Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Contents
Preface .............................................................................................................................................................. - 1 Preparing Documents ....................................................................................................................................... - 2 General Safety .......................................................................................................................................... - 2 Maintenance Rules ................................................................................................................................... - 3 Specification ........................................................................................................................................... - 13 Failure Diagnosis.................................................................................................................................... - 15 Inspection/Adjustment ........................................................................................................................... - 22 Inspection and Maintenance of the Electrical System .................................................................................... - 43 1. Battery/Charging System ........................................................................................................................... - 44 1.1 Preparing Documents ....................................................................................................................... - 44 1.2 Failure Diagnosis.............................................................................................................................. - 45 1.3 Battery .............................................................................................................................................. - 46 1.4 Charging System .............................................................................................................................. - 47 1.5 Voltage/Current Regulator ................................................................................................................ - 48 1.6 Magnetor Charging Coil ................................................................................................................... - 48 1.7 Magnetor Disassembly ..................................................................................................................... - 49 2. Ignition System .......................................................................................................................................... - 52 2.1 Preparing Documents ....................................................................................................................... - 52 2.2 Failure Diagnosis.............................................................................................................................. - 53 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 3.1 Preparing Documents ....................................................................................................................... - 58 3.2 Failure Diagnosis.............................................................................................................................. - 59 3.3 Startup Motor ................................................................................................................................... - 59 3.4 Starter Relay ..................................................................................................................................... - 61 4. Bulbs/ Switches / Meters ............................................................................................................................ - 63 4.1 Preparing Documents ....................................................................................................................... - 63 4.2 Failure Diagnosis.............................................................................................................................. - 64 4.3 Replacement of Headlamp Bulbs ..................................................................................................... - 64 4.4 Replacement of Front Position Lamp Bulbs .................................................................................... - 65 4.5 Replacement of Tail Lamp ............................................................................................................... - 66 4.6 Replacement of Rear Registration Plate Lamp Bulbs ...................................................................... - 67 4.7 Replacement of Front Steering Lamp Bulbs .................................................................................... - 68 4.8 Replacement of Rear Steering Lamp Bulbs ..................................................................................... - 68 4.9 Meters ............................................................................................................................................... - 68 4.10 Main Switch ................................................................................................................................... - 69 4.11 Horn ................................................................................................................................................ - 69 4.12 Handlebar Switch ........................................................................................................................... - 70 Inspection and Maintenance of the Motorcycle Body .................................................................................... - 71 5. Brake .......................................................................................................................................................... - 74 1
5.1 Maintenance Instruction ................................................................................................................... - 74 5.2 Failure Diagnosis.............................................................................................................................. - 75 5.3 Front Disc Brake .............................................................................................................................. - 76 5.4 Rear Disc Brake ............................................................................................................................... - 80 6. Body ........................................................................................................................................................... - 84 6.1 Disassembly ..................................................................................................................................... - 84 6.2 Assembly .......................................................................................................................................... - 84 7. Front Wheel/Handlebar/Front Suspension ................................................................................................. - 88 7.1 Preparing Documents ....................................................................................................................... - 88 7.2 Failure Diagnosis.............................................................................................................................. - 89 7.3 Front Wheel ...................................................................................................................................... - 90 7.4 Steering Handlebar ........................................................................................................................... - 95 7.5 Front Fork ......................................................................................................................................... - 97 8. Rear Wheel/Rear Suspension ................................................................................................................... - 101 8.1 Preparing Documents ..................................................................................................................... - 101 8.2 Failure Diagnosis............................................................................................................................ - 101 8.3 Rear Wheel ..................................................................................................................................... - 102 8.4 Rear Absorber................................................................................................................................. - 106 8.5 Chain Drive .................................................................................................................................... - 108 8.6 Rear Swinging Arm ........................................................................................................................ - 110 9. Fuel Tank .................................................................................................................................................. - 113 9.1 Preparing Documents ..................................................................................................................... - 113 9.2 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 11.1 Preparing Documents ................................................................................................................... - 124 11.2 Failure Diagnosis .......................................................................................................................... - 124 11.3 Fuel Pump..................................................................................................................................... - 125 12. Cylinder Head ........................................................................................................................................ - 130 12.1 Preparing Documents ................................................................................................................... - 130 12.2 Failure Diagnosis.......................................................................................................................... - 130 12.3 Cylinder Head .............................................................................................................................. - 132 13. Crankcase ............................................................................................................................................... - 140 13.1 Preparing Documents ................................................................................................................... - 140 13.2 Failure Diagnosis.......................................................................................................................... - 143 13.3 Upper Box .................................................................................................................................... - 144 13.4 Piston ............................................................................................................................................ - 145 13.5 Lower Box .................................................................................................................................... - 150 13.5 Lower Box .................................................................................................................................... - 151 13.6 Clutch ........................................................................................................................................... - 154 2
13.7 Gearshift Mechanism ................................................................................................................... - 157 13.8 Crankshaft Connecting Rod Assembly Chamber and Variable Speed Chamber .......................... - 161 14. Cooling System ...................................................................................................................................... - 167 14.1 Preparing Documents ................................................................................................................... - 167 14.2 Failure Diagnosis.......................................................................................................................... - 168 14.3 Water Pump .................................................................................................................................. - 168 Inspection and Maintenance of Exhaust Emission System .......................................................................... - 171 15. Exhaust Emission & Control System ..................................................................................................... - 172 15.1 Warranty on the Exhaust Emission & Control System ................................................................. - 172 15.2 Instructions on Periodic Maintenance .......................................................................................... - 173 15.3 Mechanical Function of the Exhaust Control System .................................................................. - 173 15.4 Catalytic Transfer System ............................................................................................................ - 174 15.5 Measures When the Idle Speed Emission Value Exceeds the Standard ....................................... - 176 Inspection and Maintenance of Electronic Fuel Injection (EFI) System ...................................................... - 177 16. Electronic Fuel Injection System ........................................................................................................... - 178 16.1 Introduction of Electronic Fuel Injection System......................................................................... - 178 16.2 Components of Electronic Fuel Injection System ........................................................................ - 178 16.3 Methods for Fault Diagnosis and Maintenance ............................................................................ - 192 16.4 Common Fault Removal Techniques ........................................................................................... - 202 RK6 Circuit Diagram ........................................................................................................................................... 0
Preface
This maintenance manual is used for operating and maintaining Motorcycle
RK6.
Preparing Documents include all necessary instructions and statements.
Please carefully read this manual before operation.
Inspection & Adjustment states how to check and adjust your motorcycle. All
safety rules and maintenance regulations shall be carried out from the beginning of
periodic inspection.
Except for Chapter I, the rest chapters explain the disassembly/ assembly/
inspection of Electronic Fuel Injection System, engine, entire motorcycle and
electrical equipment.
Breakdown drawing, systematic drawing, failure analysis and statements are
contained at the first part of each chapter.
Please note that photos, pictures or instructions are for your reference only.
The actual object may differ from what is mentioned here. We will not make
notification for any discrepancy.
Qianjiang Motorcycle Corporation Ltd.
- 1 -
Preparing Documents
General Safety
Specification Table
Maintenance Rules
Inspection/Adjustment
General Safety
Carbon monoxide
Engine must be started up in a well-ventilated place, not in a closed area.
Note
Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human.
Start up engine in an open place. The exhaust cleaning system shall be adopted if engine is started up in a
closed area.
Petrol
Ventilation is required for working places. Fire is strictly forbidden in any working place or where petroleum is
stored.
Battery
Battery emits explosive gas. Therefore, it shall be far away from fire sources, naked flame or smoking places.
Make sure good ventilation during charging.
Battery contains sulfuric acid (electrolyte). It will burn your skin or eyes when contacted. Therefore, wear
protective clothing and mask.
Clean with fresh water immediately if electrolyte splashes on the skin.
Clean with fresh water at least for 15 minutes immediately and then go to the doctor if electrolyte
splashes on eyes.
