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Benelli Imperiale 400 - Workshop Manual
Benelli Imperiale 400 - Workshop Manual
Two-wheeled Motorcycle
IMPERIALE 400(BJ400-8)
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Table of Contents
Introduction.............................................................................................................................................................. - 1 -
Preparatory Information...........................................................................................................................................- 2 -
General safety.................................................................................................................................................. - 2 -
Maintenance rules............................................................................................................................................ - 3 -
Model information......................................................................................................................................... - 13 -
Motorcycle identification...............................................................................................................................- 15 -
Important Note............................................................................................................................................... - 15 -
Special tools................................................................................................................................................... - 16 -
Specification table (BJ400-8)........................................................................................................................ - 24 -
Unit conversion table..................................................................................................................................... - 26 -
Winding method of cables, wires and hoses..................................................................................................- 27 -
Troubleshooting Guide.................................................................................................................................. - 64 -
Torque and locking agent...............................................................................................................................- 74 -
Inspection / adjustment.................................................................................................................................. - 79 -
Inspection and Maintenance of Electrical System...............................................................................................- 110 -
I. Battery/Charging System..................................................................................................................................- 112 -
1.1 Preparatory Information.........................................................................................................................- 112 -
1.2 Fault Diagnosis...................................................................................................................................... - 113 -
1.3 Battery.................................................................................................................................................... - 114 -
1.4 Charging System.................................................................................................................................... - 120 -
1.5 Disassembly of Voltage and Current Regulator.................................................................................... - 121 -
1.6 Alternator............................................................................................................................................... - 122 -
II. Ignition System................................................................................................................................................- 126 -
2.1 Preparatory Information.........................................................................................................................- 126 -
2.2 Fault Diagnosis...................................................................................................................................... - 128 -
2.3 Trigger....................................................................................................................................................- 129 -
2.4 Ignition Coil........................................................................................................................................... - 129 - ka
2.5 Spark Plug.............................................................................................................................................. - 131 - -d
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2.6 ECU........................................................................................................................................................- 132 -
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III. Starter System................................................................................................................................................ - 134 -
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3.1 Preparatory Information.........................................................................................................................- 134 -
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3.2 Fault Diagnosis...................................................................................................................................... - 135 -
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3.3 Starter Motor.......................................................................................................................................... - 135 -
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3.4 Starter Relay...........................................................................................................................................- 136 -
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IV. Bulbs /Switches/Meters..................................................................................................................................- 139 -
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4.1 Preparatory Information.........................................................................................................................- 140 -
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4.2 Fault Diagnosis...................................................................................................................................... - 140 -
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4.3 Replacement of headlight bulb.............................................................................................................. - 141 -
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4.4 Replacement of Turn Signal Light Bulb................................................................................................- 142 -
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4.5 Replacement of Taillight Bulb............................................................................................................... - 143 -
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4.6 Replacement of License Light Bulb...................................................................................................... - 143 -
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4.7 Meters.....................................................................................................................................................- 144 -
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4.8 Ignition Switch.......................................................................................................................................- 146 -
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4.9 Electric horn...........................................................................................................................................- 147 -
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4.10 Handlebar Switch.................................................................................................................................- 149 -
4.11 Inspection of switch............................................................................................................................. - 151 -
4.12 Speed sensor.........................................................................................................................................- 152 -
4.13 Oxygen sensor......................................................................................................................................- 153 -
4.14 Fuel level sensor.................................................................................................................................. - 154 -
4.15 Relay and fuse box...............................................................................................................................- 156 -
4.16 Fuse...................................................................................................................................................... - 160 -
Inspection and Maintenance of Chassis...............................................................................................................- 163 -
V. Brake................................................................................................................................................................- 170 -
5.1 Preparatory Information.........................................................................................................................- 170 -
5.2 Fault Diagnosis...................................................................................................................................... - 171 -
5.3 Front Brake Disc.................................................................................................................................... - 172 -
5.4 Rear Brake Disc..................................................................................................................................... - 174 -
5.5 Brake lever, brake pedal........................................................................................................................ - 177 -
5.6 Caliper....................................................................................................................................................- 180 -
5.7 Brake pad............................................................................................................................................... - 187 -
5.8 Master cylinder...................................................................................................................................... - 190 -
5.9 Brake fluid............................................................................................................................................. - 195 -
5.10 Brake hose............................................................................................................................................- 199 -
5.11 Anti-lock brake system (ABS).............................................................................................................- 202 -
VI. Body Cover.................................................................................................................................................... - 237 -
VII. Front Wheel/Front Suspension.....................................................................................................................- 244 -
7.1 Preparatory Information.........................................................................................................................- 244 -
7.2 Fault Diagnosis...................................................................................................................................... - 245 -
7.3 Front Wheel............................................................................................................................................- 245 -
7.4 Handlebar............................................................................................................................................... - 250 -
7.5 Front Fork.............................................................................................................................................. - 254 -
7.6 Front Shock Absorber............................................................................................................................ - 262 -
VIII. Rear wheel/rear suspension.........................................................................................................................- 272 - ka
8.1 Preparation of Information.................................................................................................................... - 272 - -d
8.2 Fault Diagnosis...................................................................................................................................... - 272 - n is
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8.3 Rear wheel............................................................................................................................................. - 273 -
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8.4 Rear shock absorber...............................................................................................................................- 278 -
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8.5 Rear Rocker Arm................................................................................................................................... - 280 -
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8.6 Chain drive.............................................................................................................................................- 283 -
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IX. Fuel Tank/Seat............................................................................................................................................... - 294 -
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9.1 Preparatory Information.........................................................................................................................- 294 -
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9.2 Fault Diagnosis...................................................................................................................................... - 294 -
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9.3 Seat.........................................................................................................................................................- 295 -
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9.4 Fuel Tank................................................................................................................................................- 296 -
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X. Frame...............................................................................................................................................................- 306 -
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10.1 Preparatory Information.......................................................................................................................- 306 -
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10.2 Fault Diagnosis.................................................................................................................................... - 307 -
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10.3 Frame................................................................................................................................................... - 307 -
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10.4 Sidestand.............................................................................................................................................. - 309 -
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10.5 Center stand......................................................................................................................................... - 310 -
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10.6 Pedal.....................................................................................................................................................- 311 -
10.7 Muffler................................................................................................................................................. - 315 -
10.8 Disassembly/installation of engine...................................................................................................... - 317 -
Inspection and maintenance of engine.................................................................................................................- 331 -
XI. Lubrication System........................................................................................................................................- 338 -
11.1 Preparatory Information.......................................................................................................................- 338 -
11.2 Troubleshooting................................................................................................................................... - 339 -
11.3 Fuel Pump............................................................................................................................................ - 340 -
XII. Cylinder Head Cover....................................................................................................................................- 346 -
12.1 Preparatory Information.......................................................................................................................- 346 -
12.2 Fault Diagnosis.................................................................................................................................... - 346 -
12.3 Cylinder head cover............................................................................................................................. - 347 -
XIII. Cylinder Head............................................................................................................................................. - 355 -
13.1 Preparatory Information.......................................................................................................................- 355 -
13.2 Fault Diagnosis.................................................................................................................................... - 356 -
13.3 Cylinder head....................................................................................................................................... - 357 -
XIV. Cylinder Block and Piston.......................................................................................................................... - 372 -
14.1 Preparatory Information.......................................................................................................................- 372 -
14.2 Fault Diagnosis.................................................................................................................................... - 375 -
14.3 Cylinder Block..................................................................................................................................... - 375 -
14.4 Piston....................................................................................................................................................- 377 -
14.5 Crankshaft connecting rod................................................................................................................... - 381 -
XV. Crankcase......................................................................................................................................................- 386 -
15.1 Preparatory Information.......................................................................................................................- 386 -
15.2 Disassembly and Installation of Crankcase Bearing........................................................................... - 387 -
15.3 Crankcase............................................................................................................................................. - 388 -
XVI. Clutch.......................................................................................................................................................... - 395 -
16.1 Preparatory Information.......................................................................................................................- 395 -
16.2 Fault Diagnosis.................................................................................................................................... - 396 - ka
16.3 Right Cover.......................................................................................................................................... - 397 - -d
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16.4 Clutch................................................................................................................................................... - 397 -
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XVII. Gearshift Mechanism................................................................................................................................ - 405 - ra
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17.1 Preparatory Information.......................................................................................................................- 405 -
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17.2 Fault Diagnosis.................................................................................................................................... - 405 -
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17.3 Gearshift Mechanism...........................................................................................................................- 406 -
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XVIII. Drive System............................................................................................................................................- 414 -
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18.1 Preparatory Information.......................................................................................................................- 414 -
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18.2 Fault Diagnosis.................................................................................................................................... - 415 -
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18.3 Drive system........................................................................................................................................ - 415 -
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18.4 Installation............................................................................................................................................- 420 -
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XIX. Electric Starter Mechanism.........................................................................................................................- 425 -
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19.1 Preparatory Information.......................................................................................................................- 425 -
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19.2 Troubleshooting................................................................................................................................... - 425 -
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19.3 Electric starter mechanism...................................................................................................................- 426 -
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XX. Exhaust Emission Control System...............................................................................................................- 432 -
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20.1 Guarantee of Exhaust Emission Control System................................................................................ - 432 -
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20.2 Regular Maintenance Notice............................................................................................................... - 432 -
20.3 Mechanical Function of Exhaust Control System...............................................................................- 433 -
20.4 Catalyst Conversion System................................................................................................................ - 434 -
XXI. Fuel injection system (EFI)........................................................................................................................ - 436 -
21.1 Introduction to EFI...............................................................................................................................- 436 -
21.2 EFI system........................................................................................................................................... - 437 -
21.3 EFI part position.................................................................................................................................. - 439 -
21.4 Technical parameters........................................................................................................................... - 440 -
21.5 Precautions for EFI Overhaul.............................................................................................................. - 441 -
21.6 ECU......................................................................................................................................................- 443 -
21.7 Fuel Pump............................................................................................................................................ - 446 -
21.8 Throttle Body....................................................................................................................................... - 453 -
21.9 Fuel injector......................................................................................................................................... - 459 -
21.10 Intake pressure and temperature sensor.............................................................................................- 465 -
21.11 Oxygen sensor....................................................................................................................................- 467 -
21.12 Temperature sensor of engine cylinder head..................................................................................... - 470 -
21.13 Canister solenoid valve (ECP)...........................................................................................................- 472 -
21.14 Ignition coil........................................................................................................................................- 474 -
21.15 Fault maintenance and diagnosis method of EFI system.................................................................. - 474 -
21.16 Common troubleshooting methods for electronic fuel inject system................................................- 484 -
Circuit Diagram of BJ400-8 (electronic injection version, exported)........................................................- 492 -
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Introduction
This Maintenance Manual is the explanation for the maintenance essentials of motorcycle
Preparatory Information includes all matters needing attention for operation in the
Inspection and adjustment is the explanation for the essentials of inspection and
Chapter II and subsequent chapters are the explanations for the decomposition,
combination and inspection of the others of electrical equipment, motorcycle and engine.
Exploded diagrams and system diagrams, maintenance fault diagnosis and instructions
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Preparatory Information
Carbon monoxide
If the engine must be started, ensure that the workplace is well-ventilated and do not operate the engine in a closed place.
Note
Exhaust gas contains carbon monoxide, a kind of toxic gas, which may cause people to lose consciousness and possibly lead
to death.
It is necessary to operate the engine in an open place, and exhaust cleaning system should be used when the engine is
operated in a closed place.
Gasoline a
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Workers should operate in a well-ventilated workplace. Smoke and fire are strictly prohibited in the workplace or the
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place where gasoline is stored.
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Battery may emit explosive gas. Keep it away from spark, open flames and smoking area. Keep it well ventilated when it
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is being charged.
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Battery contains sulfuric acid (electrolyte). Burns may be caused when it contacts with skin or eyes. Therefore, workers
should wear protective clothing and mask. R A
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——If electrolyte splashes on the skin, rinse it immediately with fresh water.
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——If electrolyte splashes in the eyes, rinse them with fresh water immediately for more than 15 minutes and consult a
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The electrolyte is toxic. If you accidentally drink electrolyte, you should immediately drink plenty of water, milk and
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magnesium oxide milk (a laxative antacid) or vegetable oil, and consult a doctor. Keep it out of the reach of children.
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Maintenance rules
Installation of Battery
Disconnect the battery cable and battery before any
operation on the motorcycle to prevent the engine from
accidentally starting. Disconnect the negative wire (-) first,
then disconnect the positive wire (+). After completing the
operation, connect the positive wire (+) to the positive
terminal (+) of the battery, then connect the negative wire (-)
to the negative terminal (-).
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Solvent
Use a solvent with a high flash point when cleaning
parts. Use a solvent with a high flash point according to the
instructions provided by the solvent manufacturer.
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Store the removed parts
After cleaning all parts (including subassemblies), store
the parts in a clean area. Cover the parts with a clean cloth
or plastic film to prevent any foreign objects from falling
into them before reassembly.
Check
Major accidents may be caused in case of using worn
or damaged parts. Visually inspect the removed parts for
corrosion, discoloration or other damage. The limits for the
use of individual parts are detailed in the corresponding
sections of this Manual. If any damage is found, or the part
has exceeded the operating limit, the part must be replaced.
Replacement part
Replacement parts must be original Benelli parts or
parts recommended by Benelli. Parts such as washers,
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O-rings, oil seals, grease seals, circlips or cotter pins must -d
be replaced with new ones once removed.
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Assembly sequence
In most cases, the assembly sequence is the reverse of
disassembly sequence, but if the Maintenance Manual
describes the assembly sequence, it must be assembled in
the order given.
Fastening sequence
In general, when fixing parts with a few of bolts, nuts
or screws, place the parts in the corresponding holes, then
screw them in without applying torque, and then tighten
them in the specified order to prevent warping or
deformation which may result in part failure. Conversely, if
you want to unscrew the bolt, nut or screw, first twist a
quarter turn, loosen it, and then continue to unscrew it. If the
tightening sequence is not specified, tighten the fasteners
alternately in a diagonal way.
Locking torque
If you apply the wrong torque to a bolt, nut or screw,
serious damages may be caused. Therefore, the fastener
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must be tightened to the specified torque with a high-quality -d
torque wrench.
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Force
Common sense and basic judgment are required during
the process of removing and installing parts to prevent
excessive force which may result in difficult maintenance or
excessive maintenance costs. If necessary, use a pneumatic
wrench to remove the screw with locking agent. If you need
to hit the fastener, please use a mallet.
Gasket, O-ring
If the gasket or O-ring is hardened, shrunk or damaged
after being removed, its sealing performance will be
reduced. Remove the old gasket and thoroughly clean the
sealing surface to prevent any gasket material or other
materials from remaining on the sealing surface. A new
gasket must be used for reinstallation and the used O-ring
seal should be replaced.
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Press fitting
Parts such as bearings and oil seals must be pressed for
proper fitting, so it is required to apply a small amount of oil
to the contact area. It must be aligned with the contact area
and slowly pressed into the part during installation.
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Circlip, cotter pin
Replace the removed circlip or cotter pin with a new
one. In order to prevent deformation, the opening of circlip
or cotter pin should not be too large during installation.
Lubrication
In order to minimize the wear during running-in period,
it is necessary to lubricate the rotating or sliding parts. Inject
the proper amount of lubricating oil or grease as specified,
and each lubrication point will be given in this Manual.
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Wire
Two-color line: first the base color, then the color of
stripe. Only the wires of the same color are allowed to be
connected, except as noted.
1. Disconnect
Wire
Connector
Joint
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Wire
Connector
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If there is moisture, use compressed air to dry.
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If there is rust, connect the connected parts for several times -
or use a rust remover. Replace the seriously rusted parts
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timely.
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3. Check
All connectors
If any of the joints are loose, reconnect them properly.
Note
If the “A” pin on the terminal is flat, please bend it.
4. Check
Wire
Connector
Joint
Note
Make sure all joints are securely assembled.
5. Check
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Cable arrangement
Loose cable is a potential safety hazard of electrical
safety.Check the next cable after clamping the cable, to
ensure electrical safety;
Wire clamps are not allowed to bend in the direction of
the solder joint;
Bundle the cable at the designated location;
Cables are not allowed to be placed at the end of frame
or at the corners;
Cables are not allowed to be placed at the ends of bolts
or screws;
Keep cables away from heat source or the position
where the cable may be caught during movement;
Cables should not be kept too tight or loose when being
placed along the faucet handle, and must not interfere with
adjacent parts in any steering position;
Cables should be smoothly placed and must not be
twisted or knotted;
Before connectors are mated, check whether the
connector sheath is damaged and the connector is opened
excessively;
If the cable is at a sharp or corner, please protect it with
tape or a hose;
After the cable is repaired, use tapes to securely bind
the exposed area;
The control wire must not bend or twist. If the control
line is damaged, inflexible operation may be caused;
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Model information
Europe
BJ400-8 (European regulation) left view
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Non-European
BJ400-8 (non-European) left view
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Motorcycle identification
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specifications of dealers used.
2. Only metric tools can be used for maintenance work. Metric bolts, nuts and screws are not interchangeable with
imperial fasteners.
3. During reassembly work, use new washers, O-rings, split pins and locking plates.
4. When tightening bolts or nuts, first tighten the bolts with large diameter or leaning to the inner side, and then gradually
tighten them to the specified torque in the diagonal order, unless otherwise specified.
5. Wash the removed parts with a cleaning solution. Lubricate all sliding surfaces before assembly.
6. After assembly, check whether all parts have been correctly installed and operated.
7. Degrease and remove oil before measurement. Add recommended lubricant to the lubrication location during assembly.
8. When the engine and drive system need to be stored for a long time after being disassembled, please apply lubricant to
the surface of the parts to prevent rust and dust.
Special tools
Special tool refers to a tool specially designed for assembling or disassembling some parts of motorcycle and using it
on a specific location. Appropriate special tools are indispensable for complete and accurate adjustment and assembly
operations. Parts should be disassembled and assembled safely, reliably and quickly using special tools, so as to improve
work efficiency and save labor.
1. Tools for maintenance of engine
When disassembling the engine, certain parts can be smoothly assembled and disassembled only using specially
designed tools.
The list and pictures of special tools for the disassembly and assembly of engine parts are shown in Tables 1-1 and 1-2.
Table 1-1
Designation: Note
Special socket wrench Used to remove the flywheel bolts, Fig. 1-3
Clutch holder Fig. 1-4
Flywheel puller Fig. 1-5
Feeler gauge Fig. 1-6
Bearing removal tool Fig. 1-7
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Bearing installation tool Fig. 1-8
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Oil seal replacer Fig. 1-9
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Disassembly tool handle Fig. 1-10
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Piston pin pull-out device Fig. 1-11
Piston ring opening clamp Fig. 1-12
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Spark plug socket wrench r
Fig. 1-13
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Measuring clutch thickness
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Cylinder diameter tester - Fig. 1-15
Dial gauge .A
Measure inner diameter of piston pin, Fig. 1-16
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Table 1-2
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Fig. 1-7 Fig. 1-8
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AYFig. 1-9 ①Handle
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Fig. 1-12
Fig. 1-11
①Opening clamp ②Piston
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Fig. 1-13 Fig. 1-14 n is
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Fig. 1-15
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2. Tools for chassis maintenance
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Acommon and special tools for the disassembly and assembly of chassis parts are shown in
The list and pictures of
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Tables 1-17 and 1-18.
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Table 1-17
Designation: Note
Torque wrench Fig. 1-19
Allen wrench Fig. 1-20
Socket wrench Fig. 1-21
Micrometer Fig. 1-22
Magnetic frame, V-shaped block Fig. 1-23
Dial gauge Fig. 1-24
Vernier caliper Fig. 1-25
Spring snap ring pliers Fig. 1-26
Knock-on screwdriver Fig. 1-27
Front fork oil seal installation tool Fig. 1-28
Hook wrench Fig. 1-29
Jack Fig. 1-30
Accessories of jack Fig. 1-31
Screwdriver for outer race of head tube Fig. 1-32
Mounting tools for steering tube bearing Fig. 1-33
Front fork seal driving tool Fig. 1-34
Four-jaw 300-QCLM4-001 Fig. 1-35
Seven-jaw 300-QCLM7-001 Fig. 1-36
(1) Common tools for chassis maintenance
Table 1-18 (continued)
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Fig. 1-23 Fig. 1-24
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Fig. 1-29 Fig. 1-30
Fig. 1-33
(2) Special tools for maintenance of chassis: Front fork seal driving tool.
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Fig. 1-34
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(3) Steering nut wrench.
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Fig. 1-35 Fig. 1-36
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Fig. 1-37
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Fig. 1-38 Fig. 1-39
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Specification table (BJ400-8)
Model BJ400-8 Engine type QJ73FMQ-A
Full length 2170mm Fuel type Unleaded gasoline
Full width 820mm Number of cylinders 1
Full height 1120mm Inner diameter * stroke Ø72.7×90
Wheel Base 1440mm Total displacement 374cm³
Terrain clearance 170mm Compression ratio 8.5:1
Seat height 880mm Maximum horsepower 15.5kW/5500 r/min
Tank capacity 12L±0.5L Maximum torque 29.0N.m/4500 r/min
Front axle 92kg Idle speed 1400±100 r/min
Weight
Rear axle 114kg Cylinder pressure 1.25MPa/1500rpm
(Curb weight)
Total 205kg Fuel vaporization system EFI (fuel injection)
Frame type Cradle back bone frame Throttle valve D37-1
Common inner and
Front Starting mode Electric starting
outer tire
identity
Common inner and
Rear Ignition mode ECU
outer tire
Tire Front 100/90-19 Spark plug model BR7ES/CR7HSA
Specifications Engine
Rear 130/80-18 Spark plug gap 0.6~0.7mm
Front 220±10Kpa Cooling mode Air-cooled
Air pressure Pressure and splash
Rear 250±10Kpa Lubrication mode
lubrication
Front 2.15×19 Oil type API SE, SF or SG
Specifications
Rear 3.00×18 Oil viscosity SAE 10W-50
Rim Completely
Front Spoke Oil 2.8L
identity disassembled
capacity
Rear Spoke When replaced 2.4L
Telescopic sleeve, oil
Type of front shock absorber Type Dry type
damping type
Stroke of front shock absorber 121mm Air Element Paper
Cleaner Rated air flow: below
Hydraulic spring,
Type of rear shock absorber Intake resistance 127m3/h, air intake
damping shock absorber
resistance: 1.2±0.1KPa
Stroke of rear shock absorber 55.5mm Type Compound impedance
Catalyst
Front brake: Single disc φ300×5mm Muffler
(with/without)
With
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Brake
Operation method Manual identity Redox type -d
Rear brake Single disc φ240×5mm Clutch type
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Wet multi-plate friction
Electric
ignition coil
ission
gear D imFourth 1.000
E K
R G
E O
Y G
W A
T O
M O
Y - - 24 -
P
CO
BJ400-8
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 25 -
CO
Unit conversion table
CO
Winding method of cables, wires and hoses
Arrange the main along the Arrange the main along the
left side of tube at the head, left side of tube at the head,
ka
and fix it using a tie and fix it using a hook
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 27 -
CO
Arrange the main along the
left side of tube at the head,
and fix it using a hook
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 28 -
CO
Arrange the main along the
left side of tube at the head,
and fix it using a clamp
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 29 -
CO
Arrange the main cable and ABS
tube above the engine, and fix it
with ABS front hydraulic brake
tube using a clamp
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 30 -
CO
Arrange the main cable along
the mounting lug and inside
the frame
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 31 -
CO
ECU inserter
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
RG
O Fix the power output line
G E using a tie
AY
O W
O T
- M
P Y - 32 -
CO
Fix the cylinder temperature sensor
ka
inserter with the upper throttle valve
inserter wire using a tie -d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 33 -
CO
Arrange the main cable
along the left side of
headlight holder, and fix it
using a tie
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
Fix the positive wire of battery
using a tie ORG
G E
AY
O W
O T
- M
P Y - 34 -
CO
Pass the positive wire of battery
and main cable above the
battery box
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 35 -
CO
Fix the motor wire at the inside of engine
outlet pipe, and clip the motor wire into
the place between the outlet pipe and
motor
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 36 -
CO
Arrange the motor wire
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W Connect the motor wire
O T
- M
P Y - 37 -
CO
Position for connecting the bond strap
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 38 -
CO
Alignment of brake pipe:
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 39 -
CO
ABS front hydraulic brake
tube wire
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 40 -
CO
Fix the ABS rear hydraulic
brake tube wire using M cable
clip
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 41 -
CO
Arrange the rear inlet tube of
ABS rear hydraulic brake, and
pass the rear oil pump plug wire
through the left by bypassing
the frame
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 42 -
CO
Fix the rear oil pump plug
wire and rear outlet tube of
rear hydraulic brake using M
cable clip
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 43 -
CO
Arrange the reservoir along
the inside of rear frame
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 44 -
CO
Fix the rear wheel speed sensor Clip the rubber cover on the
and the rear outlet tube of rear rear outlet tube of rear hydraulic
hydraulic brake using M cable brake in the mounting clamp at
clip the front of rear rocker arm
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
ORG
G E
AY
O W
O T
- M
P Y - 45 -
CO
Fix the rear wheel speed sensor and Clip the rubber cover on the rear
the rear outlet tube of rear hydraulic outlet tube of rear hydraulic brake in
brake using M cable clip the mounting clamp at the rear of
rear rocker arm
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
ORG
G E
AY
O W
O T
- M
P Y - 46 -
CO
Rear outlet tube of rear
hydraulic brake
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N IS
R A
A B
E K
O RG
G E Fix ABS tube line using
AY mounting clamp
O W
O T
- M
P Y - 47 -
CO
Fix ABS tube and speed sensor wire
of front wheel using M cable clip
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 48 -
CO
ka
-d
n is
Fix ABS tube and speed sensor wire of
bra
front wheel using M cable clip
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 49 -
CO
使用绑扎带将前轮速传感
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 50 -
CO
Other matters:
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 51 -
CO
Arrange the accelerator cable Arrange the ABS tube line and
and clutch cable along the left oxygen sensor wirealong the
of frame, and fix it using a tie left side of frame, and fix them
using a tie
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 52 -
CO
Arrange the accelerator cable
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 53 -
CO
Arrange the motor cable
along the outlet pipe of
engine, and fix it using a tie
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 54 -
CO
Arrange the wire along the frame, Arrange the clutch
and fix it using a tie
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E Arrange the oxygen sensor
CO
Arrange the oxygen sensor
wire along the frame, and fix it
using a clamp
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 56 -
CO
Arrange the accelerator cable and right handle
combination switch wire along the right of headlight
holder, and fix it using a tie, and pass it through the
mounting clip at the right
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 57 -
CO
Arrange the clutch cable and and left handle
combination switch wire along the left of
headlight holder, and fix it using a tie, and pass it
through the mounting clip at the right
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
Fix the sidestand stop switch
wire using a soft wire clip
AY
O W
O T
- M
P Y - 58 -
CO
Arrange the sidestand stop
switch wire
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 59 -
CO
Arrange the wire of rear fender
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 60 -
CO
Arrange the wire of rear fender
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 61 -
CO
Arrange the wire of rear fender
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 62 -
CO
Fix the outlet tube of tank using
a upper mounting clip of
mounting lug
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 63 -
CO
Troubleshooting Guide
Note
○ For most of the faults of EFI, see the chapter “EFI”.
○ This table is not exhaustive. It is not possible to list the
possible causes of each problem. It can only be used as a
basic guide to help solve some common problems.
The starter motor is rotating, but the engine does not work:
Motorcycle rollover sensor (EFI) is working;
The anti-theft control system has failed;
The overrunning clutch has failed;
The starting idler gear has failed. a
k
The engine does not run: -d
n is
The valve is seized; b ra
The valve ejector rod is seized; Ka
Cylinder and piston are seized;
io s
Crankshaft is seized;
The small end of the connecting rod is seized; it r
The big end of the connecting rod is seized; D im
The drive gear or bearing is seized; -
Camshaft is seized;
S.A
Starting idler gear is seized;
Balance shaft bearing is seized; N I S
R A
Fuel does not flow: A B
E K
There is no fuel in the fuel tank;
The fuel pump has failed; O RG
The tank vent is blocked; G E
Y
Check whether the fuel filter is blocked;
A
Fuel hose is blocked
O W
O T
- M
P Y - 64 -
CO
No sparks; sparks are weak:
Motorcycle rollover sensor (EFI) is detached;
The main switch is not rotated to "ON".
The engine stop switch is not rotated to "OFF";
The clutch handle is not pinched or the gear position is not in the neutral position;
Battery voltage is low;
The anti-theft control system has failed;
The spark plug is dirty, broken or the gap is improper;
Spark plug is not applicable
Short circuit or poor contact of ignition coil;
The ignition coil has failed;
The engine control unit (ECU) has failed;
The camshaft position sensor has failed;
The gear switch, starting lock switch or sidestand switch has failed;
The crankshaft sensor has failed;
The main switch or engine stop switch is short circuited;
The starting system circuit is shorted or open;
Main fuse or main switch fuse is burnt out
Others:
The engine control unit (ECU) has failed;
ka
The negative pressure value of throttle valve is out of balance;
The oil viscosity is too high; -d
The drive system has failed; n is
Brake drags;
b ra
The clutch is slipping;
Engine overheating; Ka
Air suction valve has failed; io s
Secondary air compensating valve has failed it r
D im
It cannot run properly at a high speed or the power A - is insufficient:
S.
