rk6 service manual

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Service manual of RK6

KEEWAY Motorcycle Corporation Ltd.

1

Contents

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

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

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

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

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

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

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

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

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

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

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

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

1.4 Charging System .............................................................................................................................. - 47 -

1.5 Voltage/Current Regulator ................................................................................................................ - 48 -

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

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

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



2.3 Ignition System Check ..................................................................................................................... - 54 -

2.4 ECU Group ....................................................................................................................................... - 55 -

2.5 Ignition Coil ..................................................................................................................................... - 56 -

2.6 Sensor of the Crankshaft .................................................................................................................. - 56 -

3. Startup System ............................................................................................................................................ - 58 -



3.3 Startup Motor ................................................................................................................................... - 59 -

3.4 Starter Relay ..................................................................................................................................... - 61 -

4. Bulbs/ Switches / Meters ............................................................................................................................ - 63 -



4.3 Replacement of Headlamp Bulbs ..................................................................................................... - 64 -

4.4 Replacement of Front Position Lamp Bulbs .................................................................................... - 65 -

4.5 Replacement of Tail Lamp ............................................................................................................... - 66 -

4.6 Replacement of Rear Registration Plate Lamp Bulbs ...................................................................... - 67 -

4.7 Replacement of Front Steering Lamp Bulbs .................................................................................... - 68 -

4.8 Replacement of Rear Steering Lamp Bulbs ..................................................................................... - 68 -

4.9 Meters ............................................................................................................................................... - 68 -

4.10 Main Switch ................................................................................................................................... - 69 -

4.11 Horn ................................................................................................................................................ - 69 -

4.12 Handlebar Switch ........................................................................................................................... - 70 -

Inspection and Maintenance of the Motorcycle Body .................................................................................... - 71 -

5. Brake .......................................................................................................................................................... - 74 -

2

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


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

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

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

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

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

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



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

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

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

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

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

8.2 Failure Diagnosis ............................................................................................................................ - 101 -

8.3 Rear Wheel ..................................................................................................................................... - 102 -

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

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

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

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

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

9.2 Failure Diagnosis ............................................................................................................................ - 113 -

9.3 Fuel Tank ........................................................................................................................................ - 114 -

10. Disassembly and Installation of Engine ................................................................................................. - 116 -

10.1 Preparing Documents ................................................................................................................... - 116 -

10.2 Disassembly of Engine ................................................................................................................. - 116 -

10.3 Installation of the Engine ............................................................................................................. - 122 -

Inspection and Maintenance of Engine ........................................................................................................ - 123 -

11. Lubricating System ................................................................................................................................. - 124 -


11.2 Failure Diagnosis .......................................................................................................................... - 124 -

11.3 Fuel Pump ..................................................................................................................................... - 125 -

12. Cylinder Head ........................................................................................................................................ - 130 -



12.3 Cylinder Head .............................................................................................................................. - 132 -

13. Crankcase ............................................................................................................................................... - 140 -



13.3 Upper Box .................................................................................................................................... - 144 -

13.4 Piston ............................................................................................................................................ - 145 -

13.5 Lower Box .................................................................................................................................... - 150 -

13.5 Lower Box .................................................................................................................................... - 151 -

13.6 Clutch ........................................................................................................................................... - 154 -

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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 -



14.3 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

- 1 -

Preface

This maintenance manual is used for operating and maintaining Motorcycle

RK6.

Preparing Documents include all necessary instructions and statements.

Please carefully read this manual before operation.

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

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

periodic inspection.

Except for Chapter I, the rest chapters explain the disassembly/ assembly/

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

electrical equipment.

Breakdown drawing, systematic drawing, failure analysis and statements are

contained at the first part of each chapter.

Please note that photos, pictures or instructions are for your reference only.

The actual object may differ from what is mentioned here. We will not make

notification for any discrepancy.

Qianjiang Motorcycle Corporation Ltd.

- 2 -

Preparing Documents

General Safety Maintenance Rules

Specification Table Inspection/Adjustment

General Safety

Carbon monoxide

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

Note

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

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

closed area.

Petrol

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

stored.

Battery

Battery emits explosive gas. Therefore, it shall be far away from fire sources, naked flame or smoking places.

Make sure good ventilation during charging. Battery contains sulfuric acid (electrolyte). It will burn your skin or eyes when contacted. Therefore, wear

protective clothing and mask.

—— Clean with fresh water immediately if electrolyte splashes on the skin.

—— Clean with fresh water at least for 15 minutes immediately and then go to the doctor if electrolyte

splashes on eyes.

Electrolyte is poisonous. Drink a large quantity of fresh water, milk, milk of magnesia (laxative antacid) or

mineral oil if electrolyte is swollen accidentally. Then go to the doctor. It shall be unreachable for children.

Machine Oil

It may trigger cancer if repeatedly expose the hands in the air after contacting with oil. Although there is little

possibility for you to contact with oil in the daily life, wash hands thoroughly with water and soap if you have

contacted. And it shall be unreachable for children.

Thermal Energy

Parts of the engine and cooling system produce heat, which can last for some time before the engine gets

started. Deal with these parts with gloves or after the engine and cooling system cools down.

- 3 -

Maintenance Rules

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

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

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

Wash and dry parts with air compressor after disassembly and

before measurement of attrition value.

Solvent or oil can easily damage aging rubber articles. Check

rubber before reassembly and replace rubber if necessary.

套：boot

When loosening assembly parts, please start form outside to

inside. Small assembly parts shall be loosened first.

Complex assembly parts, such as gearbox, shall be stored in

proper order for facilitating installation in the future.

Please specially note important connections before disassembly.

Replace parts which will not be in use before disassembly.

- 4 -

Bolts and screws with different length shall be separately used for

different assembly parts and shields, and they shall be correctly

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

you are confused.

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

whether the oil seal is smooth or damaged during assembly.

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

insert its end into the bottom of the connector so that the hose clip

can properly fix the connector. Rubber or plastic dirt-proof boot

shall be mounted at the original design position.

槽：groove 夹子：clip 接头：connector

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

bearing rollers shall be supported by tools. Ball bearings may be

damaged during disassembly and have to be replaced if only one

roller (either inside or outside) is imposed with force.

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

occasion as mentioned.

- 5 -

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.

- 6 -

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

Significant Notes

1. Please apply valid Qianjiang parts and accessories. Any part or accessory not in accordance with the design

specification of Qianjiang Company may cause damage to engine.

2. Only metric tools are valid for maintenance and repair. Metric screws, bolts and nuts can not be exchanged

with imperial fasteners.

3. New gaskets, O-rings, cotter pins and locking pieces shall be applied for re-assembly.

4. Bolts with large diameter or positioned inside shall be fastened first and then diagonally screw down until

reaching required torque, otherwise there is special instruction.

5. Wash disassembled parts with cleanser. Lubricate all sliding surface before assembly.

6. Check whether all the parts and accessories are correctly mounted and operated after assembly.

7. Clean and remove oil before measurement. Add recommended lubricant to the lubricating areas during

assembly.

8. Apply lubricant to the surface of engine and driving system if they are dismantled for long-term storage,

which can prevent rust and dirt.

Frame Number

Frame

Rivets

Frame Number

Engine Number

- 7 -

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 gauge

Bearing disassembly tools

Bearing assembly tools

Oil seal remover

Handle for dismantling tools

Piston pin pulling device

Piston pin pliers

Socket spanner for spark plug

Clutch thickness measuring device

Cylinder diameter measuring device

Dial indicator

Dial indicator, V-block

Dial indicator

Assembly/disassembly tool for valve catheter

Assembly tool for valve catheter

Adjustment tool for valve space

Assembly/disassembly tool for valve spring

Valve catheter reamer

Disassembly tool for crankcase

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

Fig.1-4

Fig. 1-4

Fig. 1-5

Fig. 1-6

Fig. 1-7

Fig. 1-8

Fig. 1-9

Fig. 1-10

Fig. 1-11

Fig. 1-12

Fig. 1-13

Fig. 1-14

Fig. 1-15

Measuring the inner diameter of the piston pin, Fig. 1-16

For measuring the bending of the valve rod，Fig. 1-17

For measuring the external diameter of the valve rod，Fig. 1-18

Fig. 1-19

Fig. 1-20

Fig. 1-21

Fig. 1-22

Fig. 1-23

Fig. 1-24

Table 1-2 (continued)

Fig. 1-3 Fig. 1-4

- 8 -

Fig. 1-5 Fig. 1-6 厚度规（塞尺）：feeler gauge

Fig. 1-7 Fig. 1-8

Fig. 1-9 Fig. 1-10

①handle

Fig. 1-11 Fig. 1-12 ①pliers ②piston

- 9 -

Fig.1-13 Fig.1-14

Fig. 1-15 Fig. 1-16

Fig. 1-17 Fig. 1-18

Fig. 1-19 Fig. 1-20

Fig. 1-21 Fig. 1-22

- 10 -

Fig. 1-23 Fig. 1-24

2．Tools for repairing the chassis

Table and drawing (1-25, 1-26) of ordinary tools and special tools for disassembling/assembling chassis

parts are as follows:

Fig. 1-25

Name Remark

Torque spanner

Inner hexagon spanner

Socket spanner

Micrometer

Magnetic rack, V-block

Dial indicator

Vernier calipers

Circlip pliers

Screwdriver with striking cap

Tool for assembling oil seal of front fork

Tool for hammering seal of front fork

Steering nut spanner

Fig. 1-27

Fig. 1-28

Fig. 1-29

Fig. 1-30

Fig. 1-31

Fig. 1-32

Fig. 1-33

Fig. 1-34

Fig. 1-35

Fig. 1-36

Fig. 1-37

Fig. 1-38

(1) Ordinary tools for repairing the chassis

Table 1-26 (continued)

Fig. 1-27 Fig. 1-28

Fig. 1-29 Fig. 1-30

- 11 -

Fig. 1-31 Fig. 1-32

Fig. 1-33 Fig. 1-34

Fig. 1-35 Fig. 1-36

(2) Special tools for repairing the chassis: tool for hammering seal of front fork

Fig. 1-37

(3) Steering nut spanner

Fig. 1-38

3．Tools for electric parts

- 12 -

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

Fig. 1-42

- 13 -

Specification

Motorcycle Model RK6

Engine

Engine Type BJ465MS-A

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

Width mm 800 No. of

cylinder 4

Height mm 1100 ID × stroke 65.0×45.2

Wheelbase mm 1480 Total

displacement 600cc

Petrol tank capacity 15L Startup Electric

Weight kg

(Curb weight)

Forward

shaft 115 Cooling Liquid cooling

Back-

shaft 105 Lubrication Pressure splash

lubrication

Total 220 Clutch type Wet multi-chip

Tire Size

Front

tire

120/70

ZR 17

Transmi-

ssion

devices

Variable

speed Six variable speed

Rear tire 180/55

ZR 17 Transmission Chain

Electric

devices

Battery

capacity 12V-9AH

Primary

transmission

ratio

1.864

Magnetor Flywheel permanent

magnet

Transmisson

ratio of gear 1 2.846

Spark plug CR9E(NGK) Transmission


Spark plug

gap 0.6-0.7mm

Transmission


Ignition TLI Transmission


Perfor

mance

Max. Hp 60.0kW/11000rpm Transmission


Max. torque 55N.m/8000rpm Transmission


Compression

ratio 11.5：1

Final

Transmission

ratio

3.286

Max. speed 185km/h

Brake

Dia. of front

liquid brake

disc（mm）

320mm

Fuel

consumption

limit

≤5.2L/100km

Dia. of rear

liquid brake

disc（mm）

240mm

- 14 -

RK6

- 15 -

Failure Diagnosis

Diagnosis on difficulty or failure in starting up

Failure Diagnosis Adjustment & Inspection Causes of Failure

- 16 -

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 spark

Normal Too low

No

Test compression pressure

No ignition

outbreak of

the engine

Ignition outbreak

of the engine but

no sign of startup

Wet spark plug Dry spark plug

Disassemble once agian the

spark plug to check

No petrol in the tank

Oil tube of fuel injector blocked

Oil 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 group

Abnormal trigger

Open circuit or short circuit of

ignition coil’s wire


ignition coil

Abnormal main switch

Abnormal charging coil

Abnormal clutch for startup

Abnormal piston of cylinder and

piston ring

Leakage of cylinder gasket

Abnormal automatic choke

actuation

Intake manifold with air

Incorrect ignition time

Abnormal adjustment to throttle

valve and bolt

Excessive oil injected to fuel

injector


actuation

Throttle opens too large

- 17 -

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 time Incorrect ignition

time

Adjust ignition timing and

use ignition timing light

Normal Too low

Test compression pressure

No Yes

Polluted and

discolored

No pollution nor

discoloration

Disassemble the spark plug to

check

Blocking check to Carburetor

Normal Abnormal

Yes No

Engine knock No engine knock

Accelerated driving or

running

Overheated engine

Check the lubrication of

cylinder head

Normal High oil level

Check oil level in crankcase

if it is high or polluted

Air filter blocked

Abnormal petrol



blocked

Exhaust pipe blocked


Abnormal throttle valve

Abnormal CPU group

Abnormal trigger

Abnormal piston of cylinder and

piston ring

Leakage of cylinder gasket

Contaminant removal

Contaminant removal

Heat value of spark plug does

not conform

Excessive oil

Insufficient oil

No replacement of oil

Abrasion in piston cylinder

Mixed gas too thin

Abnormal petrol

Too much carbon fouling in the

combustion chamber

Earlier ignition time

Too much carbon fouling in the

combustion chamber

Abnormal petrol

Clutch slipping

Thin mixed gas

Earlier ignition time

- 18 -

Unsmooth gyration（especially in low speed）


Normal Abnormal

Adjust ignition time

Good Bad

Adjustment to throttle valve and

bolt

Yes No

Disassemble spark plug

into its cap and ground it

with engine to check if it

can spark

Good

spark-over

Bad spark-over

Bad Good

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

insulation piece

Throttle valve fixed, bolt

loosened

Heat insulation piece ruptured

Negative pressure pipe ruptured

Spark plug abnormal or polluted

Abnormal CPU

Abnormal ignition coil


spark plug’s wire


Negative pressure pipe damaged

Air pass-hole blocked

- 19 -

Unsmooth gyration (high speed)


Normal Abnormal

Adjust ignition time

Normal Abnormal

No Blocked

Spring broken

Weak elasticity

Good

Blocked oil injector

Abnormal CUP group

Abnormal trigger

Little oil in petrol tank

Petrol filter of the pipe blocked



blocked

Abnormal automatic oil ring

Remove

Abnormal spring

- 20 -

Poor battery charging (over discharge or over charge)


No voltage rise Voltage rises to normal

value, and back to

original voltage value

after flameout

Test the voltage of

battery’s two ends, and

stat engine

Normal Abnormal

Check the plug of voltage

regulator if it is loose

Voltage

available

No voltage

Test the resistance value of

alternator’s coil

Normal Abnormal

Normal voltage Voltage above

normal value

Start the engine, connect the red wire of the

voltage regulator’s socket to the multimeter,

while anode and cathode wire to the voltage

between parts of the body

Check if the red wire of voltage regulator’s

socket connects the multimeter, while

anode and cathode wire to the voltage

between parts of the body

Poor battery charging

Overcharging

Normal Loose

Bad connection

Check if charging wire of the voltage

regulator connects well

Use monomer of the voltage regulator

to test impedance

Battery used up

Poor battery

Poor connection of the plug

Open circuit of the red wire of

the charging wire

Voltage regulator

Open circuit of the white wire of

the charging wire

Abnormal coil

Poor connection of the joint

Open circuit of alternator’s

white wire

Poor battery

Poor connection of the joint and

charging wire to the ground

Abnormal voltage regulator

- 21 -

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 conduction between terminals

of CDI group’s plugs, and test

resistance value

Normal Abnormal

Abnormal Normal

Check relevant parts

Check plugs of CDI group if they

are loose

Normal Abnormal

Abnormal

Use CDI tester to check ignition coil

Use CDI tester to check CDI group

Original spark plug abnormal

Spark plug cap loose

Bad connection of the plug


Abnormal charging coil

Abnormal trigger


Breakage of main wire

Bad connection of the plug and

socket

Abnormal CPU group


- 22 -

Inspection/Adjustment

Preparing information Periodic Maintenance & Inspection Table

Engine oil/ Oil filter Liquid coolant

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

Adjustment of throttle cable Air filter

Spark plug Battery

Fuse replacement Cylinder pressure

The slackness of the drive chain Free stroke of front brake

Free stroke of rear brake Headlamp

Clutch Front/rear suspension system

Bolt/nut/fastener Rim/tire

Fixing steering stem bearing & handlebar Throttle valve

Components lubrication

Preparing Principles

General

Warning!

• Make sure that it is well ventilated before starting the engine. It is forbidden to start it in a closed area.

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

• Petrol is liable to volatile or exploded under certain condition. Ventilation is required and no any fire exists in

working places. Fire is strictly forbidden in working areas or where oil is stored.

- 23 -

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

RK6 Front 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

- 24 -

Periodic Maintenance & Inspection Table

Service cycle and time

Inspection item

Per

300

Km

Per

1000

Km

Per

3000

Km

Per

6000

Km

Per

12000

Km

Per

14500

Km Tools

New

One

month

Three

months

Six

months

Twelve

months

Fifteen

months

* Air filter I C C R C Ordinary tools

* Petrol filter I I R Ordinary tools

* Fuel filter C C C Ordinary tools

Replacement of engine

fuel R Replacement every 1000KM Ordinary tools

Tire pressure I I I I I I Tire pressure

gauge, inflator

Battery inspection I I I I I I Densimeter,

multimeter

Actuation gap inspection I I I I I I Ordinary tools

Inspection of steering

handle fastening I I I Ordinary tools

Absorber working

inspection I I I Ordinary tools

Screw fastening

inspection I I I I I I Torque spanner

Oil leakage inspection for

gearbox I I I I I I Ordinary tools

* Inspection or replacement

of spark plug I I R R I Ordinary tools

* Replacement of gearbox

oil I Replacement every 5000KM Ordinary tools

Lubrication of each part L L Lubricator

Muffler I I I I I I Ordinary tools

* Ignition timing I I I I I I Timing lamp

* Carburetor A I A A A A Tachometer, CO

HC analyzer * Exhaust gas inspection at

idle speed A I A A A A

* Throttle inspection I I I I I Ordinary tools

Fuel pipeline inspection I I I I I Ordinary tools

Lighting/metering/electric

devices I I I I I I Visual multimeter

Main stand bracket I I I Ordinary tools

Absorber I I I I Ordinary tools

* Torque force of engine

bolts I I I I I Torque spanner

Front/rear brake I I I I Ordinary

Drive chain I I I I A Ordinary

Clutch I I I I Ordinary

* Valve I I I I I Feeler

- 25 -

Anticipated Inspection

1 Ignition system—obviously continuous ignition abnormality, engine fire or overheating, which requires

inspection and maintenance.

