524702974-Benelli-Imperiale-400

Maintenance Manual of
Two-wheeled Motorcycle
IMPERIALE 400(BJ400-8)
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
O
K
E
RG
O
E
G
Y
A
W
CO
Y
P
T
O
M
im
D
-
s
o
i
r
it
Ka
k
-d
Table of Contents
Introduction.............................................................................................................................................................. - 1 Preparatory Information...........................................................................................................................................- 2 General safety.................................................................................................................................................. - 2 Maintenance rules............................................................................................................................................ - 3 Model information......................................................................................................................................... - 13 Motorcycle identification...............................................................................................................................- 15 Important Note............................................................................................................................................... - 15 Special tools................................................................................................................................................... - 16 Specification table (BJ400-8)........................................................................................................................ - 24 Unit conversion table..................................................................................................................................... - 26 Winding method of cables, wires and hoses..................................................................................................- 27 Troubleshooting Guide.................................................................................................................................. - 64 Torque and locking agent...............................................................................................................................- 74 Inspection / adjustment.................................................................................................................................. - 79 Inspection and Maintenance of Electrical System...............................................................................................- 110 I. Battery/Charging System..................................................................................................................................- 112 1.1 Preparatory Information.........................................................................................................................- 112 1.2 Fault Diagnosis...................................................................................................................................... - 113 1.3 Battery.................................................................................................................................................... - 114 1.4 Charging System.................................................................................................................................... - 120 1.5 Disassembly of Voltage and Current Regulator.................................................................................... - 121 1.6 Alternator............................................................................................................................................... - 122 II. Ignition System................................................................................................................................................- 126 2.1 Preparatory Information.........................................................................................................................- 126 2.2 Fault Diagnosis...................................................................................................................................... - 128 2.3 Trigger....................................................................................................................................................- 129 2.4 Ignition Coil........................................................................................................................................... - 129 2.5 Spark Plug.............................................................................................................................................. - 131 2.6 ECU........................................................................................................................................................- 132 III. Starter System................................................................................................................................................ - 134 3.1 Preparatory Information.........................................................................................................................- 134 3.2 Fault Diagnosis...................................................................................................................................... - 135 3.3 Starter Motor.......................................................................................................................................... - 135 3.4 Starter Relay...........................................................................................................................................- 136 IV. Bulbs /Switches/Meters..................................................................................................................................- 139 4.1 Preparatory Information.........................................................................................................................- 140 4.2 Fault Diagnosis...................................................................................................................................... - 140 4.3 Replacement of headlight bulb.............................................................................................................. - 141 4.4 Replacement of Turn Signal Light Bulb................................................................................................- 142 4.5 Replacement of Taillight Bulb............................................................................................................... - 143 4.6 Replacement of License Light Bulb...................................................................................................... - 143 4.7 Meters.....................................................................................................................................................- 144 4.8 Ignition Switch.......................................................................................................................................- 146 4.9 Electric horn...........................................................................................................................................- 147 -
b
is
n
ra
.A
S
S
I
N
A
R
B
A
O
K
E
RG
O
E
G
Y
A
W
CO
Y
P
T
O
M
im
D
-
s
o
i
r
it
Ka
a
k
-d
4.10 Handlebar Switch.................................................................................................................................- 149 4.11 Inspection of switch............................................................................................................................. - 151 4.12 Speed sensor.........................................................................................................................................- 152 4.13 Oxygen sensor......................................................................................................................................- 153 4.14 Fuel level sensor.................................................................................................................................. - 154 4.15 Relay and fuse box...............................................................................................................................- 156 4.16 Fuse...................................................................................................................................................... - 160 Inspection and Maintenance of Chassis...............................................................................................................- 163 V. Brake................................................................................................................................................................- 170 5.1 Preparatory Information.........................................................................................................................- 170 5.2 Fault Diagnosis...................................................................................................................................... - 171 5.3 Front Brake Disc.................................................................................................................................... - 172 5.4 Rear Brake Disc..................................................................................................................................... - 174 5.5 Brake lever, brake pedal........................................................................................................................ - 177 5.6 Caliper....................................................................................................................................................- 180 5.7 Brake pad............................................................................................................................................... - 187 5.8 Master cylinder...................................................................................................................................... - 190 5.9 Brake fluid............................................................................................................................................. - 195 5.10 Brake hose............................................................................................................................................- 199 5.11 Anti-lock brake system (ABS).............................................................................................................- 202 VI. Body Cover.................................................................................................................................................... - 237 VII. Front Wheel/Front Suspension.....................................................................................................................- 244 7.1 Preparatory Information.........................................................................................................................- 244 7.2 Fault Diagnosis...................................................................................................................................... - 245 7.3 Front Wheel............................................................................................................................................- 245 7.4 Handlebar............................................................................................................................................... - 250 7.5 Front Fork.............................................................................................................................................. - 254 7.6 Front Shock Absorber............................................................................................................................ - 262 VIII. Rear wheel/rear suspension.........................................................................................................................- 272 8.1 Preparation of Information.................................................................................................................... - 272 8.2 Fault Diagnosis...................................................................................................................................... - 272 8.3 Rear wheel............................................................................................................................................. - 273 8.4 Rear shock absorber...............................................................................................................................- 278 8.5 Rear Rocker Arm................................................................................................................................... - 280 8.6 Chain drive.............................................................................................................................................- 283 IX. Fuel Tank/Seat............................................................................................................................................... - 294 9.1 Preparatory Information.........................................................................................................................- 294 9.2 Fault Diagnosis...................................................................................................................................... - 294 9.3 Seat.........................................................................................................................................................- 295 9.4 Fuel Tank................................................................................................................................................- 296 X. Frame...............................................................................................................................................................- 306 10.1 Preparatory Information.......................................................................................................................- 306 10.2 Fault Diagnosis.................................................................................................................................... - 307 10.3 Frame................................................................................................................................................... - 307 10.4 Sidestand.............................................................................................................................................. - 309 10.5 Center stand......................................................................................................................................... - 310 -
b
is
n
ra
.A
S
S
I
N
A
R
B
A
O
K
E
RG
O
E
G
Y
A
W
CO
Y
P
T
O
M
im
D
-
s
o
i
r
it
Ka
a
k
-d
10.6 Pedal.....................................................................................................................................................- 311 10.7 Muffler................................................................................................................................................. - 315 10.8 Disassembly/installation of engine...................................................................................................... - 317 Inspection and maintenance of engine.................................................................................................................- 331 XI. Lubrication System........................................................................................................................................- 338 11.1 Preparatory Information.......................................................................................................................- 338 11.2 Troubleshooting................................................................................................................................... - 339 11.3 Fuel Pump............................................................................................................................................ - 340 XII. Cylinder Head Cover....................................................................................................................................- 346 12.1 Preparatory Information.......................................................................................................................- 346 12.2 Fault Diagnosis.................................................................................................................................... - 346 12.3 Cylinder head cover............................................................................................................................. - 347 XIII. Cylinder Head............................................................................................................................................. - 355 13.1 Preparatory Information.......................................................................................................................- 355 13.2 Fault Diagnosis.................................................................................................................................... - 356 13.3 Cylinder head....................................................................................................................................... - 357 XIV. Cylinder Block and Piston.......................................................................................................................... - 372 14.1 Preparatory Information.......................................................................................................................- 372 14.2 Fault Diagnosis.................................................................................................................................... - 375 14.3 Cylinder Block..................................................................................................................................... - 375 14.4 Piston....................................................................................................................................................- 377 14.5 Crankshaft connecting rod................................................................................................................... - 381 XV. Crankcase......................................................................................................................................................- 386 15.1 Preparatory Information.......................................................................................................................- 386 15.2 Disassembly and Installation of Crankcase Bearing........................................................................... - 387 15.3 Crankcase............................................................................................................................................. - 388 XVI. Clutch.......................................................................................................................................................... - 395 16.1 Preparatory Information.......................................................................................................................- 395 16.2 Fault Diagnosis.................................................................................................................................... - 396 16.3 Right Cover.......................................................................................................................................... - 397 16.4 Clutch................................................................................................................................................... - 397 XVII. Gearshift Mechanism................................................................................................................................ - 405 17.1 Preparatory Information.......................................................................................................................- 405 17.2 Fault Diagnosis.................................................................................................................................... - 405 17.3 Gearshift Mechanism...........................................................................................................................- 406 XVIII. Drive System............................................................................................................................................- 414 18.1 Preparatory Information.......................................................................................................................- 414 18.2 Fault Diagnosis.................................................................................................................................... - 415 18.3 Drive system........................................................................................................................................ - 415 18.4 Installation............................................................................................................................................- 420 XIX. Electric Starter Mechanism.........................................................................................................................- 425 19.1 Preparatory Information.......................................................................................................................- 425 19.2 Troubleshooting................................................................................................................................... - 425 19.3 Electric starter mechanism...................................................................................................................- 426 XX. Exhaust Emission Control System...............................................................................................................- 432 20.1 Guarantee of Exhaust Emission Control System................................................................................ - 432 -
b
is
n
ra
.A
S
S
I
N
A
R
B
A
O
K
E
RG
O
E
G
Y
A
W
CO
Y
P
T
O
M
im
D
-
s
o
i
r
it
Ka
a
k
-d
20.2 Regular Maintenance Notice............................................................................................................... - 432 20.3 Mechanical Function of Exhaust Control System...............................................................................- 433 20.4 Catalyst Conversion System................................................................................................................ - 434 XXI. Fuel injection system (EFI)........................................................................................................................ - 436 21.1 Introduction to EFI...............................................................................................................................- 436 21.2 EFI system........................................................................................................................................... - 437 21.3 EFI part position.................................................................................................................................. - 439 21.4 Technical parameters........................................................................................................................... - 440 21.5 Precautions for EFI Overhaul.............................................................................................................. - 441 21.6 ECU......................................................................................................................................................- 443 21.7 Fuel Pump............................................................................................................................................ - 446 21.8 Throttle Body....................................................................................................................................... - 453 21.9 Fuel injector......................................................................................................................................... - 459 21.10 Intake pressure and temperature sensor.............................................................................................- 465 21.11 Oxygen sensor....................................................................................................................................- 467 21.12 Temperature sensor of engine cylinder head..................................................................................... - 470 21.13 Canister solenoid valve (ECP)...........................................................................................................- 472 21.14 Ignition coil........................................................................................................................................- 474 21.15 Fault maintenance and diagnosis method of EFI system.................................................................. - 474 21.16 Common troubleshooting methods for electronic fuel inject system................................................- 484 Circuit Diagram of BJ400-8 (electronic injection version, exported)........................................................- 492 -
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
O
K
E
RG
O
E
G
Y
A
W
CO
Y
P
T
O
M
im
D
-
s
o
i
r
it
Ka
k
-d
Introduction
This Maintenance Manual is the explanation for the maintenance essentials of motorcycle
(BJ400-8, electronic injection version).
Preparatory Information includes all matters needing attention for operation in the
Maintenance Manual. Please read this Manual carefully before operation.
Inspection and adjustment is the explanation for the essentials of inspection and
adjustment, as well as the safety of motorcycles and performance maintenance methods of
parts, which should be implemented from the time of regular inspection.
Chapter II and subsequent chapters are the explanations for the decomposition,
combination and inspection of the others of electrical equipment, motorcycle and engine.
Exploded diagrams and system diagrams, maintenance fault diagnosis and instructions
are provided above all chapters.
a
Note:
is
n
ra
k
-d
b
Ka
The style or structure of the motorcycle and the photographs, pictures
iosor instructions on
the Manual are subject to change without further notice.
.
S
S
D
A
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
-1-
i
tr
i
m
Preparatory Information
General safety
Specification table
Maintenance rules
Unit conversion table
Model information
Winding method of cables, wires and hoses
Motorcycle identification
Troubleshooting Guide
Important Note
Torque and locking agent
Special tools
Inspection / adjustment
General safety
Carbon monoxide
If the engine must be started, ensure that the workplace is well-ventilated and do not operate the engine in a closed place.
Note
Exhaust gas contains carbon monoxide, a kind of toxic gas, which may cause people to lose consciousness and possibly lead
to death.
It is necessary to operate the engine in an open place, and exhaust cleaning system should be used when the engine is
operated in a closed place.
Gasoline
a
is
n
ra
Workers should operate in a well-ventilated workplace. Smoke and fire are strictly prohibited in the workplace or the
place where gasoline is stored.
b
Accumulator
im
D
-
s
o
i
r
it
Ka
Battery may emit explosive gas. Keep it away from spark, open flames and smoking area. Keep it well ventilated when it
is being charged.
.A
S
S
I
N
A
Battery contains sulfuric acid (electrolyte). Burns may be caused when it contacts with skin or eyes. Therefore, workers
should wear protective clothing and mask.
R
B
A
K
E
RG
——If electrolyte splashes on the skin, rinse it immediately with fresh water.
O
——If electrolyte splashes in the eyes, rinse them with fresh water immediately for more than 15 minutes and consult a
doctor.
E
G
Y
A
W
O
The electrolyte is toxic. If you accidentally drink electrolyte, you should immediately drink plenty of water, milk and
magnesium oxide milk (a laxative antacid) or vegetable oil, and consult a doctor. Keep it out of the reach of children.
CO
Y
P
T
O
M
-2-
k
-d
Maintenance rules
Please read the following precautions before checking,
disassembling or assembling the motorcycle. In order to
facilitate the actual operations, each chapter is provided with
remarks, illustrations, pictures, Note and detailed
instructions as needed. This section describes the special
considerations in the process of removing and reassembling
or disassembling and reassembling common parts.
Pay special attention to the followings:
Installation of Battery
Disconnect the battery cable and battery before any
operation on the motorcycle to prevent the engine from
accidentally starting. Disconnect the negative wire (-) first,
then disconnect the positive wire (+). After completing the
operation, connect the positive wire (+) to the positive
terminal (+) of the battery, then connect the negative wire (-)
to the negative terminal (-).
Sharp edge of part
To avoid scratching the hand with sharp edges, wear
gloves when moving parts with large size or weight.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
-3-
im
D
-
s
o
i
r
it
Ka
k
-d
Solvent
Use a solvent with a high flash point when cleaning
parts. Use a solvent with a high flash point according to the
instructions provided by the solvent manufacturer.
Cleaning the motorcycle before disassembly
Thoroughly clean the motorcycle before disassembly. If
dust or other foreign matter enters the sealed part during the
disassembly process, excessive wear may be caused and
thus the performance of motorcycle may be reduced.
Sort out and clean the removed parts
a
The removed parts may be confused. Therefore, the
removed parts should be arranged in the order of
disassembly, and the parts should be cleaned and reinstalled.
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
-4-
im
D
-
s
o
i
r
it
Ka
k
-d
Store the removed parts
After cleaning all parts (including subassemblies), store
the parts in a clean area. Cover the parts with a clean cloth
or plastic film to prevent any foreign objects from falling
into them before reassembly.
Check
Major accidents may be caused in case of using worn
or damaged parts. Visually inspect the removed parts for
corrosion, discoloration or other damage. The limits for the
use of individual parts are detailed in the corresponding
sections of this Manual. If any damage is found, or the part
has exceeded the operating limit, the part must be replaced.
Replacement part
Replacement parts must be original Benelli parts or
parts recommended by Benelli. Parts such as washers,
O-rings, oil seals, grease seals, circlips or cotter pins must
be replaced with new ones once removed.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
-5-
im
D
-
s
o
i
r
it
Ka
k
-d
Assembly sequence
In most cases, the assembly sequence is the reverse of
disassembly sequence, but if the Maintenance Manual
describes the assembly sequence, it must be assembled in
the order given.
Fastening sequence
In general, when fixing parts with a few of bolts, nuts
or screws, place the parts in the corresponding holes, then
screw them in without applying torque, and then tighten
them in the specified order to prevent warping or
deformation which may result in part failure. Conversely, if
you want to unscrew the bolt, nut or screw, first twist a
quarter turn, loosen it, and then continue to unscrew it. If the
tightening sequence is not specified, tighten the fasteners
alternately in a diagonal way.
Locking torque
If you apply the wrong torque to a bolt, nut or screw,
serious damages may be caused. Therefore, the fastener
must be tightened to the specified torque with a high-quality
torque wrench.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
-6-
im
D
-
s
o
i
r
it
Ka
k
-d
Force
Common sense and basic judgment are required during
the process of removing and installing parts to prevent
excessive force which may result in difficult maintenance or
excessive maintenance costs. If necessary, use a pneumatic
wrench to remove the screw with locking agent. If you need
to hit the fastener, please use a mallet.
Gasket, O-ring
If the gasket or O-ring is hardened, shrunk or damaged
after being removed, its sealing performance will be
reduced. Remove the old gasket and thoroughly clean the
sealing surface to prevent any gasket material or other
materials from remaining on the sealing surface. A new
gasket must be used for reinstallation and the used O-ring
seal should be replaced.
Liquid gasket, locking agent
If you need to use liquid gasket or locking agent, you
must first clean the contact surface to avoid any oil residue
on the contact surface before using the liquid gasket or
locking agent. Do not use too much liquid gasket or locking
agent, as excessive liquid gasket or locking agent may block
the oil passage and cause serious damage.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
-7-
im
D
-
s
o
i
r
it
Ka
k
-d
Press fitting
Parts such as bearings and oil seals must be pressed for
proper fitting, so it is required to apply a small amount of oil
to the contact area. It must be aligned with the contact area
and slowly pressed into the part during installation.
Ball bearing and needle bearing
Do not remove the balls or needles in the bearing
unless necessary. Once removed, it must be replaced with a
new one. When pressing the bearing, pay attention to
making the manufacturer and the size mark face outward.
Apply force to the correct bearing race (as shown) and press
the bearing into place.
If the force is applied to incorrect bearing race, the
bearing may be damaged because of stress in the inner and
outer races.
Oil seal, grease seal
Do not remove the compressed oil seal or grease seal if
it is not necessary. Once removed, it must be replaced with a
new one. When pressing the new oil seal, pay attention to
making the manufacturer and the size mark face outward.
Make sure the oil seal is in the proper position during
installation.
a
b
is
n
ra
Apply a specified amount of grease to the edges of oil
seal before installation.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
-8-
im
D
-
s
o
i
r
it
Grease
Ka
k
-d
Circlip, cotter pin
Replace the removed circlip or cotter pin with a new
one. In order to prevent deformation, the opening of circlip
or cotter pin should not be too large during installation.
Lubrication
In order to minimize the wear during running-in period,
it is necessary to lubricate the rotating or sliding parts. Inject
the proper amount of lubricating oil or grease as specified,
and each lubrication point will be given in this Manual.
Engine rotation direction
When the crankshaft is rotated by hands, an incorrect
direction of rotation may cause a misjudgment of relevant
gap adjustment. So please rotate the crankshaft in the
positive direction (clockwise from the output).
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
-9-
im
D
-
s
o
i
r
it
Ka
k
-d
Wire
Two-color line: first the base color, then the color of
stripe. Only the wires of the same color are allowed to be
connected, except as noted.
Cable connector check
Make sure that there are no rust, moisture or other
defects on the connector.
1. Disconnect
Wire
Connector
Joint
a
2. Check
b
Wire
Connector
Joint
If there is moisture, use compressed air to dry.
If there is rust, connect the connected parts for several times
or use a rust remover. Replace the seriously rusted parts
timely.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 10 -
im
D
-
s
o
i
r
it
Ka
k
-d
3. Check
All connectors
If any of the joints are loose, reconnect them properly.
Note
If the “A” pin on the terminal is flat, please bend it.
4. Check
Wire
Connector
Joint
Note
Make sure all joints are securely assembled.
5. Check
Continuity (using a multimeter)
Note
If there are no items that need to be checked, please
clean the terminals.
When checking the wire sheath, follow Steps I to III
For quick correction, please use the [Contact Reagent]
available from most of parts stores.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 11 -
im
D
-
s
o
i
r
it
Ka
k
-d
Cable arrangement
Loose cable is a potential safety hazard of electrical
safety.Check the next cable after clamping the cable, to
ensure electrical safety;
Wire clamps are not allowed to bend in the direction of
the solder joint;
Bundle the cable at the designated location;
Cables are not allowed to be placed at the end of frame
or at the corners;
Cables are not allowed to be placed at the ends of bolts
or screws;
Keep cables away from heat source or the position
where the cable may be caught during movement;
Cables should not be kept too tight or loose when being
placed along the faucet handle, and must not interfere with
adjacent parts in any steering position;
Cables should be smoothly placed and must not be
twisted or knotted;
Before connectors are mated, check whether the
connector sheath is damaged and the connector is opened
excessively;
If the cable is at a sharp or corner, please protect it with
tape or a hose;
After the cable is repaired, use tapes to securely bind
the exposed area;
The control wire must not bend or twist. If the control
line is damaged, inflexible operation may be caused;
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 12 -
im
D
-
s
o
i
r
it
Ka
k
-d
Model information
Europe
BJ400-8 (European regulation) left view
BJ400-8 (European regulation) right view
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 13 -
im
D
-
s
o
i
r
it
Ka
k
-d
Non-European
BJ400-8 (non-European) left view
BJ400-8 (non-European) right view
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 14 -
im
D
-
s
o
i
r
it
Ka
k
-d
Motorcycle identification
1．The representation method of frame number ① is:
*ZBNP09 ？ ？ ？ ？ ？ ？ ？ ？ ？ ？ ？ *, as shown in the
figure. The 10th digit of vehicle identification code is the
year, the 11th digit is the production factory code, and a “*”
mark is added at the beginning and the end of the frame
number.
2. Frame nameplate riveting position, as shown in the figure.
Frame nameplate, as shown in the figure.
3. The serial number of engine is marked at the housing of
crankcase, as shown in the figure.
Engine number: BJ173FMQ-A*□□□□□□□*(exported)
a
is
n
ra
b
.A
S
S
im
D
-
s
o
i
r
it
Ka
I
N
A
R
B
A
K
E
RG
EO
G
Important Note Y
A
W
TO
1. Please use the
parts from dealers. Damage may be caused to the engine when the parts that do not meet the design
O
M
- 15 Y
P
CO
k
-d
specifications of dealers used.
2. Only metric tools can be used for maintenance work. Metric bolts, nuts and screws are not interchangeable with
imperial fasteners.
3. During reassembly work, use new washers, O-rings, split pins and locking plates.
4. When tightening bolts or nuts, first tighten the bolts with large diameter or leaning to the inner side, and then gradually
tighten them to the specified torque in the diagonal order, unless otherwise specified.
5. Wash the removed parts with a cleaning solution. Lubricate all sliding surfaces before assembly.
6. After assembly, check whether all parts have been correctly installed and operated.
7. Degrease and remove oil before measurement. Add recommended lubricant to the lubrication location during assembly.
8. When the engine and drive system need to be stored for a long time after being disassembled, please apply lubricant to
the surface of the parts to prevent rust and dust.
Special tools
Special tool refers to a tool specially designed for assembling or disassembling some parts of motorcycle and using it
on a specific location. Appropriate special tools are indispensable for complete and accurate adjustment and assembly
operations. Parts should be disassembled and assembled safely, reliably and quickly using special tools, so as to improve
work efficiency and save labor.
1. Tools for maintenance of engine
When disassembling the engine, certain parts can be smoothly assembled and disassembled only using specially
designed tools.
The list and pictures of special tools for the disassembly and assembly of engine parts are shown in Tables 1-1 and 1-2.
Table 1-1
Designation:
Note
Special socket wrench
Used to remove the flywheel bolts, Fig. 1-3
Clutch holder
Fig. 1-4
Flywheel puller
Fig. 1-5
Feeler gauge
Fig. 1-6
Bearing removal tool
Fig. 1-7
Bearing installation tool
Fig. 1-8
Oil seal replacer
Fig. 1-9
Disassembly tool handle
Fig. 1-10
Piston pin pull-out device
Fig. 1-11
Piston ring opening clamp
Fig. 1-12
Spark plug socket wrench
Fig. 1-13
Measuring clutch thickness
im
D
- Fig. 1-15
s
o
i
r
it
.A
S
S
Dial gauge
Measure inner diameter of piston pin, Fig. 1-16
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
- 16 -
is
n
ra
b
Ka
Fig. 1-14
Cylinder diameter tester
T
O
M
a
k
-d
Table 1-2
Fig. 1-3
Fig. 1-4
Thickness gauge (feeler gauge)
Fig. 1-5
Fig. 1-6
a
Fig. 1-7
Fig. 1-8
.A
S
S
im
D
-
s
o
i
r
it
I
N
A
R
B
A
K
E
RG
O
E
G
YFig. 1-9
A
W
Fig. 1-10
①Handle
O
CO
Y
P
T
O
M
- 17 -
Ka
b
is
n
ra
k
-d
Fig. 1-12
Fig. 1-11
①Opening clamp ②Piston
a
Fig. 1-13
is
n
ra
Fig. 1-14
b
.A
S
S
im
D
-
s
o
i
r
it
Ka
I
N
A
R
B
A
K
E
RG
Fig. 1-16
O
E
2. Tools for chassis maintenance
G
Y
The list and pictures of
Acommon and special tools for the disassembly and assembly of chassis parts are shown in
W
Tables 1-17 and 1-18.
TO
O
M
- 18 Y
P
CO
Fig. 1-15
k
-d
Table 1-17
Designation:
Note
Torque wrench
Fig. 1-19
Allen wrench
Fig. 1-20
Socket wrench
Fig. 1-21
Micrometer
Fig. 1-22
Magnetic frame, V-shaped block
Fig. 1-23
Dial gauge
Fig. 1-24
Vernier caliper
Fig. 1-25
Spring snap ring pliers
Fig. 1-26
Knock-on screwdriver
Fig. 1-27
Front fork oil seal installation tool
Fig. 1-28
Hook wrench
Fig. 1-29
Jack
Fig. 1-30
Accessories of jack
Fig. 1-31
Screwdriver for outer race of head tube
Fig. 1-32
Mounting tools for steering tube bearing
Fig. 1-33
Front fork seal driving tool
Fig. 1-34
Four-jaw 300-QCLM4-001
Fig. 1-35
Seven-jaw 300-QCLM7-001
Fig. 1-36
(1) Common tools for chassis maintenance
Table 1-18 (continued)
Fig. 1-19
a
Fig. 1-20
b
is
n
ra
1. Socket head
2. Jiggle bar
3. Ratchet wrench
.A
S
S
I
N
A
4. Connecting rod
R
B
A
Fig. 1-21
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 19 -
im
D
-
s
o
i
r
it
Fig. 1-22
Ka
k
-d
Fig. 1-23
Fig. 1-24
Fig. 1-25
Fig. 1-26
a
b
is
n
ra
s
o
i
r
it
Fig. 1-27
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 20 -
imFig. 1-28
D
-
Ka
k
-d
Fig. 1-29
Fig. 1-30
Fig. 1-31
Fig. 1-32
Fig. 1-33
(2) Special tools for maintenance of chassis: Front fork seal driving tool.
a
b
is
n
ra
.A
S
S
Fig. 1-34
I
N
A
(3) Steering nut wrench.
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 21 -
im
D
-
s
o
i
r
it
Ka
k
-d
Fig. 1-35
Fig. 1-36
3. Tools for electrical parts
The list and pictures of special tools for the testing of electrical parts are shown in Table 1-37, Table 1-38 and 1-39.
Table 1-31
Designation:
Note
Multimeter
Fig. 1-37
Ignition tester
Fig. 1-38
Electronic fuel injection fault diagnosis tester
Fig. 1-39
Table 1-32 (continued)
a
b
Fig. 1-37
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 22 -
is
n
ra
im
D
-
s
o
i
r
it
Ka
k
-d
Fig. 1-38
Fig. 1-39
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 23 -
im
D
-
s
o
i
r
it
Ka
k
-d
Specification table (BJ400-8)
Model
Full length
Full width
Full height
Wheel Base
Terrain clearance
Seat height
Tank capacity
Frame type
Front
identity
Rear
Front
Specifications
Air pressure
Specifications
Rim
Engine type
Fuel type
Number of cylinders
Inner diameter * stroke
Total displacement
Compression ratio
Maximum horsepower
Maximum torque
Idle speed
Cylinder pressure
Fuel vaporization system
QJ73FMQ-A
Unleaded gasoline
1
Ø72.7×90
374cm³
8.5:1
15.5kW/5500 r/min
29.0N.m/4500 r/min
1400±100 r/min
1.25MPa/1500rpm
EFI (fuel injection)
Cradle back bone frame
Common inner and
outer tire
Common inner and
outer tire
100/90-19
Throttle valve
D37-1
Starting mode
Electric starting
Ignition mode
ECU
Spark plug model
BR7ES/CR7HSA
Front axle
Rear axle
Total
Weight
(Curb weight)
Tire
BJ400-8
2170mm
820mm
1120mm
1440mm
170mm
880mm
12L±0.5L
92kg
114kg
205kg
identity
Rear
130/80-18
Spark plug gap
0.6～0.7mm
Front
220±10Kpa
Cooling mode
Rear
250±10Kpa
Lubrication mode
Front
Rear
2.15×19
3.00×18
Air-cooled
Pressure and splash
lubrication
API SE, SF or SG
SAE 10W-50
Front
Spoke
Rear
Spoke
Telescopic sleeve, oil
damping type
121mm
Type of front shock absorber
Stroke of front shock absorber
Type of rear shock absorber
Electric
equipment
Oil type
Oil viscosity
Completely
Oil
disassembled
capacity
When replaced
Air
Cleaner
Hydraulic spring,
damping shock absorber
Stroke of rear shock absorber
Brake
Engine
55.5mm
Paper
Rated air flow: below
127m3/h, air intake
resistance: 1.2±0.1KPa
Compound impedance
Intake resistance
Type
Catalyst
(with/without)
identity
Manual
Rear brake
Single disc φ240×5mm
Clutch type
Operation method
Battery capacity/type
Type of alternator
Alternator capacity
Type of ignition coil
Foot-operated
12V8Ah-(YTX9-BS)
Three-phase alternator
320W/pm
Open magnetic circuit
ignition coil
4Ω/13.5KΩ
Speed-varying mode
First
Second
Third
Gear ratio
Fourth
12V/29KV
Delphi
MT05
s
o
i
r
it
A
BR
A
K
E
G
R
im
D
Fifth
.A
S
S Final drive mode
NI
O
E
G
Y
A
W
O
CO
Element
Operation method
Final reduction ratio
Maximum speed
It is subject to change without notice and may not be applicable in every country.
Y
P
Dry type
Single disc φ300×5mm
Transm
ission
gear
T
O
M
- 24 -
2.4L
Type
Front brake:
Primary/secondary
resistor
Primary/secondary
voltage
ECU
ECU model
Muffler
2.8L
With
Redox type
Wet multi-plate friction
type
Five-speed transmission
2.643
1.684
1.278
is
n
ra
b
Ka
1.000
0.864
Chain drive
3.286
120km/h
a
k
-d
BJ400-8
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 25 -
im
D
-
s
o
i
r
it
Ka
k
-d
Unit conversion table
Unit prefix:
Length unit:
Prefix
Sign:
Power
Km × 0.6214 = miles
mega
M
× 1 000 000
m × 3.281 = miles
kilo
k
× 1 000
mm × 0.03937 =feet
centi
c
×0.01
milli
m
×0.001
Unit of torque:
micro
μ
× 0.000001
N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
Unit of mass:
kg ×2.205=lb
g × 0.03527 = oz
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
kgf·m × 86.80 = in·lb
Unit of volume
L × 0.2642 = gallon (US)
L × 0.2200 = gallon (imp)
L × 1.057 = quart (US)
L × 0.8799 = quart (imp)
Unit of pressure:
kPa × 0.01020 = kgf/cm²
kPa × 0.1450 = psi
kPa × 0.7501 = cmHg
L × 2.113 = pint (US)
L × 1.816 = pint (imp)
mL × 0.03381 = ounce (US)
mL × 0.02816 = ounce (imp)
mL × 0.06102 = cubic inch
kgf/cm² × 98.07 = kPa
kgf/cm² × 14.22 = psi
cmHg×1.333=kPa
Mechanical unit:
N × 0.1020 = kg
N × 0.2248 = lb
Unit of speed:
km/h × 0.6214 = mph
Unit of power:
kW ×1.360=PS
kW ×1.341=HP
kg ×9.807=N
kg ×2.205=lb
PS × 0.7355 = kW
PS × 0.9863 = HP
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 26 -
is
n
ra
b
Unit of temperature:
.A
S
S
a
im
D
-
s
o
i
r
it
Ka
k
-d
Winding method of cables, wires and hoses
Alignment of main cable:
Arrange the main along the
left side of tube at the head,
and fix it using a tie
Arrange the main along the
left side of tube at the head,
and fix it using a hook
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 27 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the main along the
left side of tube at the head,
and fix it using a hook
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 28 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the main along the
left side of tube at the head,
and fix it using a clamp
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 29 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the main cable and ABS
tube above the engine, and fix it
with ABS front hydraulic brake
tube using a clamp
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 30 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the main cable along
the mounting lug and inside
the frame
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 31 -
im
D
-
s
o
i
r
it
Ka
k
-d
ECU inserter
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O Fix the power output line
E
G
Y
A
W
using a tie
O
CO
Y
P
T
O
M
- 32 -
im
D
-
s
o
i
r
it
Ka
k
-d
a
Fix the cylinder temperature sensor
inserter with the upper throttle valve
inserter wire using a tie
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 33 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the main cable
along the left side of
headlight holder, and fix it
using a tie
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
Fix the positive wire of battery
using a tie
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 34 -
im
D
-
s
o
i
r
it
Ka
k
-d
Pass the positive wire of battery
and main cable above the
battery box
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 35 -
im
D
-
s
o
i
r
it
Ka
k
-d
Fix the motor wire at the inside of engine
outlet pipe, and clip the motor wire into
the place between the outlet pipe and
motor
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 36 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the motor wire
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
O
E
G
Y
A
W
CO
Y
P
T
O
M
Connect the motor wire
- 37 -
im
D
-
s
o
i
r
it
Ka
k
-d
Position for connecting the bond strap
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 38 -
im
D
-
s
o
i
r
it
Ka
k
-d
Alignment of brake pipe:
Arrange the ABS front
hydraulic brake tube wire
downward along the inside of
mounting lug
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 39 -
im
D
-
s
o
i
r
it
Ka
k
-d
ABS front hydraulic brake
tube wire
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 40 -
im
D
-
s
o
i
r
it
Ka
k
-d
Fix the ABS rear hydraulic
brake tube wire using M cable
clip
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 41 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the rear inlet tube of
ABS rear hydraulic brake, and
pass the rear oil pump plug wire
through the left by bypassing
the frame
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 42 -
im
D
-
s
o
i
r
it
Ka
k
-d
Fix the rear oil pump plug
wire and rear outlet tube of
rear hydraulic brake using M
cable clip
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 43 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the reservoir along
the inside of rear frame
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 44 -
im
D
-
s
o
i
r
it
Ka
k
-d
Fix the rear wheel speed sensor
and the rear outlet tube of rear
hydraulic brake using M cable
clip
Clip the rubber cover on the
rear outlet tube of rear hydraulic
brake in the mounting clamp at
the front of rear rocker arm
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 45 -
im
D
-
s
o
i
r
it
Ka
k
-d
Fix the rear wheel speed sensor and
the rear outlet tube of rear hydraulic
brake using M cable clip
Clip the rubber cover on the rear
outlet tube of rear hydraulic brake in
the mounting clamp at the rear of
rear rocker arm
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 46 -
im
D
-
s
o
i
r
it
Ka
k
-d
Rear outlet tube of rear
hydraulic brake
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
O
K
E
RG
E
G
Y
A
W
Fix ABS tube line using
mounting clamp
O
CO
Y
P
T
O
M
- 47 -
im
D
-
s
o
i
r
it
Ka
k
-d
Fix ABS tube and speed sensor wire
of front wheel using M cable clip
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 48 -
im
D
-
s
o
i
r
it
Ka
k
-d
a
Fix ABS tube and speed sensor wire of
front wheel using M cable clip
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 49 -
im
D
-
s
o
i
r
it
Ka
b
is
n
ra
k
-d
使用绑扎带将前轮速传感
Fix the speed sensor wire of front
wheel using a tie
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 50 -
im
D
-
s
o
i
r
it
Ka
k
-d
Other matters:
Arrange the accelerator cable
and meter headlight wire along
the right side of tube at the head,
and fix it using a tie
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 51 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the accelerator cable
and clutch cable along the left
of frame, and fix it using a tie
Arrange the ABS tube line and
oxygen sensor wirealong the
left side of frame, and fix them
using a tie
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 52 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the accelerator cable
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 53 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the motor cable
along the outlet pipe of
engine, and fix it using a tie
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 54 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the wire along the frame,
and fix it using a tie
Arrange the clutch
a
b
is
n
ra
.A
S
S
im
D
-
I
N
A
R
B
A
O
K
E
RG
E
G
Y
A
W
Arrange the oxygen sensor
wire along the frame, and fix
it using a tie
O
CO
Y
P
T
O
M
- 55 -
s
o
i
r
it
Ka
k
-d
Arrange the oxygen sensor
wire along the frame, and fix it
using a clamp
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 56 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the accelerator cable and right handle
combination switch wire along the right of headlight
holder, and fix it using a tie, and pass it through the
mounting clip at the right
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 57 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the clutch cable and and left handle
combination switch wire along the left of
headlight holder, and fix it using a tie, and pass it
through the mounting clip at the right
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
Fix the sidestand stop switch
wire using a soft wire clip
O
CO
Y
P
T
O
M
- 58 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the sidestand stop
switch wire
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 59 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the wire of rear fender
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 60 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the wire of rear fender
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 61 -
im
D
-
s
o
i
r
it
Ka
k
-d
Arrange the wire of rear fender
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 62 -
im
D
-
s
o
i
r
it
Ka
k
-d
Fix the outlet tube of tank using
a upper mounting clip of
mounting lug
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 63 -
im
D
-
s
o
i
r
it
Ka
k
-d
Troubleshooting Guide
Note
○ For most of the faults of EFI, see the chapter “EFI”.
○ This table is not exhaustive. It is not possible to list the
possible causes of each problem. It can only be used as a
basic guide to help solve some common problems.
Diagnostic procedure for the fault that engine cannot be started or it is
difficult to start the engine:
Starter motor does not work:
The main switch or engine stop switch is not turned on;
The starter lock switch or the gear switch has failed;
The starter motor has failed;
Battery voltage is low;
The starter relay is in poor contact or cannot operate normally;
The contact of start button is poor;
The starting system circuit is shorted or open;
The main switch has failed;
The engine stop switch has failed;
30 A main fuse or main switch fuse is burnt out
The starter motor is rotating, but the engine does not work:
Motorcycle rollover sensor (EFI) is working;
The anti-theft control system has failed;
The overrunning clutch has failed;
The starting idler gear has failed.
a
The engine does not run:
The valve is seized;
The valve ejector rod is seized;
Cylinder and piston are seized;
Crankshaft is seized;
The small end of the connecting rod is seized;
The big end of the connecting rod is seized;
The drive gear or bearing is seized;
Camshaft is seized;
Starting idler gear is seized;
Balance shaft bearing is seized;
b
Fuel does not flow:
There is no fuel in the fuel tank;
The fuel pump has failed;
The tank vent is blocked;
Check whether the fuel filter is blocked;
Fuel hose is blocked
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 64 -
im
D
-
s
o
i
r
it
Ka
k
-d
No sparks; sparks are weak:
Motorcycle rollover sensor (EFI) is detached;
The main switch is not rotated to "ON".
The engine stop switch is not rotated to "OFF";
The clutch handle is not pinched or the gear position is not in the neutral position;
Battery voltage is low;
The anti-theft control system has failed;
The spark plug is dirty, broken or the gap is improper;
Spark plug is not applicable
Short circuit or poor contact of ignition coil;
The ignition coil has failed;
The engine control unit (ECU) has failed;
The camshaft position sensor has failed;
The gear switch, starting lock switch or sidestand switch has failed;
The crankshaft sensor has failed;
The main switch or engine stop switch is short circuited;
The starting system circuit is shorted or open;
Main fuse or main switch fuse is burnt out
There is a problem with the fuel/air mixture:
Bypass screw and / or idle adjustment screw is out of
order;
Air duct is blocked;
Air filter is clogged, poorly sealed or missing;
The oil filling port cover, crankcase vent pipe or air filter
drain pipe leaks;
Too low cylinder pressure:
The spark plug is loosened;
The cylinder head is not tightened;
The cylinder or piston is worn;
The piston ring is damaged (worn, weakened, damaged or stuck);
The clearance between piston ring and piston ring groove is too large;
The cylinder head gasket is damaged;
The cylinder head is deformed;
Valve spring is damaged or or its elasticity is poor;
There is no valve clearance;
The valve is not installed properly (valve bending, wear or carbon deposits on the valve seat)
It cannot run properly at a low speed:
Sparks are weak:
Battery voltage is low;
The anti-theft control system has failed;
The ignition coil has failed;
Short circuit or poor contact of ignition coil;
The spark plug is dirty, broken or the clearance is improper;
Spark plug is not applicable;
The engine control unit (ECU) has failed;
The camshaft position sensor has failed;
The crankshaft sensor has failed
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 65 -
im
D
-
s
o
i
r
it
a
Ka
b
is
n
ra
k
-d
There is a problem with the fuel/air mixture:
Bypass screw is not adjusted properly;
Air duct is blocked;
Exhaust pipe or vent hole is blocked;
The idle air way is blocked;
Air filter is clogged, leaking or missing;
The tank vent is blocked;
The fuel pump has failed;
Throttle valve assembly holder is loosened;
Breather pipe holder is loosened
The cylinder pressure is low:
The spark plug is loosened;
The cylinder head is not tightened firmly;
There is no valve clearance;
The cylinder or piston is worn;
The piston ring is damaged (worn, weakened, damaged or stuck);
The clearance between piston ring and piston ring groove is too large;
The cylinder head gasket is damaged;
The cylinder head is deformed;
Valve spring is damaged or or its elasticity is poor;
The valve is not installed properly (valve bending, wear or carbon deposits on the valve seat)
Camshaft or cam is worn
The main switch continues to run after being cut off:
The main switch has failed;
The engine stop switch has failed;
Fuel injector has failed;
The negative terminal (-) of battery or the engine control unit (ECU) ground wire is loosened;
There is carbon deposit on the valve seat;
Engine overheating
Others:
The engine control unit (ECU) has failed;
The negative pressure value of throttle valve is out of balance;
The oil viscosity is too high;
The drive system has failed;
Brake drags;
The clutch is slipping;
Engine overheating;
Air suction valve has failed;
Secondary air compensating valve has failed
a
b
is
n
ra
s
o
i
r
it
Ka
im
D
- is insufficient:
It cannot run properly at a high speed or the power
A
.
S
S
I
Ignition is abnormal:
AN
R
B
The spark plug is dirty, broken or not adjusted properly;
A
K
Spark plug is not applicable;
E
Short circuit or poor contact of ignition coil;G
R
The ignition coil has failed
O
E
The engine control unit (ECU) has failed
G
Y
Awith the fuel/air mixture:
There is a problem
W
TOpoorly sealed or there is no air filter;
O
Air filter is clogged,
M
- 66 Y
P
CO
k
-d
Vent pipe holder is loosened;
There is water or foreign matter in the fuel;
Throttle valve assembly holder is loosened;
Insufficient fuel supply to fuel injector;
The air duct of tank is blocked;
Fuel hose is blocked;
The fuel pump has failed;
The cylinder pressure is low:
The spark plug is loosened;
The cylinder head is not tightened firmly;
There is no valve clearance;
The cylinder or piston is worn;
The piston ring is poor (worn, weakened, damaged or stuck);
The clearance between piston ring and groove is too large;
The cylinder head gasket is damaged;
The cylinder head is deformed;
Valve spring is damaged or or its elasticity is poor;
The valve is not installed properly (valve bending, wear or carbon deposits on the contact surface)
There is a click sound:
There is carbon deposit in the combustion chamber;
The fuel is inferior or fuel type is not applicable;
Spark plug is not applicable;
The engine control unit (ECU) has failed
Others:
The throttle valve cannot be fully opened;
Brake drags;
The clutch is slipping;
Engine overheating;
The fuel level is too high;
The fuel viscosity is too high;
The drive system has failed;
Camshaft or cam is worn;
Air suction valve has failed;
Secondary air compensating valve has failed;
Catalyst is melted due to overheating of muffler
a
b
The temperature is too high:
Ignition is abnormal:
The spark plug is dirty, broken or not adjusted properly;
Spark plug is not applicable;
The engine control unit (ECU) has failed
.A
S
S
I
N
A
R
B
A
K
E
RG
The muffler is overheated:
For the Benelli emission control system, do not start the
engine even if the cylinder does not ignite or is not running
properly (must be repaired by the nearest maintenance
point);
For the Benelli emission control system, if the battery has
run out, do not start the motorcycle (connect the other fully
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 67 -
im
D
-
s
o
i
r
it
Ka
k
-d
charged battery with a jumper and then electrically start the
engine);
For the Benelli emission control system, do not start the
engine if the ignition is not normal due to dirty spark plugs
or poor contact of ignition coil;
For the Benelli emission control system, when the main
switch is turned "off", do not ride the motorcycle and taxi
using inertia force (turn "on" the main switch and start the
engine);
The engine control unit (ECU) has failed
There is a problem with the fuel/air mixture:
Throttle valve assembly holder is loosened;
Vent pipe holder is loosened;
Air filter is poorly sealed or there is no air filter;
The fuel filter is blocked
The cylinder pressure is high:
There is carbon deposit in the combustion chamber;
The output force of engine is insufficient:
The clutch is slipping;
The fuel level is too high;
The fuel viscosity is too high;
The drive system has failed;
Brake drags
Not properly lubricated:
The fuel level is too low;
The fuel is inferior or fuel type is not applicable;
a
The clutch is not working properly:
The clutch is slipping:
b
The friction pad is worn or deformed;
The steel sheet is worn or deformed;
Clutch spring is damaged or or its elasticity is poor;
The clutch housing is unevenly worn;
The master cylinder of clutch has failed;
The slave cylinder of clutch has failed;
The clutch cannot be separated properly:
The clutch pad is deformed or too rough;
Clutch spring is not pressed evenly;
Engine oil is deteriorated;
The fuel viscosity is too high;
The fuel level is too high;
The clutch housing is seized to the drive shaft;
The clutch housing nut is loosened;
The clutch housing spline is damaged;
The friction pad of clutch is not installed properly
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 68 -
im
D
-
s
o
i
r
it
Ka
k
-d
The slave cylinder of clutch has failed;
Clutch oil is deteriorated;
There is air in the clutch fuel tube;
The primary cup or the secondary cup of master cylinder of clutch is broken;
The inner wall of master cylinder of clutch is damaged;
There is a problem with shifting:
It is unable to operate the gear smoothly; control pedal cannot be reset:
The clutch cannot be separated:
The fork is bent or stuck;
The gear gear is stuck on the shaft;
Gear lever is blocked
The elasticity of shifting and resetting spring is poor or or it is damaged;
The pin of shifting and resetting spring is loosened;
The spring at the claw of shift connecting rod
is damaged;
The spring at the claw of shift connecting rod
is damaged;
The shift claw is damaged
Jump
The fork of shift fork is worn or bent;
Shift gear groove is worn;
The joint between the protrusion of the inner edge of gear and recess is worn;
The groove of shift drum is worn;
The elasticity of gear lever spring is poor or or it is damaged;
The guide pin of shift fork is worn;
Drive shaft, output shaft and/or gear spline is worn
Excessive speed change:
The elasticity of gear lever spring is poor or or it is damaged;
The spring at the claw of shift connecting rod
is damaged;
a
The engine makes an unusual noise:
b
There is a click sound:
The engine control unit (ECU) has failed;
There is carbon deposit in the combustion chamber;
The fuel is inferior or fuel type is not applicable;
Spark plug is not applicable;
Engine overheating
The piston makes a sound:
.A
S
S
I
N
A
R
B
A
K
E
RG
The clearance between the cylinder and the piston is too large;
The cylinder or piston is worn;
The connecting rod is bent;
The piston pin or its hole is worn;
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 69 -
im
D
-
s
o
i
r
it
Ka
k
-d
The valve makes noise:
The valve clearance is incorrect;
Valve spring is damaged or or its elasticity is poor;
The camshaft bearing is worn;
The valve lifter is worn
Other noises:
The clearance at t he small end of connecting rod is too
large;
The clearance at t he big end of connecting rod is too large;
The clearance between piston ring and piston ring groove is
too large;
The piston ring is worn, damaged or stuck;
Piston ring groove is worn;
Piston is seized or damaged;
The cylinder head gasket is leaking;
The exhaust pipe of cylinder head connecting portion is
leaking;
The crankshaft runout is too large;
The engine is loosened;
The crankcase bearing is worn;
The main gear is worn or notched;
Camshaft chain tensioner has failed;
The camshaft chain, sprocket or guide is worn;
Air suction valve is damaged;
Secondary air compensating valve is damaged;
The alternator rotor is loose;
The catalyst is melted due to overheating of muffler (Benelli
emission pollution control system)
The drive system makes an unusual noise:
Clutch makes a noise:
The function of clutch shock absorber is weak or it is damaged;
The clearance between the clutch housing and the friction pad is too large;
The clutch housing is worn;
The outer friction pad is not installed properly
a
b
The drive device makes a noise:
The bearing is worn;
The drive gear is worn or notched;
Metal fragments are stuck on the rotating teeth of gear;
Insufficient oil;
.A
S
S
The drive system makes a noise:
I
N
A
R
B
A
The chain is not properly adjusted;
Chain is worn;
The rear sprocket and/or the engine sprocket are worn;
The chain is not applied with sufficient lubricant;
The rear wheel is not adjusted evenly
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 70 -
im
D
-
s
o
i
r
it
Ka
k
-d
The frame makes an unusual noise:
The front fork makes a noise:
The lubricant is insufficient or the film is too thin;
The elasticity of spring is poor or or it is damaged;
The rear shock absorber makes a noise:
The shock absorber is broken;
The brake disc makes a noise:
The brake pads are not installed correctly;
The surface of brake pad is polished;
The brake disc is deformed;
The caliper has failed;
Other noises:
Brackets, nuts, bolts and other parts are not properly installed or locked.
Excessive exhaust gas:
White exhaust:
Piston oil ring is worn;
The cylinder is worn;
Valve seal is damaged;
Valve guide is worn;
The fuel level is too high
a
Black exhaust:
is
n
ra
The fuel filter is blocked
b
Brown exhaust:
Breather pipe clamp is loosened
Air filter is poorly sealed or there is no air filter;
Poor performance and / or stability:
It is difficult to rotate the handlebar:
I
N
A
.A
S
S
R
B
The wires and cables are not wound in the correct way;A
K
The hoses are not wound in the correct way; E
The wires are not wound in the correct way;G
R
The steering stem nut is too tight;
O
E
The steering stem bearing is broken;
G
The steering stem bearing isY
not applied with sufficient lubricant;
The steering stem is bent;A
Wlow
The tire pressure isO
too
T
O
M
- 71 Y
P
CO
im
D
-
s
o
i
r
it
Ka
k
-d
The handlebars vibrate or shake severely:
The tire is worn;
The main axis bearing of swing arm is worn;
The rim is deformed or unbalanced;
The wheel bearing is worn;
Handlebar holder bolt is loosened;
The steering stem nut is loosened;
The runout of front and rear axles is too large;
Engine mounting bolt is loosened;
The handlebar is placed on one side:
The frame is bent;
The wheels are not aligned properly;
The swing arm is bent or twisted;
The runout of main axis of swing arm is too large;
The steering stem is not adjusted properly;
The front fork is bent;
The oil level of left and right front shock absorber is uneven
The damping effect is not ideal:
(too hard)
Excessive front shock absorber oil;
The viscosity of front shock absorber oil is too high;
Rear shock absorber oil is too thick
The tire pressure is too high;
The front fork is bent;
(too soft)
The tire pressure is too low;
The font shock absorber oil is insufficient and / or leaking;
The viscosity of front shock absorber oil is too low;
Rear shock absorber oil is too thin
The front fork and rear shock absorber springs have poor elasticity;
Rear shock absorber is leaking
a
Brake is unable to work properly
There is air in the brake tube;
The friction pad or brake disc is worn;
The brake fluid is leaking;
The brake disc is deformed;
The friction pad is polluted;
The brake fluid is deteriorated;
The primary cup or the secondary cup of master cylinder is broken;
The inner wall of master cylinder is damaged
R
B
A
K
E
RG
Battery has run out:
O
Power is insufficient;
There is a problem with the battery (voltage is too low);
Poor contact of battery cable;
The load is too large (eg, the power of bulb is too large);
The main switch has failed;
The alternator has failed;
E
G
Y
A
W
O
CO
Y
P
.A
S
S
I
N
A
Battery has failed
T
O
M
b
- 72 -
is
n
ra
im
D
-
s
o
i
r
it
Ka
k
-d
There is a problem with the line;
The regulator/rectifier has failed
Battery is overcharged:
The alternator has failed;
The regulator/rectifier has failed
There is a problem with battery;
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 73 -
im
D
-
s
o
i
r
it
Ka
k
-d
Torque and locking agent
Locking torque and related parameters of nuts, bolts and screws
The table below lists the basic torques for bolts and nuts (different thread diameters correspond to different locking
torques). This table is only for the bolts and nuts that do not require specific torque values. All values in the table below
apply to the threads cleaned with an anhydrous solvent.
Locking torques and related parameters of nuts
Basic locking torques
Nut
N·m
kgf·m
4
2.3
0.2
5
4.5
0.4
6
10
1.0
8
25
2.5
10
45
4.5
12
80
8.0
14
130
13.0
16
200
20.0
18
240
24.0
20
325
32.5
Locking torque and related parameters of bolts and screws
Basic locking torques
Grade 10.9
Grade 8.8
Bolt/screw
M4×0.7
M5×0.8
M6×1
M8×1.25
M8×1(*)
M10×1.5
M10×1.25(*)
M12×1.75
M12×1.5(*)
M12×1.25(*)
M14×2
M14×1.5(*)
M16×2
M16×1.5(*)
M18×2.5
M18×1.5(*)
M20×2.5
M20×1.5(*)
M22×2.5
M22×1.5(*)
M24×3
M24×2(*)
*: fine thread
N.m
3
6
10
22
25
45
50
80
85
90
130
150
200
225
265
320
390
440
540
600
670
750
N.m
4.2
7.5
13
30
36
65
70
110
120
130
185
205
280
310
370
450
550
630
750
850
950
1050
O
CO
Y
P
T
O
M
- 74 -
Kg.f·m
0.4
0.8
1.3
3.0
3.6
6.5
7.0
11.0
12.0
13.0
18.5
20.5
28.0
31.0
37.0
45.0
55.0
63.0
75.0
85.0
95.0
105.0
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
Kg.f·m
0.3
0.6
1.0
2.2
2.5
4.5
5.0
8.0
8.5
9.0
13.0
15.0
20.0
22.5
26.5
32.0
39.0
44.0
54.0
60.0
67.0
75.0
im
D
-
Grade 12.9
N.m
5.2
9
16
40
45
80
85
135
145
150
220
245
335
360
450
550
650
750
900
1000
1130
1250
s
o
i
r
it
Kg.f·m
0.5
0.9
1.6
4.0
4.5
8.0
8.5
13.5
14.5
15.0
22.0
24.5
33.5
36.0
45.0
55.0
65.0
75.0
90.0
100.0
113.0
125.0
Ka
b
is
n
ra
a
k
-d
Main locking torque specifications
The table below lists the locking torques for the primary fasteners that require locking agent or silicone sealants.
The letters in the "Remarks" column have the following meanings:
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
Torque
Fastener
Note
N·m
kgf·m
Fuel Injection System (EFI)
Air filter element cover bolt
6
0.70
Air filter element bracket screw
6
0.70
Camshaft position sensor bolt
10
1.0
Crankshaft sensor bolt
5.9
0.60
Pipe clamp bolt
2.0
0.20
Fuel tank mounting bolt
10
1.0
Fuel pump bolt
4
0.4
S
Inlet air pressure sensor bracket screw
10
1.0
Oxygen sensor
25
2.5
ECU bolt
3.9
0.40
L
Speed sensor bolt
3.9
0.40
L
Engine cylinder head and cylinder head cover
Cylinder head cover bolt
10
1.0
L
Camshaft sprocket mounting bolt
15
1.5
L
Camshaft cover bolt
10
1.0
S
Camshaft chain guide bolt
12
1.2
S
Camshaft chain tensioner mounting bolt
10
1.0
Cylinder head bolt (M11)
50
5.0
L(3)
Exhaust pipe mounting bolt
22
2.2
Spark plug
25
2.5
Clutch
Clutch cover bolt
10
1.0
L(1)
Clutch wheel hub nut
120
12.0
R
Clutch spring bolt
10
1.0
Engine lubrication system
Engine oil drain bolt M12
30
3.0
Stopper of oil filler
Tighten
fuel pump bolt using hands
10
1.0
Fuel pump cover bolt
10
1.0
Crankshaft/ drive mechanism
Balancer shaft clamp nut M14
40
4.0
12
1.2
S
Assembling bolt M6
Crankcase bolt
12
1.2
S
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 75 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
Continued
Fastener
Flywheel locknut
Driving gear nut
Shift positioner bolt M6
Disassembly/Installation of Engine
Front bracket bolt of engine (M10)
Front mounting bolt of engine (M10)
Rear mounting bolt of engine (M10)
Wheel/tire
Front axle nut
Front wheel axle
Rear wheel axle
Rear wheel axle nut
Final drive mechanism
Upper stop block bolt of chain
Chain protective block bolt
Engine sprocket cover bolt
Engine sprocket nut
Rear sprocket nut
Speed sensor bolt
Brake
Purge valve
Hollow bolt of brake hose
Pivot bolt of brake lever
Pivot bolt locknut of brake lever
Brake pedal bolt
Mounting bolt of front brake disc
Front brake light switch screw
Mounting bolt of primary cylinder reservoir cap of front
brake
Front caliper assembly bolt
Front caliper mounting bolt
Purge valve of front master cylinder
Clamp bolt of front master cylinder
Mounting bolt of rear brake disc
Rear caliper assembly bolt
Rear caliper mounting bolt
Rear primary cylinder mounting bolt
Rear master cylinder push rod locknut
Suspension system
Front axle clamp nut
Front shock absorber clamp bolt (upper)
Front shock absorber clamp bolt (lower)
Top plug of front shock absorber
Piston rod nut of front shock absorber
Rear shock absorber bolt (upper)
Rear shock absorber bolt (lower)
Rear shock absorber nut (lower)
Mounting nut of rear rocker arm axis
Rear rocker arm shaft
N·m
90
80
12
4.5
5.0
5.0
S
AL、S
AL、S
100～113
100～113
100～113
100～113
10.0～11.3
10.0～11.3
10.0～11.3
10.0～11.3
AL
G
G
AL
10
10
10
125
50
3.9
1.0
1.0
1.0
12.5
5.0
0.4
L
L
7.8
30
6
6
22
12
1.2
1.2
0.80
3.0
0.6
0.6
2.2
1.2
0.12
0.12
27
22
7.8
12
22
22
22
12
12
2.8
2.2
0.80
1.2
2.2
2.2
2.2
1.2
1.2
20
22
22
22
28
45
45
45
108
108
2.0
i
D2.0m
.A
S
S
I
N
A
K
E
RG
O
O
CO
Y
P
T
O
M
Note
kgf·m
9.0
8.0
1.2
45
50
50
R
B
A
E
G
Y
A
W
Torque
- 76 -
-
3.1
2.2
2.8
4.5
4.5
4.5
10.8
10.8
MO
L
Si
L、S
S
L、S
is
n
ra
b
s
o
i
r
it
Ka
AL
AL
a
k
-d
Continued
Fastener
Steering system
Steering stem clamp nut
Steering stem locknut
Clamp screw of upper bracket
Handlebar positioning double-end stud mounting nut
Handlebar bolt
Left switch clamp screw
Right switch clamp screw
Rear clamp bolt of left lever
Pivot bolt of left lever
Pivot bolt locknut of left lever
Grip end bolt
Frame
Front seat cushion bolt
Rear seat lock bolt
Bolt of rear grab rail
Mounting bolt of holder of rear fender bracket
Mounting bolt of rear fender bracket
Front left pedal bracket mounting bolt
Shift rod mounting base bolt
Shift rod assembly bolt
Front right pedal bracket bolt
Rear left pedal bracket bolt
Rear right pedal bracket bolt
Muffler cylinder mounting bolt
Rear bolt of muffler cylinder
Rear locknut of muffler cylinder
Sidestand bolt
Locknut of side stand bolt
Sidestand flameout switch bolt
Battery holder bolt
Electrical System
Alternator cover bolt
Alternator wire holding plate
Alternator rotor bolt
Camshaft position sensor bolt
Camshaft sensor bolt
Camshaft sensor cover bolt
Grounding terminal bolt of engine
Front brake light switch screw
Front turn signal light mounting nut
Fuel level sensor nut
Lower bracket bolt of headlight
Lower mounting bolt of headlight
Left switch clamp screw
License plate light cover mounting screw
Oil pressure switch
Oxygen sensor
Rear turn signal light mounting nut
N·m
CO
Y
P
10
10
22
10
10
45
10
10
45
25
25
22
22
22
50
45
6
10
1.0
1.0
2.2
1.0
1.0
4.5
1.0
1.0
4.5
2.5
2.5
2.2
2.2
2.2
5.0
4.5
0.6
1.0
10
10
100
9.8
5.9
9.8
10
1.2
6
10
10
10
3.5
0.90
15
25
6
1.0
1.0
10.0
1.0
0.60
1.0
1.0
0.12
0.6
1.0
10
1.0
0.35
0.09
1.5
2.5
0.6
I
N
A
R
B
A
K
E
RG
O
T
O
M
0.25
2.4
2.5
4.5
2.5
0.35
0.35
1.0
0.6
0.6
1.0
- 77 -
-
Note
kgf·m
2.5
24
25
45
25
3.5
3.5
10
6
6
10
.A
S
S
O
E
G
Y
A
W
Torque
Dim
AL
AL
AL
L
L
S
is
n
ra
L
L(1)
b
s
o
i
r
it
Ka
L
SS
a
k
-d
Continued
Fastener
N·m
10
3.5
6
3.9
10
6
10
10
6
Rectifier bolt
Right switch clamp screw
Sidestand flameout switch bolt
Speed sensor bolt
Starter relay bolt
Starter motor joint nut
Bond strap bolt
Starter motor mounting bolt
Starter motor binding post locknut
Torque
Note
kgf·m
1.0
0.36
0.6
0.40
0.6
0.6
0.6
1.0
0.6
L
L
L
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 78 -
im
D
-
s
o
i
r
it
Ka
k
-d
Inspection / adjustment
Preparation standard
Inspection of brake
Regular maintenance checklist
Inspection of brake fluid level
Engine Oil/Filter
Inspection of wear of brake pad
Inspection/adjustment of throttle cable
Inspection of CBS
Air filter
Inspection of brake light switch
Spark plug
Headlight
Accumulator
Clutch cable
Ignition timing
Front/rear suspension system
Cylinder pressure
Bolt/nut/fixture
Drive chain slackness
Tire specifications
Free stroke of front/rear brake
Rim / tire
Inspection of brake fluid for leakage
Steering Column Bearing and Handlebar
Fixator
a
Preparation standard
b
Satisfactory
Warning!
• Before the engine is running, make sure that the
surrounding air is well ventilated. Do not start the
engine in a confined place, because exhaust gas
contains carbon monoxide which may cause people
to lose consciousness or die.
•Under certain conditions, gasoline is volatile and
explosive. Workplaces must be ventilated and flame
should be extinguished. Smoke and fire are strictly
prohibited in the workplace or the place where
gasoline is stored.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
is
n
ra
T
O
M
- 79 -
im
D
-
s
o
i
r
it
Ka
k
-d
Specifications
Engine
Idle speed
1400±100rpm/min
Spark plug gap
0.6～0.7mm
Spark plug specifications
BR7ES/CR7HSA
Combustion chamber type
Spherical
Ignition time
BTDC 15degrees ±1 degree 1500±100rpm
Motorcycle body
Free stroke of front brake lever
10～20mm
Free stroke of rear brake pedal
20～30mm
Specifications
Tire pressure unit: Kpa
Tire pressure
Front tire
100/90-19
220±10kpa
Rear tire
130/80-18
250±10kpa
Torque
Front axle locknut
100～113N·m
value
Rear wheel mounting nut
100～113N·m
Relevant component certifications
Model
Designation:
Certification number
Note
Front tire (tire and tube)
E4-75R-0013977
Use environment-friendly
Rear tire (tire and tube)
E4-75R-0013978
tubeless tire
Headlight
E9 50R-00 11971
Taillight/brake light
E9 50R-00 11972
Front / rear turn signal light
E3 50R-00 1027
Rear license plate light
E9 50R-00 11973
Rear view mirror
Rear view mirror
E7 00050 1
Horn
Horn
E4 000148
Side reflector
E4 023273
Amber (oval)
Rear reflector
E4 02.3327
Red (rectangle)
Tire
Lights
Reflector
is
n
ra
ab
K
Muffler barrel with
Muffler
IS
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 80 -
S.A
im
D
-
sEuropean regulation
o
i
r
it
mark: e13 BENELLI
EX-P09
a
k
-d
Mark: e13 BENELLI
Air filter
AF-P09
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 81 -
im
D
-
s
o
i
r
it
Ka
k
-d