Electrolyte is poisonous. Drink a large quantity of fresh water, milk, milk of magnesia (laxative antacid) or
mineral oil if electrolyte is swollen accidentally. Then go to the doctor. It shall be unreachable for children.
Machine Oil
It may trigger cancer if repeatedly expose the hands in the air after contacting with oil. Although there is little
possibility for you to contact with oil in the daily life, wash hands thoroughly with water and soap if you have
contacted. And it shall be unreachable for children.
Thermal Energy
Parts of the engine and cooling system produce heat, which can last for some time before the engine gets
started. Deal with these parts with gloves or after the engine and cooling system cools down.
- 2 -
Maintenance Rules
Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage.
Clean up the surface of components or assembly parts before removing or opening the shield for maintenance,
which can prevent dirt from falling into the engine, the chassis or the braking system.
Wash and dry parts with air compressor after disassembly and
before measurement of attrition value.
boot
- 3 -
Bolts and screws with different length shall be separately used for
different assembly parts and shields, and they shall be correctly
mounted. Insert a bolt into a hole to check whether it is proper if
you are confused.
Fill the groove with grease before mounting an oil seal. Check
whether the oil seal is smooth or damaged during assembly.
- 4 -
- 5 -
Identification
1The frame number, see figure
Frame Number
Frame
Frame Number
Rivets
Significant Notes
1. Please apply valid Qianjiang parts and accessories. Any part or accessory not in accordance with the design
specification of Qianjiang Company may cause damage to engine.
2. Only metric tools are valid for maintenance and repair. Metric screws, bolts and nuts can not be exchanged
with imperial fasteners.
3. New gaskets, O-rings, cotter pins and locking pieces shall be applied for re-assembly.
4. Bolts with large diameter or positioned inside shall be fastened first and then diagonally screw down until
reaching required torque, otherwise there is special instruction.
5. Wash disassembled parts with cleanser. Lubricate all sliding surface before assembly.
6. Check whether all the parts and accessories are correctly mounted and operated after assembly.
7. Clean and remove oil before measurement. Add recommended lubricant to the lubricating areas during
assembly.
8. Apply lubricant to the surface of engine and driving system if they are dismantled for long-term storage,
which can prevent rust and dirt.
- 6 -
Special Tools
Special tools refer to tools which are specially designed for assembling or disassembling some
motorcycle parts on special positions. Applicable special tools are necessary for precise adjustment and
installation. With them, parts and accessories can be mounted safely, reliably and rapidly, which improves
efficiency and saves energy.
Remark
Fig.1-4
Flywheel puller
Fig. 1-4
Feeler gauge
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
Dial indicator
Fig. 1-15
Dial indicator
Fig. 1-19
Fig. 1-20
Fig. 1-21
Fig. 1-22
Fig. 1-23
Fig. 1-24
Fig. 1-3
Fig. 1-4
- 7 -
Fig. 1-5
Fig. 1-6
feeler gauge
Fig. 1-7
Fig. 1-8
Fig. 1-9
Fig. 1-10
handle
Fig. 1-11
Fig. 1-12
pliers piston
- 8 -
Fig.1-13
Fig.1-14
Fig. 1-15
Fig. 1-16
Fig. 1-17
Fig. 1-18
Fig. 1-19
Fig. 1-20
Fig. 1-21
Fig. 1-22
- 9 -
Fig. 1-23
Fig. 1-24
Remark
Torque spanner
Fig. 1-27
Fig. 1-28
Socket spanner
Fig. 1-29
Micrometer
Fig. 1-30
Fig. 1-31
Dial indicator
Fig. 1-32
Vernier calipers
Fig. 1-33
Circlip pliers
Fig. 1-34
Fig. 1-35
Fig. 1-36
Fig. 1-37
Fig. 1-38
Fig. 1-27
Fig. 1-28
Fig. 1-29
Fig. 1-30
- 10 -
Fig. 1-31
Fig. 1-32
Fig. 1-33
Fig. 1-34
Fig. 1-35
Fig. 1-36
(2) Special tools for repairing the chassis: tool for hammering seal of front fork
Fig. 1-37
Fig. 1-38
Table and drawings (1-39, 1-40) of special tools for testing electric parts are as follows:
Fig. 1-39
Name
Remark
Multimeter
Fig. 1-41
Ignition tester
Fig. 1-42
Fig. 1-41
Fig. 1-42
- 12 -
Specification
Motorcycle Model
RK6
Engine Type
BJ465MS-A
Length mm
2120
Fuel type
Unleaded petrol93/97
Width mm
800
No. of
cylinder
Height mm
1100
ID stroke
65.045.2
Wheelbase mm
1480
Total
displacement
600cc
15L
Startup
Electric
115
Cooling
Liquid cooling
105
Lubrication
Pressure splash
lubrication
Total
220
Clutch type
Wet multi-chip
Front
tire
120/70
ZR 17
Variable
speed
Rear tire
180/55
ZR 17
Transmission
Chain
Weight kg
(Curb weight)
Tire Size
Electric
devices
Perfor
mance
Engine
Forward
shaft
Backshaft
Battery
capacity
12V-9AH
Magnetor
Flywheel permanent
magnet
Spark plug
CR9E(NGK)
Spark plug
gap
0.6-0.7mm
Ignition
Primary
transmission
ratio
Transmisson
ratio of gear 1
1.864
2.846
Transmission
ratio of gear 2
1.947
Transmission
ratio of gear 3
1.556
TLI
Transmission
ratio of gear 4
1.333
Max. Hp
60.0kW/11000rpm
Transmission
ratio of gear 5
1.190
Max. torque
55N.m/8000rpm
Transmission
ratio of gear 6
1.083
Compression
ratio
11.51
Final
Transmission
ratio
3.286
Max. speed
185km/h
Dia. of front
liquid brake
discmm
320mm
Dia. of rear
liquid brake
discmm
240mm
Transmission
devices
Brake
Fuel
consumption
limit
5.2L/100km
- 13 -
RK6
- 14 -
Failure Diagnosis
Diagnosis on difficulty or failure in starting up
Failure Diagnosis
Causes of Failure
- 15 -
Check if petrol
pump is working
properly
No
petrol
provided to
fuel injector
Disassemble
spark
plug into its cap,
ground it with engine
to check if it can spark
Spark-over
Weak sparks
No
Normal
Too low
No
No ignition
outbreak of
the engine
Ignition outbreak
of the engine but
no sign of startup
Abnormal
actuation
automatic
choke
- 16 -
Adjustment specification
Causes of failure
Incorrect ignition
time
Abnormal trigger
Test compression pressure
Abnormal piston of cylinder and
piston ring
Normal
Too low
Leakage of cylinder gasket
Yes
Contaminant removal
Disassemble the spark plug to
check
No pollution nor
discoloration
Contaminant removal
Polluted and
discolored
Excessive oil
Insufficient oil
No replacement of oil
Normal
Abnormal
Overheated engine
Yes
No
Accelerated driving or
running
Engine knock
No engine knock
of
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
- 17 -
Causes of Failure
Abnormal
Abnormal trigger
Bad
Mixed gas too dense (tighten
bolt)
Spacer inhaled air or not
Yes
No
Bad spark-over
Bad
Air pass-hole blocked
- 18 -
Causes of Failure
Abnormal
Abnormal trigger
Abnormal
No
Good
Blocked
Spring broken
Weak elasticity
Remove
Abnormal spring
- 19 -
Causes of Failure
Poor battery
Normal
Abnormal
Voltage regulator
No voltage
Normal
of
Abnormal coil
Poor connection of the joint
Open circuit of alternators
white wire
Poor battery
Abnormal
Voltage above
normal value
value
Loose
Bad connection
- 20 -
Causes of Failure
Weak spark-over or
no spark-over
Strong spark
No sign of loose
Loose
Spark plug cap loose
Abnormal
Normal
Abnormal
Abnormal trigger
Abnormal ignition coil
Check relevant parts
Normal
Abnormal
Normal
Abnormal
- 21 -
Inspection/Adjustment
Preparing information
Liquid coolant
Air filter
Spark plug
Battery
Fuse replacement
Cylinder pressure
Headlamp
Clutch
Bolt/nut/fastener
Rim/tire
Throttle valve
Components lubrication
Preparing Principles
General
Warning!
