RK6 Service Manual

Service manual of RK6
KEEWAY Motorcycle Corporation Ltd.

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Contents
Preface .............................................................................................................................................................. - 1 Preparing Documents ....................................................................................................................................... - 2 General Safety .......................................................................................................................................... - 2 Maintenance Rules ................................................................................................................................... - 3 Specification ........................................................................................................................................... - 13 Failure Diagnosis.................................................................................................................................... - 15 Inspection/Adjustment ........................................................................................................................... - 22 Inspection and Maintenance of the Electrical System .................................................................................... - 43 1. Battery/Charging System ........................................................................................................................... - 44 1.1 Preparing Documents ....................................................................................................................... - 44 1.2 Failure Diagnosis.............................................................................................................................. - 45 1.3 Battery .............................................................................................................................................. - 46 1.4 Charging System .............................................................................................................................. - 47 1.5 Voltage/Current Regulator ................................................................................................................ - 48 1.6 Magnetor Charging Coil ................................................................................................................... - 48 1.7 Magnetor Disassembly ..................................................................................................................... - 49 2. Ignition System .......................................................................................................................................... - 52 2.1 Preparing Documents ....................................................................................................................... - 52 2.2 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.
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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.
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Maintenance Rules
Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage. Clean up the surface of components or assembly parts before removing or opening the shield for maintenance, which can prevent dirt from falling into the engine, the chassis or the braking system. Wash and dry parts with air compressor after disassembly and before measurement of attrition value.
Solvent or oil can easily damage aging rubber articles. Check rubber before reassembly and replace rubber if necessary.
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.
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Bolts and screws with different length shall be separately used for different assembly parts and shields, and they shall be correctly mounted. Insert a bolt into a hole to check whether it is proper if you are confused.
Fill the groove with grease before mounting an oil seal. Check whether the oil seal is smooth or damaged during assembly.
When installing a rubber hose (fuel, vacuum or cooling agent), 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.
groove clip 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.
Bearings will be broken under either occasion as mentioned.
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Loose cables threaten electrical safety. Check each cable after it is clamped to another for electrical safety; Wire clamps are not allowed to bend towards welding point; Bind cables at the designated place; Do not deploy cables at the end of frame or at sharp point; Do not deploy cables at the end of bolts or screws; Cable deployment shall be far from heat source and where cables may be clamped during moving; Cables along the handlebar shall be neither too tight nor too loose, and do not interface with any neighboring parts at steering positions; Cables shall be properly deployed without twist or knot; Check whether the connector jacket is damaged and whether the connector is over-stretched before mounting connectors; Adopt adhesive tape or hose to protect cables if they are positioned at sharp point or corner; Bind cables with tape after repairing; Control cables shall not be bent or twisted. Clumsy operation may be caused in light of damaged control cables.
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Identification
1The frame number, see figure
Frame Number
2Rivets of the frame sign and the frame, see figure
Frame
Frame Number
Rivets
3The serial number of the engine, see figure

Engine Number
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.
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Special Tools
Special tools refer to tools which are specially designed for assembling or disassembling some motorcycle parts on special positions. Applicable special tools are necessary for precise adjustment and installation. With them, parts and accessories can be mounted safely, reliably and rapidly, which improves efficiency and saves energy.
1Tools 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 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 Remark 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 rodFig. 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 - 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
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Fig. 1-23
Fig. 1-24
2Tools 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 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 Remark 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 - 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
(3) Steering nut spanner
Fig. 1-38
3Tools for electric parts

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Table and drawings (1-39, 1-40) of special tools for testing electric parts are as follows: Fig. 1-39
Name Multimeter Ignition tester Remark Fig. 1-41 Fig. 1-42
Fig. 1-40 (continued)
Fig. 1-41
Fig. 1-42
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Specification
Motorcycle Model Length mm Width mm Height mm Wheelbase mm Petrol tank capacity RK6 2120 800 1100 1480 15L Forward shaft Backshaft Total Front tire Rear tire Battery capacity Magnetor Electric devices Spark plug Spark plug gap Ignition Max. Hp Max. torque Compression ratio Perfor mance 115 105 220 120/70 ZR 17 180/55 ZR 17 Engine Engine Type Fuel type No. of cylinder ID stroke Total displacement Startup Cooling Lubrication Clutch type Variable speed Transmission Primary transmission ratio Transmisson ratio of gear 1 Transmission devices Transmission ratio of gear 2 Transmission ratio of gear 3 Transmission ratio of gear 4 Transmission ratio of gear 5 Transmission ratio of gear 6 Final Transmission ratio Dia. of front liquid brake discmm Brake Fuel consumption limit 5.2L/100km Dia. of rear liquid brake discmm 240mm BJ465MS-A Unleaded petrol93/97 4 65.0 45.2 600cc Electric Liquid cooling Pressure splash lubrication Wet multi-chip Six variable speed Chain 1.864 2.846 1.947 1.556 1.333 1.190 1.083 3.286
Weight kg (Curb weight)
Tire Size
12V-9AH Flywheel permanent magnet CR9E(NGK) 0.6-0.7mm TLI 60.0kW/11000rpm 55N.m/8000rpm 11.51
Max. speed
185km/h
320mm
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RK6
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Failure Diagnosis
Diagnosis on difficulty or failure in starting up
Failure Diagnosis Adjustment & Inspection Causes of Failure
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Check if petrol pump is working properly
Oil provided to fuel injector is sufficient and smooth
No petrol provided to fuel injector Disassemble spark plug into its cap, ground it with engine to check if it can spark
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 coils wire Open circuit or short circuit of ignition coil Abnormal main switch Abnormal charging coil Abnormal clutch for startup Abnormal piston of cylinder and piston ring Leakage of cylinder gasket
Spark-over
Weak sparks No
Test compression pressure
Normal
Too low No
No ignition outbreak of the engine
Ignition outbreak of the engine but no sign of startup
Abnormal actuation
automatic
choke
Intake manifold with air Incorrect ignition time
Disassemble once agian the spark plug to check
Abnormal adjustment to throttle valve and bolt
Dry spark plug
Wet spark plug
Excessive oil injected to fuel injector Abnormal automatic choke actuation Throttle opens too large
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Unsmooth gyration (No speed or weak speed)

Failure diagnosis Adjustment specification
Start engine with soft refueling accelerated gyration speed of engine Engine can not fully speed up
Causes of failure
Air filter blocked Abnormal petrol Tube of combustion chamber s Evaporation Control System blocked Exhaust pipe blocked Abnormal automatic choke Abnormal throttle valve Abnormal CPU group Abnormal trigger
Adjust ignition timing and use ignition timing light Correct ignition time Incorrect ignition time Test compression pressure
Abnormal piston of cylinder and piston ring Normal Too low Leakage of cylinder gasket
Blocking check to Carburetor No Yes Disassemble the spark plug to check No pollution nor discoloration Polluted and discolored Check oil level in crankcase if it is high or polluted Normal High oil level Check the lubrication cylinder head Normal Abnormal Overheated engine 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 Contaminant removal
Contaminant removal Heat value of spark plug does not conform Excessive oil Insufficient oil No replacement of oil
Yes
No Accelerated driving or running
Engine knock
No engine knock
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Unsmooth gyrationespecially in low speed

Failure Diagnosis Adjustment & Inspection
Adjust ignition time Abnormal CPU group Normal Abnormal Abnormal trigger
Causes of Failure
Adjustment to throttle valve and bolt
Mixed gas too thin (loosen bolt) Good Bad Mixed gas too dense (tighten bolt) Spacer inhaled air or not Abnormal spacer of heat insulation piece Throttle valve fixed, bolt loosened Heat insulation piece ruptured Negative pressure pipe ruptured Disassemble spark plug into its cap and ground it with engine to check if it can spark Good spark-over Bad spark-over
Yes
No
Spark plug abnormal or polluted Abnormal CPU Abnormal ignition coil Open circuit or short circuit of spark plugs wire Abnormal main switch
Negative pressure pipe damaged Good Bad Air pass-hole blocked
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Unsmooth gyration (high speed)

Adjust ignition time
Causes of Failure
Abnormal CUP group Normal Abnormal Abnormal trigger
Little oil in petrol tank Normal Abnormal Petrol filter of the pipe blocked Tube of combustion chamber s Evaporation Control System blocked Abnormal automatic oil ring
Blocked oil injector
No
Blocked
Remove
Good
Spring broken Weak elasticity
Abnormal spring
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Poor battery charging (over discharge or over charge)

Test the voltage of batterys two ends, and stat engine Battery used up No voltage rise Voltage rises to normal value, and back to original voltage value after flameout
Causes of Failure
Poor battery
Check the plug of voltage regulator if it is loose
Normal
Abnormal
Poor connection of the plug Open circuit of the red wire of the charging wire 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
Voltage available
No voltage
Voltage regulator Open circuit of the white wire of the charging wire Test the resistance alternator s coil value of
Normal
Abnormal
Abnormal coil Poor connection of the joint Open circuit of alternators white wire Poor battery 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
Poor battery charging Overcharging
Voltage above normal value
Normal voltage
Check if charging wire of the voltage regulator connects well Normal Loose Bad connection Use monomer of the voltage regulator to test impedance Poor connection of the joint and charging wire to the ground Abnormal voltage regulator
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No spark-over of the spark plug

