215060204 rk6 service manual

8/18/2019 215060204 RK6 Service Manual

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Service manual of RK6


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Contents

Preface .............................................................................................................................................................. - 1 -

Preparing Documents ....................................................................................................................................... - 2 -

General Safety .......................................................................................................................................... - 2 -

Maintenance Rules ................................................................................................................................... - 3 -

Specification ........................................................................................................................................... - 13 -

Failure Diagnosis.................................................................................................................................... - 15 -

Inspection/Adjustment ........................................................................................................................... - 22 -

Inspection and Maintenance of the Electrical System .................................................................................... - 43 -

1. Battery/Charging System ........................................................................................................................... - 44 -

1.1 Preparing Documents ....................................................................................................................... - 44 -

1.2 Failure Diagnosis .............................................................................................................................. - 45 -

1.3 Battery .............................................................................................................................................. - 46 -

1.4 Charging System .............................................................................................................................. - 47 -1.5 Voltage/Current Regulator ................................................................................................................ - 48 -

1.6 Magnetor Charging Coil ................................................................................................................... - 48 -

1.7 Magnetor Disassembly ..................................................................................................................... - 49 -

2. Ignition System .......................................................................................................................................... - 52 -

2.1 Preparing Documents ....................................................................................................................... - 52 -


2 3 Ignition System Check 54


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5.1 Maintenance Instruction ................................................................................................................... - 74 -


5.3 Front Disc Brake .............................................................................................................................. - 76 -

5.4 Rear Disc Brake ............................................................................................................................... - 80 -

6. Body ........................................................................................................................................................... - 84 -

6.1 Disassembly ..................................................................................................................................... - 84 -

6.2 Assembly .......................................................................................................................................... - 84 -

7. Front Wheel/Handlebar/Front Suspension ................................................................................................. - 88 -

7.1 Preparing Documents ....................................................................................................................... - 88 -7.2 Failure Diagnosis .............................................................................................................................. - 89 -

7.3 Front Wheel ...................................................................................................................................... - 90 -

7.4 Steering Handlebar ........................................................................................................................... - 95 -

7.5 Front Fork ......................................................................................................................................... - 97 -

8. Rear Wheel/Rear Suspension ................................................................................................................... - 101 -

8.1 Preparing Documents ..................................................................................................................... - 101 -

8.2 Failure Diagnosis ............................................................................................................................ - 101 -8.3 Rear Wheel ..................................................................................................................................... - 102 -

8.4 Rear Absorber ................................................................................................................................. - 106 -

8.5 Chain Drive .................................................................................................................................... - 108 -

8.6 Rear Swinging Arm ........................................................................................................................ - 110 -

9. Fuel Tank .................................................................................................................................................. - 113 -

9.1 Preparing Documents ..................................................................................................................... - 113 -

9 2 Fail re Diagnosis 113


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13.7 Gearshift Mechanism ................................................................................................................... - 157 -

13.8 Crankshaft Connecting Rod Assembly Chamber and Variable Speed Chamber .......................... - 161 -

14. Cooling System ...................................................................................................................................... - 167 -

14.1 Preparing Documents ................................................................................................................... - 167 -

14.2 Failure Diagnosis .......................................................................................................................... - 168 -

14.3 Water Pump .................................................................................................................................. - 168 -

Inspection and Maintenance of Exhaust Emission System .......................................................................... - 171 -

15. Exhaust Emission & Control System ..................................................................................................... - 172 -

15.1 Warranty on the Exhaust Emission & Control System ................................................................. - 172 -

15.2 Instructions on Periodic Maintenance .......................................................................................... - 173 -

15.3 Mechanical Function of the Exhaust Control System .................................................................. - 173 -

15.4 Catalytic Transfer System ............................................................................................................ - 174 -

15.5 Measures When the Idle Speed Emission Value Exceeds the Standard ....................................... - 176 -

Inspection and Maintenance of Electronic Fuel Injection (EFI) System ...................................................... - 177 -

16. Electronic Fuel Injection System ........................................................................................................... - 178 -

16.1 Introduction of Electronic Fuel Injection System......................................................................... - 178 -16.2 Components of Electronic Fuel Injection System ........................................................................ - 178 -

16.3 Methods for Fault Diagnosis and Maintenance ............................................................................ - 192 -

16.4 Common Fault Removal Techniques ........................................................................................... - 202 -

RK6 Circuit Diagram ........................................................................................................................................... 0


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Preface

This maintenance manual is used for operating and maintaining Motorcycle

RK6.

Preparing Documents include all necessary instructions and statements.

Please carefully read this manual before operation.

Inspection & Adjustment states how to check and adjust your motorcycle. All

safety rules and maintenance regulations shall be carried out from the beginning of

periodic inspection.

E t f Ch t I th t h t l i th di bl / bl /


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Preparing Documents

General Safety Maintenance Rules

Specification Table Inspection/Adjustment

General Safety

Carbon monoxide

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

Note

Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human.

Start up engine in an open place. The exhaust cleaning system shall be adopted if engine is started up in aclosed area.

Petrol

Ventilation is required for working places. Fire is strictly forbidden in any working place or where petroleum is

t d


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Maintenance Rules

Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage.

Clean up the surface of components or assembly parts before removing or opening the shield for maintenance,

which can prevent dirt from falling into the engine, the chassis or the braking system.

Wash and dry parts with air compressor after disassembly and

before measurement of attrition value.

Solvent or oil can easily damage aging rubber articles. Check

rubber before reassembly and replace rubber if necessary.

套： boot


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Bolts and screws with different length shall be separately used for

different assembly parts and shields, and they shall be correctly

mounted. Insert a bolt into a hole to check whether it is proper if

you are confused.

Fill the groove with grease before mounting an oil seal. Check

whether the oil seal is smooth or damaged during assembly.

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

i t it d i t th b tt f th t th t th h li


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Loose cables threaten electrical safety. Check each cable

after it is clamped to another for electrical safety;

Wire clamps are not allowed to bend towards welding

point;

Bind cables at the designated place;

Do not deploy cables at the end of frame or at sharp point;

Do not deploy cables at the end of bolts or screws;

Cable deployment shall be far from heat source and where

cables may be clamped during moving;

Cables along the handlebar shall be neither too tight nor

too loose, and do not interface with any neighboring parts

at steering positions;

Cables shall be properly deployed without twist or knot;

Check whether the connector jacket is damaged and

whether the connector is over-stretched before mounting

connectors;Adopt adhesive tape or hose to protect cables if they are

positioned at sharp point or corner;

Bind cables with tape after repairing;

Control cables shall not be bent or twisted. Clumsy

operation may be caused in light of damaged control

cables.


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Identification

1．The frame number, see figure

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

3．The serial number of the engine, see figure

Frame Number

Frame

Rivets

Frame Number

E i N b


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Special Tools

Special tools refer to tools which are specially designed for assembling or disassembling some

motorcycle parts on special positions. Applicable special tools are necessary for precise adjustment and

installation. With them, parts and accessories can be mounted safely, reliably and rapidly, which improves

efficiency and saves energy.

1．Tools for repairing the engine

Special tools are required for properly disassembling/assembling some engine parts.