2 Carbon fouling elimination—obviously insufficient horsepower, which requires carbon fouling removal

from cylinder head, piston head and exhaust system.

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

Please have your motorcycle inspected and adjusted periodically at Qianjiang distributors for being in best

condition.

The above table is established under the presupposition of 1000 km/month.

I—Inspection A—Adjustment R—Replacement C—Cleaning L—Lubrication

Note: 1. “*” Regulations on exhaust emission made by the State Environmental Protection Agency shall be

complied with. Maintenance must be carried out in accordance with the instruction manual supplied by the

company. We are not responsible for any loss rising from private adjustment or maintenance.

2. Increase frequency of washing air filter if your motorcycle runs on the sandy/gravel road or under

heavily polluted environment so as to extend its service life.

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

Engine Oil/Filter

Oil level

* Note

• The motorcycle should be parked on a flat ground when

checking its oil level.

• After the engine runs for 2-3 minutes or stops running for

about 2-3 minutes, check the oil level.

Check the oil level.

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

Check oil level

*Note

Do not tighten dipstick when check.

Check the oil level, and lay down the single shoring on the flat

ground so that the body is vertical.

Oil level must be checked regularly when oil is constantly

being consumed, and refuel to a right level.

Oil capacity: 3.0L change oil 3.2L disassemble

The working of engine and clutch will be affected if the oil

level is too high; (上限：maximum 下限：minimum)

And if it is too low that will lead to overheated engine and earlier abrasion of the components.

If refuel with inferior oil or oil of other brand or class will reduce the effect of lubrication.

Disassemble the dipstick after the engine stops, and dry it with a clean cloth.

Put the dipstick into the measurement hole with the engine on the flat ground, but do not tighten it up.

Take out the dipstick and check the oil level.

- 26 -

If it is below or near the minimum level,

Refuel with the recommended oil to the maximum level.

*Note

Check the O-ring.

Assemble the dipstick.

Oil Replacement

* Note

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

Preheat the engine.

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

bolt ① and the dipstick.

Repeatedly start the engine for several times until the oil is

discharged completed.

When the oil is discharged completely, install back the drain

bolt and the packing washer after cleaning.

Refuel recommended oil to the crankcase to a required capacity.

Assemble the dipstick.

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

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

The engine should be upright while checking.

Make sure that there is no leakage.

Replacement of the Oil Filter

*Note

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

Turn off the engine.

Make the oil filter stuck with special removal tool, spin

anticlockwise and disassemble the oil filter that needs

replacement② .

Replace on new oil filter and coat a layer of lubricant on the

O-ring.

Note:

Do not disassemble the O-ring, otherwise it will make the

O-ring out of position while installing, which can lead to

oil leakage or the damage of the engine.

Install the new oil filter to the engine with hands, spin until

it can not be screwed any further, then tighten it with

Torque spanner (torque: 12-20Nm).

Check oil leakage when the engine operates at its idle

speed for minutes.

Oil filter

- 27 -

Cooling Liquid

Check the height of the cooling liquid in the expansion kettle

during maintenance.

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

is time for maintenance.

Recommended model of the cooling liquid: FD-2

Total liquid capacity of the cooling system: about 2.0L

Remove the front shield on the right side. Find the filler mouth

of radiator water tank①.

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

Re-install the cap after injection.

Check the cooling liquid of the expansion kettle after the

engine has been turned off and cooled down.

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

and its body upright.

Observe the capacity of the cooling liquid in the expansion

kettle through the frame hole from the right side of the

motorcycle.

Keep the capacity between the mark of H and L. If the liquid is below H, remove the cap of the expansion

kettle② and then add cooling liquid.

Warning:

Add the cooling liquid after the engine is turned off

and cooled down. In case of burns, do not open the filler

cap before the engine has cooled down. The cooling

system is under pressure. In some cases, the cooling

liquid contains substances that are combustible, and

there will be visible flame when ignited. Avoid the

leakage of cooling liquid on hot motorcycle parts,

because it can cause serious burns if combust.

Avoid contact to and inhalation of the cooling

liquid, because it is highly toxic. And keep it away from

the children and domestic animals. If inhaled, seek

medical advises immediately, and if the skin or eyes

have accidentally contacted the cooling liquid, they

must be cleaned with water instantly.

- 28 -

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

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

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

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

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

vehicle.

卡箍：clamp

Fuel Injector and Oil-way

The fuel pump① has two connectors, oil passes through

the fuel filter② from one of the two connector into the

fuel injector③, and finally inject oil into the intake

manifold of the engine. When the oil is under too high

pressure, it will pass through another connector back to

the fuel pump①.

Please connect the inlet and outlet oil tubes as shown in

the figure at right.

- 29 -

Adjustment to the Steel Rope of the Throttle

*Note

Adjust the idle speed of the engine right before adjusting

the stroke of the steel rope of the throttle.

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

should be 3-5mm.

Adjust if it does not conform to the specified value.

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

The motorcycle is configured with two-lane steel rope of

the throttle, among the two ropes, A for throttle forward

(1)Remove the dustproof boot of the steel rope of the

throttle.

(2)Loosen the locking nut③.

(3)Screw in completely the adjusting nut④.

(4)Loosen the locking nut①.

(5)Rotate the adjusting nut② to make the free stroke of

controlling handlebar of the throttle to 10°～15°.

(6)Tighten up the locking nut①.

(7)Adjust nut④ to make the controlling handlebar of the

throttle flexible.

(8)Tighten up the locking nut③.

After adjusting the free stroke, the handle should be

twisted left and right to make sure that there is no change

of the idle speed of the engine.

Air Filter

Filter Replacement

Open the rear seat cushion with the key, and remove it.

钥匙：key

Pull the seat steel rope, open the front seat and take it off.

- 30 -

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.

Check whether the cartridge is stained or damaged.

Replace it if necessary.

Clean thoroughly but gently the cartridge with the cleanser.

Do not use petrol, in case of fire.

Do not distort or wring the cartridge so as not to damage

the foam.

Then apply the engine oil to it, and squeeze out the excess

oil to make the cartridge seem moist, but make sure there is

no oil dripping.

空气滤清器盖罩： cover of the air filter

油箱： fuel tank

Replacement Time

Replace it as early as possible if the motorcycle is always running on rainy days or on rugged road.

*Note

Cartridge

- 31 -

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

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

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

overheat of the engine.

Install in reverse order.

Spark Plug

Remove the spark plug:

(1)Lift up the fuel tank.

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

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

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

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

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

Check

Whether the insulator is cracked or damaged

Whether the electrodes are abrasive

The combustion condition and color

The condition is good in light grey

Combustion color of pale indicates that the ignition system

gets a breakdown or the mixed air is too thin.

The condition of wet or there is black carbon deposition

indicates that the mixed air is too thick.

If there occur any cases mentioned above, please remove with spark

plug cleaner or steel brush, and replace if necessary.

Check the spark plug visually.

Replace the cracked or abrasive insulator if necessary.

Replace the spark plug after 8000 kilometers of each driving.

Check the spark plug gap.

Gap: 0.6-0.7mm

Model: CR9E(NGK) 火花塞间隙：spark plug gap

*Note

Re-install the spark plug to the cylinder head, and screw tight with a specified torque.

Torque value: 20-25N.m

Manually install the spark plug first, and then tighten with the spark plug sleeve.

Do not make the spark plug too tight or the threads staggered, so as not to damage the threads of the cylinder

head.

When remove the spark plug, avoid impurities from entering into the engine through it.

- 32 -

Battery

Battery Disassembly

Disassemble the front seat.

Remove the mounting plate of the battery.

Remove the negative wire and then the positive wire.

Remove the battery from the battery box.

Take out the battery.

Warning!

When the positive wire is disassembled, do not make the

tool contact with the frame. Otherwise, it may cause

short-circuit spark, which may ignite gasoline and damage

the battery. It is dangerous.

Install it in reverse order.

Warning!

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

vehicle.

Check the Charging Condition (closed circuit voltage)

Open the front seat.

Remove the battery from the battery box.

Remove the negative wire and then the positive wire.

Take out the battery.

Test the voltage between battery terminals.

Fully charged: 13.1V

Insufficient charging: 12.3V（1 hour off work）

*Note

Use a voltmeter to check the charging condition.

Charging

Connection: Connect the positive pole of the charger to the positive pole of the battery.

Connect the negative pole of the charger to the negative pole of the battery.

- 33 -

Warning!

• The battery should be far away from fire source.

• Turn off the charger before or after charging to avoid

explosive danger caused by spark which may exist in any

connection.

• Comply with the current and time requirements for charging

as stated on the battery.

* Note

• Except emergencies, you should not use emergency charging.

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

伏特表：voltmeter

Charging current: standard: 0.3A

quick: 3.0A

Charging time: standard: 10-15 hours

quick: 30 minutes

charging accomplished：open-circuit voltage: above 12.8V

Fuse Replacement

The fuse is under the driver’s seat, and near the battery.

The main fuse is set on the starter relay, and the fuse box is

near the fuse. As shown in the figure ① refers to the fuse,

model: 40A, ② refers to the spare fuse of the main fuse, model:

40A, ③ refers to the fuse box, the configuration of the fuse is

shown in the figure:

Frequent fuse blowout indicates that there is short circuit or

circuit overload.

Note:

Before check or replace the fuse, set the ignition switch to “off

”, in case of short circuit or damage to other electrical

components.

Use the specified fuse only, or it will cause serious affect to the

electric system, and it can even burn the lamps of the

motorcycle or cause a fire or loss of engine traction, which is

very dangerous.

灯光: light; 燃油泵：fuel pump; 风扇：fan;

电源锁：power lock; 备用保险丝：spare fuse

- 34 -

Cylinder Pressure

Warm up the engine.

Insert the pressure gauge.

Turn the choke lever to the fully open position.

Start up the engine repeatedly,

The pressure of the cylinder: 1～1.2mpa

*Note

Start the engine until the reading does not rise.

Reasons for low pressure:

Incorrect valve adjustment

Leakage of the valve

Abrasive piston ring or cylinder

Reasons for high pressure:

Carbon deposition in the combustion chamber or piston

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

Looseness of the Drive Chain

The life of the drive chain depends on appropriate

lubrication and adjustment. Improper maintenance could

lead to earlier abrasion of the dive chain and the sprocket.

It must be maintained frequently if harshly used.

Looseness: 10-20mm

Adjustment to the drive chain: Adjust the drive chain to the sag of 10-20mm in

every 1000 kilometers’ drive. Regular adjustment may

need which depends on your driving.

Warning:

It is the maximum interval for adjustment as

recommended; in fact, you should adjust the chain

before every drive. Over loosened chain may

cause the accessory chain off the drive chain or

serious damages to the engine.

Adjust the chain according the following methods

mentioned：

- 35 -

(1)Put up the motorcycle with the support frame.

(2)Loosen the rear axle nut①.

(3)Loosen the locking nut②.

(4)Turn right or left the adjustment bolt③ to adjust the looseness of the chain, and keep the centers of the

rear and back sprockets into a straight line. There are benchmarks on the swinging arm and each chain

adjuster to facilitate your adjustment, and they can be aligned with each other and the reference from

one side to the other. Align and adjust the looseness of the chain to 10—20mm, and then fix again the

rear axle nut for the final check.

Note:

The two sprockets of the newly replaced

chain should be checked to make sure whether

they are abrasive or not, replace if necessary.

Inspect periodically the following condition of the chain:

(1)Loose pin

(2)Damaged idler wheel

(3)Dry and rusty chain

(4)Twisted or blocked chain link

(5)Excessive damage

(6)Adjust loose chain

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

chain. So the following items should be check to the sprocket:

(1)Excessively abraded gear tooth

(2)Broken or damaged gear tooth

(3)Loose fixing nut of the sprocket

Lubrication of the drive chain

Priority should be given to lubricate by the lubrication grease for the drive chain, and you may buy it or use

engine oil or other lubrication oil instead. Dip every chain joint to make the lubrication grease penetrate to the

space between the chain plates, pins, bushings and rollers.

*Note

Do not assemble new drive chain to abraded sprocket or vice versa.

The sprocket and the chain should all be in good conditions, or it will cause quick abrasion of the newly

replaced chain or sprocket.

- 36 -

Free Stroke of the Front Brake

Free stroke of front brake

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

brake lever.

Free stroke: 10-20mm

Regulator of Lever Grip of the Front Brake

Depending on the operating needs for the comfort, the

position of the lever grip of the front brake can be

adjusted by adjusting the knob with the ring nut. There

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

desired position just by moving gently forward the lever

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

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

most remote to the controlling handlebar of the throttle,

while the position 4 nearest to it.

前： front

Free Stroke of the Rear Brake

Free stroke of the brake pedal

Measure the free stroke of the brake pedal.


- 37 -

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

Adjust the free stroke of the brake pedal.

First open the nut 1.

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

Screw in 2 to reduce the free stroke;

Screw out 2 to increase the free stroke.

Tighten the fixture 1 until the specified value is met.

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

Headlamp

Disassemble the fixing bolt① of the headlamp support.

Disassemble the fixing bolt② of the headlamp support.

- 38 -

Unplug the lamp holder connector③ of the headlamp,

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

out the bulb.

*Note

Keep combustible materials and your hands a distance away

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

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

Install new headlamp bulb, lamp holder, and screw in the

bulb to the socket.

During the installation, avoid direct touch with the glass of

the bulb, 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.


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

First open the clamp nut（1）.

Then screw in or back to the adjusting device（2）.

Until the specified value of the free stroke is met.

Finally, tighten the clamp nut.

If adjusting the handle of the inhaul cable of the clutch to its

ultimate position can not meet the requirement of the free

stroke, then adjust the locking nut○A of the engine and the

adjusting nut○B with the inhaul cable.

- 39 -

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 Absorber

Compress the rear absorber upwards or downwards for check.

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

Suspend the rear wheel and check shimmy.

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

Bolt/ Nut/Fastener

Check whether each bolt, nut and fastener is loose.

If yes, tighten it to required torque.

上下压缩

上下压缩

- 40 -

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

RK6 Front 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:

Do not attempt to repair the damaged tyre.

The balance and reliability of the tyre is likely to

worsen.

Improper tyre inflation will lead to abnormal

abrasion of the tyre and threat the safety. And

insufficient inflation will cause tyre slip, or

disengage the tyre, or lead to the deflation of tyre

which is out of control. It is dangerous to drive

with excessively abraded tires, and it is adverse to

the adhesion or driving.

轮胎气压表：barometer of the tyre

Check whether the locking nut of the front wheel spindle is loose.

Check whether the fixing nut of the rear wheel is loose.

Tighten it to the required torque value if it is loose.

Torque value: fixing the front wheel spindle 55-62 N·m

fixing nut of the rear wheel spindle 85-108 N·m

- 41 -

Fixing Steering Stem Bearing and Handlebar

Move the handlebar to confirm there is no wire interference.

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

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

Throttle Body

The idle speed of the motorcycle will be reduced to some

extent due to the pollution of the throttle body. It is better to

clean it after every 5000 kilometer’s drive.

When cleaning, disconnect the negative pole of the battery,

connectors of the sensor installed on the throttle; and

remove the throttle cable, hose connected to the air filter

and the intake manifold, and the throttle body.

Open the lid on the bottom of the throttle body, spray

cleanser to its in-wall and brush the dust and carbon

deposition, etc.

After cleaning, operate in reverse order, install the throttle

and make sure that all parts are in place, and try to start the

engine successfully.

Note:

Do not let impurities block the parichnos nearby.

- 42 -

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

- 43 -

Inspection and Maintenance of the Electrical System

充电系统

充电系统： charging system

- 44 -

1. Battery/Charging System

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

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

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

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

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

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

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

1.1 Preparing Documents

Work Instructions

*Note

1. Battery can be charged or discharged repeatedly. If it is placed after discharge, its service life will be

shortened and performance is undermined. Normally, the battery performance will be degraded after two or

three years. As for battery of degraded performance (reduced capacity), whose voltage will recover temporarily

after charging but decrease sharply when loading.

2. Battery overcharge: normally, overcharge can be judged upon the battery. In the case of short circuit inside

the battery, its terminal is unable to detect voltage or the detected voltage is very low. Regulator failure: over

voltage inside the battery will shorten its service life.

3. The battery will be self-discharged if being stored for a long time, which reduces its capacity. It shall be

charged about every three months.

4. Check the charging system following the sequence listed on the failure diagnosis table.

5. Do not remove the connector when there is current through electrical parts, otherwise it will cause over

voltage and damage to electrical parts inside the voltage regulator. Please operate it after the main switch turns

off.

6. It is unnecessary to check the maintenance-free battery and add electrolyte and distilled water.

7. Check all electric loads.

8. Emergency charging can only be used under emergency situation.

9. Remove the battery from the motorcycle for emergency charging.

10. Do not use electrolyte-added batteries when interchanging batteries.

11. Use a voltmeter to check charging condition of the battery.

- 45 -


Item Specifications

Battery

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

Voltage

（20℃）

Fully charged 13.1V

Necessary

charging 12.3V(not working for 1h)

Charging current Standard: 0.8A, quick:8A

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

Magnetor Impedance of the coil

（20℃） Between white-white 1.5-3.5Ω

Voltage

regulator

Type Three-phase full wave

Charging voltage of the

battery 14.5±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

1.2 Failure Diagnosis

Power Supply Dead Interrupted Current

Battery over-discharge Poor contact of the charging wire

Unconnected battery wiring Poor contact of the charging system

Fuse blow Poor contact or short circuit of the lighting system

Poor switch

Low Voltage Poor Charging System

Poor battery charging Poor contact, short circuit or open circuit of wire terminals

Poor contact Poor voltage/current regulator

Poor charging system Poor magnetor

Poor voltage/current regulator

- 46 -

1.3 Battery

1.3.1 Battery Disassembly

As for details, please see page 31.

电瓶位置：battery position

Warning!

When the positive wire is disassembled, do not

make the tool contact with the frame. Otherwise, it

may cause short-circuit spark, which may ignite

gasoline and damage the battery. It is dangerous.