Replace on new spark plug and check again
Causes of Failure
Weak spark-over or no spark-over
Strong spark
Original spark plug abnormal
Check again after checking spark plug
No sign of loose
Loose Spark plug cap loose
Check plugs of CDI group if they are loose Normal Abnormal Check conduction between terminals of CDI groups plugs, and test resistance value
Bad connection of the plug
Abnormal main switch Abnormal charging coil
Normal
Abnormal Check relevant parts
Abnormal trigger Abnormal ignition coil
Normal
Abnormal
Breakage of main wire Bad connection of the plug and socket Use CDI tester to check CDI group
Normal
Abnormal
Abnormal CPU group
Use CDI tester to check ignition coil Abnormal Abnormal ignition coil
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Inspection/Adjustment
Preparing information Engine oil/ Oil filter Periodic Maintenance & Inspection Table Liquid coolant Fuel injector & Oil-way Air filter Battery Cylinder pressure Free stroke of front brake Headlamp Front/rear suspension system Rim/tire Throttle valve
Assembly/disassembly of radiator pipes clamp Adjustment of throttle cable Spark plug Fuse replacement The slackness of the drive chain Free stroke of rear brake Clutch Bolt/nut/fastener Fixing steering stem bearing & handlebar 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.
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Specification
Engine
ID stroke Total displacement Ignition Spark plug gap Spec. of spark plug Type of combustion chamber 65.0 45.2 600cc TLI 0.6-0.7mm CR9E(NGK) spherical
Frame
Free stroke of front brake lever Free stroke of rear brake pedal Tyre pressure unitKpa Fixing front wheel spindle Fixing nut of rear wheel spindle Front tire Rear tire 10-20mm 20-30mm Specification RK6 120/70 ZR 17 180/55 ZR 17 100-140N m 130-150N m Tire pressure 250 10kpa 290 10kpa
Torque value
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Periodic Maintenance & Inspection Table

Service cycle and time Inspection item Per 300 Km New * * * Air filter Petrol filter Fuel filter Replacement of engine fuel Tire pressure Battery inspection Actuation gap inspection 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 Lubrication of each part Muffler * * * * Ignition timing 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 Drive chain Clutch Valve I I A A I I I I I I I I I I I I I I I I I I I I A A I I I I I C R I I I I I I I I I I I I I I I I I Per 1000 Km Per 3000 Km Per 6000 Km Per 12000 Km Twelve months R R C Per 14500 Km Fifteen months C Ordinary tools Ordinary tools Ordinary tools Ordinary tools I I I Tire pressure gauge, inflator Densimeter, multimeter Ordinary tools Ordinary tools Ordinary tools I I I Torque spanner Ordinary tools Ordinary tools Ordinary tools Lubricator I I A A I I I I I I A I I Ordinary tools Timing lamp Tachometer, CO HC analyzer Ordinary tools Ordinary tools Visual multimeter Ordinary tools Ordinary tools Torque spanner Ordinary Ordinary Ordinary Feeler
Tools
One Three Six month months months C C I C
Replacement every 1000KM I I I I I I I I I I R I I I I I I I R
* *
Replacement every 5000KM L I I A A I I I I I I I I I I L I I A A I I I I I I I I I I
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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.
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; (maximum 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.
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If it is below or near the minimum level, Refuel with the recommended oil to the maximum level. *Note Check the O-ring. Assemble the dipstick.
Oil Replacement
* Note It will be easier to change oil when the engine is warming up. Preheat the engine. Place a drip pan under the engine, and disassemble the drain 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.
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 replacement . 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
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Cooling Liquid
Check the height of the cooling liquid in the expansion kettle during maintenance. Replace in time the cooling liquid when it becomes turbid or it is time for maintenance. Recommended model of the cooling liquid: FD-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.
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Assembly and Disassembly of the Clamp of the Radiators Conduit

The clamp of the radiators conduit is disposable component, so the old clamp can not be reused when disassembled. And the clamp can only be assembled by special clamp pliers, or it may not in place, which will lead to the breakdown of the vehicle.
clamp
Fuel Injector and Oil-way

The fuel pump has two connectors, oil passes through the fuel filter from one of the two connector into the fuel injector, 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 pump. Please connect the inlet and outlet oil tubes as shown in the figure at right.
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Adjustment to the Steel Rope of the Throttle

*Note Adjust the idle speed of the engine right before adjusting the stroke of the steel rope of the throttle. Check the free stroke of the steel rope of the throttle, and it should be 3-5mm. Adjust if it does not conform to the specified value. Adjust the free stroke of the steel rope of the throttle. The motorcycle is configured with two-lane steel rope 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 nut. (3)Screw in completely the adjusting nut. (4)Loosen the locking nut. (5)Rotate the adjusting nut to make the free stroke of controlling handlebar of the throttle to 10 15 . (6)Tighten up the locking nut. (7)Adjust nut to make the controlling handlebar of the throttle flexible. (8)Tighten up the locking nut. 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.
key
Pull the seat steel rope, open the front seat and take it off.
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seat steel rope
Disassemble the shield of the fuel tank and its front fixing bolt, and open the fuel tank. 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. cover of the air filter 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
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Do not start engine when disassemble the cartridge of the air filter, otherwise, the engine will intake unfiltered air, which may lead to rapid abrasion of other components, and the damage of the engine too. In addition, rotation without cartridge will cause sequential malfunctions of the carburetor, and it may lead 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.
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Battery
Battery Disassembly
Disassemble the front seat. Remove the mounting plate of the battery.
Remove the negative wire and then the positive wire. Remove the battery from the battery box. Take out the battery. Warning! When the positive wire is disassembled, do not make the tool contact with the frame. Otherwise, it may cause short-circuit spark, which may ignite gasoline and damage the battery. It is dangerous.
Install it in reverse order. Warning! To prevent short circuit, connect the positive wire first and then the negative wire. Do not remove the battery during commissioning. Otherwise, it may cause damage to inner parts of the 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: 12.3V1 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.
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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
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Cylinder Pressure
Warm up the engine. Insert the pressure gauge. Turn the choke lever to the fully open position. Start up the engine repeatedly, The pressure of the cylinder: 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 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
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(1)Put up the motorcycle with the support frame. (2)Loosen the rear axle nut. (3)Loosen the locking nut. (4)Turn right or left the adjustment bolt 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 1020mm, 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.
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Free Stroke of the Front Brake

Free stroke of front brake
Measure the free stroke of front brake at the tip of the brake lever. Free stroke: 10-20mm
Regulator of Lever Grip of the Front Brake

Depending on the operating needs for the comfort, the position of the lever grip of the front brake can be adjusted by adjusting the knob with the ring nut. There are four positions for adjustment, and you can adjust to a desired position just by moving gently forward the lever of the brake, and then rotating the adjuster of the ring nut at the arrow A . And position 1 of the front brake lever is most remote to the controlling handlebar of the throttle, while the position 4 nearest to it. front
Free Stroke of the Rear Brake

Free stroke of the brake pedal Measure the free stroke of the brake pedal. Free stroke: 20-30mm
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If specified value has not been met, it should be adjusted. Adjust the free stroke of the brake pedal. First open the nut 1. Screw in or out nut 2 to adjust the free stroke of the brake pedal. Screw in 2 to reduce the free stroke; Screw out 2 to increase the free stroke. Tighten the fixture 1 until the specified value is met. After being adjusted, dragging should not occur to the brake.
Headlamp
Disassemble the fixing bolt of the headlamp support.
Disassemble the fixing bolt of the headlamp support.
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Unplug the lamp holder connector of the headlamp, remove the lamp holder, disentwine the snap ring, and take out the bulb.
*Note Keep combustible materials and your hands a distance away from the bulb when it is light. Because the bulb is very hot at that moment, you should let it cool down before touching it. Install new headlamp bulb, lamp holder, and screw in the bulb to the socket. During the installation, avoid direct touch with the glass of the bulb, an do not make it oil-stained. Or it will affect the transparency, life and luminous flux of the bulb. Once stained with oil, wipe thoroughly with a damp cloth of alcohol or rubber solution of strong volatility.
Clutch
Check the free stroke of steel rope of the clutch. Free stroke: 10-15mm
Adjust the free stroke of the steel rope of the clutch. First open the clamp nut1. Then screw in or back to the adjusting device2. 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 nutA of the engine and the adjusting nutB with the inhaul cable.
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Front/Rear Suspension System

Front Absorber
Pull the front brake tight; compress the front absorber upwards or downwards for check. Check whether there is oil leakage in the front absorber and whether any component is damaged or loosened 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.
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Rim/Tyre
Check whether tires or rims have any crack, nail or any other damage. Check tyre pressure. *Note Check tyre pressure when it is cold.
Tyre pressure 120/70 ZR 17 180/55 ZR 17 250 10kpa 290 10kpa
Specification Front tyre RK6 Rear tyre
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 Rear tyre 1.6mm 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
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Fixing Steering Stem Bearing and Handlebar