Make sure that it is well ventilated before starting the engine. It is forbidden to start it in a closed area.
Exhaust gas, which contains monoxide, may cause unconsciousness or even death of human being.
Petrol is liable to volatile or exploded under certain condition. Ventilation is required and no any fire exists in
working places. Fire is strictly forbidden in working areas or where oil is stored.
- 22 -
Specification
Engine
ID stroke
65.045.2
Total displacement
600cc
Ignition
TLI
0.6-0.7mm
CR9E(NGK)
spherical
Frame
Free stroke of front brake lever
10-20mm
20-30mm
Specification
Torque
value
RK6
Tire pressure
Front tire
120/70 ZR 17
25010kpa
Rear tire
180/55 ZR 17
29010kpa
100-140N
m
130-150N
m
- 23 -
*
*
*
*
*
Per
300
Km
Per
1000
Km
Per
3000
Km
Per
6000
Km
Per
12000
Km
Per
14500
Km
New
Twelve
months
Fifteen
months
R
R
C
Air filter
Petrol filter
Fuel filter
Replacement of engine
fuel
I
I
C
Tire pressure
Battery inspection
Ordinary tools
Ordinary tools
Inspection of steering
handle fastening
Absorber working
inspection
Screw fastening
inspection
Oil leakage inspection for
gearbox
Inspection or replacement
of spark plug
Replacement of gearbox
oil
C
I
C
Tools
Ordinary tools
Ordinary tools
Ordinary tools
Ordinary tools
Tire pressure
gauge, inflator
Densimeter,
multimeter
Ordinary tools
Torque spanner
Ordinary tools
Ordinary tools
I
I
Ordinary tools
Lubricator
Muffler
Ordinary tools
Ignition timing
Timing lamp
Carburetor
Exhaust gas inspection at
idle speed
Throttle inspection
Fuel pipeline inspection
Lighting/metering/electric
devices
Main stand bracket
Absorber
Torque force of engine
bolts
Front/rear brake
Tachometer, CO
HC analyzer
I
I
I
I
I
I
I
I
Ordinary tools
Ordinary tools
Visual multimeter
I
I
I
I
Ordinary tools
Ordinary tools
Torque spanner
Ordinary
I
I
I
I
I
I
I
I
I
A
I
I
Ordinary
Ordinary
Feeler
*
*
Drive chain
Clutch
Valve
I
I
I
I
I
I
I
- 24 -
Anticipated Inspection
1
2
3
Ignition systemobviously continuous ignition abnormality, engine fire or overheating, which requires
inspection and maintenance.
Carbon fouling eliminationobviously insufficient horsepower, which requires carbon fouling removal
from cylinder head, piston head and exhaust system.
Piston & cylinderexcessive 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.
IInspection AAdjustment RReplacement CCleaning LLubrication
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.
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 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.
Oil filter
- 26 -
Cooling Liquid
Check the height of the cooling liquid in the expansion kettle
during maintenance.
Replace in time the cooling liquid when it becomes turbid or it
is time for maintenance.
Recommended model of the cooling liquid: FD-2
Total liquid capacity of the cooling system: about 2.0L
Remove the front shield on the right side. Find the filler mouth
of radiator water tank.
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
kettle and then add cooling liquid.
Warning:
Add the cooling liquid after the engine is turned off
and cooled down. In case of burns, do not open the filler
cap before the engine has cooled down. The cooling
system is under pressure. In some cases, the cooling
liquid contains substances that are combustible, and
there will be visible flame when ignited. Avoid the
leakage of cooling liquid on hot motorcycle parts,
because it can cause serious burns if combust.
Avoid contact to and inhalation of the cooling
liquid, because it is highly toxic. And keep it away from
the children and domestic animals. If inhaled, seek
medical advises immediately, and if the skin or eyes
have accidentally contacted the cooling liquid, they
must be cleaned with water instantly.
- 27 -
clamp
- 28 -
Air Filter
Filter Replacement
Open the rear seat cushion with the key, and remove it.
key
Pull the seat steel rope, open the front seat and take it off.
- 29 -
Disassemble the shield of the fuel tank and its front fixing
bolt, and open the fuel tank.
front fixing bolt of the fuel tank
Cartridge
Replacement Time
Replace it as early as possible if the motorcycle is always running on rainy days or on rugged road.
*Note
- 30 -
Do not start engine when disassemble the cartridge of the air filter, otherwise, the engine will intake unfiltered
air, which may lead to rapid abrasion of other components, and the damage of the engine too.
In addition, rotation without cartridge will cause sequential malfunctions of the carburetor, and it may lead to
overheat of the engine.
Install in reverse order.
Spark Plug
Remove the spark plug:
(1)Lift up the fuel tank.
(2)Disassemble the intake air temperature sensors on both side
of the air filter, and then remove the air filter.
(3)Remove the stators of the spark plug caps on both sides.
(4)Remove four spark plug, and you can see the spark plug.
(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)
spark plug gap
*Note
Re-install the spark plug to the cylinder head, and screw tight with a specified torque.
Torque value: 20-25N.m
Manually install the spark plug first, and then tighten with the spark plug sleeve.
Do not make the spark plug too tight or the threads staggered, so as not to damage the threads of the cylinder
head.
When remove the spark plug, avoid impurities from entering into the engine through it.
- 31 -
Battery
Battery Disassembly
Disassemble the front seat.
Remove the mounting plate of the battery.
Charging
Connection: Connect the positive pole of the charger to the positive pole of the battery.
Connect the negative pole of the charger to the negative pole of the battery.
- 32 -
Warning!
The battery should be far away from fire source.
Turn off the charger before or after charging to avoid
explosive danger caused by spark which may exist in any
connection.
Comply with the current and time requirements for charging
as stated on the battery.
* Note
Except emergencies, you should not use emergency charging.
Measure voltage in 30 minutes after the battery is charged.
voltmeter
Charging current: standard: 0.3A
quick: 3.0A
Charging time: standard: 10-15 hours
quick: 30 minutes
charging accomplishedopen-circuit voltage: above 12.8V
Fuse Replacement
The fuse is under the drivers 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 refers to the fuse,
model: 40A, refers to the spare fuse of the main fuse, model:
40A, 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.
: light; fuel pump; fan;
power lock; spare fuse
- 33 -
Cylinder Pressure
Warm up the engine.
Insert the pressure gauge.
Turn the choke lever to the fully open position.
Start up the engine repeatedly,
The pressure of the cylinder: 11.2mpa
*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: 10-20mm
Adjustment to the drive chain:
Adjust the drive chain to the sag of 10-20mm in
every 1000 kilometers drive. Regular adjustment may
need which depends on your driving.
Warning:
It is the maximum interval for adjustment as
recommended; in fact, you should adjust the chain
before every drive. Over loosened chain may
cause the accessory chain off the drive chain or
serious damages to the engine.
Adjust the chain according the following methods
mentioned
- 34 -
- 35 -
- 36 -
Headlamp
Disassemble the fixing bolt of the headlamp support.
- 37 -
*Note
Keep combustible materials and your hands a distance away
from the bulb when it is light. Because the bulb is very hot at
that moment, you should let it cool down before touching it.
Install new headlamp bulb, lamp holder, and screw in the
bulb to the socket.
During the installation, avoid direct touch with the glass of
the bulb, an do not make it oil-stained. Or it will affect the
transparency, life and luminous flux of the bulb.
Once stained with oil, wipe thoroughly with a damp cloth of
alcohol or rubber solution of strong volatility.
Clutch
Check the free stroke of steel rope of the clutch.
Free stroke: 10-15mm
- 38 -
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.
- 39 -
Rim/Tyre
Check whether tires or rims have any crack, nail or any
other damage.
Check tyre pressure.
*Note
Check tyre pressure when it is cold.
