. Check if the electrolyte in the storage battery switch is shortcircuited
charging coil is insufficient
2. Check if electrolyte concentration in the
storage battery is too low
3. Check if the polar plate in the storage battery
is sulfurized or shortcircuited
167
`
Failure diagnosis procedure when the drum brake fails
Drum brake fails
Check if the free stroke of brake lever is within 10mm

~ 20mm or check if the free stroke of brake pedal is
within 20mm ~ 30mm
No Yes
Readjust Separate the steel ropes of brake rocker arm and brake control cable, then
pull the brake rocker arm by hand to check
Brake rocker arm

revolves smoothly, but Brake rocker The arrow on the indicating The arrow on the indicating plate
you feel resistance plate of brake cam aligns with of brake cam does not align with
arm revolves
when holding the or exceeds the “▽”mark on the “▽”mark on the brake wheel
difficultly the brake wheel hub cap hub cap
brake handle
1. Check if the surface of brake
1. Check if the crown face of the brake block friction disc is stained with
The wire ropes of The movable cam is over-worn
brake control parts of the oil
2. Check if the brake block friction disc 2. Check if the contact area
cable can not be brake cam are is over-worn
pulled smoothly rusted or stuck between the brake block friction
3. Check if the brake wheel hub inside is
Failure diagnosis procedure
in the cover in when
foreignthe storage battery cannot be charged dis and brake hub is less than 70％
over-worn
materials The storage battery can not be charged
Disconnect the insert connector of magnetor wire

bundle and the complete vehicle cable, use the
ohmmeter to measure the resistance between the
output wire ends of charge oil, and check if it 168
` meets the standard value
The resistance value is smaller than The resistance value is equal to

standard value standard value The resistance value is infinite
Connect the insert connector between the magnetor

Short circuit of wire bundle and the complete vehicle cable, disconnect Short circuit of charge
charge coil the insert connector between the commutator or
commutation regulator and the complete vehicle cable coil or its output wire
Use the ohmmeter to measure that if the resistance

between the output wire ends of charge oil in the insert
connector is equal to the resistance of the charge coil
itself
Yes No
Place the multimeter in the 0V~20V DC The circuit from the magnetor to
voltage, measure the voltage of the insert commutator or commutation
connector to the conductor terminal of storage regulator is in poor contact or
battery (generally red wire or red/white wire) broken
and negative pole
No voltage indicates Voltage indicates
Circuit from the Use the ohmmeter to test the

insert connector commutator or test if the
to storage battery commutation regulator fails
is broken
169
`
Failure diagnosis procedure when the hydraulic disc brake fails

hydraulic disc brake fails
Check the brake fluid level in the brake primary pump liquid reserve tank
The brake fluid level below the lower limit of liquid The brake fluid level above the lower limit of
reserve tank liquid reserve tank
Fill the brake fluid to the Check if there is “sponge”

upper limit of liquid reserve feels when operating the
tank, at the same time brake lever
check if there is oil leaking
in the brake caliper, brake No Yes
hose and hose joints N
Check if the brake friction disc is There is residual air
worn to limit mark and if the brake in the fuel line of
plate is over-worn brake system
Yes No
1. Check if the surface of brake primary pump piston and oil

Replace the brake cylinder is over-worn
friction disc and 2. Check if the leather cup of brake primary pump piston cracks or
the brake plate is damaged or ageing
3. Check if the seal ring of brake caliper cracks or is damaged or
ageing
4. Check if the surface of brake caliper and oil cylinder is
over-worn
170
`
DIMENSIONS
171
`
172
`
173
`
Wiring diagram
174
`
Specified Torque
Engine
Item N-m
Cylinder head bolt 10
Cam shaft holder nut 18
Tappet lock nut 10
Tensioner lifter bolt 10
Crankcase cover LH bolt 10
Clutch hub nut 50
Drive face assy nut 50
Kick lever bolt 16
Magneto rotor nut 50
Magneto stator bolt 10
Pulse coil bolt 10
Oil pump gear nut 10
Oil filter cap 20
Engine oil drain plug 15
Gear box oil level bolt 12
Gear box bolt 16
Oil pump bolt 10
Crankcase bolt 10
Cylinder stud bolt 25
Timing chain tensioner bolt 10
Cooling fan bolt 8
Intake pipe bolt 10
Spark plug 18
175
`
Frame body
Item N-m
Front axle nut 40-52
Steering stem lock nut 30
Handlebar mounting nut 25
Handlebar clamping bolt/nut 48-52
Front fork cover bolt 23
Front fork clamping bolt 23
Front brake master cylinder bolt 10
Front brake hose union bolt 23
Front brake caliper mounting bolt 26
Front brake bleeding valve 7.5
Brake pedal bolt 23
Rear axle nut 60-80
Rear shock absorber bolt (Upper and lower) 28-35
Rear brake cam nut 11
Crankcase bracket mounting nut 98
Engine mounting bolt 32
General Torque Value
Thread Dia. N-m