Regular maintenance checklist
Maintenance mileage
and time
Inspection item
300KM
New
motorcycle
1000KM
One
month
Every
3000
KM
Every
6000
KM
Every
12000
KM
Every
15000
KM
Three
months
Six
months
Twelve
months
Fifteen
months
C
C
R
C
R
R
Tools
*
Air Cleaner
I
*
Gasoline filter
*
Oil filter
I
R
I
R
Replacement of engine oil
level gauge
R
Replaced once every 3000KM
Tire pressure
I
I
I
I
I
I
Tire pressure gauge,
inflator
Storage battery check
I
I
I
I
I
I
Hydrometer,
multimeter
Actuation clearance
inspection
I
I
I
I
I
I
General tools
Handlebar loosening
inspection
I
I
I
General tools
Shock absorber operation
inspection
I
I
I
General tools
Inspection of bolt loosening
at all parts
I
I
I
I
I
I
Torque wrench
Inspection of gearbox for oil
leakage
I
I
I
I
I
I
General tools
Inspection or replacement of
spark plug
I
I
R
R
I
General tools
L
L
*
Lubrication of parts of body
General tools
General tools
General tools
General tools
Oil lubricator
is
n
ra
Muffler
I
I
I
I
I
I
*
Ignition timing
I
I
I
I
I
I
*
Throttle valve
A
I
A
A
A
A
Timing
ab light
KTachometer
*
Idle exhaust gas inspection
A
I
A
A
A
A
CO HC analyzer
*
Throttle inspection
I
I
I
I
General tools
Fuel pipeline inspection
I
I
I
I
General tools
Electrical equipment of
lighting instrument
I
I
Visual multimeter
Side stand of main footpeg
I
Dampers
*
Engine bolt torque
Front/rear brake
I
Drive chain
*
E
G
Clutch
Y
Valve A
OW
T
O
M
Y
P
O
C
O
E
G
R
I
I
I
I
A
BR I
I
I
I
I
I
General tools
I
I
I
I
Torque wrench
I
I
I
I
General tools
I
I
I
A
General tools
I
I
I
I
General tools
I
I
I
I
Feeler gauge
KA
I
NIS
SI .A
I
im
D
I
-
s
o
i
r
it
General tools
- 82 -
General tools
a
k
-d
Expected inspection
1
Ignition system – If there is obviously abnormal continuous ignition, engine misfire, post-ignition overheating or other
phenomena, conduct maintenance inspections.
2
Carbon removal – If there is an obvious lack of horsepower, remove the carbon from cylinder head, piston head and
exhaust system.
3
Piston, cylinder – If cylinder is excessively worn, please replace it with a new one.
Please go to dealers regularly for inspection and adjust it to ensure the best conditions. The table
above is based on the monthly mileage of 1,000 kilometers.
I—Inspection A—Adjustment R—Replacement C—Cleaning L—Lubrication
Note: 1. “*” is the item in which exhaust emissions are involved. Normal maintenance must be conducted in accordance
with the provisions of the State Environmental Protection Agency and the Company’s operating instructions, and it should
not be adjusted and repaired without approval, otherwise, we will not assume any responsibility for it.
2. When riding on gravel roads or under severe environmental pollution conditions, add the number of cleaning air
filter to extend the service life.
3. Maintenance frequency should be added to the motorcycles which often run at a high speed and have a large
mileage.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 83 -
im
D
-
s
o
i
r
it
Ka
k
-d
Engine Oil/Filter
Inspection of engine oil level
When the oil is continuously consumed, check the oil
amount regularly and add it to the appropriate location.
*Note
•When checking the oil level, the motorcycle must be
parked on a flat surface. Place the center stand properly
and keep the motorcycle vertical.
•Check the oil level after the engine has run for 2-3
minutes or been parked for about 2-3 minutes.
Check the oil level.
After the engine stops, clean the dust on the oil level
indicator at the right cover [A] with a clean cloth.
Put the engine on a level surface, and check the oil level
position at the oil level indicator.
If the oil level is below or near the lower limit, add the
recommended oil to the upper limit mark.
If the oil level is too high, the operation of engine and clutch
may be affected; if it is too low, engine overheating may be
caused and thus components are worn seriously.
If you add inferior or other brands and grades of oil, the
lubrication effect may be reduced.
Replacement of engine oil level gauge
a
Warm up the engine.
*Note
The oil should be changed when warming up the engine
and the engine should be supported on the side bracket to
ensure that the oil is completely discharged.
b
Place a suitable container under the oil drain bolt of engine
to collect the oil.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 84 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove the plug screw of oil filler [A].
Remove the oil drain screw
*Note
When the oil drain cap is removed, the oil filter and
spring may pop out.
Backwash the starter motor for several times to completely
drain the oil.
After draining the oil, check the oil filter assembly.
Disassemble:
Inner hexagon screw M6×30[A]
Filter cover [B]
O-Ring [C]
Oil filter element assembly[D]
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 85 -
im
D
-
s
o
i
r
it
Ka
k
-d
Check O-ring
If damaged, replace it with a new one.
Replace the oil filter element assembly with a new one.
Make sure the oil filter element assembly and O-ring are
intact before installation.
Tighten oil drain screw.
Add the recommended oil to the crankcase from the oil filler
[A] .
a
Recommended oil
Model: API SE, SF or SG
Viscosity: SAE 10W-50
Capacity: 2.4 L (when replaced);
2.8 L (completely disassemble the engine)
b
Note
○ Do not add any chemical additives to the oil!The oils
that meet the above requirements are carefully formulated
to provide adequate lubrication action to the engine and
clutch.
○ Although oil with a viscosity of 10W-50 is
recommended for most cases, it is also necessary to make
corresponding changes according to the atmospheric
conditions in the specific use area.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 86 -
im
D
-
s
o
i
r
it
Ka
k
-d
Install the plug screw of oil filler. Start the engine, and idle
for 2-3 minutes.
Stop the engine and check whether the oil level is marked at
the upper limit of oil level indicator after a few minutes.
When checking, the engine should stand upright on the
ground.
Make sure there is no oil leakage.
Inspection/adjustment of throttle cable
*Note
The engine idle speed should be properly adjusted
before adjusting the stroke of throttle cable.
Check the free stroke [A] of throttle cable
Free stroke: 3-5mm.
If it is inconsistent with the specified value, make
adjustment.
Adjust the free stroke of throttle cable.
Adjustment steps:
 Loosen the locknut [A].
 Screw the adjusting nut [B] inward or outward
until the specified free stroke is reached. If it is
screwed in, the free stroke will increase; if it is
screwed out, the free stroke will decrease.
 Tighten the locknut.
 After adjusting the free stroke, rotate the lever to
the left and right to confirm whether the idle
speed of engine has changed.
If the upper end of adjusting throttle cable cannot reach the
specified free gap, adjust the lower end of throttle cable.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 87 -
im
D
-
s
o
i
r
it
Ka
k
-d
Disassemble:
Screw [A]
Right cover of engine [B]
Adjust the lower end of throttle cable.
Adjustment steps:
 Loosen the locknut [B].
 Screw the adjusting nut [C] inward or outward
until the specified free stroke is reached. If it is
screwed in, the free stroke will increase; if it is
screwed out, the free stroke will decrease.
 Tighten the locknut.
 After adjusting the free stroke, rotate the lever to
the left and right to confirm whether the idle
speed of engine has changed.
Air filter
a
Filter element replacement
Disassemble:
Screw [A]
Right cover [B]
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
is
n
ra
T
O
M
- 88 -
im
D
-
s
o
i
r
it
Ka
k
-d
Disassemble:
Screw [A]
Upper cover of air filter [B]
Disassemble:
Screw [A]
Filter element assembly
Check whether the filter element is contaminated or
damaged.
If there is any contamination and damage, please replace it
with a new one.
Clean the air filter element.
a
is
n
ra
*Note
Do not use the gasoline so as not to cause fires.
b
.A
S
S
Replacement time
R
B
A
If motorcycle often runs on bad roads or in rainy days, it
should be replaced ahead of time.
K
E
Gnot rotate the
When disassembling the air cleaner core,
do
R
O
engine. Otherwise, unfiltered airEmay enter the engine,
G
thus causing rapid wear of
Yits components and possibly
A
damaging the engine.In
W addition, operation without the
O
filter element T
may affect subsequent adverse operation of
O
M
Y
P
CO
*Note
I
N
A
- 89 -
im
D
-
s
o
i
r
it
Ka
k
-d
throttle and may cause the engine to overheat.
In addition, operation without the filter element may
affect subsequent adverse operation of throttle and may
cause the engine to overheat.
Installation
It should be conducted in the reverse order of disassembly
*Note
•Make sure whether the air filter has been installed before
installing air filter cover.
Spark plug
Remove the connecting wire of spark plug cap at both sides
of engine [A].
a
b
is
n
ra
Remove spark plug [A] at both sides of engine using spark
plug wrench or alternative tool
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 90 -
im
D
-
s
o
i
r
it
Ka
k
-d
test.
． Whether insulator is cracked or damaged
． Whether electrode is worn
． Burning conditions, color
—If it is light gray, combustion conditions are good.
—If it is pale white, ignition system is out of order or the
mixture is too thin.
If it is damp or black with carbon deposit, the mixture is
too thick.
In the above cases, clean it a wire brush or spark plug
cleaner, and replace it when necessary.
Check the spark plug visually.
If there is crack or wear in the insulator, please replace it
with a new one.
the gap of spark plug
Check the gap of spark plug.
Gap: 0.6-0.7mm
a
*Note
Reinstall the spark plug on the cylinder head and tighten
it according to the specified torque.
Torque value: 15N.m
Install the spark plug with hands and then tighten it using
spark plug sleeve.
b
Accumulator
.A
S
S
Battery disassembly
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 91 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove the right protector [B] using key [A].
1. First remove the negative cable [A].
2. Remove the positive cable [A].
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 92 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove the air pipe of battery from the battery.
Remove the battery holder [A].
Remove the battery [B].
Warning
When disassembling the positive electrode, tools should
not touch the frame, otherwise, short circuit and sparks
may be caused and thus gasoline may ignite, and battery
may be damaged, which are very dangerous.
Warning
The positive and negative electrodes should be removed
in the operation order.
When installing the battery, first connect the positive
electrode and then negative electrode.
Installation
It should be conducted in the reverse order of disassembly.
Warning
To prevent short circuit, first connect the positive
electrode and then the negative electrode.
Do not disengage the battery during the commissioning of
motorcycle; otherwise, the internal components may be
damaged.
Inspection of charging state (closed-circuit voltage)
Open the seat mat and remove the right protector.
Remove the battery from the battery box.
Remove the negative lead and then the positive lead.
Take out the battery.
a
Measure the voltage between battery terminals.
Fully charged: 13.1V
Undercharge: 12.3V (the battery has not worked for 1
hour)
b
*Note
Inspection under the charged state must be conducted
using a voltmeter.
.A
S
S
im
D
-
s
o
i
r
it
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
voltmeter
O
CO
Y
P
T
O
M
is
n
ra
- 93 -
Ka
k
-d
Charging
Connection method: The positive electrode of charger is
connected to the positive electrode of battery.
The negative electrode of charger is connected to the
negative electrode of battery.
Warning
• Never use a source of ignition near batteries.
• First turn off the charger switch before starting charging
or after completing charging.
to prevent sparks at the connection position and avoid the
danger of explosion.
•In the process of charging, conduct the standard
operation according to the current time marked on the
battery.
*Note
•Battery cannot be used generally during the quick
charging of battery, except in emergencies.
•Measure the voltage 30 minutes after charging.
Charging current: Standard: 0.6A
Quick: 6.0A
Charging time: Standard: 10-15 hours
Quick: 30 minutes
Completion of charging: open circuit voltage: 12.8V or
more
Ignition timing
a
*Note
Check the ignition system when the ignition timing is
incorrect.
●Warm up the engine for 3 to 5 minutes.
●Turn off the engine, and connect the timing light to the
spark plug wire.
●Remove the timing observation hole cover.
● Start the engine and let it idle.
● Check the ignition timing, and see whether the timing
light is on. If the “T” symbol on the flywheel is aligned
with the marking symbol on the left cover, the ignition
time is correct.
●Increase the engine speed and check if the “T” symbol
starts moving.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
EO
G
Y
A
It should be conducted
in
the
W reverse order of disassembly.
O
T Adjustment Method:
Ignition Timing
O
M
Y
P
CO
is
n
ra
- 94 -
im
D
-
s
o
i
r
it
Ka
k
-d
Disassemble:
Timing access plate [A]
Crankcase access plate [B]
Observe the flywheel [A] of timing access plate on the left
cover.
Timing mark [A] on the flywheel assembly.
a
b
is
n
ra
Insert the sleeve [A] into the crankcase access hole.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 95 -
im
D
-
s
o
i
r
it
Ka
k
-d
Slowly turn the sleeve to rotate the flywheel assembly, and
align the timing mark on the flywheel assembly with the
timing mark on the left cover access hole [A].
After ensuring that the timing mark below is aligned, put the
chain on the driven sprocket of camshaft, align the timing
mark [A] on the driven sprocket of camshaft with that on the
cylinder cover and put them into the camshaft, and then
complete aligning the timing marks.
Cylinder pressure
Warm up the engine.
Insert a pressure gauge.
Move the choke handle to the fully open position.
Rotate the throttle handle to the fully open position,
and backflush to start the engine.
Cylinder pressure: 1 ~ 1.2mpa
*Note
Start the engine until the meter reading no longer rises.
Reasons for low pressure:
. Improper valve adjustment
. Valve leakage
. Wear of piston ring or cylinder
. Washer of cylinder head for damage
Reasons for high pressure:
Carbon deposition in the combustion chamber or piston
Turn off the engine and remove the spark plug/spark plug
cap
It should be conducted in the reverse order of disassembly.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 96 -
im
D
-
s
o
i
r
it
Ka
k
-d
Drive chain slackness
Park the motorcycle in a flat position to keep it in an upright
position.
Check the slackness of drive chain .
Slackness of drive chain: 20-30mm.
Adjust the slackness of drive chain:
 Loosen the locknuts [A] of rear axle nut and two
drive chain adjusting nuts [B].
 Rotate the adjusting nuts [B] at both sides of rear
rocker arm, until the slackness of chain is normal.
*Note
Do not install the new drive chain on a worn sprocket or
install the worn chain on a new sprocket.
Both the sprocket and the chain must be in good
conditions; otherwise, the replaced chain or sprocket may
be worn soon.
Free stroke of brake
Free stroke of front brake
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 97 -
im
D
-
s
o
i
r
it
Ka
k
-d
Measure the free stroke of front brake lever
at the tip of brake lever.
Free stroke: 10-20mm
Free stroke of brake pedal
Measure the free stroke of brake pedal.
Free stroke: 20-30mm.
Adjust if it does not meet the specified value.
a
Adjust the free stroke of brake pedal.
Loosen the locknut [A]
Screw in or screw out the adjusting device [B]
If the adjusting device is screwed in, the free stroke
will be reduced;
If the adjusting device is screw out, the free stroke will
be increased.
Screw in or screw out it until the free stroke meets the
specified value.
Tighten the locknut [A].
After adjustment, the brake dragging phenomenon shall be
avoided.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 98 -
im
D
-
s
o
i
r
it
Ka
k
-d
Inspection of brake fluid for leakage
 The precautions for models equipped with CBS are as
follows:
 Rotate the brake lever or pedal to check whether brake
fluid leaks from the brake hose [A] and brake line [B].
★ If brake fluid leaks from any position, check or replace
the defective part.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 99 -
im
D
-
s
o
i
r
it
Ka
k
-d
a
b
is
n
ra
Check brake hoses and brake lines for damage and ensure
their installation status
●The precautions for models equipped with CBS are as
follows:
R
B
A
I
N
A
.A
S
S
K
E
Gfor corrosion,
●Check brake hoses, brake lines and fittings
R
cracks or leaks.
EO
G
○If the brake hoses and Y
brake lines are not properly
A
serviced, the high pressure
W inside the brake lines may cause
O
brake fluid to T
leak [A] or the brake hoses and the brake
O
M
- 100 Y
P
CO
im
D
-
s
o
i
r
it
Ka
k
-d
forming tubes to burst. When checking rubber hoses, bend
and twist them. When checking rubber hoses, bend and twist
them.
★If any cracks [B], swelling [C] or leaks are found on the
brake hose or brake forming tube, they must be replaced.
●Tighten all hollow bolts and nuts of brake hose.
Tightening torque for hollow bolt of brake hose: 30 N•m
●Check the winding method of brake hose.
★If the brake hoses and brake lines (models equipped with
CBS) are not wound correctly, please discharge brake hoses
and brake lines by correct winding method.
Inspection of brake
● Check whether front brake and rear brake are normal
when riding a motorcycle on a dry road.
★ If the brake is abnormal, check the brake system.
Warning
If you need to test-ride a motorcycle during
the inspection, make sure to do it at a place under
safe traffic conditions.
Inspection of brake fluid level
● Check whether the level of brake fluid in the front brake
fluid reservoir [A] is higher than the lower limit [B].
Note
○ When checking the brake fluid level, make the
brake fluid reservoir level.
a
★If the level is lower than the lower limit, add brake fluid
to the reservoir until the liquid level reaches the high liquid
level line.
b
● Follow the following procedure to properly install the
cover of the front brake fluid cup.
○After aligning the reservoir cover, tighten the two screws
[A] of the reservoir cover with a screwdriver.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 101 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Check whether the brake fluid level in the rear brake fluid
reservoir [A] is higher than the lower limit [B].
★ If the liquid level is lower than the lower limit, add brake
fluid to the reservoir until the liquid level reaches the high
liquid level line [C].
Warning
If you need to add brake fluid but are not sure about
the type and brand of brake fluid in the brake fluid
reservoir, you must replace the brake fluid in the
brake fluid tube.
After replacing brake fluid, use only brake fluid of the
same type and brand.
Recommended disc brake fluid
Grade: DOT4
●Properly install the cover of rear brake fluid reservoir
according to the following procedures.
○ First, tighten the cover [B] of rear brake fluid reservoir
with your hands clockwise [C] until you feel a little
resistance, indicating that the cover has been fixed on the
reservoir, then hold the reservoir [A] and rotate it by 1/6 turn
[D].
Inspection of wear of brake pad
●Remove the brake pads (see “Disassemble front/rear brake
pad” in chapter “Brake” for details).
●Check the thickness of friction plate of brake pad inside
the caliper [A].
★If the thickness of friction plate of any brake pad is lower
than the operating limit [B], replace the two brake pads
inside the caliper simultaneously.
Thickness of friction plate of brake pad
Standard:
Front wheel brake pad: 6.0 mm
Rear wheel brake pad: 4.0 mm
Operating limit: 3 mm
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 102 -
im
D
-
s
o
i
r
it
Ka
k
-d
Inspection of brake light switch
●Open the electric door lock.
● When the brake lever is pulled by about 15 mm, the brake
light is on.
★ If the brake light is off, check whether the brake light
switch plug is inserted properly.
★ If the brake light is off, check or replace the following
parts:
Battery;
Brake light;
Fuse;
Front brake light switch;
Rear brake light switch;
Cable harness.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 103 -
im
D
-
s
o
i
r
it
Ka
k
-d
Headlight
Remove headlight
Remove
Clamp screw [A]
Headlight [B]
Disconnect the headlight cable connector [A].
Remove the headlight
Take out
Headlight bulb [A]
Front position light bulb [B]
a
b
*Note
When the bulb is on, keep the flammable product
and your hand at a distance from the bulb, because
the bulb is hot and should be cooled before it can be
touched.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 104 -
im
D
-
s
o
i
r
it
Ka
k
-d
Install headlight
Install the front headlight bulb and front position light bulb
in the reverse order of disassembly.
*Note
Avoid touching the glass part of the bulb directly and do
not expose it to oil during installation.
Otherwise, it may affect the transparency, life and
luminous flux of bulb.
★ If it is stained with oil, wipe it thoroughly with a cloth
dampened with alcohol or volatile rubber water.
Check the headlight accuracy
● Check the accuracy of headlight beam.
★ If the headlight beam is pointing to one side instead of
pointing straight ahead, adjust the beam.
Correctly adjust the beam of headlights as follows:
Park the vehicle about 10 meters in front of the upright wall
and park it on a completely flat surface.Fig. A
Ride on the motorcycle and sit in the rider position.
Make sure that the highest point of beam, such as on the
wall, which is less than 1/10 of the horizontal axis of the
headlights.
If the beam does not fall within these ranges, make
adjustments to make it in the correct position.
Adjustment of headlight beam
● Remove the inner cover (see “Removing the Inner Cover”
in the chapter “Frame”).
● Screw in or out the adjusting screw [A], until the beam is
directly pointing to the front.
★ If the headlight beam is too low or too high, adjust the
vertical beam.
a
b
Rotating screw [A]
Rotate the screw counterclockwise to reduce the beam
Rotate the screw clockwise to raise the beam
.A
S
S
I
N
A
R
B
○ When the motorcycle is supported by its wheelsA
and
K
someone is riding on the motorcycle, turn
E on the
G
high-beam light, the brightest point should
R be slightly
O
E
lower than the horizontal line.Adjust the angle of the
G
headlights according to local
regulations.
Y
A
W
TO
O
M
- 105 Y
P
CO
Note
is
n
ra
im
D
-
s
o
i
r
it
Ka
k
-d
Clutch cable
Check the free stroke [A] of clutch cable.
Free stroke: 10-15mm.
Check the free stroke of clutch cable.
 Loosen the fastening nut [1] first.
 Screw in or screw back the adjusting device[2].
 Screw in or screw out it until the free stroke meets
the specified value.
 Finally tighten the fastening nut.
If the specified free clearance cannot be reached after
adjusting the clutch handle, adjust the lower end of clutch
cable.
Check the lower end [A] of clutch cable.
Adjustment steps:
 Loosen the locknut [C].
 Screw the adjusting nut [B] inward or outward
until the specified free stroke is reached. If it is
screwed in, the free stroke will increase; if it is
screwed out, the free stroke will decrease.
 Tighten the locknut.
After adjusting the free stroke, rotate the lever to the left and
right, to ensure that the lever of clutch can not reach the
specified free clearance.
a
b
.A
S
S
I
N
A
Front/rear suspension system
GE
R
B
A
K
R
Front part
Y
A
W
O
GE
O
CO
Y
P
T
O
M
is
n
ra
- 106 -
im
D
-
s
o
i
r
it
Ka
k
-d
Tighten the front brake and compress the front shock
absorber up and down to check the operation.
Check whether the front shock absorber leaks and its parts
are damaged and loosened.
Compress it up and down
Rear part
Compress rear shock absorber up and down to check the
operation.
Check whether the parts of rear shock absorber are damaged
and loosened.
Suspend the rear wheel, and swing the rear wheel to check
whether the engine suspension bushes are loosened.
Compress it up and down
Bolt/nut/fixture
Check whether the bolts, nuts and fixtures of various parts
of motorcycle are loosened.
If they are loosened, tighten it to the specified torque value.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 107 -
im
D
-
s
o
i
r
it
Ka
k
-d
Front / rear tire
Check tires for cracks, iron nails or other damages.
Check tire surface
Wear → Replace
1. Tire tread depth
2. Side wall
3. Wear indication
Wear limit: 1mm
Check tire pressure.
*Note
Tire pressure measurement should be conducted at cold
state.
Specified air pressure
Unit: Kpa
Tire specifications
Tire pressure
Front tire
100/90-19M/C
220±10
Rear tire
130/80-18 M/C
250± 10
Note
If there is a rotation direction at the tire, mark it with “1”
 Point the mark to the rotation direction when
installing the tire.
 Align mark “2” to the installation position of rim
valve
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 108 -
im
D
-
s
o
i
r
it
Ka
k
-d
Rim / tire
Check whether the front axle mounting nut is loose.
Check whether the rear axle mounting nut is loose.
If loose, tighten it to the specified torque value.
Torque value: Front axle fixing nut 100-113N·m
Mounting nut of rear wheel 100-113 N•m
Front rim
2.50×19
Rear wheel rim
3.00×18
Steering Column Bearing and Handlebar Fixator
Swing the handlebar from side to side, and check whether
wires are involved.
Rotate the front wheel, and freely swing the handlebar to
confirm.
If the handlebar cannot be swung smoothly, check the
steering column bearing when it is loosened.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 109 -
im
D
-
s
o
i
r
it
Ka
k
-d
Inspection and Maintenance of Electrical System
Torque Table of Fastener of Electrical System
Fastening location and fastener name
Tightening torque (N•m)
Rectifier bolt
5N·m
High-voltage coil mounting bolt
9N·m
Flywheel mounting nut
90N·m
Motorcycle protector bolt
9N·m
Starter motor clutch cover bolt
12N·m
Meter seat mounting screw
5～7N·m
Ignition switch mounting screw
10～12N·m
Horn mounting bolt
10～12N·m
Oxygen sensor
25N·m
Mounting nut of fuel level sensor
10N·m
Precautions:
There are the following important precautions in the process of overhauling the electrical system. Learn and follow all of
the following rules.
○ Do not reverse the positive and negative terminals of battery, otherwise, the diodes of electrical components may be
burned out.
○ Check the battery status before checking other parts of the electrical system. The battery must be fully charged
before conducting accurate electrical system testing.
○ The electrical components should be protected from severe impact by hammers, and are not allowed to fall on hard
surfaces. This impact on electrical components may cause damage.
○ To prevent damage to electrical components, do not disconnect the battery cable or any other electrical connections
while the ignition switch is on or while the engine is running.
○ When the starter motor cannot rotate due to large current, do not press the start button all the time, otherwise, the
current may burn out the starter motor coil.
○ Be careful not to short connect the cable between the positive terminal of battery and the ground wire of frame.
○ Sometimes a fault may involve one project, and sometimes it may involve all projects. Do not replace the faulty part
if the exact cause of fault is not found. If the fault is caused by other causes, it must be repaired or replaced
immediately, otherwise, the new parts may be damaged again.
○ Ensure that all circuit connectors are clean and tight, and check the wires for signs of burnout or wear. Broken wires
and poor contact may affect the operation of power system.
○ Measure the coil and winding resistance after the component is cooled (at room temperature).
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 110 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
Charging System
a
is
n
ra
b
Serial
number
CO
Designation:
Serial
number
1
Klaxon
2
Voltage regulator
3
Ignition coil
4
Front right turn signal
light
O
NI
A
R
B
A
8
Gauge
K
9 E Fuse box
RG
7
E
G
Y
5
Headlight
A
6
Front left turn
OW signal light
T
O
M
Y
P
Designation:
.A
S
S
Ignition switch
10
Variable-frequency flasher
11
Relay unit
12
ECU
- 111 -
im
D
-
s
o
i
r
it
Ka
Serial
number
Designation:
13
Accumulator
14
Taillight
15
Rear right turn signal light
16
License plate light
k
-d
I. Battery/Charging System
Preparatory Information--------------------- 1.1
Fault Diagnosis------------------------------- 1.2
Battery----------------------------------------- 1.3
Charging System----------------------------- 1.4
Voltage and current Regulator-------------- 1.5
Alternator--------------------------------------1.6
1.1 Preparatory Information
Note for operation
*Note
1. The battery can be used repeatedly by charging and
discharging. If the battery is placed after discharging, the
service life will be shortened and the performance will be
degraded. Generally, the performance of battery that has
been used for about 2-3 years will be degraded. For the
battery with degraded performance (reduced capacity), the
voltage will recover but the voltage will drop rapidly when a
load is applied.
2. Overcharging of battery: Generally, overcharging can be
observed on the battery body. If the battery is short-circuited
internally, no voltage is detected at the battery terminal or the
voltage is low. Regulator fault: The battery voltage will be
too high, and the battery life will be shortened.
3. If the battery is placed for a long time, the battery will
discharge by itself, and the power capacity will be reduced,
so battery must be charged once about every 3 months.
4. Charging system should be inspected in the order of fault
diagnosis table.
5. If current flows through the electrical components, do not
remove the connectors. Otherwise, the voltage may become
too high and the electronic components in voltage regulator
may be damaged. The main switch must be turned off before
operation.
6. Maintenance-free (dry-charged) batteries do not need to be
inspected, so electrolyte and distilled water are not required.
7. Check all electrical loads.
8. Emergency charging should not be used unless in an
emergency.
9. When the battery is charged in an emergency, the battery
must be removed from the motorcycle before charging.
10. Do not use liquid-filled batteries when the batteries are
a
b
K
E
RG
O
O
CO
Y
P
T
O
M
.A
S
S
I
N
A
R
B
A
E
G
Y
A
W
is
n
ra
- 112 -
im
D
-
s
o
i
r
it
Ka
k
-d
exchanged.
11. Use a voltmeter when checking the charging state of
battery.
Technical parameters
Item
Specifications
Capacity/type
Voltage
（20℃）
Accumulator
Alternator
12V8Ah（YTX9-BS)
When fully charged
13.1V
Must be charged
12.3V (Have not run for 1 hour)
Charging current
Standard: 0.8A, quick: 8A
Charging time
Standard: 10-15 hours, quick: 30 minutes
Capacity
160W/5000rpm
Coil impedance value (20℃)
0.8±0.3Ω between white and white
Type
Three-phase full-wave rectifying type
Battery charging voltage
14.5V±0.5V/5000rpm
Rectifying voltage
regulator
Lock torque value
Rectifier bolt
High-voltage coil mounting bolt
Flywheel mounting nut
Motorcycle cover bolt
Tool
5.0 N·m
9.0 N·m
90N·m
9.0 N·m
Universal wrench
Flywheel puller
Testing instrument
Multimeter
1.2 Fault Diagnosis
1.2.1 No power
a
Overdischarge of battery
Battery wire is not connected
The fuse is broken
Defective power switch
b
1.2.2 Discontinuous current
Battery wire is not connected properly
Discharging system contact is defective
Lighting system is in poor contact or short circuit
.A
S
S
1.2.3 Low voltage
Poor battery charging
Poor contact
Poor charging system
Defective rectifying voltage regulator
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 113 -
im
D
-
s
o
i
r
it
Ka
k
-d
1.2.4 Poor charging system
Defective contact, short wire or short circuit of wire connector
Defective voltage and current regulator
Poor alternator
1.3 Battery
1.3.1 Battery Disassembly
Remove the right protector [B] using key [A].
1. First remove the negative cable [A].
a
b
is
n
ra
2. Remove the positive cable [A].
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 114 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove the air pipe of battery from the battery.
Remove the battery holder [A].
Remove the battery [B].
Warning
When disassembling the positive electrode, tools
should not touch the frame, otherwise, short circuit
and sparks may be caused and thus gasoline may
ignite, and battery may be damaged, which are very
dangerous.
Warning
The positive and negative electrodes should be
removed in the operation order.
When installing the battery, first connect the positive
electrode and then negative electrode.
1.3.2 Install battery
●Load the battery into the bracket
●Connect the negative electrode (-) of cable to the battery
● Apply a thin layer of grease to the terminals to prevent
corrosion
●Connect the positive electrode (-) of cable to the battery
● Cover the (+) terminal block with the red cover [A]
● Install the battery cover on the battery and hook the strap
●Connect connector
●Connect the negative electrode (-) of cable to the frame
● Install the parts that have been removed before in the
reverse order of disassembly.
a
1.3.3 Activation of battery
b
●Fill the electrolyte
○ Make sure that the model number [A] marked on the
electrolyte bottle matches the model number [B] of the
battery. These models must be the same.
Battery model: YTX9-BS
Warning
Always use the same type of electrolyte as the one
marked on the battery. Because of different battery
types, the volume and density of the electrolyte used
are different.This is to prevent overfilling the
electrolyte and shorten battery life and battery
performance.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 115 -
im
D
-
s
o
i
r
it
Ka
k
-d
Warning
Do not tear the aluminum sealing piece [A] from the
filling port [B] before use.Ensure that a dedicated
electrolyte storage container is used to ensure the
correct volume of electrolyte is filled
○ put the battery on the horizontal surface
○ Check the seal for peeling, cracks or holes
○Removing the sealing strips
*Note
○ The battery is vacuum sealed. If the seal leaks air into
the battery, the first charge may take longer.
●Take out the electrolyte bottle from the plastic bag
●Remove the strip cover [A] from the container and set it
aside, and later use these to seal the battery later.
*Note
Do not puncture or open the seal layer [B] of electrolyte
bottle. Do not attempt to separate a single reservoir.
● Lay the electrolyte bottle down and place the six sealing
slots into the filling port of battery. Keep the electrolyte
bottle level and push down to puncture the seal of all six
reservoirs. As the seal reservoir is inserted into the filling
port, you will see bubbles rising in the reservoir.
*Note
○ Do not tilt the electrolyte bottle
a
●Check the electrolyte flow
★ If there is no air bubble rising in the filling port [A], or if
the electrolyte is not completely injected into the battery, tap
the electrolyte bottle [B] for several times.
● Keep the electrolyte bottle in this position for 20 minutes
or longer. Do not remove the container from the battery
before it becomes empty. The normal operation of battery
requires all the electrolyte in the container.
Warning
If the electrolyte in the electrolyte bottle is not
completely injected into the battery, the battery life
may be shortened.It takes at least 20 minutes for the
electrolyte to completely fill the battery. Do not
remove the electrolyte bottle until then.
● Gently remove the electrolyte bottle from the battery
● Allow the battery to stand for 60 minutes before charging
so that the electrolyte penetrates into the metal plate for
optimum performance.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 116 -
im
D
-
s
o
i
r
it
Ka
k
-d
*Note
○ If the battery is charged immediately after filling, the
battery life may be shortened.Allow the battery to stand
for at least 60 minutes after filling.
1.3.4 First charge
● Gently cover the strip [A] cover on the filling port, do not
press it completely
●The newly activated maintenance-free battery needs to be
charged for the first time.
Standard charging: 0.9A x 5-10 hours
*Note
○ Charging rate depends on the storage time and
temperature of battery and the type of charger used
○ After the first charge, allow the battery to stand for 30
minutes, then check the voltage with a voltmeter.
If the voltage is less than 12.6V, repeat the charging cycle.
● After charging is completed, press firmly with both hands
to make the strip cover [A] enter the battery (do not hit or
beat). When properly installed, the strip cover will be flush
with the top of battery.
Warning
Once the strip cover is installed in the battery, do not
move the lid or add water or electrolyte to the
battery.
a
b
is
n
ra
*Note
○ To ensure maximum battery life and increased customer
satisfaction, it is recommended to perform a 15-second
load test on the battery at the speed that is three times
greater than the ampere-hour rate of battery. Recheck the
voltage; if it is less than 12.6V, repeat the charge cycle
and load test.If it is still below 12.6V, the battery is faulty.
Precautions
1) It is not required to replenish liquid
This battery does not require replenishing liquid and
can be used before the end of its life under normal use.
It is very dangerous to pry up the sealing cap and add
water.Never do this.
2) Replenish power
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 117 -
im
D
-
s
o
i
r
it
Ka
k
-d
If the engine fails to start, the horn sound is very weak
and the lights are dim, which means that the battery has
lost power. Replenish the power for 5-10 hours using
the charging current specified in the instruction manual
(see the section "Replenishment of Power").
If a fast charge is necessary, strictly follow the
maximum charge current and time conditions indicated
on the battery.
Warning
If the charge is replenished according to the method
specified above, quality problems will not be caused to
the battery under normal conditions. However, if the
charging is not performed under the conditions
described above, the performance of battery will be
greatly degraded. Do not disassemble the seal cap
during the period of replenishing the power.
If excessive gas is inadvertently generated due to
overcharging, the safety valve will release gas to keep
the battery normal.
3) When you do not use a motorcycle for more than one
month
Recharge the battery before storing it, then remove the
negative cable. The power shall be replenished once a
month during storage.
4) Battery life
If the engine still fails to start after the battery power
has been replenished for several times, the battery has
exceeded its service life. The battery needs to be
replaced at this point (but first make sure there is no
problem with the starting system of motorcycle).
Warning
Keep the battery away from sparks and open flames
during charging as the battery may release an
explosive gas mixture containing hydrogen and
oxygen.When using the battery charger, you need to
connect the battery to the charger before turning on
the charger.
This process can prevent causing sparks at the battery
terminals and avoid igniting any battery gas.
There should be no fire source near the battery,
otherwise, any locked terminals should not be
loosened.
The electrolyte contains sulfuric acid.Be careful not to
let it touch your skin or eyes.If case of skin or eye
contact, rinse using a plenty of water.If the situation is
serious, seek medical attention.
Exchange
Full play can be given to the performance of
maintenance-free battery only when it is connected to a
suitable vehicle electrical system. Therefore, the battery can
be replaced with a maintenance-free battery when the
motorcycle is originally equipped with a maintenance-free
battery.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 118 -
im
D
-
s
o
i
r
it
Ka
k
-d
1.3.5 Inspection of charging state
● The battery can be inspected by measuring the battery
terminal voltage using a voltmeter [A].
●Disassemble battery
●Measure the voltage between battery terminals.
*Note
○ Use a digital voltmeter that can read a decimal place to
measure voltage
● If the reading is 12.6V or higher, there is no need to
replenish the battery; however, if the reading is below the
specified value, it is required to replenish the power.
Battery terminal voltage
Standard: 12.8V or above
Terminal voltage (V) [A]
Battery charging ratio (%) [B]
Need to replenish power [C]
Note [D]
Good [E]
Replenish power
●Remove the battery [A] (see battery removal section)
●Make sure to replenish the power based on the battery
terminal voltage in the following way.
Warning
The battery is sealed.Do not remove the sealing cap
[B] even while charging.Do not add water.Charging is
performed according to the current and time
described below.
a
b
Terminal voltage: between 11.5 and 12.6V
Standard charging: 0.9A × 5-10h (see the right figure)
Fast charging: 9A×1h
Warning
Do not charge quickly if possible.If fast charging is
unavoidable, standard charging will be performed
later.
Terminal voltage: less than 11.5V
Charging method: 0.9A×20h
Note
If the battery cannot be charged initially, the charging
voltage shall be increased to 25V.After increasing the
voltage, charge for no more than 5 minutes, then check
whether current is flowing to the battery.If the battery has
received current, the voltage should be reduced back to
the standard voltage and continue the operation in the
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 119 -
im
D
-
s
o
i
r
it
Ka
k
-d
ways as described in the battery packing.If there is no
current flowing to the battery after 5 minutes, please
replace the battery.
Battery [A]
Battery charger [B]
Standard value [C]
Current begins to flow [D]
• Determine battery state after replenishing power
○ After charging is completed, let the battery stand for 30
minutes and then determine the battery state by measuring
the terminal voltage according to the following table.
Standard
Judgment
12.6V or above
Good
12.0-less than 12.6V
Undercharge→Recharge
Less than 12.0V
Unavailable→Replacement
● When the battery is inspected, it should be tested with a
multimeter under the state of full charge.
●After the engine is warmed up, install the fully charged
batteries.
●Connect a voltmeter between battery terminals.
●Start the engine, slowly increase the speed and measure the
limit voltage.
Limit voltage/speed: 15V (5000rpm) (DC voltage)
●When the limit voltage is not within the specified value
range, check the voltage regulator.
1.4 Charging System
1.4.1 Inspection of Charging State
Test the battery with a multimeter in a fully charged state.
After the engine is warmed up, install the fully charged
batteries.
Connect a voltmeter between battery terminals. Remove the
main fuse, and connect an ammeter between two terminals.
Measure the current engine, slowly increase the speed and
measure the limit voltage and current.
a
b
Limit voltage/speed: 14.5±0.5V （5.000rpm）
When the limit voltage is not within the specified value
range, check the rectifying voltage regulator and lighting
system limiting voltage.
*Note
The multimeter is set to the position of DC voltage during
voltage detection, and the limiting voltage will change
slightly when the lighting system is turned on.
.A
S
S
I
N
A
R
B
A
K
E
RG
EO
G
Y (general version)
Charging simple function diagram
A
OW
T
O
M
Y
P
O
C
is
n
ra
- 120 -
im
D
-
s
o
i
r
it
Ka
k
-d
1.5 Disassembly of Voltage and Current Regulator
1.5.1 Disassembly of voltage and current regulator
Disconnect the plugs of voltage and current regulator and
cable [A]
Disassemble:
Bolt [A]
Disassembly of Voltage and Current Regulator [B]
a
b
is
n
ra
1.5.2 Inspection of Circuit at Main Wiring End
Remove the 6P plug of voltage and current regulator.
.A
S
S
Check the continuity between main wiring terminals in the
following way.
Item (wire color)
Judge
Between battery (red) and bond
strap of body
A
K
E
G
R
Between bond strap wire (black)
and bond strap of body
Y
A
W
O
CO
Y
P
T
O
M
BR
There is battery
voltage
O
GE
Between charging coil (white) and
bond strap of body
I
N
A
There is wire
There is resistance
in alternator coil
- 121 -
B
im
D
W3
W2
R
W1
s
o
i
r
it
Ka
k
-d
1.5.3 Inspection of Voltage and Current Regulator
1、 Rotate the multimeter to the position of diode;
2、 Connect the black probe to the red terminal of regulator,
and connect the red probe to the white terminals (white
1, white 2, white 3) of regulator respectively. The
pointer gauge will display a certain value, otherwise, it
indicates that regulator is damaged and needs to be
replaced.
3、 Connect the red probe to the black terminal of regulator
port, and connect the black probe to the white terminals
(white 1, white 2, white 3) of regulator respectively. The
pointer gauge will display a certain value, otherwise, it
indicates that regulator is damaged and needs to be
replaced.
*Note
•Do not touch the metal part of test rod of multimeter
with fingers during inspection.
•Use a multimeter to check. The impedance values may
be different when different multimeters are used, so the
check may not be correct.
The voltage regulator should be replaced when the
impedance between the terminals is abnormal.
1.5.4 Installation of voltage and current regulator
● Install the parts that have been removed before in the
reverse order of disassembly.
Locking torque of voltage and current regulator mounting
bolt: 10-12 N·m
1.6 Alternator
a
1.6.1 Disassembly
b
●Alternator power cable connector
● Place a suitable container under the magnet cover
● Loosen the left cover mounting bolt [A] and remove the
left cover and coil
● Pull the alternator power cable from the engine and
bracket
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 122 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Remove stator coil:
Alternator cover (see "Removing alternator cover)
Stator coil [A]
Stator coil bolt [B]
Alternator lead wire sleeve [C]
Trigger [D]
Tension disc bolt [E]
●Remove the flywheel:
Remove alternator cover (see "Removing alternator cover)
Use the flywheel remover to remove the flywheel mounting
bolts [A].
Remove it from the crankshaft using the flywheel puller
Remove the flywheel
a
1.6.2 Inspection
*Note
Check the alternator charging coil and operate at the
engine.
● There are three types of alternator faults: short circuit,
open circuit (wire is burnt out) or the magnetic property of
rotor disappears. A short or open circuit of coil will result
in low output or even no output. The disappearance of the
magnetic property of rotor will result in a low output that
may be caused by falling of alternator or hitting, or by
being placed near the electromagnetic field, or simply
because of aging.
● Turn off the ignition switch
●Remove alternator connector.
●Use a multimeter to measure the impedance between the
three white terminals of alternator.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 123 -
im
D
-
s
o
i
r
it
Ka
k
-d
test.
Stator
assembly
Remove alternator connector.
Use a multimeter to measure the impedance between the
white coils of alternator.
Standard value: 0.8±0.3Ω (20°C)
Replace the alternator coil when the measured value
exceeds the standard value.
★ If the resistance is greater than the above, or if any two
power cord multimeters have no reading (infinite value),
the stator line is broken and must be replaced. It the value
is far below this resistance, the stator is shorted and must
be replaced.
● Measure the resistance between each white power cord
and the chassis ground wire using the maximum resistance
range of the multimeter.
★ If the tester coil is used to test whether the engine body
is conducting or not; if it is conductive, there is a short
circuit between the coil and the engine, and the charging
coil needs to be checked.
★ If the resistance of stator coil is normal, but the voltage
check indicates that the alternator is faulty, it is possible
that the rotor is magnetically weakened and the rotor must
be replaced.
●Start the engine
○Run according to the revolutions per minute (rpm) given
in the Table below.
○ Keep a record of voltage readings (total of 3
measurements)
Table Output voltage of alternator
Tester
range
750 V
AC
Wring
Connect
tester (+) to
A white
power cable
Connect
tester (-+) to
Another
white power
cable
a
Reading at
5000 rpm
b
80V or
higher
★ If the value displayed on the output voltage is the value
in the table, the alternator is operating normally.
★ If the reading is much lower than the value in the table,
the alternator is faulty.
1.6.3 Installation
●Install it in the reverse order of disassembly.
.A
S
S
I
N
A
R
B
A
K
E
Locking torque of stator coil and tensionGdisc bolt:
10-12 N·m
OR
E
Locking torque of trigger bolt:G
7-9N·m
Y
Locking torque of alternator
A cover bolt: 10-12N·m
W
Locking torque of flywheel
mounting nut: 9N·m
O
T
O
M
Y
P
O
C
is
n
ra
- 124 -
im
D
-
s
o
i
r
it
Ka
k
-d
Ignition System
a
is
n
ra
b
Trigger probe
Power supply
Serial
number
Designation:
Serial
number
1
Klaxon
7
2
Voltage regulator
8
3
Ignition coil
4
Front right turn signal light
5
Headlight
6
Front left turn signal light
Y
A
W
Ignition system
.A
S
S
NI
Designation:
RA switch
Ignition
B
A
Gauge
O
GE
K
9E
Fuse box
G
R 10 Variable-frequency flasher
11
Relay unit
12
ECU
O
CO
Y
P
T
O
M
- 125 -
im
D
-
s
o
i
r
it
Ka
Serial
number
Designation:
13
Accumulator
14
Taillight
15
Rear right turn signal light
16
License plate light
k
-d
II. Ignition System
Preparatory Information-------------------------2.1
Fault Diagnosis --------------------------------- 2.2
Crankshaft sensor-------------------------------- 2.3
Ignition Coil -------------------------------------2.4
Spark Plug---------------------------------------- 2.5
ECU------------------------------------------------2.6
2.1 Preparatory Information
2.1.1 Precautions for operation
1、 Ignition system should be inspected step by step in the
order of fault diagnosis table.
2、 The ignition system is an electronic automatic angle
feeding device and it has been solidified in the ECU
group, so the ignition time does not need to be adjusted.
3、 Ignition system should be inspected in the order of fault
diagnosis table.
4、 The main reason for ignition system fault is poor contact
of connector, so first check whether the connectors are
in poor contact.
5、 Check whether the heat value of spark plug is
appropriate, because improper spark plug may cause the
engine to run unsmoothly or burn the spark plug.
a
6、 Check the main switch according to the conduction
table of switch part. (Attached)
is
n
ra
7、 Alternator and stator should be removed according to
b
the disassembly instructions.
Warning
Ignition system may generate an extremely high
voltage.Do not touch the spark plug or coil while the
engine is running; otherwise, you may be exposed to a
.A
S
S
I
N
A
serious electric shock.
*Note
R
B
A
K
E
RG
Do not disconnect battery cable or any other electrical
connections while the ignition is on or the engine is
EO
G
the electrodes of battery.The side of negative electrode
Y
should be grounded.This A
is to prevent damage to ECU.
OW
T
O
M
Y
P
O
C
running.This is to prevent damage to ECU.Do not reverse
- 126 -
im
D
-
s
o
i
r
it
Ka
k
-d
Technical parameters
Item
Spark plug
standard value
Standard
BR7ES/CR7HSA
0.6～0.7mm
Spark plug gap
0.6Ω±15％
Primary coil
Impedance of
trigger (20°C)
Secondary coil
There is a spark
plug cover
18.6KΩ±15％
There is no spark
plug cover
13.6KΩ±15％
Impedance of trigger (20°C)
240±20Ω
Maximum voltage in one measurement of ignition coil
15V
Trigger voltage
Above 1.7V
Tools
Accessories of maximum voltmeter
Multimeter
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 127 -
im
D
-
s
o
i
r
it
Ka
k
-d
2.2 Fault Diagnosis
Incorrect ignition (no spark)
Battery inspection
Not good
Charge or replace battery
Not good
Repair or replace damaged parts
Not good
Replace spark plug
Not good
Replace ignition coil
Not good
Electric
Good
Ignition system wire and connector inspection
Good
Spark plug inspection
Good
Primary coil peak voltage inspection
Good
Primary coil peak voltage inspection
lower than the specified value
Good
If ignition coil fails, replace it
Not good
The voltage is zero or
Check:
almost zero
Not good
1. Voltage of multimeter
2. Peak voltage of crankshaft sensor
a
3. Peak voltage of position sensor of camshaft
Not good
Check:
b
a
K
with a multimeter
s
o
i
test.
r
t
Good
Replace faulty parts or check them
1. The adapter is not properly connected or the adapter is faulty
2. Ignition switch and engine switch flames out
3. Peak voltage of crankshaft sensor
4. Peak voltage of position sensor of camshaft
.A
S
S
I
N
A
Good
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
-
Dim
i
R
B
A If electronic control unit is faulty, replace it
Replace faulty parts
T
O
M
- 128 -
is
n
ra
k
-d
2.3 Trigger
2.3.1 Disassembly of trigger
●Trigger [A] cannot be disassembled separately, because it
is integrated with alternator (see “Disassembly of
Alternator” for details)
●Use the tester
*Note
The trigger can be checked on the engine.
2.3.2 Inspection
● Remove trigger wire connector.
● Measure the impedance values of blue / white and green /
white outgoing lines of engine.
Standard value: 240±20Ω (20°C)
★ If the measured resistance value is higher than the
specified value, the coil circuit is disconnected and needs to
be replaced.
★ If the resistance value is lower than the specified value,
the coil is short-circuited and must be replaced.
a
2.4 Ignition Coil
b
2.4.1 Disassembly of ignition coil:
●Remove the fuel tank (see Chapter IX “Disassembly of Fuel
Tank” for details).
●Remove the spark plug cover [A]
●Remove the primary wire of ignition coil.
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
.A
S
S
I
N
A
R
B
A
T
O
M
is
n
ra
- 129 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Remove the ignition coil connector [A].
● Remove the clamp nut of ignition coil mounting bolt [A].
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 130 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Remove the ignition coil mounting bolt [A], and remove the
ignition coil [B].
●Install it in the reverse order of disassembly.
Torque value
Clamp nut of ignition coil mounting bolt 10-12N·m
2.4.2 Inspection of Ignition Coil
+
*Note
• When there is no spark in the spark plug, it is necessary
to check whether the parts of wiring are loosened or in
poor contact;
• There are many brands of multimeter, the internal
impedances are different and the tested values are
different.
●Check the primary coil
●Measure the impedance among the terminals of primary
coil.
Standard value: (0.6±10%)Ω（20℃）
★The impedance value is good in the standard value.
★If the impedance value is “∞”, it indicates that the wire in
the coil is disconnected and the ignition coil needs to be
replaced.
-
a
2.5 Spark Plug
b
2.5.1 Inspection of spark plug
●Disassemble spark plug (see section “disassembly of spark
plug”)
●Visually inspect the spark plug
○ If the center electrode of spark plug [A] and/or side
electrode [A] is corroded or damaged, or insulated
terminal [C] is broken, replace the spark plug
★If the spark plug is dirty or there is carbon deposit, replace
the spark plug
○Use a wire feeler to measure the gap [D]
○If the gap is incorrect, replace the spark plug
Spark plug gap: 0.6-0.7mm
○Use standard spark plugs or their equivalents
Spark plug: BR7ES/CR7HSA
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 131 -
im
D
-
s
o
i
r
it
Ka
k
-d
2.6 ECU
●System inspection
●Remove ECU and check the parts at wiring terminal
related to ignition system.
(See section “ECU” of electronic injection system for
details)
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 132 -
im
D
-
s
o
i
r
it
Ka
k
-d
Starter System
THE ON OFF SWITCH
BATTERY
B
RELAY
R
FLAMEOUT SWITCH
START SWITCH
a
G/Y O/R
B
O/R
G
R/W
G
is
n
ra
b
Gr
G/Y O/R
STARTOR MOTOR
im
D
-
s
o
i
r
it
Ka
MAIN SWITCH
Serial
number
Designation:
1
Klaxon
7
2
Voltage regulator
8
3
Ignition coil
4
Front right turn signal light
5
Headlight
6
Front left turn signal light
Y
A
W
O
OT
M
Y
P
O
C
Serial
number
.A
S
S
NI
Designation:
RAswitch
Ignition
B
A Gauge
Serial
number
Designation:
13
Accumulator
14
Taillight
Fuse box
15
Rear right turn signal light
10
Variable-frequency
flasher
16
License plate light
11
Relay unit
12
ECU
O
GE
K
E
9
RG
- 133 -
k
-d
III. Starter System
Preparatory Information--------------------- 3.1
Fault Diagnosis------------------------------- 3.2
Starter Motor----------------------------------3.3
Starter Relay---------------------------------- 3.4
3.1 Preparatory Information
Precautions for operation
Starter motor can be removed on the engine.
Starter clutch should be disassembled in accordance with the working procedures.
Technical parameters
Item
standard value
Operating limit
Length of starter motor brush
12.5mm
8.5mm
Stater idle shaft bushing
8.3mm
Outer diameter of starter idle shaft
7.94mm
a
Lock torque value
Starter motor clutch cover bolt
12 N•m
b
Tools
Mounting nut wrench
Universal fixing wrench
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 134 -
im
D
-
s
o
i
r
it
Ka
k
-d
3.2 Fault Diagnosis
3.2.1 Start failure
•The fuse is broken
•Insufficient battery power
•Detective ignition switch
• Defective starter clutch
• Defective brake switch
• Defective starter relay
• Defective connecting wire
• Defective starter motor
3.2.2 Too weak rotation force of starter motor
•Insufficient battery power
• Defective connecting wire
•The gear of starter motor is struck by foreign body
3.2.3 Starter motor can rotate but rotation engine cannot work
• Defective starter clutch
•Reverse rotation of starter motor
•Insufficient battery power
3.3 Starter Motor
a
3.3.1 Disassembly
*Note
b
Before disassembling starter motor, first turn off the main
switch, remove the bond strap of battery, then turn on the
power and check whether starter motor
is running to confirm safety.
remove starter motor cable [B] connector.
Remove the starter motor mounting bolt [A], and remove the
starter motor.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 135 -
im
D
-
s
o
i
r
it
Ka
k
-d
3.3.2 Installation
Install the starter motor in the reverse order of
disassembly.
Torque value
Starter motor mounting bolt
10-12 N•m
3.4 Starter Relay
3.4.1 Operation Inspection
Remove the body protector.
When the main switch is related to “ON”, check whether a
“click” sound is made
after turning on starter motor.
It is normal when a sound is made.
When there is no sound: • Check starter relay voltage.
•Check bond strap circuit of starter
relay.
•Check the operation of starter
relay.
Starter relay
3.4.2 Inspection of Voltage of Starter Relay
Erect main foot, and measure the voltage between the
negative electrode (green/yellow) of starter relay connector
and bond strap of motorcycle body.
Place the main switch at the position of “ON”, pull the brake
lever and ensure that the battery voltage meets the
regulations.
When no voltage is applied to the starter relay wire, check
the continuity and wire of brake switch.
R
B
A
K
E
RG
CO
Y
P
S.A
im
D
-
s
o
i
r
it Black
Bond strap
Starter relay
O
GE
O
T
O
M
is
n
ra
b
Ka
IS
N
A
Y
A
W
a
- 136 -
Green/
yellow
k
-d
3.4.3 Inspection of Bond Strap Circuit of Starter Relay
Remove starter relay connector.
Check the continuity between black wire connector terminal
and bond strap of body.
Ensure that the continuity between black wire connector
terminal and bond strap of body is good after start button is
pressed.
When it is nonconductive, check the continuity and wire of
start button.
Green yellow / line
3.4.4 Operation Inspection
Connect the starter relay to the battery and connect the
terminal of starter motor to multimeter.
Connect the fully charged battery between the black and
green/yellow wires of the relay. At this point, “Da” sound is
made in the relay and the resistance indication of multimeter
is “zero”.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 137 -
im
D
-
s
o
i
r
it
Ka
k
-d
Bulbs/Meters
a
is
n
ra
b
Ka
Serial
number
Designation:
Serial
number
Designation:
1
Klaxon
7
Ignition switch
2
Voltage regulator
8
Gauge
3
Ignition coil
9
Fuse box
4
Front right turn signal light
10
5
Headlight
6
Front left turn signal light
Y
A
W
O
GE
11E
G
R
12
CO
Y
P
.A
S
S
NI
RA
Variable-frequency
B
flasher
KA
Relay unit
ECU
O
T
O
M
Serial
number
- 138 -
im
D
-
s
o
i
r
itDesignation:
13
Accumulator
14
Taillight
15
Rear right turn signal light
16
License plate light
k
-d
IV. Bulbs /Switches/Meters
Preparatory Information---------------------------------- 4.1
Fault Diagnosis-------------------------------------------- 4.2
Replacement of Headlight Bulb------------------------- 4.3
Replacement of Front Turn Signal Light Bulb-------- 4.4
Replacement of Taillight Bulb--------------------------- 4.5
Replacement of License Plate Light Bulb--------------4.3
Meters------------------------------------------------------- 4.7
Ignition Switch---------------------------------------------4.8
Electric Horn----------------------------------------------- 4.9
Handlebar Switch------------------------------------------4.10
Inspection of Switch-------------------------------------- 4.11
Speed Sensor----------------------------------------------- 4.12
Oxygen sensor--------------------------------------------- 4.13
a
Fuel Level Sensor----------------------------------------- 4.14
Relay and Fuse Box--------------------------------------- 4.15
Fuse----------------------------------------------------------4.16
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 139 -
im
D
-
b
is
n
ra
s
o
i
r
it
Ka
k
-d
4.1 Preparatory Information
Precautions for operation
Switch can be removed from motorcycle for measuring the
continuity of switch.
All plastic connectors have claws. Remove the claws before
disassembly. Be sure to align the claws with the card when
reinstalling.
When looking for an electrical fault, check the continuity of
the circuit passing through the electronics.
Before performing any inspection, confirm the battery
status, including checking whether the battery voltage is
normal.
Lock torque value
Meter mounting holder mounting screw
Ignition switch mounting bolt
Horn mounting bolt
Oxygen sensor:
Fuel level sensor mounting nut:
5-7N·m
10-12N·m
10～12N.m
25 N·m
10 N·m
a
b
4.2 Fault Diagnosis
4.2.1 The “ON” light of main switch is off.
• Defective light bulb.
• Defective switch.
• The connector is in poor contact or disconnected.
• The power of battery is weak or there is no voltage.
R
B
A
K
E
RG
O
CO
Y
P
T
O
M
.A
S
S
I
N
A
O
E
G
Y
A
W
is
n
ra
- 140 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.3 Replacement of headlight bulb
4.3.1 Disassembly
Remove
Clamp screw [A]
Headlight [B]
Disconnect the headlight cable connector [A].
a
Remove the headlight
Take out
Headlight bulb [A]
Front position light bulb [B]
b
is
n
ra
*Note
When the bulb is on, keep the flammable product
and your hand at a distance from the bulb, because
the bulb is hot and should be cooled before it can be
touched.
I
N
A
R
B
A
K
E
RG
.A
S
S
EO
G
4.3.2 Installation Y
A
W
O bulb and front position light bulb
Install the frontT
headlight
O
M
- 141 Y
P
CO
im
D
-
s
o
i
r
it
Ka
k
-d
in the reverse order of disassembly.
*Note
Avoid touching the glass part of the bulb directly and do
not expose it to oil during installation.
Otherwise, it may affect the transparency, life and
luminous flux of bulb.
★ If it is stained with oil, wipe it thoroughly with a cloth
dampened with alcohol or volatile rubber water.
4.4 Replacement of Turn Signal Light Bulb
4.4.1 Disassembly
Remove
Self-tapping screw of turn signal light [A]
Turn signal light cover [B]
Turn signal light bulb [C]
Specifications
Turn signal light bulb Rl0W
4.4.2 Installation
The bulb should be installed in the reverse order of
disassembly.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 142 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.5 Replacement of Taillight Bulb
4.5.1 Disassembly
Remove
Self-tapping screw of taillight [A]
Taillight cover [B]
Taillight bulb [B]
Specifications
Turn signal light bulb P21/5W
4.5.2 Installation
The taillight bulb should be installed in the reverse order of
disassembly.
*Note
Ensure that the sealing washer of taillight cover is in the
good state and correct position when installing the taillight.
4.6 Replacement of License Light Bulb
a
is
n
ra
4.6.1 Disassembly
b
Remove
License plate light holder [A]
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 143 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove
License plate light bulb [A]
Specifications
License plate light bulb: W5W
4.6.2 Installation
The license plate light bulb should be installed in the
reverse order of disassembly.
4.7 Meters
4.7.1 Disassembly
Remove:
Meter and cable connector [A]
Remove:
Bolt M5×16[A]
Meter assembly [D]
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 144 -
im
D
-
s
o
i
r
it
Ka
k
-d
a
b
is
n
ra
.A
S
S
I
N
A
4.7.2 Installation
R
B
A
K
E
RG
The meter should be installed in the reverse order of
disassembly.
Torque value:
Meter holder mounting screw 5-7N·m
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 145 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.8 Ignition Switch
4.8.1 Disassembly
Remove the headlight. (see replace of headlight bulb-"Disassembly" for details)
Remove the power lock cable connector [A]
Check the conduction of connector terminal.
Color
Gear
Red
Brown
Diameter
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 146 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.8.2 Replacement of Ignition Switch
4.8.2.1 Disassembly
Remove the hexalobular socket pan head screw M6 × 20[A]
and replace the ignition switch [B].
4.8.2.2 Installation
The ignition switch should be installed in the reverse order
of disassembly.
Torque value:
Ignition switch mounting bolt 10-12N·m
4.9 Electric horn
a
4.9.1 Disassembly
Remove
Horn cable connector [A]
Mounting bolt [B]
Horn [C]
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 147 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.9.2 Installation
The horn should be installed in the reverse order of
disassembly.
Torque value:
Horn mounting bolt 10～12N.m
4.9.3 Inspection
Remove the horn wire.
If the horn sounds after being connected to the battery, it is
in good conditions.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 148 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.10 Handlebar Switch
Left Handlebar Switch
1. Dimmer switch
2. Steering switch
3. Horn switch
4. Passing switch
Dimmer switch
Blue
Yellow
/ red
Steering switch
Light
blue
Red /
white
Green / Black
black
Horn button
Green
/white
Red and Brown
white
Right handlebar switch (The headlight is very bright)
5. Light control switch
6. Stop switch
7. Starting switch
Red /
white
Orange/
blue
Blackish
green
Yellow/
red
Green/
yellow
Blackish
green
Red
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 149 -
im
D
-
s
o
i
r
it
Ka
k
-d
Right handlebar switch (The headlight is always on)
5. Warning switch
6. Stop switch
7. Starting switch
Green- Orange Greenwhite
black
Stop switch
Red
Dark
green
Start button
Greenish Dark
yellow green
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 150 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.11 Inspection of switch
● Use a handheld multimeter to check whether only the
switches in the table have been turned on
○ For the switch housing and main switch, refer to the table in the
wiring diagram section
★ If the switch is open or shorted, repair or replace it with
a new switch
4.11.1 Connect the rear brake light switch
Connect the rear brake light switch
Color
BR
BL
When the brake pedal
is pressed
When the brake pedal
is released
4.11.2 Connection of sidestand switch
Connect the sidestand switch
Color
BK
G
When the brake pedal
is pressed
When the brake pedal
is released
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 151 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.12 Speed sensor
4.12.1 Disassembly of speed sensor
Warning
Do not drop the sensor, especially on a hard surface.
The shock of impact may cause damage to the sensor.
●Remove the speed sensor (see 5.11.6)
4.12.2 Inspection of speed sensor
● Remove the speed sensor (see 5.11.6)
●Connect the speed sensor connector [A] and battery [B],
10kΩ resistor [C] and handheld multimeter [D], as shown in
the figure
●Set the multimeter to the range of DC 20V (digital
multimeter)
● Use a screwdriver to slide over the entire surface of speed
sensor, and adjust the end voltage from the battery voltage
value to about 0-1V
a
b
is
n
ra
4.12.3 Installation of speed sensor
● Install the parts that have been removed before in the
reverse order of disassembly.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 152 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.13 Oxygen sensor
4.13.1 Disassembly of oxygen sensor
Warning
Do not drop the sensor, especially on a hard
surface.The shock of impact may cause damage to the
sensor.
● Disconnect the oxygen sensor connector.
●Remove the oxygen sensor [A].
4.13.2 Inspection of oxygen sensor
● See section “Inspection of Oxygen Sensor” in the chapter
“Electronic Fuel Injection System”.
4.13.3 Installation of oxygen sensor
a
Warning
Do not drop the oxygen sensor [A], especially on a
hard surface.The shock of impact may cause damage
to the sensor.Do not touch the sensing part [B] of
sensor to prevent it from being polluted with oil
stains.Oil on your hands may affect sensor
performance.
● Tighten:
Torque-oxygen sensor: 25 N·m
● Operate the oxygen sensor wires correctly (see section
"Arrangement of Cables, Wires and Hoses" in Chapter
"Appendixes")
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 153 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.14 Fuel level sensor
4.14.1 Disassembly of fuel level sensor
●Remove the fuel tank (see 9.4.1).
● Remove the four tightening nuts [A] and remove the fuel
level sensor [B] and the fuel level sensor seal [C].
○Check sensor seal
★If the sensor seal is found to be broken or swelled, it must
be replaced!
4.14.2 Inspection of fuel level sensor
● Check whether the fuel sensor float is moving smoothly
and not stuck. It should move downwards under its own
weight.
★ If the float does not move smoothly, the sensor must be
replaced.
When the float is in the position of "full" [A]
When the float is in the position of "empty" [B]
Floating arm stopper [C]
● Use the hand-held multimeter [A] to measure the
resistance around the terminal of fuel level sensor connector
[B].
Special tool - handheld multimeter:
Pointer adapter device:
★
If the multimeter reading does not meet the
requirements, or does not change smoothly according to the
up and down movement of the float, replace the sensor.
Fuel level sensor component
Standard: full fuel level [C]: 5-12Ω
Empty fuel level: 96-103Ω
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 154 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.14.3 Installation of fuel level sensor
● Install the parts that have been removed before in the reverse
order of disassembly.
Locking torque:
Fuel level sensor mounting nut: 10 N·m
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 155 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.15 Relay and fuse box
4.15.1 Disassembly of relay and fuse box
● The relay is directly on the wire harness.
● The relay [A] is in the area under the front seat cushion.
a
●Open the upper cover when disassembling
● Pull out No. 1 and No. 4 relays [A]
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 156 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Unscrew the mounting bolts with five large socket head
wrench
●Remove the relay
*Note
The relay is equipped with a diode.The relay diode cannot
be removed
Warning
Do not drop the sensor, especially on a hard
surface.The shock on relay may cause damage to it.
4.15.2 Inspection of relay circuit
● Disassemble the relay (see the section "Removing relay").
● Check the conductivity of the terminals with the following
numbers by connecting a hand-held multimeter and a 12V
battery to the relay (see the internal circuit of relay box in
this section).
★ If the reading of multimeter does not meet the
requirements, replace the relay box.
4.15.3 Inspection of relay circuit (disconnect battery)
Connect the
multimeter
Reading of
multimeter (Ω)
3-4
∞
1-2
Not ∞*
7-8
∞
5-6
Not ∞*
11-12
∞
9-10
NOT ∞*
Fuel pump
relay
Main relay
Light relay
a
b
*: Actual readings may vary depending on the handheld multimeter used.
4.15.4 Inspection of relay circuit (with battery)S.A
Fuel
pump
relay
Connect
the
multimeter
1-2
3-4
M
Y
Multimeter
reading (Ω)
IS
N
A
R
B
A
K
E
RG
O
E
G
AY 7-8
5-6 W
O
OT
Main
relay
P
O
C
Battery
connection
(+) (-)
is
n
ra
0
0
- 157 -
im
D
-
s
o
i
r
it
Ka
k
-d
Light
relay
9-10
11-12
0
(+): Connect the positive wire
(-): connect the negative wire
4.15.6 Internal circuit of relay box
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
LG/B
R/W R/WGr/RB/RG/RBL/BR/B B DG LR B/RG/RR/W R Y/R
Fuel pump relay
ECU relay
油泵继电器 ECU继
电器
主Main
继电relay
器
Headlight relay
大
灯继电器
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 158 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
● State 1: relay
● State 2: relay
●The headlights are not always on. The relay of the
motorcycle does not contain the No. 3 relay in the state 1.
Others are the same as the above-mentioned export
inspection methods.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 159 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.16 Fuse
4.16.1 Disassembly of fuse
●Remove seat cushion (see 9.3.1)
●Remove the right cover (see Chapter VI)
●Remove the seat cushion mounting base [A]
● Remove the cover [A]
a
● Use a needle-nosed pliers to pull the main fuse [A] out of
the fuse holder in a straight line
Fuse: 40A
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 160 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Fuse box [A]
●Open the buckle and lift the cover [A] .
●Use a needle-nosed pliers to pull the main fuse [B] out of
the fuse holder in a straight line
Fuse line, as shown in the right figure
A. Fuel pump: 15A (blue)
B. Headlight: 15A (blue)
C. ECU: 15A (blue)
B. ABS: 15A (blue)
a
E. Power lock: 10A (red)
D. ABS：10A (red)
is
n
ra
G. Spare fuse 10A (red)
H. Spare fuse 15A (blue)
b
I. Spare fuse 15A (blue)
4.16.2 Installation of fuse
★ If the fuse fails during operation, check the
electrical system to determine the cause and replace it
with a one of suitable amperage
● Install the fuse box on the cover in the original
position as specified.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 161 -
im
D
-
s
o
i
r
it
Ka
k
-d
4.16.3 Inspection of fuse
● Disassemble the fuse (see 4.17.1)
●Check the fuse parts
★ If the fuse is burnt out, replace it with a new one. Check
the amperage of the affected circuit before replacing the
blown fuse. If the amperage is equal to or greater than the
rated current of the fuse, check the wiring and related
components to check whether it is shorted.
Housing [A]
Fuse component [B]
Joint [C]
Blown fuse [D]
Note
○If the battery is seriously undercharged, the fuse may be
burnt out by a large current after starting the engine.
Warning
When replacing the fuse, make sure that the new fuse
matches the rated current of specified fuse in the
circuit.If a fuse whose current is higher than the rated
value is installed, damage may be caused to the line or
components.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 162 -
im
D
-
s
o
i
r
it
Ka
k
-d
Inspection and Maintenance of Chassis
Torque Value Table of Chassis Fastener
Fastening location and fastener name
Tightening torque (N•m)
Front axle mounting nut
100～113N·m
Rear axle mounting nut
100～113N·m
Mounting bolt of front brake cylinder assembly
22～29N·m
Mounting bolt of rear brake cylinder assembly
22～29N·m
Mounting bolt of front fuel pump assembly
5～9N·m
Mounting bolt of rear fuel pump assembly
5～9N·m
Mounting bolt of front brake disc
10～12N·m
Mounting bolt of rear brake disc
10～12N·m
Brake line mounting bolt
30N·m
Front caliper mounting bolt
40∼44N·m
Rear view mirror mounting bolt
22∼29N·m
Meter mounting seat mounting bolt
10∼12N·m
b
Ka
Clamp bolt of upper bracket
Upper grip positioner mounting bolt
Y
P
CO
.A
S
Handlebar positioning double-end stud locknut
IS
N
RA
Steering column bearing locknut
B
A
K
E
Steering columnGbearing
nut
R
O
Ebolt
Upper clamp
of shock absorber
G
Y
A
W
Lower
O clamp bolt of shock absorber
T
O
M
- 163 -
im
D
-
is
n
ra
s
o
22∼29N·m
i
r
it
22∼29N·m
45∼50N·m
70N·m
2N·m
22∼29N·m
22∼29N·m
a
k
-d
Headlight bracket locknut
37∼44N·m
Clamp mounting bolt
10∼12N·m
Headlight mounting bolt
10∼12N·m
Nut at the top of rear shock absorber
45∼50N·m
Nut at the bottom of rear shock absorber
45∼50N·m
Mounting nut of rear rocker arm axis
85∼98N·m
Rear sprocket mounting nut
45∼50N·m
Front seat mounting bolt
40∼45N·m
Rear seat mounting bolt
10∼12N·m
Fuel tank mounting bolt
10∼12N·m
Mounting nut of fuel level sensor
5∼9N·m
Fuel pump mounting bolt
3∼4N·m
Sidestand bolt
45～50N·m
Locknut of side stand bolt
45～50N·m
Center stand bolt
45～50N·m
Locknut of center stand bolt
45～50N·m
Mounting screw of front pedal bracket
22～29N·m
Ka
is
n
ra
b
Front exhaust pipe mounting nut
Rear mounting bolt of muffler cylinder
I
N
A
.A
S
S
Lower mounting bolt of engine
R
B
Upper mounting bolt K
ofA
engine
E
G
Front mounting
OR bolt of engine
E
G
Y
Rear upper
mounting bolt of engine
A
OW
T
O
P
O
C
M
Y
- 164 -
im
D
-
s
o
i
r
it 22～29N·m
22～29N·m
45～50N·m
45～50N·m
45～50N·m
45～50N·m
a
k
-d
Upper hanging panel mounting bolt of engine
22～29N·m
Left front hanging panel assembly mounting screw of
22～29N·m
engine
Right front hanging panel assembly mounting screw of
22～29N·m
engine
Left rear hanging panel assembly mounting screw of engine
Right rear hanging panel assembly mounting screw of
22～29N·m
22～29N·m
engine
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 165 -
im
D
-
s
o
i
r
it
Ka
k
-d
ABS brake
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 166 -
im
D
-
s
o
i
r
it
Ka
k
-d
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 167 -
im
D
-
s
o
i
r
it
Ka
k
-d
Fluid brake ABS
A
B
C
D
E
Free stroke of brake lever: 10-20mm
Thickness of friction plate: 6.0 mm
Use limit: 3.0mm
Mounting torque value of bolt 3 in the
figure: 30 N·m
Mounting torque value of bolt 8 in the
figure: 22-29 N·m
Mounting torque value of nut 19 in the
figure: 10-12 N·m
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 168 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Chinese name and specifications
Torque
Number
of
N·m
kgf·m
1
Front fuel pump assembly
1
—
—
2
Washer
8
—
—
3
Fuel hose mounting bolt
4
30
3.0
4
Front fluid brake fuel hose assembly I
1
—
—
5
Front fluid brake fuel hose assembly II
1
—
—
6
Front left brake cylinder assembly
1
—
—
7
Brake pad assembly
1set
—
—
8
Double channel ABS assembly
1
—
—
9
Hexagon bolt with flange M6×20
1
10～12
1.0～1.2
10
Oil cup assembly
1
—
—
11
Rear fuel pump assembly
1
—
—
12
Rear brake cylinder assembly
1
—
—
13
Component of rear friction pad
1set
—
—
14
Rear fluid brake fuel hose assembly I
1
—
—
15
Rear fluid brake fuel hose assembly II
1
—
—
16
Bolt M8×25
2
22～29
2.2～2.9
17
Spring washer 8
2
—
—
18
Rear fluid brake bracket
1
—
—
19
Collar
2
—
—
Note
AL
R
R
AL
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 169 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
V. Brake
Preparatory Information--------------------- 7.1
Fault Diagnosis------------------------------- 5.2
Front Brake Disc----------------------------- 5.3
Rear Brake Disc------------------------------ 5.4
Fluid Brake and ABS------------------------ 5.5
5.1 Preparatory Information
Operation Precautions
*Note
• Do not expose the brake assembly to oil when installing or removing.
• Use specified cleaning agent to avoid reducing brake performance.
* Check brake before riding
Technical parameters
Item
Brake lever, brake pedal
Brake lever position
Free clearance of brake lever
Free clearance of pedal
Pedal position
Brake pad
Thickness of friction pad:
Front brake pad