I S
Ignition is abnormal:
R AN
A
The spark plug is dirty, broken or not adjusted properly;
B
Spark plug is not applicable;
E K
Short circuit or poor contact of ignition coil;G
The ignition coil has failed O R
E
The engine control unit (ECU) has failed
G
Y
Awith the fuel/air mixture:
There is a problem W
O TOpoorly sealed or there is no air filter;
Air filter is clogged,
- M
P Y - 66 -
CO
Vent pipe holder is loosened;
There is water or foreign matter in the fuel;
Throttle valve assembly holder is loosened;
Insufficient fuel supply to fuel injector;
The air duct of tank is blocked;
Fuel hose is blocked;
The fuel pump has failed;
Others:
The throttle valve cannot be fully opened;
Brake drags;
The clutch is slipping;
Engine overheating;
The fuel level is too high;
The fuel viscosity is too high;
The drive system has failed; ka
Camshaft or cam is worn; -d
Air suction valve has failed;
n is
Secondary air compensating valve has failed;
Catalyst is melted due to overheating of muffler b ra
Ka
The temperature is too high: io s
it r
D im
Ignition is abnormal: -
S.A
The spark plug is dirty, broken or not adjusted properly; S
Spark plug is not applicable; N I
The engine control unit (ECU) has failed
R A
A B
The muffler is overheated:
E K
RG
For the Benelli emission control system, do not start the
O
E
engine even if the cylinder does not ignite or is not running
G
point); AY
properly (must be repaired by the nearest maintenance
W
For the Benelli emission control system, if the battery has
O
T
run out, do not start the motorcycle (connect the other fully
O
- M
P Y - 67 -
CO
charged battery with a jumper and then electrically start the
engine);
For the Benelli emission control system, do not start the
engine if the ignition is not normal due to dirty spark plugs
or poor contact of ignition coil;
For the Benelli emission control system, when the main
switch is turned "off", do not ride the motorcycle and taxi
using inertia force (turn "on" the main switch and start the
engine);
The engine control unit (ECU) has failed
CO
The slave cylinder of clutch has failed;
Clutch oil is deteriorated;
There is air in the clutch fuel tube;
The primary cup or the secondary cup of master cylinder of clutch is broken;
The inner wall of master cylinder of clutch is damaged;
Jump
The fork of shift fork is worn or bent;
Shift gear groove is worn;
The joint between the protrusion of the inner edge of gear and recess is worn;
The groove of shift drum is worn;
The elasticity of gear lever spring is poor or or it is damaged;
The guide pin of shift fork is worn;
Drive shaft, output shaft and/or gear spline is worn
G E
AY
O W
O T
- M
P Y - 70 -
CO
The frame makes an unusual noise:
Other noises:
Brackets, nuts, bolts and other parts are not properly installed or locked.
White exhaust:
Piston oil ring is worn;
The cylinder is worn;
Valve seal is damaged;
Valve guide is worn;
The fuel level is too high
Black exhaust: ka
-d
The fuel filter is blocked
n is
b ra
Brown exhaust:
Ka
Breather pipe clamp is loosened io s
Air filter is poorly sealed or there is no air filter; it r
D im
Poor performance and / or stability: -
S.A
N I S
It is difficult to rotate the handlebar: A
B R
The wires and cables are not wound in the correct way;A
The hoses are not wound in the correct way; E
K
The wires are not wound in the correct way;G
The steering stem nut is too tight; O R
The steering stem bearing is broken;
G E
The steering stem bearing isY not applied with sufficient lubricant;
The steering stem is bent;A
The tire pressure isO Wlow
too
O T
- M
P Y - 71 -
CO
The handlebars vibrate or shake severely:
The tire is worn;
The main axis bearing of swing arm is worn;
The rim is deformed or unbalanced;
The wheel bearing is worn;
Handlebar holder bolt is loosened;
The steering stem nut is loosened;
The runout of front and rear axles is too large;
Engine mounting bolt is loosened;
CO
There is a problem with the line;
The regulator/rectifier has failed
Battery is overcharged:
The alternator has failed;
The regulator/rectifier has failed
There is a problem with battery;
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
ORG
G E
AY
O W
O T
- M
P Y - 73 -
CO
Torque and locking agent
CO
Main locking torque specifications
The table below lists the locking torques for the primary fasteners that require locking agent or silicone sealants.
The letters in the "Remarks" column have the following meanings:
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
Torque
Fastener Note
N·m kgf·m
Fuel Injection System (EFI)
Air filter element cover bolt 6 0.70
Air filter element bracket screw 6 0.70
Camshaft position sensor bolt 10 1.0
Crankshaft sensor bolt 5.9 0.60
Pipe clamp bolt 2.0 0.20
Fuel tank mounting bolt 10 1.0
Fuel pump bolt 4 0.4 S
Inlet air pressure sensor bracket screw 10 1.0
Oxygen sensor 25 2.5
ECU bolt 3.9 0.40 L
Speed sensor bolt 3.9 0.40 L
Engine cylinder head and cylinder head cover
Cylinder head cover bolt 10 1.0 L
Camshaft sprocket mounting bolt 15 1.5 L
Camshaft cover bolt 10 1.0 S
Camshaft chain guide bolt 12 1.2 S
Camshaft chain tensioner mounting bolt 10 1.0
ka
Cylinder head bolt (M11)
Exhaust pipe mounting bolt
50
22
5.0
2.2
L(3)
-d
Spark plug 25 2.5 n is
Clutch b ra
Clutch cover bolt
Clutch wheel hub nut
10
120
1.0
12.0
Ka L(1)
R
Clutch spring bolt 10 1.0 io s
Engine lubrication system it r
Engine oil drain bolt M12 30 D im 3.0
Stopper of oil filler - - - Tighten
fuel pump bolt using hands 10
S.A 1.0
Fuel pump cover bolt 10
S 1.0
Crankshaft/ drive mechanism N I
Balancer shaft clamp nut M14 R A 40 4.0
Assembling bolt M6 A B 12 1.2 S
Crankcase bolt
E K 12 1.2 S
O RG
G E
AY
O W
O T
- M
P Y - 75 -
CO
Continued
Torque
Fastener Note
N·m kgf·m
Flywheel locknut 90 9.0
Driving gear nut 80 8.0
Shift positioner bolt M6 12 1.2
Disassembly/Installation of Engine
Front bracket bolt of engine (M10) 45 4.5 S
Front mounting bolt of engine (M10) 50 5.0 AL、S
Rear mounting bolt of engine (M10) 50 5.0 AL、S
Wheel/tire
Front axle nut 100~113 10.0~11.3 AL
Front wheel axle 100~113 10.0~11.3 G
Rear wheel axle 100~113 10.0~11.3 G
Rear wheel axle nut 100~113 10.0~11.3 AL
Final drive mechanism
Upper stop block bolt of chain 10 1.0 L
Chain protective block bolt 10 1.0 L
Engine sprocket cover bolt 10 1.0
Engine sprocket nut 125 12.5 MO
Rear sprocket nut 50 5.0
Speed sensor bolt 3.9 0.4 L
Brake
Purge valve 7.8 0.80
Hollow bolt of brake hose 30 3.0
Pivot bolt of brake lever 6 0.6 Si
Pivot bolt locknut of brake lever 6 0.6
Brake pedal bolt 22 2.2
Mounting bolt of front brake disc 12 1.2 L、S
Front brake light switch screw 1.2 0.12
Mounting bolt of primary cylinder reservoir cap of front 1.2 0.12
brake
Front caliper assembly bolt 27 2.8
Front caliper mounting bolt 22 2.2
Purge valve of front master cylinder 7.8 0.80
ka
Clamp bolt of front master cylinder
Mounting bolt of rear brake disc
12
22
1.2
2.2
S
L、S
-d
Rear caliper assembly bolt 22 2.2 n is
Rear caliper mounting bolt 22 2.2 b ra
Rear primary cylinder mounting bolt 12 1.2 Ka
Rear master cylinder push rod locknut
Suspension system
12 1.2
io s
Front axle clamp nut 20 2.0 it r AL
Front shock absorber clamp bolt (upper)
Front shock absorber clamp bolt (lower)
22
22 - D2.0m
i
3.1 AL
Top plug of front shock absorber 22
S.A 2.2
Piston rod nut of front shock absorber
Rear shock absorber bolt (upper) N I S
28
45
2.8
4.5
Rear shock absorber bolt (lower) R A 45 4.5
Rear shock absorber nut (lower)
A B 45 4.5
Mounting nut of rear rocker arm axis
E K 108 10.8
Rear rocker arm shaft 108 10.8
O RG
G E
AY
O W
O T
- M
P Y - 76 -
CO
Continued
Torque
Fastener Note
N·m kgf·m
Steering system
Steering stem clamp nut 2.5 0.25 AL
Steering stem locknut 24 2.4 AL
Clamp screw of upper bracket 25 2.5
Handlebar positioning double-end stud mounting nut 45 4.5 AL
Handlebar bolt 25 2.5 L
Left switch clamp screw 3.5 0.35
Right switch clamp screw 3.5 0.35
Rear clamp bolt of left lever 10 1.0
Pivot bolt of left lever 6 0.6
Pivot bolt locknut of left lever 6 0.6
Grip end bolt 10 1.0
Frame
Front seat cushion bolt 10 1.0
Rear seat lock bolt 10 1.0
Bolt of rear grab rail 22 2.2
Mounting bolt of holder of rear fender bracket 10 1.0
Mounting bolt of rear fender bracket 10 1.0
Front left pedal bracket mounting bolt 45 4.5
Shift rod mounting base bolt 10 1.0
Shift rod assembly bolt 10 1.0
Front right pedal bracket bolt 45 4.5
Rear left pedal bracket bolt 25 2.5
Rear right pedal bracket bolt 25 2.5
Muffler cylinder mounting bolt 22 2.2
Rear bolt of muffler cylinder 22 2.2
Rear locknut of muffler cylinder 22 2.2
Sidestand bolt 50 5.0
Locknut of side stand bolt 45 4.5
Sidestand flameout switch bolt 6 0.6
Battery holder bolt 10 1.0
Electrical System
Alternator cover bolt 10 1.0
Alternator wire holding plate 10 1.0 L ka
Alternator rotor bolt 100 10.0 S -d
Camshaft position sensor bolt
Camshaft sensor bolt
9.8
5.9
1.0
0.60 L n is
Camshaft sensor cover bolt 9.8 1.0 b ra
L(1)
Grounding terminal bolt of engine 10 1.0 Ka
Front brake light switch screw
Front turn signal light mounting nut
1.2
6
0.12
0.6 io s
Fuel level sensor nut 10 1.0 it r L
Lower bracket bolt of headlight
Lower mounting bolt of headlight
10
10 - Dim
10
1.0
Left switch clamp screw 3.5
S.A 0.35
License plate light cover mounting screw
Oil pressure switch N I S
0.90
15
0.09
1.5 SS
Oxygen sensor RA 25 2.5
Rear turn signal light mounting nut
A B 6 0.6
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Continued
Torque
Fastener Note
N·m kgf·m
Rectifier bolt 10 1.0
Right switch clamp screw 3.5 0.36
Sidestand flameout switch bolt 6 0.6 L
Speed sensor bolt 3.9 0.40 L
Starter relay bolt 10 0.6 L
Starter motor joint nut 6 0.6
Bond strap bolt 10 0.6
Starter motor mounting bolt 10 1.0
Starter motor binding post locknut 6 0.6
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Inspection / adjustment
Inspection of brake fluid for leakage Steering Column Bearing and Handlebar
Fixator
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Preparation standard
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Satisfactory Ka
Warning! io s
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• Before the engine is running, make sure that the
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surrounding air is well ventilated. Do not start the -
engine in a confined place, because exhaust gas
S.A
contains carbon monoxide which may cause people
N I S
to lose consciousness or die.
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•Under certain conditions, gasoline is volatile and
A B
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explosive. Workplaces must be ventilated and flame
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should be extinguished. Smoke and fire are strictly
prohibited in the workplace or the place where
gasoline is stored. G E
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Specifications
Engine
Idle speed 1400±100rpm/min
Spark plug gap 0.6~0.7mm
Spark plug specifications BR7ES/CR7HSA
Combustion chamber type Spherical
Ignition time BTDC 15degrees ±1 degree 1500±100rpm
Motorcycle body
Free stroke of front brake lever 10~20mm
Free stroke of rear brake pedal 20~30mm
Specifications Tire pressure
Tire pressure unit: Kpa Front tire 100/90-19 220±10kpa
Rear tire 130/80-18 250±10kpa
Torque Front axle locknut 100~113N·m
value Rear wheel mounting nut 100~113N·m
Relevant component certifications
Model Designation: Certification number Note
Front tire (tire and tube) E4-75R-0013977 Use environment-friendly
Tire
Rear tire (tire and tube) E4-75R-0013978 tubeless tire
Headlight E9 50R-00 11971
Taillight/brake light E9 50R-00 11972
Lights
Front / rear turn signal light E3 50R-00 1027
Rear license plate light E9 50R-00 11973
Rear view mirror Rear view mirror E7 00050 1
Horn Horn E4 000148
Side reflector E4 023273 Amber (oval)
Reflector
Rear reflector E4 02.3327 Red (rectangle) ka
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K ab
Muffler barrel with
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Muffler it r
mark: e13 BENELLI
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Mark: e13 BENELLI
Air filter
AF-P09
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Regular maintenance checklist
Every Every Every Every
Maintenance mileage 300KM 1000KM 3000 6000 12000 15000
and time KM KM KM KM
Tools
New One Three Six Twelve Fifteen
motorcycle month months months months months
Inspection item
* Air Cleaner I C C R C General tools
* Gasoline filter I I R General tools
* Oil filter R R R General tools
Replacement of engine oil
R Replaced once every 3000KM General tools
level gauge
Tire pressure gauge,
Tire pressure I I I I I I
inflator
Hydrometer,
Storage battery check I I I I I I
multimeter
Actuation clearance
I I I I I I General tools
inspection
Handlebar loosening
I I I General tools
inspection
Shock absorber operation
I I I General tools
inspection
Inspection of bolt loosening
I I I I I I Torque wrench
at all parts
Inspection of gearbox for oil
I I I I I I General tools
leakage
Inspection or replacement of
*
spark plug
I I R R I General tools
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Lubrication of parts of body L L Oil lubricator -d
Muffler I I I I I I n is
General tools
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*
*
Ignition timing
Throttle valve A
I I
I
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A
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A
I
A A
I
ab light
Timing
KTachometer
* Idle exhaust gas inspection A I A A A A io s CO HC analyzer
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* Throttle inspection I I I I I General tools
Fuel pipeline inspection I I I D
I
im I General tools
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Electrical equipment of
I I I SI .A I I Visual multimeter
NIS
lighting instrument
Side stand of main footpeg I A I I General tools
Dampers BR I I I I General tools
* Engine bolt torque I
E KA I I I I Torque wrench
Front/rear brake
R G I I I I General tools
Drive chain
E O I I I I A General tools
Clutch
Y G I I I I General tools
* Valve A I I I I I Feeler gauge
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Expected inspection
1 Ignition system – If there is obviously abnormal continuous ignition, engine misfire, post-ignition overheating or other
phenomena, conduct maintenance inspections.
2 Carbon removal – If there is an obvious lack of horsepower, remove the carbon from cylinder head, piston head and
exhaust system.
3 Piston, cylinder – If cylinder is excessively worn, please replace it with a new one.
Please go to dealers regularly for inspection and adjust it to ensure the best conditions. The table
above is based on the monthly mileage of 1,000 kilometers.
I—Inspection A—Adjustment R—Replacement C—Cleaning L—Lubrication
Note: 1. “*” is the item in which exhaust emissions are involved. Normal maintenance must be conducted in accordance
with the provisions of the State Environmental Protection Agency and the Company’s operating instructions, and it should
not be adjusted and repaired without approval, otherwise, we will not assume any responsibility for it.
2. When riding on gravel roads or under severe environmental pollution conditions, add the number of cleaning air
filter to extend the service life.
3. Maintenance frequency should be added to the motorcycles which often run at a high speed and have a large
mileage.
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Engine Oil/Filter
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Remove the plug screw of oil filler [A].
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Check O-ring
If damaged, replace it with a new one.
Recommended oil
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Model: API SE, SF or SG -d
Viscosity: SAE 10W-50
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Capacity: 2.4 L (when replaced);
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2.8 L (completely disassemble the engine) Ka
Note
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○ Do not add any chemical additives to the oil!The oils it r
that meet the above requirements are carefully formulated
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to provide adequate lubrication action to the engine and -
clutch. S.A
○ Although oil with a viscosity of 10W-50 is N I S
recommended for most cases, it is also necessary to makeR A
corresponding changes according to the atmospheric A B
conditions in the specific use area. E K
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Install the plug screw of oil filler. Start the engine, and idle
for 2-3 minutes.
Stop the engine and check whether the oil level is marked at
the upper limit of oil level indicator after a few minutes.
When checking, the engine should stand upright on the
ground.
Make sure there is no oil leakage.
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Disassemble:
Screw [A]
Right cover of engine [B]
Air filter
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Filter element replacement -d
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Disassemble:
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Screw [A]
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Right cover [B]
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Disassemble:
Screw [A]
Upper cover of air filter [B]
Disassemble:
Screw [A]
Filter element assembly
Installation
It should be conducted in the reverse order of disassembly
*Note
•Make sure whether the air filter has been installed before
installing air filter cover.
Spark plug
Remove the connecting wire of spark plug cap at both sides
of engine [A].
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Remove spark plug [A] at both sides of engine using spark -
plug wrench or alternative tool S.A
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test.
. Whether insulator is cracked or damaged the gap of spark plug
*Note
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Reinstall the spark plug on the cylinder head and tighten -d
it according to the specified torque.
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Torque value: 15N.m
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Install the spark plug with hands and then tighten it using Ka
spark plug sleeve.
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Accumulator D im
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S.A
Battery disassembly I S
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Remove the right protector [B] using key [A].
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Remove the air pipe of battery from the battery.
Remove the battery holder [A].
Remove the battery [B].
Warning
When disassembling the positive electrode, tools should
not touch the frame, otherwise, short circuit and sparks
may be caused and thus gasoline may ignite, and battery
may be damaged, which are very dangerous.
Warning
The positive and negative electrodes should be removed
in the operation order.
When installing the battery, first connect the positive
electrode and then negative electrode.
Installation
It should be conducted in the reverse order of disassembly.
Warning
To prevent short circuit, first connect the positive
electrode and then the negative electrode.
Do not disengage the battery during the commissioning of
motorcycle; otherwise, the internal components may be
damaged.
Inspection of charging state (closed-circuit voltage)
Open the seat mat and remove the right protector.
Remove the battery from the battery box.
Remove the negative lead and then the positive lead.
Take out the battery.
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Measure the voltage between battery terminals. -d
Fully charged: 13.1V n is
Undercharge: 12.3V (the battery has not worked for 1 b ra
hour) Ka
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*Note
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Inspection under the charged state must be conducted
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using a voltmeter. -
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Charging
Connection method: The positive electrode of charger is
connected to the positive electrode of battery.
The negative electrode of charger is connected to the
negative electrode of battery.
Warning
• Never use a source of ignition near batteries.
• First turn off the charger switch before starting charging
or after completing charging.
to prevent sparks at the connection position and avoid the
danger of explosion.
•In the process of charging, conduct the standard
operation according to the current time marked on the
battery.
*Note
•Battery cannot be used generally during the quick
charging of battery, except in emergencies.
•Measure the voltage 30 minutes after charging.
Ignition timing
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*Note -d
Check the ignition system when the ignition timing is
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incorrect.
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●Warm up the engine for 3 to 5 minutes.
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●Turn off the engine, and connect the timing light to the it r
spark plug wire.
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●Remove the timing observation hole cover. -
● Start the engine and let it idle. S.A
● Check the ignition timing, and see whether the timing N I S
light is on. If the “T” symbol on the flywheel is aligned R A
with the marking symbol on the left cover, the ignitionA B
time is correct. E K
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●Increase the engine speed and check if the “T” symbol
starts moving.
G EO
A Y
It should be conducted
W reverse order of disassembly.
in the
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T Adjustment Method:
Ignition Timing
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Disassemble:
Timing access plate [A]
Crankcase access plate [B]
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Insert the sleeve [A] into the crankcase access hole. it r
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Slowly turn the sleeve to rotate the flywheel assembly, and
align the timing mark on the flywheel assembly with the
timing mark on the left cover access hole [A].
After ensuring that the timing mark below is aligned, put the
chain on the driven sprocket of camshaft, align the timing
mark [A] on the driven sprocket of camshaft with that on the
cylinder cover and put them into the camshaft, and then
complete aligning the timing marks.
Cylinder pressure
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Warm up the engine.
-d
Insert a pressure gauge.
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Move the choke handle to the fully open position.
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Rotate the throttle handle to the fully open position,
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and backflush to start the engine.
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Cylinder pressure: 1 ~ 1.2mpa
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*Note
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Start the engine until the meter reading no longer rises. -
Reasons for low pressure: S.A
. Improper valve adjustment
N I S
. Valve leakage
R A
. Wear of piston ring or cylinder
A B
. Washer of cylinder head for damage
E K
Reasons for high pressure:
O RG
Carbon deposition in the combustion chamber or piston
G E
Turn off the engine and remove the spark plug/spark plug
cap AY
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It should be conducted in the reverse order of disassembly.
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Drive chain slackness
Park the motorcycle in a flat position to keep it in an upright
position.
Check the slackness of drive chain .
Slackness of drive chain: 20-30mm.
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Measure the free stroke of front brake lever
at the tip of brake lever.
Free stroke: 10-20mm
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Adjust the free stroke of brake pedal.
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Loosen the locknut [A]
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Screw in or screw out the adjusting device [B] Ka
If the adjusting device is screwed in, the free stroke
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will be reduced; it r
If the adjusting device is screw out, the free stroke will
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be increased. -
Screw in or screw out it until the free stroke meets the S.A
specified value. N I S
Tighten the locknut [A]. R A
A
After adjustment, the brake dragging phenomenon shall be B
avoided. E K
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Inspection of brake fluid for leakage
The precautions for models equipped with CBS are as
follows:
Rotate the brake lever or pedal to check whether brake
fluid leaks from the brake hose [A] and brake line [B].
★ If brake fluid leaks from any position, check or replace
the defective part.
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Check brake hoses and brake lines for damage and ensure S.A
their installation status N I S
●The precautions for models equipped with CBS are as R A
follows: A B
E K
R Gfor corrosion,
●Check brake hoses, brake lines and fittings
cracks or leaks.
G EO
○If the brake hoses and Y brake lines are not properly
A
serviced, the high pressure
W inside the brake lines may cause
brake fluid to T O
leak [A] or the brake hoses and the brake
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forming tubes to burst. When checking rubber hoses, bend
and twist them. When checking rubber hoses, bend and twist
them.
★If any cracks [B], swelling [C] or leaks are found on the
brake hose or brake forming tube, they must be replaced.
●Tighten all hollow bolts and nuts of brake hose.
Tightening torque for hollow bolt of brake hose: 30 N•m
●Check the winding method of brake hose.
★If the brake hoses and brake lines (models equipped with
CBS) are not wound correctly, please discharge brake hoses
and brake lines by correct winding method.
Inspection of brake
● Check whether front brake and rear brake are normal
when riding a motorcycle on a dry road.
★ If the brake is abnormal, check the brake system.
Warning
If you need to test-ride a motorcycle during
the inspection, make sure to do it at a place under
safe traffic conditions.
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★If the level is lower than the lower limit, add brake fluid
to the reservoir until the liquid level reaches the high liquid
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level line.
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● Follow the following procedure to properly install the
cover of the front brake fluid cup. D im
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○After aligning the reservoir cover, tighten the two screws
S.A
[A] of the reservoir cover with a screwdriver.
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● Check whether the brake fluid level in the rear brake fluid
reservoir [A] is higher than the lower limit [B].
★ If the liquid level is lower than the lower limit, add brake
fluid to the reservoir until the liquid level reaches the high
liquid level line [C].
Warning
If you need to add brake fluid but are not sure about
the type and brand of brake fluid in the brake fluid
reservoir, you must replace the brake fluid in the
brake fluid tube.
After replacing brake fluid, use only brake fluid of the
same type and brand.
Recommended disc brake fluid
Grade: DOT4
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Inspection of brake light switch
●Open the electric door lock.
● When the brake lever is pulled by about 15 mm, the brake
light is on.
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Headlight
Remove headlight
Remove
Clamp screw [A]
Headlight [B]
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Install headlight
Install the front headlight bulb and front position light bulb
in the reverse order of disassembly.
*Note
Avoid touching the glass part of the bulb directly and do
not expose it to oil during installation.
Otherwise, it may affect the transparency, life and
luminous flux of bulb.
★ If it is stained with oil, wipe it thoroughly with a cloth
dampened with alcohol or volatile rubber water.
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Clutch cable
Check the free stroke [A] of clutch cable.
Free stroke: 10-15mm.
Rear part
Compress rear shock absorber up and down to check the
operation.
Compress it up and down
Check whether the parts of rear shock absorber are damaged
and loosened.
Suspend the rear wheel, and swing the rear wheel to check
whether the engine suspension bushes are loosened.
Bolt/nut/fixture
Check whether the bolts, nuts and fixtures of various parts
of motorcycle are loosened.
If they are loosened, tighten it to the specified torque value.
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Front / rear tire
Check tires for cracks, iron nails or other damages.
Check tire surface
Wear → Replace
1. Tire tread depth
2. Side wall
3. Wear indication
Wear limit: 1mm
Note
If there is a rotation direction at the tire, mark it with “1”
Point the mark to the rotation direction when
installing the tire.
Align mark “2” to the installation position of rim
valve
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Rim / tire
Check whether the front axle mounting nut is loose.
Check whether the rear axle mounting nut is loose.
If loose, tighten it to the specified torque value.
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Inspection and Maintenance of Electrical System
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Charging System
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Serial Serial S.A Serial
number
Designation:
number
Designation:
NI S number
Designation:
1 Klaxon 7 R A
Ignition switch 13 Accumulator
2 Voltage regulator 8 A
Gauge
B 14 Taillight
K
3 Ignition coil 9 E Fuse box 15 Rear right turn signal light
Front right turn signal ORG
4 E 10 Variable-frequency flasher 16 License plate light
light G
5 Headlight AY 11 Relay unit
6
T OW signal light
Front left turn 12 ECU
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I. Battery/Charging System
Battery----------------------------------------- 1.3
Alternator--------------------------------------1.6
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exchanged.
11. Use a voltmeter when checking the charging state of
battery.
Technical parameters
Item Specifications
Capacity/type 12V8Ah(YTX9-BS)
Voltage When fully charged 13.1V
Accumulator (20℃) Must be charged 12.3V (Have not run for 1 hour)
Charging current Standard: 0.8A, quick: 8A
Charging time Standard: 10-15 hours, quick: 30 minutes
Capacity 160W/5000rpm
Alternator
Coil impedance value (20℃) 0.8±0.3Ω between white and white
Rectifying voltage Type Three-phase full-wave rectifying type
regulator Battery charging voltage 14.5V±0.5V/5000rpm
1.2.1 No power
Overdischarge of battery
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Battery wire is not connected -d
The fuse is broken
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Defective power switch
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1.2.2 Discontinuous current o s
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Battery wire is not connected properly
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Discharging system contact is defective -
Lighting system is in poor contact or short circuit S.A
N I S
1.2.3 Low voltage R A
A B
Poor battery charging
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Poor contact
Poor charging system O RG
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Defective rectifying voltage regulator
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1.2.4 Poor charging system
Defective contact, short wire or short circuit of wire connector
Defective voltage and current regulator
Poor alternator
1.3 Battery
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2. Remove the positive cable [A]. io s
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Remove the air pipe of battery from the battery.
Remove the battery holder [A].
Remove the battery [B].
Warning
When disassembling the positive electrode, tools
should not touch the frame, otherwise, short circuit
and sparks may be caused and thus gasoline may
ignite, and battery may be damaged, which are very
dangerous.
Warning
The positive and negative electrodes should be
removed in the operation order.
When installing the battery, first connect the positive
electrode and then negative electrode.
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Warning
Do not tear the aluminum sealing piece [A] from the
filling port [B] before use.Ensure that a dedicated
electrolyte storage container is used to ensure the
correct volume of electrolyte is filled
○ put the battery on the horizontal surface
○ Check the seal for peeling, cracks or holes
○Removing the sealing strips
*Note
○ The battery is vacuum sealed. If the seal leaks air into
the battery, the first charge may take longer.
●Take out the electrolyte bottle from the plastic bag
●Remove the strip cover [A] from the container and set it
aside, and later use these to seal the battery later.
*Note
Do not puncture or open the seal layer [B] of electrolyte
bottle. Do not attempt to separate a single reservoir.
● Lay the electrolyte bottle down and place the six sealing
slots into the filling port of battery. Keep the electrolyte
bottle level and push down to puncture the seal of all six
reservoirs. As the seal reservoir is inserted into the filling
port, you will see bubbles rising in the reservoir.
*Note
○ Do not tilt the electrolyte bottle
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●Check the electrolyte flow
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★ If there is no air bubble rising in the filling port [A], or if n is
the electrolyte is not completely injected into the battery, tap b ra
the electrolyte bottle [B] for several times. Ka
● Keep the electrolyte bottle in this position for 20 minutes io s
or longer. Do not remove the container from the battery it r
before it becomes empty. The normal operation of battery D im
requires all the electrolyte in the container.
-
Warning S.A
If the electrolyte in the electrolyte bottle is not N I S
completely injected into the battery, the battery life R A
may be shortened.It takes at least 20 minutes for the A B
E K
electrolyte to completely fill the battery. Do not
remove the electrolyte bottle until then.
O RG
E
● Gently remove the electrolyte bottle from the battery
G
● Allow the battery to stand for 60 minutes before charging
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so that the electrolyte penetrates into the metal plate for
O
optimum performance.
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*Note
○ If the battery is charged immediately after filling, the
battery life may be shortened.Allow the battery to stand
for at least 60 minutes after filling.
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*Note
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○ To ensure maximum battery life and increased customer -
satisfaction, it is recommended to perform a 15-second S.A
load test on the battery at the speed that is three times
N I S
greater than the ampere-hour rate of battery. Recheck the A
voltage; if it is less than 12.6V, repeat the charge cycleB R
A
and load test.If it is still below 12.6V, the battery is faulty.
K
Precautions E
1) It is not required to replenish liquid
O RG
This battery does not require replenishing liquid and
G E
can be used before the end of its life under normal use.
AY
It is very dangerous to pry up the sealing cap and add
W
water.Never do this.
O
T
2) Replenish power
O
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If the engine fails to start, the horn sound is very weak
and the lights are dim, which means that the battery has
lost power. Replenish the power for 5-10 hours using
the charging current specified in the instruction manual
(see the section "Replenishment of Power").
If a fast charge is necessary, strictly follow the
maximum charge current and time conditions indicated
on the battery.
Warning
If the charge is replenished according to the method
specified above, quality problems will not be caused to
the battery under normal conditions. However, if the
charging is not performed under the conditions
described above, the performance of battery will be
greatly degraded. Do not disassemble the seal cap
during the period of replenishing the power.
If excessive gas is inadvertently generated due to
overcharging, the safety valve will release gas to keep
the battery normal.