Move the handlebar to confirm there is no wire interference. Rotate the front wheel and move the handlebar freely for check. If the handlebar moves difficultly, release it and then check the bearing of the fixing steering stem.
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.
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Components Lubrication
Appropriate lubrication is of great importance to the normal operation of each part of the motorcycle, to an extended life and to the safety drive. Lubricate the motorcycle after a long time running or exposure in the rain or after cleaning. As for detailed points for lubrication and maintenance, see the following figure:
motorcycle lubrication grease 1 axis of the rear brake pedal 2 single bracket joint and spring hook 3 pin of the gearshift riding rod 4 throttle cable 5 pin of the front brake handle 6 clutch handlepin
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Inspection and Maintenance of the Electrical System
charging system
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1. Battery/Charging System
Preparing Documents-----------------------1.1 Failure Diagnosis----------------------------1.2 Battery-----------------------------------------1.3 Charging System-----------------------------1.4
Voltage/Current Regulator -------------------1.5 Charging Coil of Magnetor ------------------1.6 Disassembly of Magnetor -------------------1.7
1.1 Preparing Documents

Work Instructions
*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.
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Item Capacity/Type Battery Voltage 20 Fully charged Necessary charging Specifications 12V-9AH/ dry-charged 13.1V 12.3V(not working for 1h) Standard: 0.8A, quick:8A Standard: 10-15 hours, quick: 30 mins Between white-white 1.5-3.5 Three-phase full wave 14.5 0.5V/5.000rpm
Charging current Charging time Magnetor Voltage regulator Impedance of the coil 20 Type Charging voltage of the battery
Tightening Torque Force

Rectifier bolt High-voltage coil fixing bolt Flywheel fixing nut Body guard bolt 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
1.2 Failure Diagnosis Power Supply Dead

Battery over-discharge Unconnected battery wiring Fuse blow Poor switch
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
Poor battery charging Poor contact Poor charging system Poor voltage/current regulator
Poor Charging System

Poor contact, short circuit or open circuit of wire terminals Poor voltage/current regulator Poor magnetor
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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.
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*Note Except emergencies, you should not use emergency charging. Measure voltage in 30 minutes after the battery is charged. Charging current: standard: 0.8A quick: 8.0A Charging time: standard: 10-15 hours quick: 30 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.
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1.5 Voltage/Current Regulator

1.5.1 Main Wiring Check
Remove the shield of the body. Remove 4p plug of the voltage/current regulator. Check conductivity between main wiring terminals. Item (wire color) Between Battery(red) and GND of the body Between GND wire (black) and GND of the body Between charging coil (white) and the GND of the body Judgment With battery voltage With lead 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: 1.5-3.520 Replace the magnetor coil when the measured value exceeds the standard value.
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1.7 Magnetor Disassembly

1.7.1 Disassembly
Loosen the fixing nuts on the left cover, and remove the left cover and the magnetic coil. Left cover and the magnetic coil
Bolt
Fix the flywheel with the universal fixing spanner. Remove fixing bolts of the flywheel. Remove the flywheel with the flywheel remover. Remove the solid key. Remove the conductor joint. Remove the stator.
Bolt
Loosen the four fixing bolts of the magnetic coil, and remove the magnetic coil.
Bolt
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Loosen the locking nuts of the flywheel with electric, pneumatic tools or torque spanner. Remove the flywheel assembly.
Locking nut of the flywheel
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
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/2 /2 ECU2 /2 /2
/1 /1 / / ECU1 /1 /1
power, trigger, ignition system black, white, red, orange, green, blue
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2. Ignition System
Preparing Documents -----------------2.1 Failure Diagnosis ---------------------2.2 Ignition System Check ---------------2.3 ECU Group----------------------------2.4 Ignition Coil ---------------------------2.5 Trigger ---------------------------------2.6

Work 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 dont 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 Spark plug recommended Spark plug gap Ignition coil Primary coil impedance20 Impedance of trigger20 Measure the maximum primary voltage of the ignition coil Trigger voltage Standard Standard value CR9E(NGK) 0.6-0.7mm 65050m 100-300 14V Above 1.7V
Tools
Attachments to the Maximum Voltage Table Multimeter
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2.2 Failure Diagnosis

No spark-over of the spark plug Abnormality Cause (confirm it sequentially as follows) The inner resistance is too small and it should be tested by required tester. Low speed of the crankshaft. Interfered tester (It is normal that voltage is always beyond the required value upon several measurements.) Poor wiring contact of the ignition system. Poor ignition coil. Poor charging coil (measured at the maximum voltage). Incorrect connection of the tester. Poor main switch. Poor contact of ECU terminal. Short circuit or poor contact of the GND of ECU. Poor contact of charging coil (measured at the maximum voltage). Poor trigger (measured at the maximum voltage). Poor terminal of high-voltage wires. Poor ECU group (when item - is checked to be abnormal or there is no spark for spark plug.) Poor spark plug or secondary leakage of the ignition coil. Poor ignition coil. The inner resistance is too small and it should be tested by required tester. Low speed of the crankshaft. Interfered tester (It is normal that voltage is always beyond the required value upon several measurements.) Poor charging coil (Item - is checked to be normal.) Poor ignition coil. Poor charging coil. The inner resistance is too small and it should be tested by required tester. Low speed of the crankshaft. Interfered tester (It is normal that voltage is always beyond the required value upon several measurements.) Poor trigger (Item - is checked to be normal.) Poor ignition coil. Poor trigger.
Ignition coil
Too low high-voltage
No or interrupted high voltage Side voltage
Normal high voltage, but no spark
Charging coil
No high voltage
No or interrupted high voltage
Too low high-voltage Trigger
No or interrupted high voltage
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2.3 Ignition System Check

*Note When there is no spark, check whether there is loose wiring or poor contact, and make sure all voltage values are normal. There are kinds of multimeters with different impedances and different test values.
Connect a high-pressure shunt or an ammeter with an input impedance above 10M10CV to the multimeter. multimeter
2.3.1 Primary Voltage of the Ignition Coil (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.
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2.3.2 Sensor of the Crankshaft

*Note Install the spark plug on the cylinder head and carry out measurement when the compression pressure is normal. Remove 18 connectors of ECU group. Connect the peak-voltage shunt between the charging coil (blue/white terminal) with 18 connector 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.
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2.5 Ignition Coil

2.5.1 Disassembly
Remove the body. Remove the spark plug cap. Remove the primary lead of the ignition coil. Remove the fixing bolts and then the ignition coil. Install the ignition coil in reverse order. *Note Install the primary coil with black/red terminal.
2.5.2 Check the Primary Coil

Measure the impedance between terminals of the primary coil. Standard: (40.2) (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: 100-30020 Replace the magnetor if the measured value exceeds the standard value.
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BATTERY
G/Y G/Y
Startup Schematic Diagram
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3. Startup System
Preparing Documents ----------------3.1 Failure Diagnosis ---------------------3.2 Startup Motor -------------------------3.3 Starter Relay --------------------------3.4 Starter Clutch--------------------------3.5

Work Instructions
Disassemble the startup motor on the engine. For the disassembly of the startup clutch, please comply with related regulations
Item Length of the brush of the startup motor Bushing of the startup idler shaft Outer diameter of the startup idler shaft Standard 12.5mm Limit for use 8.5mm 8.3mm 7.94mm
Tightening torque force

Bolts for the clutch cover of the startup motor Retaining nut for the clutch of the startup motor 12 N m 95 N m
Tools
Spanner for retaining nuts Universal fixing spanner
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Startup failure Weak in rotation of the startup motor
Fuse blow Low battery Poor main switch Poor startup clutch Poor brake switch Poor starter relay Poor wiring contact Poor startup motor Low battery Poor wiring contact Gear seized
No rotation of RE rotary engine of the startup motor

Poor startup clutch Reversal rotation of the startup motor Low battery
3.3 Startup Motor

3.3.1 Disassembly
Loosen the two fixing bolts of the startup motor, and remove the motor. Bolt
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.
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Remove the wire clip of the startup motor. Remove the fixing bolts of the startup motor, separate the front cover and the back cover, and dismantle the startup motor. Roll the waterproof rubber case and dismantle the connector of the startup motor. 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. carbon brush
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3.3.4 Assembly
Lubricate the oil seal inside the front cover with grease. Install the brush on the bracket. Lubricate moving parts at two ends of the brush shaft with grease. Press each brush into the bracket, * Note Pay special attention that the contact surface between the brush and the armature shall not be damaged. Pay attention that the armature shaft shall not damage lips of the oil seal. and install the back cover of the electric machine. Aim the screw hole of the motor shell at the screw hole of the front cover for installation. Lock screws in the shell. * Note When the shell and the front cover are assembled, it is easy to pull the front cover with magnet to attract the armature. Press it gently for assembly.
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. starter relay
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3.4.2 Check Voltage of the Starter Relay