Rear brake pad
Brake disc
Outer diameter:
Front brake disc:
Rear brake disc:
Thickness:
Front brake disc:
Rear brake disc:
Oscillation
Brake fluid
Grading
Y
P
CO
Standard
Lower operating limit
4-way adjustable (for riders to choose)
Nonadjustable
Adjustable
Approximately 20 mm above the top of the footpeg
–––
–––
–––
–––
6.0 mm
4.0 mm
Φ300mm
φ240mm
.A
S
S
I
N
A
R
B
A
K
E
RG
4.8 ∼ 5.0mm
4.8 ∼ 5.0 mm
≤TIR 0.15 mm
EO
G
Y
A
DOT4
W
- 170 -
is
n
ra
b
Ka
3 mm
3 mm
–––
–––
4.5 mm
4.5 mm
TIR 0.3 mm
–––
TO
O
M
-
-
Dim
s
o
i
r
it
a
k
-d
Torque value
Front wheel axle mounting nut
Rear wheel axle mounting nut
Mounting bolt of front brake cylinder assembly
Mounting bolt of rear brake cylinder assembly
Mounting bolt of front fuel pump
Mounting bolt of rear fuel pump assembly
Mounting bolt of front fluid brake disc
Mounting bolt of rear fluid brake disc
Brake tube mounting bolt
100-113 N•m
100-113 N•m
22-29 N•m
22-29 N•m
5-9 N•m
5-9 N•m
10-12 N·m
10-12 N·m
30 N·m
5.2 Fault Diagnosis
5.2.1 Poor brake performance
1. Proper adjustment of brake
2. Wear of brake shoe, friction pad assembly and fluid brake disc
3. Improper installation of brake shoe and friction pad assembly
4. Pollution of brake shoe, friction pad assembly and fluid brake disc
5.2.1 Slow reaction of brake or tight lever
1. Proper adjustment of brake
2. Wear of brake shoe, friction pad assembly and fluid brake disc
3. Improper installation of brake shoe and friction pad assembly
5.2.1 Abnormal noise of brake
a
1. Wear of brake shoe, friction pad assembly and fluid brake disc
2. Pollution of brake shoe, friction pad assembly and fluid brake disc
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 171 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.3 Front Brake Disc
5.3.1 Disassembly of front brake disc
Remove the front axle
Remove the front wheel. (see chapter “Front Wheel” –
“Disassembly”)
Remove the clamp screw [A] of front brake disc
Note:
After removing the front brake disc clamp screw, clean
the residual glue on the screw thread with alcohol.
Note:
When disassembling the clamp screw of front brake
disc, follow the instructions on the right figure
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 172 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.3.2 Installation of front brake disc
● Mount the brake disc on the wheel with the marked side
facing outward.
○ Mount the sensor rotor on the brake disc with the marked
side [A] facing outward
Insert the front brake disc into the edge of rim, and insert 6
clamp screws [A] after applying one drop of thread sealant
at the end of thread.
*Note
1. Shake the bottle to make the sealant return to even,
and prevent the nozzle from contacting with metallic
substances.
2. Each thread engagement position should be applied
with the sealant for more than 3-5 buckles, and the thread
clearance shall be filled with sealant.
Tighten the bolt to the brake disc in the form of a cross step
by step, and tighten 6 screws according to the following
torque value:
Torque value:
Clamp screw of brake disc 10-12N·m
a
b
*Note
• Do not expose the brake assembly to oil when installing
or removing.
• Use specified cleaning agent to avoid reducing brake
performance.
.A
S
S
I
N
A
R
B
A
*Note
K
E
RG
If there is grease on the brake shoe, braking performance
will be reduced and the brake will fail.
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 173 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.3.3 Inspection of front brake disc
Check the brake disc for wear, and replace it if necessary.
Measure the brake disc and record the maximum value.
If the thickness of brake disc is smaller than the maintenance
value, it should be replaced.
Specifications
Diameter of front fluid brake disc
Thickness of front brake disc:
Allowable limit:
Thickness of front brake disc:
*Note
φ300mm
5.0mm
4mm
• Use a micrometer
for measurement.
Measure the jump value at the edge of front brake disc
Available limit 0.15mm
5.4 Rear Brake Disc
5.3.1 Disassembly of rear brake disc
a
Remove rear wheel. (see chapter “Rear Wheel” –
“Disassembly”)
Remove the clamp screw of rear brake disc [A]
b
Note:
After removing the front brake disc clamp screw, clean the
residual glue on the screw thread with alcohol.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 174 -
im
D
-
s
o
i
r
it
Ka
k
-d
Note:
When disassembling the clamp screw of rear brake
disc, follow the instructions on the right figure.
5.3.2 Installation of rear brake disc
●Mount the brake disc on the wheel with the marked side
facing outward.
○ Mount the sensor rotor on the brake disc with the marked
side [A] facing outward
Insert the rear brake disc into the edge of rim, and insert 6
clamp screws [A] after applying one drop of thread sealant
at the end of thread.
a
is
n
ra
*Note
1. Shake the bottle to make the sealant return to even,
and prevent the nozzle from contacting with metallic
substances.
2. Each thread engagement position should be applied
with the sealant for more than 3-5 buckles, and the thread
clearance shall be filled with sealant.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 175 -
im
D
-
s
o
i
r
it
Ka
k
-d
Tighten the bolt to the brake disc in the form of a cross step
by step, and tighten 6 screws according to the following
torque value:
Torque value:
Clamp screw of brake disc
10-12N·m
*Note
• Do not expose the brake assembly to oil when
installing or removing.
• Use specified cleaning agent to avoid reducing
brake performance.
*Note
If there is grease on the brake shoe, braking
performance will be reduced and the brake will fail.
5.3.3 Inspection of rear brake disc
Check the brake disc for wear, and replace it if necessary.
Measure the brake disc and record the maximum value.
If the thickness of brake disc is smaller than the maintenance
value, it should be replaced.
Specifications
Diameter of rear fluid brake disc
Thickness of rear fluid brake disc
Allowable limit:
Thickness of rear fluid brake disc
*Note
φ240mm
5.0mm
4mm
• Use a micrometer for measurement.
Measure the jump value at the edge of front brake disc
Available limit
0.15mm
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 176 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.5 Brake lever, brake pedal
5.5.1 Adjustment of position of brake lever
●The brake lever adjuster has 4 positions so that the rider
can adjust the position of the brake lever according to the
size of his hand.
● Push the brake lever forward and rotate the adjuster [A] so
that the number is aligned with the arrow mark [B] on the
brake lever.
○ When the arrow mark is aligned with the number 4, the
distance between the brake grip and the brake lever is the
smallest; when the arrow mark is aligned with the number 1,
the distance between the brake grip and the brake lever is
the largest.
Front
5.5.2 Inspection of position of brake pedal
● Check whether the brake pedal [A] is in the correct
position.
Footpeg [B]
Pedal position [C]
Standard: approximately 20 mm above the top of the
footpeg
★ If the position of pedal is not correct, adjust the position
of brake pedal.
a
5.5.3 Adjustment of position of brake pedal
b
Note
○ Generally, it is not necessary to adjust the position
of the pedal, but if the push rod lock nut is removed,
the position of the pedal must be adjusted.
● Loosen the lock nut [A] and rotate the push rod [B] to
make the pedal n the correct position.
● Locking torque
Locking torque of push rod locknut of rear master
cylinder: 10 N·m
●Check whether the brake light switch is normal (see
“Inspection / Adjustment” – “Checking whether the brake
light switch is able to work normally” for details)
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
is
n
ra
T
O
M
- 177 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.5.4 Disassembly of brake pedal
●Disassemble:
Rear master cylinder mounting bolt [A]
●Disassemble:
Brake pedal return spring [A]
Link mounting screw [B]
Rear brake pedal mounting bolt and gasket [C]
Rear brake pedal [D]
5.5.5 Installation of brake pedal
a
● Apply grease to the rear brake pedal mounting shaft [A]
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 178 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Install:
Brake pedal [A],
Rear brake pedal mounting screw and gasket [B]
Torque value:
Locking torque of brake pedal bolt: 10-12 N•m
● Hang the lower end of the brake pedal return spring [A]
on the spring pin of frame.
● Hang the upper end of the brake pedal return spring [B] on
the spring pin of frame.
●Rear rear master cylinder mounting screw [A].
Locking torque of rear master cylinder mounting screw:
10 N·m
○Press the brake pedal [B], align the joint hole of master
cylinder, and install the mounting screw [C] and nut.
Locking torque of joint mounting screw of rear master
cylinder: 10 N·m
●Check the position of brake pedal (see "Checking the
Position of Brake Pedal" for details).
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 179 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.6 Caliper
5.6.1 Disassembly of front caliper
● Loosen the hollow bolt [A] at the lower end of the brake
hose and tighten it slightly.
●Unscrew the caliper mounting bolt [B], separate the caliper
[C] and the brake disc.
Note
Do not remove the caliper mounting bolts.To remove
the caliper, simply remove the caliper mounting bolts,
as brake fluid may leak after removing the caliper
mounting bolts.
● Remove the hollow bolt [A] and the brake hose on the
caliper
Note
If brake fluid spills out, rinse it immediately!
Note
○If you need to disassemble after removing the caliper
and there is no compressed air available, please
disassemble the caliper before removing the brake hose
(see “Removing the Front Caliper” for details).
5.6.2 Disassembly of rear caliper
● Loosen the hollow bolt [A] at the lower end of the brake
hose and tighten it slightly.
● Unscrew the caliper mounting bolt [B], separate the
caliper [C] and the brake disc.
Note
Do not remove the caliper mounting bolts.To remove
the caliper, simply remove the caliper mounting bolts,
as brake fluid may leak after removing the caliper
mounting bolts.
● Remove the hollow bolt [A] and the brake hose on the
caliper
Note
If brake fluid spills out, rinse it immediately!
Note
○If you need to disassemble after removing the caliper
and there is no compressed air available, please
disassemble the caliper before removing the brake hose
(see “Removing the Rear Caliper” for details).
a
b
is
n
ra
R
B
A
I
N
A
.A
S
S
K
E
5.6.3 Installation of caliper G
R
O
● Install the caliper and the lower end
of the brake hose.
E
G
○ Replace the gaskets on both
sides of the hose joint with
Y
A
new ones.
OW
● Locking torque
T
O
M
- 180 Y
P
CO
im
D
-
s
o
i
r
it
Ka
k
-d
Locking torque of caliper mounting bolt:
Front caliper: 34 N·m
Rear caliper: 25 N·m
Hollow bolt of brake hose: 25 N•m
● Check the level in the brake fluid reservoir.
● Discharge the air inside the brake line (see “Exhausting
the Air inside the Brake Line” for details).
● Check whether the performance of brake is normal and the
brake fluid leaks.
Warning
Clench the brake lever or step on the brake pedal until
the brake pad is against the brake disc, thus allowing
the brake pedal or brake pedal to perform its normal
function.Do not ride a motorcycle before completing
the above operations!If the above operations are not
completed, the brake lever or pedal may not work
properly when used for the first time.
5.6.4 Disassembly of front caliper
● Before removing the front caliper, first drain the front
brake fluid.
●Loosen front caliper mounting bolt [B] and hollow bolt
[A], and then gently remove them.
●Disassemble:
Front caliper [C] (see “Removing the Front Caliper” in the
chapter “Brakes”),
a
●Disassemble:
Front caliper assembly bolt [B]
Front caliper assembly bolt [C]
Front caliper [F]
Front caliper [F]
Front caliper [F]
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 181 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Remove the mounting pin [A] of brake pad
●Remove front brake pad spring [D], front left brake pad
[B], front right brake pad [C]
●Remove the piston with compressed air.
The method for removing piston is as follows:
○ Install a rubber gasket [A] and a wooden board [B] with a
thickness of 10 mm (0.4 in.) or more in the middle of the
caliper, and secure the rubber gasket and the wood board
with the appropriate bolts and nuts, as shown in the figure.
Open one of the oil ports [C].
○Inject the compressed air [D] into oil port slowly, until the
piston touches the rubber gasket. If the caliper is half open,
block the hose joint [E] during operation.
Press bolt [F] and nut: [G].
Warning
To avoid serious injuries, do not put your fingers or
palms in front of the piston!Otherwise, the piston may
crush your hands or your fingers when the
compressed air is injected into the caliper.
○ Pull out the piston by hands [A].
● Remove the dust seal [B] and the oil seal [C].
Note
a
○If compressed air is not available, remove the piston
from both calipers as follows (connect brake hose to
caliper).
○ Prepare a container to hold the brake fluid.
Front brake pad spring and brake pad (see “Removing
the Front Brake Plate” in the chapter “Brakes”).
○ Press the brake lever until the piston is pushed out of
the brake cylinder, and then remove the caliper.
b
.A
S
S
5.6.5 Assembly of front caliper
● Clean the caliper parts (except the brake pads).
Note
I
N
A
R
B
A
K
E
RG
Parts must be cleaned with disc brake fluid, isopropyl
alcohol or ethanol!
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 182 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Replace the oil seal [A] with a new one.
○ Add silicone grease to the oil seal and install it into the
brake cylinder by hands.
●If the dust seal [B] is broken, replace it with a new one!
○ Add silicone grease to the dust seal and install it into the
brake cylinder by hands.
● Apply brake fluid to the outside of piston [A] and press it
into the brake cylinder [B] by hands.
●Replace the guide post dust cover II [A] and the guide post
dust cover II [D].
● Apply grease to the guide post dust cover I [A] and the
guide post dust cover II [D], and install the guide post [B]
and the guide post [C].
● Apply some thread fastening glue to the threads of the
front caliper mounting bolts and tighten the bolts.
Locking torque of front caliper mounting bolt: 27 N·m
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 183 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.6.7 Disassembly of rear caliper
● Before removing the rear caliper, first drain the brake
fluid.
●Loosen the hollow bolt of rear caliper [A], and then gently
tighten them (Tighten them a little bit, and do not tighten too
much).
● Unscrew the caliper mounting bolt [B], separate the
caliper [C] and the brake disc.
●Disassemble:
Rear caliper [B] (see “Removing the Rear Caliper” in the
chapter “Brakes”),
Brake plate (see “Removing rear brake pad” in the chapter
“Brakes”),
Rear caliper assembly bolt,
O-Ring
● Remove the piston on the caliper as follows.
● The method of removing the piston on the caliper is the
same as the method of removing the front caliper.
● Use a piece of wood against the piston on the caliper,
blow compressed air into the brake hose joint to squeeze the
piston of caliper
Warning
To avoid serious injuries, do not put your fingers or
palms behind the piston!Otherwise, the piston may
crush your hands or your fingers when the
compressed air is injected into the caliper.
●Disassemble:
Oil seal [A],
Dust seal [B],
Guide post dust cover I [C],
Guide post dust cover II [D],
Dust cover of bleed screw [E]
a
b
is
n
ra
Note
○If compressed air is not available, remove the piston
from both calipers as follows (connect brake hose to
caliper).
○ Prepare a container to hold the brake fluid.
Front brake pad spring and brake pad (see “Removing
rear brake pad” in the chapter “Brakes”).
○ Press the brake lever to remove the caliper piston.
.A
S
S
I
N
A
R
B
A
K
E
G
5.6.8 Assembly of rear caliper
R
EO
● Clean the caliper parts (exceptG
the brake pads).
Y
Note
A
Parts must be cleaned
OW with disc brake fluid, isopropyl
T
alcohol or O
ethanol!
M
Y
P
O
C
- 184 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Install the bleed screw and bleed screw cap.
Locking torque of bleeder screw: 7.8 N·m
●Apply brake fluid to the inner wall of brake cylinder.
● Replace the oil seal [A] with a new one.
○ Add silicone grease to the oil seal and install it into the
brake cylinder by hands.
● Replace the dust seal [B] with a new one.
● Apply brake fluid to the outside of piston and press it into
the brake cylinder by hands.
●Replace the guide post dust cover II [C] and the guide post
dust cover II [D].
● Apply grease to the guide post dust cover I [C] and the
guide post dust cover II [D], and install the guide post [A]
and the guide post [B].
●Apply some thread fastening glue to the threads of the rear
caliper mounting bolts and tighten the bolts.
Locking torque of rear caliper mounting bolt: 37 N·m
Install brake pad (see “Installing rear brake pad” in the
chapter “Brakes”).
●Wipe the brake fluid splashed onto the caliper with a damp
cloth.
a
b
5.6.9 Inspection of fluid sea of caliper for damage
●In order to maintain a gap between the brake pad and the
brake disc, an oil seal (piston seal) [A] is placed around the
piston. If the oil seal is damaged, the brake pads may be
excessively worn and the brakes may fail, thus causing the
temperature of the brake pad or brake fluid to rise.
● If any of the following conditions occur in the fluid seal,
please replace it!
○ The brake fluid leaks around the brake pads.
○The brake temperature is too high.
○ The wears of the inner and outer surfaces of brake pad
vary greatly.
○ The oil seal and the piston are stuck together.
★ If you replace the oil seal, please replace the dust seal
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 185 -
is
n
ra
im
D
-
s
o
i
r
it
Ka
k
-d
[B]. In addition, all oil seals must be replaced each time
when the brake pads are replaced.
5.6.10 Inspection of dust seal of caliper for damage
● Check the dust seal [B] for cracks, wear, expansion or
other damage.
★ If any dust seal is damaged, please replace it with a new
one!
Piston [C],
Oil seal [A]
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 186 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.6.11 Inspection of the caliper piston and brake cylinder for damage
● Visually inspect the piston [A] and the brake cylinder
surface [B].
★ If the brake cylinder and piston are severely worn or
rusted, please replace the caliper!
5.7 Brake pad
5.7.1 Remove the front brake pad
a
● Before removing the front caliper, first drain the front
brake fluid.
●Loosen front caliper mounting bolt [B] and hollow bolt
[A], and then gently remove them.
●Disassemble:
Front caliper [C] (see “Removing the Front Caliper” in the
chapter “Brakes”),
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 187 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Remove the mounting pin [A] of brake pad
● Remove front brake pad spring [D], front left brake pad
[B], front right brake pad [C]
Note
When the pin A is pulled out, the safety spring B should
be pressed
5.7.2 Installation of front brake pad
● Push the caliper piston by hand as far as possible.
●Install:
Install it in the reverse order of disassembly.
● Check: brake fluid level [A]; if it is below the minimum
score, add the recommended brake fluid to the correct level.
● Check: Brake lever operation; if the brake lever is soft or
slight, exhaust the air in the brake circuit.
Warning
Grasp the brake lever until the brake pad is against
the brake disc, thus allowing the brake lever to
perform its normal function.Do not ride a motorcycle
before completing the above operations!If the above
operations are not completed, the brake may not work
properly when used for the first time.
5.7.3 Disassembly of Rear Brake Pad
a
● Remove the bolt [A] from the brake caliper and rotate the
rear caliper [C] in the B direction.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 188 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Completely lift rear brake caliper[C]
●Disassemble:
Brake pad [D]
5.7.4 Installation of rear brake pad
● Push the caliper piston by hand as far as possible.
●Install:
Install it in the reverse order of disassembly.
● Install the caliper (see “Installing Caliper” for details).
●Check brake fluid level [A]; if it is below the minimum
score, add the recommended brake fluid to the correct level.
● Check: Brake pedal operation; if the brake pedal is soft or
slight, exhaust the air in the brake circuit.
Warning
Grasp the brake lever until the brake pad is against
the brake disc, thus allowing the brake lever to
perform its normal function.Do not ride a motorcycle
before completing the above operations!If the above
operations are not completed, the brake may not work
properly when used for the first time.
a
b
5.7.5 Inspection of wear of brake pad
● See “Inspection / Adjustment” – "Inspection of Wear of
Brake Pad" for details.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 189 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.8 Master cylinder
5.8.1 Disassemble front master cylinder
● Loosen the hollow bolt [A] at the lower end of the brake
hose and tighten it slightly.
Note
Do not remove the caliper mounting bolts.To remove
the caliper, simply remove the caliper mounting bolts,
as brake fluid may leak after removing the caliper
mounting bolts.
●Disconnect the front brake light switch connector [A].
a
●Disconnect the front master cylinder mounting bolt [A].
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 190 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Remove the hollow bolt [A] and the brake hose on the
caliper [B]
Note
If brake fluid spills out, rinse it immediately!
● Remove the front master cylinder component.
●Disassemble:
Brake lever pivot shaft bolt [A]
Locknut [B]
Brake lever [C]
Front brake light switch mounting screw [D].
Spring shim [E]
Flat washer [F]
Front brake light switch [G]
Front master cylinder [H]
5.8.2 Installation of front master cylinder
●Install:
Install it in the reverse order of disassembly.
●Lock the upper clamp bolt [A] first, and then tighten the
lower clamp bolt [B].
Locking torque of front master cylinder fastening bolt:
10 N·m
●Replace the gaskets on both sides of the hose joint with
new ones.
● Locking torque
Locking torque for hollow bolt of brake hose: 30 N•m
● Discharge the air inside the brake line (see “Exhausting
the Air inside the Brake Line” for details).
● Check whether the performance of brake is normal and the
brake fluid leaks.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 191 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.8.3 Disassembly of rear master cylinder
●Remove the reservoir [A]
● Discharge the brake fluid into a container.
Note
If brake fluid spills out, rinse it immediately!
●Disassemble:
Rear brake light switch sensor [A]
Brake hose [B],
Fuel pump mounting screw [C]
Rear master cylinder [D]
Note
If brake fluid spills out, rinse it immediately!
5.8.4 Installation of rear master cylinder
● Replace the gaskets on both sides of the hose joint with
new ones.
●Install:
Install it in the reverse order of disassembly.
● Locking torque
Locking torque of rear master cylinder mounting screw:
10 N·m
Locking torque of rear brake light switch sensor: 30 N•m
●Discharge the air inside the brake line (see “Exhausting the
Air inside the Brake Line” for details).
●Check whether the performance of brake is normal and the
brake fluid leaks.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 192 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.8.5 Disassembly of front master cylinder
● Remove the front master cylinder (see “Disassembly of
Front Master Cylinder” in the chapter “Brakes”).
● Remove the reservoir cap mounting screw [F], reservoir
cap [E], connector [C] and O-ring.
● Unscrew the locknut [E] and the pivot bolt [F], and then
remove the brake lever.
● Remove the circlip [G].
Special tool—inside circlip pliers:
● Pull out the piston assembly [H].
Note
It is forbidden to remove the cup [I] from the piston,
because it may be damaged once removed.
●Replacement
Sealing cap: [A],
Circlip: [B],
O-ring seal: [D],
Circlip: [G],
Piston assembly: [H],
Diaphragm: [I].
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 193 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.8.6 Disassembly of rear master cylinder
● Remove the rear master cylinder (see “Disassembly of
Rear Master Cylinder” in the chapter “Brakes”).
● Remove the connector [H] and the seal [H].
● Slide the dust cover [A] out
● Remove the circlip [B].
Special tool—inside circlip pliers:
●Remove the piston assembly [D] and the return spring [F].
Note
It is forbidden to remove the cup [C] and cup [E] from
the piston, because it may be damaged once removed.
●Replacement
Dust cover [A]
Circlip: [B],
Piston assembly [D],
Seal [H],
Diaphragm: [I].
5.8.7 Assembly of master cylinder
● Before assembly, clean all parts with brake fluid or
alcohol, including master cylinder.
Note
Except brake pad and disc, other brake parts can only
be cleaned with disc brake fluid, isopropyl alcohol or
ethanol. Dot not clean the above parts with other
liquid.Gasoline, oil or other gasoline distillates may
corrode rubber parts.If oil spills onto any part, it will
be difficult to clean thoroughly and eventually corrode
the rubber parts inside the disc brake.
●Apply brake fluid to new parts and inner wall of brake
cylinder.
●Be careful not to scratch the piston or the inner wall of
brake cylinder.
●Apply silicon grease to the brake lever pivot bolt.
●Tighten the brake lever pivot bolt and locknut.
Locking torque of fastening screw of front brake fluid
reservoir cap: 1.2N·m
Locking torque of front brake lever pivot bolt: 3.0 N·m;
Locking torque of locknut of front brake lever pivot bolt:
6 N·m;
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 194 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.8.8 Check the master cylinder (visual inspection)
● Remove the master cylinder (see “Disassembly of Front /
Rear Master Cylinder” for details).
● Remove the front and rear master cylinders (see
"Inspection / Adjustment" - "Replacing Rubber Parts of
Master Cylinder" for details).
●Inspect the inner wall of each master cylinder and the outer
surface of each piston for scratches, rust or dents.
★ If any master cylinder or piston is damaged, please
replace them!
● Check the primary cup and secondary cup.
★ If the cup is worn, damaged, softened (corroded) or
swelled, the entire piston (including cup) should be replaced.
★ If you find that brake fluid is leaking from the brake
lever, replace the the entire piston (including cup)!
●Check the dust cover for damage.
★ If the dust cover is damaged, please replace it!
● Check whether the piston return spring is damaged.
★ If the piston return spring is damaged, please replace it!
● Check whether the relief port and supply port are blocked.
★ If the relief port is blocked, the brake pad may produce
resistance to the brake disc. Clean all oil holes using the
compressed air
5.9 Brake fluid
5.9.1 Inspection of level of brake fluid
● See "Inspection / Adjustment" — "Inspection of Level of
Brake Fluid" for details.
a
5.9.2 Replacement of brake fluid
●Park the motorcycle on a flat ground
Note
○Support the motorcycle with a parking rack and make
sure that it is upright
●Check brake fluid level
★ If it is lower than the minimum mark of oil immersion
lens [A], add the recommended brake fluid to the correct
level.
● Remove the brake fluid cylinder cover [B] from the brake
pump
● Check the brake fluid cylinder diaphragm on the cylinder.
If there is any damage/wear, please replace the brake fluid
cylinder diaphragm
Note
Brake fluid may quickly corrode the surface of
painted part, so if the brake fluid spills on any plastic
part, it must be thoroughly rinsed immediately.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 195 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Hold the brake handle and add brake fluid until the brake
fluid level is above the oil immersion lens of master cylinder
Warning
Use only the prescribed brake fluid.Other brake fluids
may cause deterioration of rubber gasket, thus
resulting in leakage and improper operation of brake
system.
Use the same brand of brake fluid in the process of
adding brake fluid.The mixture of different brake
fluids may cause harmful chemical reactions and thus
result in the reduction of brake system performance.
When adding brake fluid, be careful not to allow any
water to enter the container.Water will significantly
reduce the boiling point of the brake fluid, which will
generate steam bubbles when heated, and thus lead to
a reduction in brake system.
Note
○ The steps for replacing the front brake fluid are as
follows.The procedures for replacing the rear brake fluid
are the same as the procedures for replacing the front
brake fluid.
●Replacement of brake fluid
1. With the main cylinder level, remove the brake fluid
cylinder head.
2. Install the pipe on the front end of oil drain screw [A]
and prepare the oil pan at the front end of hose.
3. Loosen the oil drain screws.
4. Operate the brakes for several times until the oil drain
screw no longer discharges the brake fluid.
5. Tighten oil drain screw.
6. Inject the brake fluid above the lower limit.
7. Pull the brake handle to fill the brake fluid hose with
brake fluid.
8. Slowly move the brake handle until no bubbles appear
in the small holes in the brake cylinder and a force is
felt at the the brake handle.
9. Release the air.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 196 -
im
D
-
s
o
i
r
it
Ka
k
-d
After the adjustment is completed, install it in the reverse
order of disassembly.
Note
○ Frequently check the brake fluid level of reservoir and
replenish the new brake fluid as needed. If the brake fluid
in the reservoir is used up during the replacement of
brake fluid, the air in the brake hose must be drained.
● Remove the transparent plastic hose.
● Install the diaphragm and reservoir cap.
●Properly install the rear brake fluid reservoir cap according
to the following procedures.
○ First, tighten the front / rear brake fluid reservoir cap [B]
with your hands clockwise [C] until you feel a little
resistance, indicating that the cap has been fixed on the
reservoir of master cylinder of storage tank, then hold the
brake fluid reservoir cap [A] and rotate it by 1/6 turn [D].
● Tighten:
Locking torque of fastening screw of front brake fluid
reservoir cap: 1.2N·m
●Tighten the bleeder screw and install the rubber cover.
Locking torque of bleeder screw: 7.8 N·m
● After replacing the brake fluid, check whether the
performance of brake is good, whether the braking is
blocked, and whether the brake fluid leaks.
★ If necessary, blow out the air in the brake hose.
a
b
5.9.3 Exhaust the air inside the brake line
The brake fluid has a very small compression factor, so
almost all operations of brake lever or brake pedal are
transmitted directly to the caliper, thus producing a braking
effect. But the air is easy to compress. If air enters the brake
line, part of the operations of brake lever or brake pedal will
be used to compress the air, thus causing the brake lever or
brake pedal to become soft and reducing braking
performance.
.A
S
S
I
N
A
R
B
A
K
E
RG
Warning
If the brake lever or brake pedal is soft after replacing the
brake fluid or loosening the brake line joint, the air inside
the brake line must be exhausted.
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 197 -
im
D
-
s
o
i
r
it
Ka
k
-d
Note
○ The steps for exhausting the air from the rear brake line
are as follows.The steps of for exhausting the air from the
front brake line are the same.
Order of releasing the air
1. Remove the brake fluid cylinder head.
2. Remove the brake fluid cylinder diaphragm.
3. Install the pipe on the front end of oil drain screw and
prepare the oil pan at the front end of hose.
4. After braking for a few times, grasp the brake lever and
loosen the oil drain screw by about 1/2 turn, and then
tighten it again.
5. Repeat the above operations until all bubbles are
removed from the oil drain screw.
6. Install the brake fluid cylinder diaphragm
7. Install the brake fluid cylinder head
Note
○ The level of brake fluid must be checked frequently in
the process of exhausting the air, and replenish the fluid
as needed.If the brake fluid in the reservoir is completely
exhausted in the process of exhausting air, the exhaust
operation must be repeated because the air may have
entered the brake line.
○ To exhaust the air more thoroughly, tap the brake hose
between the caliper and reservoir.
Warning
The precautions for handling disc brakes are as follows:
1. It is forbidden to reuse brake fluid!
2. If the container containing the brake fluid is not sealed
or has been opened for a long time, the brake fluid inside
the container must not be used!
3. Do not mix brake fluids of different types or brands.
This will reduce the boiling point of the brake fluid,
resulting in brake failure or corrosion of rubber brake parts.
4. Do not open the reservoir cap for a long time to prevent
the brake fluid from getting wet.
5. Do not replace brake fluid in rain or strong winds!
6. In addition to brake pads and brake discs, only disc
brake fluid, isopropyl alcohol or alcohol can be used to
clean the brake parts. Do not clean the above parts with any
other liquid! Gasoline, oil or other gasoline distillates may
corrode rubber parts. Gasoline, oil or other gasoline
distillates may corrode rubber parts. If oil is splashed on
any part, it will be difficult to completely clean and
eventually corrode the rubber parts inside the disc brake.
7. When handling brake pads or brake discs, prevent any
brake fluid or other oil from splashing on them. If you
accidentally spill any brake fluid or other oil on the brake
pads or discs, clean them using solvent with a high flash
point! Do not use any solvents that may leave oily
residues! If the brake fluid or oil cannot be completely
removed from the brake pad, replace it with a new one!
8. The brake fluid may quickly corrode the surface of
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 198 -
im
D
-
s
o
i
r
it
Ka
k
-d
painted part, so if any brake fluid spills, it must be wiped!
9. The air in the brake line must be drained whenever the
brake line connector or exhaust valve is opened!
5.10 Brake hose
5.10.1 Disassembly / installation of brake hose and brake line
Note
Brake fluid may quickly corrode the surface of
painted part, so if the brake fluid spills on any plastic
part, it must be thoroughly rinsed immediately.
●Remove the hollow bolt of brake hose [A].
●When removing brake hose, be careful not to spill brake
fluid on any painted part.
●When removing brake hose [B], temporarily fix the end of
brake hose in a high place to minimize the loss of brake
fluid.
●If brake fluid overflows, clean it immediately.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 199 -
im
D
-
s
o
i
r
it
Ka
k
-d
a
b
is
n
ra
●All sides of brake line fittings are equipped with washers.
They needs to be replaced with new ones when installed.
● Tighten:
Locking torque for hollow bolt of brake hose: 25 N•m
● Avoid excessively bending, snarling, squeezing or twisting
the brake hose when installing, and arrange the brake hose
in accordance with the section "Winding Method of Cables,
Wires and Hoses" of chapter "Appendix".
●Fill the brake line with brake fluid after installing brake
hose. (See “replacement of brake fluid” for details).
.A
S
S
im
D
-
s
o
i
r
it
I
N
A
R
B
A
K
E
RG
EO
G
5.10.2 Inspection Y
of brake hoses and replacement of brake lines
A
OW
Note
T
O
M
- 200 Y
P
CO
Ka
k
-d
Brake fluid may quickly corrode the surface of
painted part, so if the brake fluid spills on any plastic
part, it must be thoroughly rinsed immediately.
Remove the rear brake hose clamp [A].
●When removing the rear brake hose, be careful not to spill
brake fluid on any painted part.
●When removing the rear brake hose [B], temporarily fix
the end of brake hose in a high place to minimize the loss of
brake fluid.
●If brake fluid overflows, clean it immediately.
●The rear brake fuel hose needs to be replaced with new
ones when installed.
● Avoid excessively bending, snarling, squeezing or twisting
the brake hose when installing, and arrange the brake hose
in accordance with the subsection "Winding Method of
Cables, Wires and Hoses" of chapter "Appendix".
●Fill the rear brake hose with brake fluid after installation.
(See “replacement of brake fluid” for details).
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 201 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.11 Anti-lock brake system (ABS)
5.11.1 Part position
a
1. Front wheel speed sensor
2. Gear ring of front wheel speed sensor
3. Rear wheel speed sensor
4. Gear ring of rear wheel speed sensor
5.ABS self-diagnosis system connector
6.ABS fuse box
7. ABS hydraulic mechanism
8. ABS indicator (LED).
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 202 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.11.2 ABS system circuit diagram
1. ABS Switch
2. Ignition Switch
3. Installation of Ground Wire
5. Ignition Fuse
6.ABS Fuse (40A)
7. Meter panel
8.ABS Diagnostic System Connector
9. Front Wheel Speed Sensor
10. Rear Wheel Speed Sensor
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 203 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.11.3 Pin name
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 204 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.11.4 ABS overhaul
5.11.4.1 Precautions for ABS overhaul
There are the following important precautions in the process of
overhauling the ABS system.
○The power supply of this ABS system must be supplied by a
12V sealed battery.Do not use any other power source!
○Do not connect the battery cable reversely. Otherwise, the ABS
hydraulic mechanism will be damaged.
○ To avoid damage to ABS parts, do not disconnect the battery
cable or any other electrical connectors while the ignition switch
is in the “ON” position or while the engine is running.
○Be careful not to short-circuit the wire that directly connect the
positive (+) electrode of the battery and the ground wire of the
chassis.
○If any ABS electrical connector is disconnected, do not turn the
ignition switch to “ON”! The ABS hydraulic mechanism will
remember the fault code.
○Do not spray water on electrical parts, ABS parts, joints, wires
and electric wires!
○If the motorcycle is equipped with a transceiver, ensure that the
operation of the ABS system is not affected by the radio waves
emitted by the antenna.The antenna shall be as far away as
possible from the ABS hydraulic mechanism.
○Turn the ignition switch to “OFF” before the ABS electrical
connector is disconnected.
○Do not hit the ABS parts with a hammer or drop the ABS parts
on a hard surface. Otherwise, the ABS parts will be damaged.
It is not allowed to disassemble the ABS parts!Even if it is found
that the ABS parts are faulty, do not disassemble the ABS parts
for repair. Please replace them directly!
ABS has many brake tubes and wires.And ABS can not detect the
faults of traditional brake systems (wear of brake disc, uneven
wear of brake pad and other mechanical faults).In order to
prevent faults, please check whether the brake tube is properly
connected, whether the electric wires are arranged correctly, and
whether the brake performance is normal.Remember to check the
brake fluid for leakage and completely discharge the air from the
brake tube!
Warning
If any brake tube connectors are loosened, including the
coupling nut or bleeder screw of the ABS hydraulic
mechanism, the air in the brake tube must be discharged.
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 205 -
is
n
ra
b
.A
S
S
I
N
A
R
B
A
Note
If there is air in the brake tube, do not ride the motorcycle,
otherwise the ABS will fail.
a
im
D
-
s
o
i
r
it
Ka
k
-d
○If the tire pressure is incorrect and the other tires or wheels
installed instead of those recommended by the manufacturer
are deformed, the ABS indicator (LED) [A] will be on. If the
indicator is on, please remove the faults and delete the fault
code!
Warning
If the other tires are used instead of those recommended
by the manufacturer, the ABS will fail and the braking
distance will increase, resulting in a traffic accident for
the rider. Therefore, this motorcycle must use the
standard tires recommended by the manufacturer.If the
other tires are used instead of those recommended by
the manufacturer, the ABS will fail and the braking
distance will increase, resulting in a traffic accident for
the rider. Therefore, this motorcycle must use the
standard tires recommended by the manufacturer.
○If the engine is started when the motorcycle is supported by
the bracket and it is not in the neutral position, the ABS
indicator (LED) will be on. If the indicator is on, turn the
ignition switch to “OFF” and clear the fault code (front wheel
speed sensor failure).
○ ABS will make noise when it is running, and the rider will
feel the reaction force of the brake rod and brake pedal. This
situation is normal and is intended to alert the rider that ABS is
running normally.○ ABS will make noise when it is running,
and the rider will feel the reaction force of the brake rod and
brake pedal. This situation is normal and is intended to alert
the rider that ABS is running normally.
○ Once the ABS hydraulic mechanism detects a fault code, it
will remember the fault code. Therefore, after the overhaul is
completed, remember to delete the fault code! However, do
not delete the fault code during troubleshooting. Please delete
the fault code until all inspections and repairs have been
completed to avoid the repeated entry of the previous fault
code and unnecessary overhaul work.
○ All the fault codes stored in the ABS hydraulic mechanism
must be deleted before the motorcycle is delivered to the
customer. Ensure that the ABS indicator (LED) will be on by
using the diagnosis features.In order to make the diagnosis
accurate, make sure that the battery is fully charged. Try riding
the motorcycle (driving speed: above 20km/h (12mph)) and
observe whether the ABS indicator (LED) will be on. Finally,
try riding the motorcycle (driving speed: above 30km/h
(20mph)), slam the brake and observe whether the motorcycle
can stop smoothly, and whether the ABS works normally (you
can feel the reaction force of the brake pad and brake
pedal).So far, the inspection process is finished.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 206 -
is
n
ra
im
D
-
s
o
i
r
it
Ka
k
-d
5.11.4.2 Overview of ABS fault removal
If an error occurs to ABS, the ABS indicator (LED) will be
on to alert the rider. In addition, the fault information will be
stored in the memory of the ABS hydraulic mechanism.
Therefore, after faults are removed, you must delete the fault
code and start the diagnostic program to confirm that the
signal output is normal. If the ABS fault indicator (LED) is
constantly on, first thoroughly find out the background of the
fault and then start the repair work.For example, ask the rider
about the current situation [B] when the fault occurs and try
to determine the cause of the fault [C].Do not completely rely
on the ABS self-diagnosis function, and combine common
sense to remove faults.For example: Check whether the brake
performance is normal, whether the brake fluid level is
correct and whether the brake fluid leaks.
Under the following circumstances, the ABS indicator
(LED) will be on even if ABS is running normally.At that
time, please turn the ignition switch to “OFF” to turn off the
indicator. If you ride the motorcycle again without deleting
the fault code, the indicator will become on again.
○ The rider rides the motorcycle on the undulating road all
the time.
○ When the motorcycle is supported by the bracket, the
engine is started and is not in the neutral position, and the
rear wheel is rotated.
○ The front wheel leaves the ground due to sudden
acceleration.
○ ABS is suffered from severe electrical interference.
○ The tire pressure is abnormal.Please adjust the tire
pressure!
○ The tires with different specifications from those of
standard tires are used.Please replace them with standard
tires!
○ The wheels are deformed.Please replace the wheels!
Most ABS fault removal work involves verifying
whether the circuit is normal.The ABS parts have been
assembled and adjusted by the manufacturer, so there is no
need to disassemble or repair the ABS parts.However, the
ABS hydraulic mechanism can be replaced if necessary.
The basic fault removal steps are shown below:
●Carry out the pre-diagnosis inspection (preliminary
inspection).
●Determine the fault by using the self-diagnostic function.
●Check the joints of the ABS hydraulic mechanism and the
circuits and connectors between the suspected faulty ABS
parts with a multimeter.
Special tool: Multimeter:
a
b
K
E
RG
O
O
CO
Y
P
T
O
M
.A
S
S
I
N
A
R
B
A
E
G
Y
A
W
is
n
ra
- 207 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Visually check whether the electric wires are burnt or worn.
★ If any electric wires are damaged, please replace them!
● Disassemble each connector [A] and check whether the
inside is corroded, dirty or damaged.
★ If any connector is corroded or contaminated, carefully
clean it!If the connector is damaged, replace it!
● Check whether the circuit is normal.
○ Find both ends of the wire that may fail by using the circuit
diagram.
○ Connect the multimeter with both ends of the wire.
Special tool—multimeter:
○ Set the range of the multimeter to ×1Ω, and then read the
reading of the multimeter.
★ If the reading of the multimeter is not 0Ω, it indicates that
the wire is damaged.Replace the main cable [B] if necessary.
● Repeat the conduction detection of the circuit to reduce the
number of the parts that may fail and then detect the ABS
parts.
★ If the circuit and the connectors are normal, the next
suspect object is the ABS parts, and they shall be detected
one by one.
★ If it is found that any ABS part is abnormal, please
replace it!
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 208 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.11.4.3 ABS diagnostic flow chart
A fault occurs
Identify the fault
Collect information from the rider
Carry out the pre-diagnosis
inspection (Phase 1 and Phase 2).
Make diagnosis
Check by other means than diagnosis
Check by diagnosis
If there is a problem with the cable or connector
If there is a problem with the ABS part
Repair or replacement
Check ABS parts
With Replacement
NG
Final inspection
OK
End
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 209 -
im
D
-
s
o
i
r
it
Ka
k
-d
Questions need to be asked for the rider
○ Each rider reacts differently to the fault, so it is necessary to confirm which problem the rider is experiencing.
○ By asking the rider, find out what went wrong and under what circumstances.Only by knowing clearly about the faults
can you help yourself to reproduce the problem in the workshop.
○ Diagnostic tables can help you avoid ignoring any key points, so you must use a diagnostic table.
Sample of diagnostic table
Name of rider:
Registration number (license plate number):
First registration year:
Model:
Engine number:
Frame number
Date of fault:
Frequency:
Weather
Mileage:
Phenomenon
□The brake lever
vibrates or makes
noise
□The indicator
light is flashing
□The brake pedal
vibrates or makes
noise
□The indicator
light is always
on
□Brake
distance
is
too
long
□The brake
lever moves
abnormally
□ The brake
pedal
is
moving
abnormally
□ABS
failure
□ABS can
run, but the
indicator
light is out
□ ABS runs
too
frequently
□ At startup
The state of engine in the event
□ After startup
of a fault
□Speed: ≥5000r/min
Road conditions
□The road surface is very slippery (□ snow road, gravel road, □ other)
□The road is undulating
□Other
Driving conditions
□Turn a corner at high speed
□ Driving speed ≥10km/h (6mph)
□ Driving speed ≥10km/h(6mph)
□ Parking
□Turn a corner
Brake
□ Gentle braking
□ Sudden braking
Other conditions
□The brake lever stroke is large
□ The pedal stroke is large
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 210 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.11.4.4 Carry out the pre-diagnosis inspection (Phase 1)
● Level in the brake fluid reservoir.
NG
Replenish brake fluid.
NG
Repair the brake line.
NG
Repair or replace the master cylinder.
NG
Replace the defective parts.
NG
Repair or replace the caliper.
NG
Replace the wheel bearing or rear axle.
OK
Check the brake fluid for leakage.
OK
Check the function of the brake lever and brake pedal.
OK
Check the brake pads and brake discs.
OK
The front and rear wheels should be able to rotate smoothly
without any braking resistance.
OK
The free clearance of the wheel bearing should not be too
large.
The bending amount of rear axle or the runout of brake disc
should not be too large.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 211 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.11.4.5 Carry out the pre-diagnosis inspection (Phase 2)
Check the ABS indicator (LED).
No (not be on)
○ Is the indicator light on after the ignition
switch is turned "on"?
Check power cables and meter panels
Yes
Check whether the light is flashing after
pressing and holding the ABS switch for 3-5
seconds.
No (not flash)
Check the cable line, check whether the
connector is plugged in properly, and check
whether the front and rear wheel speed sensors
are damaged.
Yes
Is the indicator light on after the ignition
switch is turned "off" and then "on"?
No (not be on)
Check power cables and meter panels
Yes (on)
Drive for more than 1 minute (including 1
minute) at ≥6km/h (3.7mph)
Is the indicator light off when the motorcycle is Yes
running?
ABS is normal
No
Make a diagnosis and find the fault code for repair or
replacement.
Ask the rider whether the fault has occurred again.
5.11.4.6 Overview of diagnosis
The ABS hydraulic mechanism will remember and store the fault code so that the service personnel can easily
troubleshoot it. The fault code memory is directly powered by the battery and cannot be removed by the ignition switch.
The ABS hydraulic mechanism is able to remember all the fault codes (6 codes). If there are more fault codes, all the
existing fault codes (6 codes) must be deleted before they can be stored in the ABS hydraulic mechanism. If there is no
fault, the ABS indicator (LED) light will be on, indicating that "ABS is OK".
Self-diagnostic procedures
○If any fault occurs in ABS, the ABS indicator (LED) [A]
will be on.
b
is
n
ra
Note
○ A fully charged battery must be used for diagnostics,
otherwise, the indicator light may flash very slowly or not
flash.
○The motorcycle is in a stopped state.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 212 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
5.11.4.7 Check the ABS indicator (LED)
● Rotate the ignition switch to "ON".
★ If the ABS indicator light (LED) [A] is on for a while
and automatically goes out, it is normal.
★ If the ABS indicator light (LED) is always on, skip to the
following steps: “ABS indicator light (LED) is on
(motorcycle is driving – no fault code)”.
● Rotate the ignition switch to "OFF".
★ If the ABS indicator light (LED) [A] is out, it is normal.
★ If the ABS indicator light (LED) is always on, skip to the
following steps: “ABS indicator light (LED) is on (rotate the
ignition switch to "OFF")”.
5.11.4.8 ABS indicator (LED) is on (rotate the ignition switch to "OFF")
● Conduct the Step I of test.
○ Check the pin voltage between the black/white lead
terminal of the meter connector [A] and the ground wire.
Special tool—multimeter:
○ Rotate the ignition switch to "ON".
Pin Voltage
Standard: about 10V
★ If the pin voltage is not within the specified range,
perform the Step II.
★ If the pin voltage is correct, replace the meter.
● Conduct the Step II of test.
○ Disconnect the meter connector.
○ Check the line between the black/white lead terminal of
the connector at main cable side [A] and the ground wire.
★ If the line is normal, replace or repair the main cable.
★ If the line is abnormal, perform Step III.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 213 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Conduct the Step III of test.
○ Disconnect the ABS hydraulic mechanism connector.
○ Check the line between the black/white lead terminal of
connector at the main cable side [A] and the black/white
lead terminal of connector at the main cable side [B].
★ If the line is normal, replace the ABS hydraulic
mechanism.
★ If the line is abnormal, replace or repair the main cable.
5.11.4.9 ABS indicator (LED) is on (motorcycle is driving - no fault code)
●Test
○ Disconnect the ABS hydraulic mechanism connector and
meter connector.
○ Check the line between the black/white lead terminal of
ABS connector at the main cable side [A] and the
black/white lead terminal of wheel speed sensor connector at
the main cable side [B].
Check the front/rear wheel speed sensor and gear ring for
damage.
Check whether the ABS fuse on the cable is normal.
Special tool—multimeter:
★ If the line, front/rear wheel speed sensor and gear ring
are normal, and the fuse is also normal, replace the ABS
hydraulic mechanism.
★ If the line, front/rear wheel speed sensor and gear ring,
fuse are not normal, replace or repair them.
Battery terminal voltage
Standard: battery voltage ≥ 12V
a
★ If the battery terminal voltage is not within the specified
range, replace the battery.
★ If the battery terminal voltage is normal, perform the
next step.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 214 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.11.4.10 The difference between front and rear wheel speeds is abnormal (fault code:
front: C0084~C0088; rear: C0104~C0108)
● Conduct the Step I of test.
○Perform the following checks and repair defective parts.
The tire pressure is abnormal;
Non-recommended standard tires are installed on
motorcycles (tire specifications are incorrect);
Deformation of wheel or tire;
the rotating teeth of sensor rotor are cracked or blocked by
foreign matters.
★If the above parts are normal, perform Step II.
● Conduct the Step II of test.
○Recheck the fault code; delete the fault code and regain the
fault code.
★If the ABS indicator light (LED) [A] is on, the ECU fault
code indicates that the ABS hydraulic mechanism is faulty.
Therefore, the ABS should be replaced.
★If the ABS indicator light (LED) is out, the ABS is normal
(no fault code is stored; temporary fault).
5.11.4.11 Wheel speed sensor is open or shorted (front: C0080~C0083; rear:
C0100~C0103)
○Check whether the ABS sensor connector is loose or not
inserted properly
○Check whether the ABS sensor is damaged
★ If the wheel speed sensor is damaged, replace the wheel
speed sensor.
5.11.4.12 Check the line of wheel speed sensor (fault code: front: C0080-C0083; rear:C0100-C0103)
nis
ra
● Conduct the Step I of test.
○ Disconnect the ABS hydraulic mechanism connector and
the front wheel speed sensor connector.
○ Connect the two lead terminals of connector at the main
cable side with a jumper and check the line between the two
lead terminals of connector at the main cable side.
★ If the line is not normal, perform Step II.
★ If the line is abnormal, replace or repair the main cable.
.A
S
S
I
N
A
R
B
A
● Conduct the Step II of test.
○ Connect the two lead terminals of connector at the main
cable side with a jumper and check the line between the two
lead terminals of connector at the main cable side.
★If the line is normal, replace the front wheel speed sensor.
K
E
RG
CO
EO
G
Y or repair the main cable.
★ If the line is abnormal,
replace
A
OW
T
O
M
Y
P
- 215 -
im
D
-
s
o
i
r
it
b
Ka
a
dk
5.11.4.13 Relay fault (C0044-C0046)
★ Replace ABS.
5.11.4.14 ABS normally open valve solenoid circuit is open-circuited or the resistance
is too large (front: C0121; rear: C0161)
★Replace ABS.
5.11.4.15 ABS normally closed valve solenoid circuit is open-circuited or the resistance
is too large (front: C0131; rear: C0171)
★ Replace ABS.
5.11.4.16 ABS voltage is too high, ABS voltage is too low (too high: C0053; too low:
C0047, C0052)
Standard: battery voltage ≥ 12V
★ If the battery terminal voltage is not within the specified
range, replace the battery or charge and discharge.
5.11.4.17 ABS pump or motor fault (C0070-C0074)
★ There is still a fault after ensuring the line is normal.
Please replace the ABS.
5.11.4.18 Intermittent signal of wheel speed sensor (front: C0084-C0088; rear:
C0104-C0108)
○ Check whether the clearance between the wheel speed
sensor and the gear ring surface is between 0.5-1.2 mm.
○Check whether the wheel speed gear ring is deformed or
any tooth is missing
★ If the clearance is not within the range, adjust the
clearance
★ If wheel speed gear ring is damaged, replace wheel
speed gear ring
a
5.11.4.19 ABS wheel speed difference is too high
○ Check whether the wheels or tires with different
specifications have been replaced
○Check whether the tire is winded in situ
★Use the wheel and tires the same as the originals
★ Please turn off the electric door lock after the tire is
winded in situ, then open the electric door lock
b
.A
S
S
5.11.4.20 Brake diode breakdown (C0062)
○Check whether the diode of the main cable of the
motorcycle body harness is intact
★ If the diode is damaged, replace it
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 216 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.11.4.21 Brake switch line fault (C0060-C0061)
○ABS function will not be affected. Please disconnect the
ABS hydraulic mechanism connector and check the line
between brake signal cable to the ABS connector.
★ If the line is normal, please repair the main cable.
★ Test it for several times; if the line is normal, please clear
the fault code and retest the ABS.
5.11.4.22 ABS indicator light (LED) fault (C0210-C0213)
○ Disconnect the ABS hydraulic mechanism connector and
check the line between ABS indicator cable to the ABS
connector terminal.
★If the line is abnormal, please repair the main cable.
★ If the line is normal, please replace the meter panel and
retest.
5.11.4.23 Speed output port fault (C0230-C0231)
○ Disconnect the ABS hydraulic mechanism connector and
check the line between wheel speed output port to the ABS
connector terminal.
★If the line is abnormal, please repair the main cable.
★ If the line is normal, please replace the meter panel and
retest.
5.11.4.24 Front wheel speed sensor signal is abnormal (fault code: C0084-C0088)
● Conduct the Step I of test.
○ Measure the clearance between the front wheel speed
sensor and the sensor rotor.
Feeler gauge [A]
b
Clearances
Standard: 0.5-1.2mm (0.02-0.047in.)
★ If the measured value is beyond the above standards,
check each part for deformation or looseness and adjust
accordingly.
Re-measure the clearance.
★ If the measured value is normal, perform Step II.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 217 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
● Conduct the Step II of test.
○ Check whether there are iron filings or other magnetic
deposits between the sensor [A] and the sensor gear ring
[B], and whether the groove of sensor gear ring is clogged.
○ Check the installation of the sensor and observe whether it
is loose.
○ Check the tip of the sensor and sensor gear ring for
deformation or damage (eg, the teeth of the sensor gear ring
are notched).
★ If the sensor and sensor gear ring are in poor conditions,
clean the deposit on it and reinstall or replace the defective
parts correctly.
★ If the above parts are normal, perform Step III.
● Conduct the Step III of test.
○ Recheck the fault code; delete the fault code, perform the
pre-diagnosis check (Phase I and II), and re-read the fault
code.
★ If the ABS indicator light (LED) [A] is on, the ECU fault
code indicates that the ABS hydraulic mechanism is faulty.
Therefore, the ABS hydraulic mechanism should be
replaced.
★ If the ABS indicator light (LED) is out, the ABS is
normal (no fault code is stored; temporary fault).
5.11.4.25 Rear wheel speed sensor signal is abnormal (fault code: C0104-C0108)
● Conduct the Step I of test.
○ Measure the clearance between the rear wheel speed
sensor and the sensor gear ring.
Feeler gauge [A]
Clearances
Standard: 0.5-1.2mm (0.02-0.047in.)
a
b
★ If the measured value is beyond the above standards,
check each part for deformation or looseness and adjust
accordingly.
Re-measure the clearance.
★ If the measured value is normal, perform Step II.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 218 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Conduct the Step II of test.
○ Check whether there are iron filings or other magnetic
deposits between the sensor [A] and the sensor gear ring
[B], and whether the groove of sensor gear ring is clogged.
○ Check the installation of the sensor and observe whether it
is loose.
○ Check the tip of the sensor and sensor gear ring for
deformation or damage (eg, the teeth of the sensor gear ring
are notched).
★ If the sensor and sensor gear ring are in poor conditions,
clean the deposit on it and reinstall or replace the defective
parts correctly.
★ If the above parts are normal, perform Step III.
● Conduct the Step III of test.
○ Recheck the fault code; delete the fault code.
★ If the ABS indicator light (LED) [A] is on, the ECU fault
code indicates that the ABS hydraulic mechanism is
faulty.Therefore, the ABS hydraulic mechanism should be
replaced.
★ If the ABS indicator light (LED) is out, the ABS is
normal (no fault code is stored; temporary fault).
5.11.4.26 Check ECU (fault code: C0044-C0046)
● Conduct the Step I of test.
○ Recheck the fault code; delete the fault code, perform the
pre-diagnosis check (Phase I and II), and re-gain the fault
code.
★ If the ABS indicator light (LED) [A] is on, the ECU fault
code indicates that the ABS hydraulic mechanism is faulty.
Therefore, the ABS hydraulic mechanism should be
replaced.
★ If the ABS indicator light (LED) is out, the ABS is
normal (no fault code is stored; temporary fault).
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 219 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.11.5 ABS hydraulic mechanism
5.11.5.1 Disassemble ABS hydraulic mechanism
Note
The ABS hydraulic mechanism have been
precisely set and adjusted before leaving the
factory, so care must be taken during operation.
Never use a hammer to strike it or drop it on a
hard surface and prevent it from touching or be
stuck to the mud.
● Discharge the brake fluid from the front brake line and the
rear brake line.
○Press the brake lever and pedal to release the brake fluid
through the bleed screw.
●Disassemble:
battery (see “Electrical System” - “Removal of Battery”).
●Disassemble
Bolt [A]
●ABS cover [B]
a
is
n
ra
● Clean the ABS hydraulic mechanism.
Note
Clean all connectors on the ABS hydraulic
mechanism and the rear master cylinder, as the
dirt around the hollow bolts may contaminate the
brake fluid during the removal/installation of
brake line.
Before removing the brake hose, lay a rag
around the ABS hydraulic mechanism to prevent
the brake fluid from seeping into the parts.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 220 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Remove the brake line connecting bolts [A], [B], [C], [D].
● Seal the opening of brake hose with a tape to prevent
brake fluid from leaking or foreign matter from
contaminating the brake fluid.
Note
Brake fluid may quickly corrode the painted
part, so if the brake fluid spills on any plastic
part, it must be thoroughly rinsed immediately.
● Disconnect the connector [A].
○ Loosen the connector [B] by the method as shown on the
right.
●Remove the bolt [A].
●Remove the ABS hydraulic mechanism and bracket [B].
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 221 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Remove the bolt and bracket.
Note
ABS hydraulic mechanism has been precisely set and
adjusted before leaving the factory, so do not
disassemble and repair the ABS hydraulic mechanism!
5.11.5.2 Install ABS hydraulic mechanism
● Install the ABS hydraulic mechanism on the bracket [B].
Note
Brake fluid may quickly corrode the painted part, so
if the brake fluid spills on any plastic part, it must be
thoroughly rinsed immediately.
●Lock the bolt [A] to the frame.
●Arrange the wires correctly and securely fasten the
connector [A].
○ Mount the joint [B] by the method as shown on the right.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 222 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Install the brake line correctly, as shown in the figure.
● Lock the brake line connecting bolts [A], [B], [C], [D].
Locking torque for connecting nut of brake line: 17 N•m
● Discharge the air inside the brake line (see “Exhausting
the Air inside the Brake Line” for details).|
● Check whether the performance of brake is normal and the
brake fluid leaks.
●Install the parts disassembled previously (see the
corresponding chapters).
5.11.5.3 Check ABS hydraulic mechanism
●Remove the ABS hydraulic mechanism (see “Removing
the ABS Hydraulic Mechanism” for details).
● Visually inspect ABS hydraulic mechanism.
★ If the ABS hydraulic mechanism is cracked or damaged,
please replace it!
● Visually inspect the connector terminal [A].
★ If the ABS hydraulic mechanism or main cable is
cracked, bent or damaged, please replace it!
★ If the ABS hydraulic mechanism connector is blocked by
mud or dust, blow it off with compressed air.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 223 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.11.6 Speed sensor
5.11.6.1 Remove front wheel speed sensor
Note
Wheel speed sensors are precisely machined, so
care must be taken during operation. Never use a
hammer to strike it or drop it on a hard surface and
prevent it from touching or be stuck to the mud.
Do not disassemble or repair the wheel speed
sensor!
●Disassemble:
Headlight [see "Removing Headlight" for details],
Front wheel speed sensor connector [A]
● Remove the connector.
●Disassemble:
Bolt [A]
Front wheel speed sensor [B]
a
b
is
n
ra
5.11.6.2 Install front wheel speed sensor
●Install it in the reverse order of disassembly.
○Properly arrange the wire (see "Appendix" - "Winding
Method of Cables, Wires and Hoses" for details).
.A
S
S
I
N
A
R
B
A
K
E
G sensor
5.11.6.3 Remove rear wheel speed
R
EO
G
Note
Yare precisely machined, so
A
Wheel speed sensors
OWduring operation. Never use a
care must beTtaken
O
M
Y
P
O
C
- 224 -
im
D
-
s
o
i
r
it
Ka
k
-d
hammer to strike it or drop it on a hard surface and
prevent it from touching or be stuck to the mud.
Do not disassemble or repair the wheel speed
sensor!
●Disassemble:
Right cover (see “Removing Right Cover” for details).
Rear wheel speed sensor connector [A]
● Remove the connector.
●Disassemble:
Bolt [A],
Rear wheel speed sensor [B]
5.11.6.4 Install rear wheel speed sensor
a
●Install it in the reverse order of disassembly.
○ Properly arrange the wire (see "Appendix" - "Winding
Method of Cables, Wires and Hoses" for details).
b
5.11.6.5 Check front wheel speed sensor
●Remove the front wheel speed sensor [A] from the front
fork.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 225 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Remove the rear wheel speed sensor from the caliper
bracket [A]
●Visually inspect wheel speed sensor.
★ If the wheel speed sensor is cracked, bent or damaged,
please replace it!
5.11.6.6 Check the clearance of wheel speed sensor
★ Lift the front / rear wheel from the ground with a jack
(see “Wheels/Tires” - “Removing Front / Rear Wheel”).
●Slowly rotate the wheel and measure the clearance at
several different points between the sensor and the sensor
gear ring.
Feeler gauge [A]
Feeler gauge [B]
Clearances
Standard:
Front wheel: 0.5-1.2mm
Rear wheel: 0.5-1.2mm
Note
○ Sensor clearance cannot be adjusted.
a
★ If the clearance is not within the specified range, check
the hub bearing (see “Wheel/Tire” – “Checking Hub
Bearing”), the installation and function of sensor (see
“Checking Wheel Rotation Sensor” for details).
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 226 -
im
D
-
s
o
i
r
it
Ka
k
-d
5.11.6.7 Check the gear ring of wheel speed sensor
●Disassemble:
Wheel (see “Wheel/Tire” – “Removing Front / Rear
Wheel”)
Brake plate mounting bolt [A],
Sensor gear ring [B]
● Visually inspect the gear ring of wheel speed sensor.
★ If the rotor is deformed or damaged (there is a notch [A]
on the rotating tooth), please replace it with a new one!
★ If there are iron filings or other magnetic deposits on the
rotor [B], please clean!
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 227 -
im
D
-
s
o
i
r
it
Ka
k
-d
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 228 -
im
D
-
s
o
i
r
it
Ka
k
-d
Front fender
*Note
Do not damage the covering parts of body
when disassembling.
Remove the body in the following order
The insert plate and cover plate of body
are aligned with their slots respectively.
The hooks of parts should be installed
correctly when assembling.
Do
not
damage
the
fittings
when
installing covering parts.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 229 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Front fender assembly
1
—
—
2
Cross recessed pan head screw M5×106
4
—
—
3
Hexagon nut M5
4
—
—
4
Hexagon bolt with flange M6×12/polished head
4
10～12
1.0～1.2
5
Fluid brake hose clamp
1
—
—
6
Cross recessed pan head screw M6×16
2
—
—
7
Front fender rubber assembly
1
—
—
8
Hexagon flange nut M6
3
10～12
1.0～1.2
9
Front wheel speed sensor bracket
1
—
—
10
Front wheel speed sensor
1
—
—
11
Hexagon bolt with flange M6×16
1
10～12
1.0～1.2
12
Hexagon socket cap screw M10×50
2
40～44
4.0～4.4
Note
S
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 230 -
im
D
-
s
o
i
r
it
Ka
k
-d
Cover
*Note
Do not damage the covering parts of body when
disassembling.
Remove the body in the following order
The insert plate and cover plate of body are aligned with
their slots respectively.
The hooks of parts should be installed correctly when
assembling.
Do not damage the fittings when installing covering
parts.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 231 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Left cover of engine II
1
—
—
2
Left cover of engine I
1
—
—
3
Bolt M5×12
5
10～12
1.0～1.2
4
Screw M6×15.2
2
10～12
1.0～1.2
5
Right cover of engine I
1
—
—
6
Right cover of engine II
1
—
—
7
Screw M6×20
2
10～12
1.0～1.2
8
Collar
2
—
—
9
Rubber collar
2
—
—
10
Left protector
1
—
—
11
Right protector
1
—
—
Note
S
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 232 -
im
D
-
s
o
i
r
it
Ka
k
-d
Rear fender 1
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 233 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Front part of rear fender
1
—
—
2
Bolt M6×19.2
2
10～12
1.0～1.2
3
Screw M6×15.2
4
10～12
1.0～1.2
4
Rear right turn signal light
1
—
—
5
Taillight
1
—
—
6
Self-locking nut M6
4
10～12
1.0～1.2
7
Tail of rear fender
1
—
—
8
License plate light
1
—
—
9
Flat washer Φ5
2
—
—
10
Spring washer φ5
2
—
—
11
Hexagon nut M5
2
—
—
12
Hexagon bolt with flange M6×12/polished head
4
10～12
1.0～1.2
13
Collar
2
—
—
14
Rear left turn signal light
1
—
—
15
Rear reflector
1
—
—
16
Rear license holder
1
—
—
17
Connecting plate of rear left and right pedal
1
—
—
18
Hexagon flange nut M6
2
10～12
1.0～1.2
19
Reinforcing plate at the tail of rear fender
1
—
—
20
Headlight bushing
2
—
—
Note
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 234 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
Rear fender
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 235 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Bolt M10×1.25×20
6
10～12
1.0～1.2
2
Rear fender assembly
1
—
—
1
—
—
2
—
—
1
—
—
Front reinforcing plate assembly II of rear
3
fender
4
Rear rack screw I
Front reinforcing plate assembly II of rear
5
fender
Note
6
All-metal hexagon flange locknut M10
6
40～44
4.0～4.4
AL
7
Left rear pedal assembly
1
—
—
8
Hexagon bolt with flange M6×12/polished head
4
10～12
1.0～1.2
9
Handle
2
—
—
10
Inner hexagon screw M10×80
2
40～44
4.0～4.4
AL
11
Hexagon socket cap screw M10×60
4
40～44
4.0～4.4
AL
12
Hexagon socket cap screw M10×16
2
40～44
4.0～4.4
AL
13
Washer 10
2
—
—
14
Left frame cover assembly
1
—
—
15
Hexagon bolt with flange M8×45
2
22～29
2.2～2.9
AL
16
Self-locking nut M8
2
22～29
2.2～2.9
AL
17
Right rear pedal assembly
1
—
—
18
Right cover assembly of frame
1
—
—
19
Liner tube of container
2
—
—
20
Hexagon socket cap screw M10×60
6
40～44
4.0～4.4
AL
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 236 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
VI. Body Cover
Remove the body in the following order
Seat cushion → left/right cover → left/right cover of engine →
left/right handle
→
left/right cover assembly of frame
↓
→ left/right rear pedal assembly → rear fender assembly → rear left/right turn signal light
→ tail light → tail of rear fender
↓
→license plate light → rear reflector → rear license plate support → reinforcing plate at
tail of rear fender → front of rear fender
↓
→ front fender assembly
*Note
Do not damage the covering parts of body when disassembling.
Remove the body in the following order
The insert plate and cover plate of body are aligned with their slots respectively.
The hooks of parts should be installed correctly when assembling.
Do not damage the fittings when installing covering parts.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 237 -
a
b
is
n
ra
im
D
-
s
o
i
r
it
Ka
k
-d
Front wheel
A
Tire size: 100/90-19
Rim specifications: 2.15×19 spoked
wheel
B
Rim runout limit value:
Vertical: 2.0 mm
Horizontal: 2.0 mm
C
D
Diameter of front fluid brake disc:
300mm
Bending limit of front wheel axle:
0.2mm
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 238 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Front wheel axle
1
100～113
10.0～11.3
2
Front wheel left collar
1
—
—
3
Screw M6×20
6
10～12
1.0～1.2
4
Front wheel gear ring
1
—
—
5
Front brake disc
1
—
—
6
Dust ring
2
—
—
7
Air valve
1
—
—
8
Front wheel rim assembly
1
—
—
9
Inner tube and cushion belt
1
—
—
10
Inner and outer tubes
1
—
—
11
Front wheel right collar
1
—
—
12
Slef-locking nut M16×1.5
1
100～113
10.0～11.3
Note
G
L、S
G
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 239 -
im
D
-
s
o
i
r
it
Ka
k
-d
Console assembly
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 240 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Left rearview mirror assembly
1
—
—
2
Right rearview mirror assembly
1
—
—
3
Handlebar assembly
1
—
—
4
Screw M6×35
2
10～12
1.0～1.2
5
Washer 6
2
—
—
6
Spring washer 6
2
—
—
7
Handle block
2
—
—
8
Left handlebar jacket
1
—
—
9
Left combination switch
1
—
—
10
Right combination switch
1
—
—
11
Right grip assembly
1
—
—
12
Throttle cable assembly
1
—
—
13
Clutch cable assembly
1
—
—
14
Clutch handle component
1
—
—
15
ABS switch assembly
1
—
—
16
Screw M6×25-8.8-ZG
2
10～12
1.0～1.2
17
Bolt M6×12
1
10～12
1.0～1.2
18
Washer Φ6
1
—
—
19
Self-locking nut M6
1
10～12
1.0～1.2
20
Brake pedal welding assembly
1
—
—
21
Hexagon socket cap screw M12×50
1
50～55
5.0～5.5
22
Brake mounting base
1
—
—
23
Joint M6
1
—
—
24
Washer Φ6
1
—
—
25
Bolt M6×25
1
10～12
1.0～1.2
26
Rear foot pump piston screw
1
—
—
27
Hexagon bolt with flange M6×25
2
10～12
1.0～1.2
28
Brake pedal return spring
1
—
—
29
Hexagon bolt M6×30
1
10～12
1.0～1.2
30
Hexagon flange nut M6
1
10～12
1.0～1.2
s
o
i
r
it
Note
a
is
n
ra
b
Ka
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 241 -
im
D
-
k
-d
Front Fork
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 242 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Chinese name and specifications
1
Torque
Number
Note
of
N·m
kgf·m
Hexagon socket cap screw M18×25
4
22～29
2.2～2.9
2
Upper handlebar holder
1
—
—
3
Lower handlebar holder
2
—
—
4
Damper
4
5
Handlebar positioning double-end stud
2
—
—
6
Clamp screw of upper bracket
1
25
2.5
7
Upper bracket
1
—
—
8
Bolt M8×25
2
22～29
2.2～2.9
AL
9
Self-locking nut M10×1.25
2
45～50
4.5～5.0
AL
10
Hexalobular socket pan head screw M6×20
2
10～12
1.0～1.2
11
Clamp nut of upper bracket
1
70
7.0
12
Nut
1
2
0.2
13
Dust ring
2
—
—
14
Steering bearing
2
—
—
15
Lower bracket assembly
1
—
—
16
Bolt M10×1.25×20
4
22～29
2.2～2.9
17
Lower mounting bracket of headlight
1
—
—
18
Fluid brake hose clamp
1
—
—
19
Front license holder
1
—
—
20
Hexagon bolt with flange M6×20
2
10～12
1.0～1.2
21
Front reflector
2
—
—
22
Front left shock absorber assembly
1
—
—
23
Front right shock absorber assembly
1
—
—
AL、S
AL
R、G
AL、S
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO:Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 243 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
VII. Front Wheel/Front Suspension
Preparatory Information-------------------------7.1
Fault Diagnosis------------------------------- 7.2
Front Wheel----------------------------------- 7.3
Handlebar------------------------------------- 7.4
Front Fork------------------------------------- 7.5
Front Shock Absorber----------------------- 7.6
7.1 Preparatory Information
Operation Precautions
Before the front wheel is disassembled, support the bottom
of the motorcycle with jacks and do not reverse the front
wheel when it floats above the ground.
There should be no grease attached to the friction pad,
friction pad assembly or fluid brake disc during operation.
Technical parameters
Measuring position
Item
Front wheel axle
Bending degree
Front wheel
Torque value Tools
Rim shimmy
Standard value (mm)
Allowable limit (mm)
0.2
Vertical direction
Horizontal direction
is
n
ra
2.0
Within 1.0
s
o
i
r
Front axle locknut
Bearing removal rod
100∼113 N·m
it
m
Front caliper mounting bolt
Locknut wrench
40∼44 N·m
Di
Rear view mirror mounting bolt
Torque
wrench
22∼29 N·m
A
.
S
Meter mounting seat mounting bolt
10∼12 N·m
S
I
Clamp bolt of upper bracket
22∼29 N·m N
A
Upper grip positioner mounting bolt
22∼29 R
N·m
B
Handlebar positioning double-end stud
45∼50
A N·m
K
locknut
E
G
Steering column bearing locknut
70 N·m
R
O
E
Steering column bearing nut
2 N·m
G
Upper clamp bolt of shockY
absorber
22∼29 N·m
A
Lower clamp bolt ofW
shock absorber
22∼29 N·m
O
Headlight bracket
37∼44 N·m
T locknut
O
M
- 244 Y
P
CO
2.0
b
Ka
a
k
-d
10∼12 N·m
10∼12 N·m
Clamp mounting bolt
Headlight mounting bolt
7.2 Fault Diagnosis
7.2.1Turning Difficulty of Handlebar
The handlebar bearing fails.
The handlebar bearing fails.
The tire pressure is too low.
Tire leaks.
7.2.2Instability of Direction
The handlebar bearing fails.
The tire pressure is not enough.
The front fork and front wheel axle are bent.
The front wheel tire is deformed and deviates.
7.2.3 Front Wheel Shimmy
The rim is deformed.
The front wheel axle bearing is worn.
Detective tire.
7.2.4 Rotation Difficulty of Wheel
The wheel axle bearing fails or the gear seat fails.
a
7.2.5 Abnormal Sound of Front Shock Absorber
Friction sound of shock absorber guard.
The bolts of all parts of shock absorber are loose.
b
7.3 Front Wheel
7.3.1 Disassembly
.A
S
S
I
N
A
Note:
The motorcycle must be firmly supported.
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 245 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove
Front wheel axle locknut [A].
Remove the front wheel axle [A]
Remove the front wheel
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 246 -
im
D
-
s
o
i
r
it
Ka
k
-d
7.3.2 Inspection
7.3.2.1 Bending Inspection of Wheel Axle
Put the wheel axle on the V-shaped seat and measure the
eccentricity with a dial gauge.
Available limit: Replace the wheel axle if the
eccentricity is 0.2mm above
Axle
7.3.2.2 Rim Shimmy Inspection
Put the rim on an accurate bracket and check the
amplitude of the rim.
Rotate the wheel with hands and read the
amplitude.
Available limit:
Vertical direction: Replace the rim if the
amplitude is 2.0mm or above.
Horizontal direction: Replace the rim if the
amplitude is 2.0mm or above.
swinging
swinging
swinging
swinging
a
7.3.2.3Inspection of Front Wheel Bearing