Table and drawing (1-1, 1-2) of special tools for disassembling/assembling engine parts are as follows:

Table 1-1

Name Remark

Special socket spanner

Clutch clamp holder

Flywheel puller

Feeler gaugeBearing disassembly tools

Bearing assembly tools

Oil seal remover

Handle for dismantling tools

Piston pin pulling device

Piston pin pliers

S k f k l

Used for assembling/disassembling bolts for flywheels, Fig. 1-3

Fig.1-4

Fig. 1-4

Fig. 1-5Fig. 1-6

Fig. 1-7

Fig. 1-8

Fig. 1-9

Fig. 1-10

Fig. 1-11

Fi 1 12


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Fig. 1-5 Fig. 1-6厚度规（塞尺）：feeler gauge

Fig. 1-7 Fig. 1-8


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Fig.1-13 Fig.1-14

Fig. 1-15 Fig. 1-16


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Fig. 1-23 Fig. 1-24

2．Tools for repairing the chassisTable and drawing (1-25, 1-26) of ordinary tools and special tools for disassembling/assembling chassis

parts are as follows:

Fig. 1-25

Name Remark

Torque spanner

Inner hexagon spanner

Socket spanner

Micrometer

Magnetic rack, V-block

Dial indicator

Vernier calipers

Circlip pliers

Fig. 1-27

Fig. 1-28

Fig. 1-29

Fig. 1-30

Fig. 1-31

Fig. 1-32

Fig. 1-33

Fig. 1-34


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Fig. 1-31 Fig. 1-32

Fig. 1-33 Fig. 1-34


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

Fig. 1-39

Name Remark

Multimeter

Ignition tester

Fig. 1-41

Fig. 1-42

Fig. 1-40 (continued)

Fig. 1-41


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Specification

Motorcycle Model RK6

Engine

Engine Type BJ465MS-A

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

Width mm 800No. of

c linder4

Height mm 1100 ID × stroke 65.0×45.2

Wheelbase mm 1480Total

displacement600cc

Petrol tank capacity 15L Startup Electric

Weight kg

(Curb weight)

Forward

shaft115 Cooling Liquid cooling

Back-

shaft105 Lubrication Pressure splash

lubrication

Total 220 Clutch type Wet multi-chip

Tire Size

Front

tire

120/70ZR 17

Variable

speedSix variable speed

Rear tire180/55ZR 17

Transmission Chain

Battery

capacity12V-9AH

Primary

transmission 1.864


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RK6


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Failure Diagnosis

Diagnosis on difficulty or failure in starting up

Failure Diagnosis Adjustment & Inspection Causes of Failure


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Oil provided to fuel

injector is sufficient

and smooth

No petrol

provided to

fuel injector

Check if petrol

pump is working

properly

Spark-over Weak sparks

No

Disassemble spark

plug into its cap,

ground it with engine

to check if it can s ark

Normal Too low

No

Test compression pressure

No petrol in the tank

Oil tube of fuel injector blockedOil tube of petrol pump blocked

Tube of combustion chamber ’s

Evaporation Control System

blocked

Petrol air filter blocked

Low oil pressure of petrol pump

Abnormal spark plug

Polluted spark plug

Abnormal CPU groupAbnormal trigger

Open circuit or short circuit of

ignition coil’s wire

Open circuit or short circuit of

ignition coil

Abnormal main switch

Abnormal charging coil

Abnormal clutch for startup

Abnormal piston of cylinder and

piston ring

Leakage of cylinder gasket


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Unsmooth gyration (No speed or weak speed)Failure diagnosis Adjustment specification Causes of failure

accelerated

gyration speed

of engine

Engine can not

fully speed up

Start engine with

soft refueling

Correct

ignition timeIncorrect ignition

time

Adjust ignition timing and

use ignition timing light

Normal Too low

Test compression pressure

No Yes

Blocking check to Carburetor

Air filter blocked

Abnormal petrol

Tube of combustion chamber ’s

Evaporation Control System

blocked

Exhaust pipe blockedAbnormal automatic choke

Abnormal throttle valve

Abnormal CPU group

Abnormal trigger

Abnormal piston of cylinder and

piston ring

Leakage of cylinder gasket


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Unsmooth gyration（

especially in low speed）


Normal Abnormal

Adjust ignition time

Good Bad

Adjustment to throttle valve and

bolt

Spacer inhaled air or not

Abnormal CPU group

Abnormal trigger

Mixed gas too thin (loosen bolt)

Mixed gas too dense (tighten

bolt)

Abnormal spacer of heat


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Unsmooth gyration (high speed)


Normal Abnormal

Adjust ignition time

Normal Abnormal

No Blocked

Blocked oil injector

Abnormal CUP group

Abnormal trigger

Little oil in petrol tank

Petrol filter of the pipe blocked

Tube of combustion chamber ’sEvaporation Control System

blocked

Abnormal automatic oil ring

Remove


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No spark-over of the spark plug


Weak spark-over or

no spark-over

Strong spark

Replace on new spark

plug and check again

No sign of loose Loose

Check again after

checking spark plug

Normal Abnormal

Check plugs of CDI group if they

are loose

Original spark plug abnormal

Spark plug cap loose

Bad connection of the plug


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Inspection/Adjustment

Preparing information Periodic Maintenance & Inspection Table

Engine oil/ Oil filter Liquid coolant

Assembly/disassembly of radiator pipe’s clamp Fuel injector & Oil-way

Adjustment of throttle cable Air filter

Spark plug Battery

Fuse replacement Cylinder pressure

The slackness of the drive chain Free stroke of front brake

Free stroke of rear brake Headlamp

Clutch Front/rear suspension system

Bolt/nut/fastener Rim/tire


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Specification

Engine

ID × stroke 65.0×45.2

Total displacement 600cc

Ignition TLI

Spark plug gap 0.6-0.7mm

Spec. of spark plug CR9E(NGK)

Type of combustion chamber spherical

Frame

Free stroke of front brake lever 10-20mm

Free stroke of rear brake pedal 20-30mm

Tyre pressure unit：Kpa

Specification Tire pressure

RK6Front tire 120/70 ZR 17 250±10kpa

Rear tire 180/55 ZR 17 290±10kpa

Torque

value

Fixing front wheel

spindle

100-140N·m

Fixing nut of rear

wheel spindle

130-150N·m


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Periodic Maintenance & Inspection Table

Service cycle and time

Inspection item

Per300Km

Per1000Km

Per3000Km

Per6000Km

Per12000

Km

Per14500Km Tools

NewOne

monthThree

monthsSix

monthsTwelvemonths

Fifteenmonths

* Air filter I C C R C Ordinary tools

* Petrol filter I I R Ordinary tools

* Fuel filter C C C Ordinary tools

Replacement of enginefuel

R Replacement every 1000KM Ordinary tools

Tire pressure I I I I I ITire pressure

gauge, inflator

Battery inspection I I I I I IDensimeter,

multimeterActuation gap inspection I I I I I I Ordinary tools

Inspection of steeringhandle fastening

I I I Ordinary tools

Absorber workinginspection

I I I Ordinary tools

Screw fasteninginspection

I I I I I I Torque spanner


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Anticipated Inspection

1 Ignition system — obviously continuous ignition abnormality, engine fire or overheating, which requiresinspection and maintenance.

2 Carbon fouling elimination — obviously insufficient horsepower, which requires carbon fouling removalfrom cylinder head, piston head and exhaust system.

3 Piston & cylinder — excessive abrasion; replace cylinder if it is blocked.

Please have your motorcycle inspected and adjusted periodically at Qianjiang distributors for being in bestcondition.The above table is established under the presupposition of 1000 km/month.I — Inspection A — Adjustment R — Replacement C — Cleaning L — Lubrication

Note: 1. “*” Regulations on exhaust emission made by the State Environmental Protection Agency shall becomplied with. Maintenance must be carried out in accordance with the instruction manual supplied by thecompany. We are not responsible for any loss rising from private adjustment or maintenance.

2. Increase frequency of washing air filter if your motorcycle runs on the sandy/gravel road or underheavily polluted environment so as to extend its service life.

3. Motorcycles which often run at high speed or with high mileage shall be maintained frequently.

Engine Oil/Filter

Oil level


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If it is below or near the minimum level,

Refuel with the recommended oil to the maximum level.