*Note

To prevent short circuit, connect the positive wire

first and then the negative wire.

Check the charging condition (closed circuit voltage).

Remove the seat.

Remove cables of the battery.

Test the voltage between battery terminals.

Fully charged: 13.1V

Insufficient charging: 12.3V (not working for 1

hour)

* Note

Use a voltmeter to check the charging condition.

1.3.2 Charging

Connection method: connect the positive pole of the charger with the positive pole of the battery;

connect the negative pole of the charger with the negative pole of the battery.

Warning!

• The battery should be far away from fire source.

• Turn off the charger before or after charging to

avoid explosive danger caused by spark which

may exist in any connection.

• Comply with the current and time requirements

for charging as stated on the battery.

- 47 -

*Note

• Except emergencies, you should not use

emergency charging.

• Measure voltage in 30 minutes after the battery

is charged.

Charging current: standard: 0.8A

quick: 8.0A

Charging time: standard: 10-15 hours

quick: 30 mins

Charging completed: open circuit voltage: above 12.8V

1.4 Charging System

1.4.1 Short-circuit Test

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

Turn off the switch. Check the short-circuit.

*Note

Connect the positive terminal of the multimeter

with the negative terminal of the battery.

Check whether there is short-circuit in the main switch or in the main wire in the case of any abnormality.

1.4.2 Charging Check

Use a multimeter to check the charging status of the battery when it is being fully charged.

Install the fully charged battery after the engine warms up.

Connect a voltmeter between terminals.

Remove the main fuse and connect an ammeter between terminals.

Start the engine and increase its speed gradually to measure the limiting voltage and current.

Limiting voltage/speed: 14-15V （5.000rpm）

Check the voltage regulator if the limiting voltage is not within its required range.

Check the limiting voltage of the lighting system.

Remove the seat.

*Note

Set the multimeter to the AC voltage position.

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

Check the voltage/current regulator if the limiting voltage is not within its required range.

- 48 -

1.5 Voltage/Current Regulator

1.5.1 Main Wiring Check

Remove the shield of the body.

Remove 4p plug of the voltage/current regulator.

Check conductivity between main wiring terminals.

Item (wire color) Judgment

Between Battery(red) and

GND of the body

With battery

voltage

Between GND wire (black)

and GND of the body With 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,

otherwise it indicates the damage of the voltage regulator and replacement is needed.

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

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

otherwise it indicates the damage of the voltage regulator and replacement is needed.

*Note

• Do not touch any metal part of the test rod of the

multimeter with your finger for check.

• Check with multimeter. Different multimeters

show different impedance and different results.

Replace the voltage-current regulator when the impedance between terminals is abnormal.

1.6 Magnetor Charging Coil

*Note

Check the magnetor charging coil on the engine.

Check

Remove the 6p connector of the magnetor.

Measure the impedance between the three white terminals of the magnetor with the multimeter.

Standard: 1.5-3.5Ω（20℃）

Replace the magnetor coil when the measured value exceeds the standard value.

白白白

Ω

- 49 -

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.

Loosen the four fixing bolts of the magnetic coil,

and remove the magnetic coil.

Bolt

Left cover and

the magnetic coil

Bolt

Bolt

- 50 -

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.

Clean up the crankshaft and the taper part of the flywheel.

Install the solid key into the groove above the upper crankshaft key and confirm it.

Aim the groove in the flywheel at the solid key on the shaft.

* Note

Ensure there is no any bolt in the inner magnetic

side of the flywheel.

Fix the flywheel with the universal spanner and tighten fixing nuts.

Torque force: 9.0 N·m

Locking nut of

the flywheel

- 51 -

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

电源

触发头

电源：power, 触发头：trigger, 点火系统：ignition system

黑：black, 白：white, 红：red, 橙：orange, 绿：green, 蓝：blue

- 52 -

2. Ignition System

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

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

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

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

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

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


Work Instructions 1. Check the ignition system following the sequence listed in the table of failure diagnosis.

2. This ignition system is an electronically and automatically angling device. It is solidified in the ECU group

and you don’t have to adjust the ignition time.

3. Check the ignition system following the sequence listed in the table of failure diagnosis.

4. Do not make ECU of the ignition system fall down or hang down or hammer it with strong force (primary

causes for failure). Pay special attention during disassembly.

5. Failure of the ignition system is mostly caused by poor contact of the socket. Check whether each connector

is in good condition.

6. Check whether the heat value used for the spark plug is proper. If not, the engine may work abnormally or

the spark plug may be burnt.

7. Check in this chapter is based on the maximum voltage. It also refers to check on the impedance of the

ignition coil.

8. Check the main switch according to the conduction table.

9. Remove the magnetor and the stator according to instructions.


Item Standard value

Spark plug

recommended Standard CR9E(NGK)

Spark plug gap 0.6-0.7mm

Ignition coil

impedance（20℃） Primary coil 650±50mΩ

Impedance of trigger（20℃） 100-300Ω

Measure the maximum primary voltage of the ignition coil 14V

Trigger voltage Above 1.7V

Tools

Attachments to the Maximum Voltage Table

Multimeter

- 53 -


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 item ①-⑦ is checked to

be abnormal or there is no spark for spark plug.)

Normal high voltage, but no spark

①Poor spark plug or secondary leakage of the

ignition coil.

②Poor ignition coil.

Charging

coil

No high voltage






measurements.)

④Poor charging coil (Item ①-③ is checked to be

normal.)

No or interrupted high voltage ①Poor ignition coil.

②Poor charging coil.

Trigger

Too low high-voltage






measurements.)

④Poor trigger (Item ①-③ is checked to be

normal.)

No or interrupted high voltage ①Poor ignition coil.

②Poor trigger.

- 54 -

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.

Connect the lead of the ignition coil and also the shunt

between the primary coil terminal (black/red) and the GND.

Press the startup motor or step the actuating lever to

measure the maximum primary voltage of the ignition coil.

Minimum voltage: above 95V

*Note

Never touch any metal part of the test rod with

your finger to avoid electric shock.

高压分流器

万用表

- 55 -

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 and

the 18 connector (white/green terminal).

Press the startup motor or step the actuating lever to measure

the maximum voltage of the charging coil.

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

Minimum voltage: above 95V

*Note

Never touch any metal part of the test rod with

your finger to avoid electric shock.

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

body and the magnetor terminal.

• If the voltage of ECU is measured to be abnormal while the voltage at the magnetor terminal is normal, it is

caused by poor contact or disconnected wiring.

• If the voltage at both ECU and magnetor terminal appears to be abnormal, it is caused by poor charging coil.

Please refer to charging coil check.

2.4 ECU Group

2.4.1 System Check

Check the system.

Remove the ECU Group, and check components

of the ignition system at the terminal.

- 56 -

2.5 Ignition Coil

2.5.1 Disassembly

Remove the body.

Remove the spark plug cap.

Remove the primary lead of the ignition coil.

Remove the fixing bolts and then the ignition coil.

Install the ignition coil in reverse order.

*Note

Install the primary coil with black/red

terminal.

2.5.2 Check the Primary Coil

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

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

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

2.6 Sensor of the Crankshaft

*Note

Check the trigger on the engine.

Check

Remove the shield of the body.

Remove the trigger terminal.

Measure the impedance between the blue/white terminal of

the side wire of the engine and the body GND.

Standard: 100-300Ω（20℃）

Replace the magnetor if the measured value exceeds the

standard value.

- 57 -

启动示意图：Startup Schematic Diagram

启动示意图

BATTERY

G/Y

G/Y

M

- 58 -

3. Startup System

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

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

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

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

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


Work Instructions

Disassemble the startup motor on the engine.

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


Item Standard Limit for use

Length of the brush of the

startup motor 12.5mm 8.5mm

Bushing of the startup idler

shaft 8.3mm

Outer diameter of the startup

idler shaft 7.94mm

Tightening torque force

Bolts for the clutch cover of the startup motor 12 N·m

Retaining nut for the clutch of the startup motor 95 N·m

Tools

Spanner for retaining nuts

Universal fixing spanner

- 59 -


Startup failure Weak in rotation No rotation of RE rotary engine

of the startup motor of the startup motor

• Fuse blow • Low battery • Poor startup clutch

• Low battery • Poor wiring contact • Reversal rotation of the startup motor

• Poor main switch • Gear seized • Low battery

• Poor startup clutch

• Poor brake switch

• Poor starter relay

• Poor wiring contact

• Poor startup motor

3.3 Startup Motor

3.3.1 Disassembly

Loosen the two fixing bolts of the startup motor,

and remove the motor.

* Note

Before the startup motor is disassembled, turn off the

main switch, remove the GND wire of the battery, and

then power on to check whether the startup motor

works for ensuring safety.

Bolt

Startup motor

- 60 -

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.

Clean the commutator surface if there is metal power attached to it.

Check conduction between the surfaces of other components.

Ensure non-conduction between armature shafts of the commutator.

Check the conduction of the shell of the startup motor.

Ensure non-conduction between the conduction terminal and the startup motor shell.

Check conduction between the conduction terminal and the brush.

Replace any abnormal part.

Check conduction of the brush bracket. Replace it when there is conduction.

Measure the length of the brush.

Limit for use: replace it if lower than 8.5mm

Check smooth rotation of the needle bearing inside the front cover and whether it is loose when press-in.

Replace it if there is any abnormality.

Check whether the oil seal is abraded or damaged.

碳刷：carbon brush

碳刷

- 61 -

3.3.4 Assembly

Lubricate the oil seal inside the front cover with grease.

Install the brush on the bracket.

Lubricate moving parts at two ends of the brush shaft

with grease.

Press each brush into the bracket,

* Note

• Pay special attention that the contact surface between

the brush and the armature shall not be damaged.

• Pay attention that the armature shaft shall not damage

lips of the oil seal.

and install the back cover of the electric machine.

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

Lock screws in the shell.

* Note

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

easy to pull the front cover with magnet to attract the

armature. Press it gently for assembly.

3.3.5 Installation

Install the lead of the startup motor and the dustproof boot.

And then install the startup motor.

Install the wire clip for rear brake.

3.4 Starter Relay

3.4.1 Check

When the main switch is “on”, check there is “click” sound at

the time of pressing the startup motor.

With click sound, it is normal.

Without click sound: • check voltage of the starter relay;

• check the GND loop of the starter relay;

• check the movement of the starter relay.

启动继电器：starter relay

- 62 -

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.

3.4.4 Check

Connect the starter relay to the battery, and the

terminal of the startup motor to the multimeter.

Connect the fully charged battery between the black

wire and the green/yellow wire of the relay. The relay

shall sound “click” and the multimeter shall indicate

resistance of “zero”.

Ω

Ω

- 63 -

4. Bulbs/ Switches / Meters

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

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

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

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

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

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

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

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

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

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

Horn ---------------------------------------------------------------------------------4.11

Handlebar Switch -----------------------------------------------------------------4.12


Work Instructions

Remove the switch from the vehicle to measure its condition.

All plastic connectors have clamping jaws,

lift the clamping jaws and clamps before disassembly,

and make sure that the clamping holes aim at the clamping jaws when installing.

When looking up for electric faults,

check the continuity of the circuit passing through the electronic devices.

The state of the battery must be confirmed before carrying out any inspection,

including the voltage, to confirm that whether it is normal or not.

- 64 -


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

• Poor bulbs.

• Poor switch.

• Bad contact or broken wires

• Weak battery power or no voltage.

4.3 Replacement of Headlamp Bulbs

Remove the two fixing bolts① of the headlamp at

the bottom left and bottom right of the meter.

Lower the headlamp forward, you can see the back

of the headlamp, and remove its dustproof cover②.

- 65 -

The figure below shows the bulb of the dipped

headlight③, and the bulb of the headlight on full

beam④, remove the power cord socket, bulb snap,

fixing bolts and the bulb snap buckle of the dipped

headlight and the headlight on full beam that need to

be replaced, and finally remove the damaged bulb.

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

new one of the same specification.

*Note

Keep combustible materials and your hands a distance

away from the bulb when it is light. Because the bulb

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

down before touching it.

Install the bulb in reverse order.

During the installation, avoid direct touch with the

glass of the bulb, 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

The front position lamp and the headlamp are in one

lamp body, as shown in the figure, there is a front

position lamp bulb① on the right and left sides.

(1) Operate according to the prompts of the above

chapter—Replacement of the Headlamp Bulbs.

(2) Remove the damaged bulb, and replace on a new

one of the same specification.

(3) Install the bulb in reverse order.

- 66 -

4.5 Replacement of Tail Lamp

The illuminant of the tail lamp is LED, replace the whole

lamp if necessary.

(1) Remove the passenger’s seat and the driver’s.

(2) Remove the tow fixing nuts① of the tail-hood shield,

and then move it horizontally backward to take it

down.

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

combination.

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

combination.

(5) Remove the cable of the rear lamp combination, take

off the damaged lamp, and replace on a new one of

the same specification.

(6) Install the lamp in reverse order.

- 67 -

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.


- 68 -

4.7 Replacement of Front Steering Lamp Bulbs

The illuminant of the front steering lamp is LED,

replace the whole lamp if necessary.

(1) Operate according to the prompts of the above

chapter—Replacement of the Headlamp Bulbs.

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

steering lamp.

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

same specification.


4.8 Replacement of Rear Steering Lamp Bulbs

The illuminant of the rear steering lamp is LED, replace

the whole lamp if necessary.

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

steering lamp from the back of bracket of the rear

registration plate.

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

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


4.9 Meters

Remove the rearview mirror;

Remove the handle cover, and unplug the connectors.

Remove the nuts the meter.

Install the meter in reverse order.

- 69 -

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.

4.11 Horn

Check

Remove horn wires.

It shows good when the horn wire is connected to the battery.

- 70 -

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

接线原理图：Schematic diagram of wiring

大灯开关：headlamp switch

启动按钮：start button

兰：blue

黄/红：yellow/red

浅兰：light blue

黑：black

棕：grey

红/白：red/white

棕/白：grey/white

绿：green

白：white

- 71 -

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

Fixing bolt of the rear swinging arm axle M14

Front wheel spindle M16

Fixing nut of the rear wheel spindle M24

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

70-105

100-140

130-150

- 72 -

Front Disc Brake

1. handlebar assembly of the front brake disc 2.handlebar screw 3.fixing cover 4.bolt M6×23 5.hexagon

flange screw 6.brake switch 7.screw M4×12 8.nut M6 9.brake hose assembly 10.11. bleed nipple

12.mounting bolt of the oil tube 13.gasket 14.bolt M10×1.25×55 15.front left brake cylinder assembly

16.brake shoes 17.bolt M8×16 18.D.320front brake disc 19.front right brake cylinder assembly

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

C Thickness of the brake shoes:7.8mm

Limit for use:3.8mm

D Torque for mounting bolt 4 in the

figure:5-10N·m

E Torque for mounting bolt 5 in the

figure:30-35N·m

F

Torque for mounting bolt 11 in the

figure:

5-7N·m

G Torque for mounting bolt 12 in the

figure:30-35N·m

H Torque for mounting bolt 14 in the

figure:37-55N·m

I Torque for mounting bolt 17 in the

figure:22-34N·m

- 73 -

Rear Disc Brake

1.pin 2.joint M6 3.cotter 4.nut M6 5.pushrod 6.rear fuel pump assembly 7.gasket 8.rear brake

indicator 9.rear brake hose assembly 10.mounting bolt of the oil tube 11.rear brake cylinder assembly

12.brake shoes 13.rear disc brake 14.screw M6×20 15.bolt M8×1.25×20

A Dia of the rear disc brake: 240mm

B Thickness of the rear disc brake: 5.0mm


C Thickness of the brake shoes: 7.0mm


D Torque for mounting bolt 15 in the

figure:30-35N·m: 22-34 N·m

E Torque for mounting bolt 14 in the

figure:30-35N·m: 5-10 N·m

F Torque for mounting bolt 10 in the

figure:30-35N·m: 30-35 N·m

G Torque for mounting bolt 8 in the

figure:30-35N·m: 30-35 N·m

- 74 -

5. Brake

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

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

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

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

5.1 Maintenance Instruction

Work Instructions

*Note

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

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

Check the brake system through the brake lever and pedals.

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

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

oil cup, and the first thing you should do is to make sure that the liquid in the

cup is aclinic.

Never let the earth, water or other dirt into an open cup.

Use the DOT4 brake liquid taken out from a sealed container when doing

maintenance, and do not mix it with other type of liquid, since they can not

coexist.

* Check the brake before riding.*

5.1.1Specification

Item Standard Limit for use Item Standard Limit for use

Front

Special brake liquid DOT4 -

Rear

Special brake liquid DOT4 -

Thickness of the left/right

brake disc 4.0mm 3.6mm Thickness of the brake disc 5.0mm 4.5mm

Thickness of the left/right

brake shoe 7.8mm 3.8mm Thickness of the brake shoe 7.0mm 3.7mm

Dia. of the left/right brake disc Φ320mm - Dia. of the brake disc Φ240mm -

The jump of the brake surface

of the left/right brake disc 0.1mm -

The jump of the brake

surface of the brake disc 0.1mm -

I.D. of the pump oil cylinder Φ16+0.043

0 mm - I.D. of the pump oil cylinder Φ11+0.027

0 mm -

O.D. of the oil-pumping

piston Φ16

-0.032

-0.059 mm - O.D. of the oil-pumping

piston Φ11

-0.032

-0.059 mm -

I.D. of the caliper cylinder Φ34+0.08

+0.03 mm - I.D. of the caliper cylinder Φ32+0.08

+0.03 mm -

O.D. of the caliper piston 32-0.032

-0.065 mm - O.D. of the caliper piston Φ32-0.032

-0.065 mm -

- 75 -

5.1.2 Torque Force

Fixing the front wheel spindle 100-140N·m

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

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

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

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


5.2.1 Poor Brake Performance

1. Improper adjustment of the brake

2. Abraded brake shoes assembly or disc brake

3. Improper installation of the brake shoes assembly

4. Stained brake shoes assembly or disc brake

5.2.2 Slow Reaction or Tight Lever

1. Improper adjustment of the brake

2. Abraded brake shoes assembly or disc brake

3. Improper installation of the brake shoes assembly

5.2.3 Abnormal Noise

1． Abraded brake shoes assembly or disc brake

2． Stained brake shoes assembly or disc brake

5.2.4 Soft or Flossy Brake Lever/Pedal

1. Air in the hydraulic system

2. Leakage of the hydraulic system

3. Stained brake pedal/disc

4. Abraded seal of the caliper piston

5. Abraded brake pedal/disc

6. Stained caliper

7. Abnormal slip of the caliper

8. Insufficient brake liquid

9. Blocked brake liquid channel

10. Bended/fragmentary caliper piston

11. Bended/fragmentary piston of the main cylinder

12. Stained piston of the main cylinder

13. Bending braking lever/pedal

5.2.5 Brake Stuck or Pulled to One Side

1． Stained brake pedal/disc

2． Wheel deviation

- 76 -

3． Blocked or limited joint of the brake hose

4． Bending/fragmentary brake disc

5． Abnormal slip of the caliper

5.2.6 Brake Resistance

1． Strained brake pedal/disc

2． Wheel deviation

3． Abraded brake pedal/disc

4． Bending/fragmentary brake pedal/disc


5.2.7 Stiff Brake Lever/Pedal

1． Blocked/limited brake system

2． Sticked/abraded caliper piston


4． Blocked/limited brake liquid channel

5． Abraded sealing gasket of the caliper piston

6． Sticked/abraded piston of the main cylinder

7． Bending brake lever/pedal

5.3 Front Disc Brake

5.3.1 Disassembly

*Note

Replace the brake shoes assembly.