b
Bearing
The front wheel rotates unsmoothly or it is too
loose→Replace the bearing
Oil Seal
Damage/wear→Replacement
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 247 -
im
D
-
s
o
i
r
it
Ka
k
-d
7.3.2.4 Inspection of spoke
Check the spoke ①, replace it if bent or damaged; tighten it if loose.
Tighten the spoke; the locking torque of spoke is 3.0n ·m.
7.3.3 Replacement of Bearing
7.3.3.1 Disassembly of Bearing
Remove the oil seal [1].
Note:
To avoid damaging the rim, please put a cloth [2] between
the screwdriver and the surface of rim
Remove the bearing [3] with a bearing puller.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 248 -
im
D
-
s
o
i
r
it
Ka
k
-d
7.3.3.2 Inspection of Bearing
Check the rolling conditions of bearing.
If the bearing does not roll, it may be worn or loose and thus
it should be replaced with a new one.
Clearance
Clearance
Axial direction
Radial direction
7.3.3.3 Installation of Bearing
Note:
The bearing disassembled should be replaced with a
new one.
Then push the bearing with bearing installation tools.
*Note
Do not apply pressure on the inner race ring [1] or
ball bearing [2] of wheel bearing and only apply
pressure to the outer race ring [3] of bearing
Use the seat in line with the diameter of outer race
ring [4] of bearing
7.3.4 Installation
a
Install it in the reverse order of disassembly.
Note
•The oil seal on the front wheel should be lubricated.
•The engagement part or mobile part of gear seat
assembly should be lubricated.
b
Note
• When the odometer gear seat assembly fails to lock the
front wheel axle, the odometer gear seat assembly will be
deformed.
• After the wheel axle is installed, rotate the wheel to
confirm whether the speedometer drive shaft rotates.
.A
S
S
I
N
A
R
B
A
Torque value:
Front wheel axle locknut
K
E
RG
EO N·m
100-113
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 249 -
im
D
-
s
o
i
r
it
Ka
k
-d
7.4 Handlebar
7.4.1 Disassembly
Disassemble
Remove the left rearview mirror assembly [A]
Remove the left rearview mirror assembly [B]
a
Remove
Primary cylinder of front brake [A]
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 250 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove
Left lever assembly [B]
Remove
Mounting bolt of grip end assembly [A]
Grip end assembly [B]
a
b
Remove
Left combination switch [A]
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 251 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove
Right combination switch [A]
Throttle grip [B]
Remove
Left handlebar cover [A]
*Note:
Compress the compressed air between the left
handlebar and left handlebar grip [1] and slowly
press the left handlebar grip.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 252 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove the mounting screw at the upper seat of handlebar
[A]
Remove upper seat of handlebar [B]
Remove the handlebar assembly
7.4.2 Inspection
test.
Handlebar
Deformation / bending→replacement
a
b
is
n
ra
7.4.3 Installation
Install it in the reverse order of disassembly.
Torque value:
Mounting screw at the upper seat of handlebar 22-29N•m
Mounting screw of grip end
10-12 N•m
Mounting bolt of left lever assembly
10-12 N•m
Mounting bolt of primary cylinder of front brake 10-12 N•m
I
N
A
.A
S
S
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 253 -
im
D
-
s
o
i
r
it
Ka
k
-d
*Note:
When installing the mounting screw at the upper seat of
handlebar, finally fix the 2 screws [A] below
*Note:
When installing the left lever assembly, first fix the screw
[A] below
7.5 Front Fork
a
7.5.1 Disassembly
Support the center stand of motorcycle.
Remove the meter (see Chapter VI for details)
Remove headlight (see Chapter VI for details)
Remove the handlebar (see this section for details)
Remove the front wheel (see this section for details)
Remove the front fender (see Chapter VI for details)
Remove the caliper of front brake (see Chapter V “Brake”
for details)
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 254 -
im
D
-
s
o
i
r
it
Ka
k
-d
Loosen the clamp bolt of upper bracket [A]
Disassemble
Supporting bolt [A]
Upper bracket [B]
Loosen the clamp bolt of lower bracket[A]
Remove the front shock absorber
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 255 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Remove locknut of steering stem [E].
Special tool - steering stem locknut wrench (four-claw):
●Remove nut of steering stem [E].
Special tool - steering stem nut wrench (seven-claw):
Special tool - steering stem locknut wrench (four-claw):
300-QCLM4-001
Special tool - steering stem nut wrench (seven-claw):
300-QCLM7-001
a
b
Disassemble
Upper steel bowl of upper bearing [A]
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 256 -
im
D
-
s
o
i
r
it
Ka
k
-d
Disassemble
Support and lower bracket [A]
7.5.2 Inspection of Steering Column
test.
Steering column
Deformation / bending→replacement
a
Clean the rolling ball and bearing race
test.
Bearing race[A]
Ball[B]
Wear/damage→Replacement
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 257 -
im
D
-
s
o
i
r
it
Ka
k
-d
Replacement step:
Disassemble the bearing race with a long rod ① and a
hammer and remove it from the groove of head pipe, as
shown in the figure
Disassemble the bearing race of steering lever with a flat
chisel ② and a hammer, as shown in the figure
*Note:
Balls, bearing races and dust seals are always replaced
in sets.
The ball and bearing race mounted obliquely will
cause the wear of rack, therefore, they shall be
mounted horizontally carefully.
Do not strike the surfaces of ball and direction axle.
7.5.3 Installation
Install it in the reverse process of disassembly
*Note
Apply grease to the steel bowl of bottom bearing confirm
that the number of balls (21), check whether the
handlebar is not rotatable (to prevent the steel balls from
falling) and then install the steering stem.
Support the handlebar, apply grease to the steel bowl of
top bearing and confirm the number of balls (19). (17)
Apply grease to the race of top seat.
Apply grease to the race of top seat. Rotate the handlebar
horizontally to make the steel balls contact tightly.
*Note
When installing the front shock absorber, first tighten the
clamping bolts.
Ensure that the end of inner fork is flush with the head of
handlebar.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
Torque value:
Nut of steering axle
2 N·m
Locknut of steering axle
70 N·m
Upper clamp bolt of front shock 22∼29 N·
absorber
Lower clamp bolt of front shock 22∼29 N·m
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 258 -
im
D
-
s
o
i
r
it
Ka
k
-d
absorber
Mounting bolt at the bracket of
headlight
Mounting bolt at the lower
bracket of headlight
Mounting bolt of brake clamp
Mounting bolt of front fender
bracket
10∼12 N·m
10∼12 N·m
10∼12 N·m
10∼12 N·m
● Replace the inner race of bearing and oil seal with new
ones.
●Apply grease to oil seal.
● Put the oil seal [A] on the steering stem, then install the
inner race of lower ball bearing [B] and apply grease to the
steering stem [C].
Special tool - special tooling for installing the steering tube
bearing [D]:
● Install the lower ball bearing [A] to the steering stem.
● Apply grease to the following parts.
Inner and outer races,
lower and upper ball bearings
○The lower ball bearing is the same as the upper ball
bearing.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 259 -
im
D
-
s
o
i
r
it
Ka
k
-d
Note:
Assemble or disassemble the steering axle nut [1] with a
steering nut wrench
[1]。
Note:


Make the torque wrench perpendicular to the
steering nut wrench.
Rotate the direction axle left and right several times
to check whether it rotates smoothly.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 260 -
im
D
-
s
o
i
r
it
Ka
k
-d
Diagram of front shock absorber
O-ring ø33×2.65
End cap
Liner tube
Washer
Dust cap
Oil seal clip
Oil seal 41×54×11
Collar clip
DU collar 1
Damping spring
a
Piston ring
Buffer spring
b
DU collar 2
Front branch tube
combination
.A
S
S
Piston pipe
Positioning sleeve
Y
A
W
I
N
A
R
B
Sealing washer
A
K
Inner hexagon
screw
EM10×30
G
OROuter cylinder
E
G
O
CO
Y
P
T
O
M
is
n
ra
- 261 -
im
D
-
s
o
i
r
it
Ka
k
-d
7.6 Front Shock Absorber
7.6.1 Disassembly
Disassemble
Cap bolt ① and O-ring seal
Oil drainage
Disassemble
Plug ①
Spring ②
Disassemble
Dust ring ①
Wire clamp ②
a
Note:
Do not damage the surface of inner tube
b
is
n
ra
Disassemble
Bolt ①
Hold the shock absorber lever and loosen the bolts with the
T-shaped handle ② and the shock absorber clamp.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 262 -
im
D
-
s
o
i
r
it
Ka
k
-d
Disassemble
Bolt ①
Washer ②
Disassemble
Oil seal ①
7.6.2 Inspection
test.
Bending degree of inner tube
a
b
in both ships
Free length of front shock absorber spring: 319.5mm
Minimum free length: 314.5mm
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 263 -
im
D
-
s
o
i
r
it
Ka
k
-d
test.
Damper rod ①
Shock absorber piston ring ②
Scratch, damage, bending → Replacement
Spring ③
Oil plug rod ④
Wear, damage→Replacement
Waste→Clean all oil holes using the compressed air
Note:
Do not attempt to straighten the bent damper bar,
otherwise,
it may seriously damage the damper rod.
7.6.3 Installation
Install it in the reverse process of disassembly
Note
Be sure to use the following new parts when
reassembling the shock absorber
 Oil Seal
 Dust ring
Ensure that all parts are clean before re-installation
Installation
Shock absorber piston ring ①
Spring ②
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 264 -
im
D
-
s
o
i
r
it
Ka
k
-d
Installation
Damper rod ①
Oil plug rod ②
Inner tube ③
Outer tube ④
Installation
Washer ①New
Bolt (damper rod) ②
Note: When assembling bolt
adhesive
② , add thread-locking
Tighten
Bolt (damper rod) ①
Torque value: 15-20N•m
Note
a
Tighten the bolt ① of damper rod with the
T-shaped handle ② and the shock absorber clamp.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 265 -
im
D
-
s
o
i
r
it
Ka
k
-d
Installation
Oil seal ①New
Installation
Dust ring ①New
Wire clamp ②New
test.
Extension of inner tube
Unable to extend smoothly - recheck after disassembly
a
Refuel
Measuring cup ①
Shock absorber: SA40
Oil capacity: 450±2ml
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 266 -
im
D
-
s
o
i
r
it
Ka
k
-d
After refueling, slowly move the shock absorber [1] up and
down, to fill the tube with oil
Installation
Plug ①
Spring ②
Installation
Cap bolt ① and O-ring seal
Note
Do not damage the surface of inner tube
Torque value of cap bolt: 12-18 N·m
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 267 -
im
D
-
s
o
i
r
it
Ka
k
-d
Rear wheel and rear drive
A
Tire size: 130/80-18
Rim specifications: 3.00×18/spoked wheel
B
Rim runout limit value:
Vertical: 2.0 mm
Horizontal: 2.0 mm
C
Diameter of rear fluid brake disc: 240mm
D
Bending limit of rear wheel axle: 0.2mm
E
Chain specification: 525HO-1×110
F
Sprocket specification: 46 teeth
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 268 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
Note
1
Rear wheel axle M16×1.5×310
1
100～113
10.0～11.3
2
Left collar of rear wheel
1
—
—
3
Lip-type seal assembly
1
—
—
R、G
4
Circlip Φ62
1
—
—
R
5
Bearing 0×62×23.8
1
—
—
6
O-ring seal φ53×φ3.55
1
—
—
7
Chain drive collar
1
—
—
8
Self-locking nut M10×1.25
5
45～50
4.5～5.0
9
Chain 525HO-1×110
1
—
—
10
Sprocket 46-gear
1
—
—
11
Sprocket hub
1
—
—
12
Sprocket mounting bolt M10×1.25×41
5
45～50
4.5～5.0
13
Rear wheel damper
5
—
—
14
Air valve
1
—
—
15
Rear wheel rim assembly
1
—
—
16
Inner tube and cushion belt
1
—
—
17
Tire and tube 130/80-18
1
—
—
18
Dust seal of rear hub
1
—
—
19
Right collar of rear wheel
1
—
—
20
Rear brake disc component
1
—
—
21
Screw M6×20
6
10～12
1.0～1.2
22
Screw M6×12
2
10～12
1.0～1.2
23
Rear wheel speed sensor mounting base
1
—
—
24
Rear wheel speed sensor
1
—
—
1
10～12
1.0～1.2
25
Hexagon bolt with flange
M6×12/polished head
26
Rear brake bracket assembly
1
—
—
27
Slef-locking nut M16×1.5
1
100～113
10.0～11.3
G
R、G
AL、S
R、G
L、S
a
is
n
ra
AL
b
Ka
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 269 -
im
D
-
s
o
i
r
it
k
-d
Rear Suspension
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 270 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
Note
1
Rear rocker arm mounting shaft
1
85～98
8.5～9.8
G
2
External collar of rear rocker arm
2
—
—
3
Oil seal of rear rocker arm
2
—
—
G
4
Elastic collar for hole φ30
2
—
—
R
5
Needle bearing NA6903
2
—
—
G
6
Rolling bearing 61903-2RS/P26
2
—
—
7
Middle shaft sleeve of rear rocker arm
1
—
—
8
Self-locking nut M14×1.5
1
85～98
8.5～9.8
AL
9
Rear rocker arm welding assembly
1
45～50
4.5～5.0
AL
10
Chain protective block
1
—
—
11
Screw M6×12
2
10～12
1.0～1.2
12
Collar
2
—
—
13
Chain adjuster assembly
2
—
—
14
Rubber washer of protector
1
—
—
15
Drive chain cover
1
—
—
16
Screw M6×15.2
2
10～12
1.0～1.2
17
Washer
6
—
—
18
Rear shock absorber assembly
2
—
—
19
Rear rack mounting collar
2
—
—
20
Cap nut M10×1.25
4
45～50
4.5～5.0
AL
AL
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 271 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
VIII. Rear wheel/rear suspension
Preparatory Information---------------------8.1
Fault Diagnosis------------------------------- 8.2
Rear Wheel------------------------------------8.3
Rear Shock Absorber------------------------ 8.4
Rear Rocker Arm-----------------------------8.5
Chain Drive ----------------------------------8.6
8.1 Preparation of Information
Note for operation
There should be no oil stains attached on the surface of brake disc or friction pad.
Technical parameters
Item
Swinging amplitude
of rear wheel
Standard value (mm)
Available limit (mm)
Vertical direction
2.0
Horizontal direction
2.0
a
is
n
ra
Torque value
Mounting nut of rear wheel
Nut at the top of rear shock absorber
Nut at the bottom of rear shock absorber
Mounting nut of rear rocker arm axis
Mounting nut of rear sprocket
R
B
A
K
E
RG
8.2.1 Rear Wheel Shimmy
O
E
G
Y
A
W
Deformation of rim
Wear of rear wheel bearing
Tire fault
Wear or damage of rocker arm pivot shaft bearing
O
CO
Y
P
.A
S
S
I
N
A
8.2 Fault Diagnosis
T
O
M
b
100-113 N•m
45-50 N·m
45-50 N·m
85-98 N·m
45-50N·m
- 272 -
im
D
-
s
o
i
r
it
Ka
k
-d
Improper adjustment of drive chain adjuster
Bent frame or rocker arm
8.2.2 Inflexible rotation of wheel
Incorrect adjustment of brake
Wear of rear wheel bearing
Too tight drive chain
8.2.3 Poor brake performance
Incorrect adjustment of brake
The friction pad of brake is worn
The fluid brake disc is worn
Improper installation of brake friction pad
8.2.4 Inflexible Brake Pedal or Slow Return
Wear or break of return spring
Incorrect adjustment of brake
The fluid brake disc is worn or dirty
Improper installation of brake friction pad
8.2.5 Abnormal sound of brake
The friction pad of brake is worn
The fluid brake disc is worn
The friction pad of brake is dirty
The fluid brake disc is dirty
a
8.3 Rear wheel
8.3.1 Disassembly
b
Support the center stand and park the motorcycle, so that
the motorcycle is lifted from the ground.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 273 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove
Rear brake caliper [A]
Loosen
Chain adjuster bolt [A]
Disassemble
Rear wheel axle mounting nut [A]
a
b
is
n
ra
Disassemble
Rear wheel axle [A]
Pull out the rear wheel axle from right side to left side
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 274 -
im
D
-
s
o
i
r
it
Ka
k
-d
Disassemble rear wheel
8.3.2 Inspection
8.3.2.1 Bending Inspection of Wheel Axle
Put the wheel axle on the V-shaped seat and measure the
eccentricity with a dial gauge.
Available limit: Replace the wheel axle if the
eccentricity is 0.2mm above
a
Axle
is
n
ra
8.3.2.2 Rear Rim Shimmy Inspection
Put the rim on an accurate bracket and check the
amplitude of the rim.
Rotate the wheel with hands and read the
amplitude.
Available limit:
Vertical direction: Replace the rim if the
amplitude is 2.0mm or above.
Horizontal direction: Replace the rim if the
amplitude is 2.0mm or above.
b
swinging
swinging
.A
S
S
swinging
swinging
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 275 -
im
D
-
s
o
i
r
it
Ka
k
-d
8.3.2.3 Inspection of Rear Wheel Bearing


Bearing
The front wheel rotates unsmoothly or it is too
loose→Replace the bearing
Oil Seal
Damage/wear→Replacement
8.3.2.4 Inspection of spoke
Check the spoke ①, replace it if bent or damaged; tighten it if loose.
Tighten the spoke; the locking torque of spoke is 3.0n ·m.
8.3.3 Replacement of Bearing
a
8.3.3.1 Disassembly of Bearing
is
n
ra
Remove the oil seal [1].
b
Note:
To avoid damaging the rim, please put a cloth [2]
between the screwdriver and the surface of rim
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 276 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove the bearing [3] with a bearing puller.
8.3.3.2 Inspection of Bearing
Clearance
Check the rolling conditions of bearing.
If the bearing does not roll, it may be worn or loose and thus
it should be replaced with a new one.
Clearance
Axial direction
Radial direction
8.3.3.3 Installation of Bearing
Note:
The bearing disassembled should be replaced with a
new one.
a
Then push the bearing with bearing installation tools.
*Note
b
Do not apply pressure on the inner race ring [1] or
ball bearing [2] of wheel bearing and only apply
pressure to the outer race ring [3] of bearing
Use the seat in line with the diameter of outer race
ring [4] of bearing
.A
S
S
8.4.4 Installation
Install it in the reverse order of disassembly.
Note
I
N
A
R
B
A
K
E
RG
•The oil seal on the rear wheel should be lubricated.
Torque value:
Rear wheel axle locknut
O
E
G
Y
A
W
100 -113 N·m
O
CO
Y
P
T
O
M
is
n
ra
- 277 -
im
D
-
s
o
i
r
it
Ka
k
-d
8.4 Rear shock absorber
8.3.1 Disassembly
Firmly support the motorcycle
Disassemble
Lower mounting bolt of rear shock absorber [A]
Upper mounting bolt of rear shock absorber [B]
Rear shock absorber [C]
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 278 -
im
D
-
s
o
i
r
it
Ka
k
-d
8.3.2 Inspection
Rear shock absorber
test.
Rear shock absorber lever
Bending/damage → Replacement of rear shock absorber
test.
Rear shock absorber spring
Fatigue → Replacement of rear shock absorber
a
b
is
n
ra
.A
S
S
8.3.4 Installation
I
N
A
R
B
A
Install it in the reverse order of disassembly.
Install the mounting nut of rear shock absorber.
Lock it to the specified torque value.
Torque value:
Nut at the top of rear shock absorber
45-50 N·m
Nut at the bottom of rear shock absorber 45-50 N·m
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 279 -
im
D
-
s
o
i
r
it
Ka
k
-d
8.5 Rear Rocker Arm
8.5.1 Disassembly
Firmly support the motorcycle
Disassemble the rear shock absorber (see this chapter for
details)
Disassemble the rear wheel (see this chapter for details)
Disassemble
Left / right cover [A]
Disassemble
Mounting nut of rear rocker arm axle [A]
a
b
is
n
ra
Disassemble
Rear rocker arm shaft
Pull out the rear rocker arm shaft from right side to left
side
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 280 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove
Rear rocker arm
8.5.2 Inspection
test.
Rear rocker arm
Bending/damage→replacement
test.
 Tightness of rear rocker arm
If it is loose→tighten the rear rocker arm nut or
replace the collar
 Vertical movement of rear rocker arm
If the movement is not smooth, or there is any bent or
rough parts → replace the axle sleeve
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 281 -
im
D
-
s
o
i
r
it
Ka
k
-d
test.
Rear rocker arm shaft
Put the rear rocker arm shaft on the V-shaped seat and
measure the eccentricity with a dial gauge.
Available limit: Replace the wheel axle if the
eccentricity is 0.2mm above
*Note
Never try to straighten a bent axle.
Rear rocker arm axle
test.
Rear swing arm collar
Damaged → replace
test.
Chain protective block
Wear/damage /crack→ replacement
a
b
is
n
ra
8.5.3 Installation
Install it in the reverse order of disassembly.
Clean the mounting axle parts of rear rocker arm in the
solvent, and apply grease to the mounting shaft.
.A
S
S
I
N
A
R
B
A
K
E
RG
Torque value:
Mounting nut of rear rocker arm axis
O
E
G
Y
A
W
85～98 N·m
O
CO
Y
P
T
O
M
- 282 -
im
D
-
s
o
i
r
it
Ka
k
-d
8.6 Chain drive
8.6.1 Disassembly
Put the motorcycle on a flat surface and secure it.
Disassemble
Drive sprocket cover [A]
Remove the chain [A] from the drive sprocket
[B].
a
Disassemble the rear wheel (see this chapter for details)
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 283 -
im
D
-
s
o
i
r
it
Ka
k
-d
Disassemble the rear rocker arm (see this section for
details)
Remove the drive chain
Disassemble
Mounting nut of sprocket mounting bolt [A]
Note:
When disassembling the mounting nut of sprocket
mounting bolt, follow the instructions on the right
figure.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 284 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove the retainer [A] using the retainer caliper.
Disassemble
Retainer [A]
Sprocket base [B]
Sprocket [C]
Disassemble
Rear wheel damper [B]
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 285 -
im
D
-
s
o
i
r
it
Ka
k
-d
8.6.2 Inspection
Check the chain
Measure the length of 10 links . The drive chain should
be replaced if the length does not match the specified
value.
The length limit of 10 links is 158.75 mm.
*Note:
 Take measurements after stretching the chain by
hands.
 Measure the length of 10 links within the range
from the link roller ① to the inside of roller .
 Measure the length of 10 links in different positions
for 2-3 times.
Clean the drive chain
 Wash with a neutral detergent and clean the dust
as much as possible.
 Apply the chain lubricant thoroughly after
washing.
Warning
Never use volatile substances such as steam,
gasoline or solvents.
Check rotor ① and side panel ②
If it is damaged or worn, replace the drive chain.
Lubricate the drive chain and purchase drive chain
lubricants from the store.
a
b
is
n
ra
Check drive chain hardness
If it is hard, clean, lubricate or replace.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 286 -
im
D
-
s
o
i
r
it
Ka
k
-d
Check the driving sprocket and the driven sprocket.
If there is a quarter of gear wear
sprocket.
If the gear is bent, replace the sprocket.
, replace the
test.
Rear wheel damper
Damage / crack→Replacement
test.
Sprocket seat bearing
Bearing clearance or rotation is unbalanced→
replacement.
a
b
test.
Oil Seal
Wear, damage and cracking → replacement.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 287 -
im
D
-
s
o
i
r
it
Ka
k
-d
test.
Chain drive collar
Wear, damage→replacement.
8.6.3 Replacement of bearing
8.6.3.1 Disassembly of bearing
Remove the oil seal [1].
Note:
To avoid damaging the sprocket seat, please put a cloth
[2] between the screwdriver and the surface of rim
Remove the bearing [3] with a bearing puller.
a
is
n
ra
b
8.6.3.2 Inspection of Bearing
im
D
Clearance.A
S
S
Check the rolling conditions of bearing.
If the bearing does not roll, it may be worn or loose and thus
it should be replaced with a new one.
I
N
A
s
o
i
r
it
Ka
Clearance
R
B
A
K
E
RG
O
E
G
Y
A
W
Axial direction
O
OT
P
O
C
M
Y
- 288 -
Radial direction
k
-d
8.6.3.3 Installation of Bearing
Note:
The bearing disassembled should be replaced with a
new one.
Then push the bearing with bearing installation tools.
*Note
Do not apply pressure on the inner race ring [1] or ball
bearing [2] of wheel bearing and only apply pressure
to the outer race ring [3] of bearing
Use the seat in line with the diameter of outer race
ring [4] of bearing
8.6.3 Installation
Install it in the reverse order of disassembly.
Adjust the drive chain slackness.
If the chain slackness is too smallness, the engine and other
important parts may be overloaded.
The chain slackness should be kept within the specified
limits.
Torque value:
Locknut of sprocket bolt
45～50 N·m
*Note
a
The side of sprocket marked with the number of
teeth [A] is outward.
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 289 -
im
D
-
s
o
i
r
it
Ka
k
-d
*Note
Tighten the nut by 2-3 times in the order shown in
the right figure.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 290 -
im
D
-
s
o
i
r
it
Ka
k
-d
Seat Cushion
No
Chinese name and specifications
Torque
Number of
N·m
kgf·m
1
Boss bolt M10
2
40～45
4.0～4.5
2
Front seat cushion spring
2
—
—
3
Pressing sleeve of front seat cushion spring
2
—
—
4
Front seat cushion assembly
1
—
—
5
Rear seat cushion assembly
1
—
—
6
Rear seat mounting plate assembly
1
—
—
7
Rear grab rail
1
—
—
8
Bolt M6×30
4
10～12
1.0～1.2
9
Hexagon bolt with flange M6×14
2
10～12
1.0～1.2
10
Self-locking nut M8
2
22～29
2.2～2.9
Note
a
Ka
b
is
n
ra
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 291 -
im
D
-
s
o
i
r
it
k
-d
Fuel tank
A
Fuel tank volume: 12L±0.5L
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 292 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Fuel tank assembly
1
—
—
2
Rear rack screw II
2
—
—
3
Rubber washer liner tube
2
—
—
4
Buffer rubber of fuel tank
2
—
—
5
Screw M4×5
2
—
—
6
Left cover assembly of fuel tank
1
—
—
7
Right cover assembly of fuel tank
1
—
—
8
Cushion
2
—
—
9
Sensor rubber washer
1
—
—
10
Oil level sensor assembly
1
—
—
11
Hexagon flange nut M6
4
10～12
1.0～1.2
12
Fuse hose assembly
1
—
—
13
Filter assembly
1
—
—
14
Filter jacket
1
—
—
15
Fuel pump assembly
1
—
—
16
Bolt M5×16
6
3～4
0.3～0.4
17
Dump valve assembly
1
—
—
18
Plate clamp
3
—
—
19
Fuel hose 4.5×8.5×190
1
—
—
20
Fuel hose 4.5×8.5×
1
—
—
21
Wire clamp Φ10.5
1
—
—
22
Fuel hose 7×11×800
1
—
—
Note
R
S
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 293 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
IX. Fuel Tank/Seat
Preparatory Information--------------------- 9.1
Fault Diagnosis------------------------------- 9.2
Seat---------------------------------------------9.3
Fuel Tank-------------------------------------- 9.4
9.1 Preparatory Information
Precautions for operation
The disassembly site should be away from the fire source.
Tighten bolts and nuts to the specified torque values during assembly.
Check whether all the parts are installed or operated correctly after assembly.
Technical parameters
Item
Standard
Allowable limit
Tank capacity
12L±0.5L
/
a
Locking torque
Mounting bolt of front seat
Mounting bolt of rear seat
Fuel tank mounting bolt
Fuel level sensor mounting bolt
Fuel pump mounting bolt
40-45 N·m
10-12N·m
10-12 N·m
5–9 N·m
3-4 N·m
b
.A
S
S
9.2 Fault Diagnosis
Reduction of gasoline quantity
Natural consumption of gasoline
Gasoline leakage
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 294 -
im
D
-
s
o
i
r
it
Ka
k
-d
9.3 Seat
9.3.1 Disassembly
Disassemble
Mounting bolt of front seat [A]
Front seat [B]
Disassemble
Front mounting bolt of rear seat M6×14[A]
Bolt M6×30[B]
Rear grab rail [C]
Rear seat [D]
Disassemble
Self-locking nut M8 [A]
Pressing sleeve of front seat cushion spring [B]
Front seat cushion spring [C]
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 295 -
im
D
-
s
o
i
r
it
Ka
k
-d
9.3.2 Inspection
test.
Seat Cushion
Breakage or damage → replacement
9.3.3 Installation
Install it in the reverse order of “disassembly”
Torque value:
Mounting bolt of front seat
Mounting bolt of rear seat
40-45 N·m
10-12N·m
9.4 Fuel Tank
9.4.1 Disassembly
a
Warning
Gasoline is extremely flammable and may
even cause explosion in some cases.Therefore, it
must be ensured that the above operations are
performed in a well-ventilated area, and any fire
source or spark is strictly prohibited, including
any devices with indicators.No smoking!Close the
electric door lock!Disconnect the negative
electrode (-) of battery
In order to minimize the amount of spilled
fuel, the fuel in the fuel tank should be extracted
when the engine is cool.If some fuel spills, it must
be thoroughly cleaned.
b
.A
S
S
I
N
A
R
B
A
K
E
G"Cushion"
Remove the front seat cushion (see
R
EO
"Removing")
G
Y
A
OW
T
O
M
Y
P
O
C
is
n
ra
-
- 296 -
im
D
-
s
o
i
r
it
Ka
k
-d
Disassemble
Bolt [A]
Remove fuel level sensor wire connector.
Disconnect:
Connector between fuel hose and fuel pump [B]
Warning
The fuel hose connector must be covered with a
cloth when being removed.The residual pressure in the
fuel pipeline when the hose is removed may cause the
ejection of fuel.
Note:



Remove the fuel hose with hands. Do not remove the
hose with tools forcibly.
Although the fuel in the fuel tank has been removed,
there may still be fuel residuals, so be careful when
disassembling the fuel hose.
Do not remove the fuel hose from the fuel hose
connector. Remove the connector from the fuel
pump interface.
a
Remove the fuel tank from the frame
Disassemble
Screw M4×5[A]
Fuel tank lock [B]
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 297 -
im
D
-
s
o
i
r
it
Ka
k
-d
Disassemble
Nut [A]
Fuel level sensor assembly [B]
Sensor rubber washer [C]
Disassemble
Bolt [A]
Fuel pump assembly [B]
Note
Do not drop the fuel pump, especially avoid falling on
hard surfaces, otherwise the fuel pump may be
damaged.
a
b
9.4.2 Inspection
● Inspection
Fuel tank
Rust / damage / oil leakage→replacement
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 298 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Inspection
Rubber part
Buffer rubber [A]
Rubber cover [B]
Sensor rubber washer [C]
Crack/damage→Replacement
● Inspection
 Inspect fuel pump
Fuel pump
Block-clean it
Crack/damage→Replace fuel pump assembly