Set up the main stand, and measure voltage between the negative pole of the green/yellow wire of the starter relay terminal and the body ground connection. When the main switch is on, hold the brake lever. The battery voltage shall comply with regulations. When there is no voltage at the starter relay terminal, check the conduction of the brake switch and leads. 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.
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4. Bulbs/ Switches / Meters

Preparing Documents -------------------------------------------------------------4.1 Failure Diagnosis ------------------------------------------------------------------4.2 Replacement of Headlamp Bulbs------------------------------------------------4.3 Replacement of Front Position Lamp Bulbs------------------------------------4.4 Replacement of Tail Lamp--------------------------------------------------------4.5 Replacement of Rear Registration Plate Lamp Bulbs-------------------------4.6 Replacement of Front Steering Lamp Bulbs -----------------------------------4.7 Replacement of Rear Steering Lamp Bulbs ------------------------------------4.8 Meters--------------------------------------------------------------------------------4.9 Main Switch -----------------------------------------------------------------------4.10 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.
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The ignition switch ON is not light, which due to Poor bulbs. Poor switch. Bad contact or broken wires Weak battery power or no voltage.
4.3 Replacement of Headlamp Bulbs

Remove the two fixing bolts 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 cover.
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The figure below shows the bulb of the dipped headlight, and the bulb of the headlight on full beam, 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 bulb on the right and left sides. (1) Operate according to the prompts of the above chapterReplacement 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.
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4.5 Replacement of Tail Lamp

The illuminant of the tail lamp is LED, replace the whole lamp if necessary. (1) Remove the passengers seat and the drivers. (2) Remove the tow fixing nuts of the tail-hood shield, and then move it horizontally backward to take it down.
(3) Remove the two fixing nuts of the rear lamp combination.
(4) Remove the three fixing bolts 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.
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4.6 Replacement of Rear Registration Plate Lamp Bulbs

(1) Remove the fixing nuts of the rear registration plate lamp to take down the tail-hood of it.
(2) Take off the damaged bulb, and replace on a new one of the same specification.
(3) Install the lamp in reverse order.
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4.7 Replacement of Front Steering Lamp Bulbs

The illuminant of the front steering lamp is LED, replace the whole lamp if necessary. (1) Operate according to the prompts of the above chapterReplacement of the Headlamp Bulbs. (2) Remove the fixing nuts of the right or left steering lamp. (3) Remove the cable of the front steering lamp, take off the damaged lamp, and replace on a new one of the same specification. (4) Install the lamp in reverse order.
4.8 Replacement of Rear Steering Lamp Bulbs

The illuminant of the rear steering lamp is LED, replace the whole lamp if necessary. (1) Remove the fixing nuts 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. (3) Install the lamp in reverse order.
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.
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4.10 Main Switch

4.10.1 Check
Remove the front shield. Remove the main switch lead terminal. Check the conduction of the terminal.
POWER LOCK
ON OFF
LOCK
R/W
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.
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4.12 Handlebar Switch

Switch classification: 1. Light changing switch 2. Start switch 3. Steering switch 4. Horn switch 5. Turn off switch 6. Warning switch
/ /
// /
Schematic diagram of wiring headlamp switch start button blue /yellow/red light blue black grey /red/white /grey/white green white
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Inspection and Maintenance of the Motorcycle Body

Torque Force Table of the Body
Name of fastening parts and fasteners 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 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
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Front Disc Brake

A Dia. of the front left/right brake disc:320mm Thickness of the front left/right brake disc:4.0mm Limit for use: 3.6mm Thickness of the brake shoes:7.8mm Limit for use:3.8mm Torque for mounting bolt 4 in the figure:5-10N m Torque for mounting bolt 5 in the figure:30-35N m Torque for mounting bolt 11 in the figure: 5-7N m Torque for mounting bolt 12 in the figure:30-35N m Torque for mounting bolt 14 in the figure:37-55N m Torque for mounting bolt 17 in the figure:22-34N m
C D E
G H I
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
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Rear Disc Brake

A B C D E F G Dia of the rear disc brake: 240mm Thickness of the rear disc brake: 5.0mm Limit for use: 4.5mm Thickness of the brake shoes: 7.0mm Limit for use: 3.7mm Torque for mounting bolt 15 in the figure:30-35N m: 22-34 N m Torque for mounting bolt 14 in the figure:30-35N m: 5-10 N m Torque for mounting bolt 10 in the figure:30-35N m: 30-35 N m Torque for mounting bolt 8 in the figure:30-35N m: 30-35 N m
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
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5. Brake
Maintenance Instruction ------------------------5.1 Failure Diagnosis --------------------------------5.2 Front Disc Brake ---------------------------------5.3 Rear Disc Drake ---------------------------------5.4
5.1 Maintenance Instruction

Work Instructions
*Note
A stained brake disc or protective gasket will reduce brake force, so discard stained gasket and clean the brake disc with quality brake degreaser. Check the brake system through the brake lever and pedals. Spilled brake liquid is harmful to the focusing and paint of the equipment, and the rubber parts too. So be careful whenever you remove the cap of the 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 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 O.D. of the oil-pumping piston I.D. of the caliper cylinder O.D. of the caliper piston Standard DOT4 4.0mm 7.8mm 320mm 0.1mm Limit for use 3.6mm 3.8mm Rear Item Special brake liquid Thickness of the brake disc Thickness of the brake shoe Dia. of the brake disc The jump of the brake surface of the brake disc I.D. of the pump oil cylinder O.D. of the oil-pumping piston I.D. of the caliper cylinder O.D. of the caliper piston Standard DOT4 5.0mm 7.0mm 240mm 0.1mm 11+0.027 mm 0 11-0.032 -0.059 mm 32+0.08 +0.03 mm 32-0.032 -0.065 mm Limit for use 4.5mm 3.7mm -
I.D. of the pump oil cylinder 16+0.043 mm 0 16-0.032 -0.059 mm 34+0.08 +0.03 mm 32-0.032 -0.065 mm
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5.1.2 Torque Force

Fixing the front wheel spindle Mounting screw of the front left brake cylinder assembly Mounting screw of the front right brake cylinder assembly Fixing nut of the rear wheel spindle Mounting screw of the rear brake cylinder assembly 100-140N m 37-55N m 37-55N m 130-150N m 22-34N m

5.2.1 Poor Brake Performance
1. 2. 3. 4. Improper adjustment of the brake Abraded brake shoes assembly or disc brake Improper installation of the brake shoes assembly 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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Air in the hydraulic system Leakage of the hydraulic system Stained brake pedal/disc Abraded seal of the caliper piston Abraded brake pedal/disc Stained caliper Abnormal slip of the caliper Insufficient brake liquid Blocked brake liquid channel Bended/fragmentary caliper piston Bended/fragmentary piston of the main cylinder Stained piston of the main cylinder Bending braking lever/pedal
5.2.5 Brake Stuck or Pulled to One Side

1 Stained brake pedal/disc 2 Wheel deviation
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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 2 3 4 5 Strained brake pedal/disc Wheel deviation Abraded brake pedal/disc Bending/fragmentary brake pedal/disc Abnormal slip of the caliper
5.2.7 Stiff Brake Lever/Pedal

1 2 3 4 5 6 7 Blocked/limited brake system Sticked/abraded caliper piston Abnormal slip of the caliper Blocked/limited brake liquid channel Abraded sealing gasket of the caliper piston Sticked/abraded piston of the main cylinder 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: Nut of the rearview 1. brake handle mirror 2. fuel pump assembly 3. brake hose assembly 4. left/right brake cylinder assembly Fixing screw of the fuel pump 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.
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Fixing screw of the handle
Fixing bolt of the brake hose Brake hose
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
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Remove the front wheel spindle. Remove the front wheel. Remove the disc brake off the front rim. front wheel front wheel spindle front left disc brake 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 Thickness of the front brake disc *Note Measure them with micrometer.
320mm 4.0mm
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Measure the thickness of the brake shoes. If the thickness of the brake disc or the brake shoe is below the required value for maintenance or it is stained with grease, please replace it. Limit for use: 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
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.
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5.4 Rear Disc Brake