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

Remove following assemblies from the right grip and the front absorber.

Front brake:

1. brake handle

2. fuel pump assembly

3. brake hose assembly

4. left/right brake cylinder assembly

5. left/right brake disc

*Note

Do not stain the brake assembly with oil spots during

installation or disassembly.

Clean it with required cleaning agent to maintain the brake performance.

Nut of the rearview

mirror

Fixing screw of the fuel pump

- 77 -

Loosen the fixing screws of the brake cylinder assembly.

Remove the brake cylinder assembly from the front absorber.

Fixing screw of the handle

Fixing bolt of the brake hose

Brake hose

Bleed nipple


Right brake cylinder assembly

Fixing bolt of the brake cylinder

Bleed nipple


Left brake cylinder assembly

Fixing bolt of the brake

cylinder

- 78 -

Remove the front wheel spindle.

Remove the front wheel.

Remove the disc brake off the front rim.

前轮：front wheel

前轮轴：front wheel spindle

前左液刹：front left disc brake

固定螺钉：fixing screws

5.3.2 Check

Check whether the brake shoes assembly and the brake

disc are abraded. Replace brake shoes if necessary.

Measure the brake shoes and the brake disc. Record

maximum values.

Specification

Diameter of the front brake disc Φ320mm

Thickness of the front brake disc 4.0mm

*Note

Measure them with micrometer.

- 79 -

Measure the thickness of the brake shoes.

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

below the required value for maintenance or it is stained

with grease, please replace it.

Limit for use: brake shoe 3.8mm

brake disc 3.6mm

Note:

Replace brake shoes in pair.

5.3.3 Installation

Install the brake disc and the front wheel.

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

Do not stain shoes and the brake disc with grease.

* Note

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

Tighten bolts and nuts to the required torque force.

Torque force:

Fixing the front wheel spindle 120N·m

The bolt of the brake disc 28N·m

The fixing bolt of the fuel pump assembly 8N·m

Mounting bolt of the front brake cylinder assembly 50N·m

Do not stain the brake shoes with oil spots.

Use brake cleaning agent to clean brake shoes with oil spots.

*Note

Any grease on brake shoes will reduce the brake performance.

*Note

• Do not stain the brake assembly with oil spots during installation or disassembly.

• Clean it with required cleaning agent to maintain the brake performance.

- 80 -

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.

Loosen the fixing screws of the oil pump assembly.

Remove the oil pump cylinder.

Fixing screws

Right pedal cover

plate

Fixing screws

Fuel pump

assembly

- 81 -


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

固定螺钉：fixing screw

后轮轴：rear wheel spindle

5.4.2 Check

Check whether the brake shoes assembly and the brake

disc are abraded. Replace brake shoes if necessary.

Measure the brake shoes and the brake disc. Record

maximum values.

Specification

Diameter of the rear brake disc Φ240mm

Thickness of the rear brake disc 5.0mm

*Note

• Measure with micrometer.

Fixing bolt

Rear brake hose

Fixing screw

Brake cylinder

assembly

- 82 -

Measure the thickness of the brake shoes.

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

below the required value for maintenance or it is

stained with grease, please replace it.

Limit for use: brake shoe 3.7mm

brake disc 4.5mm

Note:

Replace brake shoes in pair.

5.4.3 Installation

Install the rear brake disc. Install the rear wheel.

Install the brake cylinder.

* Note

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

Tighten bolts and nuts to the required torque force.

Torque force:

Fixing the rear wheel spindle 120N·m

The bolt of the brake disc 28N·m

The fixing bolt of the fuel pump assembly 8N·m

Mounting bolt of the rear brake cylinder assembly 50N·m

Do not stain the brake shoes with oil spots.

Use brake cleaning agent to clean brake shoes with oil spots.

*Note

• Do not stain the brake assembly with oil spots during installation or disassembly.

• Clean it with required cleaning agent to maintain the brake performance.

- 83 -

Body

1. right air deflector mounting plate 2. windshield 3. left air deflector mounting plate 4. 5. right front shield 6.

right shield of the tank 7 bottom right shield 8. right shield 9. trim-cover of the right muffler 10. decorative

cover of the right muffler 11. back seat assembly 12. right rear handrail 13. left rear handrail 14. 16. left

assembly of the rear fender 17. right assembly of the rear fender 18. left shield 19. battery box 20. bottom left

shield 21. front seat assembly 22. middle shield of the tank 23. left shield of the tank 24. left front shield 25.

front shield of the tank 26.connecting board of the left/right shield

*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.

- 84 -

6. Body

6.1 Disassembly

Disassemble in the following order:

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

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

middle shield of the tank → tank assembly

↓

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

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

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

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

of the left muffler → barrel assembly of the muffler → rear fender assembly →

battery box

↓

mounting frame assembly of the headlamp → windshield → left air deflector

mounting plate → right air deflector mounting plate → headlamp

*Note

Do not damage any body part during disassembly.

Do not damage any hook or claw in the body during disassembly.

6.2 Assembly

Assembly in reverse order.

*Note

Aim panels in the body at each corresponding groove.

Ensure correct installation of each hook or claw part during assembly.

Do no damage any part during assembly.

- 85 -

Front Suspension

1. front wheel spindle 2. bolt M5×0.8×14 3. screw M6×15.2 .4. front right absorber assembly 5. bolt

M6×20 6. screw M5×0.8×12 7. bolt M6×1×14 8. suspension bush 9. mounting base under the

headlamp 10. spacer bush 11. screw M6×1×16 12. mounting base above the headlamp 13. bolt

M8×1.25×25 14. upper connecting board 15. upper base of the steering handlebar 16. bolt M8×1.25×25

17. locking screw of the inner hexagon flat end M4×6 18. pin 19. column 20. fixing screw of the upper

connecting board 21. nut 22. locking nut of the upper connecting board 23. steering bearing 24. screw

M6×8 25. fixing wire clip of the front brake tube 26. bottom connecting board 27 front left absorber

assembly 28. bolt M6×30 29. left spacer bush of the front wheel

A

Torque for mounting the fixing bolt 20 of the steering column in the figure: 50-70N·m

B

Torque for mounting the fixing bolt 16 of the upper base of the steering handlebar in the figure: 22-34N·m

C

Torque for mounting the fixing bolt 13 of the upper connecting board in the figure: 22-34N·m

D

Torque for mounting the fixing bolt 5 of the front absorber in the figure: 5-10N·m

E Torque for mounting the front wheel spindle 1 in the figure: 100-140N·m

F

Torque for mounting the locking bolt 28 of the head of the front wheel spindle in the figure: 5-10N·m

- 86 -

Handlebar

1. balance piece assembly 2. throttle lever 3. mounting base of the balance piece 4. front cover of the throttle

cable 5. screw 6. right switch group 7. handlebar 8. left switch group 9. cover of the left handlebar 10.

handle combination of the clutch 11. clutch cable assembly 12. throttle cable assembly I 13. throttle cable

assembly II

- 87 -

Front Wheel

1. bolt M8×16 2. front brake disc 3. bearing 6005-2RS/1-C3 4. middle spacer bush of the front wheel 5. front

rim 6. vacuum tyre 120/70 ZR17 7. front brake disc 8. valve

A Tyre size: front tyre: 120/70

ZR17

B Pressure of the front tyre:

250±10kpa

C Minimum non-skid depth:

1.6mm

D

Rim run-out limit:

Vertically: 2.0mm

Horizontally: 2.0mm

E Torque for mounting the bolt 1

of the brake disc: 22-34N·m

- 88 -

7. Front Wheel/Handlebar/Front Suspension

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

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

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

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

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


Work Instructions

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

which shall not be reversely rotated.

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

A stained brake disc or brake shoe will reduce brake force, so discard stained gasket and clean the brake disc

with quality brake degreaser.

Motorcycle Standards

Measurement points Item Standard

(mm) Limit for use (mm)

Front wheel spindle Bending 0.2

Front wheel Rim

shimmy

Vertically 2.0

Horizontally Within 1.0 2.0

Torque Force Tools

Fixing bolt of the upper connecting board assembly 22-34N·m Bearing puller Fixing the front wheel spindle 100-140N·m Locking nut spanner

Locking screw of the head of the front wheel spindle 5-10N·m

Fixing screw of the front absorber 5-10N·m

Fixing bolt of the steering column 50-70N·m

Assembling bolt of the front brake cylinder 37-55N·m

- 89 -


7.2.1 Difficulty in Steering

Failure or damage of the steering handlebar.

Damaged bearing of the handlebar.

Too tight of the adjusting bolt of the faucet bearing.

Insufficient tyre pressure.

7.2.2 Unsteady Steering

Damaged steering handlebar.

Insufficient tyre pressure.

Bending of the front fork or the front wheel spindle.

Deformed or unbalanced front tyre.

7.2.3 Front Tyre Shimmy

Deformed rim.

Abraded front wheel bearing.

Flawed front tyre.

Unbalanced tyre or wheel.

7.2.4 Difficulty in Wheel Rolling

Failure in the front wheel spindle bearing.

Braking fault of the brake.

Failure in the front wheel spindle.

Bending of the front wheel.

7.2.5 Abnormal Noise of the Front Absorber

Insufficient liquid in the absorber.

Fricative sound of the absorber guard.

Loose bolts in the absorber.

7.2.6 Operation Only Available in One Side or Move in Curve

Unbalanced adjustment of the left and right forks

Bending absorber

Bending wheel

Incorrect installation of the wheel

Bending frame

Broken wheel bearing

Broken central axis of the swinging arm

7.2.7 Soft Front Absorber

Insufficient liquid in the absorber

The spring of the absorber is not firm.

Too low of the tyre pressure

- 90 -

7.2.8 Too Stiff of the Front Absorber

Improper weight of the liquid

Blocked pathway of the liquid in the absorber

7.3 Front Wheel

7.3.1 Disassembly

Note:

Support the motorcycle firmly.

Support the motorcycle with a safety frame or firm crane.

Disassemble the front fender, and loosen the fixing screws①②.

Disassemble the braking caliper of the front disc brake.


Remove the brake cylinder assembly off the front absorber.

Bleed nipple

Fixing bolt of the bake hose


Fixing bolt of the brake

cylinder

- 91 -

Remove the clamping screw① of the front wheel spindle

(right front absorber)

Disassemble the front wheel spindle①

Bleed nipple

Fixing bolt of the bake hose


Fixing bolt of the brake cylinder

- 92 -

Disassemble the front wheel assembly①

Remove the left spindle sleeve of the front wheel②

Disassemble the bearing with the bearing remover.

Note:

Do not operate the brake controlling lever after the removal of the brake caliper.

- 93 -

7.3.2 Check

7.3.2.1 Check the Bending of the Wheel Spindle

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

eccentricity ratio with a dial indicator.

Limit for use: replacement when beyond 0.2mm

车轴：axle

7.3.2.2 Check the Rim Shimmy

Place the rim on a precision bracket

and check the rim shimmy.

Rotate the wheel by manual and read indication.

Limit for use:

Vertically: replacement when beyond 2.0mm

Horizontally: replacement when beyond 2.0mm

Balance of the wheel：

Warning：

The balance of the wheel directly affects the stability,

operation and safety of the motorcycle. Check the stability of

the wheel when it is removed.

Note:

In order to keep balance, mark on the tyre near the bleed

nipple by drawing a dot at the rim. Assemble the tyre when

necessary.

7.3.2.3 Balance of the Front Wheel

Note:

Paste marks of the rotating direction on wheels and tires.

Remove the dust-proof sealing ring off wheels;

Install the wheels, tires and brake disc assembly at the Checkpoints;

Stop the rotating wheels, and mark the lowest (highest) point with the chalk.

Verify the most important sector in this way for 2 or 3 times.

If the wheel is in balance, it will not stop at one point.

In order to keep the wheel in balance, put on weight to it at the higher side of the rim, and mark with the chalk

at the other side. Add enough weight to the wheel when it is on rotation until it does not stop at one point.

Do not add weight above 60g to the wheel.

- 94 -

7.3.2.4 Check the front wheel bearing

Remove the bearing①, and the middle sleeve of

the front wheel②.

Check the rolling of the bearings.

Replace it if the bearing does not roll, or the

rolling is unsmooth or unstable, or the it is abraded

or loose.

7.3.3 Bearing Replacement

Remove the front wheel spindle, front wheel, left

spindle sleeve and the middle spindle sleeve. Then

remove the oil seal and the bearing respectively with

the oil seal remover and the bearing puller.

Note:

Replace dismantled bearings with new ones.

Lubricate the bearings with grease during installation.

Then press the bearings in with bearing installation

tools.

*Note

• Bearings must be pressed in horizontally.

游隙 clearance 轴向 axially 径向 radial

7.3.4 Installation


Note:

Lubricate the front wheel spindle, left spindle sleeve of the front wheel, bearing 6005-2RS/1-C3, and the

middle spindle sleeve.

Albany grease is suggested.

When tighten the front wheel and the caliper assembly of the disc brake, make sure that the brake disc is

between the brake pads.

The free stroke of the front brake lever can not be adjusted.

*Note

Torque of fixing the front wheel spindle: 100-140N·m

- 95 -

7.4 Steering Handlebar

7.4.1 Disassembly

Remove the left/right rearview mirror assembly.

Remove the oil pump assembly of the front brake.

Remove the right switch group.

Remove the mounting base assembly of the throttle

cable.

Right rearview mirror

Left rearview mirror

Mounting base assembly of the throttle

cable

Oil pump assembly

Fixing screw

Right switch group

Fixing screw

- 96 -

Remove the left handle assembly.

Remove the left switch group.

Remove the balance block assembly①.

Remove the right handle assembly②.

Remove the balance block③.

Remove the fixing bolts② of the upper base of the

steering handlebar.

Turn the upper base① of the steering handlebar.

Remove the tube of the handlebar.

7.4.2 Installation

Install in reverse order.

Note:

Fixing screw of the upper base of the steering handlebar

Torque: 22-34N·m

Left switch group

Left handle

assembly

Fixing screw

- 97 -

7.5 Front Fork

7.5.1 Disassembly

Support well the middle bracket of the motorcycle.

Disassemble the front wheel.

Disassemble the brake caliper and the brake pipe clamp.

Remove the steering handlebar.

Remove the pillar bolt①.

Remove the meter and the meter bracket.

Loosen the fixing bolts① of the upper connecting

board.

Remove the upper connecting board②.

Remove the headlamp and its bracket.

Loosen the clamping bolts① of the upper

connecting board.

Remove the front absorber.

- 98 -

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

- 99 -

Rear Wheel/Rear Suspension

1. rear wheel spindle 2. screw M6×20 3. right spacer bush of the rear wheel 4. DIA.240 disc brake 5.

bearing 6006-2RS1-3C 6. spacer bush of the rear wheel 7. valve 8. rear rim 9. vacuum tyre 180/55 ZR17 1.

bearing 6006-2RS1-3C 11. buffer bushing 12. left spindle sleeve of the rear wheel 13. bearing 30×62×23.8

14. spindle sleeve of the sprocket wheel 15. fixing bolt of the sprocket wheel 16. sprocket wheel rim 17.

sprocket wheel 18. retaining ring Φ62 19. self-locking bolt M10×1.25 20. self-locking bolt M24×1.5

A Tyre size: rear tyre: 180/55 ZR

17

B Pressure of the rear tyre:

290±10kpa

C Minimum non-skid depth:

2.0mm

D

Rim run-out limit:

Vertically: 2.0mm

Horizontally: 2.0mm

E Torque for mounting the bolt 2 in

the figure: 5-10N·m

F Torque for mounting nut 19 in the

figure: 37-55N·m

G Torque for mounting nut 20 in the

figure: 130-150N·m

- 100 -

Rear Suspension/Rear Absorber

1. screw 2. mounting sleeve of the rear swinging arm 3. rolling bearing 61905-2RS 4. straight pin 4×8 5.

middle spacer bush 6. mounting sleeve of the rear swinging arm 7. sleeve 8. rear absorber assembly 9.

mounting gasket of the rear absorber 10. fixing spindle of the rear absorber 11. nut M10×1.25 12. supporting

board of the brake clamp 13. rear chain cover 14 bolt M6×8 15. bolt M6×1×14 16. chain protecting block 17

bolt M6×1×14 18 front chain cover 19 bolt M6×1×14 20 fixing spindle of the rear absorber

A Torque 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

- 101 -

8. Rear Wheel/Rear Suspension

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

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

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

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

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

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


Work Instructions

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


Item Standard (mm) Limit for use (mm)

Rear wheel

shimmy

Vertically 2.0

Horizontally 2.0

Locking torque force

Fixing nuts for the rear wheel spindle 130-150N·m

Top bolts for the rear absorber 37-55N·m

Bottom bolts for the rear absorber 37-55N·m

Fixing bolts for the rear swinging arm 70-105N·m

Fixing nuts for the sprocket wheel 37-55N·m

Fixing bolts for the rear brake disc 5-10N·m


8.2.1 Rear Wheel Shimmy

Deformed rim

Abraded rear wheel spindle

Tyre failure

- 102 -

Abraded or damaged bearings of the swinging arm spindle

Incorrect adjustment of the drive chain

Unbalanced tires and wheels


Bending frame or the rear swinging arm

8.2.2 Inflexible Rolling of the Wheel

Bending rear disc brake

Abraded bearings of the rear wheel spindle

Too tight of the drive chain

8.2.3 Too Soft of the Suspension

Insecure or shaking damping spring

Incorrect front suspension regulator

Oil leakage of the absorber


8.2.4 Too Stiff of the Suspension

Damaged assembly bearing of the absorber

Bending tube of the absorber

Damaged bearing of the rear swinging arm axis

Bending of the rear swinging axis

Fault in the suspension regulator

Too high of the tyre pressure

8.2.5 Operation Only Available in One Side or Move in Curve

Bending rear wheel spindle

Incompetent of the axle arrangement/chain regulator on both sides

8.3 Rear Wheel

8.3.1 Disassembly

Support the motorcycle firmly with the rear

wheel above the group.