Tyre
Specification
pressure
Front tyre
120/70 ZR 17
25010kpa
Rear tyre
180/55 ZR 17
29010kpa
RK6
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.
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
fixing nut of the rear wheel spindle
55-62 N
m
85-108 N
m
- 40 -
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 kilometers drive.
When cleaning, disconnect the negative pole of the battery,
connectors of the sensor installed on the throttle; and
remove the throttle cable, hose connected to the air filter
and the intake manifold, and the throttle body.
Open the lid on the bottom of the throttle body, spray
cleanser to its in-wall and brush the dust and carbon
deposition, etc.
After cleaning, operate in reverse order, install the throttle
and make sure that all parts are in place, and try to start the
engine successfully.
Note:
Do not let impurities block the parichnos nearby.
- 41 -
Components Lubrication
Appropriate lubrication is of great importance to the normal operation of each part of the motorcycle, to an
extended life and to the safety drive. Lubricate the motorcycle after a long time running or exposure in the rain
or after cleaning. As for detailed points for lubrication and maintenance, see the following figure:
motorcycle
lubrication
grease
3 pin of the
gearshift riding rod
4 throttle cable
6 clutch handlepin
- 42 -
charging system
- 43 -
1. Battery/Charging System
Preparing Documents-----------------------1.1
Failure Diagnosis----------------------------1.2
Battery-----------------------------------------1.3
Charging System-----------------------------1.4
Voltage/Current Regulator -------------------1.5
Charging Coil of Magnetor ------------------1.6
Disassembly of Magnetor -------------------1.7
- 44 -
Preparing Principles
Item
Specifications
Capacity/Type
Battery
Magnetor
Voltage
regulator
Voltage
20
12V-9AH/ dry-charged
Fully charged
13.1V
Necessary
charging
Charging current
Charging time
Type
14.50.5V/5.000rpm
5.0 N
m
9.0 N
m
5.0 N
m
9.0 N
m
Tools
Universal fixing spanner
Flywheel remover
Test instrument
Multimeter
Interrupted Current
Poor contact of the charging wire
Poor contact of the charging system
Poor contact or short circuit of the lighting system
Low Voltage
- 45 -
1.3 Battery
1.3.1 Battery Disassembly
As for details, please see page 31.
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.
Install it in reverse order.
*Note
To prevent short circuit, connect the positive wire
first and then the negative wire.
Check the charging condition (closed circuit voltage).
Remove the seat.
Remove cables of the battery.
Test the voltage between battery terminals.
Fully charged: 13.1V
Insufficient charging: 12.3V (not working for 1
hour)
* Note
Use a voltmeter to check the charging condition.
1.3.2 Charging
Connection method: connect the positive pole of the charger with the positive pole of the battery;
connect the negative pole of the charger with the negative pole of the battery.
Warning!
The battery should be far away from fire source.
Turn off the charger before or after charging to
avoid explosive danger caused by spark which
may exist in any connection.
Comply with the current and time requirements
for charging as stated on the battery.
- 46 -
*Note
Except emergencies, you should not use
emergency charging.
Measure voltage in 30 minutes after the battery
is charged.
Charging current: standard: 0.8A
quick: 8.0A
Charging time: standard: 10-15 hours
quick: 30 mins
Charging completed: open circuit voltage: above 12.8V
- 47 -
Judgment
With battery
voltage
With lead
Resistance in the
coil of the
magnetor.
*Note
Check
Remove the 6p connector of the magnetor.
Measure the impedance between the three white terminals of the magnetor with the multimeter.
Standard: 1.5-3.520
Replace the magnetor coil when the measured value exceeds the standard value.
- 48 -
1.7.1 Disassembly
Loosen the fixing nuts on the left cover, and
remove the left cover and the magnetic coil.
Bolt
Bolt
Bolt
- 49 -
Locking nut of
the flywheel
1.7.2 Installation
- 50 -
/2
/2
ECU2
/2
/2
/1
/1
/ /
ECU1
/1
/1
- 51 -
2. Ignition System
Preparing Documents -----------------2.1
Failure Diagnosis ---------------------2.2
Ignition System Check ---------------2.3
ECU Group----------------------------2.4
Ignition Coil ---------------------------2.5
Trigger ---------------------------------2.6
Preparing Principles
Item
Spark plug
recommended
Standard value
Standard
CR9E(NGK)
0.6-0.7mm
65050m
100-300
14V
Above 1.7V
Tools
Attachments to the Maximum Voltage Table
Multimeter
- 52 -
Ignition
coil
Charging
coil
No high voltage
- 53 -
- 54 -
- 55 -
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: 100-30020
Replace the magnetor if the measured value exceeds the
standard value.
- 56 -
BATTERY
G/Y
G/Y
- 57 -
3. Startup System
Preparing Documents ----------------3.1
Failure Diagnosis ---------------------3.2
Startup Motor -------------------------3.3
Starter Relay --------------------------3.4
Starter Clutch--------------------------3.5
Preparing Principles
Item
Standard
12.5mm
8.5mm
8.3mm
7.94mm
12 N
m
95 N
m
Tools
Spanner for retaining nuts
Universal fixing spanner
- 58 -
Fuse blow
Low battery
Poor main switch
Poor startup clutch
Poor brake switch
Poor starter relay
Poor wiring contact
Poor startup motor
Weak in rotation
Low battery
Poor wiring contact
Gear seized
Startup motor
* Note
Before the startup motor is disassembled, turn off the
main switch, remove the GND wire of the battery, and
then power on to check whether the startup motor
works for ensuring safety.
- 59 -
3.3.2 Breakdown
Remove screws in the shell, front cover, motor housing and other parts.
3.3.3 Check
- 60 -
3.3.4 Assembly
Lubricate the oil seal inside the front cover with grease.
Install the brush on the bracket.
Lubricate moving parts at two ends of the brush shaft
with grease.
Press each brush into the bracket,
* Note
Pay special attention that the contact surface between
the brush and the armature shall not be damaged.
Pay attention that the armature shaft shall not damage
lips of the oil seal.
and install the back cover of the electric machine.
Aim the screw hole of the motor shell at the screw hole of the front cover for installation.
Lock screws in the shell.
* Note
When the shell and the front cover are assembled, it is
easy to pull the front cover with magnet to attract the
armature. Press it gently for assembly.
3.3.5 Installation
Install the lead of the startup motor and the dustproof boot.
And then install the startup motor.
Install the wire clip for rear brake.
- 61 -
3.4.4 Check
Connect the starter relay to the battery, and the
terminal of the startup motor to the multimeter.
Connect the fully charged battery between the black
wire and the green/yellow wire of the relay. The relay
shall sound click and the multimeter shall indicate
resistance of zero.
- 62 -
- 63 -
- 64 -
- 65 -
- 66 -
(2) Take off the damaged bulb, and replace on a new one
of the same specification.
- 67 -
4.9 Meters
Remove the rearview mirror;
Remove the handle cover, and unplug the connectors.
Remove the nuts the meter.
Install the meter in reverse order.
- 68 -
POWER LOCK
ON
OFF
LOCK
R/W
4.11 Horn
Check
Remove horn wires.
It shows good when the horn wire is connected to the battery.