*Note

Check the O-ring.

Assemble the dipstick.

Oil Replacement

* Note

It will be easier to change oil when the engine is warming up.

Preheat the engine.

Place a drip pan under the engine, and disassemble the drain

bolt① and the dipstick.

Repeatedly start the engine for several times until the oil is

discharged completed.

When the oil is discharged completely, install back the drain

bolt and the packing washer after cleaning.

Refuel recommended oil to the crankcase to a required capacity.

Assemble the dipstick.

Start the engine to run in an idle speed for 2-3 minutes.

Stop the engine, and check if the dipstick is at the maximum level several minutes later.


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Cooling Liquid

Check the height of the cooling liquid in the expansion kettle

during maintenance.

Replace in time the cooling liquid when it becomes turbid or it

is time for maintenance.

Recommended model of the cooling liquid: FD-2Total liquid capacity of the cooling system: about 2.0L

Remove the front shield on the right side. Find the filler mouthof radiator water tank ①.

Open the filler cap and inject a right amount of cooling liquid.

Re-install the cap after injection.

Check the cooling liquid of the expansion kettle after the

engine has been turned off and cooled down.

While checking, make sure the motorcycle is on the flat ground

and its body upright


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Assembly and Disassembly of the Clamp of the Radiator’s Conduit

The clamp of the radiator’s conduit is disposable component, so

the old clamp can not be reused when disassembled. And the

clamp② can only be assembled by special clamp pliers①, or it

may not in place, which will lead to the breakdown of the

vehicle.

卡箍：clamp


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Adjustment to the Steel Rope of the Throttle

*Note

Adjust the idle speed of the engine right before adjusting

the stroke of the steel rope of the throttle.

Check the free stroke of the steel rope of the throttle, and it

should be 3-5mm.

Adjust if it does not conform to the specified value.Adjust the free stroke of the steel rope of the throttle.

The motorcycle is configured with two-lane steel rope ofthe throttle, among the two ropes, A for throttle forward(1)Remove the dustproof boot of the steel rope of the

throttle.

(2)Loosen the locking nut③.

(3)Screw in completely the adjusting nut④.(4)Loosen the locking nut①.(5)Rotate the adjusting nut② to make the free stroke of

controlling handlebar of the throttle to 10°～15°.(6)Tighten up the locking nut①.(7)Adjust nut④ to make the controlling handlebar of thethrottle flexible.(8)Tighten up the locking nut③.


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座垫钢索：seat steel rope

Disassemble the shield of the fuel tank and its front fixing

bolt, and open the fuel tank.

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

Disassemble the cover of the air filter.

Take off its cartridge.


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Do not start engine when disassemble the cartridge of the air filter, otherwise, the engine will intake unfiltered

air, which may lead to rapid abrasion of other components, and the damage of the engine too.

In addition, rotation without cartridge will cause sequential malfunctions of the carburetor, and it may lead tooverheat of the engine.

Install in reverse order.

Spark Plug

Remove the spark plug:

(1)Lift up the fuel tank.

(2)Disassemble the intake air temperature sensors① on both side

of the air filter, and then remove the air filter.

(3)Remove the stators② of the spark plug caps on both sides.

(4)Remove four spark plug③, and you can see the spark plug④.

(5)Remove the spark plug with the spark plug demolition sleeve.

Check

Whether the insulator is cracked or damaged


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Battery

Battery Disassembly

Disassemble the front seat.

Remove the mounting plate of the battery.

Remove the negative wire and then the positive wire.Remove the battery from the battery box.

Take out the battery.

Warning!

When the positive wire is disassembled, do not make the

tool contact with the frame. Otherwise, it may cause

short-circuit spark, which may ignite gasoline and damage

the battery. It is dangerous.

Install it in reverse order.

Warning!

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


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Warning!

• The battery should be far away from fire source.

• Turn off the charger before or after charging to avoidexplosive danger caused by spark which may exist in any

connection.

• Comply with the current and time requirements for charging

as stated on the battery.

* Note

• Except emergencies, you should not use emergency charging.

• Measure voltage in 30 minutes after the battery is charged.

伏特表：voltmeter

Charging current: standard: 0.3A

quick: 3.0A

Charging time: standard: 10-15 hours

quick: 30 minutes

charging accomplished：open-circuit voltage: above 12.8V

Fuse Replacement


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Cylinder Pressure

Warm up the engine.

Insert the pressure gauge.

Turn the choke lever to the fully open position.

Start up the engine repeatedly,

The pressure of the cylinder: 1～1.2mpa

*Note

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

Incorrect valve adjustment

Leakage of the valve

Abrasive piston ring or cylinder

Reasons for high pressure:

Carbon deposition in the combustion chamber or piston

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


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(1)Put up the motorcycle with the support frame.(2)Loosen the rear axle nut①.(3)Loosen the locking nut②.

(4)Turn right or left the adjustment bolt③ to adjust the looseness of the chain, and keep the centers of therear and back sprockets into a straight line. There are benchmarks on the swinging arm and each chainadjuster to facilitate your adjustment, and they can be aligned with each other and the reference from

one side to the other. Align and adjust the looseness of the chain to 10 — 20mm, and then fix again therear axle nut for the final check.

Note:

The two sprockets of the newly replaced

chain should be checked to make sure whether

they are abrasive or not, replace if necessary.

Inspect periodically the following condition of the chain:

(1)Loose pin(2)Damaged idler wheel

(3)Dry and rusty chain

(4)Twisted or blocked chain link(5)Excessive damage

(6)Adjust loose chain

If the chain has defects as mentioned above, then there is a high possibility that the sprocket will damage the

chain. So the following items should be check to the sprocket:(1)Excessively abraded gear tooth

(2)Broken or damaged gear tooth(3)Loose fixing nut of the sprocket


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Free Stroke of the Front Brake

Free stroke of front brake

Measure the free stroke of front brake at the tip of the

brake lever.

Free stroke: 10-20mm

Regulator of Lever Grip of the Front Brake

Depending on the operating needs for the comfort, the

position of the lever grip of the front brake can be

adjusted by adjusting the knob with the ring nut. There

are four positions for adjustment, and you can adjust to a

desired position just by moving gently forward the lever

of the brake, and then rotating the adjuster of the ring nut

at the arrow ○A. And position 1 of the front brake lever is

most remote to the controlling handlebar of the throttle,

while the position 4 nearest to it.

前： front


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If specified value has not been met, it should be adjusted.

Adjust the free stroke of the brake pedal.

First open the nut 1.

Screw in or out nut 2 to adjust the free stroke of the brake pedal.

Screw in 2 to reduce the free stroke;

Screw out 2 to increase the free stroke.Tighten the fixture 1 until the specified value is met.

After being adjusted, dragging should not occur to the brake.

Headlamp

Disassemble the fixing bolt① of the headlamp support.


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Unplug the lamp holder connector ③ of the headlamp,

remove the lamp holder, disentwine the snap ring, and take

out the bulb.

*Note

Keep combustible materials and your hands a distance away

from the bulb when it is light. Because the bulb is very hot at

that moment, you should let it cool down before touching it.

Install new headlamp bulb, lamp holder, and screw in the bulb to the socket.

During the installation, avoid direct touch with the glass of

the bulb, an do not make it oil-stained. Or it will affect the

transparency, life and luminous flux of the bulb.

Once stained with oil, wipe thoroughly with a damp cloth of

alcohol or rubber solution of strong volatility.

Clutch

Check the free stroke of steel rope of the clutch.

Free stroke: 10-15mm


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Front/Rear Suspension System

Front Absorber

Pull the front brake tight; compress the front absorber upwards or downwards for check.