3) When you do not use a motorcycle for more than one
month
Recharge the battery before storing it, then remove the
negative cable. The power shall be replenished once a
month during storage.
4) Battery life
If the engine still fails to start after the battery power
has been replenished for several times, the battery has
exceeded its service life. The battery needs to be
replaced at this point (but first make sure there is no
problem with the starting system of motorcycle).
Warning
Keep the battery away from sparks and open flames
during charging as the battery may release an
explosive gas mixture containing hydrogen and ka
oxygen.When using the battery charger, you need to -d
connect the battery to the charger before turning on
n is
the charger.
b ra
This process can prevent causing sparks at the battery
terminals and avoid igniting any battery gas.
Ka
There should be no fire source near the battery, io s
otherwise, any locked terminals should not be it r
loosened. D im
The electrolyte contains sulfuric acid.Be careful not to -
let it touch your skin or eyes.If case of skin or eye S.A
contact, rinse using a plenty of water.If the situation is
N I S
serious, seek medical attention.
R A
Exchange
A B
Full play can be given to the performance of
K
E
maintenance-free battery only when it is connected to a
RG
suitable vehicle electrical system. Therefore, the battery can
O
E
be replaced with a maintenance-free battery when the
G
motorcycle is originally equipped with a maintenance-free
battery. AY
O W
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1.3.5 Inspection of charging state
● The battery can be inspected by measuring the battery
terminal voltage using a voltmeter [A].
●Disassemble battery
●Measure the voltage between battery terminals.
*Note
○ Use a digital voltmeter that can read a decimal place to
measure voltage
O P
C
1.5 Disassembly of Voltage and Current Regulator
Disassemble:
Bolt [A]
Disassembly of Voltage and Current Regulator [B]
ka
-d
n is
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Ka
1.5.2 Inspection of Circuit at Main Wiring End io s
it r
Remove the 6P plug of voltage and current regulator.
D im
-
Check the continuity between main wiring terminals in the S.A
following way.
N I S
Item (wire color) Judge A B W3
strap of body E K
voltage
R
1.6 Alternator a
k
-d
1.6.1 Disassembly n is
b ra
●Alternator power cable connector Ka
● Place a suitable container under the magnet cover io s
● Loosen the left cover mounting bolt [A] and remove the it r
left cover and coil D im
-
● Pull the alternator power cable from the engine and
S.A
bracket S
N I
R A
A B
E K
O RG
G E
AY
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●Remove stator coil:
Alternator cover (see "Removing alternator cover)
Stator coil [A]
Stator coil bolt [B]
Alternator lead wire sleeve [C]
Trigger [D]
Tension disc bolt [E]
ka
1.6.2 Inspection -d
n is
*Note
b ra
Check the alternator charging coil and operate at the Ka
engine.
io s
● There are three types of alternator faults: short circuit, it r
open circuit (wire is burnt out) or the magnetic property of
D im
rotor disappears. A short or open circuit of coil will result -
in low output or even no output. The disappearance of the
S.A
magnetic property of rotor will result in a low output that
N I S
may be caused by falling of alternator or hitting, or by
R A
being placed near the electromagnetic field, or simply
A B
because of aging.
E K
● Turn off the ignition switch
●Remove alternator connector.
O RG
E
●Use a multimeter to measure the impedance between the
G
Y
three white terminals of alternator.
A
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test. Stator
Remove alternator connector. assembly
Tester
Wring
Reading at ka
range
Connect Connect
5000 rpm -d
tester (+) to tester (-+) to
n is
750 V A white
Another
80V or b ra
AC power cable
white power
cable
higher Ka
io s
★ If the value displayed on the output voltage is the value
it r
in the table, the alternator is operating normally.
D im
★ If the reading is much lower than the value in the table, -
the alternator is faulty.
S.A
I S
1.6.3 Installation A N
●Install it in the reverse order of disassembly. B R
K A
E
Locking torque of stator coil and tensionGdisc bolt:
10-12 N·m
E OR
Locking torque of trigger bolt:G
7-9N·m
Y
A cover bolt: 10-12N·m
Locking torque of alternator
O W
Locking torque of flywheel mounting nut: 9N·m
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Ignition System
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Trigger probe
io s
Power supply
Ignition system it r
D im
-
Serial Serial S.A Serial
number
Designation:
number NI
Designation: S number
Designation:
1 Klaxon 7
B RA switch
Ignition 13 Accumulator
2 Voltage regulator 8
K A Gauge 14 Taillight
3 Ignition coil 9E Fuse box 15 Rear right turn signal light
4 Front right turn signal light
G
R 10 Variable-frequency flasher 16 License plate light
O
5 Headlight
Y GE 11 Relay unit
6 Front left turn signal light
A 12 ECU
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II. Ignition System
Preparatory Information-------------------------2.1
Fault Diagnosis --------------------------------- 2.2
Crankshaft sensor-------------------------------- 2.3
Ignition Coil -------------------------------------2.4
Spark Plug---------------------------------------- 2.5
ECU------------------------------------------------2.6
EO
running.This is to prevent damage to ECU.Do not reverse
G
the electrodes of battery.The side of negative electrode
should be grounded.This A
Y
is to prevent damage to ECU.
T OW
M O
Y - - 126 -
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C
Technical parameters
Item standard value
Spark plug Standard BR7ES/CR7HSA
Spark plug gap 0.6~0.7mm
Primary coil 0.6Ω±15%
There is a spark
Impedance of 18.6KΩ±15%
plug cover
trigger (20°C) Secondary coil
There is no spark
13.6KΩ±15%
plug cover
Impedance of trigger (20°C) 240±20Ω
Maximum voltage in one measurement of ignition coil 15V
Trigger voltage Above 1.7V
Tools
Accessories of maximum voltmeter
Multimeter
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2.2 Fault Diagnosis
Good
Ignition system wire and connector inspection Not good Repair or replace damaged parts
Good
Good
Primary coil peak voltage inspection Not good Replace ignition coil
Good
If ignition coil fails, replace it The voltage is zero or Check: Not good
almost zero
1. Voltage of multimeter
it r
test.
Dim
2. Ignition switch and engine switch flames out
CO
2.3 Trigger
2.3.2 Inspection
● Remove trigger wire connector.
● Measure the impedance values of blue / white and green /
white outgoing lines of engine.
Standard value: 240±20Ω (20°C)
★ If the measured resistance value is higher than the
specified value, the coil circuit is disconnected and needs to
be replaced.
★ If the resistance value is lower than the specified value,
the coil is short-circuited and must be replaced.
ka
-d
2.4 Ignition Coil n is
b ra
Ka
2.4.1 Disassembly of ignition coil: io s
it r
●Remove the fuel tank (see Chapter IX “Disassembly of Fuel
D im
Tank” for details). -
●Remove the spark plug cover [A] S.A
●Remove the primary wire of ignition coil.
N I S
R A
A B
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● Remove the ignition coil connector [A].
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●Remove the ignition coil mounting bolt [A], and remove the
ignition coil [B].
*Note
• When there is no spark in the spark plug, it is necessary
to check whether the parts of wiring are loosened or in
poor contact;
+
• There are many brands of multimeter, the internal
-
impedances are different and the tested values are
different.
●Check the primary coil
●Measure the impedance among the terminals of primary
coil.
Standard value: (0.6±10%)Ω(20℃)
★The impedance value is good in the standard value.
★If the impedance value is “∞”, it indicates that the wire in
the coil is disconnected and the ignition coil needs to be ka
replaced. -d
n is
2.5 Spark Plug b ra
Ka
2.5.1 Inspection of spark plug io s
it r
●Disassemble spark plug (see section “disassembly of spark
D im
plug”) -
●Visually inspect the spark plug
S.A
○ If the center electrode of spark plug [A] and/or side
N I S
electrode [A] is corroded or damaged, or insulated A
terminal [C] is broken, replace the spark plug B R
A
★If the spark plug is dirty or there is carbon deposit, replace
K
the spark plug E
○Use a wire feeler to measure the gap [D]
O RG
E
○If the gap is incorrect, replace the spark plug
G
Spark plug gap: 0.6-0.7mm
Y
A
○Use standard spark plugs or their equivalents
W
O
Spark plug: BR7ES/CR7HSA
T
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2.6 ECU
●System inspection
●Remove ECU and check the parts at wiring terminal
related to ignition system.
(See section “ECU” of electronic injection system for
details)
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Starter System
G/Y O/R
ka
B
O/R
G G -d
R/W
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Gr
G/Y O/R
STARTOR MOTOR
io s
it r
D im MAIN SWITCH
-
Serial Serial S.A Serial
number
Designation:
number NI
Designation: S number
Designation:
1 Klaxon 7
B RAswitch
Ignition 13 Accumulator
2 Voltage regulator 8
K A Gauge 14 Taillight
3 Ignition coil E9 Fuse box 15 Rear right turn signal light
O RG Variable-frequency
4 Front right turn signal light 10 16 License plate light
Y GE flasher
5 Headlight A 11 Relay unit
6
O W
Front left turn signal light 12 ECU
M OT
Y - - 133 -
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III. Starter System
Starter Motor----------------------------------3.3
Technical parameters
Item standard value Operating limit
Length of starter motor brush 12.5mm 8.5mm
Stater idle shaft bushing 8.3mm
Outer diameter of starter idle shaft 7.94mm
ka
Lock torque value -d
Starter motor clutch cover bolt 12 N•m n is
b ra
Tools Ka
Mounting nut wrench io s
Universal fixing wrench it r
D im
-
S.A
N I S
R A
A B
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ORG
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3.2 Fault Diagnosis
3.2.3 Starter motor can rotate but rotation engine cannot work
• Defective starter clutch
•Reverse rotation of starter motor
•Insufficient battery power
ka
3.3.1 Disassembly -d
n is
*Note
b ra
Ka
Before disassembling starter motor, first turn off the main
switch, remove the bond strap of battery, then turn on the
io s
power and check whether starter motor
it r
is running to confirm safety.
D im
remove starter motor cable [B] connector. -
Remove the starter motor mounting bolt [A], and remove the
S.A
starter motor.
N I S
R A
A B
E K
O RG
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3.3.2 Installation
Install the starter motor in the reverse order of
disassembly.
Torque value
Starter motor mounting bolt 10-12 N•m
Starter relay
N IS
R A
A B Bond strap
E K
O RG Starter relay
Y GE
W A
T O
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Y - - 136 -
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3.4.3 Inspection of Bond Strap Circuit of Starter Relay
Remove starter relay connector.
Check the continuity between black wire connector terminal
and bond strap of body. Green yellow / line
Ensure that the continuity between black wire connector
terminal and bond strap of body is good after start button is
pressed.
When it is nonconductive, check the continuity and wire of
start button.
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Bulbs/Meters
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io s
Serial Designation: Serial Designation: Serial
r
itDesignation:
number number D im
number
-
1 Klaxon 7 Ignition switch
S.A 13 Accumulator
2 Voltage regulator 8 Gauge 14 Taillight
NI S
3 Ignition coil 9 Fuse box 15 Rear right turn signal light
4 Front right turn signal light 10 RA
Variable-frequency
B 16 License plate light
KA
flasher
5 Headlight 11E Relay unit
R G
6 Front left turn signal light
O 12 ECU
Y GE
W A
T O
M O
Y - - 138 -
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CO
IV. Bulbs /Switches/Meters
Meters------------------------------------------------------- 4.7
Ignition Switch---------------------------------------------4.8
Handlebar Switch------------------------------------------4.10
CO
4.1 Preparatory Information
CO
4.3 Replacement of headlight bulb
4.3.1 Disassembly
Remove
Clamp screw [A]
Headlight [B]
*Note
Avoid touching the glass part of the bulb directly and do
not expose it to oil during installation.
Otherwise, it may affect the transparency, life and
luminous flux of bulb.
★ If it is stained with oil, wipe it thoroughly with a cloth
dampened with alcohol or volatile rubber water.
4.4.1 Disassembly
Remove
Self-tapping screw of turn signal light [A]
Turn signal light cover [B]
Turn signal light bulb [C]
Specifications
Turn signal light bulb Rl0W
4.4.2 Installation
The bulb should be installed in the reverse order of a
k
disassembly.
-d
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4.5 Replacement of Taillight Bulb
4.5.1 Disassembly
Remove
Self-tapping screw of taillight [A]
Taillight cover [B]
Taillight bulb [B]
Specifications
Turn signal light bulb P21/5W
4.5.2 Installation
The taillight bulb should be installed in the reverse order of
disassembly.
*Note
Ensure that the sealing washer of taillight cover is in the
good state and correct position when installing the taillight.
CO
Remove
License plate light bulb [A]
Specifications
License plate light bulb: W5W
4.6.2 Installation
The license plate light bulb should be installed in the
reverse order of disassembly.
4.7 Meters
4.7.1 Disassembly
Remove:
Meter and cable connector [A]
Remove:
Bolt M5×16[A]
Meter assembly [D]
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S.A
N I S
4.7.2 Installation R A
A B
K
The meter should be installed in the reverse order of
E
disassembly.
Torque value: O RG
G E
Meter holder mounting screw 5-7N·m
AY
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4.8 Ignition Switch
4.8.1 Disassembly
Remove the headlight. (see replace of headlight bulb--
"Disassembly" for details)
Remove the power lock cable connector [A]
Gear Diameter
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4.8.2 Replacement of Ignition Switch
4.8.2.1 Disassembly
4.8.2.2 Installation
ka
4.9.1 Disassembly -d
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Remove
b ra
Horn cable connector [A]
Ka
Mounting bolt [B]
io s
Horn [C]
it r
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4.9.2 Installation
The horn should be installed in the reverse order of
disassembly.
Torque value:
Horn mounting bolt 10~12N.m
4.9.3 Inspection
Remove the horn wire.
If the horn sounds after being connected to the battery, it is
in good conditions.
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4.10 Handlebar Switch
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Right handlebar switch (The headlight is always on)
5. Warning switch
6. Stop switch
7. Starting switch
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4.11 Inspection of switch
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4.12 Speed sensor
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4.12.3 Installation of speed sensor
Ka
io s
it r
● Install the parts that have been removed before in the
D im
reverse order of disassembly. -
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N I S
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4.13 Oxygen sensor
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4.14 Fuel level sensor
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4.15 Relay and fuse box
● The relay [A] is in the area under the front seat cushion.
ka
●Open the upper cover when disassembling -d
● Pull out No. 1 and No. 4 relays [A]
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● Unscrew the mounting bolts with five large socket head
wrench
●Remove the relay
*Note
The relay is equipped with a diode.The relay diode cannot
be removed
Warning
Do not drop the sensor, especially on a hard
surface.The shock on relay may cause damage to it.
O P
C
Light
9-10 11-12 0
relay
(+): Connect the positive wire
(-): connect the negative wire
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
LG/B
R/W R/WGr/RB/RG/RBL/BR/B B DG LR B/RG/RR/W R Y/R
CO
● State 1: relay
● State 2: relay
●The headlights are not always on. The relay of the
motorcycle does not contain the No. 3 relay in the state 1.
Others are the same as the above-mentioned export
inspection methods.
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4.16 Fuse
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● Use a needle-nosed pliers to pull the main fuse [A] out of
n is
the fuse holder in a straight line
b ra
Fuse: 40A
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●Fuse box [A]
CO
4.16.3 Inspection of fuse
● Disassemble the fuse (see 4.17.1)
●Check the fuse parts
★ If the fuse is burnt out, replace it with a new one. Check
the amperage of the affected circuit before replacing the
blown fuse. If the amperage is equal to or greater than the
rated current of the fuse, check the wiring and related
components to check whether it is shorted.
Housing [A]
Fuse component [B]
Joint [C]
Blown fuse [D]
Note
○If the battery is seriously undercharged, the fuse may be
burnt out by a large current after starting the engine.
Warning
When replacing the fuse, make sure that the new fuse
matches the rated current of specified fuse in the
circuit.If a fuse whose current is higher than the rated
value is installed, damage may be caused to the line or
components.
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Inspection and Maintenance of Chassis
CO
Headlight bracket locknut 37∼44N·m
Y G
Rear upper
A mounting bolt of engine 45~50N·m
T OW
MO
Y - - 164 -
O P
C
Upper hanging panel mounting bolt of engine 22~29N·m
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ABS brake
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Fluid brake ABS
A Free stroke of brake lever: 10-20mm
Thickness of friction plate: 6.0 mm
B
Use limit: 3.0mm
Mounting torque value of bolt 3 in the
C
figure: 30 N·m
Mounting torque value of bolt 8 in the
D
figure: 22-29 N·m
Mounting torque value of nut 19 in the
E
figure: 10-12 N·m
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Front fuel pump assembly 1 — —
2 Washer 8 — —
3 Fuel hose mounting bolt 4 30 3.0 AL
4 Front fluid brake fuel hose assembly I 1 — —
5 Front fluid brake fuel hose assembly II 1 — —
6 Front left brake cylinder assembly 1 — —
7 Brake pad assembly 1set — — R
8 Double channel ABS assembly 1 — —
9 Hexagon bolt with flange M6×20 1 10~12 1.0~1.2
10 Oil cup assembly 1 — —
11 Rear fuel pump assembly 1 — —
12 Rear brake cylinder assembly 1 — —
13 Component of rear friction pad 1set — — R
14 Rear fluid brake fuel hose assembly I 1 — —
15 Rear fluid brake fuel hose assembly II 1 — —
16 Bolt M8×25 2 22~29 2.2~2.9 AL
17 Spring washer 8 2 — —
18 Rear fluid brake bracket 1 — —
19 Collar 2 — —
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part. ka
S: Observe the specified tightening sequence. -d
Si: Apply silicon grease. n is
SS: Apply silicone sealant. b ra
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V. Brake
Operation Precautions
*Note
• Do not expose the brake assembly to oil when installing or removing.
• Use specified cleaning agent to avoid reducing brake performance.
* Check brake before riding
Technical parameters
Item Standard Lower operating limit
Brake lever, brake pedal
Brake lever position 4-way adjustable (for riders to choose) –––
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Free clearance of brake lever Nonadjustable ––– -d
Free clearance of pedal Adjustable –––
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Pedal position Approximately 20 mm above the top of the footpeg –––
bra
Brake pad Ka
Thickness of friction pad:
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Front brake pad 6.0 mm it r 3 mm
Rear brake pad
Brake disc
4.0 mm
- Dim 3 mm
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Torque value
Front wheel axle mounting nut 100-113 N•m
Rear wheel axle mounting nut 100-113 N•m
Mounting bolt of front brake cylinder assembly 22-29 N•m
Mounting bolt of rear brake cylinder assembly 22-29 N•m
Mounting bolt of front fuel pump 5-9 N•m
Mounting bolt of rear fuel pump assembly 5-9 N•m
Mounting bolt of front fluid brake disc 10-12 N·m
Mounting bolt of rear fluid brake disc 10-12 N·m
Brake tube mounting bolt 30 N·m
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5.3 Front Brake Disc
Note:
When disassembling the clamp screw of front brake
disc, follow the instructions on the right figure
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5.3.2 Installation of front brake disc
● Mount the brake disc on the wheel with the marked side
facing outward.
○ Mount the sensor rotor on the brake disc with the marked
side [A] facing outward
Insert the front brake disc into the edge of rim, and insert 6
clamp screws [A] after applying one drop of thread sealant
at the end of thread.
*Note
1. Shake the bottle to make the sealant return to even,
and prevent the nozzle from contacting with metallic
substances.
2. Each thread engagement position should be applied
with the sealant for more than 3-5 buckles, and the thread
clearance shall be filled with sealant.
Tighten the bolt to the brake disc in the form of a cross step a
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by step, and tighten 6 screws according to the following
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torque value:
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Torque value:
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Clamp screw of brake disc 10-12N·m
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*Note
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• Do not expose the brake assembly to oil when installing
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or removing. -
• Use specified cleaning agent to avoid reducing brake S.A
performance.
N I S
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*Note A B
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If there is grease on the brake shoe, braking performance
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will be reduced and the brake will fail.
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5.3.3 Inspection of front brake disc
Check the brake disc for wear, and replace it if necessary.
Measure the brake disc and record the maximum value.
If the thickness of brake disc is smaller than the maintenance
value, it should be replaced.
Specifications
Diameter of front fluid brake disc φ300mm
Thickness of front brake disc: 5.0mm
Allowable limit:
Thickness of front brake disc: 4mm
*Note
• Use a micrometer
for measurement.
Measure the jump value at the edge of front brake disc
Available limit 0.15mm
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Note:
When disassembling the clamp screw of rear brake
disc, follow the instructions on the right figure.
Insert the rear brake disc into the edge of rim, and insert 6
clamp screws [A] after applying one drop of thread sealant a
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at the end of thread.
-d
*Note
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1. Shake the bottle to make the sealant return to even,
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and prevent the nozzle from contacting with metallic
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substances.
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2. Each thread engagement position should be applied
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with the sealant for more than 3-5 buckles, and the thread
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clearance shall be filled with sealant. -
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Tighten the bolt to the brake disc in the form of a cross step
by step, and tighten 6 screws according to the following
torque value:
Torque value:
Clamp screw of brake disc 10-12N·m
*Note
• Do not expose the brake assembly to oil when
installing or removing.
• Use specified cleaning agent to avoid reducing
brake performance.
*Note
If there is grease on the brake shoe, braking
performance will be reduced and the brake will fail.
Specifications
Diameter of rear fluid brake disc φ240mm
Thickness of rear fluid brake disc 5.0mm
Allowable limit:
Thickness of rear fluid brake disc 4mm
*Note
• Use a micrometer for measurement.
Measure the jump value at the edge of front brake disc
Available limit 0.15mm
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5.5 Brake lever, brake pedal
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5.5.3 Adjustment of position of brake pedal is
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Note
○ Generally, it is not necessary to adjust the position
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of the pedal, but if the push rod lock nut is removed,
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the position of the pedal must be adjusted.
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● Loosen the lock nut [A] and rotate the push rod [B] to -
make the pedal n the correct position. S.A
● Locking torque
N I S
Locking torque of push rod locknut of rear master
R A
cylinder: 10 N·m
A B
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●Check whether the brake light switch is normal (see
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“Inspection / Adjustment” – “Checking whether the brake
light switch is able to work normally” for details)
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5.5.4 Disassembly of brake pedal
●Disassemble:
Rear master cylinder mounting bolt [A]
●Disassemble:
Brake pedal return spring [A]
Link mounting screw [B]
Rear brake pedal mounting bolt and gasket [C]
Rear brake pedal [D]
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●Install:
Brake pedal [A],
Rear brake pedal mounting screw and gasket [B]
Torque value:
Locking torque of brake pedal bolt: 10-12 N•m
● Hang the lower end of the brake pedal return spring [A]
on the spring pin of frame.
● Hang the upper end of the brake pedal return spring [B] on
the spring pin of frame.
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5.6 Caliper
Note
○If you need to disassemble after removing the caliper
and there is no compressed air available, please
disassemble the caliper before removing the brake hose
(see “Removing the Front Caliper” for details).
Warning
Clench the brake lever or step on the brake pedal until
the brake pad is against the brake disc, thus allowing
the brake pedal or brake pedal to perform its normal
function.Do not ride a motorcycle before completing
the above operations!If the above operations are not
completed, the brake lever or pedal may not work
properly when used for the first time.
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●Disassemble:
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Front caliper assembly bolt [B]
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Front caliper assembly bolt [C]
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Front caliper [F]
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Front caliper [F]
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Front caliper [F] -
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● Remove the mounting pin [A] of brake pad
●Remove front brake pad spring [D], front left brake pad
[B], front right brake pad [C]
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● Replace the oil seal [A] with a new one.
○ Add silicone grease to the oil seal and install it into the
brake cylinder by hands.
●If the dust seal [B] is broken, replace it with a new one!
○ Add silicone grease to the dust seal and install it into the
brake cylinder by hands.
●Replace the guide post dust cover II [A] and the guide post
dust cover II [D].
● Apply grease to the guide post dust cover I [A] and the
guide post dust cover II [D], and install the guide post [B]
and the guide post [C].
● Apply some thread fastening glue to the threads of the
front caliper mounting bolts and tighten the bolts.
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Locking torque of front caliper mounting bolt: 27 N·m -d
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5.6.7 Disassembly of rear caliper
● Before removing the rear caliper, first drain the brake
fluid.
●Loosen the hollow bolt of rear caliper [A], and then gently
tighten them (Tighten them a little bit, and do not tighten too
much).
● Unscrew the caliper mounting bolt [B], separate the
caliper [C] and the brake disc.
●Disassemble:
Rear caliper [B] (see “Removing the Rear Caliper” in the
chapter “Brakes”),
Brake plate (see “Removing rear brake pad” in the chapter
“Brakes”),
Rear caliper assembly bolt,
O-Ring
● Remove the piston on the caliper as follows.
● The method of removing the piston on the caliper is the
same as the method of removing the front caliper.
● Use a piece of wood against the piston on the caliper,
blow compressed air into the brake hose joint to squeeze the
piston of caliper
Warning
To avoid serious injuries, do not put your fingers or
palms behind the piston!Otherwise, the piston may
crush your hands or your fingers when the
compressed air is injected into the caliper.
●Disassemble:
Oil seal [A],
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Dust seal [B],
Guide post dust cover I [C],
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Guide post dust cover II [D],
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Dust cover of bleed screw [E]
Note
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○If compressed air is not available, remove the piston
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from both calipers as follows (connect brake hose to
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caliper). -
○ Prepare a container to hold the brake fluid.
S.A
Front brake pad spring and brake pad (see “Removing
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rear brake pad” in the chapter “Brakes”).
R A
○ Press the brake lever to remove the caliper piston.
A B
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5.6.8 Assembly of rear caliper R G
● Clean the caliper parts (exceptG
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the brake pads).
Note A Y
OW with disc brake fluid, isopropyl
Parts must be cleaned
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alcohol or O
ethanol!
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● Install the bleed screw and bleed screw cap.
Locking torque of bleeder screw: 7.8 N·m
●Apply brake fluid to the inner wall of brake cylinder.
● Replace the oil seal [A] with a new one.
○ Add silicone grease to the oil seal and install it into the
brake cylinder by hands.
● Replace the dust seal [B] with a new one.
● Apply brake fluid to the outside of piston and press it into
the brake cylinder by hands.
●Replace the guide post dust cover II [C] and the guide post
dust cover II [D].
● Apply grease to the guide post dust cover I [C] and the
guide post dust cover II [D], and install the guide post [A]
and the guide post [B].
●Apply some thread fastening glue to the threads of the rear
caliper mounting bolts and tighten the bolts.
Locking torque of rear caliper mounting bolt: 37 N·m
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[B]. In addition, all oil seals must be replaced each time
when the brake pads are replaced.
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5.6.11 Inspection of the caliper piston and brake cylinder for damage
● Visually inspect the piston [A] and the brake cylinder
surface [B].
★ If the brake cylinder and piston are severely worn or
rusted, please replace the caliper!
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● Remove the mounting pin [A] of brake pad
● Remove front brake pad spring [D], front left brake pad
[B], front right brake pad [C]
Note
When the pin A is pulled out, the safety spring B should
be pressed
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●Completely lift rear brake caliper[C]
●Disassemble:
Brake pad [D]
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5.8 Master cylinder
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● Remove the hollow bolt [A] and the brake hose on the
caliper [B]
Note
If brake fluid spills out, rinse it immediately!
● Remove the front master cylinder component.
●Disassemble:
Brake lever pivot shaft bolt [A]
Locknut [B]
Brake lever [C]
Front brake light switch mounting screw [D].
Spring shim [E]
Flat washer [F]
Front brake light switch [G]
Front master cylinder [H]
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5.8.3 Disassembly of rear master cylinder
●Remove the reservoir [A]
● Discharge the brake fluid into a container.
Note
If brake fluid spills out, rinse it immediately!
●Disassemble:
Rear brake light switch sensor [A]
Brake hose [B],
Fuel pump mounting screw [C]
Rear master cylinder [D]
Note
If brake fluid spills out, rinse it immediately!
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5.8.5 Disassembly of front master cylinder
● Remove the front master cylinder (see “Disassembly of
Front Master Cylinder” in the chapter “Brakes”).
● Remove the reservoir cap mounting screw [F], reservoir
cap [E], connector [C] and O-ring.
● Unscrew the locknut [E] and the pivot bolt [F], and then
remove the brake lever.
● Remove the circlip [G].
Special tool—inside circlip pliers:
● Pull out the piston assembly [H].
Note
It is forbidden to remove the cup [I] from the piston,
because it may be damaged once removed.
●Replacement
Sealing cap: [A],
Circlip: [B],
O-ring seal: [D],
Circlip: [G],
Piston assembly: [H],
Diaphragm: [I].
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5.8.6 Disassembly of rear master cylinder
● Remove the rear master cylinder (see “Disassembly of
Rear Master Cylinder” in the chapter “Brakes”).
● Remove the connector [H] and the seal [H].
● Slide the dust cover [A] out
● Remove the circlip [B].
Special tool—inside circlip pliers:
●Remove the piston assembly [D] and the return spring [F].
Note
It is forbidden to remove the cup [C] and cup [E] from
the piston, because it may be damaged once removed.
●Replacement
Dust cover [A]
Circlip: [B],
Piston assembly [D],
Seal [H],
Diaphragm: [I].
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Note
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Brake fluid may quickly corrode the surface of
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painted part, so if the brake fluid spills on any plastic
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part, it must be thoroughly rinsed immediately.
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● Hold the brake handle and add brake fluid until the brake
fluid level is above the oil immersion lens of master cylinder
Warning
Use only the prescribed brake fluid.Other brake fluids
may cause deterioration of rubber gasket, thus
resulting in leakage and improper operation of brake
system.
Use the same brand of brake fluid in the process of
adding brake fluid.The mixture of different brake
fluids may cause harmful chemical reactions and thus
result in the reduction of brake system performance.
When adding brake fluid, be careful not to allow any
water to enter the container.Water will significantly
reduce the boiling point of the brake fluid, which will
generate steam bubbles when heated, and thus lead to
a reduction in brake system.
Note
○ The steps for replacing the front brake fluid are as
follows.The procedures for replacing the rear brake fluid
are the same as the procedures for replacing the front
brake fluid.
●Replacement of brake fluid ka
1. With the main cylinder level, remove the brake fluid -d
cylinder head.