- 69 -
/ /
// /
- 70 -
Tightening torqueN
m
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
- 71 -
C
D
E
G
H
I
1. handlebar assembly of the front brake disc 2.handlebar screw 3.fixing cover 4.bolt M623 5.hexagon
flange screw 6.brake switch 7.screw M412 8.nut M6 9.brake hose assembly 10.11. bleed nipple
12.mounting bolt of the oil tube 13.gasket 14.bolt M101.2555 15.front left brake cylinder assembly
16.brake shoes 17.bolt M816 18.D.320front brake disc 19.front right brake cylinder assembly
- 72 -
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 M620 15.bolt M81.2520
- 73 -
5. Brake
Maintenance Instruction ------------------------5.1
Failure Diagnosis --------------------------------5.2
Front Disc Brake ---------------------------------5.3
Rear Disc Drake ---------------------------------5.4
5.1.1Specification
Item
Special brake liquid
Thickness of the left/right
brake disc
Thickness of the left/right
brake shoe
Dia. of the left/right brake disc
The jump of the brake surface
Front
of the left/right brake disc
Standard
DOT4
Item
Special brake liquid
Standard
DOT4
4.0mm
3.6mm
5.0mm
4.5mm
7.8mm
3.8mm
7.0mm
3.7mm
320mm
240mm
0.1mm
0.1mm
11+0.027
mm
0
Rear
16-0.032
-0.059 mm
11-0.032
-0.059 mm
34+0.08
+0.03 mm
32+0.08
+0.03 mm
32-0.032
-0.065 mm
32-0.032
-0.065 mm
- 74 -
100-140N
m
37-55N
m
37-55N
m
130-150N
m
22-34N
m
- 76 -
Bleed nipple
Fixing bolt of the brake hose
Right brake cylinder assembly
Fixing bolt of the brake cylinder
Loosen the fixing screws of the brake cylinder assembly.
Remove the brake cylinder assembly from the front absorber.
Bleed nipple
Fixing bolt of the brake hose
Left brake cylinder assembly
Fixing bolt of the brake
cylinder
- 77 -
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
Thickness of the front brake disc
320mm
4.0mm
*Note
Measure them with micrometer.
- 78 -
brake shoe
brake disc
3.8mm
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
The bolt of the brake disc
The fixing bolt of the fuel pump assembly
Mounting bolt of the front brake cylinder assembly
120N
m
28N
m
8N
m
50N
m
- 79 -
- 80 -
cylinder
Fixing screw
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
240mm
Thickness of the rear brake disc
5.0mm
*Note
Measure with micrometer.
- 81 -
brake shoe
brake disc
3.7mm
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
The bolt of the brake disc
The fixing bolt of the fuel pump assembly
Mounting bolt of the rear brake cylinder assembly
120N
m
28N
m
8N
m
50N
m
- 82 -
Body
*Note:
Do not damage any body part during disassembly.
Do not damage any hook or claw in the body during
disassembly.
Aim panels in the body at each corresponding
groove.
Ensure correct installation of each hook or claw
part during assembly.
Do not damage any part during assembly.
1. right air deflector mounting plate 2. windshield 3. left air deflector mounting plate 4. 5. right front shield 6.
right shield of the tank 7 bottom right shield 8. right shield 9. trim-cover of the right muffler 10. decorative
cover of the right muffler 11. back seat assembly 12. right rear handrail 13. left rear handrail 14. 16. left
assembly of the rear fender 17. right assembly of the rear fender 18. left shield 19. battery box 20. bottom left
shield 21. front seat assembly 22. middle shield of the tank 23. left shield of the tank 24. left front shield 25.
front shield of the tank 26.connecting board of the left/right shield
- 83 -
6. Body
6.1 Disassembly
Disassemble in the following order:
back seat assembly front seat assembly front shield of the tank left shield
of the tank right shield of the tank left front shield right front shield
middle shield of the tank tank assembly
rear connecting board of the left/right shield left rear handrail right rear
handrail bottom left shield left shield bottom right shield right shield
taillight rear bottom fender decorative cover of the right muffler
trim-cover of the right muffler decorative cover of the left muffler trim-cover
of the left muffler barrel assembly of the muffler rear fender assembly
battery box
6.2 Assembly
Assembly in reverse order.
*Note
Aim panels in the body at each corresponding groove.
Ensure correct installation of each hook or claw part during assembly.
Do no damage any part during assembly.
- 84 -
Front Suspension
A
1. front wheel spindle 2. bolt M50.814 3. screw M615.2 .4. front right absorber assembly 5. bolt
M620 6. screw M50.812 7. bolt M6114 8. suspension bush 9. mounting base under the
headlamp 10. spacer bush 11. screw M6116 12. mounting base above the headlamp 13. bolt
M81.2525 14. upper connecting board 15. upper base of the steering handlebar 16. bolt M81.2525
17. locking screw of the inner hexagon flat end M46 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
M68 25. fixing wire clip of the front brake tube 26. bottom connecting board 27 front left absorber
assembly 28. bolt M630 29. left spacer bush of the front wheel
- 85 -
Handlebar
1. balance piece assembly 2. throttle lever 3. mounting base of the balance piece 4. front cover of the throttle
cable 5. screw 6. right switch group 7. handlebar 8. left switch group 9. cover of the left handlebar 10.
handle combination of the clutch 11. clutch cable assembly 12. throttle cable assembly I 13. throttle cable
assembly II
- 86 -
Front Wheel
A
B
C
1. bolt M816 2. front brake disc 3. bearing 6005-2RS/1-C3 4. middle spacer bush of the front wheel 5. front
rim 6. vacuum tyre 120/70 ZR17 7. front brake disc 8. valve
- 87 -
Failure Diagnosis-----------------------------7.2
Front Wheel-----------------------------------7.3
Handlebar--------------------------------------7.4
Front Suspension-----------------------------7.5
Motorcycle Standards
Standard
(mm)
Measurement points
Item
Bending
Front wheel
Rim
shimmy
Vertically
Horizontally
Torque Force
Fixing bolt of the upper connecting board assembly
Fixing the front wheel spindle
Locking screw of the head of the front wheel spindle
Fixing screw of the front absorber
Fixing bolt of the steering column
Assembling bolt of the front brake cylinder
2.0
Within 1.0
2.0
Tools
22-34N
m
Bearing puller
100-140N
m Locking nut spanner
5-10N
m
5-10N
m
50-70N
m
37-55N
m
- 88 -
Deformed rim.
Abraded front wheel bearing.
Flawed front tyre.
Unbalanced tyre or wheel.
Bleed nipple
Fixing bolt of the bake hose
Right brake cylinder assembly
Fixing bolt of the brake
cylinder
Disassemble the braking caliper of the front disc brake.
Loosen the fixing screws of the brake cylinder assembly.
Remove the brake cylinder assembly off the front absorber.
- 90 -
Bleed nipple
Fixing bolt of the bake hose
Right brake cylinder assembly
Fixing bolt of the brake cylinder
- 91 -
Note:
Do not operate the brake controlling lever after the removal of the brake caliper.
- 92 -
7.3.2 Check
7.3.2.1 Check the Bending of the Wheel Spindle
Place the wheel spindle on the V-base and measure the
eccentricity ratio with a dial indicator.
Limit for use: replacement when beyond 0.2mm
axle
- 93 -
axially
radial
7.3.4 Installation
Install it in reverse order.
Note:
Lubricate the front wheel spindle, left spindle sleeve of the front wheel, bearing 6005-2RS/1-C3, and the
middle spindle sleeve.
Albany grease is suggested.
When tighten the front wheel and the caliper assembly of the disc brake, make sure that the brake disc is
between the brake pads.
The free stroke of the front brake lever can not be adjusted.
*Note
Torque of fixing the front wheel spindle: 100-140N
m
- 94 -
7.4.2 Installation
Install in reverse order.
Note:
Fixing screw of the upper base of the steering handlebar
Torque: 22-34N
m
- 96 -
the
upper
- 97 -
Tools:
Fixing nut spanner.
Special disassembly tool for bearing cup.
*Note:
The opening of the body guard shall be cleaned with cloth.
The upper/lower bearing cup shall be dismantled with a special disassembly tool for bearing cup.
7.5.3 Installation
Note:
Make sure that the hole of the front wheel spindle is concentric when installing the left and right
absorber.
Steps are contrary to the process of disassembly.