5.4.1 Disassembly
*Note Replace the brake shoes assembly. If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place. Remove the following assembly off the frame and the rear swinging arm. Rear disc brake: (1) Fuel pump assembly (2) Brake hose assembly (3) Brake cylinder assembly (4) Brake discs
Loosen the fixing screws of the right pedal cover plate. Right pedal cover plate Fixing screws
Loosen the fixing screws of the oil pump assembly. Remove the oil pump cylinder. Fuel pump assembly Fixing screws
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Loosen the fixing screws of the brake cylinder assembly. Remove the brake cylinder assembly off the rear swinging arm. Rear brake hose Fixing bolt Brake assembly cylinder
Fixing screw
Remove the rear wheel spindle. Then take off the rear wheel. Remove the bake disc off the rear rim. rear wheel rear brake disc fixing screw 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 240mm Thickness of the rear brake disc 5.0mm *Note Measure with micrometer.
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Measure the thickness of the brake shoes. If the thickness of the brake disc or the brake shoe is below the required value for maintenance or it is stained with grease, please replace it. Limit for use: 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
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.
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Body
*Note: Do not damage any body part during disassembly. Do not damage any hook or claw in the body during disassembly. Aim panels in the body at each corresponding groove. Ensure correct installation of each hook or claw part during assembly. Do not damage any part during assembly.
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
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6. Body
6.1 Disassembly
Disassemble in the following order:
back seat assembly front seat assembly front shield of the tank left shield of the tank right shield of the tank left front shield right front shield middle shield of the tank tank assembly rear connecting board of the left/right shield left rear handrail right rear handrail bottom left shield left shield bottom right shield right shield taillight rear bottom fender decorative cover of the right muffler trim-cover of the right muffler decorative cover of the left muffler trim-cover 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.
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Front Suspension
A Torque for mounting the fixing bolt 20 of the steering column in the figure: 50-70Nm Torque for mounting the fixing bolt 16 of the upper base of the steering handlebar in the figure: 22-34Nm Torque for mounting the fixing bolt 13 of the upper connecting board in the figure: 22-34Nm Torque for mounting the fixing bolt 5 of the front absorber in the figure: 5-10Nm Torque for mounting the front wheel spindle 1 in the figure: 100-140Nm Torque for mounting the locking bolt 28 of the head of the front wheel spindle in the figure: 5-10Nm
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
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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
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Front Wheel
A B C
Tyre size: front tyre: 120/70 ZR17 Pressure of the front tyre: 250 10kpa Minimum non-skid depth: 1.6mm Rim run-out limit: Vertically: 2.0mm Horizontally: 2.0mm Torque for mounting the bolt 1 of the brake disc: 22-34N m
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
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7. Front Wheel/Handlebar/Front Suspension

Preparing Documents--------------------------7.1
Failure Diagnosis-----------------------------7.2 Front Wheel-----------------------------------7.3 Handlebar--------------------------------------7.4 Front Suspension-----------------------------7.5

Work Instructions
Before removing the front wheel, you should use jack to support the body bottom and suspend the front wheel which shall not be reversely rotated. Pay attention that the brake shoes and the brake disc shall not be stained with grease during operation. A 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 Front wheel spindle Front wheel Rim shimmy Item Bending Vertically Horizontally Within 1.0 Standard (mm) Limit for use (mm) 0.2 2.0 2.0
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
Tools
22-34N m Bearing puller 100-140N m Locking nut spanner 5-10N m 5-10N m 50-70N m 37-55N m
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7.2.1 Difficulty in Steering
Failure or damage of the steering handlebar. Damaged bearing of the handlebar. Too tight of the adjusting bolt of the faucet bearing. Insufficient tyre pressure.
7.2.2 Unsteady Steering

Damaged steering handlebar. Insufficient tyre pressure. Bending of the front fork or the front wheel spindle. Deformed or unbalanced front tyre.
7.2.3 Front Tyre Shimmy

Deformed rim. Abraded front wheel bearing. Flawed front tyre. Unbalanced tyre or wheel.
7.2.4 Difficulty in Wheel Rolling

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
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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 screws.
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.
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Bleed nipple Fixing bolt of the bake hose Right brake cylinder assembly Fixing bolt of the brake cylinder
Remove the clamping screw of the front wheel spindle (right front absorber)
Disassemble the front wheel spindle
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Disassemble the front wheel assembly Remove the left spindle sleeve of the front wheel
Disassemble the bearing with the bearing remover.
Note: Do not operate the brake controlling lever after the removal of the brake caliper.
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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
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.
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7.3.2.4 Check the front wheel bearing

Remove the bearing, and the middle sleeve of the front wheel. 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. clearance 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
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7.4 Steering Handlebar

7.4.1 Disassembly
Remove the left/right rearview mirror assembly. Right rearview mirror
Left rearview mirror
Remove the oil pump assembly of the front brake. Remove the right switch group. Remove the mounting base assembly of the throttle cable. Oil pump assembly Mounting base assembly of the throttle cable Fixing screw Right switch group Fixing screw
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Remove the left handle assembly. Remove the left switch group. Left handle assembly Fixing screw Left switch group
Remove the balance block assembly. Remove the right handle assembly. Remove the balance block.
Remove the fixing bolts of the upper base of the steering handlebar. Turn the upper base 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
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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 bolt.
Remove the meter and the meter bracket. Loosen the fixing bolts of the upper connecting board. Remove the upper connecting board.
Remove the headlamp and its bracket. Loosen the clamping bolts of connecting board. Remove the front absorber.
the
upper
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Tools: Fixing nut spanner. Special disassembly tool for bearing cup. *Note: The opening of the body guard shall be cleaned with cloth. The upper/lower bearing cup shall be dismantled with a special disassembly tool for bearing cup.
7.5.3 Installation
Note: Make sure that the hole of the front wheel spindle is concentric when installing the left and right absorber. Steps are contrary to the process of disassembly.
Note: Fixing screws for the bottom connecting board: Fixing screws for the upper connecting board:
10N.m 28N.m
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Rear Wheel/Rear Suspension

A B C Tyre size: rear tyre: 180/55 ZR 17 Pressure of the rear tyre: 290 10kpa Minimum non-skid depth: 2.0mm Rim run-out limit: Vertically: 2.0mm Horizontally: 2.0mm Torque for mounting the bolt 2 in the figure: 5-10N m Torque for mounting nut 19 in the figure: 37-55N m Torque for mounting nut 20 in the figure: 130-150N m
E F G
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 62 19. self-locking bolt M10 1.25 20. self-locking bolt M24 1.5
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Rear Suspension/Rear Absorber

A Torque for mounting bolt 1 in the figure: 70-105 N m Torque for mounting nut 10 in the figure: 37-55 N m Torque for mounting nut 10 in the figure: 37-55 N m
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
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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 Rear wheel shimmy Vertically Horizontally Standard (mm) Limit for use (mm) 2.0 2.0
Locking torque force

Fixing nuts for the rear wheel spindle Top bolts for the rear absorber Bottom bolts for the rear absorber Fixing bolts for the rear swinging arm Fixing nuts for the sprocket wheel Fixing bolts for the rear brake disc 130-150N m 37-55N m 37-55N m 70-105N m 37-55N m 5-10N m

8.2.1 Rear Wheel Shimmy
Deformed rim Abraded rear wheel spindle Tyre failure
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Abraded or damaged bearings of the swinging arm spindle Incorrect adjustment of the drive chain Unbalanced tires and wheels Too low of the tyre pressure Bending frame or the rear swinging arm
8.2.2 Inflexible Rolling of the Wheel

Bending rear disc brake Abraded bearings of the rear wheel spindle Too tight of the drive chain
8.2.3 Too Soft of the Suspension

Insecure or shaking damping spring Incorrect front suspension regulator Oil leakage of the absorber Too low of the tyre pressure
8.2.4 Too Stiff of the Suspension

Damaged assembly bearing of the absorber Bending tube of the absorber Damaged bearing of the rear swinging arm axis Bending of the rear swinging axis Fault in the suspension regulator 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.
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Caliper of the rear disc brake Fixing screws of the caliper of the rear disc brake Adjusting screw of the rear wheel 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.
Nut of the rear wheel spindle
Left chain adjusting block Adjusting screw of the rear wheel
Remove the rear wheel spindle and the right adjusting block of the chain. rear wheel rear disc brake box fixing screws rear wheel spindle
Take the chain off the big sprocket wheel. Chain
Big sprocket wheel
- 103 -
Remove the rear wheel assembly.
Remove the supporting board of the brake clamp.
Supporting board of the brake clamp
Remove the sprocket wheel assembly. Remove the fixing bolts of the sprocket wheel. Fixing bolts of the sprocket wheel
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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
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8.4 Rear Absorber

8.4.1 Disassemble the Rear Absorber
Remove the upper/lower fixing nut of the rear absorber. Remove the rear absorber.
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 it in reverse order. Install the upper fixing nut and lower fixing bolt of the rear absorber. Lock to the specified torque force.
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Fixing bolts Torque force: 37-55 N m
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8.5 Chain Drive

8.5.1. Disassembly
Put the motorcycle on level ground, and firmly support it. Remove the left rear cover. Fixing bolt of the left rear cover
Engine 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 doesnt meet the specified value, replace the drive chain. The limit value of the length of ten chain links is 1587.5mm.
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* 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 and side panels , 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.
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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
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.
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.
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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 Dont 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. Rear swinging arm
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 Bearing
8.6.3 Install the Rear Swinging Arm

Install it in reverse order. Spindle bush of the pivot should be greased, Note: Bolts for the rear swinging arm spindle Torque force: 70-105N m
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Fuel Tank
Gasoline capacity of the A gasoline tank: 150.2L B Torque force of bolt 3: 5-10Nm Torque force of bolt 6: 5-10Nm Torque force of bolt 9: 5-10Nm Torque force of bolt 12: 5-10Nm 16 22-37Nm
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
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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.
Item Gasoline tank capacity Standard 15 0.2L Limit for use /
Tightening torque force