Check whether there is oil leakage in the front absorber and whether any component is damaged or loosened

（上下压缩：compress upwards or downwards）

Rear AbsorberCompress the rear absorber upwards or downwards for check.

Check whether each part of the rear absorber is damaged or loosened.

Suspend the rear wheel and check shimmy.

Check whether the suspension bushing of the engine is loose or not.

上下压缩

上下压缩


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Rim/Tyre

Check whether tires or rims have any crack, nail or any

other damage.

Check tyre pressure.

*Note

Check tyre pressure when it is cold.

Specification Tyre

pressure

RK6Front tyre 120/70 ZR 17 250±10kpa

Rear tyre 180/55 ZR 17 290±10kpa

When the non-skid depth on the central thread of the tyre

reaches to the figure in the table, the tyre should be

replaced.

Minimum non-skid depth

Front tyre 1.6mm

Rear tyre 2.0mm

Warning:


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Fixing Steering Stem Bearing and Handlebar

Move the handlebar to confirm there is no wire interference.

Rotate the front wheel and move the handlebar freely for check.

If the handlebar moves difficultly, release it and then check the bearing of the fixing steering stem.


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Components Lubrication

Appropriate lubrication is of great importance to the normal operation of each part of the motorcycle, to an

extended life and to the safety drive. Lubricate the motorcycle after a long time running or exposure in the rain

or after cleaning. As for detailed points for lubrication and maintenance, see the following figure:

□Ｙmotorcycle lubrication □Ｚ grease

○1 axis of the rear brake pedal □Ｚ ○2 single bracket joint and spring hook □Ｚ ○3 pin of the

gearshift riding rod □Ｚ

○4 throttle cable □Ｙ ○5 pin of the front brake handle □Ｚ ○6 clutch handle（ pin） □Ｙ


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Inspection and Maintenance of the Electrical System


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1. Battery/Charging System

Preparing Documents-----------------------1.1

Failure Diagnosis----------------------------1.2

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

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

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

Charging Coil of Magnetor ------------------1.6

Disassembly of Magnetor -------------------1.7

1.1 Preparing Documents

Work Instructions


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Preparing Principles

Item Specifications

Battery

Capacity/Type 12V-9AH/ dry-charged

Voltage

（20℃）

Fully charged 13.1V

Necessary

charging12.3V(not working for 1h)

Charging current Standard: 0.8A, quick:8A

Charging time Standard: 10-15 hours, quick: 30 mins

MagnetorImpedance of the coil

（20℃） Between white-white 1.5-3.5Ω

Voltage

regulator

Type Three-phase full wave

Charging voltage of the

battery14.5±0.5V/5.000rpm

Tightening Torque Force Tools

Rectifier bolt 5.0 N·m Universal fixing spanner

High-voltage coil fixing bolt 9.0 N·m Flywheel remover

Flywheel fixing nut 5.0 N·m Test instrument

Body guard bolt 9.0 N·m Multimeter


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1.3 Battery

1.3.1 Battery Disassembly

As for details, please see page 31.

电瓶位置： battery position

Warning!

When the positive wire is disassembled, do not

make the tool contact with the frame. Otherwise, it

may cause short-circuit spark, which may ignite

gasoline and damage the battery. It is dangerous.


*Note

To prevent short circuit, connect the positive wire

first and then the negative wire.

Check the charging condition (closed circuit voltage).

Remove the seat


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*Note

• Except emergencies, you should not use

emergency charging.

• Measure voltage in 30 minutes after the battery

is charged.

Charging current: standard: 0.8A

quick: 8.0A

Charging time: standard: 10-15 hours

quick: 30 minsCharging completed: open circuit voltage: above 12.8V

1.4 Charging System

1.4.1 Short-circuit Test

Remove the earth lead from the battery. Install a voltmeter between the negative terminal and the earth lead.

Turn off the switch. Check the short-circuit.

*Note

Connect the positive terminal of the multimeter

with the negative terminal of the battery.


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1.5 Voltage/Current Regulator

1.5.1 Main Wiring Check

Remove the shield of the body.

Remove 4p plug of the voltage/current regulator.

Check conductivity between main wiring terminals.

Item (wire color) Judgment

Between Battery(red) andGND of the body

With batteryvoltage

Between GND wire (black)

and GND of the bodyWith lead

Between charging coil (white)

and the GND of the body

Resistance in the

coil of the

magnetor.

1.5.2 Voltage-current Regulator Check

1. Choose diode file with multimeter.

2. The black probe connects to the red wire terminal of the voltage regulator, and the red probe connects

respectively with the white wire terminal (white 1, white 2, white 3). The pointer gauge shows a certain value,

h i i i di h d f h l l d l i d d


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1.7 Magnetor Disassembly

1.7.1 Disassembly

Loosen the fixing nuts on the left cover, and

remove the left cover and the magnetic coil.

Fix the flywheel with the universal fixing

spanner.

Remove fixing bolts of the flywheel.

Remove the flywheel with the flywheel remover.

Remove the solid key.Remove the conductor joint.

Remove the stator.

Bolt

Left cover andthe magnetic coil

Bolt


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Loosen the locking nuts of the flywheel with

electric, pneumatic tools or torque spanner.

Remove the flywheel assembly.

1.7.2 Installation

Install the stator on the body of the engine.

Connect the magnetor joint.

Locking nut of

the flywheel


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白

/

绿

蓝

/

白

ECU2

ECU1

黑/红1

黑/白1

橙/绿1

黑/红1

黑

黑

黑

黑

黑/红2

橙/绿2

黑/白2

黑/红2

电源


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2. Ignition System

Preparing Documents -----------------2.1

Failure Diagnosis ---------------------2.2

Ignition System Check ---------------2.3

ECU Group----------------------------2.4

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

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


Work Instructions1. Check the ignition system following the sequence listed in the table of failure diagnosis.2. This ignition system is an electronically and automatically angling device. It is solidified in the ECU groupand you don’t have to adjust the ignition time. 3 Ch k th i iti t f ll i th li t d i th t bl f f il di i


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2.2 Failure Diagnosis

No spark-over of the spark plug

Ignition

coil

Abnormality Cause (confirm it sequentially as follows)

Too low high-voltage

①The inner resistance is too small and it should be

tested by required tester.

②Low speed of the crankshaft.

③Interfered tester (It is normal that voltage is

always beyond the required value upon several

measurements.)

④Poor wiring contact of the ignition system.

⑤Poor ignition coil.

⑥Poor charging coil (measured at the maximum

voltage).

Side

voltage

No or interrupted high voltage

①Incorrect connection of the tester.

②Poor main switch.

③Poor contact of ECU terminal.④Short circuit or poor contact of the GND of ECU.

⑤Poor contact of charging coil (measured at the

maximum voltage).

⑥Poor trigger (measured at the maximum voltage).

⑦Poor terminal of high-voltage wires.

⑧Poor ECU group (when item①-⑦ is checked to

b b l th i k f k l )


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2.3 Ignition System Check

*Note

• When there is no spark, check whether there is

loose wiring

or poor contact, and make sure all voltage values

are normal.

• There are kinds of multimeters with different

impedances and different test values.

Connect a high-pressure shunt or an ammeter with

an input impedance above 10MΩ10CV to the multimeter. （万用表：multimeter ）

2.3.1 Primary Voltage of the Ignition Coil (高压分流器：high-pressure shunt)

If you replace the original spark plug with a better one, make ground connection with the engine.

*Note

Make sure all wiring is correct before test.

Cylinder compression pressure normally refers to

the test value when the spark plug is installed on

the cylinder head.

高压分流器

万用表


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2.3.2 Sensor of the Crankshaft

*Note

Install the spark plug on the cylinder head and

carry out measurement when the compression

pressure is normal.