Note:
Fixing screws for the bottom connecting board:
Fixing screws for the upper connecting board:
10N.m
28N.m
- 98 -
E
F
G
1. rear wheel spindle 2. screw M620 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 306223.8
14. spindle sleeve of the sprocket wheel 15. fixing bolt of the sprocket wheel 16. sprocket wheel rim 17.
sprocket wheel 18. retaining ring 62 19. self-locking bolt M101.25 20. self-locking bolt M241.5
- 99 -
1. screw 2. mounting sleeve of the rear swinging arm 3. rolling bearing 61905-2RS 4. straight pin 48 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 M101.25 12. supporting
board of the brake clamp 13. rear chain cover 14 bolt M68 15. bolt M6114 16. chain protecting block 17
bolt M6114 18 front chain cover 19 bolt M6114 20 fixing spindle of the rear absorber
- 100 -
Preparing Principles
Item
Rear wheel
shimmy
Standard (mm)
Vertically
2.0
Horizontally
2.0
130-150N
m
37-55N
m
37-55N
m
70-105N
m
37-55N
m
5-10N
m
Deformed rim
Abraded rear wheel spindle
Tyre failure
- 101 -
- 102 -
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.
rear wheel
rear disc brake box
fixing screws
rear wheel spindle
Big sprocket
wheel
- 103 -
- 104 -
8.3.2 Check
8.3.2.1 Check the Rim Shimmy
Rotate the wheel by manual and measure the
eccentricity ratio with a dial indicator.
Limit for use:
Vertically: replacement when beyond 2.0mm
Horizontally: replacement when beyond 2.0mm
When the rear wheel indication goes beyond the limit for
use, the rear wheel bearing is loosened leading to the rear
wheel shimmy. Replace the rear wheel bearing after check.
8.3.3 Installation
Install the rear wheel in reverse order, and lock the nuts.
Fixing nuts for the rear wheel spindle
Torque force: 130-150 N
m
- 105 -
- 106 -
Fixing bolts
Torque force: 37-55 N
m
- 107 -
8.5.2 Check
Measure the length of ten chain links
- 108 -
* Note:
Measure after stretching the chain by hand.
Range from chain link roller (1) to the inside of roller (11).
Measure the length of ten chain links.
Measure the length of ten chain links of different parts 2-3 times.
Clean the drive chain, put it into the kerosene,
and wash off the dust as much as possible,
then take the chain out of kerosene and dry it.
- 109 -
is frayed,
8.5.4. Installation
Install it in reverse order.
Fixing nuts
Torque force: 37-55 N
m
Note:
Adjust the laxation degree of the drive chain and the free stroke of the brake pedal.
If the laxation degree of the chain is too small, engine and other vital parts will be overloaded.
The laxation degree of the chain should be kept within the prescribed limit value.
- 110 -
Bearing
- 111 -
Fuel Tank
Gasoline capacity of the
A
gasoline tank:
150.2L
1.fuel tank body assembly 2.gasket 6.412.51.6 3.bolt M670 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 5,3101
11.oil level sensor assembly 12.bolt M625 bolt M625 13. rubber gasket tube 14.fuel tank front
mounting pad 15.fuel tank front mounting board 16.bolt M81.2520 17.fuel tank cover support
assembly 18.fuel tank lock 19.socket head cap screw M530 20.socket head cap screw M514 21.fuel
tank cover seal gasket
- 112 -
9. Fuel Tank
Preparing Documents -----------9.1
Failure Diagnosis -----------9.2
Fuel Tank -----------------9.3
9.1 Preparing Documents
Work Instructions:
It shall be dismantled far from fire sources.
Tighten all the bolts and screws to the required torque value for assembly.
After assembly, check whether all the parts are correctly installed and operated.
Preparing Principles
Item
Standard
150.2L
22-37N
m
5-10 N
m
5-10 N
m
5-10N
m
5-10N
m
- 113 -
- 114 -
9.3.2 Installation
Install it in reverse order.
22-37N
m
5-10 N
m
5-10 N
m
5-10N
m
5-10N
m
- 115 -
10N.m
50N.m
- 116 -
Note:
Confirm the left and right limits are set at
positions when installing the front seat.
- 117 -
Note:
Confirm the throttle cable assemblyI and throttle
cable assemblyII are set at positions;
Confirm the oil pipe is connected well to place
without oil leakage after the correct installation of
the throttle body assembly.
Confirm the electric components are connected at
positions;
- 118 -
Canister assembly
- 119 -
- 120 -
- 121 -
Place an appropriate holder under the frame in case of rollover when disassembling the engine.
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 hasnt been regulated well. Therefore, attention should be given to the regulation in this
regard prior to the testing the engine.
a.
b.
c.
d.
- 122 -
Tightening torque (N
m)
20~25
10~12
60~62
100~110
10~12
Crankcase bolt M6
10~12
Crankcase bolt M8
22~24
35~39
23~27
10~12
Flywheel bolt M8
20~24
Fuel filter
18~22
40~45
40~45
95~105
10~12
10~12
20~25
10~12
10~12
Spark plug
22~25
- 123 -
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
Item
Fuel capacity
Standard
3.0L
When disassembling
3.2L
0.04-0.11mm
0.15mm
0.04-0.11mm
0.15mm
Burnt engine
No fuel pressure or low fuel pressure
Blocked fuel pipes
- 124 -
Remove the screw, take down the fuel pump cover, and decompose
the fuel pump.
Screw
- 125 -
Check the clearance between outer rotor and fuel pump cover
Limit for use: 0.15mm.
Gauge
- 126 -
As shown below
Outer rotor
Inner rotor
Pump body
Pump shaft
Note: After the combination, the inner and outer rotors should rotate flexiblely without stagnation.
Installation
Install it in reverse order.
- 127 -
Piston cooler
- 128 -
- 129 -
Standard
0.03
0.05
Intake
013-0.19
__
Exhaust
0.19-0.25
__
Intake
3.97-3.98
3.96
Exhaust
3.97-3.98
3.96
Intake
4.03-4.04
4.07
Exhaust
4.03-4.04
4.07
Intake
0.05-0.07
0.11
Exhaust
0.05-0.07
0.11
Intake
1.0-1.1
1.5
Exhaust
1.0-1.1
1.5
Intake
38.8
37.3
Exhaust
41.6
40.1
0.041-0.054
0.08
Valve gap
Valve spring
Camshaft
Free length
cylinder head
- 131 -
Cylinder
cover shade
Locating bolt
- 132 -
Camshaft holder
Camshaft
Camshaft chain
Camshaft sprocket
Guide chain
plate
Cylinder
cover
Loosen the cylinder cover locking bolt.
Remove the cylinder cover.
Remove the top stem, compress the valve spring with valve
spring compression tools, and remove the valve block.
Remove the valve adjusting gasket, valve spring, valve spring
upper/lower seat and valve.
- 133 -
Camshaft
Camshaft sprocket
Bolt
Valve spring
Valve spring
lower seat
Valve block
Valve spring
upper seat
Top
stem
Valve adjusting
gasket
Ruler
Gauge
Check
Eliminate carbon deposit in the cylinder cover.
Measure the flatness of the joint surface of the cylinder cover.
Limit for use: 0.05mm.
When the flatness of the joint surface of cylinder cover
exceeds the limit for use, place the fine-sand paper on the flat
plate, with the joint surface of cylinder cover fitting the sand
paper, and mill it according to 8-shape.
- 134 -
Vernier calipers
Measure the free length of valve intake/ exhaust spring.
Limit for use: intake spring: 37.3mm.
exhaust spring: 40.1mm.
Tester
Measure the inner diameter of each valve catheter.
Limit for use: intake/ exhaust: 4.07mm.
Limit for use of the clearance between valve and valve catheter:
Intake valve: 0.11mm.
Exhaust valve: 0.11mm.
- 135 -
Screwdriver
12.3.4 Replace the Valve Catheter
Note: When the clearance between valve and valve catheter
exceeds the limit, replace the valve catheter. After the replacement,
trim the surface of the valve seating.
Put the valve catheter in the freezer of the refrigerator to cool for
one hour.
Heat the cylinder head to 100-150 with an electric furnace or a
hot oven.
Fix the cylinder head, disassemble the valve catheter from the
upper side of cylinder head with valve catheter disassembly tools.
Valve
reamer
- 136 -
Rugged part
25
60
1.0mm
45
- 137 -
If the contact is the part where the valve is too high, please
lower the valve seating with a flat milling cutter at
25angle.