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2. Install the pipe on the front end of oil drain screw [A]
and prepare the oil pan at the front end of hose. b ra
3. Loosen the oil drain screws. Ka
4. Operate the brakes for several times until the oil drain
io s
screw no longer discharges the brake fluid. it r
5. Tighten oil drain screw.
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6. Inject the brake fluid above the lower limit. -
7. Pull the brake handle to fill the brake fluid hose with
S.A
brake fluid.
8. Slowly move the brake handle until no bubbles appear N I S
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in the small holes in the brake cylinder and a force is
A
felt at the the brake handle. A B
9. Release the air.
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After the adjustment is completed, install it in the reverse
order of disassembly.
Note
○ Frequently check the brake fluid level of reservoir and
replenish the new brake fluid as needed. If the brake fluid
in the reservoir is used up during the replacement of
brake fluid, the air in the brake hose must be drained.
● Remove the transparent plastic hose.
● Install the diaphragm and reservoir cap.
●Properly install the rear brake fluid reservoir cap according
to the following procedures.
○ First, tighten the front / rear brake fluid reservoir cap [B]
with your hands clockwise [C] until you feel a little
resistance, indicating that the cap has been fixed on the
reservoir of master cylinder of storage tank, then hold the
brake fluid reservoir cap [A] and rotate it by 1/6 turn [D].
● Tighten:
Locking torque of fastening screw of front brake fluid
reservoir cap: 1.2N·m
●Tighten the bleeder screw and install the rubber cover.
Locking torque of bleeder screw: 7.8 N·m ka
● After replacing the brake fluid, check whether the -d
performance of brake is good, whether the braking is
n is
blocked, and whether the brake fluid leaks.
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★ If necessary, blow out the air in the brake hose.
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Note
○ The steps for exhausting the air from the rear brake line
are as follows.The steps of for exhausting the air from the
front brake line are the same.
Note
○ The level of brake fluid must be checked frequently in
the process of exhausting the air, and replenish the fluid
as needed.If the brake fluid in the reservoir is completely
exhausted in the process of exhausting air, the exhaust
operation must be repeated because the air may have
entered the brake line.
○ To exhaust the air more thoroughly, tap the brake hose
between the caliper and reservoir.
Warning
The precautions for handling disc brakes are as follows:
1. It is forbidden to reuse brake fluid!
2. If the container containing the brake fluid is not sealed
or has been opened for a long time, the brake fluid inside
the container must not be used!
3. Do not mix brake fluids of different types or brands. ka
This will reduce the boiling point of the brake fluid, -d
resulting in brake failure or corrosion of rubber brake parts.
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4. Do not open the reservoir cap for a long time to prevent
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the brake fluid from getting wet.
5. Do not replace brake fluid in rain or strong winds! Ka
6. In addition to brake pads and brake discs, only disc io s
brake fluid, isopropyl alcohol or alcohol can be used to it r
clean the brake parts. Do not clean the above parts with any D im
other liquid! Gasoline, oil or other gasoline distillates may -
corrode rubber parts. Gasoline, oil or other gasoline S.A
distillates may corrode rubber parts. If oil is splashed on
N I S
any part, it will be difficult to completely clean and A
eventually corrode the rubber parts inside the disc brake.
B R
7. When handling brake pads or brake discs, prevent any
K A
E
brake fluid or other oil from splashing on them. If you
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accidentally spill any brake fluid or other oil on the brake
pads or discs, clean them using solvent with a high flash
G E
point! Do not use any solvents that may leave oily
AY
residues! If the brake fluid or oil cannot be completely
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removed from the brake pad, replace it with a new one!
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8. The brake fluid may quickly corrode the surface of
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painted part, so if any brake fluid spills, it must be wiped!
9. The air in the brake line must be drained whenever the
brake line connector or exhaust valve is opened!
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●All sides of brake line fittings are equipped with washers.
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They needs to be replaced with new ones when installed. it r
● Tighten:
D im
Locking torque for hollow bolt of brake hose: 25 N•m -
● Avoid excessively bending, snarling, squeezing or twisting S.A
the brake hose when installing, and arrange the brake hose N IS
in accordance with the section "Winding Method of Cables,R A
Wires and Hoses" of chapter "Appendix". A B
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●Fill the brake line with brake fluid after installing brake
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hose. (See “replacement of brake fluid” for details).
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5.10.2 Inspection Y
of brake hoses and replacement of brake lines
A
Note
T OW
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Brake fluid may quickly corrode the surface of
painted part, so if the brake fluid spills on any plastic
part, it must be thoroughly rinsed immediately.
Remove the rear brake hose clamp [A].
●When removing the rear brake hose, be careful not to spill
brake fluid on any painted part.
●When removing the rear brake hose [B], temporarily fix
the end of brake hose in a high place to minimize the loss of
brake fluid.
●If brake fluid overflows, clean it immediately.
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5.11 Anti-lock brake system (ABS)
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1. Front wheel speed sensor
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2. Gear ring of front wheel speed sensor
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3. Rear wheel speed sensor Ka
4. Gear ring of rear wheel speed sensor
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5.ABS self-diagnosis system connector it r
6.ABS fuse box
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7. ABS hydraulic mechanism -
8. ABS indicator (LED). S.A
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5.11.2 ABS system circuit diagram
1. ABS Switch
2. Ignition Switch
3. Installation of Ground Wire
5. Ignition Fuse
6.ABS Fuse (40A)
7. Meter panel
8.ABS Diagnostic System Connector
9. Front Wheel Speed Sensor
10. Rear Wheel Speed Sensor
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5.11.3 Pin name
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5.11.4 ABS overhaul
5.11.4.1 Precautions for ABS overhaul
There are the following important precautions in the process of
overhauling the ABS system.
○The power supply of this ABS system must be supplied by a
12V sealed battery.Do not use any other power source!
○Do not connect the battery cable reversely. Otherwise, the ABS
hydraulic mechanism will be damaged.
○ To avoid damage to ABS parts, do not disconnect the battery
cable or any other electrical connectors while the ignition switch
is in the “ON” position or while the engine is running.
○Be careful not to short-circuit the wire that directly connect the
positive (+) electrode of the battery and the ground wire of the
chassis.
○If any ABS electrical connector is disconnected, do not turn the
ignition switch to “ON”! The ABS hydraulic mechanism will
remember the fault code.
○Do not spray water on electrical parts, ABS parts, joints, wires
and electric wires!
○If the motorcycle is equipped with a transceiver, ensure that the
operation of the ABS system is not affected by the radio waves
emitted by the antenna.The antenna shall be as far away as
possible from the ABS hydraulic mechanism.
○Turn the ignition switch to “OFF” before the ABS electrical
connector is disconnected.
○Do not hit the ABS parts with a hammer or drop the ABS parts
on a hard surface. Otherwise, the ABS parts will be damaged.
It is not allowed to disassemble the ABS parts!Even if it is found
that the ABS parts are faulty, do not disassemble the ABS parts
for repair. Please replace them directly!
ABS has many brake tubes and wires.And ABS can not detect the
faults of traditional brake systems (wear of brake disc, uneven ka
wear of brake pad and other mechanical faults).In order to -d
prevent faults, please check whether the brake tube is properly n is
connected, whether the electric wires are arranged correctly, and b ra
whether the brake performance is normal.Remember to check the Ka
brake fluid for leakage and completely discharge the air from the
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brake tube!
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Warning
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If any brake tube connectors are loosened, including the -
coupling nut or bleeder screw of the ABS hydraulic S.A
mechanism, the air in the brake tube must be discharged.
N I S
R A
Note
A B
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If there is air in the brake tube, do not ride the motorcycle,
E
otherwise the ABS will fail.
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○If the tire pressure is incorrect and the other tires or wheels
installed instead of those recommended by the manufacturer
are deformed, the ABS indicator (LED) [A] will be on. If the
indicator is on, please remove the faults and delete the fault
code!
Warning
If the other tires are used instead of those recommended
by the manufacturer, the ABS will fail and the braking
distance will increase, resulting in a traffic accident for
the rider. Therefore, this motorcycle must use the
standard tires recommended by the manufacturer.If the
other tires are used instead of those recommended by
the manufacturer, the ABS will fail and the braking
distance will increase, resulting in a traffic accident for
the rider. Therefore, this motorcycle must use the
standard tires recommended by the manufacturer.
○If the engine is started when the motorcycle is supported by
the bracket and it is not in the neutral position, the ABS
indicator (LED) will be on. If the indicator is on, turn the
ignition switch to “OFF” and clear the fault code (front wheel
speed sensor failure).
○ ABS will make noise when it is running, and the rider will
feel the reaction force of the brake rod and brake pedal. This
situation is normal and is intended to alert the rider that ABS is
running normally.○ ABS will make noise when it is running,
and the rider will feel the reaction force of the brake rod and
brake pedal. This situation is normal and is intended to alert
the rider that ABS is running normally.
○ Once the ABS hydraulic mechanism detects a fault code, it
will remember the fault code. Therefore, after the overhaul is
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completed, remember to delete the fault code! However, do -d
not delete the fault code during troubleshooting. Please delete
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the fault code until all inspections and repairs have been
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completed to avoid the repeated entry of the previous fault Ka
code and unnecessary overhaul work.
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○ All the fault codes stored in the ABS hydraulic mechanism it r
must be deleted before the motorcycle is delivered to the
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customer. Ensure that the ABS indicator (LED) will be on by -
using the diagnosis features.In order to make the diagnosis S.A
accurate, make sure that the battery is fully charged. Try riding N I S
the motorcycle (driving speed: above 20km/h (12mph)) and R A
A B
observe whether the ABS indicator (LED) will be on. Finally,
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try riding the motorcycle (driving speed: above 30km/h
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(20mph)), slam the brake and observe whether the motorcycle
O
E
can stop smoothly, and whether the ABS works normally (you
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can feel the reaction force of the brake pad and brake
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pedal).So far, the inspection process is finished.
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5.11.4.2 Overview of ABS fault removal
If an error occurs to ABS, the ABS indicator (LED) will be
on to alert the rider. In addition, the fault information will be
stored in the memory of the ABS hydraulic mechanism.
Therefore, after faults are removed, you must delete the fault
code and start the diagnostic program to confirm that the
signal output is normal. If the ABS fault indicator (LED) is
constantly on, first thoroughly find out the background of the
fault and then start the repair work.For example, ask the rider
about the current situation [B] when the fault occurs and try
to determine the cause of the fault [C].Do not completely rely
on the ABS self-diagnosis function, and combine common
sense to remove faults.For example: Check whether the brake
performance is normal, whether the brake fluid level is
correct and whether the brake fluid leaks.
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● Visually check whether the electric wires are burnt or worn.
★ If any electric wires are damaged, please replace them!
● Disassemble each connector [A] and check whether the
inside is corroded, dirty or damaged.
★ If any connector is corroded or contaminated, carefully
clean it!If the connector is damaged, replace it!
● Check whether the circuit is normal.
○ Find both ends of the wire that may fail by using the circuit
diagram.
○ Connect the multimeter with both ends of the wire.
Special tool—multimeter:
○ Set the range of the multimeter to ×1Ω, and then read the
reading of the multimeter.
★ If the reading of the multimeter is not 0Ω, it indicates that
the wire is damaged.Replace the main cable [B] if necessary.
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5.11.4.3 ABS diagnostic flow chart
A fault occurs
Make diagnosis
If there is a problem with the cable or connector If there is a problem with the ABS part
With Replacement
NG
Final inspection
OK
End
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Questions need to be asked for the rider
○ Each rider reacts differently to the fault, so it is necessary to confirm which problem the rider is experiencing.
○ By asking the rider, find out what went wrong and under what circumstances.Only by knowing clearly about the faults
can you help yourself to reproduce the problem in the workshop.
○ Diagnostic tables can help you avoid ignoring any key points, so you must use a diagnostic table.
Sample of diagnostic table
Name of rider: Registration number (license plate number):
First registration year: Model:
Engine number: Frame number
Date of fault: Frequency:
Weather Mileage:
□The brake lever □The brake
□The indicator
vibrates or makes lever moves
light is flashing □Brake □ABS can
noise abnormally □ ABS runs
distance □ABS run, but the
Phenomenon □ The brake too
□The brake pedal □The indicator is too failure indicator
pedal is frequently
vibrates or makes light is always long light is out
moving
noise on
abnormally
□ At startup
The state of engine in the event
□ After startup
of a fault
□Speed: ≥5000r/min
□The road surface is very slippery (□ snow road, gravel road, □ other)
Road conditions □The road is undulating
□Other
□Turn a corner at high speed
□ Driving speed ≥10km/h (6mph)
Driving conditions □ Driving speed ≥10km/h(6mph)
□ Parking ka
□Turn a corner -d
□ Gentle braking n is
Brake
□ Sudden braking b ra
□The brake lever stroke is large Ka
Other conditions
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□ The pedal stroke is large
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5.11.4.4 Carry out the pre-diagnosis inspection (Phase 1)
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5.11.4.5 Carry out the pre-diagnosis inspection (Phase 2)
Check the ABS indicator (LED). No (not be on) Check power cables and meter panels
○ Is the indicator light on after the ignition
switch is turned "on"?
Yes
Check whether the light is flashing after Check the cable line, check whether the
pressing and holding the ABS switch for 3-5 No (not flash) connector is plugged in properly, and check
seconds. whether the front and rear wheel speed sensors
Yes are damaged.
Is the indicator light on after the ignition No (not be on)
switch is turned "off" and then "on"? Check power cables and meter panels
Yes (on)
Drive for more than 1 minute (including 1
minute) at ≥6km/h (3.7mph)
Is the indicator light off when the motorcycle is Yes ABS is normal
running?
No
Make a diagnosis and find the fault code for repair or Ask the rider whether the fault has occurred again.
replacement.
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5.11.4.7 Check the ABS indicator (LED)
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● Conduct the Step III of test.
○ Disconnect the ABS hydraulic mechanism connector.
○ Check the line between the black/white lead terminal of
connector at the main cable side [A] and the black/white
lead terminal of connector at the main cable side [B].
★ If the line is normal, replace the ABS hydraulic
mechanism.
★ If the line is abnormal, replace or repair the main cable.
●Test
○ Disconnect the ABS hydraulic mechanism connector and
meter connector.
○ Check the line between the black/white lead terminal of
ABS connector at the main cable side [A] and the
black/white lead terminal of wheel speed sensor connector at
the main cable side [B].
Check the front/rear wheel speed sensor and gear ring for
damage.
Check whether the ABS fuse on the cable is normal.
Special tool—multimeter:
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5.11.4.10 The difference between front and rear wheel speeds is abnormal (fault code:
front: C0084~C0088; rear: C0104~C0108)
● Conduct the Step I of test.
○Perform the following checks and repair defective parts.
The tire pressure is abnormal;
Non-recommended standard tires are installed on
motorcycles (tire specifications are incorrect);
Deformation of wheel or tire;
the rotating teeth of sensor rotor are cracked or blocked by
foreign matters.
★If the above parts are normal, perform Step II.
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5.11.4.13 Relay fault (C0044-C0046)
★ Replace ABS.
5.11.4.14 ABS normally open valve solenoid circuit is open-circuited or the resistance
is too large (front: C0121; rear: C0161)
★Replace ABS.
5.11.4.15 ABS normally closed valve solenoid circuit is open-circuited or the resistance
is too large (front: C0131; rear: C0171)
★ Replace ABS.
5.11.4.16 ABS voltage is too high, ABS voltage is too low (too high: C0053; too low:
C0047, C0052)
Standard: battery voltage ≥ 12V
★ If the battery terminal voltage is not within the specified
range, replace the battery or charge and discharge.
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5.11.4.21 Brake switch line fault (C0060-C0061)
5.11.4.24 Front wheel speed sensor signal is abnormal (fault code: C0084-C0088) a
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● Conduct the Step I of test.
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○ Measure the clearance between the front wheel speed
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sensor and the sensor rotor.
Feeler gauge [A]
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Clearances
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Standard: 0.5-1.2mm (0.02-0.047in.) -
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★ If the measured value is beyond the above standards,
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check each part for deformation or looseness and adjust
R A
accordingly.
A B
Re-measure the clearance.
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★ If the measured value is normal, perform Step II.
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● Conduct the Step II of test.
○ Check whether there are iron filings or other magnetic
deposits between the sensor [A] and the sensor gear ring
[B], and whether the groove of sensor gear ring is clogged.
○ Check the installation of the sensor and observe whether it
is loose.
○ Check the tip of the sensor and sensor gear ring for
deformation or damage (eg, the teeth of the sensor gear ring
are notched).
★ If the sensor and sensor gear ring are in poor conditions,
clean the deposit on it and reinstall or replace the defective
parts correctly.
★ If the above parts are normal, perform Step III.
5.11.4.25 Rear wheel speed sensor signal is abnormal (fault code: C0104-C0108)
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● Conduct the Step II of test.
○ Check whether there are iron filings or other magnetic
deposits between the sensor [A] and the sensor gear ring
[B], and whether the groove of sensor gear ring is clogged.
○ Check the installation of the sensor and observe whether it
is loose.
○ Check the tip of the sensor and sensor gear ring for
deformation or damage (eg, the teeth of the sensor gear ring
are notched).
★ If the sensor and sensor gear ring are in poor conditions,
clean the deposit on it and reinstall or replace the defective
parts correctly.
★ If the above parts are normal, perform Step III.
● Conduct the Step III of test.
○ Recheck the fault code; delete the fault code.
★ If the ABS indicator light (LED) [A] is on, the ECU fault
code indicates that the ABS hydraulic mechanism is
faulty.Therefore, the ABS hydraulic mechanism should be
replaced.
★ If the ABS indicator light (LED) is out, the ABS is
normal (no fault code is stored; temporary fault).
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5.11.5 ABS hydraulic mechanism
Note
The ABS hydraulic mechanism have been
precisely set and adjusted before leaving the
factory, so care must be taken during operation.
Never use a hammer to strike it or drop it on a
hard surface and prevent it from touching or be
stuck to the mud.
● Discharge the brake fluid from the front brake line and the
rear brake line.
○Press the brake lever and pedal to release the brake fluid
through the bleed screw.
●Disassemble:
battery (see “Electrical System” - “Removal of Battery”).
●Disassemble
Bolt [A]
●ABS cover [B]
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● Clean the ABS hydraulic mechanism.
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Note
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Clean all connectors on the ABS hydraulic
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mechanism and the rear master cylinder, as the
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dirt around the hollow bolts may contaminate the
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brake fluid during the removal/installation of
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brake line. -
Before removing the brake hose, lay a rag S.A
around the ABS hydraulic mechanism to prevent
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the brake fluid from seeping into the parts.
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● Remove the brake line connecting bolts [A], [B], [C], [D].
● Seal the opening of brake hose with a tape to prevent
brake fluid from leaking or foreign matter from
contaminating the brake fluid.
Note
Brake fluid may quickly corrode the painted
part, so if the brake fluid spills on any plastic
part, it must be thoroughly rinsed immediately.
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●Remove the bolt and bracket.
Note
ABS hydraulic mechanism has been precisely set and
adjusted before leaving the factory, so do not
disassemble and repair the ABS hydraulic mechanism!
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● Install the brake line correctly, as shown in the figure.
● Lock the brake line connecting bolts [A], [B], [C], [D].
Locking torque for connecting nut of brake line: 17 N•m
● Discharge the air inside the brake line (see “Exhausting
the Air inside the Brake Line” for details).|
● Check whether the performance of brake is normal and the
brake fluid leaks.
●Install the parts disassembled previously (see the
corresponding chapters).
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5.11.6 Speed sensor
Note
Wheel speed sensors are precisely machined, so
care must be taken during operation. Never use a
hammer to strike it or drop it on a hard surface and
prevent it from touching or be stuck to the mud.
Do not disassemble or repair the wheel speed
sensor!
●Disassemble:
Headlight [see "Removing Headlight" for details],
Front wheel speed sensor connector [A]
● Remove the connector.
●Disassemble:
Bolt [A]
Front wheel speed sensor [B]
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5.11.6.2 Install front wheel speed sensor -
S.A
●Install it in the reverse order of disassembly. N I S
○Properly arrange the wire (see "Appendix" - "Winding RA
Method of Cables, Wires and Hoses" for details). A B
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5.11.6.3 Remove rear wheel speed R G sensor
G EO
Note
A Yare precisely machined, so
Wheel speed sensors
OWduring operation. Never use a
care must beTtaken
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C
hammer to strike it or drop it on a hard surface and
prevent it from touching or be stuck to the mud.
Do not disassemble or repair the wheel speed
sensor!
●Disassemble:
Right cover (see “Removing Right Cover” for details).
Rear wheel speed sensor connector [A]
● Remove the connector.
●Disassemble:
Bolt [A],
Rear wheel speed sensor [B]
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●Remove the rear wheel speed sensor from the caliper
bracket [A]
●Visually inspect wheel speed sensor.
★ If the wheel speed sensor is cracked, bent or damaged,
please replace it!
★ Lift the front / rear wheel from the ground with a jack
(see “Wheels/Tires” - “Removing Front / Rear Wheel”).
●Slowly rotate the wheel and measure the clearance at
several different points between the sensor and the sensor
gear ring.
Feeler gauge [A]
Feeler gauge [B]
Clearances
Standard:
Front wheel: 0.5-1.2mm
Rear wheel: 0.5-1.2mm
Note
○ Sensor clearance cannot be adjusted.
★ If the clearance is not within the specified range, check
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the hub bearing (see “Wheel/Tire” – “Checking Hub -d
Bearing”), the installation and function of sensor (see
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“Checking Wheel Rotation Sensor” for details).
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5.11.6.7 Check the gear ring of wheel speed sensor
●Disassemble:
Wheel (see “Wheel/Tire” – “Removing Front / Rear
Wheel”)
Brake plate mounting bolt [A],
Sensor gear ring [B]
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Front fender
*Note
Do not damage the covering parts of body
when disassembling.
Remove the body in the following order
The insert plate and cover plate of body
are aligned with their slots respectively.
The hooks of parts should be installed
correctly when assembling.
Do not damage the fittings when
installing covering parts.
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Front fender assembly 1 — —
2 Cross recessed pan head screw M5×106 4 — —
3 Hexagon nut M5 4 — —
4 Hexagon bolt with flange M6×12/polished head 4 10~12 1.0~1.2
5 Fluid brake hose clamp 1 — —
6 Cross recessed pan head screw M6×16 2 — —
7 Front fender rubber assembly 1 — —
8 Hexagon flange nut M6 3 10~12 1.0~1.2
9 Front wheel speed sensor bracket 1 — —
10 Front wheel speed sensor 1 — — S
11 Hexagon bolt with flange M6×16 1 10~12 1.0~1.2
12 Hexagon socket cap screw M10×50 2 40~44 4.0~4.4
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
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Cover
*Note
Do not damage the covering parts of body when
disassembling.
Remove the body in the following order
The insert plate and cover plate of body are aligned with
their slots respectively.
The hooks of parts should be installed correctly when
assembling.
Do not damage the fittings when installing covering
parts.
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Left cover of engine II 1 — —
2 Left cover of engine I 1 — —
3 Bolt M5×12 5 10~12 1.0~1.2
4 Screw M6×15.2 2 10~12 1.0~1.2
5 Right cover of engine I 1 — —
6 Right cover of engine II 1 — —
7 Screw M6×20 2 10~12 1.0~1.2
8 Collar 2 — —
9 Rubber collar 2 — —
10 Left protector 1 — — S
11 Right protector 1 — —
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
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Rear fender 1
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Front part of rear fender 1 — —
2 Bolt M6×19.2 2 10~12 1.0~1.2
3 Screw M6×15.2 4 10~12 1.0~1.2
4 Rear right turn signal light 1 — —
5 Taillight 1 — —
6 Self-locking nut M6 4 10~12 1.0~1.2
7 Tail of rear fender 1 — —
8 License plate light 1 — —
9 Flat washer Φ5 2 — —
10 Spring washer φ5 2 — —
11 Hexagon nut M5 2 — —
12 Hexagon bolt with flange M6×12/polished head 4 10~12 1.0~1.2
13 Collar 2 — —
14 Rear left turn signal light 1 — —
15 Rear reflector 1 — —
16 Rear license holder 1 — —
17 Connecting plate of rear left and right pedal 1 — —
18 Hexagon flange nut M6 2 10~12 1.0~1.2
19 Reinforcing plate at the tail of rear fender 1 — —
20 Headlight bushing 2 — —
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum ka
disulfide-containing grease prepared in a weight ratio of 10:1) -d
R: Replace the part. n is
S: Observe the specified tightening sequence. b ra
Si: Apply silicon grease. Ka
SS: Apply silicone sealant. io s
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Rear fender
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Bolt M10×1.25×20 6 10~12 1.0~1.2
2 Rear fender assembly 1 — —
Front reinforcing plate assembly II of rear
3 1 — —
fender
4 Rear rack screw I 2 — —
Front reinforcing plate assembly II of rear
5 1 — —
fender
6 All-metal hexagon flange locknut M10 6 40~44 4.0~4.4 AL
7 Left rear pedal assembly 1 — —
8 Hexagon bolt with flange M6×12/polished head 4 10~12 1.0~1.2
9 Handle 2 — —
10 Inner hexagon screw M10×80 2 40~44 4.0~4.4 AL
11 Hexagon socket cap screw M10×60 4 40~44 4.0~4.4 AL
12 Hexagon socket cap screw M10×16 2 40~44 4.0~4.4 AL
13 Washer 10 2 — —
14 Left frame cover assembly 1 — —
15 Hexagon bolt with flange M8×45 2 22~29 2.2~2.9 AL
16 Self-locking nut M8 2 22~29 2.2~2.9 AL
17 Right rear pedal assembly 1 — —
18 Right cover assembly of frame 1 — —
19 Liner tube of container 2 — —
20 Hexagon socket cap screw M10×60 6 40~44 4.0~4.4 AL
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent. ka
M: Apply the grease containing molybdenum disulfide. -d
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum n is
disulfide-containing grease prepared in a weight ratio of 10:1) b ra
R: Replace the part. Ka
S: Observe the specified tightening sequence. io s
Si: Apply silicon grease. it r
SS: Apply silicone sealant. D im
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VI. Body Cover
→ left/right rear pedal assembly → rear fender assembly → rear left/right turn signal light
→license plate light → rear reflector → rear license plate support → reinforcing plate at
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Front wheel
A Tire size: 100/90-19
Rim specifications: 2.15×19 spoked
wheel
B Rim runout limit value:
Vertical: 2.0 mm
Horizontal: 2.0 mm
Diameter of front fluid brake disc:
C
300mm
Bending limit of front wheel axle:
D
0.2mm
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Front wheel axle 1 100~113 10.0~11.3 G
2 Front wheel left collar 1 — —
3 Screw M6×20 6 10~12 1.0~1.2 L、S
4 Front wheel gear ring 1 — —
5 Front brake disc 1 — —
6 Dust ring 2 — — G
7 Air valve 1 — —
8 Front wheel rim assembly 1 — —
9 Inner tube and cushion belt 1 — —
10 Inner and outer tubes 1 — —
11 Front wheel right collar 1 — —
12 Slef-locking nut M16×1.5 1 100~113 10.0~11.3
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
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Console assembly
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Left rearview mirror assembly 1 — —
2 Right rearview mirror assembly 1 — —
3 Handlebar assembly 1 — —
4 Screw M6×35 2 10~12 1.0~1.2
5 Washer 6 2 — —
6 Spring washer 6 2 — —
7 Handle block 2 — —
8 Left handlebar jacket 1 — —
9 Left combination switch 1 — —
10 Right combination switch 1 — —
11 Right grip assembly 1 — —
12 Throttle cable assembly 1 — —
13 Clutch cable assembly 1 — —
14 Clutch handle component 1 — —
15 ABS switch assembly 1 — —
16 Screw M6×25-8.8-ZG 2 10~12 1.0~1.2
17 Bolt M6×12 1 10~12 1.0~1.2
18 Washer Φ6 1 — —
19 Self-locking nut M6 1 10~12 1.0~1.2
20 Brake pedal welding assembly 1 — —
21 Hexagon socket cap screw M12×50 1 50~55 5.0~5.5
22 Brake mounting base 1 — —
23 Joint M6 1 — —
24 Washer Φ6 1 — —
25 Bolt M6×25 1 10~12 1.0~1.2
26 Rear foot pump piston screw 1 — — ka
27 Hexagon bolt with flange M6×25 2 10~12 1.0~1.2 -d
28 Brake pedal return spring 1 — — n is
b ra
Ka
29 Hexagon bolt M6×30 1 10~12 1.0~1.2
30 Hexagon flange nut M6 1 10~12 1.0~1.2
io s
r
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
it
G: Apply grease.
D im
L: Apply locking agent. -
M: Apply the grease containing molybdenum disulfide. S.A
I S
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
N
A
disulfide-containing grease prepared in a weight ratio of 10:1)
R
R: Replace the part.
A B
K
S: Observe the specified tightening sequence.
E
Si: Apply silicon grease.
SS: Apply silicone sealant. O RG
G E
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Front Fork
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Hexagon socket cap screw M18×25 4 22~29 2.2~2.9 AL、S
2 Upper handlebar holder 1 — —
3 Lower handlebar holder 2 — —
4 Damper 4
5 Handlebar positioning double-end stud 2 — —
6 Clamp screw of upper bracket 1 25 2.5
7 Upper bracket 1 — —
8 Bolt M8×25 2 22~29 2.2~2.9 AL
9 Self-locking nut M10×1.25 2 45~50 4.5~5.0 AL
10 Hexalobular socket pan head screw M6×20 2 10~12 1.0~1.2
11 Clamp nut of upper bracket 1 70 7.0 AL
12 Nut 1 2 0.2
13 Dust ring 2 — —
14 Steering bearing 2 — — R、G
15 Lower bracket assembly 1 — —
16 Bolt M10×1.25×20 4 22~29 2.2~2.9 AL、S
17 Lower mounting bracket of headlight 1 — —
18 Fluid brake hose clamp 1 — —
19 Front license holder 1 — —
20 Hexagon bolt with flange M6×20 2 10~12 1.0~1.2
21 Front reflector 2 — —
22 Front left shock absorber assembly 1 — —
23 Front right shock absorber assembly 1 — —
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent. ka
M: Apply the grease containing molybdenum disulfide. -d
MO:Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum n is
disulfide-containing grease prepared in a weight ratio of 10:1) b ra
R: Replace the part. Ka
S: Observe the specified tightening sequence. io s
Si: Apply silicon grease. it r
SS: Apply silicone sealant. D im
-
S.A
N I S
R A
A B
E K
O RG
G E
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VII. Front Wheel/Front Suspension
Preparatory Information-------------------------7.1
Handlebar------------------------------------- 7.4
Operation Precautions
Before the front wheel is disassembled, support the bottom
of the motorcycle with jacks and do not reverse the front
wheel when it floats above the ground.