Remove 18 connectors of ECU group. Connect the

peak-voltage shunt between the charging coil

(blue/white terminal) with 18 connector andthe 18 connector (white/green terminal).

Press the startup motor or step the actuating lever to measure

the maximum voltage of the charging coil.

Connection: positive pole to blue/white; negative pole to white/green.

Minimum voltage: above 95V

*Note

Never touch any metal part of the test rod with

your finger to avoid electric shock.

When the maximum voltage measured at the terminal of ECU Group is abnormal; dismantle the shield of the

b d d h i l


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2.5 Ignition Coil

2.5.1 Disassembly

Remove the body.

Remove the spark plug cap.

Remove the primary lead of the ignition coil.

Remove the fixing bolts and then the ignition coil.

Install the ignition coil in reverse order.

*Note

Install the primary coil with black/red

terminal.

2.5.2 Check the Primary Coil

Measure the impedance between terminals of the primary coil. Standard: (4±0.2)Ω (20℃)

It shows good if the impedance is within the range of standard values.

Replace the primary coil if the impedance shows ∞ which indicates that the coil breaks.


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启动示意图：Startup Schematic Diagram

启动示意图

BATTERY

G/Y

G/Y

M


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3. Startup System

Preparing Documents ----------------3.1

Failure Diagnosis ---------------------3.2

Startup Motor -------------------------3.3

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

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


Work Instructions

Disassemble the startup motor on the engine.

For the disassembly of the startup clutch, please comply with related regulations


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Startup failure Weak in rotation No rotation of RE rotary engine

of the startup motor of the startup motor

• Fuse blow • Low battery • Poor startup clutch

• Low battery • Poor wiring contact • Reversal r otation of the startup motor

• Poor main switch • Gear seized • Low battery

• Poor startup clutch

• Poor brake switch

• Poor starter relay

• Poor wiring contact

• Poor startup motor

3.3 Startup Motor

3.3.1 Disassembly

Loosen the two fixing bolts of the startup motor,

and remove the motor.


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Remove the wire clip of the startup motor.

Remove the fixing bolts of the startup motor, separate

the front cover and the back cover, and dismantle the

startup motor.

Roll the waterproof rubber case and dismantle the

connector of the startup motor.

换向器：commutator

3.3.2 Breakdown

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

3.3.3 Check

Check other components.

Replace any part with abraded damaged or burnt surface

碳刷


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3.3.4 Assembly

Lubricate the oil seal inside the front cover with grease.

Install the brush on the bracket.

Lubricate moving parts at two ends of the brush shaft

with grease.

Press each brush into the bracket,

* Note

• Pay special attention that the contact surface between

the brush and the armature shall not be damaged.

• Pay attention that the armature shaft shall not damage

lips of the oil seal.

and install the back cover of the electric machine.

Aim the screw hole of the motor shell at the screw hole of the front cover for installation.

Lock screws in the shell.* Note

When the shell and the front cover are assembled, it is

easy to pull the front cover with magnet to attract the

armature. Press it gently for assembly.


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3.4.2 Check Voltage of the Starter Relay

Set up the main stand, and measure voltage between the

negative pole of the green/yellow wire of the starter relay

terminal and the body ground connection.

When the main switch is “on”, hold the brake lever. The

battery voltage shall comply with regulations.

When there is no voltage at the starter relay terminal,

check the conduction of the brake switch and leads.

启动继电器：starter relay

3.4.3 Check GND Loop of the Starter Relay

Remove the starter relay connector.Check conduction between the black wire of the lead terminal and the body ground connection.

When the startup button is pressed, it shall show good conduction between the black wire of the terminal and

the body ground connection.

Check conduction of the startup button and leads when it is not conducted.

Ω


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4. Bulbs/ Switches / Meters

Preparing Documents -------------------------------------------------------------4.1

Failure Diagnosis ------------------------------------------------------------------4.2

Replacement of Headlamp Bulbs------------------------------------------------4.3

Replacement of Front Position Lamp Bulbs------------------------------------4.4

Replacement of Tail Lamp--------------------------------------------------------4.5

Replacement of Rear Registration Plate Lamp Bulbs-------------------------4.6

Replacement of Front Steering Lamp Bulbs -----------------------------------4.7

Replacement of Rear Steering Lamp Bulbs ------------------------------------4.8

Meters--------------------------------------------------------------------------------4.9

Main Switch 4 10


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The ignition switch “ON” is not light, which due to

• Poor bulbs.

• Poor switch.

• Bad contact or broken wires

• Weak battery power or no voltage.

4.3 Replacement of Headlamp Bulbs

Remove the two fixing bolts① of the headlamp at

the bottom left and bottom right of the meter.


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The figure below shows the bulb of the dipped

headlight③, and the bulb of the headlight on full

beam④, remove the power cord socket, bulb snap,

fixing bolts and the bulb snap buckle of the dippedheadlight and the headlight on full beam that need to

be replaced, and finally remove the damaged bulb.

Aim the position of the light snap, and replace on a

new one of the same specification.

*Note

Keep combustible materials and your hands a distanceaway from the bulb when it is light. Because the bulb

is very hot at that moment, you should let it cool

down before touching it.

Install the bulb in reverse order.

During the installation, avoid direct touch with the

glass of the bulb, an do not make it oil-stained. Or it

will affect the transparency, life and luminous flux of

the bulb.

Once stained with oil, wipe thoroughly with a damp cloth of alcohol or rubber solution of strong volatility.

Install headlamp devices.

4.4 Replacement of Front Position Lamp Bulbs


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4.5 Replacement of Tail Lamp

The illuminant of the tail lamp is LED, replace the wholelamp if necessary.

(1)

Remove the passenger’s seat and the driver’s.

(2)

Remove the tow fixing nuts① of the tail-hood shield,

and then move it horizontally backward to take it

down.

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

combination


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4.6 Replacement of Rear Registration Plate Lamp Bulbs

(1)

Remove the fixing nuts① of the rear registration plate lamp to take down the tail-hood② of it.

(2)

Take off the damaged bulb, and replace on a new one

of the same specification.


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4.7 Replacement of Front Steering Lamp Bulbs

The illuminant of the front steering lamp is LED,replace the whole lamp if necessary.

(1)

Operate according to the prompts of the above

chapter — Replacement of the Headlamp Bulbs.

(2) Remove the fixing nuts① of the right or left

steering lamp.

(3) Remove the cable of the front steering lamp, take off the damaged lamp, and replace on a new one of the

same specification.

(4)

Install the lamp in reverse order.

4.8 Replacement of Rear Steering Lamp Bulbs

The illuminant of the rear steering lamp is LED, replace

the whole lamp if necessary.

(1)

Remove the fixing nuts① of the right or left

steering lamp from the back of bracket of the rear

registration plate.

(2) Remove the cable of the rear steering lamp, take off

the damaged lamp, and replace on a new one of the same specification.


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4.10 Main Switch

4.10.1 Check

Remove the front shield.

Remove the main switch lead terminal.

Check the conduction of the terminal.

R/WR

ON

LOCK

OFF

POWER LOCK

4.10.2 Replacement of Main Switch

Remove the front shield.

Remove the fixing bolts, and take off the fixing socket of the main switch.

Remove the fixing bolts, and replace the main switch.