If the contact is the part where the valve is too low, raise
the valve seating with a inner milling cutter at 60angle.
Refine the valve seating again with a refining milling cutter
at 45angle to meet the specifications required.
After grinding the valve seating, please coat the polish on
the surface of valve to gently polish the valve.
60
12.3.6 Installation
Install it in reverse order.
Note:
When installing the valve spring, the end with smaller pitch of the spring shall be installed towards the
combustion chamber.
When installing the valve collet, install it by compressing the valve spring with valve spring compression
tools
When installing the valve, the surface of the valve stem shall be coated with proper amount of fuel prior
to installing to the valve catheter.
- 138 -
- 139 -
13. Crankcase
Preparing Documents------------------------------------------------------13.1
Failure Diagnosis-----------------------------------------------------------13.2
Upper Box-------------------------------------------------------------------13.3
Piston------------------------------------------------------------------------13.4
Lower Box------------------------------------------------------------------13.5
Clutch-----------------------------------------------------------------------13.6
Variable Speed Gear Transmission---------------------------------------13.7
Camshaft Connecting Rod Assembly-------------------------------------13.8
Work Instructions:
- 140 -
All components must be cleaned and blown with high-pressure gas before test.
The crankcase is thin-section casting thus shall not suffer impact during operation which may cause
deformation or fracture.
Lubricant in the crankcase should be drained out before operation.
- 141 -
Standard
use
65.100
65.110
0.008
0.050
0.006
0.050
0.03
0.05
Upper box
Limit for
64.90
64.91
16 (0.002, 0.008)
16.04
16-0.008, 0
15.96
0.002-0.016
0.04
Ring 1
0.05-0.09
0.11
Ring 2
0.04-0.08
0.11
Ring 1
0.15-0.30
0.5
Ring 2
0.25-0.45
0.65
Fuel ring
0.20-0.70
1.0
16 (0.016, 0.034)
16.04
0.016-0.042
Thickness
1.5 (0-0.09)
1.48
0.025-0.05
0.065
0.1-0.25
0.5
0.008-0.016
0.05
1.5 (0-0.012)
1.44
0.03-0.05
0.07
2.45
3-0.1, 0
2.6
24.3-0.15, +0.15
22.8
23.5-0.2, +0.2
22.4
11.973-11.984
11.96
12-12.018
12.03
Thickness of fork
5.80-5.90
5.75
41.9-42.1
41.5
5.45-5.55
5.65
Connecting-rod
Clearance
bearing
connecting-rod
between
bearing
the
and
crankshaft
Left-right clearance of the larger
Connecting rod
Main-shaft
bearing
Lower box
and crankshaft
Thickness of friction disc
Clutch
Length of pressure spring
Variable
speed
transmission
gear
- 142 -
- 143 -
Upper box
Check
Check the abrasion of the inner wall of the cylinder.
If it is serious, replace it.
Spacer
Remove the spacer and locating pin.
Locating pin
- 144 -
13.4 Piston
13.4.1 Disassembly
Remove the retainer ring of the piston pin.
Note: during assembly, do not make the retainer ring fall
into the crankcase.
Remove the piston pin and the piston.
Push into
Piston ring
Gauge
- 145 -
Remove the piston ring, and install each piston ring on the
cylinder bottom.
Note:
Press the piston ring into the cylinder with piston head.
Measure the joint gap of the piston ring.
Limit for use: ring 1: 0.5mm.
Piston ring
ring 2: 0.65mm.
Gauge
Tester
1
2
3
- 146 -
90
11mm
Tester
In
Ex
Top
Middle
Bottom
- 147 -
Gauge
Upper box
Inner diameter of
smaller
end
of
connecting rod
the
the
Tester
Connecting-rod bearing
- 148 -
Plastic gauge
Top ring
Ring 2
Fuel ring
Note:
Do not scratch the piston or break the piston ring.
After the piston ring is installed, it shall be able to rotate
freely in the piston ring groove.
- 149 -
Note:
Do not make any object fall into the crankcase.
Install the piston, piston pin and retainer ring.
Note:
The dot mark on the top of the piston shall be installed
towards the intake valve.
Dot mark
- 150 -
Flywheel assembly
- 151 -
Bolt
Clutch cover
Right cover
Release stem assembly
Remove the fixing bolt, clutch, gearshift arm assembly and fuel pump sprocket.
Remove the spacer and locating pin.
Clutch assembly
- 152 -
- 153 -
13.6 Clutch
13.6.1 Disassembly
Unscrew the four bolts of the release plate in diagonally staggered sequence.
Loosen the clutch nut.
Remove the sleeve, bearing, release plate
and the clutch spring.
See the breakdown drawing for the disassembly of parts.
.
Clutch nut
Unscrew the clutch locking nut with the special tool, and remove the locking nut and gasket.
Remove the center holder of clutch.
Remove the clutch disc and friction disc.
Remove the clutch pressure plate.
See the breakdown drawing for the disassembly of
parts.
Remove the spline gasket.
Remove the shell assembly.
Shell assembly
- 154 -
- 155 -
13.6.3 Check
Check the shell groove for burrs and brakeage, if
trimmed excessively by the file, replace it.
Check the pressure plate and the tooth profile of the
center holder for damage, if damaged, replace it.
Driven hub
Free length
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.
Thickness
- 156 -
Fork
Fork shaft
Pressure plate
Gearshift drum
Ratchet
13.7.2.1 Check
Before the breakage, the gearshift plate should flexibly return without being seized.
Check the gearshift plate and gearshift shaft assembly for abrasion. If heavily abrasive, replace the assembly.
Check the gearshift locating plate for abrasion, If heavily abrasive, replace the assembly.
- 157 -
Check whether the gearshift shaft is bent, if excessively bent, replace it.
Check the return spring for decreasing elasticity, if necessary, replace it.
- 158 -
Crankcase bolt
Lower box
Countershaft assembly
Gearshift drum
Fork
Fork shaft
- 159 -
13.7.2.2 Check
Fork shaft
Micrometer
Tester
Vernier calipers
- 160 -
Depository for
the main shaft
Depository
for
the
crankshaft connecting rod
Depository for
the countershaft
Gearshift chamber
- 161 -
Countershaft assembly
Main shaft
assembly
Gearshift drum
assembly
Gearshift arm
assembly
Fork shaft
- 162 -
Countershaft
assembly
asseml
Main shaft
assembly
Drive gear
- 163 -
13.8.1.2 Check
Measure the left-right clearance of the larger end of the connecting rod.
Limit for use: 0.5mm.
Measuring point at the
clearance between the larger
end of the connecting rod
- 164 -
13.8.1.3 Assembly
Assemble in reverse order of breakdown and disassembly.
Remove the main shaft assembly
Remove the countershaft assembly.
- 165 -
Countershaft assembly
13.8.2.2 Check
Check the abrasion of gear surface and driving-claw point of the gear respectively.
If it is seriously abraded or damaged, replace it.
Gear surface
Check whether the bearing and oil seal are damaged, If yes,
replace it.
Driving claw
Note:
Removed bearing cannot be used any more. It shall be
replaced.
Use special tools to dismantle the bearing and the oil seal.
dissipate heat, and transfers heat to the outside air with the help of radiators fin.
- 168 -
Bolt
Loosen the bolt, and remove the water pump cover.
Water pump cover
Check
Check the abrasion of the blade assembly.
If it is serious, replace it.
Note: Dont damage the spacer and the joint surface of box
during operation.
Installation
Install it in reverse order.
- 169 -
Reservoir
t
Cylinder cover
Thermostat
Pressure valve
Oil
cooler
Water pump
Radiator
Cylinder block
Water direction
- 170 -
1 exhaust pipe gasket assembly 2 screw M830 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 M610
- 171 -
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.
- 172 -
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
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: Clean the air filter frequently if the motorcycle runs in sandy road or under seriously polluted
condition to extend the service life of the engine.
Increase 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.
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.
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,
CO2andN2 for discharge.
(2) Transfer catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used.