There should be no grease attached to the friction pad,
friction pad assembly or fluid brake disc during operation.
Technical parameters
Measuring position Item Standard value (mm) Allowable limit (mm)
ka
Front wheel axle Bending degree 0.2 -d
Front wheel Rim shimmy
Vertical direction 2.0
n is
Horizontal direction Within 1.0 2.0
b ra
Torque value Tools Ka
io s
Front axle locknut 100∼113 N·m it
Bearing removal rod r
Front caliper mounting bolt 40∼44 N·m Di
Locknut wrench
m
Rear view mirror mounting bolt 22∼29 N·m TorqueA -
wrench
Meter mounting seat mounting bolt 10∼12 N·m S .
Clamp bolt of upper bracket 22∼29 N·m N I S
Upper grip positioner mounting bolt 22∼29 R
N·m
A
Handlebar positioning double-end stud
B
A N·m
45∼50
locknut E K
Steering column bearing locknut R G 70 N·m
Steering column bearing nut E O 2 N·m
Upper clamp bolt of shockY
G
absorber 22∼29 N·m
Lower clamp bolt ofW
A
shock absorber 22∼29 N·m
Headlight bracket
O
T locknut 37∼44 N·m
M O
Y - - 244 -
P
CO
Clamp mounting bolt 10∼12 N·m
Headlight mounting bolt 10∼12 N·m
7.2.2Instability of Direction
The handlebar bearing fails.
The tire pressure is not enough.
The front fork and front wheel axle are bent.
The front wheel tire is deformed and deviates.
CO
Remove
Front wheel axle locknut [A].
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
ORG
G E
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7.3.2 Inspection
Put the wheel axle on the V-shaped seat and measure the
eccentricity with a dial gauge.
Axle
ka
7.3.2.3Inspection of Front Wheel Bearing -d
n is
Bearing b ra
The front wheel rotates unsmoothly or it is too Ka
loose→Replace the bearing io s
Oil Seal it r
Damage/wear→Replacement D im
-
S.A
N I S
R A
A B
E K
O RG
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7.3.2.4 Inspection of spoke
Note:
To avoid damaging the rim, please put a cloth [2] between
the screwdriver and the surface of rim
CO
7.3.3.2 Inspection of Bearing
If the bearing does not roll, it may be worn or loose and thus
it should be replaced with a new one.
Clearance
Note:
The bearing disassembled should be replaced with a
new one.
7.3.4 Installation
ka
Install it in the reverse order of disassembly. -d
Note
n is
•The oil seal on the front wheel should be lubricated.
b ra
•The engagement part or mobile part of gear seat Ka
assembly should be lubricated.
io s
it r
Note D im
• When the odometer gear seat assembly fails to lock the -
front wheel axle, the odometer gear seat assembly will be S.A
deformed. N I S
• After the wheel axle is installed, rotate the wheel to R A
confirm whether the speedometer drive shaft rotates. A B
E K
Torque value: RG
Front wheel axle locknut
G EO N·m
100-113
AY
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7.4 Handlebar
7.4.1 Disassembly
Disassemble
Remove the left rearview mirror assembly [A]
Remove the left rearview mirror assembly [B]
Remove ka
Primary cylinder of front brake [A] -d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
ORG
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Remove
Left lever assembly [B]
Remove
Mounting bolt of grip end assembly [A]
Grip end assembly [B]
ka
-d
n is
b ra
Remove Ka
Left combination switch [A]
io s
it r
D im
-
S.A
N I S
RA
A B
E K
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Remove
Right combination switch [A]
Throttle grip [B]
Remove
Left handlebar cover [A]
*Note:
Compress the compressed air between the left
handlebar and left handlebar grip [1] and slowly
press the left handlebar grip.
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
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Remove the mounting screw at the upper seat of handlebar
[A]
Remove upper seat of handlebar [B]
7.4.2 Inspection
test.
Handlebar
Deformation / bending→replacement
ka
-d
n is
b ra
Ka
io s
it r
7.4.3 Installation im
- D
Install it in the reverse order of disassembly.
S.A
Torque value:
N I S
Mounting screw at the upper seat of handlebar 22-29N•m
R A
Mounting screw of grip end B
10-12 N•m
A
Mounting bolt of left lever assembly
E K 10-12 N•m
RG
Mounting bolt of primary cylinder of front brake 10-12 N•m
E O
Y G
W A
T O
M O
Y - - 253 -
P
CO
*Note:
When installing the mounting screw at the upper seat of
handlebar, finally fix the 2 screws [A] below
*Note:
When installing the left lever assembly, first fix the screw
[A] below
CO
Loosen the clamp bolt of upper bracket [A]
Disassemble
Supporting bolt [A]
Upper bracket [B]
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
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●Remove locknut of steering stem [E].
Special tool - steering stem locknut wrench (four-claw):
●Remove nut of steering stem [E].
Special tool - steering stem nut wrench (seven-claw):
ka
-d
n is
b ra
Disassemble Ka
Upper steel bowl of upper bearing [A]
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
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Disassemble
Support and lower bracket [A]
ka
-d
n is
Clean the rolling ball and bearing race
b ra
test.
Ka
Bearing race[A]
io s
Ball[B]
it r
Wear/damage→Replacement
D im
-
S.A
N I S
RA
A B
E K
O RG
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Replacement step:
Disassemble the bearing race with a long rod ① and a
hammer and remove it from the groove of head pipe, as
shown in the figure
*Note:
Balls, bearing races and dust seals are always replaced
in sets.
The ball and bearing race mounted obliquely will
cause the wear of rack, therefore, they shall be
mounted horizontally carefully.
Do not strike the surfaces of ball and direction axle.
7.5.3 Installation
Install it in the reverse process of disassembly
*Note
Apply grease to the steel bowl of bottom bearing confirm
ka
that the number of balls (21), check whether the
handlebar is not rotatable (to prevent the steel balls from
-d
falling) and then install the steering stem. n is
Support the handlebar, apply grease to the steel bowl of b ra
top bearing and confirm the number of balls (19). (17) Ka
Apply grease to the race of top seat.
io s
Apply grease to the race of top seat. Rotate the handlebar it r
horizontally to make the steel balls contact tightly.
D im
-
*Note S.A
When installing the front shock absorber, first tighten the
N I S
clamping bolts.
R A
B
Ensure that the end of inner fork is flush with the head of
A
handlebar.
E K
Torque value:
O RG
Nut of steering axle
G E 2 N·m
Locknut of steering axle
Y 70 N·m
A
Upper clamp bolt of front shock 22∼29 N·
W
absorber
T O
O
Lower clamp bolt of front shock 22∼29 N·m
M
Y - - 258 -
P
CO
absorber
Mounting bolt at the bracket of 10∼12 N·m
headlight
Mounting bolt at the lower 10∼12 N·m
bracket of headlight
Mounting bolt of brake clamp 10∼12 N·m
Mounting bolt of front fender
10∼12 N·m
bracket
● Replace the inner race of bearing and oil seal with new
ones.
●Apply grease to oil seal.
● Put the oil seal [A] on the steering stem, then install the
inner race of lower ball bearing [B] and apply grease to the
steering stem [C].
Special tool - special tooling for installing the steering tube
bearing [D]:
CO
Note:
Assemble or disassemble the steering axle nut [1] with a
steering nut wrench
[1]。
Note:
Make the torque wrench perpendicular to the
steering nut wrench.
Rotate the direction axle left and right several times
to check whether it rotates smoothly.
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
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Diagram of front shock absorber
O-ring ø33×2.65
End cap
Liner tube
Washer
Dust cap
Oil seal clip
Oil seal 41×54×11
Collar clip
DU collar 1
Damping spring
Piston ring ka
Buffer spring -d
n is
b ra
DU collar 2
Ka
Front branch tube io s
combination it r
D im
-
S.A
Piston pipe
N I S
Positioning sleeve
R A
A
Sealing washer
B
Inner hexagon
K
EM10×30
screw
G
E OROuter cylinder
Y G
W A
TO
M O
Y - - 261 -
P
CO
7.6 Front Shock Absorber
7.6.1 Disassembly
Disassemble
Cap bolt ① and O-ring seal
Oil drainage
Disassemble
Plug ①
Spring ②
Disassemble
Dust ring ①
Wire clamp ②
Note: ka
Do not damage the surface of inner tube -d
n is
b ra
Ka
Disassemble
io s
Bolt ① it r
Hold the shock absorber lever and loosen the bolts with the D im
T-shaped handle ② and the shock absorber clamp.
-
S.A
N I S
R A
A B
E K
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Disassemble
Bolt ①
Washer ②
Disassemble
Oil seal ①
7.6.2 Inspection
test.
Bending degree of inner tube
ka
-d
n is
b ra
in both ships
Ka
Free length of front shock absorber spring: 319.5mm
io s
Minimum free length: 314.5mm
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
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test.
Damper rod ①
Shock absorber piston ring ②
Scratch, damage, bending → Replacement
Spring ③
Oil plug rod ④
Wear, damage→Replacement
Waste→Clean all oil holes using the compressed air
Note:
Do not attempt to straighten the bent damper bar,
otherwise,
it may seriously damage the damper rod.
7.6.3 Installation
Install it in the reverse process of disassembly
Note
Be sure to use the following new parts when
reassembling the shock absorber
Oil Seal
Dust ring
Ensure that all parts are clean before re-installation
Installation
Shock absorber piston ring ①
Spring ②
ka
-d
n is
b ra
Ka
io s
it r
D im
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S.A
N I S
R A
A B
E K
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Installation
Damper rod ①
Oil plug rod ②
Inner tube ③
Outer tube ④
Installation
Washer ①New
Bolt (damper rod) ②
Tighten
Bolt (damper rod) ①
Torque value: 15-20N•m
ka
Note -d
Tighten the bolt ① of damper rod with the
n is
T-shaped handle ② and the shock absorber clamp.
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
OW
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Installation
Oil seal ①New
Installation
Dust ring ①New
Wire clamp ②New
test.
Extension of inner tube
Unable to extend smoothly - recheck after disassembly
ka
Refuel -d
Measuring cup ①
n is
Shock absorber: SA40
b ra
Oil capacity: 450±2ml Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
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After refueling, slowly move the shock absorber [1] up and
down, to fill the tube with oil
Installation
Plug ①
Spring ②
Installation
Cap bolt ① and O-ring seal
Note
Do not damage the surface of inner tube
Torque value of cap bolt: 12-18 N·m
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
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Rear wheel and rear drive
A Tire size: 130/80-18
Rim specifications: 3.00×18/spoked wheel
Rim runout limit value:
B
Vertical: 2.0 mm
Horizontal: 2.0 mm
C Diameter of rear fluid brake disc: 240mm
D Bending limit of rear wheel axle: 0.2mm
E Chain specification: 525HO-1×110
F Sprocket specification: 46 teeth
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Rear wheel axle M16×1.5×310 1 100~113 10.0~11.3 G
2 Left collar of rear wheel 1 — —
3 Lip-type seal assembly 1 — — R、G
4 Circlip Φ62 1 — — R
5 Bearing 0×62×23.8 1 — —
6 O-ring seal φ53×φ3.55 1 — — R、G
7 Chain drive collar 1 — —
8 Self-locking nut M10×1.25 5 45~50 4.5~5.0 AL、S
9 Chain 525HO-1×110 1 — —
10 Sprocket 46-gear 1 — —
11 Sprocket hub 1 — —
12 Sprocket mounting bolt M10×1.25×41 5 45~50 4.5~5.0
13 Rear wheel damper 5 — —
14 Air valve 1 — —
15 Rear wheel rim assembly 1 — —
16 Inner tube and cushion belt 1 — —
17 Tire and tube 130/80-18 1 — —
18 Dust seal of rear hub 1 — — R、G
19 Right collar of rear wheel 1 — —
20 Rear brake disc component 1 — —
21 Screw M6×20 6 10~12 1.0~1.2 L、S
22 Screw M6×12 2 10~12 1.0~1.2
23 Rear wheel speed sensor mounting base 1 — —
24 Rear wheel speed sensor 1 — —
Hexagon bolt with flange
25
M6×12/polished head
1 10~12 1.0~1.2
ka
26 Rear brake bracket assembly 1 — — -d
27 Slef-locking nut M16×1.5 1 100~113 10.0~11.3 AL n is
b ra
Ka
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
io s
L: Apply locking agent.
it r
M: Apply the grease containing molybdenum disulfide.
D im
-
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
S.A
R: Replace the part.
N I S
S: Observe the specified tightening sequence.
R A
Si: Apply silicon grease.
A B
SS: Apply silicone sealant.
E K
ORG
G E
AY
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Rear Suspension
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Rear rocker arm mounting shaft 1 85~98 8.5~9.8 G
2 External collar of rear rocker arm 2 — —
3 Oil seal of rear rocker arm 2 — — G
4 Elastic collar for hole φ30 2 — — R
5 Needle bearing NA6903 2 — — G
6 Rolling bearing 61903-2RS/P26 2 — —
7 Middle shaft sleeve of rear rocker arm 1 — —
8 Self-locking nut M14×1.5 1 85~98 8.5~9.8 AL
9 Rear rocker arm welding assembly 1 45~50 4.5~5.0 AL
10 Chain protective block 1 — —
11 Screw M6×12 2 10~12 1.0~1.2 AL
12 Collar 2 — —
13 Chain adjuster assembly 2 — —
14 Rubber washer of protector 1 — —
15 Drive chain cover 1 — —
16 Screw M6×15.2 2 10~12 1.0~1.2
17 Washer 6 — —
18 Rear shock absorber assembly 2 — —
19 Rear rack mounting collar 2 — —
20 Cap nut M10×1.25 4 45~50 4.5~5.0 AL
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum ka
disulfide-containing grease prepared in a weight ratio of 10:1) -d
R: Replace the part. n is
S: Observe the specified tightening sequence. b ra
Si: Apply silicon grease. Ka
SS: Apply silicone sealant. io s
it r
D im
-
S.A
N I S
R A
A B
E K
ORG
G E
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VIII. Rear wheel/rear suspension
Preparatory Information---------------------8.1
Rear Wheel------------------------------------8.3
Technical parameters
Item Standard value (mm) Available limit (mm)
Swinging amplitude Vertical direction 2.0
of rear wheel Horizontal direction 2.0 ka
-d
Torque value n is
Mounting nut of rear wheel 100-113 N•m bra
Nut at the top of rear shock absorber 45-50 N·m Ka
Nut at the bottom of rear shock absorber 45-50 N·m io s
Mounting nut of rear rocker arm axis 85-98 N·m it r
Mounting nut of rear sprocket 45-50N·m D im
-
S.A
N I S
8.2 Fault Diagnosis R A
A B
E K
8.2.1 Rear Wheel Shimmy
O RG
Deformation of rim G E
Y
Wear of rear wheel bearing
A
Tire fault
O W
T
Wear or damage of rocker arm pivot shaft bearing
O
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Improper adjustment of drive chain adjuster
Bent frame or rocker arm
CO
Remove
Rear brake caliper [A]
Loosen
Chain adjuster bolt [A]
Disassemble
Rear wheel axle mounting nut [A]
ka
-d
n is
b ra
Ka
io s
it r
Disassemble
D im
Rear wheel axle [A] -
Pull out the rear wheel axle from right side to left side S.A
N I S
RA
A B
E K
O RG
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Disassemble rear wheel
8.3.2 Inspection
Axle
ka
-d
8.3.2.2 Rear Rim Shimmy Inspection n is
b ra
Put the rim on an accurate bracket and check the swinging
Ka
amplitude of the rim.
io s
Rotate the wheel with hands and read the swinging it r
amplitude.
D im
Available limit: -
Vertical direction: Replace the rim if the swinging S.A
amplitude is 2.0mm or above.
N I S
Horizontal direction: Replace the rim if the swinging
R A
amplitude is 2.0mm or above. A B
E K
O RG
G E
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8.3.2.3 Inspection of Rear Wheel Bearing
Bearing
The front wheel rotates unsmoothly or it is too
loose→Replace the bearing
Oil Seal
Damage/wear→Replacement
CO
Remove the bearing [3] with a bearing puller.
If the bearing does not roll, it may be worn or loose and thus
it should be replaced with a new one.
Clearance
CO
8.4 Rear shock absorber
8.3.1 Disassembly
Firmly support the motorcycle
Disassemble
Lower mounting bolt of rear shock absorber [A]
Upper mounting bolt of rear shock absorber [B]
Rear shock absorber [C]
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
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8.3.2 Inspection
Rear shock absorber
test.
Rear shock absorber lever
Bending/damage → Replacement of rear shock absorber
test.
Rear shock absorber spring
Fatigue → Replacement of rear shock absorber
ka
-d
n is
b ra
Ka
io s
it r
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-
S.A
8.3.4 Installation I S
A N
Install it in the reverse order of disassembly.
B R
Install the mounting nut of rear shock absorber.
K A
Lock it to the specified torque value. E
Torque value:
O RG
G E
Nut at the top of rear shock absorber 45-50 N·m
Y
Nut at the bottom of rear shock absorber 45-50 N·m
A
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8.5 Rear Rocker Arm
8.5.1 Disassembly
Firmly support the motorcycle
Disassemble the rear shock absorber (see this chapter for
details)
Disassemble the rear wheel (see this chapter for details)
Disassemble
Left / right cover [A]
Disassemble
Mounting nut of rear rocker arm axle [A]
ka
-d
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Ka
Disassemble
io s
Rear rocker arm shaft it r
Pull out the rear rocker arm shaft from right side to left D im
side
-
S.A
N I S
R A
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Remove
Rear rocker arm
8.5.2 Inspection
test.
Rear rocker arm
Bending/damage→replacement
test.
Tightness of rear rocker arm
If it is loose→tighten the rear rocker arm nut or
replace the collar
Vertical movement of rear rocker arm a
k
If the movement is not smooth, or there is any bent or
-d
rough parts → replace the axle sleeve
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test.
Rear rocker arm shaft
Put the rear rocker arm shaft on the V-shaped seat and
measure the eccentricity with a dial gauge.
Available limit: Replace the wheel axle if the
eccentricity is 0.2mm above
*Note
Never try to straighten a bent axle.
test.
Rear swing arm collar
Damaged → replace
test.
Chain protective block
Wear/damage /crack→ replacement
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8.5.3 Installation -
S.A
Install it in the reverse order of disassembly.
N I S
Clean the mounting axle parts of rear rocker arm in the
R A
solvent, and apply grease to the mounting shaft.
A B
E K
Torque value:
Mounting nut of rear rocker arm axis ORG 85~98 N·m
G E
AY
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8.6 Chain drive
8.6.1 Disassembly
Put the motorcycle on a flat surface and secure it.
Disassemble
Drive sprocket cover [A]
CO
Disassemble the rear rocker arm (see this section for
details)
Remove the drive chain
Disassemble
Mounting nut of sprocket mounting bolt [A]
Note:
When disassembling the mounting nut of sprocket
mounting bolt, follow the instructions on the right
ka
figure. -d
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Remove the retainer [A] using the retainer caliper.
Disassemble
Retainer [A]
Sprocket base [B]
Sprocket [C]
Disassemble
Rear wheel damper [B]
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8.6.2 Inspection
Check the chain
Measure the length of 10 links . The drive chain should
be replaced if the length does not match the specified
value.
The length limit of 10 links is 158.75 mm.
*Note:
Take measurements after stretching the chain by
hands.
Measure the length of 10 links within the range
from the link roller ① to the inside of roller .
Measure the length of 10 links in different positions
for 2-3 times.
Warning
Never use volatile substances such as steam,
gasoline or solvents.
CO
Check the driving sprocket and the driven sprocket.
If there is a quarter of gear wear , replace the
sprocket.
If the gear is bent, replace the sprocket.
test.
Rear wheel damper
Damage / crack→Replacement
test.
Sprocket seat bearing
Bearing clearance or rotation is unbalanced→
replacement.
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test. Ka
Oil Seal
io s
Wear, damage and cracking → replacement. it r
D im
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test.
Chain drive collar
Wear, damage→replacement.
Note:
To avoid damaging the sprocket seat, please put a cloth
[2] between the screwdriver and the surface of rim
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-d
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8.6.3.2 Inspection of Bearing it r
D im
Check the rolling conditions of bearing. Clearance-
If the bearing does not roll, it may be worn or loose and thus S .A
it should be replaced with a new one.
N I S
R A Clearance
A B
E K
O RG
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AY
O W Axial direction Radial direction
M OT
Y - - 288 -
O P
C
8.6.3.3 Installation of Bearing
Note:
The bearing disassembled should be replaced with a
new one.
8.6.3 Installation
Install it in the reverse order of disassembly.
Torque value:
Locknut of sprocket bolt 45~50 N·m
*Note
ka
The side of sprocket marked with the number of
-d
teeth [A] is outward.
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*Note
Tighten the nut by 2-3 times in the order shown in
the right figure.
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Seat Cushion
Torque
No Chinese name and specifications Number of Note
N·m kgf·m
1 Boss bolt M10 2 40~45 4.0~4.5
2 Front seat cushion spring 2 — —
3 Pressing sleeve of front seat cushion spring 2 — —
4 Front seat cushion assembly 1 — —
5 Rear seat cushion assembly 1 — —
6 Rear seat mounting plate assembly 1 — —
7 Rear grab rail 1 — — a
k
8 Bolt M6×30 4 10~12 1.0~1.2
-d
9 Hexagon bolt with flange M6×14 2 10~12 1.0~1.2
n is
10 Self-locking nut M8 2 22~29 2.2~2.9
b ra
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque. Ka
G: Apply grease.
io s
L: Apply locking agent. it r
M: Apply the grease containing molybdenum disulfide.
D im
-
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1) S.A
R: Replace the part.
N I S
S: Observe the specified tightening sequence. R A
Si: Apply silicon grease. A B
SS: Apply silicone sealant. E K
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Fuel tank
A Fuel tank volume: 12L±0.5L
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Fuel tank assembly 1 — —
2 Rear rack screw II 2 — —
3 Rubber washer liner tube 2 — —
4 Buffer rubber of fuel tank 2 — —
5 Screw M4×5 2 — —
6 Left cover assembly of fuel tank 1 — —
7 Right cover assembly of fuel tank 1 — —
8 Cushion 2 — —
9 Sensor rubber washer 1 — —
10 Oil level sensor assembly 1 — —
11 Hexagon flange nut M6 4 10~12 1.0~1.2
12 Fuse hose assembly 1 — —
13 Filter assembly 1 — — R
14 Filter jacket 1 — —
15 Fuel pump assembly 1 — —
16 Bolt M5×16 6 3~4 0.3~0.4 S
17 Dump valve assembly 1 — —
18 Plate clamp 3 — —
19 Fuel hose 4.5×8.5×190 1 — —
20 Fuel hose 4.5×8.5× 1 — —
21 Wire clamp Φ10.5 1 — —
22 Fuel hose 7×11×800 1 — —
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide. ka
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum -d
disulfide-containing grease prepared in a weight ratio of 10:1) n is
R: Replace the part. b ra
S: Observe the specified tightening sequence. Ka
Si: Apply silicon grease. io s
SS: Apply silicone sealant. it r
D im
-
S.A
N I S
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IX. Fuel Tank/Seat
Seat---------------------------------------------9.3
Technical parameters
Item Standard Allowable limit
ka
Locking torque -d
n is
Mounting bolt of front seat 40-45 N·m
b ra
Mounting bolt of rear seat 10-12N·m
Ka
Fuel tank mounting bolt 10-12 N·m
io s
Fuel level sensor mounting bolt 5–9 N·m
it r
Fuel pump mounting bolt 3-4 N·m
D im
-
9.2 Fault Diagnosis S.A
N I S
R A
Reduction of gasoline quantity A B
E K
Natural consumption of gasoline
Gasoline leakage
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9.3 Seat
9.3.1 Disassembly
Disassemble
Mounting bolt of front seat [A]
Front seat [B]
Disassemble
Front mounting bolt of rear seat M6×14[A]
Bolt M6×30[B]
Rear grab rail [C]
Rear seat [D]
Disassemble
Self-locking nut M8 [A]
Pressing sleeve of front seat cushion spring [B]
Front seat cushion spring [C]
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9.3.2 Inspection
test.
Seat Cushion
Breakage or damage → replacement
9.3.3 Installation
Install it in the reverse order of “disassembly”
Torque value:
Mounting bolt of front seat 40-45 N·m
Mounting bolt of rear seat 10-12N·m
9.4.1 Disassembly
ka
Warning -d
Gasoline is extremely flammable and may n is
even cause explosion in some cases.Therefore, it b ra
must be ensured that the above operations are Ka
performed in a well-ventilated area, and any fire
io s
source or spark is strictly prohibited, including it r
any devices with indicators.No smoking!Close the D im
electric door lock!Disconnect the negative -
electrode (-) of battery S.A
In order to minimize the amount of spilled N I S
fuel, the fuel in the fuel tank should be extracted R A
A
when the engine is cool.If some fuel spills, it must
B
be thoroughly cleaned. E K
R G"Cushion"
Remove the front seat cushion (see -
"Removing")
G EO
A Y
T OW
M O
Y - - 296 -
O P
C
Disassemble
Bolt [A]
Remove fuel level sensor wire connector.
Disconnect:
Connector between fuel hose and fuel pump [B]
Warning
The fuel hose connector must be covered with a
cloth when being removed.The residual pressure in the
fuel pipeline when the hose is removed may cause the
ejection of fuel.
Note:
Remove the fuel hose with hands. Do not remove the
hose with tools forcibly.
Although the fuel in the fuel tank has been removed,
there may still be fuel residuals, so be careful when
disassembling the fuel hose.
Do not remove the fuel hose from the fuel hose
connector. Remove the connector from the fuel ka
pump interface. -d
Remove the fuel tank from the frame n is
Disassemble b ra
Screw M4×5[A] Ka
Fuel tank lock [B]
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Disassemble
Nut [A]
Fuel level sensor assembly [B]
Sensor rubber washer [C]
Disassemble
Bolt [A]
Fuel pump assembly [B]
Note
Do not drop the fuel pump, especially avoid falling on
hard surfaces, otherwise the fuel pump may be
damaged.
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-d
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9.4.2 Inspection Ka
io s
● Inspection
it r
Fuel tank
D im
Rust / damage / oil leakage→replacement -
S.A
N I S
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● Inspection
Rubber part
Buffer rubber [A]
Rubber cover [B]
Sensor rubber washer [C]
Crack/damage→Replacement
● Inspection
Inspect fuel pump
Fuel pump
Block-clean it
Crack/damage→Replace fuel pump assembly
ka
-d
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Ka
io s
● Inspection it r
Fuel hose
D im
If any wear, crack [B] or expansion [C] is found → the fuel -
pipe must be replaced. S.A
N I S
R A
A B
E K
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● Inspection
Dump valve
Damage/fault→Replacement
9.4.3 Installation
Install it in the reverse order of “disassembly”
Torque value:
Fuel tank mounting bolt 10-12 N·m
Fuel level sensor mounting bolt 5–9 N·m
Fuel pump mounting bolt 3-4 N·m
Note:
Do not damage the mounting surface of fuel tank when
installing the fuel pump
Use new fuel pump seal ring
Note:
See Chapter XVIII for the details of fuel pump
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Frame
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Bolt M10×1.25×135 1 45~50 4.5~5.0 AL、S
2 0Bolt M8×60 4 22~29 2.2~2.9
3 Rear front hanging panel assembly of engine 1 — —
4 Front buffer collar of engine 2 — —
5 Right front hanging panel assembly of engine 1 — —
6 Self-locking nut M10×1.25 4 45~50 4.5~5.0 AL、S
7 Frame welding assembly 1 — —
8 Bolt M10×1.25×155 1 45~50 4.5~5.0 AL、S
9 Frame cover 2 — —
10 Hexagon bolt with flange M10×1.25×170 1 45~50 4.5~5.0 AL、S
11 Left rear hanging panel assembly of engine 1 — —
12 Front buffer collar assembly of engine 2 — —
13 Bolt M8×25 4 22~29 2.2~2.9
14 Right rear hanging panel assembly of engine 1 — — AL
15 Rubber washer of protector 3 — —
16 Hexagon bolt with flange M6×16 3 10~12 1.0~1.2
17 Left clamp of frame II 1 — —
18 Rubber washer of cover 4 — —
19 Bolt M8×75 2 22~29 2.2~2.9
20 Left cover mounting base of engine 1 — —
21 Left upper hanging panel assembly of engine 1 — —
22 Hexagon bolt with flange M10×1.25×60 1 45~50 4.5~5.0
23 Right upper hanging panel of engine 1 — —
24 Right cover mounting base of engine 1 — —
25 Self-locking nut M8 2 22~29 2.2~2.9
26 Right clamp of frame 1 — — ka
27 Hexagon flange nut M6 1 10~12 1.0~1.2 -d
28 Headlight bracket collar 1 — — n is
b ra
Ka
29 Ignition coil mounting base 1 — —
30 Hexagon bolt with flange M6×80 1 10~12 1.0~1.2
io s
31 Left clamp of frame I 1 — —
it r
32 Seat mounting base 1 —
D im —
33 Screw M6×12 4 10~12
A - 1.0~1.2
34 Buffering rubber ring of seat cushion 2 —.
S —
I S
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
N
A
G: Apply grease. Si: Apply silicon grease. SS: Apply silicone sealant.
R
L: Apply locking agent. A B
K
M: Apply the grease containing molybdenum disulfide.
E
RG
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
O
E
disulfide-containing grease prepared in a weight ratio of 10:1)
G
R: Replace the part.
Y
A
S: Observe the specified tightening sequence.