M5 bolt and nut 4
M6 bolt and nut 9
M8 bolt and nut 12
M10 bolt and nut 26
M12 bolt and nut 39
176
`

Service Manual - ZNEN - CRUZER 50 EU4 - GER - Vers 05 2018

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual - ZNEN - CRUZER 50 EU4 - GER - Vers 05 2018

Uploaded by

Copyright:

Available Formats

Service and Maintenance

Motorcycle CRUZER50 Maintenance Manual

2-8 Electronic carburetor .......................................................... 41

4-1 Outer Parts ................................................................... 109

1-1 Motorcycle Vehicle Identification Number (VIN) and Engine Number

1-2 Brief Introduction to the Whole Motorcycle

1-3 Brief Introduction to the Whole Motorcycle

Brief Introduction to the Whole Motorcycle ①. Front braking handgrip

1-4 Brief Introduction to the Whole Motorcycle

1-5 Instrument combination

indicates that “Turning signal light” is open.

it indicates that the “Right turning signal light” is on.

indicates that the “High beam lamp” is on.

⑧. Speedometer：It indicates the current driving speed of the motorcycle.

1-6 Left combination switch

① High beam lamp switch:

1-7 Right combination switch

① Double flash switch:

② Electric start button:

1-8 Ignition lock switch

1-9 Fuel tank

1-10 Operation of Left Combination Switch

1-11 Operation of Right Combination Switch

When the motorcycle needs electric start, press the button “ ”.

Operation of Electric Startup

The foot-stepped startup of the motorcycle is done in the following steps：

1-13 SIDE STAND FLAMEOUT SWITCH

1-16 STARTING OFF/ACCELERATION / DECELERATION/BRAKING

The speed can be adjusted by opening and closing the throttle. To

Model CRUZER 4T Type of engine BN139QMB

Full length mm 1900 Type of fuel lead-free gasoline（92/95）

Type of clutch Dry centrifugal type

Carburetor model E-Carburetor

Magneto capacity 95W/4000rpm

Ignition type ECU Rear brake drum

2-2 Periodic Maintenance & Inspection List

Airfilter Clean/ Exchange   Exchange  

Wheels, Rims Control     

Tire Control of tread depth / Pressure    

Wheel bearing Control/ Exchange    

Tax bearing Control/ Clean / Lubricate    Lubricate 

Glands cover Control/ Retighten    

Brake system Control/ Clean / Exchange    

Side stand Control/ Clean / Lubricate    

Telescopic fork Control    

Shock absorber rear Control    

Oil strainer / Spin filter Clean   

Engine oil / Oil filter Exchange / Control Exchange  Exchange  Exchange

Transmission oil Exchange   

Valves Control / Adjust     

Variomatic belt Control/ Exchange  Exchange 

Variomatic rolls Control/ Exchange  Exchange 

Drive chain / Pinion Control / Clean / Exchange     

Cables / Bowden Control / Clean / Lubricate     

Throttle Control / Adjust / Lubricate    

Lights / switch Control / Adjust     

Fuel line / Filter Control / Exchange  Exchange  

Idle speed Control / Adjust     

Exhaust system Control / Retighten    

2-3 Part Function Description and Maintenance of

Function and troubleshooting of components of ECS

ECU function introduction

ECU test procedure