Front fixing bolts for the gasoline tank Rear fixing bolts for the gasoline tank Fixing bolts for the fuel tank front mounting pad Fixing bolts for the fuel pump Fixing bolts for the oil level sensor 22-37N m 5-10 N m 5-10 N m 5-10N m 5-10N m
9.2 Failure Diagnosis 9.2.1 Decreasing Gasoline

Natural consumption of gasoline Leakage of gasoline
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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
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Remove the rear fixing bolt of the fuel tank. Rear fixing bolt of the fuel tank
Remove the fuel tank.
9.3.2 Installation
Install it in reverse order.
Torque force for mounting: Front fixing bolts for the gasoline tank Rear fixing bolts for the gasoline tank Fixing bolts for the fuel tank front mounting pad Fixing bolts for the fuel pump Fixing bolts for the oil level sensor
22-37N m 5-10 N m 5-10 N m 5-10N m 5-10N m
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10. Disassembly and Installation of Engine

Preparing Documents -------------10.1 Disassembly and Installation of Engine ----------10.2

Work Instructions
It shall be dismantled far from fire sources. Tighten all the bolts and screws to the required torque value for assembly. After assembly, check whether all the parts are correctly installed and operated.
Locking torque force

Gearshift rod bolt: Engine fixing bolt: 10N.m 50N.m
10.2 Disassembly of Engine

Support the motorcycle firmly to make its rear wheel above the ground.
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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.
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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;
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Disassemble the canister assembly
Canister assembly
Disassemble the clutch steel rope assembly
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
- 119 -
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
- 120 -
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
- 121 -
10.3 Installation of the Engine

Install it in reverse order. 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 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. Checking method of engine fuel Pull out the fuel rod, wipe it off with a clean cloth. 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. 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. The oil level should always be kept between the lowest limit and the toppest limit.
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Inspection and Maintenance of Engine

Table of Torque Force of Fasteners
Name of fastening parts and fasteners 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 Tightening torque (N m) 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
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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 Item Fuel capacity When oil change When disassembling The radial clearance between inner and outer rotors The clearance between outer rotor and pump body Standard 3.0L 3.2L 0.04-0.11mm 0.04-0.11mm Limit for use 0.15mm 0.15mm
Fuel pump rotor

Decreasing fuel Natural consumption of fuel Fuel leakage Burnt engine No fuel pressure or low fuel pressure Blocked fuel pipes
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11.3 Fuel Pump

11.3.1 Disassembly
Remove the clutch cover, loosen the fuel pump fixing bolt, take down the fuel pump drive sprocket and the fuel pump drive chain.
Fuel pump chain Screw Fuel pump drive sprocket
Remove the screw. Remove the fuel pump body. Screw Fuel pump body
Remove the screw, take down the fuel pump cover, and decompose the fuel pump.
Screw
Fuel pump cover
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Check the radial clearance between inner and outer rotors Limit for use: 0.15mm. Gauge
Check the clearance between outer rotor and fuel pump cover Limit for use: 0.15mm.
Gauge
- 126 -
11.3.2 Assembly of Fuel Pump

As shown below Fuel pump drive sprocket
Fuel pump cover
Outer rotor
Pump body
Inner rotor
Pump shaft
Note: After the combination, the inner and outer rotors should rotate flexiblely without stagnation. Installation Install it in reverse order.
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11.3.3 Lubricating Systematic Drawing
Piston cooler
--- exhaust camshaft --- intake camshaft ---piston cooler --- crankshaft connecting rod mechanism --- main oil channel --- oil cooler ---main shaft --- fuel pump --- fuel filter --- fuel strainer --- relief valve ---countershaft
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- 129 -
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
Item Standard 0.03 Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust 013-0.19 0.19-0.25 3.97-3.98 3.97-3.98 4.03-4.04 4.03-4.04 0.05-0.07 0.05-0.07 1.0-1.1 1.0-1.1 38.8 41.6 0.041-0.054 Limit for use 0.05 __ __ 3.96 3.96 4.07 4.07 0.11 0.11 1.5 1.5 37.3 40.1 0.08
Flatness of cylinder cover

Valve gap
Outer diameter of valve stem

Valve Valve catheter
Inner diameter of valve catheter Clearance between valve stem and valve catheter
Width of valve seat
Valve spring
Free length
Camshaft
Fitting clearance between camshaft and
cylinder head

Low compression pressure Valve clearance maladjustment Noise in Cylinder head Valve clearance maladjustment
- 130 -
Burnt or bent valve Poor air-tightness of valve seat Cylinder head gasket leaks gas Poor installation of spark plug
Damaged valve spring Over high compression pressure Too much carbon fouling in the combustion chamber.
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12.3 Cylinder Head

12.3.1 Disassembly
Remove the ignition coil. Loosen six locating bolts, remove the gasket and cylinder cover shade.
Cylinder cover shade
Locating bolt
Loosen the fastening bolt, and remove the air-distributing chain regulator. Fastening bolt Air-distributing chain regulator
Loosen the four sprocket bolts of the camshaft.
Sprocket bolt of the camshaft Measure the fitting clearance between camshaft and cylinder head. Limit for use: 0.08mm. Gauge
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Loosen the camshaft holder.
Camshaft holder
Remove the camshaft, camshaft sprocket and chain.
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.
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12.3.2 Cam Assembly Breakdown
Seal cover D13
Camshaft Camshaft sprocket
Bolt
12.3.3 Valve Breakdown Valve Valve spring lower seat Valve block Top stem
Valve spring
Valve spring upper seat
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.
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Vernier calipers
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 Micrometer 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 mustnt be rotated anti-clockwise.
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.
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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.
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.
Valve reamer
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
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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.
Rugged part
Remove 1/4 of the outer end of valve seating with a milling cutter at 25 angle.
25
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.
60
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
1.0mm
45
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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.
High contact surface 25 Low contact surface
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

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:
- 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.
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Standard of benchmark items and table of limit for use

Item Standard Cylinder I 65 (0.025, 0.03) Diameter of the cylinder Cylindricity of the cylinder Roundness of the cylinder Flatness of the cylinder Outer diameter of piston (measured in piston skirt) Inner diameter of piston pin hole Outer diameter of piston pin Upper box Clearance between piston pin hole and piston pin Clearance between piston ring and ring groove Joint gap of the piston ring Ring 1 Ring 2 Ring 1 Ring 2 Fuel ring Inner diameter of the smaller head of connecting rod. Clearance between connecting rod and piston pin Thickness Connecting-rod bearing Clearance connecting-rod crankshaft Left-right clearance of the larger Connecting rod end of the connecting rod Radial clearance of the larger end of the connecting rod Main-shaft bearing Thickness Clearance between main shaft and crankshaft Thickness of friction disc Clutch Length of pressure spring Outer diameter of fork shaft Variable speed transmission gear Diameter of fork inner hole Thickness of fork Outer diameter of gearshift drum Width of gearshift drum lock groove 0.1-0.25 0.008-0.016 1.5 (0-0.012) 0.03-0.05 2.8 (-0.05, +0.05) 3-0.1, 0 24.3-0.15, +0.15 23.5-0.2, +0.2 11.973-11.984 12-12.018 5.80-5.90 41.9-42.1 5.45-5.55 0.5 0.05 1.44 0.07 2.45 2.6 22.8 22.4 11.96 12.03 5.75 41.5 5.65 between bearing the and 0.025-0.05 0.065 Cylinder II 65 (0.03, 0.035) 0.008 0.006 0.03 Piston I 65 (-0.03, -0.025) Piston II 65 (-0.025, -0.02) 16 (0.002, 0.008) 16-0.008, 0 0.002-0.016 0.05-0.09 0.04-0.08 0.15-0.30 0.25-0.45 0.20-0.70 16 (0.016, 0.034) 0.016-0.042 1.5 (0-0.09) Limit for use 65.100 65.110 0.050 0.050 0.05 64.90 64.91 16.04 15.96 0.04 0.11 0.11 0.5 0.65 1.0 16.04 1.48
Lower box
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Low compression pressure Abrasive, burnt or ruptured piston Abrasive or damaged cylinder or piston Damaged spacer or crankcase leakage Over-high compression pressure Too much carbon deposit in the combustion chamber White smoke from the exhaust pipe Abrasive or damaged piston ring Abrasive or damaged cylinder or piston
Abnormal noise of the piston 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 isnt 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
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13.3 Upper Box

BJ465MS/QJ465MS Engine cylinder block Namely it is part of the upper box.
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
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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.
Retainer ring of the piston

Piston pin
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. 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
Measure the inner diameter of the piston pin hole. Limit for use: 16.04mm.
Tester
Measure the outer diameter of the piston pin. Limit for use: 15.96mm. Clearance between piston pin hole and piston pin. Limit for use: 0.04mm.
1 2 3
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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.
90 11mm
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.
Tester
Measure the roundness of the inner wall of the cylinder (inner diameter difference at X direction and Y direction). Limit for use: 0.050mm. 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). Limit for use: 0.050mm.
In
Top Middle
Ex
Bottom
- 147 -
Check the flatness of the cylinder surface.. Limit for use: 0.05mm. Ruler
Gauge
Upper box
Measure the inner diameter of the smaller end of the connecting rod. Limit for use: 16.04mm.
Inner diameter of smaller end of connecting rod Tester
the the
Measure the clearance between connecting-rod bearing and crankshaft. Limit for use: 0.065mm.
Connecting-rod bearing
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Measure the clearance between main shaft bearing and crankshaft. Limit for use: 0.07mm.
Main shaft bearing
Plastic gauge
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.
Top ring Ring 2 Fuel ring
- 149 -
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
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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.
Motor idle gear