W
T O
M O
Y - - 302 -
P
CO
Pedal
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Front pedal welding assembly 1 — — AL、S
2 Pedal mounting screw 4 22~29 2.2~2.9
3 Mounting bushing of front foot rest lever 4 — —
4 Front pedal buffer rubber washer 4
5 Rubber cover of pedal 2 — —
6 Thin nut M12×1.25 1 45~50 4.5~5.0
7 Spring washer φ12 1 — —
8 Mounting washer of sidestand 1 — — AL
9 Sidestand welding assembly 1 — — AL
10 Sidestand flameout switch 1 — —
11 Bolt M5×0.8×14 2 4~7 0.4~0.7 AL
12 Mounting screw of sidestand 1 45~50 4.5~5.0
13 Sidestand spring assembly 1 — —
14 Washer 6 1 — — R、G
15 Bolt M6×8 1 10~12 1.0~1.2
16 Mounting bolt of sidestand 2 45~50 4.5~5.0 AL、S
17 Hexagon nut M10×1.25 2 45~50 4.5~5.0
18 Center stand welding assembly 1 — —
19 Sidestand spring 1 — —
20 Rubber damper 1
21 Rear pedal assembly 2 — —
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide. ka
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum -d
disulfide-containing grease prepared in a weight ratio of 10:1) n is
R: Replace the part. b ra
S: Observe the specified tightening sequence. Ka
Si: Apply silicon grease. io s
SS: Apply silicone sealant. it r
D im
-
S.A
N I S
R A
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E K
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Muffler
Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Muffler welding assembly 1 — — ka
2 Exhaust seal ring assembly 1 — — -d
3 Oxygen sensor 1 — — n is
4 22~29 2.2~2.9 b ra
Ka
Hexagon nut with flange M8 4
5 Bolt M8×35 2 22~29 2.2~2.9
io s
6 Guard bush 2 — —
it r
7 Rubber cover II 2 —
D
— im
- torque.
AL: Tighten the fastening bolts alternatively in accordance with the higher locking
A
G: Apply grease. S .
L: Apply locking agent.
N I S
M: Apply the grease containing molybdenum disulfide. A
MO: Apply the oil solvent containing molybdenum
R
B disulfide. (A mixture of engine oil and molybdenum
A
Kratio of 10:1)
disulfide-containing grease prepared in a weight
R: Replace the part. G E
R
EOsequence.
S: Observe the specified tightening
G
Si: Apply silicon grease.
A Y
SS: Apply silicone sealant.
T OW
M O
Y - - 305 -
P
CO
X. Frame
Frame------------------------------------------ 10.3
Sidestand-------------------------------------- 10.4
Footpeg ---------------------------------------10.6
Muffler-----------------------------------------10.7
Y G
Front exhaust pipe mounting nut 22~29 N·m
W A
Rear mounting bolt of muffler cylinder 22~29 N·m
T O
Lower mounting bolt of engine 45~50 N·m
M O
Y - - 306 -
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CO
Upper mounting bolt of engine 45~50 N·m
Front mounting bolt of engine 45~50 N·m
Rear upper mounting bolt of engine 45~50 N·m
Upper hanging panel mounting bolt of engine 22~29 N·m
Left front hanging panel assembly mounting screw of engine 22~29 N·m
Right front hanging panel assembly mounting screw of engine 22~29 N·m
Left rear hanging panel assembly mounting screw of engine 22~29 N·m
Right rear hanging panel assembly mounting screw of engine 22~29 N·m
CO
10.4 Sidestand
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●Disassemble:
Sidestand spring [A]
Thin nut M12×1.25[B]
Spring washer φ12[C]
Bolt M6×8[D]
Washer 6 [E]
Mounting screw of sidestand [F]
Mounting washer of sidestand [G]
Sidestand welding assembly [H]
CO
●Disassemble:
Sidestand spring [A]
Hexagon nut M10×1.25[B]
Bolt [C]
Center stand welding assembly [D]
Rubber damper [E]
10.6 Pedal
●Disassemble: ka
Screw [A] -d
Front pedal assembly [B]
n is
Mounting bushing of front foot rest lever [C]
b ra
Front pedal buffer rubber washer [D] Ka
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S.A
N I S
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● Remove rubber cover of footpeg [B] from the welding
assembly [A] of front pedal.
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10.6.2 Left rear footpeg
●Disassemble
Cotter pin [A]
Footpeg mounting pin [B]
Left rear pedal [C]
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10.6.3 Rear right footpeg
●Disassemble
Cotter pin [A]
Footpeg mounting pin [B]
Right rear pedal [C]
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10.7 Muffler
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●Disassemble:
D im
Oxygen sensor [A]. -
S.A
N I S
RA
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10.7.2 Installation of muffler
● Install the parts that have been removed before in the
reverse order of disassembly (see the corresponding
chapters).
● Replace the exhaust pipe gasket [A] with a new one.
Locking torque:
Front exhaust pipe mounting nut: 22-29 N·m
Rear mounting bolt of muffler barrel: 22-29 N•m
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10.8 Disassembly/installation of engine
ka
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Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Frame welding assembly 1 — —
2 Self-locking nut M8 2 22~29 2.2~2.9 AL、S
3 Right cover mounting base of engine 1 — —
4 Self-locking nut M10×1.25 1 45~50 4.5~5.0 AL、S
5 Right upper hanging panel of engine 1 — —
6 Bolt M8×25 2 22~29 2.2~2.9 AL、S
7 0Bolt M8×60 2 22~29 2.2~2.9 AL、S
8 Self-locking nut M10×1.25 1 45~50 4.5~5.0 AL、S
9 Right rear hanging panel assembly of engine 1 — —
10 Self-locking nut M10×1.25 1 45~50 4.5~5.0 AL、S
11 Front buffer collar of engine 1 — —
12 Self-locking nut M10×1.25 1 45~50 4.5~5.0 AL、S
13 Right front hanging panel assembly of engine 1 — —
14 Bolt M10×1.25×135 1 45~50 4.5~5.0 AL、S
15 Rear front hanging panel assembly of engine 1 — —
16 Front buffer collar of engine 1 — —
17 Bolt M10×1.25×155 1 45~50 4.5~5.0 AL、S
18 0Bolt M8×60 2 22~29 2.2~2.9 AL、S
19 Left rear hanging panel assembly of engine 1 — —
20 Hexagon bolt with flange M10×1.25×170 1 45~50 4.5~5.0 AL、S
21 Bolt M8×25 2 22~29 2.2~2.9 AL、S
22 Hexagon bolt with flange M10×1.25×60 1 45~50 4.5~5.0 AL、S
23 Bolt M8×75 2 22~29 2.2~2.9 AL、S
24 Left cover mounting base of engine 1 — —
25 Left upper hanging panel assembly of engine 1 — —
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque. ka
G: Apply grease. -d
L: Apply locking agent. n is
M: Apply the grease containing molybdenum disulfide. b ra
MO:Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum Ka
disulfide-containing grease prepared in a weight ratio of 10:1) io s
it r
R: Replace the part.
S: Observe the specified tightening sequence. D im
-
Si: Apply silicon grease.
S.A
SS: Apply silicone sealant.
N I S
R A
A B
E K
ORG
G E
AY
O W
O T
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P Y - 318 -
CO
10.8.2 Disassembly of Engine
● Lift the rear wheel from the ground by fixing the center
stand[A].
CO
● Loosen the nut [A] and remove the clutch wire connector
[B]
●Loosen the nut [A] and remove the throttle cable connector
[B].
ka
●Disconnect each air tube [A] -d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 320 -
CO
●Remove the spark plug cap [A].
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 321 -
CO
● Disconnect the connectors of each cable.
●Loosen:
Front mounting bolt of engine [A].
●Disassemble:
Left front hanging panel assembly mounting bolt of engine
[A].
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 322 -
CO
●Disassemble:
Right front hanging panel assembly mounting bolt of engine
[A].
●Disassemble:
Remove the rear lower mounting bolt of engine [A].
●Disassemble:
Remove the rear upper mounting nut of engine [A].
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 323 -
CO
●Disassemble:
Remove the upper mounting nut of engine [A].
●Disassemble:
Right rear hanging panel assembly mounting bolt of engine
[A].
●Disassemble:
Left rear hanging panel assembly mounting bolt of engine [A].
ka
-d
n is
b ra
Ka
io s
it r
D im
●Disassemble: -
Right upper hanging panel assembly mounting nut of engine S.A
[A]. N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 324 -
CO
●Disassemble:
Left upper hanging panel assembly mounting bolt of engine
[A].
●Disassemble:
Rear lower mounting bolt of engine [A].
ka
-d
n is
10.8.2 Installation of Engine b ra
Ka
●Support the engine with a suitable frame.
io s
●Install the rear lower mounting bolt of engine [A], and do
it r
not tighten the corresponding nut too tightly;
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 325 -
CO
●Install the left upper hanging panel of engine [A] and
install the bolt [B].
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 326 -
CO
●Install the upper mounting bolt of engine [A], and do not
tighten the corresponding nut too tightly;
●Install the left rear hanging panel of engine [A], install the
bolt [B] and do not tighten it too tightly;
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 327 -
CO
●Install the rear upper mounting bolt of engine [A], and do
not tighten the corresponding nut too tightly;
●Install the left front hanging panel of engine [A], install the
bolt [B] and do not tighten it too tightly;
ka
-d
n is
b ra
Ka
io s
it r
●Install the front mounting bolt of engine [A], and do not
D im
tighten the corresponding nut too tightly; -
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 328 -
CO
●Tighten the bolts, screws or nuts as follows:
○Step I: Lock the locknut of rear lower mounting bolt of
engine
○Step II: Lock the locknut of upper mounting bolt of engine
○Step III: Lock the locknut of front mounting bolt of engine
○Step IV: Lock the locknut of rear upper mounting bolt of
engine
○Step V: Lock the clamping nut on the upper hanging panel
of left engine
○Step VI: Lock the clamping bolt on the left front hanging
panel assembly of left engine
○Step VII: Lock the clamping bolt on the right front hanging
panel assembly of right engine
○Step VIII: Lock the clamping bolt on the left rear hanging
panel assembly of left engine
○Step IX: Lock the clamping bolt on the right rear hanging
panel assembly of right engine
○Step X: Mark each fastening bolt, screw and nut that
locked to the specified torque.
Note
○ Fasten the mounting bolts, screws or nuts in three
steps
○Locking torque:
Rear lower mounting bolt of engine: 45-50 N·m
Upper mounting bolt of engine: 45-50 N·m
Front mounting bolt of engine 45-50N·m
Rear upper mounting bolt of engine: 45-50 N·m
Upper hanging panel mounting bolt of engine:
22-29 N·m
Left front hanging panel assembly mounting bolt of ka
engine: 22-29 N·m -d
Right front hanging panel assembly mounting bolt of
n is
engine: 22-29 N·m
b ra
Left rear hanging panel assembly mounting bolt of Ka
engine: 22-29 N·m
io s
Right rear hanging panel assembly mounting bolt of engine: it r
22-29 N·m
D im
● Properly arrange the wire, cable and hose (see "Appendix" -
- "Winding Method of Cables, Wires and Hoses" for details). S.A
●Install the parts disassembled previously (see the N I S
corresponding chapters). R A
●Adjustment: A B
E K
○ Throttle cable (see “Periodic Maintenance” – “Checking
Throttle Control System”),
O RG
E
● Drive chain (see “Periodic Maintenance” – “Inspection of
G
Y
Slackness of Drive Chain” for details)
A
W
● Fill the engine with oil (see "Periodic Maintenance" -
O
T
"Replacing Oil" for details),
O
- M
P Y - 329 -
CO
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 330 -
CO
Inspection and maintenance of engine
CO
Clutch locknut 45~50N·m
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
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P Y - 332 -
CO
Main parameters of engine
Four stroke, single cylinder, four valves, double
Engine type
spark plugs
Cooling mode Air-cooled
Cylinder diameter×stroke (mm) 72.7×90
Displacement (ml) 373.5
Compression ratio 8.5:1
Maximum net power / corresponding speed 15.5kW/5500 r/min
Maximum torque/ corresponding rotating speed 29.0N.m/4500 r/min
Injection type Electronic fuel injection
Starting mode Electric starting
Idle speed 1400r/min
Spark plug model BR7ES/CR7HSA
Maximum lift Maximum lift range 10.5mm
range of Intake
Opening angle 354°
intake/exhaust valve
Closing angle 572°
valves, opening
and closing angle Maximum lift range 10.5mm
Exhaust ka
with respect to the
Opening angle 150°
-d
dead point, and valve n is
Closing angle 367° b ra
valve clearance
Ka
Lubrication mode s
Splash lubrication, pressure lubrication
io
it r
Amount of oil added
D im
2.8L
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 333 -
CO
Lubrication System Diagram
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
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P Y - 334 -
CO
ka
-d
n is
b ra
Ka
①Camshaft
io s
②Crankshaft it r
③Oil filter
D im
④Fuel pump -
⑤Oil filter S.A
⑥Primary shaft N I S
⑦Primary shaft RA
⑧Piston A B
⑨Clutch E K
O RG
G E
AY
OW
O T
- M
P Y - 335 -
CO
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
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P Y - 336 -
CO
Fuel pump
Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Bolt M6×15 1 10~12 1.0~1.2
2 Pressure plate 1 — —
3 Retainer 10 1 — —
4 Washer 10.5×16.5×1.5 1 — —
5 Fuel pump gear assembly 1 — —
6 Cross recessed pan head screw 1 — —
7 Screw M6×30 3 10~12 1.0~1.2
8 Fuel pump shaft 1 — — a
k
9 Fuel pump cover 1 — —
-d
10 Inner rotor 1 — —
n is
11 Outer rotor 1 — —
b ra
12 Pin 3×8 2 — — Ka
13 Fuel pump body 1 — —
io s
14 Roller pin 1 — —it r
15 Pin 2.5×16 1 — m
Di —
16 Oil drip pan 1 —
- —
17 Decompression valve assembly 1 S
—
.A —
18 Bolt M6×35 1 NI S
10~12 1.0~1.2
BRA
K A
GE
O R
G E
AY
O W
O T
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P Y - 337 -
CO
XI. Lubrication System
E OR
inner and outer rotors
0.05-0.095 0.15
- M
PY - 338 -
CO
Locking torque
Mounting screw of fuel pump 10-12 N·m
Mounting bolt of fuel pump base 10-12 N·m
Tools
11.2 Troubleshooting
11.3.1 Disassembly
Remove the right cover [A]
ka
-d
n is
b ra
Disassemble:
Ka
Bolt [A]
io s
Retainer [B]
it r
Screw [C]
D im
Fuel pump [D] -
S.A
N I S
RA
A B
E K
ORG
G E
AY
O W
O T
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P Y - 340 -
CO
Remove fuel pump base.
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
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P Y - 341 -
CO
Check the clearance between external rotor and fuel pump base.
Allowable limit: 0.24mm.
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 342 -
CO
A. Retainer 10
B. Washer 10.5×16.5×1.5
C. Fuel pump gear assembly
D. Cross recessed pan head screw M6×16
E. Fuel pump cover
F. Outer rotor
G. Inner rotor
H. Fuel pump shaft
J. Pin 3×8
K. Fuel pump body
L. Roller pin
M. Pin 2.5×16
Note:
After assembly, the inner and outer rotors should be able to
rotate flexibly without clamping stagnation.
11.3.4 Installation
Install it in the reverse order of disassembly.
Locking torque:
Mounting bolt of fuel pump base 10-12 N·m
Mounting bolt of fuel pump base 10-12 N·m
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 343 -
CO
Cylinder Head Cover
10-12N·m
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
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P Y - 344 -
CO
Cylinder Head Cover
Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Bolt M6×16 4 10~12 1.0~1.2 ka
2 Cylinder gasket 4 — — -d
3 Cushion 4 — — n is
4 Right cylinder head cover 1 — — b ra
5 Left cylinder head cover 1 — — Ka
io s
6 Hexagon bolt with flange M6×30 4 10~12 r
1.0~1.2
it
7 Bolt M6×14 2 10~12
D im 1.0~1.2
8 Cylinder Head Cover 1 — - —
9 Cylinder head cover sealing washer 1 — .A —
S S
N I
R A
A B
E K
ORG
G E
AY
O W
O T
- M
P Y - 345 -
CO
XII. Cylinder Head Cover
Locking torque
Mounting bolt of cylinder head cover 10-12 N·m
ka
12.2 Fault Diagnosis -d
n is
b ra
12.2.1 Oil leakage or seepage of cylinder head cover Ka
io s
· Cylinder head cover sealing washer is damaged
it r
· Cylinder head cover is damaged
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 346 -
CO
12.3 Cylinder head cover
12.3.1 Disassembly
Disassemble:
Bolt [A]
Right cylinder head cover [B]
Disassemble:
Bolt [A]
Left cylinder head cover [B]
ka
Disassemble: -d
Bolt [A]
n is
Cylinder head cover [B]
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
ORG
G E
AY
O W
O T
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P Y - 347 -
CO
Remove the cylinder head cover sealing washer [A]
12.3.2 Inspection
Cylinder Head Cover
Damaged → replace
12.3.3 Installation
Install it in the reverse order of disassembly.
Note
When cylinder head cover is removed and reinstalled
ka
every time, the gasket of cylinder head cover must be
replaced with a new one.When installing, ensure that the
-d
n is
seal is installed in the groove of cylinder head cover, and
b ra
Ka
that the groove of cylinder head cover and the cylinder
head mounting surface should be cleaned and free of
io s
debris.
it r
D im
Locking torque: -
Mounting bolt of cylinder head cover: 10-12 N·m
S.A
Mounting bolt of left / right cylinder head cover: 10-12N·m
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 348 -
CO
Cylinder Head / Distribution
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
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P Y - 349 -
CO
Cylinder head
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
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P Y - 350 -
CO
Torque
No Chinese name and specifications Number of Note
N·m kgf·m
1 Clamp assembly 1 — —
2 Nut 6 2 10~12 1.0~1.2
3 Double end stud M6×35 2 10~12 1.0~1.2
4 Intake tube components 1 — —
5 Heat insulated pad 1 — —
6 O-Ring 42.5×1.8 2 — —
7 Damping block 3 — —
8 Spark plug 1 10~12 1.0~1.2
9 Taper plug 4 — —
10 O-Ring 2 — —
11 Valve seal components 2 — —
12 Cylinder head machining assembly 1 — —
13 Short double-end stud 2 10~12 1.0~1.2
14 O-ring seal 20×2.5 1 — —
15 Retainer 28 1 — —
16 Spark plug sleeve 1 — —
17 O-ring seal 27.4×2.4F 1 — —
18 Spark plug 1 10~12 1.0~1.2
19 Pressure plate 1 — —
20 Hexagon bolt with flange M5×12 2 4~7 0.4~0.7
21 O-ring of sprocket cover 1 — —
22 Sprocket cover 1 — —
23 Clamp 1 — —
24 Washer φ6.5 1 — —
25 Bolt M6×22 1 10~12 1.0~1.2
ka
26 Bolt M6×25 2 10~12 1.0~1.2 -d
27 Dowel pin Φ8×8 2 — —
n is
28 Inner hexagon screw M6×134 2 10~12 1.0~1.2
b ra
29 Cylinder head washer 1 — — Ka
30 Temperature sensor 1 — —
io s
31 Fuel injector 1 — —it r
32 Fuel Injector seat assembly 1 —
m
Di —
-
33 Bolt M5×12 2
S.A
4~7 0.4~0.7
N I S
R A
A B
E K
O RG
G E
AY
OW
O T
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P Y - 351 -
CO
Valve mechanism
ka
Number Torque -d
No Chinese name and specifications
of N·m kgf·m
Note
n is
1 Intake valve 1 — — b ra
2 Valve lower spring seat [5] 2 — — Ka
3 Inner spring of valve 2 — — io s
it r
4 2 — —
5
Outer spring of valve
4 — D im—
Valve lock clamp -
6 Upper spring seat of valve 2 — .A —
S
S—
NI
7 Inlet rocker arm assembly 1 —
8 Bolt M10×25 1 A 38 3.8
9 Exhaust rocker assembly BR
1 — —
10 Camshaft sprocket
E KA 1 — —
11 Inlet rocker arm shaft
R G 1 — —
12 Exhaust rocker arm shaft
E O 1 — —
13 Camshaft assembly G 1 — —
14 Exhaust valveA
Y 1 — —
T OW
M O
Y - - 352 -
P
CO
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
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P Y - 353 -
CO
Timing drive mechanism
ka
-d
n is
b ra
Ka
io s
Number Torque it r
No Chinese name and specifications
of N·m D im Note
- kgf·m
1 Bolt M6×25 2 .A
10~12
S 1.0~1.2
2 Camshaft chain regulator 1
NI S— —
3 Washer 1
A — —
4 Screw at primary guide chain plate BR
1 — —
5 Primary guide chain plate assembly
E KA 1 — —
6 Timing chain
R G 1 — —
7 O
Auxiliary guide chain plate component
E 1 — —
Y G
W A
T O
M O
Y - - 354 -
P
CO
XIII. Cylinder Head
N IS
Exhaust 1-1.2 1.5
- M
P Y - 355 -
CO
Locking torque
Stud bolt of air inlet duct 10~12 N·m
Stud bolt at exhaust side 10~12 N·m
Bolt at sprocket cavity 9.8 N·m
BR7ES/CR7HSA spark plug 10-12N·m
Sprocket bolt 38 N·m
Tools
ka
-d
n is
b ra
Micrometer Runout gauge Ka
io s
it r
13.2 Fault Diagnosis D im
-
S.A
I S
13.2.1 Compression pressure is low A N
B R
Valve clearance is not adjusted properly
K A
Valve burns out or is bent E
The airtightness of valve seat is not poor
ORG
E
The washer of cylinder head is leaking
G
The spark plug is not installedY
properly
A
T OW
M O
Y - - 356 -
P
CO
13.2.2 The sound of cylinder head is abnormal
Valve clearance is not adjusted properly
Valve spring is damaged
13.3.1 Disassembly
Remove the cylinder head/ (see 12.3.1 for details)
Remove the retainer [A] at the auxiliary spark plug using a
circlip pliers.
Remove the auxiliary spark plug [B] using a straight
screwdriver.
ka
Screw out the auxiliary spark plug [A] using a spark plug -d
socket.
n is
Observe whether the spark plug washer is clean.
b ra
If the organic oil burns out, the airtightness is poor, and O ring Ka
[B] below the spark plug needs to be replaced.
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 357 -
CO
Remove 2 fastening bolts [A], and then the tensioner assembly
[B].
Loosen 3 screws [A] and remove the sprocket cover [B] and
O-ring.
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
ORG
G E
AY
O W
O T
- M
P Y - 358 -
CO
Loosen the bolt at the side of sprocket cavity[A] and cylinder
bolt [B].
ka
-d
n is
b ra
Remove the camshaft components Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
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P Y - 359 -
CO
Valve spring compressor [1][2]
13.3.2 Inspection
●Measure valve clearance with feeler gauge [A]
○Standard of valve clearance:
Intake valve clearance: 0.98-0.12mm
Exhaust valve clearance: 0.10-0.14mm
★If there is a difference between the measured actual valve
clearance and the standard valve clearance, the actual
measured data can be compared with the standard clearance
and the valve adjusting screw can be adjusted to achieve the
standard valve clearance.
ka
-d
n is
●Measure the dimensions of rocker shaft using a
b ra
micrometer.
Ka
○Allowable limit: 11.88mm.
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 360 -
CO
●Measure the inner diameter of rocker arm hole.
Allowable limit: 12.02mm.
●Clearance between rocker arm hole and rocker arm shaft.
○Allowable limit: 0.045mm.
CO
● Measure the gradient of intake / exhaust spring of valve
[a].
○Allowable limit: 1.6mm
ka
-d
●Check the valve guide and remove the carbon deposits in
n is
the valve guide with a reamer before check.
b ra
Note Valve reamer
Ka
Rotate the reamer clockwise and do not rotate the
io s
reamer counterclockwise. it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 362 -
CO
●Measure the inner diameter of valve guide. Allowable
limit:
○Intake valve: 6.925mm,
○Exhaust valve: 6.915mm.
●Allowable limit of clearance between valve and valve
guide:
○Intake valve: 0.1mm.
○Exhaust valve: 0.1mm.
ka
Note:
-d
If the clearance between valve and valve guide
n is
exceeds the limit, replace the valve guide. After the valve
b ra
guide is replaced, the valve seat ring surface must be
Ka
finished.
io s
●Put the valve guide in the freezing cavity of refrigerator to
it r
cool it for an hour.
D im
●Use the electric furnace or oven to heat the cylinder head to -
100-150℃. S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 363 -
CO
Fix the cylinder head and remove the valve guide from the
upper side of cylinder head with the valve guide disassembly
tool [1].
CO
After the valve guide is embedded, carry out the finishing by
using the valve guide reamer.
Note: Valve reamer
Add an appropriate amount of cutting oil during cutting
with a reamer. The reamer shall be rotated clockwise.
●Remove 1/4 of outer end of valve seat ring with a 25° cutter.
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 365 -
CO
●Remove 1/4 of bottom of valve seat ring with a 60° cutter. Take
the cutter and check the positions which have been disposed.
●Grind the valve seat ring with a 45° finishing cutter to reach an
appropriate width.
○Make sure to remove all dents and uneven parts.
○If the contacted position is in the too high part of valve, please The contact surface
is high
lower the valve seat ring with a 25° flat cutter.
○If the contacted position is in the too low part of valve, raise the
valve seat ring with a 60° internal cutter.
ka
○Use the 45° finishing cutter to finish the valve seat ring again to -d
make it meet the required specification. The contact surface
n is
ra
is low
b
Ka
io s
it r
D im
-
●After the valve seat ring is grinded, apply polish to the valve S.A
surface and gently polish the valve. N IS
R A
13.3.5 Installation A B
E K
G contrary
●Installation shall be carried out in the order
R
to the disassembly order.
G EO
●Please adjust the ignition timing after installation. (see
A Y timing”)
“inspection/adjustment” —“ignition
OW of Valve:
Precautions for Installation
T
M O
Y - - 366 -
O P
C
●When the valve is installed, apply appropriate amount of
New
engine oil to the surface of the valve stem and then install product
●Knock the valve lock plate gently with a soft hammer to fix
ka
it on the valve stem. -d
n is
Note:
b ra
Do not knock the valve lock plate overly to avoid Ka
damaging the valve.
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 367 -
CO
Cylinder Block, Piston
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
160~165N.m A
B R 135~140N.m
KA
E
O RG
G E
AY
O W
O T
- M
P Y - 368 -
CO
Cylinder Block
ka
-d
n is
b ra
Ka
io s
it r
Number D im
Torque
No Chinese name and specifications - Note
of
.A
N·m
S
kgf·m
1 Dowel pin 6×10×16 2
NI S— —
2 Damping block 1
A — —
3 Cylinder block assembly BR
1 — —
4 Cylinder block washer
E KA 1 — —
5 Dowel pin 10.5×13×13
R G 2 — —
E O
Y G
W A
T O
M O
Y - - 369 -
P
CO
Piston connecting rod crankshaft balance shaft
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 370 -
CO
Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Piston ring 1 10~12 1.0~1.2
2 Piston 1 — —
3 Piston pin 1 — —
4 Piston pin retainer 2 — —
5 O-ring seal 1.8×17 1 — —
6 Balance shaft 1 — —
7 Straight key 1 — —
8 Balancer shaft gear components 1 — —
9 Washer 1 — —
10 Nut M12×1.25 1 45~50 4.5~5.0
11 Hexagon nut with flange M14×1.5 1 160~165 16.0~16.5
12 Washer 14.2×30×3 1 — —
13 Washer 2 — —
14 Key 1 — —
15 Crankshaft components 1 — —
16 Flat key 8×7×25 1 — —
17 Gear sprocket 1 — —
18 Clutch drive gear 1 — —
19 Fuel pump drive gear 1 — —
20 Washer (II) 1 — —
21 Washer (I) 1 — —
22 Crank shaft retaining nut M16×1 1 135~140 13.5~14.0
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 371 -
CO
XIV. Cylinder Block and Piston
Piston------------------------------------------ 14.4
Function of piston:
1. It can withstand the pressure generated by the combustion of
ka
combustible gas mixture in the cylinder and transmit the
-d
pressure to the connecting rod to drive the crankshaft to rotate.
n is
2. Form a combustion chamber together with the cylinder head
b ra
and other parts.
Ka
io s
Operation Precautions: it r
D im
A -
Before the inspection and measurement, all parts shall be cleaned and blown with high-pressure air.
S .
I S
R AN
A B
E K
R G
G EO
A Y
T OW
M O
Y - - 372 -
P
CO
Technical parameters
Allowable
Item standard value
limit
Inner diameter 72.7~72.715 72.815
Cylindricity 0.008 0.05
Cylinder
Roundness 0.007 0.05
Planeness 0.03 0.06
72.735~72.75
Outer diameter of piston (measurement point) 72.7
(7mm at the bottom of piston skirt)
Inner diameter of piston pin hole 17.002~17.008 17.04
Outer diameter of piston pin 17~17.006 16.96
Clearance between piston and piston pin 0.002~0.014 0.07
Piston and piston ring
Clearance between piston First ring 0.03~0.07 0.1
ring and ring groove Second ring 0.03~0.07 0.1
First ring 0.15~0.3 0.55
Piston ring joint clearance Second ring 0.25~45 0.75
Oil ring 0.20-0.7 _
Connecting rod small Inner diameter of connecting rod small end 17.012~17.021 17.05
end Clearance between connecting rod and piston pin 0.012~0.027 0.10
Lateral clearance of big end of connecting rod 0.1~0.30 0.50
Crankshaft components Radial clearance of big end of connecting rod 0.03~0.058 0.05
Run-out 0.02 0.1
Locking torque
Crank shaft retaining nut 135~140N.m
Hexagon nut with flange M14×1.5 160~165N.m
Hexagon thin nut 45-50N.m
ka
-d
Tools n is
bra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
Feeler gauge O RG Caliper
G E
AY
O W
O T
- M
P Y - 373 -
CO
Micrometer Runout gauge
① Opening clamp
② Piston
CO
14.2 Fault Diagnosis
14.3.1 Disassembly
Remove the cylinder head/ (see 12.3.1 for details)
Disassemble the cylinder head. (see 13.3.1 for details)
Remove the cylinder block [A]. ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 375 -
CO
Remove the washer [A] and dowel pin [B].
14.3.2 Inspection
Check the wear situation of inner wall of cylinder.
If the wear is serious, please replace it.
CO
Apply oil to the inner wall of cylinder, piston and piston ring.
Install the piston ring into the cylinder carefully.
*Note:
Do not damage the piston ring.
14.4 Piston
14.4.1 Disassembly
●Remove the piston pin retainer.
Note:
During disassembly, do not drop the retainer into the crankcase.