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4.12 Handlebar Switch

Switch classification:1. Light changing switch （变光开关）

2. Start switch

3. Steering switch （转向开关）

4. Horn switch （喇叭开关）

5. Turn off switch （熄火开关）

6. Warning switch

黄/红兰浅兰绿/黑橙绿/白

黑棕

变光开关转向开关

喇叭按钮

接线原理图

棕/白红/白黄黑白红/白绿黄/红

熄火开关启动按钮大灯开关


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Inspection and Maintenance of the Motorcycle Body

Torque Force Table of the Body

Name of fastening parts and fasteners Tightening torque（ N·m）

Fixing bolt of the front absorber M6

Locking screw of the front wheel spindle M6

Front fixing bolt of the fuel tank M6

Fixing bolt of the front fuel pump assembly M6

Fixing bolt of the rear fuel pump assembly M6

Fixing bolt of the fixing seat on the handlebar M8

Fixing bolt of the upper connecting bracket M8

Rear fixing bolt of the fuel tank M6

Mounting bolt of the front brake cylinder assembly M10

Mounting bolt of the rear brake cylinder assembly M8

Fixing bolt of the sprocket M10

Fixing bolt of the rear frame M10

Fixing bolt of the pillar

Top bolt of the rear absorber M10

Bottom bolt of the rear absorber M10

Fixing bolt of the engine M10

5-10

5-10

5-10

5-10

5-10

22-34

22-34

5-10

37-55

22-34

37-55

37-55

50-70

37-55

37-55

37-55


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Front Disc Brake

A

Dia. of the front left/right brake

disc:320mm

B

Thickness of the front left/right brake

disc:4.0mm

Limit for use: 3.6mm

CThickness of the brake shoes:7.8mm

Limit for use:3.8mm

DTorque for mounting bolt 4 in the

figure:5-10N·m

ETorque for mounting bolt 5 in the

figure:30-35N·m

F

Torque for mounting bolt 11 in the

figure:

5-7N·m

GTorque for mounting bolt 12 in the

figure:30-35N·m

HTorque for mounting bolt 14 in the

figure:37-55N·m

ITorque for mounting bolt 17 in the

figure:22-34N·m


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Rear Disc Brake

A Dia of the rear disc brake: 240mm

BThickness of the rear disc brake: 5.0mm


CThickness of the brake shoes: 7.0mm


DTorque for mounting bolt 15 in the

figure:30-35N·m: 22-34 N·m

ETorque for mounting bolt 14 in the

figure:30-35N·m: 5-10 N·m

FTorque for mounting bolt 10 in the

figure:30-35N·m: 30-35 N·m

GTorque for mounting bolt 8 in the

figure:30-35N·m: 30-35 N·m


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5. Brake

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

Failure Diagnosis --------------------------------5.2

Front Disc Brake ---------------------------------5.3

Rear Disc Drake ---------------------------------5.4

5.1 Maintenance Instruction

Work Instructions

*Note

A stained brake disc or protective gasket will reduce brake force, so discard

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

Check the brake system through the brake lever and pedals.

Spilled brake liquid is harmful to the focusing and paint of the equipment,

and the rubber parts too. So be careful whenever you remove the cap of the

T F


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5.1.2 Torque Force

Fixing the front wheel spindle 100-140N·m

Mounting screw of the front left brake cylinder assembly 37-55N·m

Mounting screw of the front right brake cylinder assembly 37-55N·m

Fixing nut of the rear wheel spindle 130-150N·m

Mounting screw of the rear brake cylinder assembly 22-34N·m


5.2.1 Poor Brake Performance

1.

Improper adjustment of the brake

2. Abraded brake shoes assembly or disc brake

3. Improper installation of the brake shoes assembly

4.

Stained brake shoes assembly or disc brake

5.2.2 Slow Reaction or Tight Lever

1. Improper adjustment of the brake

2. Abraded brake shoes assembly or disc brake

3.

Improper installation of the brake shoes assembly

3．

Blocked or limited joint of the brake hose


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j

4． Bending/fragmentary brake disc

5． Abnormal slip of the caliper

5.2.6 Brake Resistance

1．

Strained brake pedal/disc

2．

Wheel deviation

3． Abraded brake pedal/disc

4． Bending/fragmentary brake pedal/disc

5．

Abnormal slip of the caliper

5.2.7 Stiff Brake Lever/Pedal

1． Blocked/limited brake system

2．

Sticked/abraded caliper piston

3．

Abnormal slip of the caliper

4．

Blocked/limited brake liquid channel

5．

Abraded sealing gasket of the caliper piston6． Sticked/abraded piston of the main cylinder

7． Bending brake lever/pedal

5.3 Front Disc Brake


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Fixing screw of the handle

Fixing bolt of the brake hose

Brake hose


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Remove the front wheel spindle.

Remove the front wheel.

Remove the disc brake off the front rim.前轮：front wheel

前轮轴：front wheel spindle

前左液刹：front left disc brake

固定螺钉：fixing screws

5.3.2 Check

Check whether the brake shoes assembly and the brake

disc are abraded. Replace brake shoes if necessary.

Measure the brake shoes and the brake disc. Record

maximum values.

Specification

Diameter of the front brake disc Φ320mm

Thickness of the front brake disc 4.0mm


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Measure the thickness of the brake shoes.

If the thickness of the brake disc or the brake shoe is

below the required value for maintenance or it is stainedwith grease, please replace it.

Limit for use: brake shoe 3.8mm

brake disc 3.6mm

Note:

Replace brake shoes in pair.

5.3.3 Installation

Install the brake disc and the front wheel.

Install the front brake hose assembly and the brake cylinder assembly.

Do not stain shoes and the brake disc with grease.

* Note

Any grease on brake shoes will reduce the brake performance and even lead to failure.

5 4 Rear Disc Brake


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5.4 Rear Disc Brake

5.4.1 Disassembly

*Note

Replace the brake shoes assembly.

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

Remove the following assembly off the frame and the rear swinging arm.

Rear disc brake:

(1) Fuel pump assembly

(2)

Brake hose assembly

(3)

Brake cylinder assembly

(4)

Brake discs

Loosen the fixing screws of the right pedal cover plate.

Fixin screws

Ri ht edal cover


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Loosen the fixing screws of the brake cylinder assembly.

Remove the brake cylinder assembly off the rear

swinging arm.

Remove the rear wheel spindle.

Then take off the rear wheel.

Remove the bake disc off the rear rim.

后轮：rear wheel

后液刹盘 rear brake disc

Fixin bolt

Rear brake hose

Fixin screw

Brake c linder


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Measure the thickness of the brake shoes.

If the thickness of the brake disc or the brake shoe is

below the required value for maintenance or it isstained with grease, please replace it.

Limit for use: brake shoe 3.7mm

brake disc 4.5mm

Note:

Replace brake shoes in pair.

5.4.3 Installation

Install the rear brake disc. Install the rear wheel.

Install the brake cylinder.

* Note

Any grease on brake shoes will reduce the brake performance and even lead to failure.

Tighten bolts and nuts to the required torque force

Body


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Body

*Note:

Do not damage any body part during disassembly.

Do not damage any hook or claw in the body during

disassembly.

Aim panels in the body at each corresponding

groove.

Ensure correct installation of each hook or claw

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

6 Body


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6. Body

6.1 Disassembly

Disassemble in the following order:

back seat assembly→ front seat assembly → front shield of the tank→ left shield

of the tank→ right shield of the tank→ left front shield→ right front shield →

middle shield of the tank → tank assembly

↓

rear connecting board of the left/right shield → left rear handrail → right rear

handrail → bottom left shield→ left shield→ bottom right shield → right shield →

taillight → rear bottom fender → decorative cover of the right muffler →

trim-cover of the right muffler → decorative cover of the left muffler → trim-cover


89/212

Front Suspension

A

Torque for mounting thefixing bolt 20 of the steeringcolumn in the figure:50-70N·m

B

Torque for mounting thefixing bolt 16 of the upper base of the steering handlebarin the figure: 22-34N·m

CTorque for mounting thefixing bolt 13 of the upperconnecting board in thefigure: 22-34N·m

D

Torque for mounting thefixing bolt 5 of the frontabsorber in the figure:5-10N·m

ETorque for mounting the frontwheel spindle 1 in the figure:100-140N·m

F

Torque for mounting thelocking bolt 28 of the head ofthe front wheel spindle in thefigure: 5-10N·m


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Handlebar


91/212

Front Wheel

7. Front Wheel/Handlebar/Front Suspension


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7. Front Wheel/Handlebar/Front Suspension

Preparing Documents--------------------------7.1

Failure Diagnosis-----------------------------7.2

Front Wheel-----------------------------------7.3

Handlebar--------------------------------------7.4

Front Suspension-----------------------------7.5


Work Instructions

Before removing the front wheel, you should use jack to support the body bottom and suspend the front wheel

which shall not be reversely rotated.