- 103 -

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.

Remove the rear wheel spindle and the right adjusting block of the chain.

后轮：rear wheel

后液刹盒：rear disc brake box

固定螺钉：fixing screws

后轮轴：rear wheel spindle

Take the chain off the big sprocket wheel.

Caliper of the rear disc brake

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

Chain

Big sprocket

wheel

- 104 -

Remove the rear wheel assembly.

Remove the supporting board of the brake clamp.

Remove the sprocket wheel assembly.

Remove the fixing bolts of the sprocket wheel.

Supporting board of the brake

clamp

Fixing bolts of the sprocket

wheel

- 105 -

8.3.2 Check

8.3.2.1 Check the Rim Shimmy

Rotate the wheel by manual and measure the

eccentricity ratio with a dial indicator.

Limit for use:

Vertically: replacement when beyond 2.0mm

Horizontally: replacement when beyond 2.0mm

When the rear wheel indication goes beyond the limit for

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

wheel shimmy. Replace the rear wheel bearing after check.

8.3.3 Installation

Install the rear wheel in reverse order, and lock the nuts.

Fixing nuts for the rear wheel spindle

Torque force: 130-150 N·m

- 106 -

8.4 Rear Absorber

8.4.1 Disassemble the Rear Absorber

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

Remove the rear absorber.

8.4.2 Check the Rear Absorber

Visually inspect of the absorber for damage.

Check the following items:

——whether the absorber tube is bent or damaged

——whether the absorber has signs of deformation or oil leakage

——whether the rubber block is abraded or damaged.

——whether the spring is damaged

Check all other parts for damage or abrasion

If necessary, replace the absorber

8.4.3 Install the Rear Absorber


Install the upper fixing nut and lower fixing bolt of the rear absorber.

Lock to the specified torque force.

- 107 -

Fixing bolts


- 108 -

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

chain shade and drive chain.

8.5.2 Check

Measure the length of ten chain links ,

if the length doesn’t meet the specified value, replace

the drive chain.

The limit value of the length of ten chain links is

1587.5mm.

Fixing bolt of the left rear cover

Engine left rear cover

- 109 -

* Note:

• Measure after stretching the chain by hand.

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

• Measure the length of ten chain links.

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

Clean the drive chain, put it into the kerosene,

and wash off the dust as much as possible,

then take the chain out of kerosene and dry it.

Check the rotor ① and side panels ②,

if damaged or frayed, replace the drive chain.

The lubricant for drive chain can be purchased from the

shop to lubricate the drive chain.

Check the hardness of drive chain,

clean, lubricate or replace it if hard.

- 110 -

Check the drive sprocket and driven sprocket.

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

replace the sprocket,

the bending of the teeth of a cogwheel also requires

the replacement of sprocket.

8.5.4. Installation


Fixing nuts


Note:

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

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

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

8.6 Rear Swinging Arm

8.6.1 Disassemble the Rear Swinging

Arm

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

Disassemble the rear wheel.

Disassemble the lower fixing nut of the absorber.

Disassemble the bolt and drive chain shade.

Disassemble the fastening bolt of the swinging arm spindle

from the frame.

Disassemble the rear swinging arm spindle and rear swinging

arm assembly.

- 111 -

Disassemble the rear swinging arm spindle bearing and the

rear swinging arm spindle

8.6.2 Check the Rear Swinging Arm

Check the rear swinging arm mounting spindle, rotate the

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

bent, replace it.

*Note

Don’t attempt to straighten the spindle already bent.

Clean the parts of the rear swinging arm mounting spindle

in the solvent.

Check the sleeve of the rear swinging arm and the middle

sleeve, if damaged, replace them.

Check the bearing for the damage

Use your finger to rotate in the inner bush of the right-pivot

bearing

The bearing shall rotate smoothly and steadily, and the

installment of the bearing's outer ring on the wheel hub

should be checked for security

If the ring can not rotate smoothly and steadily, or it is

flexible in installation on the pivot, please disassemble and

discard it

8.6.3 Install the Rear Swinging Arm


Spindle bush of the pivot should be greased,

Note:

Bolts for the rear swinging arm spindle

Torque force: 70-105N·m

Bearing

Rear swinging arm

- 112 -

Fuel Tank

1.fuel tank body assembly 2.gasket 6.4×12.5×1.6 3.bolt M6×70 4.fuel pump seal gasket 5.fuel pump

assembly 6.petrol pump screw 7.fuel pipe assembly 8.filter assembly 9.bolt M6 10.gasket 5,3×10×1

11.oil level sensor assembly 12.bolt M6×25 bolt M6×25 13. rubber gasket tube 14.fuel tank front

mounting pad 15.fuel tank front mounting board 16.bolt M8×1.25×20 17.fuel tank cover support

assembly 18.fuel tank lock 19.socket head cap screw M5×30 20.socket head cap screw M5×14 21.fuel

tank cover seal gasket

A

Gasoline capacity of the

gasoline tank:

15±0.2L

B Torque force of bolt 3:

5-10N·m

D Torque force of bolt 6:

5-10N·m

E Torque force of bolt 9:

5-10N·m

F Torque force of bolt 12:

5-10N·m

G 图中螺栓 16 的扭力值：

22-37N·m

- 113 -

9. Fuel Tank

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

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

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


Work Instructions:

It shall be dismantled far from fire sources.

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

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



Gasoline tank capacity 15±0.2L /

Tightening torque force

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

Rear fixing bolts for the gasoline tank 5-10 N·m

Fixing bolts for the fuel tank front mounting pad 5-10 N·m

Fixing bolts for the fuel pump 5-10N·m

Fixing bolts for the oil level sensor 5-10N·m


9.2.1 Decreasing Gasoline

Natural consumption of gasoline

Leakage of gasoline

- 114 -

9.3 Fuel Tank

9.3.1 Disassembly

Remove the rear seat and the front seat

Remove the upper body of the fuel tank.

Remove the front fixing bolt of the fuel tank.

Remove the high-pressure oil pipe assembly.

Remove the fuel pump connector jacket.

Remove oil level sensor connector jacket

Front fixing bolt of the fuel tank.

Oil level sensor

Fuel pump

High-pressure oil pipe assembly

Fuel pump connector jacket

Oil level sensor connector jacket

- 115 -

Remove the rear fixing bolt of the fuel tank.

Remove the fuel tank.

9.3.2 Installation


Torque force for mounting:

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

Rear fixing bolts for the gasoline tank 5-10 N·m

Fixing bolts for the fuel tank front mounting pad 5-10 N·m

Fixing bolts for the fuel pump 5-10N·m

Fixing bolts for the oil level sensor 5-10N·m

Rear fixing bolt of

the fuel tank

- 116 -

10. Disassembly and Installation of Engine

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

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


Work Instructions

It shall be dismantled far from fire sources.

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

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

Locking torque force

Gearshift rod bolt: 10N.m Engine fixing bolt: 50N.m

10.2 Disassembly of Engine

Support the motorcycle firmly to make its rear

wheel above the ground.

- 117 -

Unscrew the clamp of the engine water pump

inlet/outlet, remove the cooling water-pipe and

exhaust the coolant

Disassemble the front and rear seats

Disassembly of the rear seat

Insert the key into the guard lock, and open it

clockwise;

Slightly push the back of the rear seat with your

right hand, pull the rear seat upwards and

backwards

Remove the rear seat;

Disassembly of the front seat

Remove the rear seat;

Hold the front seat cable with hands;

Slightly push the back of the front seat with

your left hand, pull the front seat upwards and

backwards

Remove the front seat;

Note:

Confirm the left and right limits are set at

positions when installing the front seat.

- 118 -

Disassemble the fuel tank assembly

See 9.3.1 Disassembly of the fuel tank

Disassemble the air filter assembly

Disassemble the air filter fixing bolt

Disassemble the air filter hoop

Disassemble the connector jacket of the intake air

temperature sensor;

Disconnect the breather rubber pipe from the vent

of cylinder cover;

Remove the air filter

Note:

The stepper motor of the throttle body should be

set well to position when installing the air filter.

Disassemble the throttle body assembly

Remove the throttle cable assemblyI and throttle

cable assembly II;

Disassemble four throttle body hoops in 1-2-4-3

order;

Remove the connector jacket of the intake air

pressure sensor.

Remove the ejector connector jacket;

Remove the connector jacket of the idle stepper

motor;

Remove the canister desorption rubber pipe;

Remove the intake oil pipe;

Remove the throttle body assembly

Note:

Confirm the throttle cable assemblyI and throttle

cable assemblyII are set at positions;

Confirm the oil pipe is connected well to place

without oil leakage after the correct installation of

the throttle body assembly.

Confirm the electric components are connected at

positions;

- 119 -

Disassemble the canister assembly

Disassemble the clutch steel rope assembly

Disconnect the battery wire, disassemble the starter motor wire

and the ground wire

Disassemble the FBT connector jacket, rectifier

and outlet water temperature switch connector

jacket

Battery wire

Clutch steel rope assembly

Canister assembly

- 120 -

Disassemble the anterior segment of muffler exhaust

pipe

Disassemble the radiator filler, water tank, and

disconnect the fan switch connector jacket

Disconnect the crankshaft position sensor, neutral

switch connector jacket

Disconnect the single-kickstand flameout switch

connector jacket and disassemble the single-kickstand

flameout switch

Single kickstand flameout switch

- 121 -

Disassemble gearshift lever swing arm and the left cover of

the engine

Disassemble the small sprocket and detach the chain from the

sprocket

Release the engine fixing bolt and lift the engine

- 122 -

10.3 Installation of the Engine


Note:

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

Engine fuel: 3.2L when assembling.

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

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

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

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

regard prior to the testing the engine.

Checking method of engine fuel

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

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

lowest limit, increase the fuel.

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

is lower than the lowest position, increase the fuel.

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

- 123 -

Inspection and Maintenance of Engine

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 M6

Crankcase bolt M6

Crankcase bolt M8

Crankcase bolt M10

Connecting rod bolt

Left/right crankcase cover bolt M6

Flywheel bolt M8

Fuel filter

Fuel filter connecting bolt

Fuel filter bolt M14

Round nut M20

Clutch release plate bolt M6

Cylinder cover shade bolt M6

Camshaft sprocket bolt M7

Fuel pump bolt M6

Gearshift positioning plate bolt M6

Spark plug

20~25

10~12

60~62

100~110

10~12

10~12

22~24

35~39

23~27

10~12

20~24

18~22

40~45

40~45

95~105

10~12

10~12

20~25

10~12

10~12

22~25

- 124 -

11. Lubricating System

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

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

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


Function of the lubricating system:

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

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

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

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

Work Instructions:

Clean all parts carefully and blow the parts surface clean with high-pressure gas after disassembly of the fuel

pump.

Foreign matter shall not fall into the crankcase when the carburetor is disassembled

Standard of benchmark items and table of limit for use


Fuel capacity When oil change 3.0L ＿

When disassembling 3.2L ＿

Fuel pump rotor

The radial clearance between

inner and outer rotors 0.04-0.11mm 0.15mm

The clearance between

outer rotor and pump body 0.04-0.11mm 0.15mm


Decreasing fuel Burnt engine

Natural consumption of fuel No fuel pressure or low fuel pressure

Fuel leakage Blocked fuel pipes

- 125 -

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.

Remove the screw.

Remove the fuel pump body.

Remove the screw, take down the fuel pump cover, and decompose

the fuel pump.

Fuel pump chain

Fuel pump drive sprocket

Screw

螺钉

Screw

Fuel pump cover

Screw

Fuel pump body

- 126 -

Check the radial clearance between inner and outer rotors

Limit for use: 0.15mm.

Check the clearance between outer rotor and fuel pump cover


Gauge

Gauge

- 127 -

11.3.2 Assembly of Fuel Pump

As shown below

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

Fuel pump

drive sprocket

- 128 -

11.3.3 Lubricating Systematic Drawing

排气凸轮轴--- exhaust camshaft 进气凸轮轴--- intake camshaft 活塞冷却器---piston cooler 曲轴连杆

机构--- crankshaft connecting rod mechanism 主油道--- main oil channel 油冷器--- oil cooler 主轴

---main shaft 机油泵--- fuel pump 机油滤清器--- fuel filter 机油集滤器--- fuel strainer 溢流阀--- relief

valve 副轴---countershaft

Piston cooler

- 129 -

- 130 -

12. Cylinder Head

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

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

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


Function of the cylinder head:

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

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

Work Instructions:

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

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

high-pressure air before check.

Standard of benchmark items and table of limit for use Unit: mm


Flatness of cylinder cover 0.03 0.05

Valve

Valve catheter

Valve gap Intake 013-0.19 __

Exhaust 0.19-0.25 __

Outer diameter of valve stem Intake 3.97-3.98 3.96

Exhaust 3.97-3.98 3.96

Inner diameter of valve catheter Intake 4.03-4.04 4.07

Exhaust 4.03-4.04 4.07

Clearance between valve stem

and valve catheter

Intake 0.05-0.07 0.11

Exhaust 0.05-0.07 0.11

Width of valve seat Intake 1.0-1.1 1.5

Exhaust 1.0-1.1 1.5

Valve spring Free length Intake 38.8 37.3

Exhaust 41.6 40.1

Camshaft Fitting clearance between camshaft and

cylinder head 0.041-0.054 0.08


Low compression pressure Noise in Cylinder head

Valve clearance maladjustment Valve clearance maladjustment

- 131 -

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

- 132 -

12.3 Cylinder Head

12.3.1 Disassembly

Remove the ignition coil.

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

Loosen the fastening bolt, and remove the air-distributing

chain regulator.

Loosen the four sprocket bolts of the camshaft.

Measure the fitting clearance between camshaft and cylinder

head.


Sprocket bolt of the camshaft

Gauge

Air-distributing chain regulator

Fastening bolt

Cylinder

cover shade

Locating bolt

- 133 -

Loosen the camshaft holder.

Remove the camshaft, camshaft sprocket and chain.

Loosen the cylinder cover locking bolt.

Remove the cylinder cover.

Remove the top stem, compress the valve spring with valve

spring compression tools, and remove the valve block.

Remove the valve adjusting gasket, valve spring, valve spring

upper/lower seat and valve.

Camshaft holder

Camshaft

Camshaft sprocket

Camshaft chain

Guide chain

plate

Cylinder

cover

- 134 -

12.3.2 Cam Assembly Breakdown

12.3.3 Valve Breakdown

Check

Eliminate carbon deposit in the cylinder cover.

Measure the flatness of the joint surface of the cylinder cover.


When the flatness of the joint surface of cylinder cover

exceeds the limit for use, place the fine-sand paper on the flat

plate, with the joint surface of cylinder cover fitting the sand

paper, and mill it according to 8-shape.

Valve

Valve spring

Valve spring

lower seat

Valve spring

upper seat

Top

stem

Valve adjusting

gasket

Valve block

Ruler

Gauge

Seal cover D13 Camshaft

Camshaft sprocket Bolt

- 135 -

Measure the free length of valve intake/ exhaust spring.

Limit for use: intake spring: 37.3mm.

exhaust spring: 40.1mm.

Measure the outer diameter of the valve stem.

Limit for use: intake valve 3.96mm

exhaust valve 3.96mm

Check the valve catheter after eliminating the carbon deposit

in it with a reamer.

Note: The reamer should be rotated clockwise, and mustn’t be

rotated anti-clockwise.

Measure the inner diameter of each valve catheter.

Limit for use: intake/ exhaust: 4.07mm.

Limit for use of the clearance between valve and valve catheter:

Intake valve: 0.11mm.

Exhaust valve: 0.11mm.

Vernier calipers

Micrometer

Tester

- 136 -

12.3.4 Replace the Valve Catheter

Note: When the clearance between valve and valve catheter

exceeds the limit, replace the valve catheter. After the replacement,

trim the surface of the valve seating.

Put the valve catheter in the freezer of the refrigerator to cool for

one hour.

Heat the cylinder head to 100-150℃ with an electric furnace or a

hot oven.

Fix the cylinder head, disassemble the valve catheter from the

upper side of cylinder head with valve catheter disassembly tools.

Put a new o-ring on the new valve catheter.

Install the valve catheter from the top of the cylinder head.

Note: The cylinder head shall not be damaged when installing

the valve catheter.

After inserting the valve catheter, trim with a valve catheter

reamer.

Note: Add proper amount of cutting oil when cutting with an

reamer. And the reamer should be rotated clockwise.

Eliminate the carbon deposit in the combustion chamber and

valve, clean thoroughly the intake/exhaust valve. Check the

width of the contact surface of the valve seat (width of the

valve seating).

Limit for use: intake/ exhaust: 1.5mm.

Contact surface of the valve seat

Screwdriver

Valve

reamer

- 137 -

12.3.5 Trim of Valve Seating

Remove the rugged or ragged parts of the valve seating

surface with a milling cutter at 45°angle.

Note: Coat a transparent or prussian-blue cladding on the

valve seating to get a better view.

Remove 1/4 of the outer end of valve seating with a milling

cutter at 25°angle.

Remove 1/4 of the bottom of valve seating with a milling

cutter at 60°angle. Take down the milling cutter and check the

parts treated.

Grind the valve seating with a refining milling cutter at

45°angle to achieve the proper width.

All dents and ragged parts must be removed.

Standard width of the valve seating: intake: 1.0mm

exhaust: 1.0mm

Rugged part

25°

60°

45°

1.0mm

- 138 -

If the contact is the part where the valve is too high, please

lower the valve seating with a flat milling cutter at

25°angle.

If the contact is the part where the valve is too low, raise

the valve seating with a inner milling cutter at 60°angle.

Refine the valve seating again with a refining milling cutter

at 45°angle to meet the specifications required.