Performance inspection of fuel pump (see Chapter
XVII for details)
a
b
is
n
ra
● Inspection
Fuel hose
If any wear, crack [B] or expansion [C] is found → the fuel
pipe must be replaced.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 299 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Inspection
Dump valve
Damage/fault→Replacement
9.4.3 Installation
Install it in the reverse order of “disassembly”
Torque value:
Fuel tank mounting bolt
Fuel level sensor mounting bolt
Fuel pump mounting bolt
10-12 N·m
5–9 N·m
3-4 N·m
Note:
Do not damage the mounting surface of fuel tank when
installing the fuel pump
Use new fuel pump seal ring
Note:
See Chapter XVIII for the details of fuel pump
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 300 -
im
D
-
s
o
i
r
it
Ka
k
-d
Frame
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 301 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Bolt M10×1.25×135
1
45～50
4.5～5.0
2
0Bolt M8×60
4
22～29
2.2～2.9
3
Rear front hanging panel assembly of engine
1
—
—
4
Front buffer collar of engine
2
—
—
5
Right front hanging panel assembly of engine
1
—
—
6
Self-locking nut M10×1.25
4
45～50
4.5～5.0
7
Frame welding assembly
1
—
—
8
Bolt M10×1.25×155
1
45～50
4.5～5.0
9
Frame cover
2
—
—
10
Hexagon bolt with flange M10×1.25×170
1
45～50
4.5～5.0
11
Left rear hanging panel assembly of engine
1
—
—
12
Front buffer collar assembly of engine
2
—
—
13
Bolt M8×25
4
22～29
2.2～2.9
14
Right rear hanging panel assembly of engine
1
—
—
15
Rubber washer of protector
3
—
—
16
Hexagon bolt with flange M6×16
3
10～12
1.0～1.2
17
Left clamp of frame II
1
—
—
18
Rubber washer of cover
4
—
—
19
Bolt M8×75
2
22～29
2.2～2.9
20
Left cover mounting base of engine
1
—
—
21
Left upper hanging panel assembly of engine
1
—
—
22
Hexagon bolt with flange M10×1.25×60
1
45～50
4.5～5.0
23
Right upper hanging panel of engine
1
—
—
24
Right cover mounting base of engine
1
—
—
25
Self-locking nut M8
2
22～29
2.2～2.9
26
Right clamp of frame
1
—
—
27
Hexagon flange nut M6
1
10～12
1.0～1.2
28
Headlight bracket collar
1
—
—
29
Ignition coil mounting base
1
—
—
30
Hexagon bolt with flange M6×80
1
10～12
1.0～1.2
31
Left clamp of frame I
1
—
—
32
Seat mounting base
1
—
33
Screw M6×12
4
10～12
34
Buffering rubber ring of seat cushion
2
I
N
A
A
—.
S
S
s
o
i
r
it
Note
AL、S
AL、S
AL、S
AL、S
AL
a
is
n
ra
b
Ka
im
D
- 1.0～1.2
—
—
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease. Si: Apply silicon grease. SS: Apply silicone sealant.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 302 -
k
-d
Pedal
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 303 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
Note
1
Front pedal welding assembly
1
—
—
AL、S
2
Pedal mounting screw
4
22～29
2.2～2.9
3
Mounting bushing of front foot rest lever
4
—
—
4
Front pedal buffer rubber washer
4
5
Rubber cover of pedal
2
—
—
6
Thin nut M12×1.25
1
45～50
4.5～5.0
7
Spring washer φ12
1
—
—
8
Mounting washer of sidestand
1
—
—
AL
9
Sidestand welding assembly
1
—
—
AL
10
Sidestand flameout switch
1
—
—
11
Bolt M5×0.8×14
2
4～7
0.4～0.7
12
Mounting screw of sidestand
1
45～50
4.5～5.0
13
Sidestand spring assembly
1
—
—
14
Washer 6
1
—
—
15
Bolt M6×8
1
10～12
1.0～1.2
16
Mounting bolt of sidestand
2
45～50
4.5～5.0
17
Hexagon nut M10×1.25
2
45～50
4.5～5.0
18
Center stand welding assembly
1
—
—
19
Sidestand spring
1
—
—
20
Rubber damper
1
21
Rear pedal assembly
2
—
—
AL
R、G
AL、S
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 304 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
Muffler
No
CO
Chinese name and specifications
Torque
Number
of
N·m
kgf·m
1
Muffler welding assembly
1
—
—
2
Exhaust seal ring assembly
1
—
—
3
Oxygen sensor
1
—
—
4
Hexagon nut with flange M8
4
22～29
2.2～2.9
5
Bolt M8×35
2
22～29
2.2～2.9
6
Guard bush
2
—
—
7
Rubber cover II
—
—
a
is
n
ra
b
s
o
i
r
it
im
D
- torque.
AL: Tighten the fastening bolts alternatively in accordance with the higher locking
A
.
G: Apply grease.
S
S
L: Apply locking agent.
I
N
M: Apply the grease containing molybdenum disulfide. A
R
B disulfide. (A mixture of engine
MO: Apply the oil solvent containing molybdenum
A
Kratio of 10:1)
disulfide-containing grease prepared in a weight
E
G
R: Replace the part.
R
S: Observe the specified tightening
EOsequence.
G
Si: Apply silicon grease.
Y
A
SS: Apply silicone sealant.
OW
T
O
M
- 305 Y
P
2
Note
Ka
oil and molybdenum
k
-d
X. Frame
Preparatory Information--------------------- 10.1
Fault Diagnosis------------------------------- 10.2
Frame------------------------------------------ 10.3
Sidestand-------------------------------------- 10.4
center stand----------------------------------- 10.5
Footpeg ---------------------------------------10.6
Muffler-----------------------------------------10.7
Disassembly / installation of engine------- 10.8
10.1 Preparatory Information
Precautions for operation
Keep the disassembly site clean.
Lift the engine using a jack or other supporting devices.
Tighten bolts and nuts to the specified torque values during assembly.
Check whether all the parts are installed or operated correctly after assembly.
Disassemble the engine when repairing the following parts:
—Cylinder head box valve
—Cylinder and piston
a
b
is
n
ra
Specifications
2.4 L when changing oil
1.2L when disassembling
Oil capacity of engine:
Locking torque
Sidestand bolt
Locknut of side stand bolt
center stand bolt
Locknut of center stand bolt
Mounting screw of front pedal bracket
Front exhaust pipe mounting nut
Rear mounting bolt of muffler cylinder
Lower mounting bolt of engine
I
N
A
BR
A
K
E
G
R
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
.A
S
S
- 306 -
im
D
-
45～50 N·m
45～50 N·m
45～50 N·m
45～50 N·m
22～29 N·m
22～29 N·m
22～29 N·m
45～50 N·m
s
o
i
r
it
Ka
k
-d
Upper mounting bolt of engine
Front mounting bolt of engine
Rear upper mounting bolt of engine
Upper hanging panel mounting bolt of engine
Left front hanging panel assembly mounting screw of engine
Right front hanging panel assembly mounting screw of engine
Left rear hanging panel assembly mounting screw of engine
Right rear hanging panel assembly mounting screw of engine
45～50 N·m
45～50 N·m
45～50 N·m
22～29 N·m
22～29 N·m
22～29 N·m
22～29 N·m
22～29 N·m
10.2 Fault Diagnosis
10.2.1 Compression pressure is low
Wear, burning loss or damage of piston
Wear or damage of cylinder and piston
10.2.2 The gear cannot be engaged
Variable-speed shift fork is broken or deformed
The guide pin of shift fork is broken
10.2.3 It's hard to shift gears
The clutch is not completely disengaged
The return spring of transmission is not working properly
10.2.4 Abnormal sound of crankcase
Scattered or broken parts in the crankcase
a
10.2.5 Engine is automatically stopped
Stuck clutch
b
10.3 Frame
10.3.1 Disassembly of frame
● Drain the oil (see "Periodic Maintenance" - "Replacing
Oil" for details),
●Disassemble:
Seat cushion (see “Frame” – “Removing Seat Cushion”)
Fuel tank (see “Fuel Tank” – “Removing Fuel Tank” for
details)
Cover (see “Cover Parts”)
Rear fender (see “Cover Parts” for details)
Muffler (see “Muffler” – “Removing Muffler” for details)
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
is
n
ra
T
O
M
- 307 -
im
D
-
s
o
i
r
it
Ka
k
-d
Engine (see "Engine" - "Removing Engine" for details)
Brake (see "Front Calipers" - "Removing Front Calipers",
"Rear Calipers" - "Removing Rear Calipers", "Front Master
Cylinder" - "Removing Front Master Cylinder", "Rear
Master Cylinder" - "Removing Rear Master Cylinder")
Rear wheel (see “Rear Wheel” – “Removing Rear Wheel”)
Front wheel (see “Front Wheel” – “Removing Front
Wheel”)
Suspension system (see “Front Shock Absorber” –
“Removing Front Shock Absorber”, “Rear Shock Absorber”
– “Removing Rear Shock Absorber” for details)
Rear swing arm (see “Rear Swing Arm” - "Removing Rear
Swing Arm" for details).
Sidestand (see "Sidestand" - "Removing Sidestand")
Front and rear footpegs (see "Front Footpeg Assembly" "Removing Front Footpeg", "Rear Left Footpeg" "Removing Rear Left Footpeg", "Rear Right Footpeg" "Removing Rear Right Footpeg")
Center stand (see "Center Stand" - "Removing Center
Stand")
● Remove cables and other electrical components.
10.3.2 Installation of frame
● Install the parts that have been removed before in the
reverse order of disassembly (see the corresponding
chapters).
10.3.3 Inspection of frame
a
● Visually check the frame [A] for cracks, dents, bends or
deformations.
★ If the frame is damaged, please replace it!
b
Warning
A repaired frame may fail during use and thus cause
an accident.Therefore, if there is any crack, dent, bend
or deformation on the frame, please replace it!
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 308 -
im
D
-
s
o
i
r
it
Ka
k
-d
10.4 Sidestand
10.4.1 Disassembly of sidestand
● Lift the rear wheel from the ground by fixing the center
stand[A].
●Remove the screw [B], and remove the sidestand stop
switch [A].
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 309 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Disassemble:
Sidestand spring [A]
Thin nut M12×1.25[B]
Spring washer φ12[C]
Bolt M6×8[D]
Washer 6 [E]
Mounting screw of sidestand [F]
Mounting washer of sidestand [G]
Sidestand welding assembly [H]
10.4.2 Installation of sidestand
● Apply grease to the movable parts of sidestand [H].
● Apply locking agent to the threads of sidestand bolt [F].
● Tighten the bolt and lock it with the nut [B].
Locking torque:
Sidestand bolt [A]:
45-50 N·m
Locknut of sidestand bolt [B]: 45-50 N·m
● Install the spring [A] with the long one facing up.
10.5 Center stand
10.5.1 Disassembly of center stand
a
● Put away the center stand [A], support the sidestand [B],
and park the motorcycle on the ground.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 310 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Disassemble:
Sidestand spring [A]
Hexagon nut M10×1.25[B]
Bolt [C]
Center stand welding assembly [D]
Rubber damper [E]
10.5.2 Installation of center stand
● Apply grease to the movable parts of center stand [E].
● Apply locking agent to the threads of center stand bolt [C].
● Tighten the bolt and lock it with the nut [B].
Locking torque:
Center stand bolt [A]:
45-50 N·m
Locknut of center stand bolt [B]:
45-50 N·m
● Install the spring [A] with the long one facing up.
10.6 Pedal
10.6.1 Front pedal assembly
10.6.1.1 Disassembly of front pedal assembly
a
●Disassemble:
Screw [A]
Front pedal assembly [B]
Mounting bushing of front foot rest lever [C]
Front pedal buffer rubber washer [D]
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 311 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Remove rubber cover of footpeg [B] from the welding
assembly [A] of front pedal.
10.6.1.2 Installation of front pedal assembly
●Add grease to the footpeg mounting bushing before
installation.
● Install the parts that have been removed before in the
reverse order of disassembly.
Locking torque:
Front footpeg bracket mounting screw: 22-29 N·m
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 312 -
im
D
-
s
o
i
r
it
Ka
k
-d
10.6.2 Left rear footpeg
10.6.2.1 Disassembly of left rear footpeg
●Disassemble
Cotter pin [A]
Footpeg mounting pin [B]
Left rear pedal [C]
10.6.2.2 Installation of left rear footpeg
●Add grease to the footpeg mounting pin before installation.
● Install the parts that have been removed before in the
reverse order of disassembly.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 313 -
im
D
-
s
o
i
r
it
Ka
k
-d
10.6.3 Rear right footpeg
10.6.3.1 Disassembly of right rear footpeg
●Disassemble
Cotter pin [A]
Footpeg mounting pin [B]
Right rear pedal [C]
10.6.3.2 Installation of rear right footpeg
●Add grease to the footpeg mounting pin before installation.
● Install the parts that have been removed before in the
reverse order of disassembly.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 314 -
im
D
-
s
o
i
r
it
Ka
k
-d
10.7 Muffler
10.7.1 Disassembly of muffler
Warning
Do not remove the muffler while the engine is
heated up, to avoid burns.Do not disassemble the
muffler before it has cooled down.
● Disconnect the oxygen sensor cable connector.
● Remove the mounting nut of front exhaust pipe [A].
●Remove the muffler hanging panel and frame mounting
bolt at the left side [A]
●Remove the muffler [B].
a
b
is
n
ra
●Disassemble:
Oxygen sensor [A].
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 315 -
im
D
-
s
o
i
r
it
Ka
k
-d
10.7.2 Installation of muffler
● Install the parts that have been removed before in the
reverse order of disassembly (see the corresponding
chapters).
● Replace the exhaust pipe gasket [A] with a new one.
Locking torque:
Front exhaust pipe mounting nut:
22-29 N·m
Rear mounting bolt of muffler barrel:
22-29 N•m
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 316 -
im
D
-
s
o
i
r
it
Ka
k
-d
10.8 Disassembly/installation of engine
10.8.1 Exploded View of disassembly/installation of engine
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 317 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
Note
1
Frame welding assembly
1
—
—
2
Self-locking nut M8
2
22～29
2.2～2.9
3
Right cover mounting base of engine
1
—
—
4
Self-locking nut M10×1.25
1
45～50
4.5～5.0
5
Right upper hanging panel of engine
1
—
—
6
Bolt M8×25
2
22～29
2.2～2.9
AL、S
7
0Bolt M8×60
2
22～29
2.2～2.9
AL、S
8
Self-locking nut M10×1.25
1
45～50
4.5～5.0
AL、S
9
Right rear hanging panel assembly of engine
1
—
—
10
Self-locking nut M10×1.25
1
45～50
4.5～5.0
11
Front buffer collar of engine
1
—
—
12
Self-locking nut M10×1.25
1
45～50
4.5～5.0
13
Right front hanging panel assembly of engine
1
—
—
14
Bolt M10×1.25×135
1
45～50
4.5～5.0
15
Rear front hanging panel assembly of engine
1
—
—
16
Front buffer collar of engine
1
—
—
17
Bolt M10×1.25×155
1
45～50
4.5～5.0
AL、S
18
0Bolt M8×60
2
22～29
2.2～2.9
AL、S
19
Left rear hanging panel assembly of engine
1
—
—
20
Hexagon bolt with flange M10×1.25×170
1
45～50
4.5～5.0
AL、S
21
Bolt M8×25
2
22～29
2.2～2.9
AL、S
22
Hexagon bolt with flange M10×1.25×60
1
45～50
4.5～5.0
AL、S
23
Bolt M8×75
2
22～29
2.2～2.9
AL、S
24
Left cover mounting base of engine
1
—
—
25
Left upper hanging panel assembly of engine
1
—
—
AL、S
AL、S
AL、S
AL、S
AL、S
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO:Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 318 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
10.8.2 Disassembly of Engine
● Lift the rear wheel from the ground by fixing the center
stand[A].
● Slowly grab the brake rod, and fasten it using a tire.
Warning
When disassemble the engine, the worker must grip
the brake rod, otherwise, the motorcycle may topple
and fall, thus causing accidents and resulting in
personal injury.
● Drain the oil (see "Periodic Maintenance" - "Replacing
Oil" for details),
●Disassemble:
Seat cushion (see "Cushion" - "Removing Seat Cushion" for
details),
cover (see “Frame” – “Removing Cover” for details).
fuel tank (see “Electronic Fuel Injection System (EFI)”
-“Removal of Fuel Tank” for details),
muffler (see “Frame” – “Removing Muffler” for details),
Drive chain (see "Drive" - ​ ​ "Removing Drive Chain")
●Support the engine with a suitable frame to keep the engine
in balance.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 319 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Loosen the nut [A] and remove the clutch wire connector
[B]
●Loosen the nut [A] and remove the throttle cable connector
[B].
a
●Disconnect each air tube [A]
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 320 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Remove the spark plug cap [A].
●Loosen the clamp between throttle and air filter [A]
●Loosen the clamp at the joint between throttle and intake
manifold [B]
●Remove the rocker arm of shift rod [A].
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 321 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Disconnect the connectors of each cable.
●Loosen:
Front mounting bolt of engine [A].
●Disassemble:
Left front hanging panel assembly mounting bolt of engine
[A].
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 322 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Disassemble:
Right front hanging panel assembly mounting bolt of engine
[A].
●Disassemble:
Remove the rear lower mounting bolt of engine [A].
●Disassemble:
Remove the rear upper mounting nut of engine [A].
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 323 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Disassemble:
Remove the upper mounting nut of engine [A].
●Disassemble:
Right rear hanging panel assembly mounting bolt of engine
[A].
●Disassemble:
Left rear hanging panel assembly mounting bolt of engine [A].
a
b
is
n
ra
●Disassemble:
Right upper hanging panel assembly mounting nut of engine
[A].
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 324 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Disassemble:
Left upper hanging panel assembly mounting bolt of engine
[A].
●Disassemble:
Rear lower mounting bolt of engine [A].
●Remove the engine with a frame.
a
10.8.2 Installation of Engine
b
●Support the engine with a suitable frame.
●Install the rear lower mounting bolt of engine [A], and do
not tighten the corresponding nut too tightly;
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 325 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Install the left upper hanging panel of engine [A] and
install the bolt [B].
●Install the right upper hanging panel of engine [A], install
the nut [B] and do not tighten it too tightly;
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 326 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Install the upper mounting bolt of engine [A], and do not
tighten the corresponding nut too tightly;
●Install the right rear hanging panel of engine [A], install
the bolt [B] and do not tighten it too tightly;
●Install the left rear hanging panel of engine [A], install the
bolt [B] and do not tighten it too tightly;
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 327 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Install the rear upper mounting bolt of engine [A], and do
not tighten the corresponding nut too tightly;
●Install the left front hanging panel of engine [A], install the
bolt [B] and do not tighten it too tightly;
●Install the right front hanging panel of engine [A], install
the bolt [B] and do not tighten it too tightly;
a
b
is
n
ra
●Install the front mounting bolt of engine [A], and do not
tighten the corresponding nut too tightly;
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 328 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Tighten the bolts, screws or nuts as follows:
○Step I: Lock the locknut of rear lower mounting bolt of
engine
○Step II: Lock the locknut of upper mounting bolt of engine
○Step III: Lock the locknut of front mounting bolt of engine
○Step IV: Lock the locknut of rear upper mounting bolt of
engine
○Step V: Lock the clamping nut on the upper hanging panel
of left engine
○Step VI: Lock the clamping bolt on the left front hanging
panel assembly of left engine
○Step VII: Lock the clamping bolt on the right front hanging
panel assembly of right engine
○Step VIII: Lock the clamping bolt on the left rear hanging
panel assembly of left engine
○Step IX: Lock the clamping bolt on the right rear hanging
panel assembly of right engine
○Step X: Mark each fastening bolt, screw and nut that
locked to the specified torque.
Note
○ Fasten the mounting bolts, screws or nuts in three
steps
○Locking torque:
Rear lower mounting bolt of engine:
45-50 N·m
Upper mounting bolt of engine:
45-50 N·m
Front mounting bolt of engine
45-50N·m
Rear upper mounting bolt of engine:
45-50 N·m
Upper hanging panel mounting bolt of engine:
22-29 N·m
Left front hanging panel assembly mounting bolt of
engine:
22-29 N·m
Right front hanging panel assembly mounting bolt of
engine:
22-29 N·m
Left rear hanging panel assembly mounting bolt of
engine:
22-29 N·m
Right rear hanging panel assembly mounting bolt of engine:
22-29 N·m
● Properly arrange the wire, cable and hose (see "Appendix"
- "Winding Method of Cables, Wires and Hoses" for details).
●Install the parts disassembled previously (see the
corresponding chapters).
●Adjustment:
○ Throttle cable (see “Periodic Maintenance” – “Checking
Throttle Control System”),
● Drive chain (see “Periodic Maintenance” – “Inspection of
Slackness of Drive Chain” for details)
● Fill the engine with oil (see "Periodic Maintenance" "Replacing Oil" for details),
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 329 -
im
D
-
s
o
i
r
it
Ka
k
-d
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 330 -
im
D
-
s
o
i
r
it
Ka
k
-d
Inspection and maintenance of engine
Table of torque value of engine fastener
Fastening location and fastener name
Tightening torque (N•m)
Fuel pump mounting screw
10∼12N·m
Fuel pump base mounting screw
10∼12N·m
Mounting bolt of cylinder head cover
10～12N·m
Double end stud of inlet air pipe
10～12N·m
Double-end stud at air exhaust side
10～12N·m
Bolt at sprocket cavity side
9.8N·m
BR7ES/CR7HSA spark plug:
10～12N·m
Sprocket bolt
38N·m
Crank shaft retaining nut
135～140N.m
Hexagon nut with flange M14×1.5
160～165N.m
Hexagonal thin nut
45～50N.m
Assembling bolt
10N·m
Oil seal cover bolt
10N·m
Gear sensor mounting bolt
Breather valve clamp plate assembly
screw
Bearing retainer screw
CO
Y
P
A
R
B
A
K
E
G
Block chain plate bolt
R
EO
G
Holder
Y bolt
A
OW Stud
T
MO
NI
.A
S
S
-
s
o
i
r
6N·m
it
m
Di
4N·m
10N·m
10N·m
10N·m
45N·m
- 331 -
a
Ka
b
is
n
ra
k
-d
Clutch locknut
45～50N·m
Clutch spring bolt
10～12N·m
Right cover mounting bolt
10～12N·m
Oil filter mounting nut
10～12N·m
Crankshaft retainer bolt
5N·m
Star wheel screw
8～10N·m
Positioning roller rocker bolt
8～10N·m
Sprocket mounting nut
110～115N·m
Flywheel locknut
90N·m
Stator assembly mounting bolt
10～12N·m
Trigger probe mounting bolt
5～7N·m
Star wheel combination mounting bolt
10～12N·m
Starter motor mounting bolt
10～12N·m
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 332 -
im
D
-
s
o
i
r
it
Ka
k
-d
Main parameters of engine
Four stroke, single cylinder, four valves, double
Engine type
spark plugs
Cooling mode
Air-cooled
Cylinder diameter×stroke (mm)
72.7×90
Displacement (ml)
373.5
Compression ratio
8.5：1
Maximum net power / corresponding speed
15.5kW/5500 r/min
Maximum torque/ corresponding rotating speed
29.0N.m/4500 r/min
Injection type
Electronic fuel injection
Starting mode
Electric starting
Idle speed
1400r/min
Spark plug model
BR7ES/CR7HSA
Maximum lift
range of
Intake
intake/exhaust
valve
Maximum lift range
10.5mm
Opening angle
354°
Closing angle
572°
Maximum lift range
10.5mm
Opening angle
150°
Closing angle
367°
valves, opening
and closing angle
with respect to the
Exhaust
dead point, and
valve
valve clearance
Lubrication mode
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
im
D
-
2.8L
.A
S
S
Y
P
is
n
ra
b
Ka
Splash lubrication, pressure lubrication
Amount of oil added
T
O
M
s
o
i
r
it
a
- 333 -
k
-d
Lubrication System Diagram
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 334 -
im
D
-
s
o
i
r
it
Ka
k
-d
a
b
is
n
ra
①Camshaft
②Crankshaft
③Oil filter
④Fuel pump
⑤Oil filter
⑥Primary shaft
⑦Primary shaft
⑧Piston
⑨Clutch
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 335 -
im
D
-
s
o
i
r
it
Ka
k
-d
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 336 -
im
D
-
s
o
i
r
it
Ka
k
-d
Fuel pump
No
Chinese name and specifications
Torque
Number
of
N·m
kgf·m
1
Bolt M6×15
1
10～12
1.0～1.2
2
Pressure plate
1
—
—
3
Retainer 10
1
—
—
4
Washer 10.5×16.5×1.5
1
—
—
5
Fuel pump gear assembly
1
—
—
6
Cross recessed pan head screw
1
—
—
7
Screw M6×30
3
10～12
1.0～1.2
8
Fuel pump shaft
1
—
—
9
Fuel pump cover
1
—
—
10
Inner rotor
1
—
—
11
Outer rotor
1
—
—
12
Pin 3×8
2
—
—
13
Fuel pump body
1
—
14
Roller pin
1
—
15
Pin 2.5×16
1
—
16
Oil drip pan
1
—
17
Decompression valve assembly
1
18
Bolt M6×35
1
NI
RA
E
G
R
B
A
K
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
.A
S
—
S
- 337 -
10～12
s
o
i
r
—
it
m
Di —
—
-
—
—
1.0～1.2
Note
a
Ka
b
is
n
ra
k
-d
XI. Lubrication System
Preparatory Information--------------------- 11.1
Fault Diagnosis------------------------------- 11.2
Fuel Pump------------------------------------- 11.3
111.1 Preparatory Information
Action of Lubrication System:
The function of the lubricating system of engine is to provide
lubricant to the friction surface of workpiece to make the dry
surface friction become into the liquid friction between
lubricant particles so as to reduce the wear of parts; cool the
parts with high heat loads; absorb the impacts of bearing and
other parts and reduce noise; increase the sealability between
the piston ring and cylinder wall; clean and remove the
impurities on the surfaces of parts.
Precautions for operation
Note
If the used engine oil is stuck to the skin for a long time, skin
cancer may be caused. Although it is unlikely the waste oil
will be disposed of every day, wash the hands thoroughly
with soap as soon as possible after disposing waste oil.
·Fuel pump can be used only when it is installed in the case of
engine.
a
·The service contents in this section must be performed after
engine oil is drained.
·When removing and installing the fuel pump, prevent dust and
b
dirt from entering the engine.
·If the wear of any parts of fuel pump wear exceeds the use
range, the fuel pump needs to be replaced.
·After installing the fuel pump, check whether the fuel pump is
leaking and the oil pressure is correct.
Technical parameters
Item
.A
S
S
I
N
A
R
When replacing the oilB
Oil capacity
A
K
When disassembling
E between
G
Radial clearance
OR
inner
and outer rotors
E
G
Clearance between outer rotor
Fuel pump rotor
Y
A
and pump
W
Rotor end gap
TO
O
M
- 338 Y
P
O
C
is
n
ra
im
D
-
s
o
i
r
it
Ka
Standard
Allowable limit
2.4L
＿
2.8L
＿
0.05-0.095
0.15
0.11-0.17
0.24
0.07-0.12
0.15
k
-d
Locking torque
Mounting screw of fuel pump
10-12 N·m
Mounting bolt of fuel pump base
10-12 N·m
Tools
Oil Pressure gauge
Connector of oil pressure gauge
11.2 Troubleshooting
11.2.1 Oil level is too low
· Oil consumption
· External leakage
· Piston ring is worn
· Improper installation of piston ring
· Cylinder body is worn
· Valve seal is worn
a
· Valve guide is worn
is
n
ra
11.2.2 Oil pressure is low
b
· Oil level is low
· Oil filter is blocked
· Fuel pump is leaking
· Waste oil is used
.A
S
S
11.2.3 There is no oil pressure
· Oil level is low
· Fuel pump gear is damaged
R
B
A
K
E
RG
· Fuel pump gear or big gear of clutch is damaged
· Fuel pump is damaged
· Fuel pump is leaking
I
N
A
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 339 -
im
D
-
s
o
i
r
it
Ka
k
-d
11.2.4 Oil pressure is high
· Oil filter is blocked
· Waste oil is used
11.2.5 Oil is polluted
· Oil filter is not changed often
· Piston ring is worn
11.2.6 Oil is emulsified
·Cylinder head washer is leaking
·Coolant is leaking
·There is water in the engine
11.3 Fuel Pump
11.3.1 Disassembly
Remove the right cover [A]
a
b
Disassemble:
Bolt [A]
Retainer [B]
Screw [C]
Fuel pump [D]
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
is
n
ra
T
O
M
- 340 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove fuel pump base.
Disassemble fuel pump
Fuel pump body
Outer rotor
Fuel pump shaft
④Inner rotor
11.3.2 Inspection of Fuel Pump
Check the radial clearance of internal and external rotors.
Allowable limit: 0.15mm.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 341 -
im
D
-
s
o
i
r
it
Ka
k
-d
Check the clearance between external rotor and fuel pump base.
Allowable limit: 0.24mm.
Check the end clearance of rotor.
Allowable limit: 0.15mm.
11.3.3 Assembly of Fuel Pump
As shown in the figure
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 342 -
im
D
-
s
o
i
r
it
Ka
k
-d
A. Retainer 10
B. Washer 10.5×16.5×1.5
C. Fuel pump gear assembly
D. Cross recessed pan head screw M6×16
E. Fuel pump cover
F. Outer rotor
G. Inner rotor
H. Fuel pump shaft
J. Pin 3×8
K. Fuel pump body
L. Roller pin
M. Pin 2.5×16
Note:
After assembly, the inner and outer rotors should be able to
rotate flexibly without clamping stagnation.
11.3.4 Installation
Install it in the reverse order of disassembly.
Locking torque:
Mounting bolt of fuel pump base 10-12 N·m
Mounting bolt of fuel pump base 10-12 N·m
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 343 -
im
D
-
s
o
i
r
it
Ka
k
-d
Cylinder Head Cover
10-12N·m
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 344 -
im
D
-
s
o
i
r
it
Ka
k
-d
Cylinder Head Cover
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Bolt M6×16
4
10～12
1.0～1.2
2
Cylinder gasket
4
—
—
3
Cushion
4
—
—
4
Right cylinder head cover
1
—
—
5
Left cylinder head cover
1
—
—
6
Hexagon bolt with flange M6×30
4
10～12
1.0～1.2
7
Bolt M6×14
2
10～12
8
Cylinder Head Cover
1
—
9
Cylinder head cover sealing washer
1
I
N
A
— .A
S
S
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 345 -
s
o
i
r
it
im
D
—
-
1.0～1.2
—
Note
a
Ka
b
is
n
ra
k
-d
XII. Cylinder Head Cover
Preparatory Information--------------------- 12.1
Fault Diagnosis------------------------------- 12.2
Cylinder Head Cover------------------------ 12.3
12.1 Preparatory Information
Precautions for operation
This section includes the services of cylinder head cover
component, cylinder head cover gasket and bolts.
When removing and storing parts, mark them to make sure
they are reinstalled in their original positions.
The disassembled parts need to be cleaned.
When removing the cylinder head cover, be careful not to
damage the matching cylinder head joint surface.
Locking torque
Mounting bolt of cylinder head cover
10-12 N·m
a
12.2 Fault Diagnosis
12.2.1 Oil leakage or seepage of cylinder head cover
· Cylinder head cover sealing washer is damaged
· Cylinder head cover is damaged
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 346 -
im
D
-
b
is
n
ra
s
o
i
r
it
Ka
k
-d
12.3 Cylinder head cover
12.3.1 Disassembly
Disassemble:
Bolt [A]
Right cylinder head cover [B]
Disassemble:
Bolt [A]
Left cylinder head cover [B]
a
Disassemble:
is
n
ra
Bolt [A]
Cylinder head cover [B]
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 347 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove the cylinder head cover sealing washer [A]
12.3.2 Inspection
Cylinder Head Cover
Damaged → replace
12.3.3 Installation
Install it in the reverse order of disassembly.
Note
When cylinder head cover is removed and reinstalled
every time, the gasket of cylinder head cover must be
replaced with a new one.When installing, ensure that the
seal is installed in the groove of cylinder head cover, and
that the groove of cylinder head cover and the cylinder
head mounting surface should be cleaned and free of
debris.
a
b
Locking torque:
Mounting bolt of cylinder head cover: 10-12 N·m
Mounting bolt of left / right cylinder head cover: 10-12N·m
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 348 -
im
D
-
s
o
i
r
it
Ka
k
-d
Cylinder Head / Distribution
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 349 -
im
D
-
s
o
i
r
it
Ka
k
-d
Cylinder head
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 350 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Chinese name and specifications
Torque
Number of
kgf·m
1
Clamp assembly
1
—
—
2
Nut 6
2
10～12
1.0～1.2
3
Double end stud M6×35
2
10～12
1.0～1.2
4
Intake tube components
1
—
—
5
Heat insulated pad
1
—
—
6
O-Ring 42.5×1.8
2
—
—
7
Damping block
3
—
—
8
Spark plug
1
10～12
1.0～1.2
9
Taper plug
4
—
—
10
O-Ring
2
—
—
11
Valve seal components
2
—
—
12
Cylinder head machining assembly
1
—
—
13
Short double-end stud
2
10～12
1.0～1.2
14
O-ring seal 20×2.5
1
—
—
15
Retainer 28
1
—
—
16
Spark plug sleeve
1
—
—
17
O-ring seal 27.4×2.4F
1
—
—
18
Spark plug
1
10～12
1.0～1.2
19
Pressure plate
1
—
—
20
Hexagon bolt with flange M5×12
2
4～7
0.4～0.7
21
O-ring of sprocket cover
1
—
—
22
Sprocket cover
1
—
—
23
Clamp
1
—
—
24
Washer φ6.5
1
—
—
25
Bolt M6×22
1
10～12
1.0～1.2
26
Bolt M6×25
2
10～12
1.0～1.2
27
Dowel pin Φ8×8
2
—
—
28
Inner hexagon screw M6×134
2
10～12
1.0～1.2
29
Cylinder head washer
1
—
—
30
Temperature sensor
1
—
31
Fuel injector
1
—
32
Fuel Injector seat assembly
1
—
33
Bolt M5×12
2
.A
S
S
4～7
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
N·m
Y
P
T
O
M
- 351 -
s
o
i
r
—
it
m
Di —
—
-
0.4～0.7
Note
a
Ka
b
is
n
ra
k
-d
Valve mechanism
a
No
CO
Chinese name and specifications
Torque
Number
of
N·m
kgf·m
1
Intake valve
1
—
—
2
Valve lower spring seat [5]
2
—
—
3
Inner spring of valve
2
—
—
4
Outer spring of valve
2
—
5
Valve lock clamp
4
—
6
Upper spring seat of valve
2
im—
D
-
7
Inlet rocker arm assembly
8
Bolt M10×25
9
Exhaust rocker assembly
10
Camshaft sprocket
11
Inlet rocker arm shaft
12
Exhaust rocker arm shaft
NI
1 A
1
BR
— .A
S
S—
1
E
Camshaft assembly G
13
Y
Exhaust valveA
14
OW
T
O
M
Y
P
O
E
G
R
KA
s
o
i
r
it
—
—
—
38
3.8
—
—
1
—
—
1
—
—
1
—
—
1
—
—
1
—
—
- 352 -
is
n
ra
Note
b
Ka
k
-d
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 353 -
im
D
-
s
o
i
r
it
Ka
k
-d
Timing drive mechanism
a
is
n
ra
b
No
Chinese name and specifications
of
1
Bolt M6×25
2
2
Camshaft chain regulator
1
3
Washer
4
Screw at primary guide chain plate
5
Primary guide chain plate assembly
6
Timing chain
7
Auxiliary guide chain plate component
O
E
G
Y
A
W
N·m
NI
CO
Y
P
—
—
—
1
—
—
1
—
—
1
—
—
O
T
O
M
1.0～1.2
—
A
1
BR
KA
.A
S
S—
10～12
im
D
- kgf·m
—
1
E
G
R
Torque
Number
s
o
i
r
it
- 354 -
Ka
Note
k
-d
XIII. Cylinder Head
Preparatory Information--------------------- 13.1
Fault Diagnosis------------------------------- 13.2
Cylinder Head-------------------------------- 13.3
13.1 Preparatory Information
Function of Cylinder Head:
Cylinder head is used to seal the cylinder and it forms a
combustion chamber with the piston to withstand the high
temperature and high pressure gas. And it can also complete the
intake and exhaust through the distribution mechanism.
Operation Precautions:
In order to ensure the sealing of cylinder head and upper box,
the cylinder head withstands great bolt locking force.
Tightening force: 19-23 N•m.
Before the inspection and measurement, all parts shall be
cleaned and blown with high-pressure air.
Technical parameters
Item
Standard (mm)
Operating limit (mm)
Planeness of cylinder head
0.05
0.05
Intake
0.08-0.12
＿
Exhaust
0.1-0.14
＿
Intake
6.975-6.985
6.925
Exhaust
6.965-6.975
Intake
7-7.015
Exhaust
7-7.015
Intake
im
D
0.025-0.05
-
0.1
1-1.2
1.5
1-1.2
1.5
37.4
36.4
37.4
36.4
36.06
35.5
35.92
35.4
11.977-11.988
11.88
12.000-12.018
12.02
0.012-0.041
0.045
Valve clearance
Outer diameter of valve stem
Valve
Valve guide
Inner diameter of valve guide:
Clearance between valve seam and
valve guide
Width of valve seat
Valve spring
CO
Free length
Exhaust
Intake
IS
N
Intake
A
R
B Exhaust
Exhaust
A
K
Intake
Camshaft
Camshaft height E
G
Exhaust
R
O
Outer diameter of
Erocker arm shaft Intake / exhaust
G
Inner diameter
Y of rocker arm hole Intake / exhaust
Rocker arm
A
Clearance between rocker arm
W
Intake / exhaust
O
shaft and rocker arm hole
T
O
M
- 355 Y
P
s
o
i
r
it
0.015-0.04
S.A
is
n
ra
b6.915
Ka 7.55
7.54
0.1
a
k
-d
Locking torque
Stud bolt of air inlet duct
10～12 N·m
Stud bolt at exhaust side
10～12 N·m
Bolt at sprocket cavity
9.8 N·m
BR7ES/CR7HSA spark plug
Sprocket bolt
10-12N·m
38 N·m
Tools
Feeler gauge
Caliper
a
Micrometer
Runout gauge
13.2 Fault Diagnosis
13.2.1 Compression pressure is low
Valve clearance is not adjusted properly
CO
R
B
A
O
E
G
The spark plug is not installedY
properly
A
OW
T
O
M
Y
P
The washer of cylinder head is leaking
I
N
A
K
E
RG
Valve burns out or is bent
The airtightness of valve seat is not poor
.A
S
S
- 356 -
im
D
-
s
o
i
r
it
Ka
b
is
n
ra
k
-d
13.2.2 The sound of cylinder head is abnormal
Valve clearance is not adjusted properly
Valve spring is damaged
13.2.3 Compression pressure is too high
Excessive carbon deposition in the combustion chamber
13.3 Cylinder head
13.3.1 Disassembly
Remove the cylinder head/ (see 12.3.1 for details)
Remove the retainer [A] at the auxiliary spark plug using a
circlip pliers.
Remove the auxiliary spark plug [B] using a straight
screwdriver.
a
Screw out the auxiliary spark plug [A] using a spark plug
is
n
ra
socket.
Observe whether the spark plug washer is clean.
b
If the organic oil burns out, the airtightness is poor, and O ring
[B] below the spark plug needs to be replaced.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 357 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove 2 fastening bolts [A], and then the tensioner assembly
[B].
Loosen 3 screws [A] and remove the sprocket cover [B] and
O-ring.
Loosen the camshaft sprocket bolt [A].
Remove camshaft driven sprocket [B] and chain.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 358 -
im
D
-
s
o
i
r
it
Ka
k
-d
Loosen the bolt at the side of sprocket cavity[A] and cylinder
bolt [B].
Remove the cylinder head components.
Remove cross recessed countersunk head screw [A], take out
the rocker shaft windshield[B], and remove the rocker shaft.
a
b
Remove the camshaft components
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 359 -
im
D
-
s
o
i
r
it
Ka
k
-d
Valve spring compressor [1][2]
Compress the valve spring with valve spring compression tool
and remove valve cotter [B].
Remove upper base of valve spring [A], outer valve spring [C],
inner valve spring [D], lower base of valve spring [E], valve
[F].
13.3.2 Inspection
●Measure valve clearance with feeler gauge [A]
○Standard of valve clearance:
Intake valve clearance: 0.98-0.12mm
Exhaust valve clearance: 0.10-0.14mm
★If there is a difference between the measured actual valve
clearance and the standard valve clearance, the actual
measured data can be compared with the standard clearance
and the valve adjusting screw can be adjusted to achieve the
standard valve clearance.
a
●Measure the dimensions of rocker shaft using a
micrometer.
○Allowable limit: 11.88mm.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 360 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Measure the inner diameter of rocker arm hole.
Allowable limit: 12.02mm.
●Clearance between rocker arm hole and rocker arm shaft.
○Allowable limit: 0.045mm.
●Measure the height of camshaft with a micrometer [a]
○Allowable limit: intake cam height: 36.06 mm
Exhaust cam height: 35.92 mm
●Clear the carbon deposits on the cylinder head.
●Measure the flatness of the cylinder head joint surface.
○Allowable limit: 0.05mm
★ When the flatness of the cylinder head joint surface
exceeds the use limit, place a fine sandpaper on the flat
plate, make the cylinder head joint surface fit the sandpaper
and sand the surface in 8 shape.
a
b
is
n
ra
●Measure the gradient of intake / exhaust spring of valve.
○Allowable limit: intake spring: 37.4mm.
Exhaust spring: 37.4mm.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 361 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Measure the gradient of intake / exhaust spring of valve
[a].
○Allowable limit: 1.6mm
Measure the external diameter of valve stem.
Allowable limit:
Intake valve: 6.925mm.
Exhaust valve: 6.915mm.
●Measure the run-out of valve stem
○Allowable limit: 0.04 mm
a
●Check the valve guide and remove the carbon deposits in
the valve guide with a reamer before check.
Valve reamer
Note
Rotate the reamer clockwise and do not rotate the
reamer counterclockwise.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 362 -
im
D
-
s
o
i
r
it
Ka
b
is
n
ra
k
-d
●Measure the inner diameter of valve guide. Allowable
limit:
○Intake valve: 6.925mm,
○Exhaust valve: 6.915mm.
●Allowable limit of clearance between valve and valve
guide:
○Intake valve: 0.1mm.
○Exhaust valve: 0.1mm.
●Clean the carbon deposits in the combustion chamber and
valve, and thoroughly rinse the intake and exhaust valves.
●Check the width of valve seat contact surface (width of
valve seat ring) [A].
○Allowable limit: intake /exhaust: 1.5mm
13.3.3 Replacement of Valve Guide
a
Note:
If the clearance between valve and valve guide
exceeds the limit, replace the valve guide. After the valve
guide is replaced, the valve seat ring surface must be
finished.
b
●Put the valve guide in the freezing cavity of refrigerator to
cool it for an hour.
●Use the electric furnace or oven to heat the cylinder head to
100-150℃.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 363 -
im
D
-
s
o
i
r
it
Ka
k
-d
Fix the cylinder head and remove the valve guide from the
upper side of cylinder head with the valve guide disassembly
tool [1].
●Put a new O-ring on the new valve guide.
●Install the valve guide from the top of cylinder head.
○Install new valve guide using valve guide mounting tool
[2] and guide using valve guide remover [1].
a
is
n
ra
Note:
Do not damage the cylinder head when installing the
valve guide.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 364 -
im
D
-
s
o
i
r
it
Ka
k
-d
After the valve guide is embedded, carry out the finishing by
using the valve guide reamer.
Valve reamer
Note:
Add an appropriate amount of cutting oil during cutting
with a reamer. The reamer shall be rotated clockwise.
13.3.4 Finishing Valve Seat Ring
●Use a 45°cutter to remove the rough or uneven parts [A] on the
surface of valve seat ring.
Note:
Apply a layer of transparent or Prussia blue coating to the
valve seat ring. so that it can be seen more clearly.
●Remove 1/4 of outer end of valve seat ring with a 25° cutter.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 365 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Remove 1/4 of bottom of valve seat ring with a 60° cutter. Take
the cutter and check the positions which have been disposed.
●Grind the valve seat ring with a 45° finishing cutter to reach an
appropriate width.
○Make sure to remove all dents and uneven parts.
○Standard valve seat ring width: intake: 1mm-1.2mm
Exhaust: 1mm-1.2mm
○If the contacted position is in the too high part of valve, please
The contact surface
is high
lower the valve seat ring with a 25° flat cutter.
○If the contacted position is in the too low part of valve, raise the
a
valve seat ring with a 60° internal cutter.
○Use the 45° finishing cutter to finish the valve seat ring again to
make it meet the required specification.
The contact surface
is low
●After the valve seat ring is grinded, apply polish to the valve
surface and gently polish the valve.
I
N
A
13.3.5 Installation
R
B
A
K
E
G contrary
●Installation shall be carried out in the order
R
to the disassembly order.
EO
G
●Please adjust the ignition timing after installation. (see
Y timing”)
A
“inspection/adjustment” —“ignition
Precautions for Installation
OW of Valve:
T
O
M
Y
P
O
C
.A
S
S
- 366 -
im
D
-
b
is
n
ra
s
o
i
r
it
Ka
k
-d
●When the valve is installed, apply appropriate amount of
engine oil to the surface of the valve stem and then install
the valve stem into the valve guide.
Valve spring retainer①
Valve oil seal②
Valve③
Valve spring④
Spring plate⑤
Note:
New
product
Before installation, check whether there are burrs at the
end of the valve. If there are burrs at the end of the valve,
polish the end of the valve stem with an oilstone.
●When installing the valve spring, install the end of spring
with smaller pitch toward the combustion chamber.
●Use the valve spring compression tool ② when installing
the valve lock clip ①.
a
●Knock the valve lock plate gently with a soft hammer to fix
it on the valve stem.
Note:
b
Do not knock the valve lock plate overly to avoid
damaging the valve.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 367 -
im
D
-
s
o
i
r
it
Ka
k
-d
Cylinder Block, Piston
Crankshaft connecting rod
45～50N.m
a
is
n
ra
b
.A
S
S
I
N
A
160～165N.m
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 368 -
im
D
-
s
o
i
r
it
Ka
135～140N.m
k
-d
Cylinder Block
a
is
n
ra
b
No
Chinese name and specifications
1
Dowel pin 6×10×16
2
Damping block
3
Cylinder block assembly
4
Cylinder block washer
5
Dowel pin 10.5×13×13
Torque
Number
N·m
2
NI
—
—
1
—
—
2
—
—
O
CO
Y
P
T
O
M
—
—
O
E
G
Y
A
W
kgf·m
—
1
A
1
BR
E
G
R
.A
S
S—
of
KA
im
D
-
s
o
i
r
it
- 369 -
Ka
Note
k
-d
Piston connecting rod crankshaft balance shaft
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 370 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Piston ring
1
10～12
1.0～1.2
2
Piston
1
—
—
3
Piston pin
1
—
—
4
Piston pin retainer
2
—
—
5
O-ring seal 1.8×17
1
—
—
6
Balance shaft
1
—
—
7
Straight key
1
—
—
8
Balancer shaft gear components
1
—
—
9
Washer
1
—
—
10
Nut M12×1.25
1
45～50
4.5～5.0
11
Hexagon nut with flange M14×1.5
1
160～165
16.0～16.5
12
Washer 14.2×30×3
1
—
—
13
Washer
2
—
—
14
Key
1
—
—
15
Crankshaft components
1
—
—
16
Flat key 8×7×25
1
—
—
17
Gear sprocket
1
—
—
18
Clutch drive gear
1
—
—
19
Fuel pump drive gear
1
—
—
20
Washer (II)
1
—
—
21
Washer (I)
1
—
—
22
Crank shaft retaining nut M16×1
1
135～140
13.5～14.0
Note
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 371 -
im
D
-
s
o
i
r
it
Ka
k
-d
XIV. Cylinder Block and Piston
Preparatory Information--------------------- 14.1
Fault Diagnosis------------------------------- 14.2
Cylinder -------------------------------------- 14.3
Piston------------------------------------------ 14.4
14.1 Preparatory Information
Function of cylinder block:
The cylinder block provides a space for gas compression,
combustion and expansion and guides the movement of piston.
It can also transfer some heat in the cylinder to the surrounding
cooling mediums.
Function of piston:
a
1. It can withstand the pressure generated by the combustion of
combustible gas mixture in the cylinder and transmit the
is
n
ra
pressure to the connecting rod to drive the crankshaft to rotate.
2. Form a combustion chamber together with the cylinder head
b
and other parts.
Operation Precautions:
s
o
i
r
it
im
D
Before the inspection and measurement, all parts shall be cleaned and blown with high-pressure
air.
A
.
S
S
I
AN
R
B
A
K
E
G
R
EO
G
Y
A
OW
T
O
M
- 372 Y
P
CO
Ka
k
-d
Technical parameters
Item
limit
Inner diameter
72.7~72.715
72.815
Cylindricity
0.008
0.05
Roundness
0.007
0.05
Planeness
0.03
0.06
Outer diameter of piston (measurement point)
72.735~72.75
(7mm at the bottom of piston skirt)
72.7
Inner diameter of piston pin hole
17.002~17.008
17.04
Outer diameter of piston pin
17~17.006
16.96
Clearance between piston and piston pin
0.002~0.014
0.07
Cylinder
Piston and piston ring
Allowable
standard value
Clearance between piston
First ring
0.03~0.07
0.1
ring and ring groove
Second ring
0.03~0.07
0.1
First ring
0.15~0.3
0.55
Second ring
0.25~45
0.75
Oil ring
0.20-0.7
＿
Piston ring joint clearance
Connecting rod small
Inner diameter of connecting rod small end
17.012~17.021
17.05
end
Clearance between connecting rod and piston pin
0.012~0.027
0.10
Lateral clearance of big end of connecting rod
0.1~0.30
0.50
Radial clearance of big end of connecting rod
0.03~0.058
0.05
Run-out
0.02
0.1
Crankshaft components
Locking torque
Crank shaft retaining nut
135~140N.m
Hexagon nut with flange
M14×1.5
Hexagon thin nut
45-50N.m
160~165N.m
a
is
n
ra
Tools
b
.A
S
S
im
D
-
s
o
i
r
it
I
N
A
R
B
A
Feeler gauge
K
E
RG
O
E
G
Y
A
W
Caliper
O
CO
Y
P
T
O
M
- 373 -
Ka
k
-d
Micrometer
Runout gauge
① Opening clamp
② Piston
Piston ring opening clamp
Piston pin pull-out device
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
Cylinder diameter tester
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 374 -
im
D
-
s
o
i
r
it
Ka
k
-d
14.2 Fault Diagnosis
14.2.1 Compression pressure is low
Wear, burning loss or damage of piston
Wear or damage of cylinder and piston
Damage of washer and leakage between crankcase and gas
14.2.2 Compression pressure is too high
Excessive carbon deposition in the combustion chamber
14.2.3 Exhaust pipe is emitting white smoke
Wear and damage of piston ring
Wear or damage of piston and cylinder
14.2.4 The sound of piston is abnormal
Damage of cylinder, piston and piston ring
Wear of piston pin hole and piston pin
14.3 Cylinder Block
14.3.1 Disassembly
Remove the cylinder head/ (see 12.3.1 for details)
Disassemble the cylinder head. (see 13.3.1 for details)
a
Remove the cylinder block [A].
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 375 -
im
D
-
s
o
i
r
it
Ka
k
-d
Remove the washer [A] and dowel pin [B].
14.3.2 Inspection
Check the wear situation of inner wall of cylinder.
If the wear is serious, please replace it.
14.3.3 Installation of cylinder
a
Install the washer [A] and dowel pin [B] on the crankcase.
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 376 -
im
D
-
s
o
i
r
it
Ka
k
-d
Apply oil to the inner wall of cylinder, piston and piston ring.
Install the piston ring into the cylinder carefully.
*Note:
Do not damage the piston ring.
14.4 Piston
14.4.1 Disassembly
●Remove the piston pin retainer.
Note:
During disassembly, do not drop the retainer into the crankcase.
●Take out the piston pin [A] and remove piston.
a
●Remove the piston ring.
○Check the piston, piston pin and piston ring.
is
n
ra
Note:
Do not break or damage the piston ring.
b
○Clear the carbon deposits inside the piston ring groove.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 377 -
im
D
-
s
o
i
r
it
Ka
k
-d
14.4.2 Inspection
●Install the piston ring.
●Measure the clearance between piston ring and piston ring
groove.
○Allowable limit: top ring: 0.1mm.
Second ring: 0.1mm.
●Remove the piston ring and install the piston rings at the
bottom of cylinder.
*Note:
Note: Press the piston ring [A] in the cylinder by using the
piston head [B].
● Measure the piston ring joint clearance.
○Allowable limit: first ring: 0.55mm.
Second ring: 0.75mm
●Measure the inner diameter of piston pin hole.
○Allowable limit: 17.04mm.
a
b
is
n
ra
●Measure the outer diameter of piston pin.
○ Allowable limit: 16.96mm.
●Clearance between piston pin hole and piston pin.
○ Allowable limit: 0.07mm.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 378 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Measure the outer diameter of piston pin.
*Note:
The measurement position forms an angle of 90 degrees
with the piston pin and it is 7mm below the piston skirt
part.
○ Allowable limit: 72.7mm.
●Check the damage and wear on the inner wall of cylinder.
*Note:
Measure the inner diameter of cylinder in the upper,
middle and lower positions in the direction which forms a
right angle (90 degrees) with the piston pin.
○ Allowable limit: 72.815mm.
●Measure the clearance between cylinder and piston ,
whichever is the greater
○Allowable limit: 0.115mm.
●Measure the roundness of inner wall of cylinder (inner
diameter difference between X and Y directions).
Allowable limit: 0.05mm
●Measure the cylindricity of inner wall of cylinder (inner
diameter difference between X and Y directions in upper,
middle and lower positions).
Allowable limit: 0.05mm
a
Upper
b
Middle
.A
S
SLower
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 379 -
is
n
ra
im
D
-
s
o
i
r
it
Ka
k
-d
●Check the planeness of cylinder surface.
○Allowable limit: 0.06mm.
●Measure the inner diameter of small end of connecting rod.
○Allowable limit: 17.05mm.
13.4.3 Installation of Piston
●Apply oil to the piston ring and piston evenly, make the
piston ring mark side up and install it properly.
*Note:
Do not scratch the piston and do not break the piston ring.
After the piston ring is installed, it can rotate freely in the
piston ring groove.
Top ring
Second ring
Oil ring
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 380 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
●Clean the washers attached to the crankcase[A].
*Note:
Foreign matters shall not fall into the crankcase.
●Install the piston, piston pin and piston pin retainer.
*Note:
Install the piston into the intake valve according to the
“IN” mark [A] at the top.
14.5 Crankshaft connecting rod
14.5.1 Inspection
a
●Measure the lateral clearance of big end of connecting rod.
○Allowable limit: 0.55mm.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
Plug gauge
- 381 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Measure the clearance of big end of connecting rod in X-Y
direction.
○ Allowable limit: 0.05mm
●Measure the run-out of crankshaft.
○ Allowable limit: 0.1mm
Measuring point
●Check whether the crankshaft bearing rotates with
abnormal noise or whether it is loose.
★ If there is abnormal noise or it is loose, replace the
crankshaft assembly.
Crankshaft bearing
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 382 -
im
D
-
s
o
i
r
it
Ka
k
-d
Crankshaft connecting rod
45~50N.m
160~165N.m
135~140N.
m
Crankcase
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 383 -
im
D
-
s
o
i
r
it
Ka
k
-d
Crankcase
a
No
Chinese name and specifications
1
Torque
Number
of
N·m
kgf·m
Crankcase machining assembly (matte black)
1
—
—
2
Taper plug
1
—
—
3
Bolt M6×75
4
10～12
4
Conical plug M10×1
3
—
5
Seal I
1
6
Oil Seal
1
7
Oil seal cover
1
8
Bolt M6×10
9
O-Ring 20.3×2.65
10
Gear sensor
11
Screw M5×16
12
13
14
Y
P
CO
E
G
Throttle plug
Y
A
Oil filter
OW
O-ring 22.4×1.8
T
O
M
-
O
E
G
R
.A
S
S—
—
I
N
A
s
o
i
r
it
1.0～1.2
im—
D
—
—
—
—
10～12
1.0～1.2
1
—
—
1
—
—
2
5～7
0.5～0.7
2
—
—
1
—
—
1
—
—
KA
B2R
- 384 -
is
n
ra
Note
b
Ka
k
-d
15
Oil filter plug
1
—
—
16
Stud
4
—
—
17
Washer 10.5×19.8×2
4
—
—
18
Self-locking nut M10×1.25
4
45～50
4.5～5.0
19
Bolt M6×60
14
10～12
1.0～1.2
20
Rolling bearing
2
—
—
21
Bearing I
2
—
—
22
Bearing II
2
—
—
23
Rubber Blanket
1
—
—
24
Plug screw
1
—
—
25
Sealing washer
1
—
—
26
Screw M6×12
5
10～12
1.0～1.2
27
Bearing retainer II
5
—
—
28
Rolling bearing
1
—
—
29
Dowel pin
2
—
—
30
Rolling bearing
1
—
—
31
Limit retaining screw
1
—
—
32
Rolling bearing
1
—
—
33
Rolling bearing
1
—
—
34
Rolling bearing
1
—
—
35
Breather pipe
1
—
—
36
Taper plug M14×1.5×10
1
—
—
37
Filter housing
1
—
—
38
Assembling washer
1
—
—
39
Holder
1
—
—
40
Bolt M6×14
2
10～12
1.0～1.2
41
Combination screw M4×10
6
3.5～4.5
0.35～0.45
42
Rivetφ3×13
1
—
—
43
Breather valve retainer
1
—
—
44
Paper washer of breather valve
1
—
—
45
Screw M6×14
2
—
—
46
Block chain plate
1
—
—
47
O-Ring
1
—
—
48
O-ring Φ12.5×1.8
1
—
—
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 385 -
im
D
-
s
o
i
r
it
a
Ka
b
is
n
ra
k
-d
XV. Crankcase
Preparatory Information------------------------------------------------------- 15.1
Dismounting and Mounting Diagram of Crankcase Bearing------------- 15.2
Crankcase------------------------------------------------------------------------ 15.3
15.1 Preparatory Information
Function of crankcase:
The crankcase is the bearing part of engine. Its main function is
to support the crankshaft, clutch, gearbox, cylinder block and
cylinder head, withstand the combustion explosion impact and
inertia force of movement of crankshaft connecting rod
mechanism and form a part of closed (oil and air seal) space.
Operation Precautions:
The crankcase is also equipped with suspension holes, and the
engine is connected with the frame and other parts through the
connection with the suspension holes on the motorcycle.
a
This section mainly introduces the disassembly and installation
of parts of crankcase, torque value of bolt specifications, Note
is
n
ra
for disassembly and installation and other services;
b
Locking torque
Assembling bolt
10 N·m
Apply oil
Oil seal cover bolt
10 N·m
Apply oil
Gear position sensor mounting screw
6 N·m
Apply oil
Breather valve retainer assembly screw
4 N·m
Apply oil
Bearing retainer screw
10 N·m
Block chain plate bolt
10 N·m
Bracket bolt
10 N·m
.A
S
S
Apply
I locking agent
N
A Apply oil
R
B
A
K
45 N·m
E
RG
Two-headed bolt
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
im
D
-
- 386 -
Apply oil
Apply oil
s
o
i
r
it
Ka
k
-d
15.2 Disassembly and Installation of Crankcase Bearing
Serial number
Note
Designation:
1
Needle bearing 6203
Apply oil
2
Rolling bearing 6322
Apply oil
3
Oil Seal
Apply oil
4
Rolling bearing 6304
Apply oil
5
Oil Seal
Apply oil
6
Rolling bearing 6304
Apply oil
7
Rolling bearing 6905
Apply oil
8
Rolling bearing 6205
Apply oil
9
Rolling bearing 6004
Apply oil
Locking torque
a
Bearing retainer screw
10 N·m
Apply locking agent
Precautions
1.
2.
3.
The bearing disassembled cannot be reused and should
be replaced with a new one;
Bearings and oil seals should be disassembled by using
special tools, to prevent damaging the crankcase body;
When installing new bearing and oil seal, apply oil or
lubricating grease with the specifications shown in the
figure;
K
E
RG
O
O
CO
Y
P
T
O
M
.A
S
S
I
N
A
R
B
A
E
G
Y
A
W
b
- 387 -
im
D
-
is
n
ra
s
o
i
r
it
Ka
k
-d
15.3 Crankcase
15.3.1 Disassembly of crankcase
●Steps for opening crankcase:
○Right crankcase assembly ①
a. Remove assembling bolt of crankcase
Precautions:
For the crankcase assembling bolt marked as shown in
the figure, first loosen 1/4 of the engagement length and then
completely loosen assembling bolt later in the staggered
mode;
○Left crankcase assembly ②
b. Open the components of right crankcase
Precautions:
Insert a screwdriver to the disassembling point in the
box, and then carefully open the upper and lower boxes;
Tap the side of box using a soft hammer, only tap the
reinforced part of box but not the processing surface of box,
tap it carefully and slowly, to ensure that the upper and lower
boxes are evenly separated;
a
b
c．Remove the dowel pin;
15.3.2 Inspection of crankcase
Precautions:
1.
2.
.A
S
S
Clean the disassembled crankcase parts with detergent;
I
N
A
Clean the disassembling surface of crankcase and the
R
B
A
joint surface of left and right covers;
3.
The crankcase is a thin-walled casting. Heavy impact
K
E
RG
should be avoided during the operation to prevent
deformation or breakage.
4.
Check Item
CO
O
E
G
Y
A
W
Before operation, the lubricant in the crankcase should
be released.
Y
P
O
T
O
M
is
n
ra
- 388 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Check the crankshaft for defects such as cracks.
★ If there is any defect, replace crankshaft components.
●Check the oil filter for clogging and damage.
★If there is any defect, replace oil filter.
● Check the timing chain
○ Visually check whether the chain is worn, and feel with
two hands whether the chain is rotating unsmoothly and
inflexibly.
★ If necessary, replace the timing chain, and adjust the
initial position of the main chain guide plate tensioner.
a
b
is
n
ra
● Check crankcase bearing
○ Rotate the inner ring of bearing with your fingers to check
whether the bearing cannot rotate flexibly and is blocked.
★If necessary, replace the new bearing with special tools.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 389 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Check oil seal
○ Check the seal lip for damage or deformation, and whether
there is any edge cut deformation in the outer ring.
★If necessary, replace the new bearing with special tools.
15.4.3 Assembly of crankcase
Precautions
● Clean the parts, apply oil or grease with the specified
specifications evenly on the seal of bearing to be replaced for
future use.
● Bearing, bearing plate:
Note:
The round edge side of retainer of bearing faces the
pressing surface of bearing, and the tightening torque of
retainer bolt should be ensured (7N•m).
● Clean the assembling surface and other joint surfaces.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 390 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Apply sealant at the assembling surface:
Note:
Apply sealant around the bolt hole evenly, and prevent
sealant going into the lubricating oil passage of crankcase.
● After the internal parts of left crankcase are assembled,
assemble the right crankcase to left crankcase, and slightly
knock the crankcase with a soft hammer;
a
●Assembling bolt
Note:
Tighten the assembling bolt on the left crankcase, the
tightening torque of which should meet the requirements
(10N•m);
Then tighten the assembling bolt on the right crankcase,
the tightening torque of which should meet the requirements
(10N•m);
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 391 -
im
D
-
s
o
i
r
it
Ka
k
-d
Clutch
Position of right cover
10N·m
12N·m
Position of clutch
10N·m
45N·m
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 392 -
im
D
-
s
o
i
r
it
Ka
k
-d
Right Cover
No
CO
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Bolt M6×38
2
10～12
1.0～1.2
2
Bolt M6×30
12
10～12
1.0～1.2
3
Inner hexagon screw M6×30
3
10～12
1.0～1.2
4
Filter cover
1
—
—
5
O-Ring
1
—
—
6
Engine oil filter assembly
1
—
—
7
Oil level indicator assembly
1
—
—
8
Conical plug M12×1.5
1
—
—
9
Conical plug M10×1
1
—
—
10
Right Cover
1
—
—
11
Dowel pin
2
—
12
Washer on the right cover
1
—
im
D
- —
13
Plug screw of oil filler
1
—
—
14
O-Ring 18×3.5
1
—
—
15
Lever spring
—
—
16
Needle bearing 12×16×10
—
—
1
—
—
1
—
—
1
—
—
1
.A
S
S
I
N
A
K
Lever oil seal
17
E
G
Operating lever riveting component
18
R
Nameplate
19
EO
G
Y
A
OW
T
O
M
Y
P
R
B
2
A
- 393 -
s
o
i
r
it
—
Note
a
Ka
b
is
n
ra
k
-d
Clutch
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Driving hub assembly of clutch.
1
—
—
2
Spline washer
1
—
—
3
Clutch component
1
—
—
4
Driven hub assembly of clutch
1
—
—
5
Lock washer
1
—
—
6
Slef-locking nut
1
45～50
4.5～5.0
7
Friction pad 2
4
—
—
8
Clutch plate
6
—
—
9
Friction pad 1
3
—
—
10
Clutch lever
1
—
—
11
Plane needle bearing
1
—
—
12
Bolt assembly
4
10～12
1.0～1.2
13
Filter spring
4
—
—
14
Driven hub base of clutch
1
—
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 394 -
s
o
i
r
it
im—
D
-
Note
a
Ka
b
is
n
ra
k
-d
XVI. Clutch
Preparatory Information--------------------- 16.1
Fault Diagnosis------------------------------- 16.2
Right Cover----------------------------------- 16.3
Clutch ---------------------------------------- 16.3
16.1 Preparatory Information
Operation Precautions:
·Install the engine on the frame, and disassemble right cover
and clutch.
·Engine oil viscosity and oil level may affect clutch separation.
When the clutch is not separated or unclear, check the engine
oil level before repairing the clutch system.
Technical parameters
Item
Standard
Allowable limit
10°-20°
—
Free length of clutch spring
35
33.7
Thickness of clutch friction
2.9-3.0
2.6
wrapping of clutch metal plate
—
0.3
Inner diameter of clutch bushing
—
—
Outer diameter of clutch bushing
—
Free corner of clutch operating lever
45-50 N·m
Clutch spring bolt
10-12 N·m
Right cover mounting bolt
10-12 N·m
Oil filter mounting bolt
10-12 N·m
Crankshaft retainer bolt
5 N·m
.A
S
S
I
N
A
K
E
RG
R
B
A
Apply locking agent to threads
O
Tools
E
G
Y
A
W
O
CO
Y
P
T
O
M
im
D
-
- 395 -
s—
o
i
r
it
is
n
ra
b
Ka
Locking torque
Clutch lock nut
a
k
-d
Central pivot universal fixer of clutch
16.2 Fault Diagnosis
16.2.1 Clutch lever is too hard to pull
·The detaching mechanism of clutch is damaged
·The detaching bearing of clutch fails
·The push rod of clutch is not installed properly
16.2.2 Clutch is slipping when accelerating
·The friction plate of clutch is worn
·The clutch spring is not elastic enough
·Engine oil is mixed with molybdenum or graphite additives
16.2.3 Clutch does not disengage or clutch disengages suddenly during the
running of motorcycle
b
·Clutch plate is wrapping
·Clutch lock nut is loosened
·The oil level is too high
·Oil viscosity is poor
.A
S
S
·The detaching mechanism of clutch is damaged
·The push rod of clutch is not installed properly
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 396 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
16.3 Right Cover
16.3.1 Disassembly of Right Cover
Loosen the clamp bolt and remove the right cover.
16.3.2 Install the right cover
●Installation shall be carried out in the order contrary to the
disassembly order.
Locking torque:
Right cover mounting bolt: 10-12 N·m
a
16.4 Clutch
b
16.4.1 Disassembly of clutch
●Fix the clutch driven hub base [A] using a dedicated clutch
central pivot universal fixer, and the clutch cannot be
rotated.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 397 -
im
D
-
s
o
i
r
it
Ka
k
-d
○Central pivot universal fixer of clutch
●Loosen bolt assembly [A] and remove clutch driven hub
base [B].
● Remove the clutch spring [A].
● Remove the clutch friction plate and clutch metal plate
[B].
a
●Loosen clutch lock nut, and remove the clutch lock nut
[A].
●Remove clutch driven hub assembly [B] and spline washer.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 398 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Remove clutch driving hub assembly [A].
●Remove clutch lever [A], thrust washer [C], plane needle
bearing [B].
16.4.2 Inspection
● Check the outer groove of clutch for any burrs or broken
marks.
★ If necessary, finish it using a file, and replace it if the
amount of finishing is too large.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 399 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Check the tooth forms of clutch central pivot plate [A] and
retainer [B] for damage.
★If damaged, replaced it.
●Measure the free length of pressure spring [A].
○Allowable limit: Replace it if the length is less than
29.7mm.
a
●Measure the thickness of friction plate with a vernier
calipers [A].
○Allowable limit: Replace it if the thickness is less than
2.6mm.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 400 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Check the flatness of clutch metal plate with a feeler
gauge.
○Allowable limit: Replace it if the flatness is more than
0.3mm.
16.4.3 Installation of clutch
●Install the clutch in the reverse order of disassembly.
Locking torque:
Clutch lock nut: 45-50 N·m
Clutch spring bolt: 10-12 N·m
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 401 -
im
D
-
s
o
i
r
it
Ka
k
-d
Gearshift Mechanism
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 402 -
im
D
-
s
o
i
r
it
Ka
k
-d
Gearshift Mechanism
a
is
n
ra
b
No
CO
Chinese name and specifications
of
N·m
—
1
Shift shaft assembly
1
2
Bolt M6×20
1
3
Washer
1
4
Stopper lever spring
1
5
Rocker arm assembly
6
Washer
7
Star wheel screw
8
Ratchet
.A
S
S—
8～10
I
N
A
E
G
Collar
9
Y
Dowel pin A
10
OW
T
O
M
Y
P
O
E
G
R
-
0.8～1.0
—
—
—
—
—
1
—
—
1
8～10
0.8～1.0
1
—
—
1
—
—
1
—
—
B1R
KA
s
o
i
r
it
kgf·m
m
Di —
Torque
Number
- 403 -
Ka
Note
k
-d
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 404 -
im
D
-
s
o
i
r
it
Ka
k
-d
XVII. Gearshift Mechanism
Preparatory Information--------------------- 17.1
Fault Diagnosis------------------------------- 17.2
Gearshift Mechanism------------------------ 17.3
17.1 Preparatory Information
Locking torque
Start wheel bolt
8-10 N·m
Positioning roller rocker bolt
8-10 N·m
Apply locking agent
17.2 Fault Diagnosis
17.2.1 It is difficult to shift gears
·Clutch operation is incorrect
·Oil viscosity is incorrect
a
·Shift fork is bent
is
n
ra
·Shift fork is bent
·Shift fork jaw is bent
b
·Gearshift positioning star wheel is damaged
·Positioning roller rocker bolt is loosened
·Positioning roller rocker is damaged
·The shift shaft and shift arm are damaged
.A
S
S
17.2.2 Shift pedal is not returned
I
N
A
·The return spring of gearshift shaft is damaged or its elasticity is weakened
R
B
A
·Gearshift shaft is bent
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 405 -
im
D
-
s
o
i
r
it
Ka
k
-d
17.3 Gearshift Mechanism
17.3.1 Disassembly
●Pull out the gearshift shaft assembly [A]
●Disassemble the following parts in order:
Positioning roller rocker bolt [A]
Washer [B]
Positioning roller rocker assembly [C]
Roller rocker spring
a
Note:
b
There are two washers behind and pay attention to
prevent missing
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 406 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Disassemble
Star wheel bolt [A]
Collar [B]
Ratchet [C]
●Remove the dowel pin [A]
17.3.2 Inspection
●Before disassembly, the shift plate [A] should be able to
return flexibly without clamping.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 407 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Check the shift shaft [A]
★Check it for bending, wear and damage
●Check the wear of shift locking plate.
★ If the wear is serious, please replace it.
●Remove the shift shaft spring [B].
★ Check the shift shaft spring for damage and weakened
elasticity, and replace it when necessary
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 408 -
im
D
-
s
o
i
r
it
Ka
k
-d
17.3.3 Installation
●Tighten the star wheel screw [A] after assembling collar
[B] and ratchet [C].
○The tightening torque is12 N·m, and apply locking agent
to the thread.
●Hook the rocker arm spring [D] to the rivet of box and
positioning roller rocker arm, install upper washer [B] and
positioning roller rocker arm [A].
○Tighten the positioning roller rocker arm bolt with a
tightening torque of 10N·m.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 409 -
im
D
-
s
o
i
r
it
Ka
k
-d
Drive system
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 410 -
im
D
-
s
o
i
r
it
Ka
k
-d
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 411 -
im
D
-
s
o
i
r
it
Ka
k
-d
Drive system
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 412 -
im
D
-
s
o
i
r
it
Ka
k
-d
No
Torque
Number
Chinese name and specifications
of
N·m
kgf·m
1
Shift drum
1
—
—
2
Prod spring
1
—
—
3
Shifting prod
1
—
—
4
Elastic retainer for shaft
1
—
—
5
Collar
1
—
—
6
Thrust washer
1
—
—
7
Auxiliary shaft combination
1
—
—
8
O-Ring
1
—
—
9
Output sprocket collar
1
—
—
10
Sprocket
1
—
—
11
Spline washer
1
—
—
12
Nut M18×1
1
110～115
11.0～11.5
13
Shift fork shaft
1
—
—
14
Shift fork III
1
—
—
15
Shift fork I
1
—
—
16
Primary Shaft Assembly
1
—
—
17
Shift fork II
1
—
—
18
Shift fork shaft I
1
—
—
Note
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 413 -
im
D
-
s
o
i
r
it
Ka
k
-d
XVIII. Drive System
Preparatory Information--------------------- 18.1
Fault Diagnosis------------------------------- 18.2
Drive system---------------------------------- 18.3
Installation------------------------------------ 18.4
18.1 Preparatory Information
Function:
Transmit torque, and decide the torque and speed of final output.
Technical parameters
Item
Shift fork
Shift fork shaft
Shift drum
standard value
Limit value
Inner diameter
10.016～10.034
10.05
Thickness of claw
4.93～5.00
4.90
Outer diameter
9.991～10.00
9.98
Outer diameter
41.8～42.0
41.7
Groove width
6.05～6.15
6.2
M4
25.020～25.041
25.06
M5
28.016～28.033
28.05
C1
20.020～20.41
C2
25.020～25.041
C3
25.020～25.041
Installation position of M5
27.967～27.98
27.95
Installation position of M4
im
24.98～24.993
D
-
24.96
19.966～19.984
15.95
24.959～24.98
24.94
24.959～24.98
24.94
0.035～0.075
0.105
0.027～0.061
0.09
0.040～0.082
0.110
0.040～0.082
0.110
Inner diameter of gear
Outer diameter of collar of
internal spline
Drive system
CO
Outer diameter of primary shaft
Installation position of C1
.A
Outer diameter of auxiliary shaft
Installation positionS
of C2
IS
Installation N
position of C3
Fit clearance between collar and
RAC1
B
A
shaft
K
E
M4
G
Tolerance clearance between
gear
R
C2
and shaftO
E
C3
G
Y
Locking torqueWA
TObolt 110-115 N·m
Sprocket mounting
O
M
- 414 PY
s
o
i
r
it
is
n
a
br25.06
20.06
Ka
22.06
a
k
-d
18.2 Fault Diagnosis
18.2.1 Drive system trips over stop or is out of gear
·Positioning roller rocker is damaged
·Positioning roller rocker spring is damaged or its elasticity is weakened·
·Positioning roller rocker bolt is loosened
·Shift fork shaft or shift fork is bent or damaged
·Gearshift star wheel is bent or damaged
·Shift fork is bent or damaged
18.2.2 The noise of engine is too large
·The gear of drive system is damaged
·The bearing of drive system is damaged
18.3 Drive system
18.3.1 Primary shaft component
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 415 -
im
D
-
s
o
i
r
it
Ka
k
-d
18.3.2 Auxiliary shaft component
18.3.3 Inspection
●Check the shift fork (applicable to all shift forks)
·Shift fork head ①
·Shift fork claw ②
★Bending, damage, wear → Replace shift fork
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 416 -
im
D
-
s
o
i
r
it
Ka
k
-d
Measure the inner diameter of shift fork hole.
Allowable limit: 10.05mm.
Measure the thickness of shift fork.
Allowable limit: 4.90mm.
●Check shift fork shaft
○Put the shift fork at a plane and roll it back and forth
★Bending→replacement
a
Warning
Do not try to straighten the bent shift fork shaft
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 417 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Measure the outer diameter of shift fork shaft.
Allowable limit: 9.98mm.
●Check the sliding of shift fork (along the shift fork shaft)
★ The shift fork cannot slide flexibly → Replace the
complete set of shift fork and shift fork shaft
●Check the shift drum
○Shift drum stroke groove
★ Damage, scratches and wear → Replace shift drum
component
○Shift drum shaft section
★Bending, wear → Replace shift drum component
a
b
is
n
ra
Measure the outer diameter of shift drum.
Allowable limit: 41.7mm.
Measure the width of lock groove of shift drum.
Allowable limit: 6.2mm.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 418 -
im
D
-
s
o
i
r
it
Ka
Lock groove
k
-d
●Measure the main axle runout (with centering device and
dial indicator)
★Exceed the limit size → replace the main axle
Limit size of main axle runout: 0.03mm
●Measure the auxiliary axle runout (with centering device
and dial indicator)
★Exceed the limit size → replace the auxiliary axle
Limit size of auxiliary axle runout: 0.03mm
● Inspection
○Gear
★ Bluegrass, pitting corrosion, wear → Replace defective
gears
○Gear pawl
★Cracks, damage, round edges → Replace defective gears
● Inspection
○ Gear engagement (gear teeth of each gear)
★Incorrect → Reassemble the drive shaft component
a
b
is
n
ra
● Inspection
○Gear rotation
★Inflexible rotation → Replace defective parts
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 419 -
im
D
-
s
o
i
r
it
Ka
k
-d
● Inspection
○Retainer
★Bending, damage, looseness → Replacement
18.4 Installation
18.4.1 Assembly of Primary Shaft Component and Auxiliary Shaft
Component
●Installation
○Spline washer ②
○Retainer ①
Note:
Make sure that the sharp edge of retainer ○
A is located on
the side opposite to spline washer; make sure that the
opening of retainer ○
b is located on the spline groove of
shaft○
c
a
b
is
n
ra
.A
S
S
●Installation
○2nd Gear of primary shaft ①
CO
R
B
A
K
E
Gprimary shaft
Install the 2nd Gear of primary shaft onR
the
②, and then measure after compaction
EO○a
G
Y
A
OW
T
O
M
Y
P
Note:
I
N
A
- 420 -
im
D
-
s
o
i
r
it
Ka
k
-d
18.4.2 Assembly of parts at the shift drum
●Installation
○Shift prod ①
○Prod spring ②
Note:
First assemble prod spring ② to the shift drum ③ , and
then assemble the shift prod ① to the shift drum ③ ; the
assembly
shall
be
conducted
when
installing
the
transmission system, to prevent parts from falling off
18.4.3 Installation of drive system
18.4.3.1 Installation
·Auxiliary shaft component ①
·Primary shaft component ②
·Shift drum component
·Left shift fork of auxiliary shaft ③
·Right shift fork of auxiliary shaft ④
·Shift fork shaft of auxiliary shaft ⑤
·Middle shift fork of primary shaft ⑥
·Shift fork shaft of primary shaft ⑦
a
·O-ring ⑧
·Collar ⑨
·Output sprocket ⑩
b
110～115N·m
·Lock nut
·Lock plate
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 421 -
im
D
-
s
o
i
r
it
Ka
k
-d
·Thrust washer
·Collar
· Retainer
Note:
·When installing the left shift fork, make sure that the
side of shift fork with the ribs on it is facing away
from the right crankcase of engine.
·When installing the right shift fork, make sure that
the side of shift fork with the ribs on it is facing away
from the left crankcase of engine. Make sure that the
shift fork head is located in the shift drum stroke
groove.
18.4.3.2 Inspection
● Transmission system
★Inflexible rotation→Repair
Note:
·Fully grease the gears, shafts, bearings and other
parts.
·When assembling, ensure that the transmission
system is in neutral and each gear can rotate freely
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 422 -
im
D
-
s
o
i
r
it
Ka
k
-d
Electric Starter
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 423 -
im
D
-
s
o
i
r
it
Ka
k
-d
Electric starting
No
Chinese name and specifications
of
N·m
kgf·m
10～12
1.0～1.2
1
Bolt M6×32
2
2
Starter motor assembly
1
3
Screw M8×14
3
22～29
2.2～2.9
4
Flywheel combination
1
—
—
5
Electric starter gear shaft
1
—
—
6
Electric starter idle shaft
1
—
7
Electric starter idle gear
1
—
8
Close-packed clutch assembly
1
im
D
- —
9
Starter gear assembly
1
10
Stator assembly
1
11
Screw M5×16
12
Screw M6×30
13
Electric starter gear
E
G
Y
A
W
O
E
G
R
.A
S
S—
—
I
N
A
Y
P
T
O
M
s
o
i
r
it
—
—
—
—
—
5～7
0.5～0.7
3
10～12
1.0～1.2
1
—
—
KA
B2R
O
CO
Torque
Number
- 424 -
Note
Ka
b
is
n
ra
a
k
-d
XIX. Electric Starter Mechanism
Preparatory Information---------------------19.1
Fault Diagnosis---------------------19.2
Electric Starter Mechanism-----------------19.3
19.1 Preparatory Information
Technical parameters
Item
Starter gear
Outer diameter of axle section
standard value
Limit value
45.653～45.677
45.573
Locking torque
Flywheel locknut
90 N·m
Stator assembly mounting bolt
10-12N·m
Trigger probe mounting bolt
5-7N·m
Star wheel combination mounting bolt
10-12N·m
Starter motor mounting bolt
10-12 N·m
a
19.2 Troubleshooting
b
19.2.1 Engine cannot start
·Overrunning clutch is damaged
· Starter wheel or idle gear is damaged
.A
S
S
Starter motor is damaged
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 425 -
im
D
-
s
o
i
r
it
Ka
k
-d
19.3 Electric starter mechanism
19.3.1 Disassembly of electric starter mechanism
● Loosen left cover bolt [A].
*Note:
Note: Loosen the bolt in a criss-cross form, and loosen the
bolt by 1/4 each time and then remove the left cover
● Remove the left cover [B]
● Loosen the outgoing line retainer mounting bolt [A], and
take down the outgoing line retainer [B].
a
b
●Loosen stator assembly mounting bolt [A] and trigger
mounting bolt [B], and remove the stator assembly [C]
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 426 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Loosen flywheel locknut [A] using the electric tools, pull
out the flywheel clutch assembly [B] using three-jaw chuck,
remove the electric starter idle gear [E], electric starter idle
gear shaft [F], electric starter gear [C] and electric starter gear
shaft [D]
●Anticlockwise rotate starter gear assembly [A], as shown in
the figure.
●Take out the starter gear assembly.
●Loosen star wheel combination mounting bolt [A] and
remove the star wheel combination [B].
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 427 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Loosen motor mounting bolt [A] and remove the starter
motor [B].
19.3.2 Installation of electric starter mechanism
●Install it in the reverse order of disassembly.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 428 -
im
D
-
s
o
i
r
it
Ka
k
-d
Muffler catalyst
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 429 -
im
D
-
s
o
i
r
it
Ka
k
-d
Emission Control
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 430 -
im
D
-
s
o
i
r
it
Ka
k
-d
a
b
is
n
ra
Ka
k
-d
Temporarily absorb the fuel steam overflowing from the fuel tank into the charcoal canister using the adsorption effect of
the activated carbon in the canister;
When negative pressure is generated in the fuel tank, air will enter the canister from the atmosphere entry, enter the
evaporating tube from the absorbing port, and finally enter the fuel tank.
When the engine is running under certain conditions, it will be absorbed under the control of EVBP, fuel steam will be led
to the engine for combustion, and the absorption capacity of the activated carbon in the canister will recover.
When the evaporation plant is blocked, the breather valve will play the following roles:
1. When positive pressure (8-15kpa) is generated in the fuel tank, the breather valve will automatically exhaust air.
2. When negative pressure (-1.0- -1.5kpa) is generated in the fuel tank, the breather valve will be automatically opened, and
air will enter the fuel tank through the breather valve.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 431 -
im
D
-
s
o
i
r
it
XX. Exhaust Emission Control System
Guarantee of Exhaust Emission Control System-------------------- 20.1
Regular Maintenance Notice/Guarantee Emission Standard------ 20.2
Mechanical Function of Exhaust Control System------------------- 20.3
Catalytic Conversion System------------------------------------------ 20.4
20.1 Guarantee of Exhaust Emission Control System
1.
1. The exhaust emission control system of the motorcycle complies with the provisions of Regulation (EU) No
134/2014. This Company will provide the guarantee in the case of completely normal use and maintenance as required
within the effective service life of the exhaust emission control system.
2. Scope of guarantee
1) Function guarantee of exhaust emission control system
It is guaranteed that the system meets the regular or irregular exhaust inspection performed by government
agencies within the scope of use (15,000 km).
3. If the following situations exist, this guarantee clause will not be applicable, but the provincial or city dealers or
service departments of this Company are still willing to serve customers at a reasonable price if there are maintenance
needs.
1) The regular maintenance is not performed according to the time or mileage specified by this Company.
2) The regular inspection, adjustment or maintenance is not carried out at the dealers or service centers of this
Company or the maintenance record certificates cannot be provided.
3) Overload or improper use.
4) The motorcycle is transformed, original parts are disassembled or other devices are installed at will.
5) The motorcycle is used for races or frequently ridden on the roads which are applicable to non-motor vehicles.
6) Damage is caused due to typhoon, flood and other weather disasters or damage and faults are caused due to
negligence, accident or impact of foreign objects.
7) The motorcycle is disused in a long term without regular maintenance.
8) The odometer is damaged and not maintained immediately or it is transformed, disused or changed artificially.
9) The motorcycle is sent to the inspection station for exhaust inspection every three months.
The new motorcycles of this Company have passed the UNECE regulation No 41 including all amendments up to
Series 04, Supplement 3 standard implemented by EU through the noise inspection results.
is
n
ra
b
20.2 Regular Maintenance Notice