Pay attention that the brake shoes and the brake disc shall not be stained with grease during operation.

A i d b k di b k h ill d b k f di d i d k d l h b k di



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7.2.1 Difficulty in Steering

Failure or damage of the steering handlebar.

Damaged bearing of the handlebar.

Too tight of the adjusting bolt of the faucet bearing.

Insufficient tyre pressure.

7.2.2 Unsteady Steering

Damaged steering handlebar.

Insufficient tyre pressure.

Bending of the front fork or the front wheel spindle.

Deformed or unbalanced front tyre.

7.2.3 Front Tyre Shimmy

Deformed rim.

Abraded front wheel bearing.

Flawed front tyre.

Unbalanced tyre or wheel.

7.2.4 Difficulty in Wheel Rolling

7.2.8 Too Stiff of the Front Absorber


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Improper weight of the liquid

Blocked pathway of the liquid in the absorber

7.3 Front Wheel

7.3.1 Disassembly

Note:Support the motorcycle firmly.

Support the motorcycle with a safety frame or firm crane.

Disassemble the front fender, and loosen the fixing screws①②.


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Remove the clamping screw① of the front wheel spindle

(right front absorber)

Bleed nipple

Fixing bolt of the bake hose

Right brake cylinder assembly

Fixing bolt of the brake cylinder

Disassemble the front wheel assembly①


96/212

y

Remove the left spindle sleeve of the front wheel②

Disassemble the bearing with the bearing remover.

7.3.2 Check


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7.3.2.1 Check the Bending of the Wheel Spindle

Place the wheel spindle on the V-base and measure the

eccentricity ratio with a dial indicator.

Limit for use: replacement when beyond 0.2mm

车轴：axle

7.3.2.2 Check the Rim Shimmy

Place the rim on a precision bracket

and check the rim shimmy.

Rotate the wheel by manual and read indication.

Limit for use:

Vertically: replacement when beyond 2.0mm

Horizontally: replacement when beyond 2.0mm

Balance of the wheel：

Warning

7.3.2.4 Check the front wheel bearing


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Remove the bearing①, and the middle sleeve of

the front wheel②.

Check the rolling of the bearings.

Replace it if the bearing does not roll, or the

rolling is unsmooth or unstable, or the it is abraded

or loose.

7.3.3 Bearing Replacement

Remove the front wheel spindle, front wheel, left

spindle sleeve and the middle spindle sleeve. Then

remove the oil seal and the bearing respectively with

the oil seal remover and the bearing puller.

Note:

7.4 Steering Handlebar


99/212

7.4.1 Disassembly

Remove the left/right rearview mirror assembly.

Right rearview mirror

Left rearview mirror

Remove the left handle assembly.

Remove the left switch group.


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Remove the balance block assembly①.

Remove the right handle assembly②.

Remove the balance block ③.

Left switch group

Left handle

Fixing screw

7.5 Front Fork


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7.5.1 DisassemblySupport well the middle bracket of the motorcycle.

Disassemble the front wheel.

Disassemble the brake caliper and the brake pipe clamp.

Remove the steering handlebar.

Remove the pillar bolt①.

Remove the meter and the meter bracket

l


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Tools:

Fixing nut spanner.Special disassembly tool for bearing cup.

*Note:

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

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

7.5.3 Installation

Note:

Make sure that the hole of the front wheel spindle is concentric when installing the left and right

absorber.

Steps are contrary to the process of disassembly.

Note:

Fixing screws for the bottom connecting board: 10N.m

Fixing screws for the upper connecting board: 28N.m


103/212

Rear Wheel/Rear Suspension

ATyre size: rear tyre: 180/55 ZR

17

BPressure of the rear tyre:

290±10kpa

CMinimum non-skid depth:

2.0mm

D

Rim run-out limit:

Vertically: 2.0mm

Horizontally: 2.0mm

ETorque for mounting the bolt 2 in

the figure: 5-10N·m

FTorque for mounting nut 19 in the

figure: 37-55N·m

GTorque for mounting nut 20 in the

figure: 130-150N·m


104/212

Rear Suspension/Rear Absorber

ATorque for mounting bolt 1

in the figure: 70-105 N·m

T

Torque for mounting nut

10 in the figure: 37-55

N·m

C

Torque for mounting nut

10 in the figure: 37-55

N·m

8. Rear Wheel/Rear Suspension


105/212

Preparing Documents --------------------8.1

Failure Diagnosis -------------------------8.2

Rear Wheel --------------------------------8.3

Rear Absorber -----------------------------8.4

Chain Drive--------------------------------8.5

Rear Swinging Arm----------------------8.6


Work Instructions

The surface of the disc brake and the brake shoes shall not be stained with oil spots.

Abraded or damaged bearings of the swinging arm spindle

Incorrect adjustment of the drive chain

Unbalanced tires and wheels


106/212

Unbalanced tires and wheels

Too low of the tyre pressure

Bending frame or the rear swinging arm

8.2.2 Inflexible Rolling of the Wheel

Bending rear disc brake

Abraded bearings of the rear wheel spindle

Too tight of the drive chain

8.2.3 Too Soft of the Suspension

Insecure or shaking damping spring

Incorrect front suspension regulator

Oil leakage of the absorber

Too low of the tyre pressure

8.2.4 Too Stiff of the Suspension

Damaged assembly bearing of the absorber

Bending tube of the absorber

Damaged bearing of the rear swinging arm axis

Bending of the rear swinging axis

Fault in the suspension regulator

Caliper of the rear disc brake


107/212

Remove the caliper of the rear disc brake.

Loosen the adjusting screws of the rear wheel.

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

Fixing screws of the caliper of

the rear disc brake

Adjusting screw of the rear wheel

Nut of the rear wheel spindle

Left chain adjusting block

Adjusting screw of the rear wheel

Remove the rear wheel assembly.


108/212

Remove the supporting board of the brake clamp.

Supporting board of the brake

8.3.2 Check

8 3 2 1 Ch k h Ri Shi


109/212

8.3.2.1 Check the Rim Shimmy

Rotate the wheel by manual and measure the

eccentricity ratio with a dial indicator.

Limit for use:

Vertically: replacement when beyond 2.0mm

Horizontally: replacement when beyond 2.0mm

When the rear wheel indication goes beyond the limit for

use, the rear wheel bearing is loosened leading to the rear

wheel shimmy. Replace the rear wheel bearing after check.


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8.4 Rear Absorber

8.4.1 Disassemble the Rear Absorber

Remove the upper/lower fixing nut of the rear absorber.

Remove the rear absorber.

Fixing bolts

Torque force: 37-55 N·m


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8 5 Chain Drive


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8.5 Chain Drive

8.5.1. Disassembly

Put the motorcycle on level ground, and firmly support it.

Remove the left rear cover.

Disassemble the rear wheel, rear absorber, the drive

Fixing bolt of the left rear cover

Engine left rear cover

* Note:

• Measure after stretching the chain by hand.


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• Range from chain link roller (1) to the inside of roller (11).

• Measure the length of ten chain links.