After grinding the valve seating, please coat the polish on

the surface of valve to gently polish the valve.

12.3.6 Installation


Note:

When installing the valve spring, the end with smaller pitch of the spring shall be installed towards the

combustion chamber.

When installing the valve collet, install it by compressing the valve spring with valve spring compression

tools

When installing the valve, the surface of the valve stem shall be coated with proper amount of fuel prior

to installing to the valve catheter.

60°

25°

High contact surface

Low contact surface

- 139 -

- 140 -

13. Crankcase

Preparing Documents------------------------------------------------------13.1

Failure Diagnosis-----------------------------------------------------------13.2

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

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

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

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

Variable Speed Gear Transmission---------------------------------------13.7

Camshaft Connecting Rod Assembly-------------------------------------13.8


Function of the upper box:

The cylinder block in the upper box provides space for gas compression, combustion and expansion, and also

guides piston movement.

It also transfers part of heat energy in the cylinder to cooling medium around.

Function of the piston:

1. It bears pressure arising from mixed gas combustion inside the cylinder and transfers such pressure to the

connecting rod for driving the crankshaft.

2. It forms combustion chamber along with the cylinder cover.

Function of the crankcase:

The crankcase is the load-bearing part of the engine. Its main function is to support the crankshaft, clutch,

gearbox, cylinder block and cylinder cover, sustain combustion shock and inertia force from the movement of

the connecting rod, and form part of closed space (oil sealing, gas sealing).

Suspension holes in the crankcase are linked with suspension holes in the body, which connects the engine to

the frame and other parts.

Work Instructions:

- 141 -

All components must be cleaned and blown with high-pressure gas before test.

The crankcase is thin-section casting thus shall not suffer impact during operation which may cause

deformation or fracture.

Lubricant in the crankcase should be drained out before operation.

- 142 -

Standard of benchmark items and table of limit for use

Item Standard Limit for

use

Upper box

Diameter of the cylinder Cylinder I 65 (0.025, 0.03) 65.100

Cylinder II 65 (0.03, 0.035) 65.110

Cylindricity of the cylinder 0.008 0.050

Roundness of the cylinder 0.006 0.050

Flatness of the cylinder 0.03 0.05

Outer diameter of piston (measured in piston skirt) Piston I 65 (-0.03, -0.025) 64.90

Piston II 65 (-0.025, -0.02) 64.91

Inner diameter of piston pin hole 16 (0.002, 0.008) 16.04

Outer diameter of piston pin 16（-0.008, 0） 15.96

Clearance between piston pin hole and piston pin 0.002-0.016 0.04

Clearance between piston ring

and ring groove

Ring 1 0.05-0.09 0.11

Ring 2 0.04-0.08 0.11

Joint gap of the piston ring

Ring 1 0.15-0.30 0.5

Ring 2 0.25-0.45 0.65

Fuel ring 0.20-0.70 1.0

Inner diameter of the smaller head of connecting rod. 16 (0.016, 0.034) 16.04

Clearance between connecting rod and piston pin 0.016-0.042 —

Connecting-rod

bearing

Thickness 1.5 (0-0.09) 1.48

Clearance between the

connecting-rod bearing and

crankshaft

0.025-0.05 0.065

Lower box

Connecting rod

Left-right clearance of the larger

end of the connecting rod 0.1-0.25 0.5

Radial clearance of the larger

end of the connecting rod 0.008-0.016 0.05

Main-shaft

bearing

Thickness 1.5 (0-0.012) 1.44

Clearance between main shaft

and crankshaft 0.03-0.05 0.07

Clutch

Thickness of friction disc 2.8 (-0.05, +0.05) 2.45

3（-0.1, 0） 2.6

Length of pressure spring 24.3（-0.15, +0.15） 22.8

23.5（-0.2, +0.2） 22.4

Variable

speed gear

transmission

Outer diameter of fork shaft 11.973-11.984 11.96

Diameter of fork inner hole 12-12.018 12.03

Thickness of fork 5.80-5.90 5.75

Outer diameter of gearshift drum 41.9-42.1 41.5

Width of gearshift drum lock

groove 5.45-5.55 5.65

- 143 -


Low compression pressure White smoke from the exhaust pipe

Abrasive, burnt or ruptured piston Abrasive or damaged piston ring

Abrasive or damaged cylinder or piston Abrasive or damaged cylinder or piston

Damaged spacer or crankcase leakage

Over-high compression pressure Abnormal noise of the piston

Too much carbon deposit in the combustion chamber Damaged cylinder, piston or piston ring

Abrasive piston pin hole and piston pin

Low compression pressure Abnormal noise in the crankcase

Crankcase leakage Loose or broken parts inside the crankcase

Engine overheating Engine automatic stopping

Clutch slipping Seized clutch

Poor lubricating

Not in gear Gear skip shift

Broken or deformed variable speed fork The clutch isn’t completely released

Broken fork guide pin Abnormal transmission return spring

Abrasive gear convex claw Abrasive gearshift drum lock groove

Out of gear automatically

Abrasive joint claw, round edge

Decreasing elasticity of variable speed gear return spring

Abrasive spline gear of spline shaft and spline groove of sliding gear, leading to higher axial force when the

gear works

Abrasive gearshift drum and fork

- 144 -

13.3 Upper Box

BJ465MS/QJ465MS Engine cylinder block

Namely it is part of the upper box.

Check

Check the abrasion of the inner wall of the cylinder.

If it is serious, replace it.

Remove the spacer and locating pin.

Upper box

Spacer

Locating pin

- 145 -

13.4 Piston

13.4.1 Disassembly

Remove the retainer ring of the piston pin.

Note: during assembly, do not make the retainer ring fall

into the crankcase.

Remove the piston pin and the piston.

Remove the piston ring.

Check the piston, piston pin and piston ring.

Note:

Do not rupture or damage the piston ring.

Eliminate carbon deposit in the groove of the piston ring.

Install the piston ring.

Measure the clearance between piston ring and piston ring

groove.

Limit for use: ring 1: 0.11mm.

ring 2: 0.11mm.

Push into Piston

Piston ring

Gauge

Retainer ring of the piston

Piston pin

- 146 -

Remove the piston ring, and install each piston ring on the

cylinder bottom.

Note:

Press the piston ring into the cylinder with piston head.

Measure the joint gap of the piston ring.

Limit for use: ring 1: 0.5mm.

ring 2: 0.65mm.

Measure the inner diameter of the piston pin hole.


Measure the outer diameter of the piston pin.


Clearance between piston pin hole and piston pin.


Tester

Piston ring

Gauge

2

1

3

- 147 -

Measure the outer diameter of the piston I and piston II.

Note:

The measuring point shall be at 90°with the piston pin, and

at the piston skirt.

Limit for use of the piston I: 64.90mm.

Limit for use of the piston II: 64.91mm.

Check whether cylinder I/II inner wall is scratched or

abraded.

Note:

It is at 90 degree with the piston pin. Measure the inner

diameter of the cylinder at the top, middle and bottom

points.

Limit for use of the cylinder I: 65.100mm.

Limit for use of the cylinder II: 64.110mm.

Measure the roundness of the inner wall of the cylinder (inner

diameter difference at X direction and Y direction).


Measure the cylindricity of the inner wall of the cylinder

(inner diameter difference at the top, middle and bottom

points of X direction and Y direction).


90°

Tester

Ex

排

In

11mm

Top

Middle

Bottom

- 148 -

Check the flatness of the cylinder surface..


Measure the inner diameter of the smaller end of the

connecting rod.


Measure the clearance between connecting-rod bearing and crankshaft.


Gauge

Upper box

Connecting-rod bearing

Ruler

Inner diameter of the

smaller end of the

connecting rod

Tester

- 149 -

Measure the clearance between main shaft bearing and crankshaft.


13.4.2 Piston Installation

Install the locating pin.

Apply fuel to each piston ring and piston. Install the piston

ring in place.

Note:

Do not scratch the piston or break the piston ring.

After the piston ring is installed, it shall be able to rotate

freely in the piston ring groove.

Plastic gauge

Main shaft bearing

Fuel ring

Top ring

Ring 2

- 150 -

Remove any residual spacer attached to the crankcase.

Note:

Do not make any object fall into the crankcase.

Install the piston, piston pin and retainer ring.

Note:

The dot mark on the top of the piston shall be installed

towards the intake valve.

Dot mark

- 151 -

13.5 Lower Box

13.5.1 Disassembly of the Crankcase Left Cover

Lossen the fixing bolt of starter motor, remove the starter motor.

Lossen the bolt of the crankcase left cover.

Remove the left cover.

Remove the electric starting bear, needle bearing and spacer.

Remove the starter motor idle gear.

Remove the spacer and locating pin hole.

Loosen the flywheel locking nut with the electric or pneumatic tool.

Pull the flywheel assembly (including the star wheel )

Flywheel assembly

Starter motor

Motor idle gear

Locating pin hole

定位销孔

- 152 -

13.5.2 Disassembly of the Clutch Cover

Loosen the fixing bolt, and remove the clutch cover.

Remove the clutch release stem from the right cover.

Remove the fixing bolt, clutch, gearshift arm assembly and fuel pump sprocket.


Driven gear

Release stem assembly

Bolt

Clutch assembly

Fuel pump sprocket

Gearshift arm assembly

Right cover

Clutch cover

- 153 -

Loosen the locking nut with the electric or pneumatic

tool, and remove the clutch.

Loosen the fuel pump screw, and remove the fuel pump

gear.

Fuel pump sprocket

Fuel pump chain

Gearshift drum assembly

- 154 -

13.6 Clutch

13.6.1 Disassembly

Unscrew the four bolts of the release plate in diagonally staggered sequence.

Loosen the clutch nut.

Remove the sleeve, bearing, release plate

and the clutch spring.

See the breakdown drawing for the disassembly of parts.

.

Unscrew the clutch locking nut with the special tool, and remove the locking nut and gasket.

Remove the center holder of clutch.

Remove the clutch disc and friction disc.

Remove the clutch pressure plate.

See the breakdown drawing for the disassembly of

parts.

Remove the spline gasket.

Remove the shell assembly.


Shell assembly

Release plate bolt

Clutch nut

Four-claw socket spanner

Universal holder

- 155 -

13.6.2 Clutch Breakdown

滚针轴承---needle bearing 轴套---sleeve 垫片---spacer 主动毂组件---drive hub assembly 从动毂---driven

hub 摩擦片---friction disc 离合器片---clutch disc 碟形弹簧---dish-shaped spring 垫圈---gasket 主动毂座

组件---drive hub housing assembly 压力弹簧---pressure spring 压板---pressure plate 螺栓---bolt 滚动轴

承--- rolling bearing

- 156 -

13.6.3 Check

Check the shell groove for burrs and brakeage, if

trimmed excessively by the file, replace it.

Check the pressure plate and the tooth profile of the

center holder for damage, if damaged, replace it.

Measure the free length of the pressure spring.

Limit for use I: replace it if lower than 22.8mm.

Limit for use II: replace it if lower than 22.4mm.

Measure the thickness of the friction disc with vernier

calipers.

Limit for use I: replace it if lower than 2.45mm.

Limit for use II: replace it if lower than 2.6mm.

Free length

Thickness

Driven hub

Drive hub assembly

- 157 -

13.7 Gearshift Mechanism

13.7.1 Disassembly

Remove the gearshift shaft assembly.

Remove the bolt and gearshift locating plate.

Remove the bolt, stop arm and spring.

Remove the locating pin.

See the breakdown drawing for the disassembly of

parts.

13.7.2 Gearshift Shaft Mechanism Breakage

13.7.2.1 Check

Before the breakage, the gearshift plate should flexibly return without being seized.

Check the gearshift plate and gearshift shaft assembly for abrasion. If heavily abrasive, replace the assembly.

Check the gearshift locating plate for abrasion, If heavily abrasive, replace the assembly.

Gearshift shaft assembly

Fork shaft spring Fork Fork shaft

Gearshift drum Gearshift drum bearing

Pressure plate

Ratchet

Gearshift arm assembly

- 158 -

Check whether the gearshift shaft is bent, if excessively bent, replace it.

Check the return spring for decreasing elasticity, if necessary, replace it.

- 159 -

Loosen the crankcase bolt.

Separate the crankcase.

Note: Do not damage the spacer and crankcase surface.

Remove the upper box.

Remove the main-/ countershaft.

Loosen the pressure plate bolt, and remove the pressure plate.

Pull the fork shaft.

Remove the gearshift drum.

Remove the gearshift fork.

Fork shaft

Upper box

Crankcase bolt

Lower box

Main shaft assembly

Countershaft assembly

Fork

Gearshift drum

- 160 -

13.7.2.2 Check

Measure the outer diameter of the fork shaft.


Measure the inner diameter of the fork hole.


Measure the thickness of the fork.


Measure the outer diameter of the gearshift drum.


Measure the width of the gearshift drum locking

groove.


Width of the lock groove

Micrometer

Fork shaft

Tester

Vernier calipers

- 161 -

13.8 Crankshaft Connecting Rod Assembly Chamber and Variable

Speed Chamber

Depository for the

crankshaft connecting rod

Depository for

the main shaft

Depository for

the countershaft

Gearshift chamber

变档室

- 162 -

Main shaft

assembly

Gearshift drum

assembly

Gearshift arm

assembly Fork shaft


- 163 -

13.8.1 Crankshaft Connecting Rod Assembly

13.8.1.1 Disassembly

Remove the upper box.


Remove the crankshaft connecting rod assembly from the lower box.

Note: Do not damage the spacer and crankcase surface.

Countershaft

assembly

asseml

副轴组件

Main shaft

assembly

Drive gear

- 164 -

13.8.1.2 Check

Measure the left-right clearance of the larger end of the connecting rod.


Measure the clearance of the larger end of the connecting rod (X-Y

direction).


Measuring point at the

clearance between the larger

end of the connecting rod

Measuring point at the larger

end of the connecting rod

- 165 -

13.8.1.3 Assembly

Assemble in reverse order of breakdown and disassembly.

Remove the main shaft assembly

Remove the countershaft assembly.

13.8.2 Main-/Counter Shaft Breakdown

13.8.2.1 Main-/Counter Shaft Breakdown

Main shaft assembly

- 166 -

13.8.2.2 Check

Check the abrasion of gear surface and driving-claw point of the gear respectively.

If it is seriously abraded or damaged, replace it.

Check whether the bearing and oil seal are damaged, If yes,

replace it.

Note:

Removed bearing cannot be used any more. It shall be

replaced.

Use special tools to dismantle the bearing and the oil seal.

13.8.2.3 Main-/Counter Shaft Assembly

Note:

Lubricate all gears and shafts with grease when assembling.

Ensure all gears without being seized after assembling.

Note:

Install the crankcase in reverse order.

Gear surface

Driving claw


- 167 -

14. Cooling System

Preparing Documents -------------------------14.1

Failure Diagnosis ------------------------------14.2

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


Function of the cooling system:

The cooling method of the engine is water cooling. Water cooling, in which the water is used as the heat

conductor, is a method of cooling high-temperature components and then transferring heat to the outside air,

thus keeping the engine working under the optimum temperature.

Specific cooling circuit:

The cooling water entering from the crankcase goes to the cylinder water jacket through the water channel

of crankcase, then goes upward through the cylinder cover, finally enters into the radiator through the pipe to

- 168 -

dissipate heat, and transfers heat to the outside air with the help of radiator’s fin.


Water leakage

Damaged seal ring

Broken pump assembly

Broken water pipe

Over high temperature in cylinder block

Damaged blade of the water pump

Blocked water pipe

Damaged cooling fan

Damaged water temperature switch

14.3 Water Pump

Disassembly

Loosen the bolt, and remove the water pump sub assembly.

Bolt

- 169 -

Loosen the bolt, and remove the water pump cover.

Remove the blade.

Check

Check the abrasion of the blade assembly.

If it is serious, replace it.

Note: Don’t damage the spacer and the joint surface of box

during operation.

Installation


Water pump sub assembly

Bolt

Water pump cover

Blade

- 170 -

Cooling Systematic Drawing

465 cooling system piping drawing

thermostat

t

Thermostat Cylinder cover

Reservoir

Cylinder block

Water pump

Water direction

Pressure valve

Radiator

Oil

cooler

- 171 -

Inspection and Maintenance of Exhaust Emission System

1 exhaust pipe gasket assembly 2 screw M8×30 3 gasket 8 4 spring gasket 8 5 muffler assembly 6

muffler buffer rubber 7 muffler decorating panel 8 heat-insulating spacer 9 combined screw M6×10

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15. Exhaust Emission & Control System

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

Instructions on the Periodic Maintenance / Compliance with Standards -------15.2

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

Catalytic Conversion System --------------------------------------------------------15.4

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

15.1 Warranty on the Exhaust Emission & Control System

15.1.1 The exhaust emission & control system of this motorcycle is in conformity with the GB 14621-2011,

GB 14622-2007, GB 19758-2005 and GB 20998-2007 standards prescribed by the state. We warrant that the

exhaust emission & control system works normally during its effective period provided that users completely

comply with all operation and maintenance requirements.

15.1.2 Warranty Range

Function warranty of the exhaust emission & control system

We warrant that it satisfies all periodic or non-periodic inspection by the related government authorities within

riding of (30000 kilometers).

15.1.3 This provision is not applicable under any following condition. However, our distributor or service store

would like to provide maintenance or repair services at reasonable prices.

(1) Users fail in periodic maintenance within the required period or kilometers.

(2) Periodic maintenance, adjustment or repair is not carried out at our distributor or service center, or there is

no evidence of maintenance record.

(3) Overload or improper operation.

(4) Refit the motorcycle, remove original parts or replace with other devices in private.

(5) Ride the motorcycle on race tracks or on any non-motorized vehicle lane frequently.

(6) Damage to the motorcycle due to extreme weather such as typhoon or flood, or damage or failure due to

negligence, crash or impact.

(7) Users fail in periodic maintenance since it is out of service for a long time.

(8) The odometer is not repaired immediately after being damaged, or it is refit, stopped, or replaced in

private.

·All new motorcycles delivered by our company have satisfied the noise test and comply with the GB

4569-2005 and GB 16169-2005 standards prescribed by the state.

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15.2 Instructions on Periodic Maintenance

It is the national requirement that all motorcycles produced domestically shall comply with exhaust

emission standards to lessen environmental pollution. We strictly accord with these exhaust emission

standards and also make great effort in purifying air and reducing pollution.