- 174 -
- 175 -
15.5 Measures When the Idle Speed Emission Value Exceeds the
Standard
Qualified
Periodic inspection (maintenance plan)
Qualified
Measure idle emission (note 1)
Qualified
Adjust Carburetor (note2)
Qualified
Remove and clean the
carburetor
Qualified for
delivery
Qualified
Replace the carburetor
Qualified
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.
- 176 -
- 177 -
- 178 -
ECU 12 is located on the left of battery and ECU 34 is behind the battery.
J2-1
J1-2
J2-2
J1-3
J2-3
J2-4
J2-5
sensor
J1-6
J2-6
J1-7
J2-7
J1-8
J2-8
J1-9
J2-9
J1-10
J2-10
J1-11
J2-11
J1-12
J2-12
J1-13
J2-13
J1-14
J2-14
J1-15
J2-15
J1-16
J2-16
J1-17
J2-17
J2-18
J1-18
Remarks:
J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey
connector.
- 180 -
2) ECU34
J1-1
J2-1
J1-2
J2-2
J1-3
J2-3
J2-4
J2-5
sensor
J1-6
J2-6
J1-7
J2-7
J1-8
J2-8
J1-9
J2-9
J2-10
J1-10
J1-11
J2-11
J1-12
J2-12
J1-13
J2-13
J1-14
J2-14
J1-15
J2-15
J1-16
J2-16
5V reference voltage
J1-17
J2-17
J2-18
J1-18
Remarks:
J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey
connector.
- 181 -
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.
- 182 -
16.2.2.2 Appearance:
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.
- 183 -
16.2.3.2 Appearance:
- 184 -
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.
- 185 -
16.2.4.2 Appearance
16.2.5.2 Appearance
- 186 -
16.2.6.1 Appearance
- 187 -
16.2.7.2 Appearance
- 188 -
16.2.8.1 Appearance
- 189 -
16.2.9.1 Appearance
16.2.10.2 Appearance
- 190 -
Back side:
Front side:
Turn on the key and run the fuel pump for about 3 seconds. If the fuel pump starts to run, refer to
step d).
Cut off the connector of the fuel pump and check whether the power supply voltage is 12V or so.
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.
- 191 -
d)
e)
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.
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.
b)
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.
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.
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.
- 193 -
Description
decimal number
P0107
263
P0108
short circuit of signal end pin of the intake pressure sensor to the
positive electrode of the battery
264
P0112
274
P0113
275
P0117
279
P0118
280
P0122
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
to the negative electrode of the battery
50
P0032
short circuit of heating end pin of the front cylinder oxygen sensor
to the positive electrode of the battery
49
P0201
513
P0202
fault of for fuel injector rear cylinder (plug-in device of the fuel
injector is not plugged)
514
P0230
560
P0232
562
P0336
822
P0337
823
P0351
849
P0352
850
P0562
1378
P0563
1379
P0560
1616
P1693
5779
- 194 -
battery
P1694
5780
P0137
short circuit of signal end pin of the rear cylinder oxygen sensor
to the negative electrode of the battery
311
P0138
short circuit of signal end pin of the rear cylinder oxygen sensor
to the positive electrode of the battery
312
P0038
short circuit of heating end pin of the rear cylinder oxygen sensor
to the positive electrode of the battery
56
P0037
short circuit of heating end pin of the rear cylinder oxygen sensor
to the negative electrode of the battery
55
- 195 -
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.
- 196 -
4Select "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.
- 197 -
5If 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.
- 198 -
Then check the corresponding fault according to the fault code list
- 199 -
engine speed
VTHROT
throtle position
VBARO
BARO
STATUSBYTE5
VAFCMET
VBAROCMET
tip-in
O2 ready
FCLCINT1
FCLCMUL1
IARDRPM
IARPMERR
FPWVC1
VO2
STATUSBYTE3
FO2STAT1
FCLREST1
VMAP
VMAPEXP
VIGN
VCLTS
VIAT
STATUSBYTE5
VCSINSYNSPRK
SATITRIG
CATLOENB
IF ENGSTATE=3
NISTBLIDLE
FO2REDY2
FCNO
FBLMCOR1
STATUSBYTE3
- 200 -
FOSHTREN
FO2REDY1
IACV lost
ignition state
SAESTA
SAIDLDYN
SPDWELL
dwell time
STATUSBYTE2
FCLCEN1
PPDSEBL
FPENABL
FTRNSAES
FTRNSDES
FTRNSAEDCLOAD
FTRNSDEINLOAD
IF IACV MODE=0
IAMTRLOST
IACMVIHB
VIGNS
FVE1
VMAPRANG
AFFNLAFR
IAINTEGOFST
IACVDSMP
STATUSBYTE2
FCLCEN2
- 201 -
Disassembling the parts of the electronic control system- common disassembly tools for auto machinery
parts
b)
c)
Circuit of the electronic control system and its electrical signal- digital multimeter (with beep)
Diagnosing the faults in the electronic control system and checking the engine's operation
d)
e)
- 202 -
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)
d)
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.
Coolant temperature and its cycling- indicate whether the thermostat operates normally.
b)
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.
When using the diagnostic apparatus, the storage battery voltage cannot be lower than 8.5V.
Though ECU is damp-proof, it is forbidden to wash its cover with a high-pressure water gun.
In common circumstances, the throttle valve should be washed every 10,000km or every 1 year.
Turn the ignition lock to "ON" to check whether the trouble light turns on.
If no
Check whether the light and circuit are normal through the inspection function of the
diagnostic apparatus's actuator.
If yes
b)
Whether the diagnostic apparatus can be connected to the system for communication
If no:
If yes:
c)
Check whether the diagnostic apparatus works normally on another normal motorcycle.
Check the faults in the ignition system- whether the spark plug can ignite normally
If no:
If yes:
Check whether the high-tension cable and spark plug are connected tightly or are damaged.
Check whether the high-tension cable is connected with the ignition coil and spark plug in a
correct way
d)
If yes:
Check whether the connection of crankshaft position sensor and its operation are normal.
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)
3) Normal
pressure
e)
Whether the oil supply line and oil return line are damaged
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)
b)
Check whether the idle speed by-pass bolt is too loose or tight. Usually it is necessary to
screw 2 turns.
16.4.3.5
Fault
Description-
Too
High/Low
Idle
Speed
(Apparent
Idle speed
is too low:
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 air valve clearance, especially the exhaust valve clearance, is too
large.
Check the oil amount in the fuel tank, the fuel filter, the oil line pressure and the oil
nozzle.
- 205 -
16.4.3.6 Fault Description- Unstable Idle Speed Slowing Down with Flameout
a)
b)
Check whether the idle air bypass hole and throttle body are too dirty
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)
e)
Check whether the trouble light turns on and whether it is because only one cylinder can work normally
to ignite.
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).
- 206 -
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
- 207 -
/ /
/ /
10A
10A
15A
ECU1
15A
10A
1 / 1 / / / /
/
2# Gr ECU J1
IN5408
30A
15A
ECU2
2#BLACK ECU J2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
/ /
/
/
/
/
/ / /
/
/
/
/ /
/ 1
// / / /
11
/ / /
/ / /1
/ / /
/1 / / / /
/
/
/ / / / / / /
/ / /
/ / /
/ /
/2
/2
/2
/
/
/
/1 / /
/1
/ /
/1
/
/
/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
/2
/
/
/
/
/
/
/
/
/
/2
/2
/2
/
/
/2
/
/
/
/
/2
/2
/
/
/
/
/2
/2
/2
/
/
/2
/
/2
/2
/2
/
/1
/2
/
/
/
/2
/
/1
/1
/
/1
/1
/
/ /1 /
/ / / / /
/
/1
/ / /
/ / /
/ /
/ / /
/ / /
3 2 1
103
12 3
/ / / /
/
/
1
1
/
/
1
1
/ /
1 1
/ /
1 1
/ / / /
1 1
/ /
/ / /
/ / /
1 1
/ / / /
11 1
/ /
/ /
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1#Gr ECU J1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1#BLACK ECU J2