• Measure the length of ten chain links of different parts 2-3 times.

Clean the drive chain, put it into the kerosene,

and wash off the dust as much as possible,

then take the chain out of kerosene and dry it.

Check the rotor① and side panels②,

if damaged or frayed replace the drive chain

Check the drive sprocket and driven sprocket.

If one fourth of the teeth of a cogwheel is frayed


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If one-fourth of the teeth of a cogwheel is frayed,

replace the sprocket,

the bending of the teeth of a cogwheel also requires

the replacement of sprocket.

8.5.4. Installation


Fixing nuts

Torque force: 37-55 N·m

Note:

Adjust the laxation degree of the drive chain and the free stroke of the brake pedal.

If the laxation degree of the chain is too small, engine and other vital parts will be overloaded.

The laxation degree of the chain should be kept within the prescribed limit value

Disassemble the rear swinging arm spindle bearing and the

rear swinging arm spindle


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8.6.2 Check the Rear Swinging Arm

Check the rear swinging arm mounting spindle, rotate the

spindle on a flat surface or measure with a dial indicator, if

bent, replace it.

*Note

Don’t attempt to straighten the spindle already bent.

Clean the parts of the rear swinging arm mounting spindle

in the solvent.

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

Rear swinging arm

Fuel Tank

A

Gasoline capacity of the

li t k


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A gasoline tank:

15 0.2L

BTorque force of bolt 3:

5 10N

m

DTorque force of bolt 6:

5 10N

m

ETorque force of bolt 9:

5 10N

m

FTorque force of bolt 12:

5 10N

m

22 37N

m

9 Fuel Tank


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9. Fuel Tank

Preparing Documents -----------9.1

Failure Diagnosis -----------9.2

Fuel Tank -----------------9.3


Work Instructions:

It shall be dismantled far from fire sources.

Tighten all the bolts and screws to the required torque value for assembly.

After assembly, check whether all the parts are correctly installed and operated.

Preparing Principles

9.3 Fuel Tank


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9.3.1 DisassemblyRemove the rear seat and the front seat

Remove the upper body of the fuel tank.

Remove the front fixing bolt of the fuel tank.

Remove the rear fixing bolt of the fuel tank.


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Remove the fuel tank.

9.3.2 Installation


Torque force for mounting:

Front fixing bolts for the gasoline tank 22-37N·m

Rear fixing bolts for the gasoline tank 5 10 N m

Rear fixing bolt of

the fuel tank

10 Disassembly and Installation of Engine


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10. Disassembly and Installation of Engine

Preparing Documents -------------10.1

Disassembly and Installation of Engine ----------10.2


Work Instructions

It shall be dismantled far from fire sources.

Tighten all the bolts and screws to the required torque value for assembly.

After assembly, check whether all the parts are correctly installed and operated.

Locking torque force

Unscrew the clamp of the engine water pump

inlet/outlet, remove the cooling water-pipe and

exhaust the coolant


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exhaust the coolant

Disassemble the front and rear seats

Disassembly of the rear seat

Insert the key into the guard lock, and open itclockwise;

Slightly push the back of the rear seat with your

right hand, pull the rear seat upwards and

backwards

Remove the rear seat;

Disassemble the fuel tank assembly

See 9.3.1 Disassembly of the fuel tank


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Disassemble the air filter assembly

Disassemble the air filter fixing bolt

Disassemble the air filter hoop

Disassemble the connector jacket of the intake air

temperature sensor;

Disconnect the breather rubber pipe from the vent

of cylinder cover;

Remove the air filter

Note:

The stepper motor of the throttle body should be

set well to position when installing the air filter.

Disassemble the throttle body assembly

Remove the throttle cable assemblyI and throttle

cable assembly II;

Disassemble four throttle body hoops in 1 2 4 3

Disassemble the canister assembly


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Disassemble the clutch steel rope assembly

Clutch steel rope assembly

Canister assembly

Disassemble the anterior segment of muffler exhaust

pipe


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Disassemble the radiator filler, water tank, and

disconnect the fan switch connector jacket

Disconnect the crankshaft position sensor neutral

Disassemble gearshift lever swing arm and the left cover of

the engine

Disassemble the small sprocket and detach the chain from the


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p

sprocket

Release the engine fixing bolt and lift the engine

10.3 Installation of the Engine


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Note:

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

Engine fuel: 3.2L when assembling.

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

After the engine works properly at idle speed for a period of time, turn the throttle handle to maximum

level, then completely relax the throttle handle, at this time if the idle speed changes, it shows that the

throttle cable hasn’t been regulated well. Therefore, attention should be given to the regulation in this

regard prior to the testing the engine.

Checking method of engine fuel

a.

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

b.

Insert the rod into the oil and remove it to check the oil level, if the oil level is lower than the

lowest limit, increase the fuel.

c.

Heating up for 5 minutes and cooling for 3 minutes, then check the oil level again, if the oil level

is lower than the lowest position, increase the fuel.

d.

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

Inspection and Maintenance of Engine


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Table of Torque Force of Fasteners

Name of fastening parts and fasteners Tightening torque (N·m)

Magnetic bolt M14

Oil pan bolt M6

cylinder double-end bolt

Flywheel locking bolt

Gearshift positioner bolt M6Crankcase bolt M6

Crankcase bolt M8

Crankcase bolt M10

Connecting rod bolt

Left/right crankcase cover bolt M6

20~25

10~12

60~62

100~110

10~12

10~12

22~24

35~39

23~27

10~12

11. Lubricating System


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Preparing Documents ------------11.1

Failure Diagnosis ------------11.2

Fuel Pump ---------------11.3


Function of the lubricating system:

The lubricating system of the engine is to provide lubricating oil to the frictional surface of each part, which

transforms dry friction into liquid friction between lubricating oil particles and also reduces abrasion of parts.

It also cools components with high thermal load, absorbs shock from bearings and other parts, reduces noise,

increases sealing between piston ring and cylinder wall, and cleans and removes particles in the surface.

Work Instructions:


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11.3 Fuel Pump

11.3.1 Disassembly Remove the clutch cover, loosen the fuel pump fixing bolt, take down

the fuel pump drive sprocket and the fuel pump drive chain.

Fuel pump chain

Fuel pump drive sprocket

Screw

Check the radial clearance between inner and outer rotors

Limit for use: 0.15mm.

Gauge


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Check the clearance between outer rotor and fuel pump cover

Limit for use: 0.15mm. Gauge

11.3.2 Assembly of Fuel Pump

As shown below Fuel pump

drive sprocket


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

Installation


Fuel pump cover Outer rotor

Pump shaft

Pump body

Inner rotor

11.3.3 Lubricating Systematic Drawing


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Piston cooler


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12. Cylinder Head


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Preparing Documents --------------------12.1

Failure Diagnosis -------------------------12.2

Cylinder Head / Valve--------------------12.3


Function of the cylinder head:

The cylinder head is used to seal the cylinder and form the combustion chamber with the piston. It bears HPHT

gas, and achieves air intake and exhaust through distribution mechanism.

Work Instructions:

The cylinder cover bears large bolt pretension to ensure sealing between the cylinder head and the upper

cylinder block. Pretension: 12 N·m, torque force: 60 N·m. All components must be cleaned and dried with

high-pressure air before check.

Burnt or bent valve Damaged valve spring

Poor air-tightness of valve seat Over high compression pressure

Cylinder head gasket leaks gas Too much carbon fouling in the combustion chamber.

Poor installation of spark plug


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12.3 Cylinder Head

12 3 1 Disassembly


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12.3.1 DisassemblyRemove the ignition coil.

Loosen six locating bolts, remove the gasket and cylinder cover shade.

Loosen the fastening bolt, and remove the air-