This motorcycle has been strictly examined before delivery and is in conformity with all exhaust emission

standards. We provide the following periodic inspection table for exhaust emission in consideration of

different use by customers. Users shall carry out periodic inspection, adjustment or maintenance

according to the schedule to ensure normal emission.

For any problem, please contact Qianjiang distributors or Qianjiang service center.

Relevant emission provisions are shown as follows:

Emission regulation CO HC NOX

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

※ The latest national regulation shall prevail if there is any change.

We are not responsible for any problem due to failure in periodic maintenance at our distributor or service

center. Please carry out necessary inspection to ensure its best condition.

Note: ①Clean the air filter frequently if the motorcycle runs in sandy road or under seriously polluted

condition to extend the service life of the engine.

②Increase maintenance if the motorcycle often runs at high speed or frequently.

Pay attention to following items to ensure meeting emission standards:

(1) Please use lead-free gasoline #93 or #97.

(2) Please use fuel with stipulated specification.

(3) Please comply with periodic maintenance requirements.

(4) For the exhaust control system, it is forbidden to make any adjustment or replacement at random

(including use of spark plug, adjustment of idle speed, ignition timing, throttle adjustment, etc.)

(5) Notes:

Since any problem in the ignition system, the charging system or the fuel system has significant

effect on the muffler device, please go to our designated distributor or service center for inspection,

adjustment or repair immediately when there is any problem found in the engine.

Please use lead-free gasoline #93 or #97. Otherwise, the muffler device (four-stroke system) will be

affected.

(6) The exhaust control system of this motorcycle is in accordance with the national regulation. For

replacement of any component, please use our original parts and have our designated distributor or

service center carry out such replacement.

15.3 Mechanical Function of the Exhaust Control System

General

This system adopts four-stroke single-cylinder engine, EFI and air conduction device to maintain

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qualified exhaust gas. Meanwhile, active carbon canister is used for exhaust gas evaporated from fuel.

※ Engine improvement

As the spark plug, spherical combustion chamber, compression ratio, ignition time, exhaust system and

other engine components are improved, as well as the intake/exhaust efficiency is enhanced, the combustion

efficiency is raised.

15.4 Catalytic Transfer System

15.4.1 Structure:

触媒：Catalytic

15.4.2 Instruction:

(1) Function of transfer catalyst is to transfer completely burnt HC, CO and NOX to harmless gas such as H2O,

CO2、and、N2 for discharge.

(2) Transfer catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used.

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※ Note that lead gasoline may invalidate catalyst.

Notes in maintaining motorcycles (gas discharge tube) with catalytic transfer:

a) For motorcycles with transfer catalyst, when the motor is running or just shut, it shall not be touched

because of high temperature.

b) Motorcycle with transfer catalyst shall not be near flammable material.

c) There is CO inside gas discharge tyre, which is harmful to health. So do not run the motor in closed

space.

d) Motorcycle with transfer catalyst shall not use lead gasoline. (prevention for catalytic poison）.

e) Do not push motorcycle to run motor. If it is necessary, you must stop for temperature of motor and

catalyst to lower down.

f) Do not shut the motor with gear up when running downward.

g) Do not drive motorcycle with bad ignition.

h) Do not remove spark plug and run motor to see whether there is spark in maintain motor ignition system.

If necessary, the time shall be short.

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Periodic inspection (maintenance plan)

Measure idle emission (note 1)

Adjust Carburetor (note2)

Remove and clean the

carburetor

Replace the carburetor

Dismantle and repair

engine

•Valve（leakage）

•Piston（abrasive）

•Combustor（cleaning）

Qualified for

delivery

Qualified

Qualified

Qualified

Qualified

Qualified

15.5 Measures When the Idle Speed Emission Value Exceeds the

Standard

Notes:

1. Measure it with the idle speed measurement program.

2. Adjust the engine speed with stop screws to live up to requirements and measure CO/HC at the idle speed.

Qualified

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Inspection and Maintenance of Electronic Fuel

Injection (EFI) System

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16. Electronic Fuel Injection System

Electronic Fuel Injection System ---------------------------------------16.1

Components of Electronic Fuel Injection System---------------------16.2

Failure Diagnosis ----------------------------------------------------------16.3

Common Troubleshooting Methods-------------------------------------16.4

16.1 Introduction of Electronic Fuel Injection System

RK6 adopts the small-scale engine electronic fuel injection system manufactured by Delphi Company, which

is controlled with four oxygen sensors within a closed loop. Besides, it is equipped with four-cylinder

independent fuel injection and ignition control functions. The three-way catalytic converter would go through

treatment with the gas after combustion in the engine, turn it into harmless gas and discharge it into the air.

This system adopts the closed-loop independent function that can efficiently eliminate the manufacturing

differences within the system and the other corresponding components, highly improving the integrity of the

motorcycle, which can also reduce the deviations of the motorcycle after a some time of actual using.

16.2 Components of Electronic Fuel Injection System

16.2.1 Engine Controller (MT05.2 ECU)

The engine controller can test the operation conditions of the engine with various sensors at any time and

guarantee the emission and economy of fuel by proper computing and self-study control output mechanism

with the driving performance optimized. Once failures are found within the engine, the control would go

through automatic diagnosis. The normal working of the system requires two ECU.

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16.2.1.1 ECU Appearance

ECU 12 is located on the left of battery and ECU 34 is behind the battery.

16.2.1.2 Definition of ECU Connector Pin

1) ECU 12：

J1-1 J2-1 Pin for activating 1-cylinder ignition coil

J1-2 Headlight control pin J2-2 Pin for system grounding

J1-3 Pin for trouble light J2-3 Pin for K line communication

J1-4

Pin for heating 2-cylinder oxygen

sensor

J2-4 Pin for crank signal high potential

J1-5

Pin for signal 2-cylinder oxygen

sensor

J2-5

Pin for activating 1-cylinder fuel injector

J1-6 Connector pin for tachometer J2-6 Pin for activating 2-cylinder fuel injector

J1-7 CAN line low signal 1 pin J2-7 Pin for heating 1-cylinder oxygen sensor

J1-8 CAN line high signal 1 pin J2-8 Pin for intake temperature sensor signal

J1-9 Pin for system grounding J2-9

J1-10 Pin for activating 2-cylinder ignition

coil J2-10

Pin for 5V system reference voltage grounding

J1-11 J2-11 Pin for intake pressure sensor signal

J1-12 J2-12 Pin for throttle position sensor signal

J1-13 J2-13 Pin for crank signal low potential

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J1-14 Dump switch (efficient at low) J2-14 Signal pin for water temperature sensor

J1-15 J2-15 Ignition power (12V positive voltage after key)

J1-16 J2-16

J1-17 J2-17 Pin for signal 1-cylinder oxygen sensor

J1-18 Pin for neutral gear switch J2-18 Battery power supply (battery 12V positive voltage)

Remarks:

J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey

connector.

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2) ECU34：

J1-1 Idle speed stepper motor high A pin J2-1 Pin for activating 4-cylinder ignition coil

J1-2 Canister solenoid valve pin J2-2 Pin for system grounding

J1-3 Pin for trouble light J2-3 Pin for K line communication

J1-4

Pin for heating 3-cylinder oxygen

sensor

J2-4 Pin for crank signal high potential

J1-5

Pin for signal 3-cylinder oxygen

sensor

J2-5

Pin for activating 4-cylinder fuel injector

J1-6 J2-6 Pin for activating 3-cylinder fuel injector

J1-7 CAN line low signal 2 pin J2-7 Pin for heating 4- cylinder oxygen sensor

J1-8 CAN line high signal 2 pin J2-8 Pin for intake temperature sensor signal

J1-9 Pin for system grounding J2-9 Pin for oil pump control signal

J1-10 Pin for activating 3-cylinder ignition

coil J2-10 Pin for 5V system reference voltage grounding

J1-11 Idle speed stepper motor low A pin J2-11 Pin for intake pressure sensor signal

J1-12 Idle speed stepper motor high B pin J2-12 Pin for throttle position sensor signal

J1-13 Idle speed stepper motor low B pin J2-13 Pin for crank signal low potential

J1-14 Dump switch (efficient at low) J2-14 Signal pin for water temperature sensor

J1-15 Pin for vehicle speed sensor J2-15 Ignition power (12V positive voltage after key)

J1-16 J2-16 5V reference voltage

J1-17 J2-17 Pin for signal 4-cylinder oxygen sensor

J1-18 Pin for neutral gear switch J2-18 Battery power supply (battery 12V positive voltage)

Remarks:

J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey

connector.

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16.2.1.3 Circuit Diagram of Electronic Injection System

Notes:

a) Keep ECU away from places of high temperature, like muffler or engine;

a) Keep ECU away from water, engine oil or any places of liquid;

b) Keep ECU away from mud or other dirt that would affect the heat dissipation function of ECU;

c) Connect with M8 bolts and make sure the tightening torque is around 3.9Nm, keep the surface neat to

prevent outside force to ECU in case of circuit board bending;

d) The DC power supply voltage of ECU of normal working is between 9V and 16V. when it's working

under a voltage not over 26V for one minute, permanent damage would not happen to ECU, neither when the

backward voltage is not over 13V.

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16.2.2 Fuel Injector

16.2.2.1 Working Principle of Fuel Injector:

The fuel injector is designed with magnet coil surrounding iron core inside. Two electrodes from magnet

coil are input control connectors of the fuel injector. When magnet coil is energizing, electromagnetic

attraction generated by magnet coil will conquer spring force and fuel oil pressure of ball valve to uplift the

ball valve. Then high pressured fuel oil (250Kpa) in fuel pipes can inject cone-shaped fuel oil to the air inlet

through value seat hole and orifice plate. After power of the fuel injector, magnetic force of the magnet coil

will automatically disappear. The ball valve closes by the action of return spring and fuel injection stops.

16.2.2.2 Appearance:

注意事项：

Fuel injector is designed with a filter which is not a repairable component because it is designed for only

filtering impurities between fuel filter to fuel injector. The impurities may cause failures such as injector

bonding, flow deviation and leakage. Thus, fuel filter system is very important.

Replace the fuel injector with parts of the same models.

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16.2.3 Throttle Body

16.2.3.1 Working Principle:

The throttle body assembly is comprised of the main casting valve body, return spring, throttle position

sensor system and idle adjusting screws.

Throttle position sensor system offers accelerograph opening for ECU; idle adjusting screws controls and

idle speed and the stability by clockwise reducing the ventilation to lower the idle speed and anticlockwise

increasing the ventilation to higher the idle speed, which is normally required around 2 circles.

16.2.3.2 Appearance:

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16.2.3.3 Cleaning

Clean the throttle body assembly with carburetor cleanser by spraying it on the inner wall of the throttle

body and brush the dusts and carbons away gently.

Notice:

Make sure the side channel is not blocked by the dirty.

16.2.4 Engine Cylinder Head Temperature Sensor

16.2.4.1 Working Principle:

This sensor is used on the air cooled engine for measuring the engine cylinder head temperature. Within

the temperature scope of the sensor, the electric resistance would vary with different temperature of the engine,

which is a negative temperature coefficient resister. It is a not a repairable part.

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16.2.4.2 Appearance

16.2.5 Intake Air Temperature Sensor

16.2.5.1 Working Principle

It is used for measuring the temperature of the intake air. Within the temperature scope of the sensor, the

electric resistance would vary with different temperatures of the engine, which is a negative temperature

coefficient resister. The intake air temperature sensor is not a repairable part.

16.2.5.2 Appearance

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16.2.6 Intake Pressure Sensor


This sensor is mainly used for measuring the absolute pressure of the intake bend tube, which, in

compliance with the change between the resistance value and the intake pressure, can measure the air input of

the engine's combustion chamber indirectly.

16.2.6.1 Appearance

16.2.7 Oxygen Sensor


Oxygen sensor is mainly used for measuring the oxygen content within the exhaust pipe of combustion

engine and for the fuel closed loop controlling in the engines, which can make sure the combustion of the

engine is maintained at a reasonable air-gasoline ratio (14.7).

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16.2.7.2 Appearance

16.2.8 Ignition Coil


The ignition coil can provide energy to the spark plug. The high voltage wire is used to connect the

ignition coil and the spark plug.

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16.2.8.1 Appearance

16.2.9 Idle Speed Stepper Engine


The idle speed control valve is used to control the ventilation circulation area aside the throttle body so as

to adjust the intake air to the engine, realizing controlling of the idle speed of the engine.

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16.2.9.1 Appearance

16.2.10 Fuel Pump Assembly


The electric pump would work together with the pressure regulator to provide 250Kpa fuel pressure for

the engine. It is installed under the gasoline tank.

16.2.10.2 Appearance

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Back side:

Front side:

16.2.10.3 Failure Diagnosis of Fuel Pump Assembly

a) Turn on the key and run the fuel pump for about 3 seconds. If the fuel pump starts to run, refer to

step d).

b) Cut off the connector of the fuel pump and check whether the power supply voltage is 12V or so.

c) If there is nothing wrong with the second step, supply 12V DC to the fuel pump with an external

storage battery. Check whether the fuel pump runs or not.

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d) If the fuel pump runs normally, check the oil pressure gauge to see whether the front supply pressure

of the nozzle is about 250Kpa when the engine is idling.

e) If the pipe pressure is lower than 220Kpa, check if there is a leakage in the oil pipe, if the fuel pump

runs backwards, or if the filter is blocked.

16.2.10.4 Common Problems

a) The reverse connection of the connector of the fuel pump assembly causes the fuel pump run

backwards, thus leading to inadequate fuel pressure for the engine. As a result, the engine

cannot work normally.

b) The fuel pump is damaged and cannot run.

Note:

1. Since a new motorcycle has no gasoline in its fuel tank at the very beginning, much air remains in the

fuel line after the tank is fueled up. Therefore, it is necessary to turn the motor over for several times to

discharge all the air in the fuel line so that the engine can operate normally. This is a normal process,

which will avoid the engine from taking a long time to start but still in failure in the later startup.

2. The gasoline can cool down the fuel pump, so do no run the pump with little or no fuel, or the fuel

pump will be overheated and damaged.

16.3 Methods for Fault Diagnosis and Maintenance

The trouble light is on the instrument panel, with a sign of FI down blew. In a normal circumstance, when

turning on the key, the trouble light will turn on to indicate the electronic control injection system is power-on

and is ready to work. If the trouble light is off, it indicates that there is no power supply in the electronic

control injection circuit and thus it cannot work. In this case, check the fuse and the connection of both

positive and negative electrodes of the storage battery. After the engine has been started, if the trouble light

turns off, it indicates that there is no fault; otherwise, if the trouble light is still on, it indicates that the

electronic control injection system is abnormal and it is necessary to remove the faults.

There are three methods for fault detection:

16.3.1 Direct Diagnosis through the Flickering Trouble Light (FI) on

the Instrument Panel

When any fault is confirmed, by switching the key for three times, i.e., turning the key on-off-on-off-on,

the trouble light will flash in corresponding fault code. Then check the fault code list for the breakdown in

correspondence.

In case of reading faults with the trouble light, the rules of flash codes are illustrated as below. Take the

open circuit of intake pressure sensor or short circuit of signal end pin to the negative electrode of the battery

as an example, after the key has been switched for three times, the trouble light will flash 10 times standing for

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0, flash once after 1.2 seconds standing for 1, flash 10 times after another 1.2 seconds standing for 0 and flash

7 times after another 1.2 seconds standing for 7, that is P0107. It shows that, except the number 0 is

represented by flashing for 10 times, other numbers from 1 to 9 will flash as the number itself shows. If there

are other fault codes, such as fault P0201, a fault in the fuel injector of front cylinder, the light of fault code

P0201 will flash in 3.2 seconds after the flashing of P0107. The trouble lights of P0107 and P0201 will flash

circularly in case of no other fault. Then faults can be checked according to the fault code list.

Decimal number will be adopted to show the fault code in PCHUD software. The decimal number in the fault

code list is corresponded to the previous hexadecimal, thus faults can be found out in correspondence. If

MULFCURR (current fault) =263, the corresponding fault code in the fault code list is P0107, i.e., a fault of

intake pressure sensor.

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MT05 Fault Code List

Fault code Description

Corresponding

decimal number

P0107

open circuit of intake pressure sensor or short circuit of signal end

pin to the negative electrode of the battery 263

P0108

short circuit of signal end pin of the intake pressure sensor to the

positive electrode of the battery 264

P0112

short circuit of signal end pin of the intake temperature sensor to

the negative electrode of the battery 274

P0113

open circuit of intake temperature sensor or short circuit of signal

end pin to the positive electrode of the battery 275

P0117

short circuit of signal end pin of the cylinder end temperature

sensor to the negative electrode of the battery 279

P0118

open circuit of cylinder end temperature sensor or short circuit of

signal end pin to the positive electrode of the battery 280

P0122

open circuit of throttle position sensor or short circuit of signal

end pin to the negative electrode of the battery 290

P0123

short circuit of signal end pin of the throttle position sensor to the

positive electrode of the battery 291

P0131

short circuit of signal end pin of the front cylinder oxygen sensor

to the negative electrode of the battery 305

P0132

short circuit of signal end pin of the front cylinder oxygen sensor

to the positive electrode of the battery 306

P0031

short circuit of heating end pin of the front cylinder oxygen sensor


P0032

short circuit of heating end pin of the front cylinder oxygen sensor


P0201 fault of for fuel injector front cylinder 513

P0202

fault of for fuel injector rear cylinder (plug-in device of the fuel

injector is not plugged) 514

P0230

open circuit of oil pump or short circuit to the negative electrode

of the battery 560

P0232 short circuit of oil pump to the positive electrode of the battery 562

P0336 signal interference of crank shaft position sensor 822

P0337 no signal of crank shaft position sensor 823

P0351 fault of ignition coil for front cylinder 849

P0352 fault of ignition coil for rear cylinder 850

P0562 voltage below level of electronic control injection system 1378

P0563 overtension of electronic control injection system 1379

P0560 fault of trouble light (damage of filament or plug-in device) 1616

P1693 short circuit of tachometer line to the negative electrode of the 5779

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battery

P1694

short circuit of tachometer line to the positive electrode of the

battery 5780

P0137

short circuit of signal end pin of the rear cylinder oxygen sensor


P0138

short circuit of signal end pin of the rear cylinder oxygen sensor


P0038

short circuit of heating end pin of the rear cylinder oxygen sensor


P0037

short circuit of heating end pin of the rear cylinder oxygen sensor


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16.3.2 Fault Diagnosis by Diagnostic Apparatus

Operation steps：

a) Find the 6-hole diagnostic port on the motorcycle.

b) Connect the connecting line to the port on the diagnostic apparatus.

c) Turn on the key to diagnose the faults.