●Take out the piston pin [A] and remove piston.
CO
14.4.2 Inspection
●Install the piston ring.
●Measure the clearance between piston ring and piston ring
groove.
○Allowable limit: top ring: 0.1mm.
Second ring: 0.1mm.
●Remove the piston ring and install the piston rings at the
bottom of cylinder.
*Note:
Note: Press the piston ring [A] in the cylinder by using the
piston head [B].
● Measure the piston ring joint clearance.
○Allowable limit: first ring: 0.55mm.
Second ring: 0.75mm
ka
-d
n is
b ra
Ka
●Measure the outer diameter of piston pin. io s
○ Allowable limit: 16.96mm. it r
●Clearance between piston pin hole and piston pin. D im
-
○ Allowable limit: 0.07mm.
S.A
N I S
R A
A B
E K
O RG
G E
AY
OW
O T
- M
P Y - 378 -
CO
●Measure the outer diameter of piston pin.
*Note:
The measurement position forms an angle of 90 degrees
with the piston pin and it is 7mm below the piston skirt
part.
○ Allowable limit: 72.7mm.
CO
●Check the planeness of cylinder surface.
○Allowable limit: 0.06mm.
CO
●Clean the washers attached to the crankcase[A].
*Note:
Foreign matters shall not fall into the crankcase.
14.5.1 Inspection ka
-d
●Measure the lateral clearance of big end of connecting rod.
n is
○Allowable limit: 0.55mm.
b ra
Plug gauge
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 381 -
CO
●Measure the clearance of big end of connecting rod in X-Y
direction.
○ Allowable limit: 0.05mm
Crankshaft bearing
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
ORG
G E
AY
O W
O T
- M
P Y - 382 -
CO
Crankshaft connecting rod
45~50N.m
160~165N.m
135~140N.
Crankcase
ka
-d
n is
bra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 383 -
CO
Crankcase
ka
-d
Number Torque n is
No Chinese name and specifications
of N·m kgf·m b ra
Note
M O
Y - - 384 -
P
CO
15 Oil filter plug 1 — —
16 Stud 4 — —
17 Washer 10.5×19.8×2 4 — —
18 Self-locking nut M10×1.25 4 45~50 4.5~5.0
19 Bolt M6×60 14 10~12 1.0~1.2
20 Rolling bearing 2 — —
21 Bearing I 2 — —
22 Bearing II 2 — —
23 Rubber Blanket 1 — —
24 Plug screw 1 — —
25 Sealing washer 1 — —
26 Screw M6×12 5 10~12 1.0~1.2
27 Bearing retainer II 5 — —
28 Rolling bearing 1 — —
29 Dowel pin 2 — —
30 Rolling bearing 1 — —
31 Limit retaining screw 1 — —
32 Rolling bearing 1 — —
33 Rolling bearing 1 — —
34 Rolling bearing 1 — —
35 Breather pipe 1 — —
36 Taper plug M14×1.5×10 1 — —
37 Filter housing 1 — —
38 Assembling washer 1 — —
39 Holder 1 — —
40 Bolt M6×14 2 10~12 1.0~1.2
41 Combination screw M4×10 6 3.5~4.5 0.35~0.45
42 Rivetφ3×13 1 — —
43 Breather valve retainer 1 — —
ka
44 Paper washer of breather valve 1 — — -d
45 Screw M6×14 2 — —
n is
46 Block chain plate 1 — —
b ra
47 O-Ring 1 — — Ka
48 O-ring Φ12.5×1.8 1 — —
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 385 -
CO
XV. Crankcase
Crankcase------------------------------------------------------------------------ 15.3
Function of crankcase:
The crankcase is the bearing part of engine. Its main function is
to support the crankshaft, clutch, gearbox, cylinder block and
cylinder head, withstand the combustion explosion impact and
inertia force of movement of crankshaft connecting rod
mechanism and form a part of closed (oil and air seal) space.
Operation Precautions:
The crankcase is also equipped with suspension holes, and the
engine is connected with the frame and other parts through the
connection with the suspension holes on the motorcycle.
This section mainly introduces the disassembly and installation
ka
of parts of crankcase, torque value of bolt specifications, Note
-d
for disassembly and installation and other services;
n is
b ra
Locking torque Ka
io s
Assembling bolt 10 N·m Apply oil
it r
Oil seal cover bolt 10 N·m Apply oil
D im
Gear position sensor mounting screw 6 N·m Apply oil -
Breather valve retainer assembly screw 4 N·m S.A
Apply oil
Bearing retainer screw 10 N·m
NApply S
I locking agent
Block chain plate bolt 10 N·m
R A Apply oil
Bracket bolt 10 N·m
A B Apply oil
Two-headed bolt K
45 N·m
E Apply oil
O RG
G E
AY
O W
O T
- M
P Y - 386 -
CO
15.2 Disassembly and Installation of Crankcase Bearing
CO
15.3 Crankcase
ka
-d
n is
b ra
c.Remove the dowel pin; Ka
io s
15.3.2 Inspection of crankcase it r
D im
Precautions: -
1. Clean the disassembled crankcase parts with detergent; S.A
2. Clean the disassembling surface of crankcase and the N I S
joint surface of left and right covers; R A
3. A
The crankcase is a thin-walled casting. Heavy impact B
E K
should be avoided during the operation to prevent
deformation or breakage.
O RG
4. E
Before operation, the lubricant in the crankcase should
G
be released.
AY
Check Item W
T O
M O
Y - - 388 -
P
CO
●Check the crankshaft for defects such as cracks.
★ If there is any defect, replace crankshaft components.
CO
● Check oil seal
○ Check the seal lip for damage or deformation, and whether
there is any edge cut deformation in the outer ring.
★If necessary, replace the new bearing with special tools.
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 390 -
CO
● Apply sealant at the assembling surface:
Note:
Apply sealant around the bolt hole evenly, and prevent
sealant going into the lubricating oil passage of crankcase.
●Assembling bolt
ka
Note: -d
Tighten the assembling bolt on the left crankcase, the
n is
tightening torque of which should meet the requirements
b ra
(10N•m); Ka
Then tighten the assembling bolt on the right crankcase,
io s
the tightening torque of which should meet the requirements it r
(10N•m);
D im
-
S.A
N IS
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 391 -
CO
Clutch
Position of right cover
10N·m
12N·m
Position of clutch
10N·m
45N·m
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
ORG
G E
AY
O W
O T
- M
P Y - 392 -
CO
Right Cover
Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Bolt M6×38 2 10~12 1.0~1.2
2 Bolt M6×30 12 10~12 1.0~1.2
3 Inner hexagon screw M6×30 3 10~12 1.0~1.2
4 Filter cover 1 — —
ka
5
6
O-Ring
Engine oil filter assembly
1
1
—
—
—
—
-d
n is
7 Oil level indicator assembly 1 — —
b ra
8 1 — —
Ka
Conical plug M12×1.5
9 Conical plug M10×1 1 — — s
10 Right Cover 1 — — rio
it
11 Dowel pin 2 —
D im —
12 Washer on the right cover 1 — - —
13 Plug screw of oil filler 1 —S.A —
14 O-Ring 18×3.5 1
N I S— —
15 Lever spring 1
R A — —
16 Needle bearing 12×16×10 A B2 — —
17 Lever oil seal E K 1 — —
18 R G
Operating lever riveting component 1 — —
19 Nameplate
G EO 1 — —
A Y
T OW
M O
Y - - 393 -
P
CO
Clutch
Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Driving hub assembly of clutch. 1 — —
2 Spline washer 1 — —
3 Clutch component 1 — —
4 Driven hub assembly of clutch 1 — —
5 Lock washer 1 — —
6 Slef-locking nut 1 45~50 4.5~5.0
7 Friction pad 2 4 — —
ka
8 Clutch plate 6 — —
-d
9 Friction pad 1 3 — —
n is
10 Clutch lever 1 — —
b ra
11 Plane needle bearing 1 — —
Ka
12 Bolt assembly 4 10~12 1.0~1.2
io s
13 Filter spring 4 — —
it r
14 Driven hub base of clutch 1 —
D im—
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 394 -
CO
XVI. Clutch
Operation Precautions:
·Install the engine on the frame, and disassemble right cover
and clutch.
·Engine oil viscosity and oil level may affect clutch separation.
When the clutch is not separated or unclear, check the engine
oil level before repairing the clutch system.
Technical parameters
Item Standard Allowable limit
Free corner of clutch operating lever 10°-20° —
ka
Free length of clutch spring 35 33.7 -d
Thickness of clutch friction 2.9-3.0 2.6
n is
wrapping of clutch metal plate — 0.3
b ra
Inner diameter of clutch bushing — —Ka
Outer diameter of clutch bushing —
io s—
it r
D im
Locking torque -
Clutch lock nut 45-50 N·m S.A
Clutch spring bolt 10-12 N·m N I S
Right cover mounting bolt 10-12 N·m R A
Oil filter mounting bolt 10-12 N·m A B
Crankshaft retainer bolt 5 N·mE K Apply locking agent to threads
O RG
Tools G E
AY
O W
O T
- M
P Y - 395 -
CO
Central pivot universal fixer of clutch
ka
16.2.3 Clutch does not disengage or clutch disengages suddenly during the -d
n is
running of motorcycle ra
b
·Clutch plate is wrapping Ka
io s
·Clutch lock nut is loosened
it r
·The oil level is too high
D im
·Oil viscosity is poor -
·The detaching mechanism of clutch is damaged
S.A
·The push rod of clutch is not installed properly
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 396 -
CO
16.3 Right Cover
Locking torque:
Right cover mounting bolt: 10-12 N·m
ka
16.4 Clutch -d
n is
b ra
16.4.1 Disassembly of clutch Ka
io s
●Fix the clutch driven hub base [A] using a dedicated clutch
it r
central pivot universal fixer, and the clutch cannot be
D im
rotated. -
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 397 -
CO
○Central pivot universal fixer of clutch
ka
-d
n is
●Loosen clutch lock nut, and remove the clutch lock nut
b ra
[A]. Ka
●Remove clutch driven hub assembly [B] and spline washer.
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 398 -
CO
●Remove clutch driving hub assembly [A].
16.4.2 Inspection
● Check the outer groove of clutch for any burrs or broken
marks.
★ If necessary, finish it using a file, and replace it if the
amount of finishing is too large. a
k
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 399 -
CO
●Check the tooth forms of clutch central pivot plate [A] and
retainer [B] for damage.
★If damaged, replaced it.
ka
-d
●Measure the thickness of friction plate with a vernier
n is
calipers [A].
b ra
○Allowable limit: Replace it if the thickness is less than Ka
2.6mm.
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 400 -
CO
●Check the flatness of clutch metal plate with a feeler
gauge.
○Allowable limit: Replace it if the flatness is more than
0.3mm.
Locking torque:
Clutch lock nut: 45-50 N·m
Clutch spring bolt: 10-12 N·m
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 401 -
CO
Gearshift Mechanism
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 402 -
CO
Gearshift Mechanism
ka
-d
n is
b ra
Ka
Number Torque io s
No Chinese name and specifications
of N·m it
kgf·m
r Note
m
Di —
1 Shift shaft assembly 1 —
-
2 Bolt M6×20 1
S .A
8~10 0.8~1.0
3 Washer 1
N I S— —
4 Stopper lever spring 1 A — —
5 Rocker arm assembly B1R — —
6 Washer
E KA 1 — —
7 Star wheel screw
R G 1 8~10 0.8~1.0
8 Ratchet
E O 1 — —
9 Collar
Y G 1 — —
10 Dowel pin A 1 — —
T OW
M O
Y - - 403 -
P
CO
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 404 -
CO
XVII. Gearshift Mechanism
Locking torque
Start wheel bolt 8-10 N·m Apply locking agent
Positioning roller rocker bolt 8-10 N·m
CO
17.3 Gearshift Mechanism
17.3.1 Disassembly
●Pull out the gearshift shaft assembly [A]
ka
-d
n is
Note:
b ra
There are two washers behind and pay attention to Ka
prevent missing
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 406 -
CO
●Disassemble
Star wheel bolt [A]
Collar [B]
Ratchet [C]
17.3.2 Inspection
●Before disassembly, the shift plate [A] should be able to a
k
return flexibly without clamping.
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 407 -
CO
●Check the shift shaft [A]
★Check it for bending, wear and damage
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 408 -
CO
17.3.3 Installation
●Tighten the star wheel screw [A] after assembling collar
[B] and ratchet [C].
○The tightening torque is12 N·m, and apply locking agent
to the thread.
●Hook the rocker arm spring [D] to the rivet of box and
positioning roller rocker arm, install upper washer [B] and
positioning roller rocker arm [A].
○Tighten the positioning roller rocker arm bolt with a
tightening torque of 10N·m.
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
R A
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 409 -
CO
Drive system
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 410 -
CO
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 411 -
CO
Drive system
ka
-d
n is
b ra
Ka
io s
it r
D im
-
S.A
N I S
RA
A B
E K
O RG
G E
AY
O W
O T
- M
P Y - 412 -
CO
Number Torque
No Chinese name and specifications Note
of N·m kgf·m
1 Shift drum 1 — —
2 Prod spring 1 — —
3 Shifting prod 1 — —
4 Elastic retainer for shaft 1 — —
5 Collar 1 — —
6 Thrust washer 1 — —
7 Auxiliary shaft combination 1 — —
8 O-Ring 1 — —
9 Output sprocket collar 1 — —
10 Sprocket 1 — —
11 Spline washer 1 — —
12 Nut M18×1 1 110~115 11.0~11.5
13 Shift fork shaft 1 — —
14 Shift fork III 1 — —
15 Shift fork I 1 — —
16 Primary Shaft Assembly 1 — —
17 Shift fork II 1 — —
18 Shift fork shaft I 1 — —
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XVIII. Drive System
Installation------------------------------------ 18.4
Function:
Transmit torque, and decide the torque and speed of final output.
Technical parameters
Item standard value Limit value
Inner diameter 10.016~10.034 10.05
Shift fork
Thickness of claw 4.93~5.00 4.90
Shift fork shaft Outer diameter 9.991~10.00 9.98
Outer diameter 41.8~42.0 41.7
Shift drum
Groove width 6.05~6.15 6.2
M4 25.020~25.041 25.06
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M5 28.016~28.033 28.05 -d
Inner diameter of gear C1 20.020~20.41 is
20.06
n
C2 25.020~25.041 a
br25.06
C3 25.020~25.041 Ka 22.06
Outer diameter of collar of
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internal spline
Installation position of M5
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27.967~27.98 27.95
and shaftO
R C2 0.040~0.082 0.110
G E C3 0.040~0.082 0.110
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Locking torqueWA
TObolt 110-115 N·m
Sprocket mounting
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18.2 Fault Diagnosis
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18.3.2 Auxiliary shaft component
18.3.3 Inspection
●Check the shift fork (applicable to all shift forks)
·Shift fork head ①
·Shift fork claw ②
★Bending, damage, wear → Replace shift fork
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Measure the inner diameter of shift fork hole.
Allowable limit: 10.05mm.
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● Measure the outer diameter of shift fork shaft.
Allowable limit: 9.98mm.
●Check the sliding of shift fork (along the shift fork shaft)
★ The shift fork cannot slide flexibly → Replace the
complete set of shift fork and shift fork shaft
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Measure the outer diameter of shift drum.
io s
Allowable limit: 41.7mm. it r
Measure the width of lock groove of shift drum.
D im Lock groove
Allowable limit: 6.2mm. -
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●Measure the main axle runout (with centering device and
dial indicator)
★Exceed the limit size → replace the main axle
Limit size of main axle runout: 0.03mm
● Inspection
○Gear
★ Bluegrass, pitting corrosion, wear → Replace defective
gears
○Gear pawl
★Cracks, damage, round edges → Replace defective gears
● Inspection
○ Gear engagement (gear teeth of each gear)
★Incorrect → Reassemble the drive shaft component
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● Inspection
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○Gear rotation it r
★Inflexible rotation → Replace defective parts
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● Inspection
○Retainer
★Bending, damage, looseness → Replacement
18.4 Installation
opening of retainer ○
b is located on the spline groove of
shaft○
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●Installation R A
○2nd Gear of primary shaft ① A B
Note: E K
Install the 2nd Gear of primary shaft onR Gprimary shaft
the
EO○a
②, and then measure after compaction
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18.4.2 Assembly of parts at the shift drum
●Installation
○Shift prod ①
○Prod spring ②
Note:
First assemble prod spring ② to the shift drum ③ , and
then assemble the shift prod ① to the shift drum ③ ; the
assembly shall be conducted when installing the
transmission system, to prevent parts from falling off
18.4.3.1 Installation
·Auxiliary shaft component ①
·Primary shaft component ②
·Shift drum component
·Left shift fork of auxiliary shaft ③
·Right shift fork of auxiliary shaft ④
·Shift fork shaft of auxiliary shaft ⑤
·Middle shift fork of primary shaft ⑥
·Shift fork shaft of primary shaft ⑦
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·O-ring ⑧
·Collar ⑨
·Output sprocket ⑩ n is
110~115N·m b ra
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·Lock nut
·Lock plate
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·Thrust washer
·Collar
· Retainer
Note:
·When installing the left shift fork, make sure that the
side of shift fork with the ribs on it is facing away
from the right crankcase of engine.
·When installing the right shift fork, make sure that
the side of shift fork with the ribs on it is facing away
from the left crankcase of engine. Make sure that the
shift fork head is located in the shift drum stroke
groove.
18.4.3.2 Inspection
● Transmission system
★Inflexible rotation→Repair
Note:
·Fully grease the gears, shafts, bearings and other
parts.
·When assembling, ensure that the transmission
system is in neutral and each gear can rotate freely
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Electric Starter
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Electric starting
Number Torque
No Chinese name and specifications
of N·m kgf·m
Note
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1 Bolt M6×32 2 10~12 1.0~1.2 -d
2 Starter motor assembly 1 n is
3 Screw M8×14 3 22~29 2.2~2.9 b ra
4 Flywheel combination 1 — — Ka
5 1 — — io s
Electric starter gear shaft
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6 Electric starter idle shaft 1 —
D im —
7 Electric starter idle gear 1 — - —
8 Close-packed clutch assembly 1 —
S .A —
9 Starter gear assembly 1
N I S— —
10 Stator assembly 1 A — —
11 Screw M5×16 B2R 5~7 0.5~0.7
12 Screw M6×30
E KA 3 10~12 1.0~1.2
13 Electric starter gear
R G 1 — —
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XIX. Electric Starter Mechanism
Preparatory Information---------------------19.1
Fault Diagnosis---------------------19.2
Technical parameters
Item standard value Limit value
Starter gear Outer diameter of axle section 45.653~45.677 45.573
Locking torque
Flywheel locknut 90 N·m
Stator assembly mounting bolt 10-12N·m
Trigger probe mounting bolt 5-7N·m
Star wheel combination mounting bolt 10-12N·m
Starter motor mounting bolt 10-12 N·m
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19.2 Troubleshooting n is
bra
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19.2.1 Engine cannot start io s
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·Overrunning clutch is damaged
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· Starter wheel or idle gear is damaged -
Starter motor is damaged S.A
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19.3 Electric starter mechanism
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●Loosen stator assembly mounting bolt [A] and trigger
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mounting bolt [B], and remove the stator assembly [C]
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●Loosen flywheel locknut [A] using the electric tools, pull
out the flywheel clutch assembly [B] using three-jaw chuck,
remove the electric starter idle gear [E], electric starter idle
gear shaft [F], electric starter gear [C] and electric starter gear
shaft [D]
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●Loosen motor mounting bolt [A] and remove the starter
motor [B].
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Muffler catalyst
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Emission Control
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Temporarily absorb the fuel steam overflowing from the fuel tank into the charcoal canister using the adsorption effect of
the activated carbon in the canister;
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When negative pressure is generated in the fuel tank, air will enter the canister from the atmosphere entry, enter the
evaporating tube from the absorbing port, and finally enter the fuel tank. D im
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When the engine is running under certain conditions, it will be absorbed under the control of EVBP, fuel steam will be led
S.A
to the engine for combustion, and the absorption capacity of the activated carbon in the canister will recover.
N I S
When the evaporation plant is blocked, the breather valve will play the following roles:
R A
1. When positive pressure (8-15kpa) is generated in the fuel tank, the breather valve will automatically exhaust air.
A B
2. When negative pressure (-1.0- -1.5kpa) is generated in the fuel tank, the breather valve will be automatically opened, and
E K
air will enter the fuel tank through the breather valve.
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XX. Exhaust Emission Control System
Guarantee of Exhaust Emission Control System-------------------- 20.1
Regular Maintenance Notice/Guarantee Emission Standard------ 20.2
Mechanical Function of Exhaust Control System------------------- 20.3
Catalytic Conversion System------------------------------------------ 20.4
N I S
that all the motor vehicles produced by all manufacturers must meet the air pollution emission standards. The
production of this Company meets the provisions of air pollution emission standards, meanwhile, the Company also
A
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strives to purify the air and take efforts to reduce air pollution.
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K A
This motorcycle has passed rigorous inspection before leaving the factory and meets the provisions of air pollution
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emission standards. However, due to the different service conditions of this product, we have formulated the following
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regular checklist on exhaust emission. To ensure normal emission, the users should carry out inspection, adjustment or
O
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maintenance in accordance with the specified time.
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For other individual problems on use, please ask the dealers or Service Center.
The relevant emission provisions are shown below:
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Emission regulation CO HC NOX
Emission standard ≤1.14g/km ≤0.38g/km 0.07g/km
※ If the emission standard changes, the newest national provision shall prevail.
If the regular inspection is not carried out at the dealers or service centers of this Company, this Company will not be
responsible for the prohibition. Please make necessary inspection at any time to maintain the best motorcycle
conditions.
Note: ①The cleaning frequency of air filter should be increased if the motorcycle is ridden on sandy roads or in the
seriously polluted environment to prolong the service life of engine.
② If the motorcycle is always ridden at a high speed or in a frequent manner with large mileage, the
maintenance degree should be increased.
Precautions for guarantee of emission standards
1) The unleaded gasoline should be restricted.
2) The engine oil with the specification specified should be used.
3) Please carry out maintenance in accordance with the provisions of the regular maintenance table.
4) For the exhaust control system, arbitrary adjustment or replacement (including use of spark plug, idle adjustment
and ignition timing) is strictly prohibited.
5) Precautions:
The catalyst device will be greatly affected due to the block of ignition system, charging system or fuel system;
therefore, please go to the dealers or service centers specified by this Company for inspection, adjustment or
maintenance if you feel that the engine is unsmooth.
6) The exhaust control system of the motorcycle complies with the national regulations. Therefore, if any parts of the
system need to be replaced, make sure to use the original parts of this Company and carry out replacement by the
specified dealer or service center
Summary
The exhaust countermeasure is to use four-stroke single-cylinder engine and air induction device, maintain a good
level of exhaust and adopt activated carbon canisters for exhaust from fuel evaporation.
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※ Engine improvement -d
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Strive to increase the combustion efficiency depending on improved spark plug, combustion chamber, compression
b
ratio, ignition time, exhaust system and other engine elements and high intake and exhaust efficiency.
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※ Air induction device io s
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After air is induced into the exhaust pipe, the chemical reaction of incompletely burnt CO and HC will occur to
D
generate harmless gases. -
Distinction Device Constituent part S.A Function
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20.4 Catalyst Conversion System
20.4.1 Structure:
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20.4.2 Description: io s
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The function of catalyst conversion is to convert the completely burnt gases (including HC, CO and NOX) into H2O,
D
CO2, N2 and other harmless gases and then discharge them. -
S.A
2. When the catalyst containing platinum, rhodium and other rare metals is converted, unleaded gasoline should be
used.
N I S
※Leaded gasoline will lead to the failure of catalyst.
R A
B
• General precautions during maintenance of motorcycles (exhaust pipes) with catalytic converters:
A
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1) The motorcycle with a catalytic converter should not be touched after the engine is turned on or off, because the
E
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temperature is high in a short time.
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2) The motorcycle with a catalytic converter should not be close to combustibles.
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3) The carbon monoxide in the exhaust pipe is harmful to human body, so do not operate the engine in a closed
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space.
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4) The motorcycle with a catalytic converter should not use leaded gasoline. (to prevent catalyst poisoning)
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5) Do not start the engine by pushing the motorcycle. If necessary, start the engine by pushing the motorcycle after
the temperature of the engine and catalytic converter is reduced.
6) Do not ride the motorcycle by putting into gear or turning off the motorcycle during downhill running.
7) Do not ride the motorcycle with poor ignition.
8) When maintaining the ignition system of engine, it is not allowed to start the engine to check whether the spark
plug can generate sparks by removing the spark plug. If it is necessary, the time should not be too long.
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XXI. Fuel injection system (EFI)
This motorcycle adopts the small engine electronic injection system from Delphi Corporation. For this system, the
closed-loop control is realized by an oxygen sensor and the ECU oil injection and ignition are controlled. A three-way
catalyst is used to carry out after treatment for the gas burnt by the engine to convert it into harmless gas and discharge it
to the air. This system adopts the closed-loop control self-learning system which can effectively eliminate the
manufacturing differences between the system and related mechanical parts, improve the overall consistency of the
motorcycle and remove the errors caused due to wear and other factors after actual use.
23X crankshaft
position target Ignition coil
gear
Nozzle
intake temperature
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Down switch Serial communication
interface of fault
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intake pressure sensor
diagnosis switch
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Ignition switch
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Battery Fault indicator
light
Engine speed
signal D im
- Metal carrier catalytic
S.A converter
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21.2 EFI system
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Connector Function Description
G
EVBP
E
Fault light
O
Tachometer
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CAN line signal is high
E
Ignition coil drive B (cylinder 2)
K
Idle stepper motor B high
A
Idle stepper motor B low
B R
Sidestand shutdown signal
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Neutral clutch switch
N
Ignition coil drive A (cylinder 1)
I
The power supply (system) is grounded
S
KW2000
S
Nozzle A
.A
Oxygen sensor of cylinder 1 is heated
-
Fuel pump control signal
D
Intake pressure signal
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23X signal is low
it
Cooling water temperature signal
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Ignition power supply
i
5V reference voltage
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Oxygen sensor signal of cylinder 1
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Battery power supply
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Number of ECU connector
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21.3 EFI part position
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21.4 Technical parameters
Item Standard
Electronic Fuel Injection System
Idling 1400 ±100 r/min (rpm)
Throttle valve assembly:
identity Cylinder-shaped
Diameter Φ37 mm
Negative pressure value of throttle valve
Bypass screw –––
ECU: MT05.2
Manufacturer Delphi
identity Electronic memory type with built-in IC igniter, sealed
with resin
Available engine speed range 100 ∼ 15000 r/min (rpm)
Fuel pressure (high pressure hose): 250 kPa
Fuel pump:
identity Fuel tank built-in friction pump
Oil pump capacity ≥67 mL (2.3 US oz.) every 3 seconds
Fuel injector:
Nozzle type Fine atomization type,
Resistance: ≈10-15 Ω at 20°C (68°F)
Main throttle sensor:
Input supply voltage DC 4.75 ∼ 5.25 V
Output supply voltage DC 0.25 - 4.65 V (throttle opening is idle to fully open)
Resistance 3 ∼ 12kΩ
Inlet air pressure sensor / atmospheric pressure sensor
Input supply voltage DC 4.75 ∼ 5.25 V
Output supply voltage DC 3.80 ∼ 4.20 V [standard atmospheric pressure]
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Inlet temperature sensor:
-d
ECU output voltage
n is
Resistance 2.0 - 2.69 kΩ at 20°C (68°F);
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0.30-0.37 kΩ at 80°C (176°F)
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Oxygen sensor (model with oxygen sensor):
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Output power supply voltage (peak value at the highest ≥DC 0.8 V
it r
air-fuel ratio)
D im
Output power supply voltage (peak value at the lowest air-fuel ≤DC 0.45 V -
ratio) S.A
Heating coil resistance I S
=6.7-12Ω at 20°C (68°F)
N
Throttle handle and throttle cable
RA
Free clearance of throttle handle A B 3∼5 mm
Air filter
E K
Element material RG Dry paper filter element
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21.5 Precautions for EFI Overhaul
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○ Do not open the electric door lock if any fuel hose is
disconnected. Otherwise, the fuel pump will run, thereby
causing fuel to be ejected from the fuel hose.
○Do not operate when the fuel pump is completely dry to
prevent the fuel pump from getting stuck.
○ Before disassembling the parts of the fuel injection
system, blow off the dirt or dust on the outside of the parts
with compressed air.
○ When any fuel hose is disconnected, fuel may be ejected
due to residual pressure in the hose Therefore, cover the
hose joint with a clean rag to prevent fuel from
overflowing.
○ When installing the hose, avoid bending, twisting or
warping the hose, and do not bend the hose as much as
possible to avoid blocking the oil circuit.
Arrange the fuel hose in accordance with section
"Winding Method of Cables, Wires and Hoses" of chapter
"Appendix".
○ Do not add any fuel antifreeze chemicals to the fuel to
avoid corroding the fuel injection system or causing
deposits in the fuel injection system.
○ If the operation method is improper, the high pressure
inside the fuel hose may cause fuel leakage [A] or fuel
hose rupture. Bend and twist when inspecting the fuel
hose.
★If the fuel hose is found to be broken or swelled, it must
be replaced!
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○ In order to maintain the correct mixing ratio of fuel and
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air (F/A), there must be no air intake leakage in the EFI Ka
system. Always tighten the filler plug [A] after adding the
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oil. it r
Locking torque of filler plug: tighten by hands.
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21.6 ECU
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21.6.3 ECU disassembly K
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●Remove rear seat cushion (see "Frame" - "Removing Rear
Seat Cushion") G E
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●Disassemble:
ECU[A]
Bolt [B]
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memory.
Restart: All outputs are set to a preset state during the
restart process. The ECU can monitor itself in real time
and automatically enter the restart when an internal error
is detected. After restart, ECU will follow the normal
procedures.
Overvoltage: The ECU will not be permanently damaged
if it is operated for 1 minute under the DC voltage of
below 24V.
Reverse voltage: The ECU will not be permanently
damaged if it is operated for 1 minute under the DC
inverse voltage of below 13V.
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21.7 Fuel Pump
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21.7.3 Fuel pump composition
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21.7.5 Working environment of fuel pump
The fuel pump assembly needs to be installed at the
bottom of fuel tank according to the requirements.