Starter motor
Locating pin hole
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
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13.5.2 Disassembly of the Clutch Cover

Loosen the fixing bolt, and remove the clutch cover.
Bolt
Clutch cover
Remove the clutch release stem from the right 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
Gearshift arm assembly
Fuel pump sprocket Driven gear
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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.
Gearshift drum assembly Fuel pump chain Fuel pump sprocket
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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. .
Release plate bolt
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.
Four-claw socket spanner Universal holder
Shell assembly
Install it in reverse order.
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13.6.2 Clutch Breakdown
---needle bearing ---sleeve ---spacer ---drive hub assembly ---driven hub ---friction disc ---clutch disc ---dish-shaped spring ---gasket ---drive hub housing assembly ---pressure spring ---pressure plate ---bolt --- rolling bearing
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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.
Drive hub assembly
Driven hub
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.
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
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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.
Gearshift shaft assembly
13.7.2 Gearshift Shaft Mechanism Breakage Fork shaft spring Fork Fork shaft
Pressure plate Gearshift drum Gearshift drum bearing 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.
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Check whether the gearshift shaft is bent, if excessively bent, replace it. Check the return spring for decreasing elasticity, if necessary, replace it.
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Loosen the crankcase bolt. Upper box Separate the crankcase. Note: Do not damage the spacer and crankcase surface. Remove the upper box.
Crankcase bolt
Lower box
Main shaft assembly
Countershaft assembly
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.
Gearshift drum Fork Fork shaft
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13.7.2.2 Check
Measure the outer diameter of the fork shaft. Limit for use: 11.96mm.
Fork shaft
Micrometer
Measure the inner diameter of the fork hole. Limit for use: 12.03mm.
Tester
Vernier calipers
Measure the thickness of the fork. Limit for use: 5.75mm.
Width of the lock groove

Measure the outer diameter of the gearshift drum. Limit for use: 41.5mm. Measure the width of the gearshift drum locking groove. Limit for use: 5.65mm.
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13.8 Crankshaft Connecting Rod Assembly Chamber and Variable Speed Chamber
Depository for the main shaft Depository for the crankshaft connecting rod Depository for the countershaft
Gearshift chamber
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Main shaft assembly Gearshift drum assembly
Fork shaft
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13.8.1 Crankshaft Connecting Rod Assembly

13.8.1.1 Disassembly
Remove the upper box. Remove the spacer and locating pin. Remove the crankshaft connecting rod assembly from the lower box.
Countershaft assembly asseml
Main shaft assembly
Drive gear
Note: Do not damage the spacer and crankcase surface.
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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
Measuring point at the larger end of the connecting rod

Measure the clearance of the larger end of the connecting rod (X-Y direction). Limit for use: 0.05mm.
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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
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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.
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.
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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
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dissipate heat, and transfers heat to the outside air with the help of radiators 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
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Water pump sub assembly
Bolt Loosen the bolt, and remove the water pump cover. Water pump cover
Remove the blade. Blade
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.
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Cooling Systematic Drawing
465 cooling system piping drawing

thermostat
Reservoir
t Cylinder cover Thermostat Pressure valve Oil cooler Water pump Cylinder block Radiator
Water direction
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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 Emission standard CO 2.0g/km HC 0.3g/km NOX 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: 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.
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:
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.
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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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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
Dismantle and repair engine Valveleakage Pistonabrasive Combustorcleaning
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.
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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 J1-2 J1-3 Headlight control pin Pin for trouble light Pin for heating 2-cylinder oxygen J1-4 sensor Pin for signal 2-cylinder oxygen J1-5 sensor J1-6 J1-7 J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 Connector pin for tachometer CAN line low signal 1 pin CAN line high signal 1 pin Pin for system grounding Pin for activating 2-cylinder ignition coil J2-6 J2-7 J2-8 J2-9 J2-10 J2-11 J2-12 J2-13 Pin for 5V system reference voltage grounding Pin for activating 2-cylinder fuel injector Pin for heating 1-cylinder oxygen sensor Pin for intake temperature sensor signal J2-5 Pin for activating 1-cylinder fuel injector J2-4 Pin for crank signal high potential J2-1 J2-2 J2-3 Pin for activating 1-cylinder ignition coil Pin for system grounding Pin for K line communication
Pin for intake pressure sensor signal Pin for throttle position sensor signal Pin for crank signal low potential - 179 -
J1-14 J1-15 J1-16 J1-17 J1-18
Dump switch (efficient at low)
J2-14 J2-15 J2-16 J2-17
Signal pin for water temperature sensor Ignition power (12V positive voltage after key)
Pin for signal 1-cylinder oxygen sensor Battery power supply (battery 12V positive voltage)
Pin for neutral gear switch
J2-18
Remarks: J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey connector.
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2) ECU34
J1-1 J1-2 J1-3 Idle speed stepper motor high A pin Canister solenoid valve pin Pin for trouble light Pin for heating 3-cylinder oxygen J1-4 sensor Pin for signal 3-cylinder oxygen J1-5 sensor J1-6 J1-7 J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-15 J1-16 J1-17 J1-18 CAN line low signal 2 pin CAN line high signal 2 pin Pin for system grounding Pin for activating 3-cylinder ignition coil Idle speed stepper motor low A pin Idle speed stepper motor high B pin Idle speed stepper motor low B pin Dump switch (efficient at low) Pin for vehicle speed sensor J2-6 J2-7 J2-8 J2-9 J2-10 J2-11 J2-12 J2-13 J2-14 J2-15 J2-16 J2-17 Pin for activating 3-cylinder fuel injector J2-5 Pin for activating 4-cylinder fuel injector J2-4 Pin for crank signal high potential J2-1 J2-2 J2-3 Pin for activating 4-cylinder ignition coil Pin for system grounding Pin for K line communication
Pin for heating 4- cylinder oxygen sensor Pin for intake temperature sensor signal Pin for oil pump control signal Pin for 5V system reference voltage grounding Pin for intake pressure sensor signal Pin for throttle position sensor signal Pin for crank signal low potential
Signal pin for water temperature sensor Ignition power (12V positive voltage after key) 5V reference voltage Pin for signal 4-cylinder oxygen sensor Battery power supply (battery 12V positive voltage)
Pin for neutral gear switch
J2-18
Remarks: J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey connector.
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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:
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) b) c) 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.
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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.
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. The fuel pump is damaged and cannot run.
b)
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

Corresponding Fault code P0107 P0108 P0112 P0113 P0117 P0118 P0122 P0123 P0131 P0132 P0031 P0032 P0201 P0202 P0230 P0232 P0336 P0337 P0351 P0352 P0562 P0563 P0560 P1693 Description open circuit of intake pressure sensor or short circuit of signal end pin to the negative electrode of the battery short circuit of signal end pin of the intake pressure sensor to the positive electrode of the battery short circuit of signal end pin of the intake temperature sensor to the negative electrode of the battery open circuit of intake temperature sensor or short circuit of signal end pin to the positive electrode of the battery short circuit of signal end pin of the cylinder end temperature sensor to the negative electrode of the battery open circuit of cylinder end temperature sensor or short circuit of signal end pin to the positive electrode of the battery open circuit of throttle position sensor or short circuit of signal end pin to the negative electrode of the battery short circuit of signal end pin of the throttle position sensor to the positive electrode of the battery short circuit of signal end pin of the front cylinder oxygen sensor to the negative electrode of the battery short circuit of signal end pin of the front cylinder oxygen sensor to the positive electrode of the battery short circuit of heating end pin of the front cylinder oxygen sensor to the negative electrode of the battery short circuit of heating end pin of the front cylinder oxygen sensor to the positive electrode of the battery fault of for fuel injector front cylinder fault of for fuel injector rear cylinder (plug-in device of the fuel injector is not plugged) open circuit of oil pump or short circuit to the negative electrode of the battery short circuit of oil pump to the positive electrode of the battery signal interference of crank shaft position sensor no signal of crank shaft position sensor fault of ignition coil for front cylinder fault of ignition coil for rear cylinder voltage below level of electronic control injection system overtension of electronic control injection system fault of trouble light (damage of filament or plug-in device) short circuit of tachometer line to the negative electrode of the decimal number 263 264 274 275 279 280 290 291 305 306 50 49 513 514 560 562 822 823 849 850 1378 1379 1616 5779
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battery P1694 P0137 P0138 P0038 P0037 short circuit of tachometer line to the positive electrode of the battery short circuit of signal end pin of the rear cylinder oxygen sensor to the negative electrode of the battery short circuit of signal end pin of the rear cylinder oxygen sensor to the positive electrode of the battery short circuit of heating end pin of the rear cylinder oxygen sensor to the positive electrode of the battery short circuit of heating end pin of the rear cylinder oxygen sensor to the negative electrode of the battery 5780 311 312 56 55
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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.
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Instructions of PCHUD Software:

1Connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line and turn on the key. 2Click the icon "HUD.EXE" to start PCHUD software 3Select "File" on the software interface, click "Open", choose "PCHUD.HAD" and select OK.
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.
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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.
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Then check the corresponding fault according to the fault code list
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Interpretation of PCHUD Software Parameter

VRPM VTHROT VBARO VMAP VMAPEXP VIGN VCLTS VIAT STATUSBYTE5 VAFCMET VBAROCMET VCSINSYNSPRK SATITRIG CATLOENB IF ENGSTATE=3 NISTBLIDLE FO2REDY2 FCNO FBLMCOR1 FCLCINT1 FCLCMUL1 IARDRPM IARPMERR FPWVC1 VO2 STATUSBYTE3 FO2STAT1 FCLREST1 5 tip-in 2 1 I 1 3 1 1 engine speed throtle position BARO manifold air pressure expect manifold air pressure ignition key voltage cylinder temperature or coolant temperature intake air temperature STATUSBYTE5 airflow correction met Baro update met sequential spark enable tip-in Spark Advance retard trigger catlyst light-off logic enable engine work in run state stable warm idle O2 ready block learn memory cell cylinder 1 block learn memory intergral of close loop correction close loop correction desired idle rpm idle rpm error base pulse width of cylinder 1 Oxygen sensor signal STATUSBYTE3 cylinder 1 oxygen sensor signal rich lean state cylinder 1 close loop correction reset
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FOSHTREN FO2REDY1 IF IACV MODE=0 IAMTRLOST IACMVIHB VIGNS FVE1 VMAPRANG AFFNLAFR SAESTA SAIDLDYN SPDWELL IAINTEGOFST IACVDSMP STATUSBYTE2 FCLCEN1 PPDSEBL FPENABL FTRNSAES FTRNSDES FTRNSAEDCLOAD FTRNSDEINLOAD FCLCEN2
1 1 1 2 1 2
Oxygen sensor heater enable cylinder 1 Oxygen sensor ready idle airflow control valve close loop correction enable IACV lost IACV move disable ignition state cylinder 1 Volumetric efficiency MAP read angle target air fuel ratio cylinder 1 Spark Advance idle dynamic Spark Advance dwell time airflow integral of idle air control valve desired position of idld air control valve STATUSBYTE2 cylinder 1 close loop correction enable prime pulse disable fuel pump enable acceleration enrich enter deceleration enlean enter acceleration enrich exit deceleration enlean exit cylinder 2 close loop correction enable
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16.4 Common Fault Removal Techniques 16.4.1 Repair Tools

a) b) c) Disassembling the parts of the electronic control system- common disassembly tools for auto machinery parts 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) Fault diagnostic apparatus for electronic control system(recommended) Fault diagnosis software(PCHUD) and port wire( if available)
Fault code list of the electronic control system( for emergency) 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) b) c) d) e) f) Engine wire harness and vacuum line- may influence the system in controlling air flow and oil supply. Assembly of Oxygen sensor- may influence the system in judging the air-fuel ratio. Engine trouble light- influences the system in fault warning. Storage battery voltage- judges whether the battery power is adequate. 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. 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) b) Coolant temperature and its cycling- indicate whether the thermostat operates normally. Storage battery voltage- shows whether the generator works normally. Too high: maybe a fault in the generator regulator. Too lowmaybe 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.
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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 yes b) If no: If yes: c) If no: If yes: d) 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. Connect the diagnostic apparatus to the system's diagnostic port. 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. Make the judgment with another ECU. Remove the fault shown by the diagnostic apparatus. Check whether the high-tension cable and spark plug are connected tightly or are damaged. Make the judgment with another ignition coil assembly Make the judgment with another ECU. Check whether the high-tension cable is connected with the ignition coil and spark plug in a correct way 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: If yes: Check whether the fuel pump relay works normally. Check whether the connection of crankshaft position sensor and its operation are normal. Make the judgment with another ECU. Check the fuel pump circuit Check whether there is enough gasoline in the fuel tank
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If no
Whether the diagnostic apparatus can be connected to the system for communication
Check the faults in the ignition system- whether the spark plug can ignite normally
1) Whether the supplied oil pressure is above 220Kpa 2) Inadequate
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) If yes f)
Whether the oil supply line and oil return line are damaged Check whether the nozzle control line is abnormal Whether it is necessary to clean the oil nozzle
Check whether the cylinder is flooded with oil Press the accelerator pedal to the limit and turn on the starter. After several seconds, there will be a sign showing the engine running. Whether the clearance of crankshaft position sensor is too large
16.4.3.3 Fault Description- Startup Failure Accompanied with Backfire

a) b) Check whether the high-tension cable of ignition coil is loose Whether the timing gear is loose.
16.4.3.4 Fault Description- Unstable Idle Speed

Idle speed control system: Oil supply system Check whether the idle speed by-pass bolt is too loose or tight. Usually it is necessary to screw 2 turns. 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. 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.
Idle speed is too low:
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16.4.3.6 Fault Description- Unstable Idle Speed Slowing Down with Flameout
a) b) Check the valve clearance Check whether the idle air bypass hole and throttle body are too dirty
16.4.3.7 Fault Description-Poor Acceleration

a) b) c) d) e) Whether the parameters at idle speed and high idle speed are normal Check the oil amount in the fuel tank, and fuel filter. Check whether the exhaust system is blocked, e.g., whether the ternary catalytic converter is clogged because of burning engine oil or damages. Check the oil line pressure and the oil nozzle. 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. 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.
b)
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).
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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
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RK6 Circuit Diagram
/ / / /
10A 10A 15A ECU1 15A 10A ECU2 15A

30A
IN5408
2# Gr ECU J1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
2#BLACK ECU J2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 / 1 / / / / /
/ /
/ / /
/ / / / / /
/ / / / 1
/ / /
// / / / 1 1
/ / /
/ /2 /2 /2 /
/
/ / /1 / / /1 / / /1
/ / /1 / / / /1 / / / / / /
/ / / / / / / / / / / / / / / /
/ / /
/2 /
/ / /
/ / / /
/2 /2 /2 /
/ /2 /
/ / / / /2 /2
/ / / / /2 / /
/2 /2
/2 /2
/ /2
/2 /2
/ /1 / / /
/1
/2 /
/1 / /1 /1 / / /1 / / / / / /
/ /1
/ / / / / / / / / / / / / /
/ / / 3 2 1 / / / 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 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1#Gr ECU J1
2 1
1#BLACK ECU J2
103

RK6 Service Manual

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Service manual of RK6

KEEWAY Motorcycle Corporation Ltd.

groove clip connector

Bearings will be broken under either occasion as mentioned.

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

3The serial number of the engine, see figure

1Tools for repairing the engine

Table 1-2 (continued)

Fig. 1-6 feeler gauge

Fig. 1-10 handle

2Tools for repairing the chassis

(3) Steering nut spanner

3Tools for electric parts

Fig. 1-40 (continued)

Weight kg (Curb weight)

Check if petrol pump is working properly

Oil provided to fuel injector is sufficient and smooth

Test compression pressure

No ignition outbreak of the engine

Ignition outbreak of the engine but no sign of startup

Intake manifold with air Incorrect ignition time

Disassemble once agian the spark plug to check

Abnormal adjustment to throttle valve and bolt

Dry spark plug

Wet spark plug

Unsmooth gyration (No speed or weak speed)

No Accelerated driving or running

Unsmooth gyrationespecially in low speed

Adjustment to throttle valve and bolt

Negative pressure pipe damaged Good Bad Air pass-hole blocked

Unsmooth gyration (high speed)

Abnormal CUP group Normal Abnormal Abnormal trigger

Blocked oil injector

Spring broken Weak elasticity

Poor battery charging (over discharge or over charge)

Check the plug of voltage regulator if it is loose

Poor battery charging Overcharging

Voltage above normal value

No spark-over of the spark plug

Weak spark-over or no spark-over

Original spark plug abnormal

Check again after checking spark plug

Loose Spark plug cap loose

Bad connection of the plug

Abnormal main switch Abnormal charging coil

Abnormal Check relevant parts

Abnormal trigger Abnormal ignition coil

Abnormal CPU group

Periodic Maintenance & Inspection Table

One Three Six month months months C C I C

Replacement every 1000KM I I I I I I I I I I R I I I I I I I R

Replacement every 5000KM L I I A A I I I I I I I I I I L I I A A I I I I I I I I I I

Check oil level

Replacement of the Oil Filter

Assembly and Disassembly of the Clamp of the Radiators Conduit

Fuel Injector and Oil-way

Adjustment to the Steel Rope of the Throttle

seat steel rope

Check the Charging Condition (closed circuit voltage)

Looseness of the Drive Chain

Free Stroke of the Front Brake

Regulator of Lever Grip of the Front Brake

Free Stroke of the Rear Brake