16.3.3 Fault Diagnosis with the Diagnostic Software PCHUD

PCHUD software is used to inspect and record the operating data of the engine. Before using the software,

connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line. The notebook

computer needs to install the K line driver software before using.

- 197 -

Instructions of PCHUD Software:

（1）Connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line and turn on

the key.

（2）Click the icon "HUD.EXE" to start PCHUD software

（3）Select "File" on the software interface, click "Open", choose "PCHUD.HAD" and select OK.

（4）Select "Parameter File" within "Setup", click the file MT05COMMON.par, choose "Comm protocol"

within "Setup", then select "Keywork2000" and click OK, meanwhile, choose 17 in Device Code.

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（5）If the real-time communication data fail to display on the soft ware interface when the power is on, check

whether the connection setting of COM port in "Setup". Under the normal circumstance, set COM Port: 4 and

Baud Rate: 10400, instead of DTR High at startup.

Normal communication is ready to make then. Current fault code is displayed in the position of MALFCURR

and historical fault code displayed on MALFHIST.

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Then check the corresponding fault according to the fault code list

- 200 -

Interpretation of PCHUD Software Parameter

VRPM 发动机转速 engine speed

VTHROT 节气门开度 throtle position

VBARO 大气压力 BARO

VMAP 进气歧管压力 manifold air pressure

VMAPEXP 进气歧管压力估计值 expect manifold air pressure

VIGN 蓄电池电压 ignition key voltage

VCLTS 发动机缸温或者冷却水温 cylinder temperature or coolant temperature

VIAT 进气温度 intake air temperature

STATUSBYTE5 状态标志 5 STATUSBYTE5

VAFCMET 空气流量学习条件满足 airflow correction met

VBAROCMET 大气压力更新条件满足 Baro update met

VCSINSYNSPRK 顺序点火标志 sequential spark enable

SATITRIG tip-in 点火角修正条件满足 tip-in Spark Advance retard trigger

CATLOENB 触媒起燃逻辑使能 catlyst light-off logic enable

IF ENGSTATE=3 发动机正常工作标志位 engine work in run state

NISTBLIDLE 暖机怠速条件满足 stable warm idle

FO2REDY2 2 缸氧传感器加热完成标志位 O2 ready

FCNO 进气效率长效学习单元 block learn memory cell

FBLMCOR1 1 缸长效学习值 cylinder 1 block learn memory

FCLCINT1 闭环学习 I 项 intergral of close loop correction

FCLCMUL1 闭环学习修正量 close loop correction

IARDRPM 目标怠速转速 desired idle rpm

IARPMERR 怠速偏差 idle rpm error

FPWVC1 1 缸喷油脉宽 base pulse width of cylinder 1

VO2 氧传感器信号 Oxygen sensor signal


FO2STAT1 1 缸氧传感器浓稀标志位 cylinder 1 oxygen sensor signal rich lean state

FCLREST1 1 缸闭环修正重置标志位 cylinder 1 close loop correction reset

- 201 -

FOSHTREN 氧传感器加热使能 Oxygen sensor heater enable

FO2REDY1 1 缸氧传感器加热完成标志位 cylinder 1 Oxygen sensor ready

IF IACV MODE=0 怠速步进电机闭环学习使能 idle airflow control valve close loop correction enable

IAMTRLOST 怠速步进电机丢步标志位 IACV lost

IACMVIHB 怠速步进电机禁止移动标志位 IACV move disable

VIGNS 点火状态标志位 ignition state

FVE1 1 缸充气效率 cylinder 1 Volumetric efficiency

VMAPRANG 进气压力读取角度 MAP read angle

AFFNLAFR 目标空燃比 target air fuel ratio

SAESTA 1 缸点火提前角 cylinder 1 Spark Advance

SAIDLDYN 怠速动态点火角 idle dynamic Spark Advance

SPDWELL 充磁时间 dwell time

IAINTEGOFST 怠速步进电机气量学习值 airflow integral of idle air control valve

IACVDSMP 怠速步进电机目标步数 desired position of idld air control valve


FCLCEN1 1 缸闭环修正使能 cylinder 1 close loop correction enable

PPDSEBL 预喷禁止标志位 prime pulse disable

FPENABL 油泵使能标志位 fuel pump enable

FTRNSAES 加速加浓使能 acceleration enrich enter

FTRNSDES 减速减稀使能 deceleration enlean enter

FTRNSAEDCLOAD 加速加浓退出 acceleration enrich exit

FTRNSDEINLOAD 减速减稀退出 deceleration enlean exit

FCLCEN2 2 缸闭环修正使能 cylinder 2 close loop correction enable

- 202 -

16.4 Common Fault Removal Techniques

16.4.1 Repair Tools

a) Disassembling the parts of the electronic control system- common disassembly tools for auto machinery

parts

b) Circuit of the electronic control system and its electrical signal- digital multimeter (with beep)

c) Diagnosing the faults in the electronic control system and checking the engine's operation

Fault diagnostic apparatus for electronic control system(recommended)

Fault diagnosis software(PCHUD) and port wire( if available)

d) Fault code list of the electronic control system( for emergency)

e) Fuel pressure gauge, range: 0 ~ 300kPa

16.4.2 The Operation Data Flow of the Engine Shown on the

Diagnostic Apparatus

Analyze and check the faults in engine through the operation data flow of the engine shown on the

diagnostic apparatus.

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16.4.2.1 Step One

a) Engine wire harness and vacuum line- may influence the system in controlling air flow and oil supply.

b) Assembly of Oxygen sensor- may influence the system in judging the air-fuel ratio.

c) Engine trouble light- influences the system in fault warning.

d) Storage battery voltage- judges whether the battery power is adequate.

e) According to the experience, judge whether the readings of coolant temperature sensor, air intake

temperature sensor, manifold absolute pressure sensor and oxygen sensor are normal.

f) Working range of throttle position sensor- Failure in completely turning on or off the sensor may

influence the power performance of the engine and part of system function.

16.4.2.2 Step Two

Check whether the power supply of ECU is cut off- the communication between the diagnostic apparatus

and the system halts after turning off the key switch.

16.4.2.3 Step Three

a) Coolant temperature and its cycling- indicate whether the thermostat operates normally.

b) Storage battery voltage- shows whether the generator works normally.

Too high: maybe a fault in the generator regulator.

Too low：maybe the inappropriate connection of generator wires or a fault in the generator

c) Manifold air pressure- may indicate whether there is an intake air leak or an air valve clearance

The air valve clearance is too small: the overhigh figure may influence the power performance of the

engine. Meanwhile, because the exhaust valve opens too early, the increased temperature of the exhausted

air will significantly reduce the service lives of oxygen sensor and ternary catalytic converter.

The air valve clearance is too large: may cause the manifold air pressure become low, thus influencing the

system in judging the engine's operation and leading to abnormal idling in the engine's warming-up.

Besides, the clogged exhaust system, e.g., foreign materials in the exhaust passage, or the blocked ternary

catalytic converter caused by the over-consumption of the engine oil, or damaged pieces inside of the

ternary catalytic converter, will lead to an overhigh figure.

d) Cycle number of the oxygen sensor reading- a small cycle number indicates the failure of the oxygen

sensor.

16.4.3 Concise Fault Removal Techniques

Please take the following steps to repair the electronic control injection system. If the fault is removed in

a certain step, the following steps can be suspended. Then check and remove the fault code by diagnostic

apparatus in compliance with the term 14.4.2.

- 204 -

When using the diagnostic apparatus, the storage battery voltage cannot be lower than 8.5V.

16.4.3.1 Daily Use and Maintenance

Unleaded gasoline #92 or #95 is strongly recommended.

Though ECU is damp-proof, it is forbidden to wash its cover with a high-pressure water gun.

The fuel filter should be replaced every 7,000-10,000km

In common circumstances, the throttle valve should be washed every 10,000km or every 1 year.

16.4.3.2 Fault Description- Startup Failure

a) Turn the ignition lock to "ON" to check whether the trouble light turns on.

If no： Check the fuse and the ground wire.

Check whether ECU's plug is tightly connected.

Check whether the light and circuit are normal through the inspection function of the

diagnostic apparatus's actuator.

Check and repair the light and its circuit.

Make the judgment with another ECU.

If yes： Connect the diagnostic apparatus to the system's diagnostic port.

b) Whether the diagnostic apparatus can be connected to the system for communication

If no: Check the fuse and the ground wire

Check whether ECU's plug is tightly connected

Check whether the diagnostic apparatus works normally on another normal motorcycle.


If yes: Remove the fault shown by the diagnostic apparatus.

c) Check the faults in the ignition system- whether the spark plug can ignite normally

If no: Check whether the high-tension cable and spark plug are connected tightly or are damaged.

Make the judgment with another ignition coil assembly


If yes: Check whether the high-tension cable is connected with the ignition coil and spark plug in a

correct way

d) Check the faults in the oil supply system

Whether the fuel pump is working- the working noise of the fuel pump can be heard in its nearby when

starting the engine.

If no: Check whether the fuel pump relay works normally.

Check whether the connection of crankshaft position sensor and its operation are normal.


Check the fuel pump circuit

If yes: 1) Whether the supplied oil pressure is above 220Kpa

2) Inadequate Check whether there is enough gasoline in the fuel tank

- 205 -

pressure： Check whether it is necessary to replace the fuel filter (note: the special

fuel filter for the electronic control injector should be replaced every

7,000-10,000km)

Whether the oil supply line and oil return line are damaged

3) Normal

pressure：

Check whether the nozzle control line is abnormal

Whether it is necessary to clean the oil nozzle

e) Check whether the cylinder is flooded with oil

If yes： Press the accelerator pedal to the limit and turn on the starter. After several seconds, there

will be a sign showing the engine running.

f) Whether the clearance of crankshaft position sensor is too large

16.4.3.3 Fault Description- Startup Failure Accompanied with Backfire

a) Check whether the high-tension cable of ignition coil is loose

b) Whether the timing gear is loose.

16.4.3.4 Fault Description- Unstable Idle Speed

Idle speed control

system:

Check whether the idle speed by-pass bolt is too loose or tight. Usually it is necessary to

screw 2 turns.

Oil supply system Whether there is an oil pipeline leak

16.4.3.5 Fault Description- Too High/Low Idle Speed (Apparent

Non-conformity to Target Idle Speed)

Idle speed

is too high:

When the water temperature is lower than 68℃, the system will increase the idle speed to

accelerate the warming up. Besides this normal process, check according to the following

steps.

Check whether the idle air bypass hole is too large.

Check whether the air valve clearance, especially the exhaust valve clearance, is too

large.

Idle speed

is too low:

Check the oil amount in the fuel tank, the fuel filter, the oil line pressure and the oil

nozzle.

Check whether the idle air bypass hole is too tiny.

Check whether the air valve clearance is too small.

- 206 -

16.4.3.6 Fault Description- Unstable Idle Speed Slowing Down with Flameout

a) Check the valve clearance

b) Check whether the idle air bypass hole and throttle body are too dirty

16.4.3.7 Fault Description-Poor Acceleration

a) Whether the parameters at idle speed and high idle speed are normal

b) Check the oil amount in the fuel tank, and fuel filter.

c) Check whether the exhaust system is blocked, e.g., whether the ternary catalytic converter is clogged

because of burning engine oil or damages.

d) Check the oil line pressure and the oil nozzle.

e) Check whether the trouble light turns on and whether it is because only one cylinder can work normally

to ignite.

16.4.3.8 Fault Description- Little Misfire

Check whether the spark plug gap meets the standard between 0.7-1mm.

16.4.3.9 Fault Description- Non-conformity between Fault Code and Fault

When Trouble Light is On

The ground wire of the system may be not connected well. Reconnect the ground wire, turn off the

storage battery power line for 3 minutes and turn it on, then start the engine.

16.4.3.10 Fault Description- Abnormally High Oil Consumption

a) Check the assembly of the oxygen sensor of two cylinders. If it is in a loose state, the oxygen sensor will

make a wrong judgment of the slight lean burn in the cylinders, and thus add more fuel, leading to

abnormally high oil consumption.

b) When the engine's mechanical parts and the oxygen sensor are confirmed to be normal, start the engine to

check the reading of the oxygen sensor. If the reading is always above 500 mV in a normal water

temperature, check whether there is a leakage in the oil nozzle.

Note

Most parts of electronic control injection system are non-repairable. Once a part is damaged, usually it

needs to be replaced.

When starting the engine, do not run any other organs of the engine (including the throttle, do not push

the throttle in the startup).

- 207 -

If the engine trouble light turns on when the engine is operating, it is necessary to check the reason and

remove the fault as early as possible.

Do not use leaded gasoline for lead will do harm to the oxygen sensor and ternary catalytic converter.

When there is an abnormal consumption of the engine oil, the fault should be removed as soon as possible,

or some substances in the engine oil will also do harm to the oxygen sensor and ternary catalytic

converter.

The air valve clearance should not be too small. If the air valve does not tightly shut off in the exhaust

process, the exhaust temperature will be too high so that the service life of ternary catalytic converter will

be reduced.

When the temperature is lower than 10℃, if the motorcycle and the engine run at a low speed for a long

time, the exhaust pipe may have carbon deposits and appear to be black. This is a normal phenomenon. It

will disappear after the engine operates at a high speed for some time or by adopting appropriate methods

to keep the engine coolant temperature in a specified range

0

RK6 Circuit Diagram

主继电器1

白3白2白1黑白3

灰

橙/黄

黑/棕1

红/白

红/白

橙/黄

淡蓝

黄

黑

蓝

绿/黑

橙

橙/白

绿/白

离合器开关

橙/红

黑

前大灯

右转向

左转向

红/白紫

前刹车开关

黑

棕

喇叭

棕

/

绿

风扇

仪表

绿/

黑

淡

蓝

红

/

白

蓝

黄

绿

/

红

红

/

白

黄/

红

电门锁左把手

右右左

橙

/

蓝

红/

白

绿

/

白

棕红/

白

红/

白

绿/

黄

右把手

左

左

右右左

点火线圈

黑

/

红1

黑

/

白1

橙/

绿1

黑

/

红1

黑 /

红1

白/

红1

白/

紫1

黑

/

红1

黑/蓝

速度传感器

灰/

红

墨

绿

红/

浅蓝

墨绿

红/黑

黑

白

/

蓝燃油泵

红/

白

橙

闪光器

喷油器

节气门传感器

边撑熄火

进气压力传感器

红/

灰1

红/

绿1

黑/

蓝

绿/黑

橙/白

橙

绿/白

黑黄

紫

左转向灯

右转向灯

后尾灯

牌照灯灯

白

/

棕

黑

/

蓝

水温传感器防侧翻传感器 1缸氧传感器

白/

灰1

黄

/

绿1

黑/

红1

黑

/

蓝

诊断仪

橙/

黄绿

黑紫红/白

后刹车开关

黄

黑

粉

红

15A10A 10A

红

/

棕

红1蓝/

黄

红

/

蓝

15A15A 10A

红/

黄

红粉

红

绿

/

红

红/

橙

红

保险盒

黑/红2

红/黄

绿

绿/蓝

黑/红2

红/白

大灯继电器

蓝/黄

蓝/绿

黄/红

棕/浅绿

红/棕

红/白

棕/绿

风扇继电器

油泵继电器

电喷控制继电器2

黑/

蓝

蓝/

橙

红/橙

黑

黑黑白/

绿

蓝/

白

触发头

13987 10 11 1221 5 63 4

1#Gr ECU J1161514 17 18

1#BLACK ECU J210 11 1265 87 9321 4 14 15 1716 1813

103℃

棕

/

浅

绿

黑

13987 10 11 1221 5 63 4

2# Gr ECU J1161514 17 18

2#BLACK ECU J210 11 1265 87 9321 4 14 15 1716 1813

黑

黑

黑/红2

白/紫2

白/红2

黑 /红2

黑/红2

橙/绿2

黑/白2

黑/红2

喷油器

点火线圈

黑/蓝

红/绿

红/灰2 进气压力传感器

黑/蓝

黑/红2

黄/绿2

白/灰24缸氧传感器

油位传感器

黄

/

蓝

进气温度

进气温度

诊断仪

白/

橙1

黑

/

蓝

黑

红/黑

电源锁ECU1燃油泵风扇灯光 ECU2启动继电器

30A保险丝

红橙/

红

粉

红

绿

/

黄

黑

绿

红/蓝

黑/红1

电喷控制继电器1

黄/

红

警示灯二极管

绿/

白

绿

/

黑

橙/

蓝

IN5408

白/橙2

黑/蓝

怠速控制阀

黑/

蓝

棕/黑棕/蓝

棕/蓝1

棕/红

棕/红1

黑橙/绿

蓝/橙黑/白黑

红/紫

红/紫

蓝/白白/紫

白/红黄/绿

白/橙黑/蓝红/灰白/绿

白/棕绿红/绿

白/灰

红/蓝

红/蓝

棕/黑棕/蓝棕/红

黑黑/白蓝/橙橙/绿黑

红/紫蓝/白

白/红

白/紫黄/绿

白/橙黑/蓝黑/橙

红/灰白/灰红/绿

绿黄/蓝

白/绿红/黄

棕/蓝

棕/红

红/紫

绿/蓝

红/黄

黑/橙1白/黑

白/黑灰/白

灰/白

白/黄

白/黄黄/紫

黄/紫

白/蓝

绿/白1绿/黑1

蓝

灰/红

红/紫1

黑红/白

棕/黑

粉红

橙/黑

橙

/

白

绿/

黑1

绿/

白1黑

灰/红1 橙/红

粉红/蓝黑/黄

黄/蓝

碳罐电磁阀黑/红2

粉红/蓝

3缸氧传感器黄/蓝2

黑/黄2

黑/红2

黑/蓝

橙/红

黑

蓝/绿黑/黄黄/蓝1

橙/黑黑/橙1

黑/橙

红/绿

灰

橙/红启动二极管

黄/

蓝1

黑

/

红1

黑

/

蓝

黑/

黄

2缸氧传感器

水温开关

墨绿

墨绿

红/紫1

灰红

/

浅蓝

棕/

白机油开关棕/白

空档灰

红/

白

白1白2

电瓶正极

电瓶正极

电瓶负极

马

达

电瓶正极

绿黑

/

棕1

红1