The pump assembly is generally designed for only
gasoline fuel and the fuel with a ethanol-gasoline fuel
ratio of 22%
Make sure that there is enough fuel in the fuel tank in
the first operation of fuel pump assembly, and do not
run it in the absence of oil.
O RG
A small amount of fuel may flow out after
disassembling fuel line, in order to avoid the risk, the
G E
blocking device at the fuel pipe should be used for
blockage. AY
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After maintenance is completed, please ensure that the
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T
fuel line and clamp are properly installed.
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After maintenance is completed, check system oil
leakage according to the provisions of “Fuel Leakage
Check Process”.
After maintenance is completed, connect the negative
electrode of battery and ensure that there is sufficient
fuel in the fuel tank when the fuel pump is running.
O TOthe direction
Installation
Arrange
of fuel pump assembly:
installing screw holes of fuel pump
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assembly asymmetrically, and installed it in the
specified direction. The pressure regulator should
face the rear of fuel tank, and ensure that the
installing surface of fuel tank is clean and flat.
Install mounting bolts on the fuel pump assembly
cover plate and tighten them evenly in the order
indicated in the following figure. Installing torque of
screw: 3- 4 Nm
The fuel pump assembly should be secured with
special bolts.It should be tightened according to
specified tightening order and torque during the
installation.Over torque an incorrect tightening
order may cause washer deformation and thus
result in leakage.
Install the fuel tank on the motorcycle.
Connect fuel pipe and fix it with a suitable clamp.
Connect the fuel pump harness connector.
Check for leaks according to “Fuel Leakage Check
Process” before the operation of engine.
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Impurities may go into the fuel pump from damaged filter screen
Do not: damage filter screen during the maintenance
and thus damage the fuel pump body
Do not: disassemble the internal parts of fuel pump
and pressure regulator “Three guarantees” will not be provided after disassembly
Do not: regulate fuel pump and pressure regulator without permission
(except replacement)
Do not: lift fuel pump assembly through fuel pump
assembly harness Harness is damaged / the power supply of fuel pump is
Do not: lift fuel pump harness in the direction vertical disconnected
to fuel pump cover plate
Do not: use damaged pipe clamp Pressure leakage/fuel leakage
Do not: use seriously damaged fuel pump filter screen Impurities may go into the fuel pump from damaged filter screen
or cut fuel pump assembly and thus damage the fuel pump body
Do not: pump oil from fuel tank using fuel pump Fuel pump is not designed for this purpose
Do not: Install screws to fix other parts using fuel
Affect fuel pump assembly installation
pump assembly
Do not: Damage fuel pump harness during the The terminal may be damaged and thus poor contact is caused / the
maintenance of fuel pump assembly power supply of fuel pump is disconnected
Do not: Contact fuel pump assembly when fuel
Avoid damaging fuel pump assembly
pumping oil from the tank manually
Please: Ensure that the tank is not damaged during
Avoid oil leakage
maintenance
Please: Only use “original” fuel pump assembly
Fake washer may cause fuel leakage
sealing washer
Please: Use designated hose clamp Ensure that there is no fuel leakage and seepage at pipe joint
Please: Fix fuel pump harness at motorcycle Reduce shock
Please: Use standard fuel The fuel with poor quality may damage the fuel pump too early
Please: Replace fuel filter within the specified time Blocked filter may reduce fuel supply
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21.8 Throttle Body
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21.8.3 Technical parameters
21.8.3.1 Throttle body:
D37mm aperture
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21.8.7 Installation of throttle body
Note the followings for installing the throttle body:
Adjust throttle wire
Ensure that all moved parts have been installed
properly, such as stepper motor assembly.
Install the connecting screw properly
Do not: release the throttle completely from any position It may cause damage -
S.A
Do not: block the bypass channel by dust or small particles It may affect idle speed stability
Do not: pick up, store or hold parts in a manner that might N I S
It may cause damage
come into collision with other parts.
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21.8.10 Idle speed stepper motor
As shown below
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21.8.10.3 Definition of pin
Dust cover
Connector
Working position
Stepper motor
On NG:B+Open circuit
C-J1-12
Stepper motor
On NG:B-Open circuit
D-J1-13
21.8.10.7 Cleaning
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21.9 Fuel injector
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21.9.9 Installation requirements for fuel injector
During the installation and removal process, please strictly
observe the following methods to avoid damage to the fuel
injector body and electronic components.
Lubrication: Apply a small amount of lubricant to
the underside of the sealing ring. ISO 10 light
mineral oil or equivalent product is recommended.
When conditions allow, apply lubricant to the fuel
injector seat, which is better than the effect of being
applied the seal ring. So that the fuel injector
contamination probability will be reduced to
minimum.
Do not allow the spray plate to come into contact
with the lubricant, which may affect the injection
quantity. Do not dip the top of the fuel injector to
into the lubricant.
All fuel injector sealing rings are factory assembled.
In principle, the sealing seals should not be reused.
Before reusing it in special conditions, please
carefully check whether the sealing ring is damaged
before use. Very small damage may cause leakage.
Carefully insert the sealing ring into the installing
seat during installation.
When installing the fuel injector connector, take
care not to damage the connector, and you can hear
a click, indicating that it has been installed properly.
Avoid unnecessary disassembly and assembly of
connector.
Harness should not be clamped too tightly, which
may cause a short circuit.
When installing the fuel injector connector, do not
rotate the fuel injector. This may cause fuel
injection target to shift. ka
21.9.10 Replacement method of fuel injector
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The following is the disassembly and replacement method of b ra
fuel injector. Ka
Note: The injector and the surrounding objects are very hot.
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Turn off the motorcycle. it r
Cut off the negative electrode of storage battery, to
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avoid accidentally starting the engine. -
Remove the fuel injector connector.
S.A
Release the fuel pressure.
N I S
Remove the fuel pipe from the fuel injector.
Remove the fuel injector from the throttle valve R A
body. A B
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Remove the fuel injector retainer and carefully
O RG
remove the fuel injector from the seat ring.
Carefully clean the impurities at the injector contact
G E
surface, and be careful not to damage the contact
surface. AY
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Apply lubricant to the sealing rings on both ends of
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the new fuel injector.
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Carefully put the head of fuel injector into the
intake pipe, and confirm that the installation
direction is consistent with the original one.
Press it in the fuel injector seat ring and secure the
clamp.
Install fuel injection hose.
Insert the fuel injector connector.
Power on the key, do not start the engine and check
fuel injector for leakage.
Start engine for running check.
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21.9.13 General failure mode and prevention and solving measures in using
process
Important note: All the following decisions are Bad Good Bad
based on normal functions of motorcycle, wiring harness
and other system parts.
Block of fuel injector: Please clean the fuel injector
by using special devices (such as ultrasonic wave) and
special cleaning agent.
Fuel leakage of fuel injector: Replace the fuel
injector with that with the same part number or that
specified by the motorcycle factory. Atomization of oil atomizer
Damage of electromagnetic coil: Please measure the
resistance of electromagnetic coil of fuel injector with a
multimeter. If the reading is about 12 (±5) Ohms, the
electromagnetic coil of fuel injector is normal; if the coil
resistance is infinite, it means that an open circuit fault has
occurred to the coil.
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21.10 Intake pressure and temperature sensor
21.10.7 Cleaning
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If necessary, the sensor can be cleaned with isopropyl -d
alcohol and then air dried. It should be soaked in isopropyl
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alcohol for not more than 1 minute, and sealing connector
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should be installed during cleaning to prevent cleaner from
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intruding into the sensor.
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21.10.8 Fault determination D im
-
1. Check whether the plug-in is loose
S.A
2. Check the fault or current data with a diagnostic
N I S
instrument
R A
3. B
Check the connection between the sensor and ECU and
A
K
check whether the abnormal operation of sensor is
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4.
caused by cables
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Sensor inspection: connect it to the cable and turn on
G E
the power; measure the voltage between two pins with
multimeter; AY
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The voltage is 4.0~ 4.65V under the atmospheric
pressure of 100kPa when the equipment is not
started.
Otherwise, the sensor fails.
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21.11.3 Installation requirements
Installation angle (angle with the horizontal plane):
≥10 degrees
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21.11.6 Characteristic curve
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The oxygen sensor is located on the exhaust manifold.
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Please remove the oxygen sensor connector and then
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remove the oxygen sensor using open-end wrench. Be
b ra
careful not to knot or twist the harness when
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disassembling.
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21.11.7 Requirements for fuel quality im
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Pb≤0.005g/L
S.A
P≤0.0002g/L
N I S
S ≤ 0.04% (weight ratio) x
R A
MMT≤0.0085g/L
A B
Si≤4ppm
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21.12 Temperature sensor of engine cylinder head
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21.12.3 Working environment n is
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The sensor is mainly used for air-cooled engine Ka
Normal operating temperature range: -40 -160°C io s
(continuous work) it r
Relative humidity at working environment: 0 ~ 100% D im
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Typical operating pressure: at minimum installation
S.A
torque, the sensor is capable of sealing the engine
N I S
coolant at an actual pressure of 206.8 kPa (30 psi) and a A
temperature of 135°C. B R
K A
Extreme working conditions: only 1 hour at maximum
temperature of 160°C. E
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21.12.4 Electrical environment
Typical working voltage: The reference voltage is
5±0.1VDC
Maximum excitation current: During the
characteristic test and calibration of the sensor under
any temperature, the performance of the sensor should
not be affected by the current of less than 1mA.
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21.13 Canister solenoid valve (ECP)
21.13.2 Appearance
The appearance of canister solenoid valve is as
shown in the right figure:
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Charcoal canister
interface
Electric interface
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Duty cycle (%)
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21.13.5 Installation requirements
G
O R
The canister solenoid valve should be installed
G E
horizontally on the motorcycle
AY
The canister solenoid valve should be installed
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close to the central axis of crankshaft to reduce
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vibration
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21.14 Ignition coil
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turned, if the fault light is on, it indicates that the electronic
injection system is powered and it can work; if the fault light
is off, it indicates that the electronic injection system circuit
is disconnected, it will not work and the connection of
positive and negative electrodes of fuse and battery should be
checked. If the fault light is off after the engine is started, it
indicates that there is no fault; on the contrary, if the fault
light is still on after the engine is started, it indicates that the
electronic injection system works abnormally and the fault
should be removed if any.
In the case that a fault is confirmed, after opening and
closing the key for 3 times, namely the operation of
opening---closing--- opening---closing –opening key, the
fault lamp will flash the flash code of corresponding fault.
Then, corresponding fault can be identified through fault
code table.
Of them, when using the method to read fault using fault
lamp, the flash code rule is as follows: for example, the fault
is the open circuit of intake pressure sensor or short circuit of
signal terminal pin to the negative electrode of storage
battery, the fault lamp will flash for 10 times to represent 0,
flash for 1 time to represent 1 after 1.2 seconds, flash for 10
times to represent 0 after 1.2 seconds, flash for 7 times to
represent 7 after 1.2 seconds, namely P0107. It can be seen
that except that number 0 is represented by flashing for 10
times, numbers 1-9 correspond to the times of flashing. If
there are other fault codes, such as fault P0201, there is fault
in the fuel injector of cylinder 1. After flashing P0107, wait
for 3.2 seconds, continue to flash P0201 fault code; if there is
no other fault, it will flash P0107 and P0201 cyclically. Then,
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relevant faults can be queried according to fault code table. -d
When using PCHUD software, the software will report
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fault code using decimal numbers. In fault code table, there is
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an one-to-one correspondence relationship between decimal Ka
numbers and previous hexadecimal numbers, and thus
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corresponding faults may be found according to the it r
correspondence relationship. For example, MULFCURR
D im
(current fault) = 263 in the software, it corresponds to P0107 -
in fault code table, namely intake pressure sensor fault. S.A
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●MT05 Fault Code Table (Remark: All fault display functions of Delphi are listed in the
fault code table. If this model does not have the corresponding function, please ignore it.)
DTC
System or Component DTC Description Related Calibration
Number
anifold Absolute Pressure P0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow
Sensor (MAP) P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh
Intake Air Temperature Sensor P0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow
(IAT) P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh
Coolant/Oil Temperature Sensor Circuit
P0117 KsDGDM_CoolantShortLow
Low Voltage
Coolant/Oil Sensor
Coolant/Oil Temperature Sensor Circuit
P0118 KsDGDM_CoolantShortHigh
High Voltage or Open
P0122 TPS Circuit Low Voltage or Open KsDGDM_TPS_ShortLow
Throttle Position Sensor (TPS)
P0123 TPS Circuit High Voltage KsDGDM_TPS_ShortHigh
P0131 O2S 1 Circuit Low Voltage KsDGDM_O2_1_ShortLow
Oxygen Sensor
P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh
P0031 O2S Heater Circuit High Voltage KsDGDM_O2_HeaterShortHigh
Oxygen Sensor Heater
P0032 O2S Heater Circuit Low Voltage KsDGDM_O2_HeaterShortLow
KsDGDM_INJ_CYL_A_FaultHig
Fuel Injector A P0201 Injector A Fault
h
KsDGDM_INJ_CYL_B_FaultHig
Fuel Injector B P0202 Injector B Fault
h
P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow
Fuel Pump Relay (FPR) ka
P0232 FPR Coil Circuit High Voltage KsDGDM_FPP_CircuitShortHigh -d
Crankshaft Position Sensor P0336 CKP Sensor Noisy Signal KsDGDM_CrankNoisySignal n is
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(CKP) P0337 CKP Sensor No Signal
ab
KsDGDM_CrankNoSignal
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Ignition Coil A P0351 Cylinder A Ignition Coil fault s
KsDGDM_EST_A_Fault
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Ignition Coil B P0352 Cylinder B Ignition Coil fault it r
KsDGDM_EST_B_Fault
Idle Control System P0505 Idle Speed Control Error
m
Di KsDGDM_IdleControl
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System Voltage
P0562 System Voltage Low
S.A KsDGDM_SysVoltLow
P0563 System Voltage High
N I S KsDGDM_SysVoltHigh
MIL P0650 R A
MIL Circuit Malfunction KsDGDM_MIL_Circuit
A B
P1693
K Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low
Tachometer E
P1694 G Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High
O P
C
P0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow
Vehicle Speed Sensor P0500 VSS No Signal KsDGDM_VSS_NoSignal
Park Neutral Switch Diag P0850 Park Neutral Switch Error KsDGDM_ParkNeutralSwitch
P0445 CCP short to high KsDGDM_CCP_CircuitShortHigh
CCP
P0444 CCP short to low/open KsDGDM_CCP_CircuitShortLow
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21.15.2 Diagnose fault using diagnostic apparatus
●Diagnostic apparatus
●Operation method:
a) Find the diagnose interface [A] at motorcycle;
b) connect connecting wire and diagnostic apparatus
interface;
c) Open the key for diagnosis;
Warning
The XCM-PT100X diagnostic apparatus is a
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high-precision instrument that should be protected
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from shock and vibration;
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If the apparatus is not working properly or the
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display is unstable after it is turned on for the first
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time, please disconnect the power cable and try
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again;
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Please ensure that the connector is always
D im
fastened in the diagnostic connector; -
It is strictly forbidden to test the electrical signals S.A
that exceed the limit;
N I S
It is strictly forbidden for the driver to operate the
R A
instrument during driving; A B
Use and storage conditions:
E K
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Environment temperature: 0~50 degrees
O
Celsius E
G
Relative humidity: less than 90%
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W A
T O
M O
Y - - 478 -
P
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21.15.3 Inspection of fault using diagnostic software PCHUD
PCHUD software is used to detect and record
engine operating data, laptop should be connected to
6-port diagnostic port of motorcycle through K line
before use, and the diagnosis port is below the rear seat
cushion. Please note that the PCHUD system only
supports 16Bit Microsoft Windows operating system or a
very small number of 32bit Windows operating systems.
It does not support 64bit systems such as Win7, Win8 or
iOS. It is necessary to install K-line driver software on
the notebook before use.
●Operating Instructions for PCHUD Software:
(1) Connect laptop and 6-hole diagnostic port of
motorcycle using K line and open the key;
(2) Click “HUD.EXE” icon and start PCHUD software;
(3) Select “File” in the software interface, click “open” to
select “PCHUD.HAD”, and then click “OK” for
confirmation.
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(4) Select “Parameter File” under “Setup”, click
O
G E
MT05common.par file, select “Comm protocol under
Y
“Setup”, select “Keyword2000” and then click OK, at the
A
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same time select 17 as the Device Code.
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(5) If the software interface cannot display the real-time
communications data, it needs to conduct the following
work: check whether there is problem in COM port
connection setting under “Setup”, generally set COM Port:
4. Baud Rate:10400, and do not select DTR High at startup
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G EO
And then conduct normal Y
communications, display the current
A
fault code at MALFCURR,
W and display historical fault code at
MALFHIST. T O
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And then query the corresponding fault according to fault code table.
●PCHUD Software Parameter Interpretation:
VRPM Engine speed engine speed
VTHROT Throttle opening throttle position
VBARO Atmospheric pressure BARO
VMAP Intake manifold pressure manifold air pressure
VMAPEXP Estimated value of intake manifold pressure expect manifold air pressure
VIGN Storage battery voltage ignition key voltage
VCLTS Temperature of cylinder temperature or coolant cylinder temperature or coolant temperature
VIAT Intake temperature intake air temperature
STATUSBYTE5 Status flag 5 STATUSBYTE5
VAFCMET Airflow learning conditions are met airflow correction met
VBAROCMET Atmospheric pressure updating conditions are met Baro update met
VCSINSYNSPR
Sequential ignition flag sequential spark enable
K
SATITRIG tip-in ignition angle correction conditions are met tip-in Spark Advance retard trigger
CATLOENB Catalyst work logic is enabled catalyst light-off logic enable
IF ENGSTATE=3 Normal working flag position of engine engine work in run state
The idle speed conditions for warming up machine
NISTBLIDLE stable warm idle
are met
FCNO Long-term learning unit of intake efficiency block learn memory cell
FBLMCOR1 Long-term learning value of cylinder cylinder 1 block learn memory
FCLCINT1 Item I of closed loop learning integral of close loop correction
FCLCMUL1 Correction of closed loop learning close loop correction
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IARDRPM Rotating sped of desired idle speed desired idle rpm
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IARPMERR Deviation of idle speed idle rpm error
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FPWVC1 Fuel injection pulse width of cylinder base pulse width of cylinder 1
b ra
VO2 Oxygen sensor signal Oxygen sensor signal
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STATUSBYTE3 Status flag 3 STATUSBYTE3
io s
FO2STAT1 Concentration mark of oxygen sensor of cylinder it r
cylinder 1 oxygen sensor signal rich lean state
FCLREST1
Correction and resetting mark of closed loop of
D im
cylinder 1 close loop correction reset
cylinder -
A sensor heater enable
FOSHTREN Oxygen sensor heater is enabled S.Oxygen
Heating completion mark of oxygen sensor of N I S
FO2REDY1 A cylinder 1 Oxygen sensor ready
cylinder
B R
IF IACV A
Closed loop learning of idle speed stepper motor is idle airflow control valve close loop correction
K
MODE=0 enabled
G E enable
IAMTRLOST
O R
Lost step flag position of idle speed stepper motor IACV lost
Flag positionE where the movement of idle speed
IACMVIHB
stepperY
G
motor is disabled
IACV move disable
VIGNS W A
Ignition state flag position ignition state
FVE1 TOCylinder filling efficiency cylinder 1 Volumetric efficiency
- MO
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VMAPRANG Intake pressure reading angle MAP read angle
AFFNLAFR Target air fuel ratio target air fuel ratio
SAESTA Ignition advance angle of cylinder cylinder 1 Spark Advance
SAIDLDYN Dynamic ignition angle at idle speed idle dynamic Spark Advance
SPDWELL Magnetizing time dwell time
IAINTEGOFST Airflow learning value of idle speed stepper motor airflow integral of idle air control valve
IACVDSMP Number of desired steps of idle speed stepper motor desired position of idle air control valve
STATUSBYTE2 Status flag 2 STATUSBYTE2
FCLCEN1 Closed loop correction of cylinder is enabled cylinder 1 close loop correction enable
PPDSEBL Flag position where pilot injection is disabled prime pulse disable
FPENABL Flag position where fuel pump is enabled fuel pump enable
FTRNSAES Acceleration and enriching are enabled acceleration enrich enter
FTRNSDES Deceleration and thinning are enabled deceleration enlean enter
FTRNSAEDCLO
Acceleration and enriching exit acceleration enrich exit
AD
FTRNSDEINLO
Deceleration and thinning exit deceleration enlean exit
AD
●Diagnosis process:
1.Insert the key on vehicle and do not start the motorcycle, please check:
Parameter Check and Record Min Max Description Units
VTHROTRAW □Norm □Abnormal 4000 9000 Absolutely throttle body voltage AD None
A B
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3. Idle The parameters can be checked 1 min for idle speed after vehicle starting. And then check the stability of
E
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EFI parameter after 3 minutes of long idle.
Parameter
G EO
Check and Record Min Max Description Units
VRPM
A Y□Abnormal
□Norm 1300 1700 engine speed rpm
VTHROT
O W □Norm □Abnormal 0 1 fully closed throttle position percent
M OT
Y - - 482 -
O P
C
MALFCURR □Norm □Abnormal 0 0 current MALF code None
VBARO □Norm □Abnormal 98 103 atmospheric pressure kpa
VMAP □Norm □Abnormal 47 53 intake pressure measured value kpa
VIGN □Norm □Abnormal 12 16 battery voltage volt
FBLMCOR1 □Norm □Abnormal 0.75 1.15 cylinder 1 block learn memory factor
FCLCINT1 □Norm □Abnormal -15 15 cylinder 1 integral of lose loop correction count
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21.16 Common troubleshooting methods for electronic fuel inject system
21.16.2.1 Step I
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a) Engine harness and the vacuum pipeline—may affect
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the system to control air flow and fuel supply
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b) Whether oxygen sensor is assembled in place—may
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affect the system to determine the air to fuel ratio Ka
c) Engine fault indicator—may affect the system to give
io s
an alarm for fault it r
d) Storage battery voltage—determine whether the D im
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power of storage battery is sufficient
S.A
e) Determine whether coolant temperature sensor, intake
N I S
temperature sensor, intake manifold absolute pressure
R A
sensor and oxygen sensor display value are normal
A B
f) K
Working range of throttle position sensor—it cannot
E
O RG
be fully opened or closed, which may affect engine
power performance and some system functions
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21.16.2.2 Step II
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plug properly
d) Check oil supply system fault
Check whether fuel pump is working—it is able to
hear the sound that the fuel pump is working near the fuel
tank when starting engine
Check whether fuel pump relay is
working normally
Check whether the connection and
Not work: working of crankshaft position sensor
is normal
Judge using ECU
Check fuel pump line
1) Check whether fuel supply pressure is
greater than 220Kpa
2) Insufficie Check whether there
nt is sufficient fuel in
pressure: the fuel tank
Check whether fuel
filter needs to be
replaced (note:
replace the fuel filter
special for electronic
Be able to injection should be
work: replaced once every
18000km)
Check whether fuel
supply pipe and fuel
return pipe are ka
damaged -d
3) Normal Check whether there n is
pressure: is any abnormality in b ra
nozzle control line Ka
Check whether nozzle io s
it r
needs to be cleaned
D im
e) Confirm whether cylinder is submerged -
After completely opening the throttle S.A
and turning on starting motor, there
N I S
If yes: A
should be working sign in engine afterR
several seconds A B
f) E K
Check whether crankshaft position sensor clearance is
too large
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21.16.3.3 Fault phenomenon—Start failure with tempering
21.16.3.5 Fault phenomenon—Too high or too low idle speed (idle speed is obviously
21.16.3.9 Fault phenomenon—Fault lamp is on, but fault code is inconsistent with
fault
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substances in the oil may damage the oxygen sensor
and three-way catalytic converter.
Valve clearance should not be too small, if the exhaust
valve is not shut off tightly, exhaust temperature may
become too high and thus shorten the life of three-way
catalytic converter.
At the temperature of below 10°C, if the vehicle and
engine run at low speed for a long time, the exhaust
pipe may have carbon deposition and become black,
which is a normal phenomenon. It will be eliminated
after a period of high-speed operation, or appropriate
means should be taken to keep the engine coolant
temperature within the specified temperature range.
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Sample of diagnostic table
Registration number (license
Name of rider: First registration year:
plate number):
Model: Engine number: Frame number:
Date of fault: Mileage:
Environment where the fault occurs
Weather □ Sunny □ Cloudy □ Rainy □ Snowy □ General □ Others:
temperature □Hot □Warm □Cold □Very cold □General □Others:
Frequency of fault □Usual □Frequent □Only once
Road conditions □Street □Road □Mountain road (□ Uphill, □ Downhill) □ Rugged road □ Gravel road
Altitude □Normal □High altitude (about 1000 m or above)
The state of the motorcycle in the event of fault
□ After the electric door lock is turned on for about 3 seconds, the FI warning message and the FI warning
sign (EFI system failure) are alternately displayed on the LCD.
Alarm indicator
□ After the electric door lock is turned on for 3 seconds, the FI flashing burglar alarm system warning
light (LED)
message and sign are displayed on the LCD screen (anti-burglar control system is faulty).
□ After the electric door lock is turned on for 3 seconds, the alarm light will go out.
□The starter motor does not run.
□ The starter motor rotates but the engine does not start.
□ The starter motor and engine are not started.
It is difficult to
□Unable to supply oil (□ no fuel in the fuel tank, no running sound of fuel pump).
start
□ Submerge cylinder (Do not open the throttle valve when starting to avoid submerging the cylinder).
□The spark plug cannot work properly.
□Other:
□ It will flame out after start.
□ It will flame out after turning on the throttle.
□ It will flame out after turning off the throttle.
Flame-out of engine □ It will flame out when moving the motorcycle.
□ It will flame out after stopping the motorcycle.
□ It will flame out when running at a constant speed.
□Other:
□ The idle speed is very low, □ the idle speed is very high, □ and the idle speed is unstable.
□ The battery voltage is low (test after charging).
□ The spark plug is loose (tighten the spark plug).
ka
□ The spark plug is dirty, broken or the gap is improper (corrected).
-d
It cannot run
□ Tempering.
□Blasting. n is
properly at a low
□It is sluggish when accelerating. b ra
speed
□ The oil viscosity is too high. Ka
□ Brake drags.
io s
□Engine overheating it r
□The clutch is slipping
D im
□Other: -
□ The spark plug is loose (tighten the spark plug).
S.A
N I
□ The spark plug model is improper (replace it).
S
□ The spark plug is dirty, broken or the gap is improper (corrected).
R A
□ Deflagration (poor or improper oil quality, replace it using the gasoline with high-octane rating).
The acceleration is □ Brake drags. A B
sluggish □The clutch is slipping
E K
□Engine overheating
O RG
□ There is a lot of oil.
G E
□ The oil viscosity is too high.
Y
□Other:
A
O W
O T
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P Y - 491 -
CO
k
-d
Circuit Diagram of BJ400-8 (electronic injection version, exported)
nis
Idle stepping motor
Diode
ra
COLOR CODE
Main relay
R/W Y/R Y/R
Y/P P/N Black B
W/Y Gr/Y
Side
b
Fuse box Right R/W Front wheel speed sensor
Starter circuit B/Y stand
switch Blue BL
Headlight relay Rear switch Instrument gear indication
ABS Rear
Ka
Ignition housing wheel
Fuel Ignition Left switch housing brake Flasher Ligt
ABS pump ECU Fuse switch ABS speed LBL
Front brake switch R switch blue
40A N/O sensor
15A 10A 15A 15A 15A 10A switch Y/Gr
B LR/N LR/G N/O
1L 1R 2L 2R
Y/R Gr LR/W W R/W
Meter unit 1L 1R 2R 2L BL/Y Brown N
M LR/W P O B/W TPS sensor
LR R R R N G/Gr LR P/Y LBL R/W O N/P R/W P/Y LG O Gr/R R/W R/W
R/W R G/Y BL/B Gr/G LR LR R LG/W G/Gr P/W
s
LR/BL BL G/B G/W R/W R/W G/B B/Y G/W B/BL Green G
P R/W B
o
Orange O
i
N/B R/BL G/B R/W B/N R/W G/Gr
Gr G/W BL Gr/R B N/B O/B
r
Yellow Y
Y/W Carbon canister
it
R/LBL valve
Red R
LG/W
im
B Rear right turn
Diode
G/W signal lamp LR
Gr Pink
Front right turn B B Rear left turn
signal lamp G/W G/B signal lamp
D
White W
B
B Purple P
Head lamp LBL
-
R/W R/W
BL
Tail /Brake lamp
P Gray Gr
.A
Front left turn B R/W LIGHT
signal lamp LG
G/B License plate lamp GREEN
B
S
B
S
Clutch switch
LG/W
N I
B
A
Horn
R
N/P
A B
BL/G
K
LR/BL
E
G/BL
G
BL/B
R/B
R
LR/G
ABS diagnosis R
terminal R/W
O
B
GE
ECU main G
relay N
Y/W
B/N
G/P
Y
Diagnosis N/R
terminal LR
B
A
N
W
R/W
Headlamp B
controller O/B
LR/N LR/G
R/LBL O/B N/R B/R W/Y LR/B LG/W B BL/W Y/G G/BL BL/LR W/G LG W/Gr N/O B P/W N/O Gr/R G/Y R/W BL/W
BL/G
O
Gr/Y N/B LR B P/N Y/P Gr/R W/B G/P W/R B/P B/BL B/W W/N BL/Y N LR/W W Gr B Y/Gr LR/W LR/G B N/B R
W W W R B
T
W W W B R R/B BL/LR B/BL Y/G W/G B/P
R/BL R/W LR/B W/N B/R W/B W/R B BL/Y B/BL W/Gr Y/W BL/W B/BL
B/N B/BL B/BL Y/W Y/W Y/W
O
Rectifier
1 2 3 4 5 6 7 8 9 10 1112 1314 15 16 17 18
1 2 3 4 5 6 7 8 9 10 1112 1314 15 16 17 18 1 2 3 4 5 6 7 8 9 10 1112 1314 15 16 17 18
M
Fuel MAP Oxygen Pickup Intake air ABS
Fuel level Rollover Water Fuel Gear position sensor
pump sensor sensor coil temperature
sensor sensor temperature Injector sensor
sensor
Ignition
-
coils
P Y
CO
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