.A
S
S
In order to ensure that the degree of environmental pollution will not become increasingly serious, the state requires
that all the motor vehicles produced by all manufacturers must meet the air pollution emission standards. The
production of this Company meets the provisions of air pollution emission standards, meanwhile, the Company also
strives to purify the air and take efforts to reduce air pollution.
This motorcycle has passed rigorous inspection before leaving the factory and meets the provisions of air pollution
emission standards. However, due to the different service conditions of this product, we have formulated the following
regular checklist on exhaust emission. To ensure normal emission, the users should carry out inspection, adjustment or
maintenance in accordance with the specified time.
For other individual problems on use, please ask the dealers or Service Center.
The relevant emission provisions are shown below:
I
N
A

R
B
A
K
E
RG
O


CO
im
D
-
s
o
i
r
it
Ka
Y
P
E
G
Y
A
W
O
T
O
M
- 432 -
a
k
-d
Emission regulation
Emission standard
CO
≤1.14g/km
HC
≤0.38g/km
NOX
0.07g/km

※ If the emission standard changes, the newest national provision shall prevail.
If the regular inspection is not carried out at the dealers or service centers of this Company, this Company will not be
responsible for the prohibition. Please make necessary inspection at any time to maintain the best motorcycle
conditions.
Note: ①The cleaning frequency of air filter should be increased if the motorcycle is ridden on sandy roads or in the
seriously polluted environment to prolong the service life of engine.
② If the motorcycle is always ridden at a high speed or in a frequent manner with large mileage, the
maintenance degree should be increased.
Precautions for guarantee of emission standards
1)
2)
3)
4)
The unleaded gasoline should be restricted.
The engine oil with the specification specified should be used.
Please carry out maintenance in accordance with the provisions of the regular maintenance table.
For the exhaust control system, arbitrary adjustment or replacement (including use of spark plug, idle adjustment
and ignition timing) is strictly prohibited.
5) Precautions:
The catalyst device will be greatly affected due to the block of ignition system, charging system or fuel system;
therefore, please go to the dealers or service centers specified by this Company for inspection, adjustment or
maintenance if you feel that the engine is unsmooth.
6) The exhaust control system of the motorcycle complies with the national regulations. Therefore, if any parts of the
system need to be replaced, make sure to use the original parts of this Company and carry out replacement by the
specified dealer or service center
20.3 Mechanical Function of Exhaust Control System
Summary
The exhaust countermeasure is to use four-stroke single-cylinder engine and air induction device, maintain a good
level of exhaust and adopt activated carbon canisters for exhaust from fuel evaporation.
※ Engine improvement
is
n
ra
Strive to increase the combustion efficiency depending on improved spark plug, combustion chamber, compression
ratio, ignition time, exhaust system and other engine elements and high intake and exhaust efficiency.
b
※ Air induction device
im
D
-
s
o
i
r
it
Ka
After air is induced into the exhaust pipe, the chemical reaction of incompletely burnt CO and HC will occur to
generate harmless gases.
Distinction
Device
.A
S
S
Constituent part
Exhaust system
I
N
Catalyst device
Catalyst converter
RA
B
A
K
E
G
OR
E
G
Y
A
W
O
OT
P
O
C
M
Y
- 433 -
Function
The canned oxydic catalyst installed in the
middle of exhaust pipe will oxidize CO,
HC and NOX.
a
k
-d
20.4 Catalyst Conversion System
20.4.1 Structure:
a
is
n
ra
b
20.4.2 Description:
1.
im
D
-
s
o
i
r
it
Ka
The function of catalyst conversion is to convert the completely burnt gases (including HC, CO and NOX) into H2O,
CO2, N2 and other harmless gases and then discharge them.
2. When the catalyst containing platinum, rhodium and other rare metals is converted, unleaded gasoline should be
used.
※Leaded gasoline will lead to the failure of catalyst.
• General precautions during maintenance of motorcycles (exhaust pipes) with catalytic converters:
1) The motorcycle with a catalytic converter should not be touched after the engine is turned on or off, because the
temperature is high in a short time.
2) The motorcycle with a catalytic converter should not be close to combustibles.
3) The carbon monoxide in the exhaust pipe is harmful to human body, so do not operate the engine in a closed
space.
4) The motorcycle with a catalytic converter should not use leaded gasoline. (to prevent catalyst poisoning)
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 434 -
k
-d
5)
6)
7)
8)
Do not start the engine by pushing the motorcycle. If necessary, start the engine by pushing the motorcycle after
the temperature of the engine and catalytic converter is reduced.
Do not ride the motorcycle by putting into gear or turning off the motorcycle during downhill running.
Do not ride the motorcycle with poor ignition.
When maintaining the ignition system of engine, it is not allowed to start the engine to check whether the spark
plug can generate sparks by removing the spark plug. If it is necessary, the time should not be too long.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 435 -
im
D
-
s
o
i
r
it
Ka
k
-d
XXI. Fuel injection system (EFI)
21.1 Introduction to EFI
This motorcycle adopts the small engine electronic injection system from Delphi Corporation. For this system, the
closed-loop control is realized by an oxygen sensor and the ECU oil injection and ignition are controlled. A three-way
catalyst is used to carry out after treatment for the gas burnt by the engine to convert it into harmless gas and discharge it
to the air. This system adopts the closed-loop control self-learning system which can effectively eliminate the
manufacturing differences between the system and related mechanical parts, improve the overall consistency of the
motorcycle and remove the errors caused due to wear and other factors after actual use.
Idle control valve
Throttle valve position
sensor
Crankshaft position sensor
Burglar alarm
Throttle body
Optional
23X crankshaft
position target
gear
Ignition coil
Heating oxygen sensor
Engine temperature sensor
Engine control module
Nozzle
intake temperature
neutral position switch
a
Down switch
Serial communication
interface of fault
diagnosis switch
intake pressure sensor
b
Ignition switch
Fault indicator
light
Battery
Engine speed
signal
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 436 -
is
n
ra
im
D
-
s
o
i
r
it
Ka
Metal carrier catalytic
converter
k
-d
Connector
O
CO
Y
P
T
O
M
O
E
G
Y
A
W
R
B
A
K
E
RG
- 437 -
I
N
A
.A
S
S
im
D
-
Battery power supply
Oxygen sensor signal of cylinder 1
5V reference voltage
Ignition power supply
Cooling water temperature signal
23X signal is low
Throttle position signal
Intake pressure signal
5V reference voltage grounding (signal
grounding)
Fuel pump control signal
Intake temperature signal
Oxygen sensor of cylinder 1 is heated
Nozzle A
23X signal is low
KW2000
The power supply (system) is grounded
Ignition coil drive A (cylinder 1)
Neutral clutch switch
Sidestand shutdown signal
Idle stepper motor B low
Idle stepper motor B high
Idle stepper motor A low
Ignition coil drive B (cylinder 2)
The power supply (system) is grounded
CAN line signal is high
CAN line signal is low
Tachometer
Fault light
EVBP
Idle control valve A high
Function Description
21.2 EFI system
a
b
s
o
i
r
it
Ka
is
n
ra
k
-d
Number of ECU connector
Connector
J1-1
J1-2
J1-3
J1-4
J1-5
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
J2-1
J2-2
J2-3
J2-4
J2-5
J2-6
J2-7
J2-8
J2-9
J2-10
J2-11
J2-12
J2-13
J2-14
J2-15
J2-16
J2-17
J2-18
Function Description
Idle control valve A high
Canister solenoid valve
Fault light
Tachometer
CAN line signal is low
CAN line signal is high
The power supply (system) is grounded
Idle control valve A low
Idle control valve B high
Idle control valve B low
Vehicle-down sensor signal (optional)
Fuel pump control signal circuit
Neutral position switch
Ignition coil drive A:
The power supply (system) is grounded
K line communication pin
23 gear signal is low
Nozzle A
Oxygen sensor is heated
Inlet temperature signal
Fuel pump control signal
5V reference voltage grounding
Inlet pressure signal
Throttle position signal
23 gear signal is high
Cylinder head temperature signal
Ignition power supply
5V reference voltage
Oxygen sensor signal
Battery power supply
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 438 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.3 EFI part position
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 439 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.4 Technical parameters
Item
Standard
Electronic Fuel Injection System
Idling
Throttle valve assembly:
identity
Diameter
Negative pressure value of throttle valve
Bypass screw
ECU：
Manufacturer
identity
1400 ±100 r/min （rpm）
Cylinder-shaped
Φ37 mm
–––
MT05.2
Delphi
Electronic memory type with built-in IC igniter, sealed
with resin
100 ∼ 15000 r/min （rpm）
250 kPa
Available engine speed range
Fuel pressure (high pressure hose):
Fuel pump:
identity
Oil pump capacity
Fuel injector:
Nozzle type
Resistance:
Main throttle sensor:
Input supply voltage
Output supply voltage
Resistance
Inlet air pressure sensor / atmospheric pressure sensor
Input supply voltage
Output supply voltage
Inlet temperature sensor:
ECU output voltage
Resistance
Fuel tank built-in friction pump
≥67 mL (2.3 US oz.) every 3 seconds
Fine atomization type,
≈10-15 Ω at 20°C (68°F)
DC 4.75 ∼ 5.25 V
DC 0.25 - 4.65 V (throttle opening is idle to fully open)
3 ∼ 12kΩ
DC 4.75 ∼ 5.25 V
DC 3.80 ∼ 4.20 V [standard atmospheric pressure]
2.0 - 2.69 kΩ at 20°C (68°F);
0.30-0.37 kΩ at 80°C (176°F)
Oxygen sensor (model with oxygen sensor):
Output power supply voltage (peak value at the highest ≥DC 0.8 V
air-fuel ratio)
Output power supply voltage (peak value at the lowest air-fuel ≤DC 0.45 V
ratio)
Heating coil resistance
=6.7-12Ω at 20°C (68°F)
.A
S
S
I
N
A
Throttle handle and throttle cable
Free clearance of throttle handle
Air filter
Element material
G
Y
WA
EO
K
E
RG
R
B
A
3∼5 mm
Dry paper filter element
O
CO
Y
P
T
O
M
im
D
-
- 440 -
s
o
i
r
it
Ka
b
is
n
ra
a
k
-d
21.5 Precautions for EFI Overhaul
21.5.1 Precautions for EFI Overhaul
There are the following important precautions in the
process of overhauling the EFI system.
○The power supply of this EFI system must be supplied
by a 12V battery. Do not use any other battery as a power
source for the EFI system.
○Do not connect the battery cable reversely. Otherwise,
the ECU may be damaged.
○ To avoid damage to EFI parts, do not disconnect the
battery cable or any other electrical connectors while the
electric door lock is in the “ON” position or while the
engine is running.
○Be careful not to short-circuit the cable that directly
connect the positive (+) electrode of the battery and the
ground wire of the chassis.
○ Disconnect the connecting wire between battery and
motorcycle during charging to avoid excessive voltage
and damage to the ECU.
○ Turn off the electric door lock before disconnecting the
EFI electrical connection, and then disconnect the battery
(-) pin. Do not pull the wire and only pull the connector.
Conversely, make sure that each EFI electrical connector
has been properly connected before starting the engine.
○ Connect the connector adapter to the power supply with
bridges properly.
a
b
is
n
ra
○ Do not open the electric door lock if no EFI electrical
connectors are connected. The ECU will remember the
fault code.
○Do not spray water on electrical parts, EFI parts
connectors, leads and electric wires!
○If the motorcycle is equipped with a transceiver, ensure
that the operation of the EFI system is not affected by the
radio waves emitted by the antenna. Run the engine at idle
speed and check the operating status of system. The
antenna shall be kept away from the ECU as far as
possible.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 441 -
im
D
-
s
o
i
r
it
Ka
k
-d
○ Do not open the electric door lock if any fuel hose is
disconnected. Otherwise, the fuel pump will run, thereby
causing fuel to be ejected from the fuel hose.
○Do not operate when the fuel pump is completely dry to
prevent the fuel pump from getting stuck.
○ Before disassembling the parts of the fuel injection
system, blow off the dirt or dust on the outside of the parts
with compressed air.
○ When any fuel hose is disconnected, fuel may be ejected
due to residual pressure in the hose Therefore, cover the
hose joint with a clean rag to prevent fuel from
overflowing.
○ When installing the hose, avoid bending, twisting or
warping the hose, and do not bend the hose as much as
possible to avoid blocking the oil circuit.
Arrange the fuel hose in accordance with section
"Winding Method of Cables, Wires and Hoses" of chapter
"Appendix".
○ Do not add any fuel antifreeze chemicals to the fuel to
avoid corroding the fuel injection system or causing
deposits in the fuel injection system.
○ If the operation method is improper, the high pressure
inside the fuel hose may cause fuel leakage [A] or fuel
hose rupture. Bend and twist when inspecting the fuel
hose.
★If the fuel hose is found to be broken or swelled, it must
be replaced!
a
○ In order to maintain the correct mixing ratio of fuel and
air (F/A), there must be no air intake leakage in the EFI
system. Always tighten the filler plug [A] after adding the
oil.
Locking torque of filler plug: tighten by hands.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 442 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.6 ECU
21.6.1 Engine controller (MT05 ECU)
The engine controller can detect the operating state of
the engine in real time through various sensors. Ensure the
original motorcycle emission and fuel economy while
optimizing the driving performance of motorcycle under
various working conditions through reasonable calculation
and self-learning control output devices. The engine
controller can also wake up the self-diagnosis when the
system is faulty.
21.6.2 ECU Appearance
The upper part of MT05 engine controller housing is
made of plastic and the bottom is made of aluminum
alloy. The picture shows the front and back of MT05
controller.
a
b
is
n
ra
.A
S
S
I
N
A
21.6.3 ECU disassembly
R
B
A
K
E
RG
O
●Remove rear seat cushion (see "Frame" - "Removing Rear
Seat Cushion")
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 443 -
im
D
-
s
o
i
r
it
Ka
k
-d
●Disassemble:
ECU[A]
Bolt [B]
21.6.4 ECU installation
●Install it in the reverse order of disassembly.
Tightening bolt torque of ECU: 3.9N•m
Warning
The mounting surface must be flat to prevent
generating external force to the controller and thus
making the circuit board bent.
21.6.5 Precautions for ECU
Precautions
Cause
Do not: Place the ECU near the exhaust pipe or engine
High temperatures may reduce the service life of ECU
and even directly damage the ECU
Do not: place the ECU near water drops, engine oil or any liquid ECU may be damaged by liquid
Do not: Allow mud or other contaminants to cover the ECU Mud or other pollutants may cover the ECU and thus
surface
affect the heat dissipation
Do not: Connect the additional power voltage to the ECU
It may cause problems with ECU performance and even
cause damage to the ECU
Do not: Wash the ECU with solvents or corrosive liquids.
It may cause damage to the ECU housing
Ka
b
is
n
ra
Please: ensure that water or large amounts of moisture should The ECU connector may be short-circuited, thus causing
not drip or adhere to the ECU connector
damage to the ECU
Please: Clean the ECU with a damp cloth and dry it
s
o
i
r
t
It can prevent ECU from ibeing damaged
m
Di
.A
S
NIS
21.6.6 ECU power supply requirements



Power supply: If the battery voltage is greater than 6.3
volts, the ECU's power supply module can start the
control chip, and this is automatically controlled by the
ECU.
Power range: The ECU can operate within the range of 9
to 16 volts of battery and ignition voltage.
Shutdown: Shut down the ECU when its ignition voltage
is below 6.2 volts. The ECU can enter the shutdown
procedures and store important information in the ECU's
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 444 -
a
k
-d



memory.
Restart: All outputs are set to a preset state during the
restart process. The ECU can monitor itself in real time
and automatically enter the restart when an internal error
is detected. After restart, ECU will follow the normal
procedures.
Overvoltage: The ECU will not be permanently damaged
if it is operated for 1 minute under the DC voltage of
below 24V.
Reverse voltage: The ECU will not be permanently
damaged if it is operated for 1 minute under the DC
inverse voltage of below 13V.
21.6.7 ECU temperature requirements
Operating temperature: The ECU is able to work
normally between minus 20 degrees Celsius and minus 85
degrees Celsius.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 445 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.7 Fuel Pump
21.7.1 Working of fuel pump
The fuel pump assembly can provide the fuel whose
gasoline pressure meets the system requirements at 250Kpa.
It is installed at the bottom of tank to provide the required
fuel oil to engine through the connecting pipes.
●Fuel pump:
The electrical principle of electric fuel pump is that
when the DC motor drives the turbine-type fuel pump to
run, the fuel in the circumferential groove of turbine rotor
will move at high speed along with the turbine rotor.Due to
the action of high-speed centrifugal force, the fuel pressure
at the outlet is increased, and at the same time, the
high-speed rotating turbine generates a certain vacuum at the
inlet of oil pump, so that the fuel is sucked from the inlet
into the space of turbine blade.The differential pressure of
fuel inlet and outlet may cause the fuel source to be
continuously pumped to the outlet side and transmitted to
the fuel line of system. The fuel transfer pressure generated
by the fuel pump can be up to 250 kPa.
●Pressure regulating device:
It is mechanical diaphragm type, and can be used to
make pressure regulation to fuel pump device, so as to
achieve the constant fuel pressure required by the system.
21.7.2Appearance of fuel pump
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 446 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.7.3 Fuel pump composition
21.7.4 Fuel pump label and logo
fume pump assembly: Make it at fuel pump assembly
installing plate in the form of label.
Fuel pump: make engraved mark at fuel pump.
Oil pressure regulator: make engraved mark on the shell.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 447 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.7.5 Working environment of fuel pump



The fuel pump assembly needs to be installed at the
bottom of fuel tank according to the requirements.
The pump assembly is generally designed for only
gasoline fuel and the fuel with a ethanol-gasoline fuel
ratio of 22%
Make sure that there is enough fuel in the fuel tank in
the first operation of fuel pump assembly, and do not
run it in the absence of oil.
21.7.6 Maintenance process of fuel pump:
21.7.6.1 Safety protection:
When conducting maintenance operation for fuel system,
care should be taken to ensure personal safety.
 Disconnect the negative electrode of storage battery of
motorcycle.
 Smoking is prohibited and a “no smoking” sign should
be placed near the operating area.
 Ensure that there is a fire extinguishing device.
 The operating environment is well ventilated and away
from open flames.
 Wear safety goggles.
 To release fuel vapors in the fuel tank, open tank cover
and refit it.
 There is still a high pressure in the fuel line after the
engine stops running, then oil may be injected after
disassembling or releasing fuel line. Refer to “Fuel
Pressure Release Process” in this section.
 A small amount of fuel may flow out after
disassembling fuel line, in order to avoid the risk, the
blocking device at the fuel pipe should be used for
blockage.
 After maintenance is completed, please ensure that the
fuel line and clamp are properly installed.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 448 -
im
D
-
s
o
i
r
it
Ka
k
-d


After maintenance is completed, check system oil
leakage according to the provisions of “Fuel Leakage
Check Process”.
After maintenance is completed, connect the negative
electrode of battery and ensure that there is sufficient
fuel in the fuel tank when the fuel pump is running.
21.7.6.2 Fault diagnosis of fuel pump assembly
Step
1
2
3
4
5
Operation
Yes
If you can hear that the fuel
After ignition key is started, fuel pump will
pump is running, please go to
run for 3 seconds.
Step IV directly.
Disconnect the connector of fuel pump, and
check whether the supply voltage of fuel Conduct Step III
pump is within the range of 10-14V
Supply 12V DC current to fuel pump.
1. Check the circuit from
Ensure that there is sufficient oil in the tank,
fuel pump to ECU;
to prevent dry running of fuel pump
2. Check ECU
Is fuel pump running?
Check whether the front fuel supply pressure
Fuel pump assembly is
of nozzle is within the range of 220-270kpa
running normally
when engine is in idle running.
1. Check whether there is
Use the oil pressure gauge to test whether the
leakage at fuel pipe joint
2. Check fuel pump
fuel hose pressure is lower than 220kpa
3. Check pressure regulator
No
If you cannot hear that the
fuel pump is running, please
conduct Step II.
Check the power supply
circuit of fuel pump
1. Check fuel pump
harness
2. Check fuel pump
Perform Step IV
1. Check whether the fuel
filter is blocked
2. Check whether fuel pipe
is bent and twisted
3. Check pressure regulator
21.7.6.3 Disassembly of fuel pump assembly:










Refer to “Fuel Pressure Release Process” to release the
fuel pressure in the fuel line.
Disconnect the negative electrode line of storage
battery.
Disconnect fuel pump assembly harness connector.
Remove the remaining fuel from the fuel tank and store
it in a suitable container, to ensure safety and reduce
contamination.
Remove the connecting fuel hose to fuel pump
assembly using spring compressor assembly
Remove the fuel tank from the motorcycle.
Do not invert the fuel tank, to avoid tank scratches and
bumps.
Affect fuel pump assembly mounting bolt.
Carefully remove the fuel pump assembly from the fuel
tank
Be careful to not damage fuel pump filter screen.
a
b
is
n
ra
I
N
A
.A
S
S
R
B
A
21.7.6.4 Installation of fuel pump assembly:
K
E assembly
 Replace the sealing washer of fuelG
pump
R
(Used washer may lead to fuelO
leakage)
E
 Lightly support the fuel pump strainer and carefully
G
put the fuel pump Y
assembly into the tank. Avoid
Ascreen of fuel pump.
damaging the W
filter
Installation
of fuel pump assembly:
TOthe direction
Arrange
installing screw holes of fuel pump
O
M
- 449 Y
P
CO
im
D
-
s
o
i
r
it
Ka
k
-d





assembly asymmetrically, and installed it in the
specified direction. The pressure regulator should
face the rear of fuel tank, and ensure that the
installing surface of fuel tank is clean and flat.
Install mounting bolts on the fuel pump assembly
cover plate and tighten them evenly in the order
indicated in the following figure. Installing torque of
screw: 3- 4 Nm
The fuel pump assembly should be secured with
special bolts.It should be tightened according to
specified tightening order and torque during the
installation.Over torque an incorrect tightening
order may cause washer deformation and thus
result in leakage.
Install the fuel tank on the motorcycle.
Connect fuel pipe and fix it with a suitable clamp.
Connect the fuel pump harness connector.
Check for leaks according to “Fuel Leakage Check
Process” before the operation of engine.
21.7.6.5 Fuel pressure release process:
Precautions:
Do not operate when the engine is in warning-up state.
After confirming that the engine is in cooling state, conduct
the following fuel pressure release operation:
 The motorcycle is in “neutral” state.
 Disconnect the connector between fuel pump
assembly harness and motorcycle harness.
 Turn on motor to start engine until the engine is
automatically extinguished. Then continuously turn
on and off the ignition key for 2-3 times, with an
internal of 3 seconds each time.
 After completing the above operations, connect the
fuel pump assembly harness connector.
a
21.7.6.6 Fuel leakage check process:
After performing any fuel system maintenance, perform fuel
leakage check test.
 Fill the tank with sufficient fuel.
 Turn on ignition key for 3 seconds, and then turn
off it for 15 seconds, repeat the above operations
for 3-4 times, to establish the oil pressure in the
fuel line.
 Check whether there is leakage in the parts of fuel
system (fuel tank, connecting pipes, pipe joint,
etc.).
21.7.7 Note for use:
Precautions
b
.A
S
S
im
D
-
s
o
i
r
it
Ka
I
N
A
R
B
A
K
E
RG
Cause
It may cause damage to the internal of fuel pump
O
E
Do not: "dry run" fuel pump (there
G is no oil at fuel
Y
pump inlet and filter screen)
It may cause damage to the internal of fuel pump
A
W
Please ensure thatO
there is sufficient fuel in the tank
T
O
M
- 450 Y
P
CO
Do not: throw or touch fuel pump
is
n
ra
k
-d
Do not: damage filter screen during the maintenance
Impurities may go into the fuel pump from damaged filter screen
and thus damage the fuel pump body
Do not: disassemble the internal parts of fuel pump
“Three guarantees” will not be provided after disassembly
and pressure regulator
Do not: regulate fuel pump and pressure regulator without permission
(except replacement)
Do not: lift fuel pump assembly through fuel pump
assembly harness
Harness is damaged / the power supply of fuel pump is
Do not: lift fuel pump harness in the direction vertical disconnected
to fuel pump cover plate
Do not: use damaged pipe clamp
Pressure leakage/fuel leakage
Do not: use seriously damaged fuel pump filter screen Impurities may go into the fuel pump from damaged filter screen
or cut fuel pump assembly
and thus damage the fuel pump body
Do not: pump oil from fuel tank using fuel pump
Fuel pump is not designed for this purpose
Do not: Install screws to fix other parts using fuel
Affect fuel pump assembly installation
pump assembly
Do not: Damage fuel pump harness during the The terminal may be damaged and thus poor contact is caused / the
maintenance of fuel pump assembly
power supply of fuel pump is disconnected
Do not: Contact fuel pump assembly when fuel
Avoid damaging fuel pump assembly
pumping oil from the tank manually
Please: Ensure that the tank is not damaged during
Avoid oil leakage
maintenance
Please: Only use “original” fuel pump assembly
Fake washer may cause fuel leakage
sealing washer
Please: Use designated hose clamp
Ensure that there is no fuel leakage and seepage at pipe joint
Please: Fix fuel pump harness at motorcycle
Reduce shock
Please: Use standard fuel
The fuel with poor quality may damage the fuel pump too early
Please: Replace fuel filter within the specified time
Blocked filter may reduce fuel supply
Please: Use specified and qualified fuel filter
Unqualified filter may damage nozzle, oil pressure regulator and
fuel pump
Please: Ensure to correctly arrange the ways of fuel
Incorrect ways and interference may damage fuel pipe
pipes and not interfere with other parts
Please: Ensure that there is sufficient fuel in the tank
Avoid “running in dry state” of fuel pump
(submerge fuel pump filter)
is
n
ra
b
Ka
s
o
i
r
Please: During the pressure regulator maintenance,
it curve of pressure regulator
Ensure the correct pressure regulation
m
i
replace two O rings simultaneously
D
Please: Take care to connect fuel pump assembly
A of connector
Avoid damaging the.terminal
harness connector
S
IS
Please: Return any collided , damaged and suspicious
N
EnsureA
to quickly and correctly find the root cause of problem
parts and describe the problems
R
B
A
K
Warning:
E
G
 Because there is no gasoline in theRfuel tank of new
O
motorcycle at the beginning, aElot of air is generated at
G
fuel pipe, so it needs Y
to start it for several times to
A
empty the air inW
the fuel line, and then the engine can
O
work properly,
T which is normal. Motorcycle will be
O
M
- 451 Y
P
CO
a
k
-d

started easily in the future.
Because gasoline can cool fuel pump, do not let fuel
pump work little oil or no gasoline, which may burn
fuel pump.
21.7.8 common problems
a) The fuel pump assembly plug-in is reversed, which
enables the fuel pump to reverse and fail to provide the
engine with sufficient fuel pressure, resulting in engine
failure.
b) The fuel pump is damaged and fails to rotate.
21.7.9 Fault maintenance and diagnosis method
The fault light is located on the meter panel with a FI
mark below. Under normal circumstances, after the key is
turned, if the fault light is on, it indicates that the electronic
injection system is powered and it can work; if the fault light
is off, it indicates that the electronic injection system circuit
is disconnected, it will not work and the connection of
positive and negative electrodes of fuse and battery should
be checked. If the fault light is off after the engine is started,
it indicates that there is no fault; on the contrary, if the fault
light is still on after the engine is started, it indicates that the
electronic injection system works abnormally and the fault
should be removed if any.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 452 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.8 Throttle Body
21.8.1 Working principle of throttle body:
The throttle body assembly is mainly composed of the
following parts: main casting valve body, bearing, shaft and
valve plate, return spring, throttle cable part, throttle
position sensor system, idle stepper motor and by-pass flow
control system. All of the above subsystems work together
to meet the requirements for following functions:
 Intake flow control
 Control of air flow at idle speed
 Throttle position detection – provide throttle
opening feedback signal for engine control system
The throttle body position sensor provides the ECU
with a throttle opening; the stepper motor on the throttle
body controls the engine idle speed to be maintained near
the target idle speed required by the ECU;
21.8.2 Appearance of throttle body:
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 453 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.8.3 Technical parameters
21.8.3.1 Throttle body:
 D37mm aperture
21.8.3.2 Throttle position sensor:
 The reference voltage is 5±0.1VDC
 Resistance between T1 and T2: 3kΩ - 12kΩ.
21.8.3.3 Idle air control valve:



Operating voltage: 7.5~14.2 VDC
Winding resistance: 53Ω ± 20%
Winding inductance: 33mH ± 20%
21.8.4 Operating temperature of throttle
Normal operating temperature: -30 ~120°C
21.8.5 Disassembly of throttle body




a
Turn off the power switch
Disconnect the negative electrode line of storage
battery.
Disconnect the connectors on throttle position sensor,
stepper motor, inlet temperature/pressure sensor (if
installed on the throttle body assembly)
Disassemble the throttle cable
Disassemble the connecting hose between the air filter
and intake manifold
21.8.6 Cleaning method of throttle
b
.A
S
S
I
N
A
R
B
A
Clean throttle body using carburetor cleaner (3M
product is recommended). Spray cleaner at the inner wall of
throttle body, and gently remove dust and carbon deposit
and other items using a brush. Be careful to prevent the
bypass air duct from being blocked by dirt.
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 454 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.8.7 Installation of throttle body
Note the followings for installing the throttle body:
 Adjust throttle wire
 Ensure that all moved parts have been installed
properly, such as stepper motor assembly.
 Install the connecting screw properly
21.8.8 Note for the installation of throttle body
 Do not immerse the throttle position sensor in the
liquid.
 Always use the throttle cable to open the valve
plate.
 Do not insert tools or other items into the inside of
the throttle body to maintain the opening of the
valve plate. This may deform the valve plate or
scratch the inner wall of throttle body. This
damage may cause the valve to be extremely easy
to open or difficult to open.
21.8.9 Note for the use of throttle body
Precautions
Cause
Please: be careful to install the connectors of all throttle
Avoid damage to wiring terminal.
body
Please: avoid any liquid from entering throttle body
Make sure it works properly
Please: Take out one throttle from the part tray and install it
So as not to damage critical parts
every time
Please: send the falling, damaged parts or parts with
suspected problems, and label to specify the existing
Quickly confirm the cause of problem
problems (only for the components within the scope of
“three guarantees")
Do not: use any dropped or squeezed parts
May cause damage to the internal of parts
Do not: store or transport near salt water without protection Corrosion may affect normal use
Do not: expose it to the environment before the completion
Corrosion may affect normal use
of assembly (such as humid environment)
Do not: test under non-system operating voltage
It may cause damage
Do not: use additional fixtures
It may cause damage
Do not: remove the packaging so that the parts may touch
It may affect minimum air leakage or cause other damages
each other
Do not: release the throttle completely from any position
It may cause damage
Do not: block the bypass channel by dust or small particles It may affect idle speed stability
Do not: pick up, store or hold parts in a manner that might
It may cause damage
come into collision with other parts.
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 455 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
21.8.10 Idle speed stepper motor
21.8.10.1 Working principle of idle speed stepper motor
The function of idle speed control valve is to control
the flow area of bypass air passage of throttle body, so as
to adjust the air volume of engine and control the idle
speed of engine.
1.Valve plate 2.Intake manifold 4. Idle stepper motor 5. By-pass port
21.8.10.2 Appearance of idle speed stepper motor
As shown below
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 456 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.8.10.3 Definition of pin
Dust cover
When the adjusting head is
extended to the utmost, the
adjusting head corresponds
to
, it can be moved
from 0.44 to 2.00mm.
Connector
Position where it is fully retracted
Working position
21.8.10.4 Characteristic parameters:
Rated voltage:
Maximum / minimum
operating voltage:
Resistance per roll (@27°C):
Minimum resistance
(@-40°C):
Inductance per roll
(@25°C):
Stepping distance (step):
Maximum stroke:
Operating temperature
range:
Minimum storage
temperature:
Weight:
12Vdc
7.5Vdc/14Vdc
53±5.3
a
35
b
0.04167mm
8.5mm(204 steps)
-40°Cto125°C(150°C
peak value)
-40°C
110 g
.A
S
S
I
N
A
21.8.10.5 Fault determination of idle stepper
BR motor:
A
K
E
G
R
Before inspection, check whether the stepper motor 4
PIN (black) connector and ECU plug-in connector are
loosened or improperly connected, and then check the
flashing of malfunction indicator light.
Check the stepper motor:
Use multimeter to measure pins A and B respectively;
Resistance between pin C and pin D
Standard: 53±20%Ω at the air temperature of 20-30℃
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
33.5mH±6(1kHz)
- 457 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.8.10.6 Inspection of circuit of idle speed stepper motor:
Stepper motor A-J1-01
On
NG: A+Open circuit
Stepper motor B-J1-11
On
NG:A-Open circuit
Stepper
C-J1-12
motor
On
NG:B+Open circuit
Stepper
D-J1-13
motor
On
NG:B-Open circuit
21.8.10.7 Cleaning
The stepper motor assembly is integrated on the throttle
valve body. When cleaning, first remove the stepper motor
and clean it with a clean rag
21.8.10.8 Resetting of speed stepper motor
The resetting method of the idle speed stepper motor is
hereby explained: After the production and debugging of
new motorcycle are finished, the debugger will take off the
storage battery and wait for packing the vehicle. This will
cause a sudden power down of the ECU and all self-learning
of ECU (including self-learning of the stepper motor), result
in the lost step of stepper motor and forget their current
locations; after the storage battery is installed and powered
on next time, the stepper motor will be in a “chaotic” state,
thus resulting in instable idle speed, high or low idle speed.
At this time, we need to reset the stepper motor. Method:
after starting the motorcycle, turn off the key and wait for 15
seconds. Then turn on the key and start the motorcycle to
check whether the stepper motor has returned to normal. If it
has not returned to normal, repeat the resetting operation.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 458 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.9 Fuel injector
21.9.1 Working principle of fuel injector
The injector is an actuator that injects the appropriate
fuel into the engine inlet in a timely and accurate manner,
and then inhales it into the combustion chamber and mix it
with the oxygen in the filled fresh air for burning.
The fuel injector should be replaced with that with
the same part number only.
21.9.2 Appearance of fuel injector
The appearance of fuel injector is shown in the right picture.
O-ring seal connected
to oil gauge or fuel
injector cap
O-ring seal connected
to air inlet duct end
a
21.9.3 Fuel injector seal ring
As shown above, O-ring seal can ensure that
leakage will not occur when fuel injector works within
the range of -40°C -150°C (-40 -302°F), and it can
resist various fuel additives (such as: ethyl alcohol).
The following data is the existing sealing ring design.
b
21.9.3.1 O-ring seal connected to oil rail or oil injection cap Dim
.A
S
S
• Size:
•Inner diameter: 6.35 mm
•Outer diameter: 14.85 mm
•Section thickness: 4.25 mm
I
N
A
R
B
A
K
E pipe end
21.9.3.2 O-ring seal connected to
Gintake
• Size:
•Inner diameter: 9.61 mm
•Outer diameter: 14.49 mm
•Section thickness: 2.44 mm
Y
A
W
R
O
GE
O
CO
Y
P
T
O
M
is
n
ra
- 459 -
-
s
o
i
r
it
Ka
k
-d
21.9.3.3 Recommended lubricants
To facilitate the installation of fuel injector, lubricant
should be applied at O-ring seal. The following table
shows the list of usable lubricants. Tests show that the
following lubricants do not have any impact on the fuel
injector.
List of recommended lubricants
Name of lubricant
Manufacturer
Viscosity (cSt) @ 40 C
Spindura 10
Spindura 22
DTE-24
DTE-25
DTE-26
Norpar 15
Drawsol 60
NocoLube AW 46
NocoLube AW 32
Advantage Spindle Oil
Equilon
Equilon
Mobil
Mobil
Mobil
Exxon / Mobil
DA Stewart
NOCO Energy
NOCO Energy
Advantage Lubrication Specialties
10
21
32
46
68
<1
1-2
46
32
10
21.9.4 Overvoltage Impact of fuel injector
The fuel injector can run at the voltage of 24V and the
working conditions of 100ms (pulse) and 200ms (one cycle
time) for 1 minute at most (run with oil). It will not affect
the flow rate, cause permanent damage to the solenoid coil
or weaken the electromagnetic performance.
21.9.5 Temperature range of fuel injector:
The standard injector operating temperature range is
as follows. Within the qualified operating temperature
range, the fuel injector flow is within the tolerance range
and fault will not be caused. Meanwhile, in a reasonable
operating environment, leakage, degradation or reduction
of service life will not be caused to fuel injector.
 Operating temperature range: - 30 ~ 125 C
 Extreme operating range (may cause some
functional degradation): - 40 ~ 150 C
 Storage temperature: -60 ~ 60 C
a
b
21.9.6 Fuel contaminants of fuel injector
Although the fuel injector has a self-cleaning function,
it is not a serviceable part, because it is designed to remove
only the impurities with small diameter accumulated in the
fuel line from the fuel filter to the injector. The impurities
with large diameter may cause injector bonding, flow
deviation and leakage and other faults, so fuel filter system
is very important.
.A
S
S
I
N
A
R
B
A
K
E
RG
is
n
ra
EO
G
Y harness arrangement
21.9.7 Fuel injector
A
OW
harness should be located away from
 The injector
T
O
M
- 460 Y
P
CO
im
D
-
s
o
i
r
it
Ka
k
-d
heat sources and the harness should be protected
from external wear or damage.
 If not necessary, do not insert or remove the injector
connector.
21.9.8 Note for Use of Fuel Injector
Precautions
Do not: Reuse the sea. If it needs to reuse it in special
conditions, please carefully check whether the sealing ring is
damaged before use.
Do not: Immerse the end of nozzle in the lubricant.
Do not: Operate it without load in the case of no oil pressure
Do not: Make water go into the fuel way during leakage
inspection.
Do not: Apply force to the head of fuel injector during
installation
Do not: Strike fuel injector when installing it at intake pipe.
Do not: Apply tension to connector.
Do not: Use fuel injector that has fallen
Do not: Store fuel injector, fuel rail or engine that has been
loaded into fuel injector in an unprotected environment.
Do not: Take fuel injector as a handle when lifting assembly
parts.
Do not: make parts be in touch with each other during
storage.
Do not: Parts are in contact with each other during
transportation.
Do not: Knock fuel injector for troubleshooting when an
fault occurs.
Do not: Replace the original fuel injector with one with the
part number not recommended.
Please: Pay special attention to protect sealing ring from
being cut by the installing seal during the installation of fuel
injector.
Please: Use correct lubricant for installation, and
immediately it into the installing hole after applying
lubricating oil.
Please: Add tests for the fuel injector whose needle valve is
stuck or cannot be mounted. (Apply the pulse to fuel injector
for less than 5 seconds using 9-15 V voltage).
Please: Before assembling fuel injector, make an oil-free
leak test to confirm that the needle valve of fuel injector has
been mounted.
Please: Prevent liquid from damaging fuel injector
Please: Be careful to disassemble harness
Please: Use recommended lubricant when installing
connector.
Please: Do not use the components that are dropped,
damaged or whose materials have problem, and describe the
problem using label.
Cause
Avoid leakage
It may block spray hole.
It may damage internal mechanical components.
It may damage fuel injector.
During the installation on nylon intake pipe, allow to apply
force in the direction of 45 degrees
It may cause fuel injector and sealing ring.
It may cause intermittent power supply.
It may be damaged.
External environment may damage the electronic and
mechanical parts of fuel injector.
It may damage fuel injector.
It may damage fuel injector.
Collision may be caused and thus fuel injector may be
damaged.
It may damage fuel injector.
It may seriously affect the performance of nozzle.
a
Protect sealing ring.
Protect sealing ring, to reduce pollution.
is
n
ra
b
Ka
s
o
i
r
Confirm the fault form of fuel
itinjector
m
i
D
It may prevent the
needle valve of fuel injector forming
Aoriginal position during the transportation
returning to .the
S
and transfer
IS process, thus resulting in fuel leakage
N
It
may
cause short circuit of solenoid coil
RA
O
E
G
R
E
G
Y
A
W
B
A
K
It may cause damage of terminal
It may cause corrosion to terminal
Ensure to quickly find the root cause of fault.
O
CO
Y
P
T
O
M
- 461 -
k
-d
21.9.9 Installation requirements for fuel injector
During the installation and removal process, please strictly
observe the following methods to avoid damage to the fuel
injector body and electronic components.
 Lubrication: Apply a small amount of lubricant to
the underside of the sealing ring. ISO 10 light
mineral oil or equivalent product is recommended.
 When conditions allow, apply lubricant to the fuel
injector seat, which is better than the effect of being
applied the seal ring. So that the fuel injector
contamination probability will be reduced to
minimum.
 Do not allow the spray plate to come into contact
with the lubricant, which may affect the injection
quantity. Do not dip the top of the fuel injector to
into the lubricant.
 All fuel injector sealing rings are factory assembled.
In principle, the sealing seals should not be reused.
Before reusing it in special conditions, please
carefully check whether the sealing ring is damaged
before use. Very small damage may cause leakage.
Carefully insert the sealing ring into the installing
seat during installation.
 When installing the fuel injector connector, take
care not to damage the connector, and you can hear
a click, indicating that it has been installed properly.
 Avoid unnecessary disassembly and assembly of
connector.
 Harness should not be clamped too tightly, which
may cause a short circuit.
 When installing the fuel injector connector, do not
rotate the fuel injector. This may cause fuel
injection target to shift.
a
21.9.10 Replacement method of fuel injector
The following is the disassembly and replacement method of
fuel injector.
Note: The injector and the surrounding objects are very hot.
 Turn off the motorcycle.
 Cut off the negative electrode of storage battery, to
avoid accidentally starting the engine.
 Remove the fuel injector connector.
 Release the fuel pressure.
 Remove the fuel pipe from the fuel injector.
 Remove the fuel injector from the throttle valve
body.
 Remove the fuel injector retainer and carefully
remove the fuel injector from the seat ring.
 Carefully clean the impurities at the injector contact
surface, and be careful not to damage the contact
surface.
 Apply lubricant to the sealing rings on both ends of
the new fuel injector.
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 462 -
im
D
-
s
o
i
r
it
Ka
k
-d
 Carefully put the head of fuel injector into the
intake pipe, and confirm that the installation
direction is consistent with the original one.
 Press it in the fuel injector seat ring and secure the
clamp.
 Install fuel injection hose.
 Insert the fuel injector connector.
 Power on the key, do not start the engine and check
fuel injector for leakage.
 Start engine for running check.
21.9.11 Replaceability of fuel injector
Only allow to replace the fuel injector with one with
the same part number.
22.2.2.14 Blocking of fuel injector
The accumulation of fuel impurities may cause flow
offset and shorten fuel injector life. When the engine is
standing, the heat of engine may produce fuel precipitation
through the head of fuel injector, and the precipitation
gathered in the injection hole may cause flow offset.
 Blockage may cause many problems, such as
small flow, large friction and accumulation of
impurities, and ultimately affect emissions and
durability. Ultimately affect emissions and
durability.
 Fuel and environmental factors may cause fuel
crystallisation or fuel injector corrosion, which
may also cause flow offset.
 Poor oxidation stability of fuel may cause
precipitation, so please use high-quality gasoline.
 Add an appropriate amount of fuel cleaner to
avoid precipitation.
 If fuel injector is blocked, please clean injector
according to the following cleaning method.
a
b
Warning:


A filter is designed inside the fuel injector, but it is
not a maintainable part, because its design function is
to filter the accumulated impurities from the fuel
filter in the oil line to the fuel injector only.
Impurities can cause the cohesion, flow deviation,
leakage and other faults of fuel injector, so the fuel
filter is very significant.
The fuel injector should be replaced with that with
the same part number only.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 463 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.9.13 General failure mode and prevention and solving measures in using
process
Important note: All the following decisions are
based on normal functions of motorcycle, wiring harness
and other system parts.
Block of fuel injector: Please clean the fuel injector
by using special devices (such as ultrasonic wave) and
special cleaning agent.
Fuel leakage of fuel injector: Replace the fuel
injector with that with the same part number or that
specified by the motorcycle factory.
Damage of electromagnetic coil: Please measure the
resistance of electromagnetic coil of fuel injector with a
multimeter. If the reading is about 12 (±5) Ohms, the
electromagnetic coil of fuel injector is normal; if the coil
resistance is infinite, it means that an open circuit fault has
occurred to the coil.
Bad
Good
Bad
Atomization of oil atomizer
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 464 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.10 Intake pressure and temperature sensor
21.10.1 Working principles of inlet pressure and temperature sensor
This sensor is used to measure the absolute pressure of
air intake elbow, reflect the size of intake pressure according
to the difference of resistance, and then calculate the intake
volume in engine combustion chamber through indirect
conversion, and it is also a non-serviceable part. It is used to
measure the intake air temperature, its resistance will change
with the intake air temperature and its characteristic is also
the
negative
temperature
coefficient
resistance
characteristic. It is also an irreparable part.
21.10.2Appearance of inlet pressure sensor
See the right figure
a
21.10.3 Working environment




Operating pressure range: 20～115kPa
Operating temperature range: -40~105°C
Relative humidity: 0 - 100% RH.
Extreme operating conditions: only 2 hours at
maximum temperature of 125°C.
b
21.10.4 Storage environment

.A
S
S
I
N
A
Storage temperature: -50°C ～150°C
21.10.5 Electrical environment
is
n
ra
R
B
A
K
E
G voltage of
Typical voltage: The operating DC reference
R
sensor circuit is 5 ± 0.1 V.
EO
G
Y
A
OW
T
O
M
- 465 Y
P
CO
im
D
-
s
o
i
r
it
Ka
k
-d
21.10.5 Pin definition
See the right figure
21.10.6 Appearance of inlet pressure sensor
See the right figure
Temperature sensor characteristic curve
Temperature:
℃
Resistance value: Ω
21.10.7 Cleaning
a
If necessary, the sensor can be cleaned with isopropyl
alcohol and then air dried. It should be soaked in isopropyl
alcohol for not more than 1 minute, and sealing connector
should be installed during cleaning to prevent cleaner from
intruding into the sensor.
b
21.10.8 Fault determination
1.
2.
3.
4.
Check whether the plug-in is loose
Check the fault or current data with a diagnostic
instrument
Check the connection between the sensor and ECU and
check whether the abnormal operation of sensor is
caused by cables
Sensor inspection: connect it to the cable and turn on
the power; measure the voltage between two pins with
multimeter;
Standard
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 466 -
im
D
-
s
o
i
r
it
Ka
k
-d
The voltage is 4.0～ 4.65V under the atmospheric
pressure of 100kPa when the equipment is not
started.
Otherwise, the sensor fails.
21.11 Oxygen sensor
21.11.1 Working principle of oxygen sensor
Oxygen sensor can be used to detect the oxygen
content in the waste gas of engine exhaust pipe for internal
fuel closed loop control of ECU, thus maintaining engine
combustion at the most reasonable state of air and fuel ratio
(14.7).
21.11.2 Appearance of oxygen sensor
See the right figure
21.11.2 Technical parameters
a
 Partially thick limit of air-fuel ratio: ＞750mVDC
 Partially thin limit of air-fuel ratio: ＜120 mVDC
 Power of oxygen sensor heater: 7.0W
(The above parameters are measured at engine
bench, the working conditions: exhaust gas
temperature: 450°C; duty cycle: 70%; 10Hz;
voltage: 13.5V).
 The resistance of heater is: 9.6±1.5Ω (measured at
21°C)
 Operating temperature range: 260-850°C
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 467 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.11.3 Installation requirements
 Installation angle (angle with the horizontal plane):
≥10 degrees
21.11.4 Oxygen sensor pin definition:
Connectors of oxygen sensor
1. Oxygen sensor heating control grounding
2. Oxygen sensor heating power supply 12V+
3. Oxygen sensor signal - (OS-)
a
4. Oxygen sensor signal+ (OS+)
21.11.5 Fault determination
1.
2.
3.
b
Conduct fault diagnosis with a diagnostic instrument
and judge the fault type
Check whether pins has fallen off
Check the voltage between the sensor signal line and
signal earth with a multimeter:
Standard
When the engine temperature is 80 degrees and
the idle speed or constant speed is 3000
revolutions, 4000 revolutions or 5000 revolutions,
the duration is more than 2 minutes.Measure
whether the voltage at both ends changes between
0-1V constantly.
Otherwise, the sensor fails.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 468 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.11.6 Characteristic curve
a
The oxygen sensor is located on the exhaust manifold.
Please remove the oxygen sensor connector and then
remove the oxygen sensor using open-end wrench. Be
careful not to knot or twist the harness when
disassembling.
b
21.11.7 Requirements for fuel quality





.A
S
S
Pb≤0.005g/L
P≤0.0002g/L
S ≤ 0.04% (weight ratio) x
MMT≤0.0085g/L
Si≤4ppm
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 469 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.12 Temperature sensor of engine cylinder head
21.12.1 Working principle of temperature sensor of engine cylinder head
The engine cylinder head temperature sensor is used
in the air cooled engine to measure the temperature of
engine cylinder head. Within the sensor temperature range,
the resistance will change with the temperature of engine
and the temperature characteristic is the negative
temperature coefficient resistance characteristic. It is an
irreparable part.
21.12.2 Appearance of temperature sensor of engine cylinder head
See the right figure
a
21.12.3 Working environment





b
The sensor is mainly used for air-cooled engine
Normal operating temperature range: -40 -160°C
(continuous work)
Relative humidity at working environment: 0 ~ 100%
Typical operating pressure: at minimum installation
torque, the sensor is capable of sealing the engine
coolant at an actual pressure of 206.8 kPa (30 psi) and a
temperature of 135°C.
Extreme working conditions: only 1 hour at maximum
temperature of 160°C.
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 470 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.12.4 Electrical environment


Typical working voltage: The reference voltage is
5±0.1VDC
Maximum
excitation
current:
During
the
characteristic test and calibration of the sensor under
any temperature, the performance of the sensor should
not be affected by the current of less than 1mA.
21.12.5 Fault Determination and Characteristic of Output Resistor
Fault performance:
This will have a large impact on start-up, because the
ECU cannot monitor the temperature of engine or achieve
accurate fuel injection.
General faults are caused by the looseness of
connection plug-in or the falling of the pin on the plug-in.
The sensor can only be replaced with that of the same
model.
Internal resistance measurement: disconnect it from the
cable; measure the resistance between pin 1 and pin 2 with
multimeter (as shown in the figure)
Standard: 25℃: 1.9-2.1KΩ
100℃：0.179～0.187KΩ
Otherwise, the sensor fails.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 471 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.13 Canister solenoid valve (ECP)
21.13.1 Overview of working principle
The canister solenoid valve is used to prevent the
fuel vapor in the canister from entering the engine intake
system and burning it in the engine. This can reduce fuel
evaporative emissions.
21.13.2 Appearance
The appearance of canister solenoid valve is as
shown in the right figure:
21.13.3 Pin of ECP solenoid valve
The connection method is as follows
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 472 -
im
D
-
s
o
i
r
it
Ka
k
-d
Charcoal canister
interface
Inlet manifold connector
Electric interface
The electromagnetic switch is
always closed
21.13.4 Technical parameters
Flow (standard L/min)
 Normal operating voltage: 8-16V VDC
 Operating temperature: -40~120°C
 Operating frequency: 16 Hz
 Maximum flow rate: 25-35L/min
The flow curve is shown in the figure below:
a
b
.A
S
S
I
N
A
Duty cycle (%)
R
B
A
21.13.5 Installation requirements
EK


G
R
O
The canister solenoid valve should be installed
horizontally on the motorcycle
The canister solenoid valve should be installed
close to the central axis of crankshaft to reduce
vibration
E
G
Y
A
W
O
CO
Y
P
is
n
ra
T
O
M
- 473 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.14 Ignition coil
21.14.1Appearance of ignition coil:
21.14.2 Fault description:
Fault performance:
If spark plug do not ignite or intermittently ignites,
engine cannot work
If the ignition coil fails and thus the spark plug does not
ignite, the ECU will turn off the injection of corresponding
cylinder, ie, do no inject fuel.
If the high-voltage wire on the ignition coil is damaged,
electrical leakage or poor ignition may be caused.
Please check: whether the signal grounding from the
ECUJ2-01 pin to ignition coil is conductive, and whether the
connection from the output terminal of relay to the positive
terminal of ignition coil is conductive.
a
b
is
n
ra
I
N
A
.A
S
S
im
D
-
s
o
i
r
it
R
B
A method of EFI system
21.15 Fault maintenance and diagnosis
K
E
G
ORusing the flashing fault lamp at meter
21.15.1 Diagnosis directly
E
G
Y
Alocated on the meter panel with a
The fault light [A] is
W
mark below. Under
TO normal circumstances, after the key is
O
M
- 474 Y
P
CO
Ka
k
-d
turned, if the fault light is on, it indicates that the electronic
injection system is powered and it can work; if the fault light
is off, it indicates that the electronic injection system circuit
is disconnected, it will not work and the connection of
positive and negative electrodes of fuse and battery should be
checked. If the fault light is off after the engine is started, it
indicates that there is no fault; on the contrary, if the fault
light is still on after the engine is started, it indicates that the
electronic injection system works abnormally and the fault
should be removed if any.
In the case that a fault is confirmed, after opening and
closing the key for 3 times, namely the operation of
opening---closing--- opening---closing –opening key, the
fault lamp will flash the flash code of corresponding fault.
Then, corresponding fault can be identified through fault
code table.
Of them, when using the method to read fault using fault
lamp, the flash code rule is as follows: for example, the fault
is the open circuit of intake pressure sensor or short circuit of
signal terminal pin to the negative electrode of storage
battery, the fault lamp will flash for 10 times to represent 0,
flash for 1 time to represent 1 after 1.2 seconds, flash for 10
times to represent 0 after 1.2 seconds, flash for 7 times to
represent 7 after 1.2 seconds, namely P0107. It can be seen
that except that number 0 is represented by flashing for 10
times, numbers 1-9 correspond to the times of flashing. If
there are other fault codes, such as fault P0201, there is fault
in the fuel injector of cylinder 1. After flashing P0107, wait
for 3.2 seconds, continue to flash P0201 fault code; if there is
no other fault, it will flash P0107 and P0201 cyclically. Then,
relevant faults can be queried according to fault code table.
When using PCHUD software, the software will report
fault code using decimal numbers. In fault code table, there is
an one-to-one correspondence relationship between decimal
numbers and previous hexadecimal numbers, and thus
corresponding faults may be found according to the
correspondence relationship. For example, MULFCURR
(current fault) = 263 in the software, it corresponds to P0107
in fault code table, namely intake pressure sensor fault.
a
b
K
E
RG
O
O
CO
Y
P
T
O
M
.A
S
S
I
N
A
R
B
A
E
G
Y
A
W
is
n
ra
- 475 -
im
D
-
s
o
i
r
it
Ka
k
-d
●MT05 Fault Code Table (Remark: All fault display functions of Delphi are listed in the
fault code table. If this model does not have the corresponding function, please ignore it.)
DTC
System or Component
DTC Description
Related Calibration
P0107
MAP Circuit Low Voltage or Open
KsDGDM_MAP_ShortLow
Sensor (MAP)
P0108
MAP Circuit High Voltage
KsDGDM_MAP_ShortHigh
Intake Air Temperature Sensor
P0112
IAT Circuit Low Voltage
KsDGDM_IAT_ShortLow
(IAT)
P0113
IAT Circuit High Voltage or Open
KsDGDM_IAT_ShortHigh
anifold
Absolute
Number
Pressure
P0117
Coolant/Oil Sensor
P0118
Coolant/Oil Temperature Sensor Circuit
Low Voltage
Coolant/Oil Temperature Sensor Circuit
High Voltage or Open
KsDGDM_CoolantShortLow
KsDGDM_CoolantShortHigh
P0122
TPS Circuit Low Voltage or Open
KsDGDM_TPS_ShortLow
P0123
TPS Circuit High Voltage
KsDGDM_TPS_ShortHigh
P0131
O2S 1 Circuit Low Voltage
KsDGDM_O2_1_ShortLow
P0132
O2S 1 Circuit High Voltage
KsDGDM_O2_1_ShortHigh
P0031
O2S Heater Circuit High Voltage
KsDGDM_O2_HeaterShortHigh
P0032
O2S Heater Circuit Low Voltage
KsDGDM_O2_HeaterShortLow
Fuel Injector A
P0201
Injector A Fault
Fuel Injector B
P0202
Injector B Fault
P0230
FPR Coil Circuit Low Voltage or Open
KsDGDM_FPP_CircuitShortLow
P0232
FPR Coil Circuit High Voltage
KsDGDM_FPP_CircuitShortHigh
P0336
CKP Sensor Noisy Signal
KsDGDM_CrankNoisySignal
(CKP)
P0337
CKP Sensor No Signal
Ignition Coil A
P0351
Cylinder A Ignition Coil fault
Ignition Coil B
P0352
Cylinder B Ignition Coil fault
Idle Control System
P0505
Idle Speed Control Error
P0562
System Voltage Low
P0563
System Voltage High
P0650
MIL Circuit Malfunction
KsDGDM_MIL_Circuit
P1693
Tachometer Circuit Low Voltage
KsDGDM_TAC_Circuit_Low
Throttle Position Sensor (TPS)
Oxygen Sensor
Oxygen Sensor Heater
Fuel Pump Relay (FPR)
Crankshaft
Position
System Voltage
MIL
Oxygen Sensor 2
Oxygen Sensor Heater 2
O
OT
P
O
C
h
KsDGDM_INJ_CYL_B_FaultHig
h
.A
S
S
I
N
A
R
B
A
K
E
P1694 G Tachometer Circuit High Voltage
OR O2S 2 Circuit Low Voltage
P0137
E
GP0138
O2S 2 Circuit High Voltage
Y
A
W
Tachometer
M
Y
Sensor
KsDGDM_INJ_CYL_A_FaultHig
P0038
O2S Heater 2 Circuit High Voltage
- 476 -
is
n
ra
ab
K
KsDGDM_EST_A_Fault
s
o
i
r
KsDGDM_EST_B_Fault
it
m
Di KsDGDM_IdleControl
KsDGDM_CrankNoSignal
-
KsDGDM_SysVoltLow
KsDGDM_SysVoltHigh
KsDGDM_TAC_Circuit_High
KsDGDM_O2_2_ShortLow
KsDGDM_O2_2_ShortHigh
KsDGDM_O2_HeaterShortHigh
a
k
-d
P0037
O2S Heater 2 Circuit Low Voltage
KsDGDM_O2_HeaterShortLow
Vehicle Speed Sensor
P0500
VSS No Signal
KsDGDM_VSS_NoSignal
Park Neutral Switch Diag
P0850
Park Neutral Switch Error
KsDGDM_ParkNeutralSwitch
P0445
CCP short to high
KsDGDM_CCP_CircuitShortHigh
P0444
CCP short to low/open
KsDGDM_CCP_CircuitShortLow
Rollover Sensor Diagnostic
P1500
Rollover Sensor malfunction/Triggered
KsDGDM_RolloverSensor
BLM_MaxAdapt
P0171
Several BLM value hit maximum
KsFDIAG_BLM_MaxAdapt
BLM_MinAdapt
P0172
Several BLM value hit minimum
KsFDIAG_BLM_MinAdapt
PESystLean
P0174
PE mode burned AFR keeps lean
KsFDIAG_PESystLean
CCP
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 477 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.15.2 Diagnose fault using diagnostic apparatus
●Diagnostic apparatus
●Operation method:
a) Find the diagnose interface [A] at motorcycle;
b) connect connecting wire and diagnostic apparatus
interface;
c) Open the key for diagnosis;






Warning
The XCM-PT100X diagnostic apparatus is a
high-precision instrument that should be protected
from shock and vibration;
If the apparatus is not working properly or the
display is unstable after it is turned on for the first
time, please disconnect the power cable and try
again;
Please ensure that the connector is always
fastened in the diagnostic connector;
It is strictly forbidden to test the electrical signals
that exceed the limit;
It is strictly forbidden for the driver to operate the
instrument during driving;
Use and storage conditions:
Environment temperature: 0~50 degrees
Celsius
Relative humidity: less than 90%
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 478 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.15.3 Inspection of fault using diagnostic software PCHUD
PCHUD software is used to detect and record
engine operating data, laptop should be connected to
6-port diagnostic port of motorcycle through K line
before use, and the diagnosis port is below the rear seat
cushion. Please note that the PCHUD system only
supports 16Bit Microsoft Windows operating system or a
very small number of 32bit Windows operating systems.
It does not support 64bit systems such as Win7, Win8 or
iOS. It is necessary to install K-line driver software on
the notebook before use.
●Operating Instructions for PCHUD Software:
(1) Connect laptop and 6-hole diagnostic port of
motorcycle using K line and open the key;
(2) Click “HUD.EXE” icon and start PCHUD software;
(3) Select “File” in the software interface, click “open” to
select “PCHUD.HAD”, and then click “OK” for
confirmation.
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
(4) Select “Parameter File” under “Setup”, click
MT05common.par file, select “Comm protocol under
“Setup”, select “Keyword2000” and then click OK, at the
same time select 17 as the Device Code.
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 479 -
im
D
-
s
o
i
r
it
Ka
k
-d
(5) If the software interface cannot display the real-time
communications data, it needs to conduct the following
work: check whether there is problem in COM port
connection setting under “Setup”, generally set COM Port:
4. Baud Rate:10400, and do not select DTR High at startup
a
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
EO
G
And then conduct normal Y
communications, display the current
A
fault code at MALFCURR,
W and display historical fault code at
O
MALFHIST. T
O
M
- 480 Y
P
CO
im
D
-
s
o
i
r
it
Ka
k
-d
And then query the corresponding fault according to fault code table.
●PCHUD Software Parameter Interpretation:
VRPM
Engine speed
engine speed
VTHROT
Throttle opening
throttle position
VBARO
Atmospheric pressure
BARO
Intake manifold pressure
manifold air pressure
Estimated value of intake manifold pressure
expect manifold air pressure
Storage battery voltage
ignition key voltage
Temperature of cylinder temperature or coolant
cylinder temperature or coolant temperature
Intake temperature
intake air temperature
Status flag 5
STATUSBYTE5
Airflow learning conditions are met
airflow correction met
VBAROCMET
Atmospheric pressure updating conditions are met
Baro update met
VCSINSYNSPR
K
Sequential ignition flag
sequential spark enable
tip-in ignition angle correction conditions are met
tip-in Spark Advance retard trigger
Catalyst work logic is enabled
catalyst light-off logic enable
Normal working flag position of engine
engine work in run state
VMAP
VMAPEXP
VIGN
VCLTS
VIAT
STATUSBYTE5
VAFCMET
SATITRIG
CATLOENB
IF ENGSTATE=3
NISTBLIDLE
FCNO
Long-term learning unit of intake efficiency
block learn memory cell
Long-term learning value of cylinder
cylinder 1 block learn memory
FCLCINT1
Item I of closed loop learning
integral of close loop correction
FCLCMUL1
Correction of closed loop learning
close loop correction
IARDRPM
Rotating sped of desired idle speed
desired idle rpm
IARPMERR
Deviation of idle speed
idle rpm error
Fuel injection pulse width of cylinder
base pulse width of cylinder 1
Oxygen sensor signal
Oxygen sensor signal
Status flag 3
STATUSBYTE3
FO2STAT1
Concentration mark of oxygen sensor of cylinder
cylinder 1 oxygen sensor signal rich lean state
FCLREST1
Correction and resetting mark of closed loop of
cylinder 1 close loop correction reset
cylinder
FOSHTREN
Oxygen sensor heater is enabled
FO2REDY1
Heating completion mark of oxygen sensor of
cylinder 1 Oxygen sensor ready
cylinder
FBLMCOR1
FPWVC1
VO2
STATUSBYTE3
IF IACV
MODE=0
IACMVIHB
VIGNS
FVE1
Y
P
im
D
-
s
o
i
r
it
a
is
n
ra
b
Ka
A sensor heater enable
.Oxygen
S
S
I
N
A
R
B
A
Closed loop learning of idle speed stepper motor is idle airflow control valve close loop correction
enabled
enable
IAMTRLOST
CO
The idle speed conditions for warming up machine
stable warm idle
are met
K
E
G
Lost step flag position
of idle speed stepper motor
R
O
Flag positionE
where the movement of idle speed
G
stepperY
motor is disabled
A
Ignition state flag position
W
MO
TOCylinder filling efficiency
- 481 -
IACV lost
IACV move disable
ignition state
cylinder 1 Volumetric efficiency
k
-d
VMAPRANG
Intake pressure reading angle
MAP read angle
Target air fuel ratio
target air fuel ratio
Ignition advance angle of cylinder
cylinder 1 Spark Advance
SAIDLDYN
Dynamic ignition angle at idle speed
idle dynamic Spark Advance
SPDWELL
Magnetizing time
dwell time
Airflow learning value of idle speed stepper motor
airflow integral of idle air control valve
Number of desired steps of idle speed stepper motor
desired position of idle air control valve
Status flag 2
STATUSBYTE2
FCLCEN1
Closed loop correction of cylinder is enabled
cylinder 1 close loop correction enable
PPDSEBL
Flag position where pilot injection is disabled
prime pulse disable
FPENABL
Flag position where fuel pump is enabled
fuel pump enable
FTRNSAES
Acceleration and enriching are enabled
acceleration enrich enter
FTRNSDES
Deceleration and thinning are enabled
deceleration enlean enter
FTRNSAEDCLO
AD
Acceleration and enriching exit
acceleration enrich exit
FTRNSDEINLO
AD
Deceleration and thinning exit
deceleration enlean exit
AFFNLAFR
SAESTA
IAINTEGOFST
IACVDSMP
STATUSBYTE2
●Diagnosis process:
1.Insert the key on vehicle and do not start the motorcycle, please check：
Parameter
Check and Record
Min
Max
Description
Units
VIGN
□Norm □Abnormal
11.5
14.6
battery voltage
volt
VTHROT
□Norm □Abnormal
0
1
fully closed throttle position
percent
VTHROT
□Norm □Abnormal
98
100
fully open throttle position
percent
VTHROTRAW
□Norm □Abnormal
4000
9000
Absolutely throttle body voltage AD
None
VBARO
□Norm □Abnormal
98
103
atmospheric pressure
kpa
VIAT
□Norm □Abnormal
-15
40
intake air temperature
degC
VCLTS
□Norm □Abnormal
-15
40
cylinder temperature or coolant temperature
degC
Parameter
Check and Record
Min
Max
Description
Start
□Norm □Abnormal
-
-
TERRCNT
□Norm □Abnormal
0
0
FUELCOFF
□Norm □Abnormal
0
0
VRLVENBL
□Norm □Abnormal
0
s
o
i
r
it counter
Fly wheel tooth error
m
i
Dthe
fuel cut-off enable,
normal flag is white, if
A
.
not blue
S
S
I sensor enable, normal is white, if not
NRollover
is
n
ra
2.Starting：
-
A
0
K
E
RG
R
B
A
blue
b
Ka
Units
count
None
None
3. Idle The parameters can be checked 1 min for idle speed after vehicle starting. And then check the stability of
EFI parameter after 3 minutes of long idle.
EO
G
□Norm
Y□Abnormal
A
W
Parameter
VRPM
VTHROT
O
OT
P
O
C
M
Y
Check and Record
□Norm □Abnormal
Min
Max
Description
Units
1300
1700
engine speed
rpm
0
1
fully closed throttle position
percent
- 482 -
a
k
-d
MALFCURR
□Norm □Abnormal
0
0
current MALF code
None
VBARO
□Norm □Abnormal
98
103
atmospheric pressure
kpa
VMAP
□Norm □Abnormal
47
53
intake pressure measured value
kpa
VIGN
□Norm □Abnormal
12
16
battery voltage
volt
PNSWTCH
□Norm □Abnormal
0
0
Neutral and Clutch switch enable flag, blue is
working
None
IACVDSMP
□Norm □Abnormal
10
80
stepping motor target value
step
vehicle speed
□Norm □Abnormal
0
0
vehicle speed
Km/h
FBLMCOR1
□Norm □Abnormal
0.75
1.15
cylinder 1 block learn memory
factor
FBLMCOR2
□Norm □Abnormal
0.75
1.15
cylinder 2 block learn memory
factor
FCLCINT1
□Norm □Abnormal
-15
15
cylinder 1 integral of lose loop correction
count
FPWVC1
□Norm □Abnormal
1.5
2.8
base pulse width of cylinder 1
ms
VO2
□Norm □Abnormal
45
850
cylinder 1 oxygen sensor voltage
mv
VO2B
□Norm □Abnormal
45
850
cylinder 2 oxygen sensor voltage
mv
Min
Max
Description
Units
4. Run with stable speed
Parameter
Check and Record
MALFCURR
□Norm □Abnormal
0
0
current MALF code
None
VCLTS
□Norm □Abnormal
40
105
cylinder temperature or coolant temperature
degC
VIGN
□Norm □Abnormal
12
16
battery voltage
volt
FBLMCOR1
□Norm □Abnormal
0.75
1.15
cylinder 1 block learn memory
factor
FCLCINT1
□Norm □Abnormal
-15
15
cylinder 1 integral of lose loop correction
count
VO2
□Norm □Abnormal
45
850
cylinder 1 oxygen sensor voltage
mv
5. Top speed with full throttle(PE mode, power enrich)
PE mode ： 70% < VTHROT < 100%, in this situation，the value of oxygen sensor(VO2 VO2B) is around
800mv.
Ka
Parameter
Check and Record
Min
Max
Description
VCLTS
□Norm □Abnormal
80
105
cylinder temperature or coolant temperature
VIGN
□Norm □Abnormal
12
16
battery voltage
volt
VO2
□Norm □Abnormal
750
950
cylinder 1 oxygen sensor voltage
mv
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
b
is
n
ra
Y
P
T
O
M
- 483 -
im
D
-
s
o
i
r
it
Units
degC
a
k
-d
21.16 Common troubleshooting methods for electronic fuel inject system
21.16.1 Maintenance tool
a)
Disassembly and assembly of electronic control
system components - common automotive mechanical
parts removal tool
b)
Electronic control system circuit and system electrical
signal - digital multimeter (with buzzer)
Electric control system fault diagnosis and engine
working condition detection
c)
 Electronic control system fault diagnostic
apparatus (recommended)
 Fault diagnosis software (PCHUD) and
interface connection (conditional use)
d)
Electronic control system fault code table (emergency
use)
e)
Fuel pressure gauge, range: 0-300kP
21.16.2Engine Working Data Flow Displayed by Diagnostic Apparatus
Analyze and determine engine fault using the engine
working data flow displayed by the diagnostic apparatus.
21.16.2.1 Step I
a)
Engine harness and the vacuum pipeline—may affect
the system to control air flow and fuel supply
b)
Whether oxygen sensor is assembled in place—may
affect the system to determine the air to fuel ratio
c)
Engine fault indicator—may affect the system to give
an alarm for fault
d)
Storage battery voltage—determine whether the
power of storage battery is sufficient
e)
Determine whether coolant temperature sensor, intake
temperature sensor, intake manifold absolute pressure
sensor and oxygen sensor display value are normal
f)
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
Working range of throttle position sensor—it cannot
be fully opened or closed, which may affect engine
power performance and some system functions
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 484 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.16.2.2 Step II
Check whether ECU power is turned off—the
communications between diagnostic apparatus and system
is interrupted after turning off key switch
21.16.2.3 Step III
a)
Storage battery voltage (14V) —Indicate whether the
generator is working properly.
Too high: there may be fault in voltage regulator;
Too low: there may be improper connection of
generator or generator fault
b)
Intake manifold pressure—it can predict whether
there is leakage in intake and valve clearance
problems.
Valve clearance is too small: this value is too high,
so engine power performance may be affected; in
addition, due to too early opening of exhaust valve
and increase in exhaust temperature, oxygen sensor
and three-way catalytic converter service life may
be significantly shortened;
Valve clearance is too large: it may cause low
intake manifold pressure, and thus affect the system
to determine the working state of engine, thus
resulting in abnormal idle speed during warm-up of
motorcycle.
In addition, if the exhaust system is blocked, for
example: a foreign body exists in the outlet; the oil
consumption is too high, thus blocking three-way
catalytic converter; three-way catalytic converter is
blocked due to internal damage, which will cause
slightly high value.
c)
a
b
Number of cycles of oxygen sensor value—the
number of cycles is too small, indicating fault of
oxygen sensor
.A
S
S
21.16.3 Simple troubleshooting
I
N
A
R
B
A
Please follow the following steps to repair EFI
system. To repair fault in one step, the subsequent steps
may be stopped. And then use diagnostic apparatus to
conduct inspection and acceptance and clear fault code
according to “Engine Working Data Flow Displayed by
Diagnostic Apparatus”.
K
E
RG
O
E
G
Y
A
W
O
T
O
M
When using diagnostic apparatus, the voltage of
CO
Y
P
is
n
ra
- 485 -
im
D
-
s
o
i
r
it
Ka
k
-d
storage battery should not be lower than 8.5 V.
21.16.3.1 Daily use and maintenance

Gasoline should be high quality without lead.

ECU has a moisture-proof function, but high-pressure
water gun should not be used to rinse its shell.

The petrol filter should be changed every 18000km.

Under normal conditions of use, clean the throttle
body every 10,000 km or 1 year.
21.16.3.2 Fault phenomenon-Start fault
a)
Rotate ignition switch to “On” position, and check
whether engine fault lamp is on.
If it is off:
It is be able
to be on:
b)

Check fuse and grounding wire

Check whether
connected firmly

It is able to check whether this lamp
and line is normal using the check
function of diagnostic apparatus
actuator

Check and repair bulb and its line

Connect diagnostic apparatus
system diagnosis interface
ECU
plug
is
to
Check whether diagnostic apparatus can be connected
to system for communications
If not:
c)
Check fuse and grounding wire

Check whether
connected firmly

Test whether diagnostic apparatus is
working normally at another normal
motorcycle

If yes:
a

ECU
Remove the fault
diagnostic apparatus
plug
indicated
is
b
by
.A
S
S
Check ignition system fault—whether normal ignition
can be made for spark plug

K
E
G
 Use another ignitionR
coil for assembly
EO
judgment
G
Y ECU
 Judge
using
A
W
OCheck whether high-voltage line is
T
O connected to ignition coil and spark
If not:
If yes:
M
Y
P
O
C
I
N
A
R
B
A
Check whether high-voltage line and
spark plug are plugged firmly or
damaged
is
n
ra
- 486 -
im
D
-
s
o
i
r
it
Ka
k
-d
plug properly
d)
Check oil supply system fault
Check whether fuel pump is working—it is able to
hear the sound that the fuel pump is working near the fuel
tank when starting engine

Check whether fuel pump relay is
working normally

Check whether the connection and
working of crankshaft position sensor
is normal

Judge using ECU

Check fuel pump line
Not work:
1) Check whether fuel supply pressure is
greater than 220Kpa
2) Insufficie
nt
pressure:

Check whether there
is sufficient fuel in
the fuel tank

Check whether fuel
filter needs to be
replaced
(note:
replace the fuel filter
special for electronic
injection should be
replaced once every
18000km)

Check whether fuel
supply pipe and fuel
return
pipe
are
damaged
Be able to
work:
3) Normal
pressure:


e)
Check whether there
is any abnormality in
nozzle control line
Check whether nozzle
needs to be cleaned
After completely opening the throttle
and turning on starting motor, there
should be working sign in engine after
several seconds
If yes:
.A
S
S
I
N
A
R
B
A
K
E
RG
Check whether crankshaft position sensor clearance is
too large
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
b
Confirm whether cylinder is submerged

f)
a
- 487 -
im
D
-
s
o
i
r
it
Ka
k
-d
21.16.3.3 Fault phenomenon—Start failure with tempering
a)
Check whether ignition coil is loosened;
b)
Check whether timing gear ring is loosened.
21.16.3.4 Fault phenomenon—Instable idle speed
Idle
control
system:
Check whether the idle bypass bolt is loose
Oil supply
system:
Check whether there is leakage in oil
pipeline
21.16.3.5 Fault phenomenon—Too high or too low idle speed (idle speed is obviously
inconsistent with target idle speed)

When the water temperature is lower
than 68 degrees, the system will
increase idle speed to accelerate
warming-up process, which is normal
phenomenon.
Check
the
items
according to the following items except
that

Adjust the negative pressure balance of
cylinder before check

Check whether valve clearance,
especially exhaust valve clearance is
too large
Too high
idle speed:
Too low
idle speed:

Check fuel quantity in fuel tank, fuel
filter, fuel line pressure and nozzle

Checking valve clearance and confirm
whether it is too small
a
is
n
ra
b
s
o
i
r
it
Ka
21.16.3.6 Fault phenomenon—Instable idle speed with deceleration
im and flameout
D
A
a)
Checking valve clearance;
b)
Check whether idle speed bypass hole and throttle
body are too dirt.
.
S
S
I
N
A
R
B
A
K power of deceleration
21.16.3.7 Fault phenomenon—Insufficient
E
G
R
EO
G
Y
A
b) Check fuel quantity
in
the
W fuel tank and fuel filter;
O
c) Check whether
T exhaust system is blocked, for
O
M
Y
P
CO
a)
Check whether the parameters are normal at idle
speed and high idle speed;
- 488 -
k
-d
example: whether three-way catalytic converter is
blocked by burning oil or damage;
d)
Check fuel line pressure and nozzle;
e)
Check whether fault lamp is on, and whether normal
ignition can be conducted for only one cylinder.
21.16.3.8 Fault phenomenon—Slight burning phenomenon
Check whether the spark plug clearance meets
specification of 0.6-0.7mm
21.16.3.9 Fault phenomenon—Fault lamp is on, but fault code is inconsistent with
fault
It may be caused due to instable connection of system
grounding wire, reconnect the grounding wire, disconnect
the power cable of battery for 3 minutes and then start the
engine.
21.16.3.10 Fault phenomenon—Extremely high fuel consumption
a)
Check whether the oxygen sensors of two cylinders are
assembled in place; if it is in the loose state, the oxygen
sensor may incorrectly judge that the combustion in the
cylinder is thin, and then increase fuel, which may
result in unusually high fuel consumption.
b)
After confirming that the engine mechanical parts and
oxygen sensor are in normal conditions, run the engine
to observe the oxygen sensor reading. If the reading is
always greater than 500 mV at normal water
temperature, check whether there is leakage in fuel
injector.
a
b
Precautions
CO

The vast majority of EFI parts cannot be repaired; after
the confirmation of damaged parts, generally
replacement is taken.

When starting the engine, do not operate any
mechanism (including the throttle, do not pull the
throttle for start) on the engine.
is
n
ra
I
N
A
.A
S
S
R
B
 If engine fault lamp becomes on during the A
engine
K
operation, cause must be checked and E
eliminated as
G
soon as possible.
OR
E
 Do not use leaded gasoline,
Gbecause lead may damage
Y
the oxygen sensor and
Athree-way catalytic converter.
W
 If oil consumption
O is abnormal, the problem should be
T
resolvedOas soon as possible, because some of the
M
- 489 PY
im
D
-
s
o
i
r
it
Ka
k
-d
substances in the oil may damage the oxygen sensor
and three-way catalytic converter.

Valve clearance should not be too small, if the exhaust
valve is not shut off tightly, exhaust temperature may
become too high and thus shorten the life of three-way
catalytic converter.

At the temperature of below 10°C, if the vehicle and
engine run at low speed for a long time, the exhaust
pipe may have carbon deposition and become black,
which is a normal phenomenon. It will be eliminated
after a period of high-speed operation, or appropriate
means should be taken to keep the engine coolant
temperature within the specified temperature range.
21.16.4 Fault diagnosis instructions for Delphi
Requirements of latest regulations of the fourth phase
of EU and China National IV Motorcycle: the motorcycle
with electronic fuel injection system must be equipped with
OBD2 fault diagnosis system, namely:
1. When the motorcycle is started, the power fault light
must be on. If there is no fault after start, the fault light
will go out; if there is any fault, the fault light will be
on.
2. If the motorcycle has experienced a historical fault
(electric spray failed during assembly, debugging or
riding, but it has returned to normal), fault light must be
on after start, but it can only go out after 4 working
cycles; at this time, historical faults cannot be detected
using diagnostic apparatus, and no fault code can be
read.
The processing method is now described as follows: If
the fault light is on, but no fault code can be read using
diagnostic apparatus, it can be determined as historical fault.
The method to remove historical fault is as follows:
Delphi system resetting method: start the motorcycle
and keep it at idle speed for 30 seconds, wait for 15 seconds
after closing the key, and then quickly opening and closing
the key for more than 5 times (the time interval should not
exceed 1 second), the last operation is to turn off the power,
wait for 15 seconds and then start to see whether the fault
light is on. If the fault light is still on, repeat the resetting
operation.
a
b
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
is
n
ra
- 490 -
im
D
-
s
o
i
r
it
Ka
k
-d
Sample of diagnostic table
Registration number
plate number):
Engine number:
Name of rider:
(license
First registration year:
Model:
Frame number:
Date of fault:
Mileage:
Environment where the fault occurs
Weather
□ Sunny □ Cloudy □ Rainy □ Snowy □ General □ Others:
temperature
□Hot □Warm □Cold □Very cold □General □Others:
Frequency of fault
□Usual □Frequent □Only once
Road conditions
□Street □Road □Mountain road (□ Uphill, □ Downhill) □ Rugged road □ Gravel road
Altitude
□Normal □High altitude (about 1000 m or above)
The state of the motorcycle in the event of fault
□ After the electric door lock is turned on for about 3 seconds, the FI warning message and the FI warning
sign (EFI system failure) are alternately displayed on the LCD.
Alarm indicator
□ After the electric door lock is turned on for 3 seconds, the FI flashing burglar alarm system warning
light (LED)
message and sign are displayed on the LCD screen (anti-burglar control system is faulty).
□ After the electric door lock is turned on for 3 seconds, the alarm light will go out.
□The starter motor does not run.
□ The starter motor rotates but the engine does not start.
□ The starter motor and engine are not started.
It is difficult to
□Unable to supply oil (□ no fuel in the fuel tank, no running sound of fuel pump).
start
□ Submerge cylinder (Do not open the throttle valve when starting to avoid submerging the cylinder).
□The spark plug cannot work properly.
□Other:
□ It will flame out after start.
□ It will flame out after turning on the throttle.
□ It will flame out after turning off the throttle.
Flame-out of engine □ It will flame out when moving the motorcycle.
□ It will flame out after stopping the motorcycle.
□ It will flame out when running at a constant speed.
□Other:
□ The idle speed is very low, □ the idle speed is very high, □ and the idle speed is unstable.
□ The battery voltage is low (test after charging).
□ The spark plug is loose (tighten the spark plug).
□ The spark plug is dirty, broken or the gap is improper (corrected).
□ Tempering.
It cannot run
□Blasting.
properly at a low
□It is sluggish when accelerating.
speed
□ The oil viscosity is too high.
□ Brake drags.
□Engine overheating
□The clutch is slipping
□Other:
□ The spark plug is loose (tighten the spark plug).
□ The spark plug is dirty, broken or the gap is improper (corrected).
□ The spark plug model is improper (replace it).
□ Deflagration (poor or improper oil quality, replace it using the gasoline with high-octane rating).
The acceleration is □ Brake drags.
sluggish
□The clutch is slipping
□Engine overheating
□ There is a lot of oil.
□ The oil viscosity is too high.
□Other:
b
is
n
ra
.A
S
S
I
N
A
R
B
A
K
E
RG
O
E
G
Y
A
W
O
CO
Y
P
T
O
M
- 491 -
im
D
-
s
o
i
r
it
Ka
a
k
-d
Diode
Main relay
Fuel
pump
Ignition
ECU
Front brake switch
R
15A 10A 15A 15A 15A 10A
B/Y
1L
Meter unit
1L
LR
R/W
R
R
R
R
N G/Gr
G/Y BL/B Gr/G LR LR
M
LR P/Y
R LG/W
P
N/B
G/Gr
P/W
R/W
B
1R
2R
1R
2L
Side
stand
Rear
switch
Rear
wheel
brake Flasher
speed
switch
sensor
Front wheel speed sensor
N/O
Y/Gr
B
2R
2L
LR/W
Gr/R
O N/P R/W
P/Y LG O
LBL R/W
LR/BL BL G/B G/W R/W R/W G/B B/Y G/W
P
R/W
Y/R
Y/P P/N
W/Y Gr/Y
b
Right R/W
Starter circuit
switch
relay
housing
Left switch housing
Ignition
Fuse
switch ABS
40A
switch
Y/R
Gr
O
R/W
Gr
B
G/W
B
LBL
R/W
BL
B
G/B
B
Clutch switch
Y/W
R/LBL
B
B
G/W
B
G/B
R/W
BL/G
R/W
Gr/G
LR/BL
G/BL
O
Yellow
Y
Red
R
Rear left turn
signal lamp
Pink
LR
White
W
Purple
P
Gray
Gr
LIGHT
GREEN
LG
Tail /Brake lamp
License plate lamp
B
G
R
O
GE
Y/W
BL/B
R/B
R/W
B
G
N
B/N
G/P
N/R
LR
B
N
R/W
B
O/B
R/LBL
BL/G
Gr/Y
W
W
W
R
W
B
B
R
R/BL
B/N
R/B
R/W LR/B
B/BL
B/BL
B/R
W/N
Y/W
W/B
Y/W
W/R
Y/W
B
BL/LR
BL/Y B/BL
B/BL Y/G
W/Gr Y/W
W/G
BL/W
O/B
N/R
LR
B
B/R W/Y LR/B
Y/P Gr/R
P/N
LG/W
B
W/B
BL/W
G/P
W/R
W/Gr
Y/G G/BL BL/LR W/G
LG
B/BL B/W W/N BL/Y
B/P
N
LR/N
LR/G
N/O
Gr
W
LR/W
B
B
G/Y
P/W N/O Gr/R
B
Y/Gr LR/W LR/G
B/P
B/BL
Rectifier
1 2 3 4 5 6 7
Battery
1#2
Rollover
sensor
Water
temperature
sensor
8
9 10 1112 1314 15 16 17 18
1#Gr ECU J1
1#1
Fuel
Injector
Fuel
pump
MAP
sensor
Ignition
coils
Oxygen
sensor
Pickup Intake air
coil
temperature
sensor
1 2 3 4 5 6 7 8
1 2 3 4 5 6
9 10 1112 1314 15 16 17 18
R
7 8 9 10 1112 1314 15 16 17 18
1#BLACK ECU J2
Gear position sensor
BL/W
N/B
ABS
Y
P
Alternator
Fuel level
sensor
R/W
- 492 -
CO
W
W
N/B
O
LR/G
R
T
O
M
Headlamp
controller
G
Orange
Rear right turn
signal lamp
R/W
Y/W
Diagnosis
terminal
N
Green
P
B
ECU main
relay
Brown
Carbon canister
valve
B
N/P
ABS diagnosis
terminal
LBL
R
B
A
K
E
Horn
Fuel pump relay
BL
Ligt
blue
I
N
A
LG/W
Headlight relay
B
Blue
TPS sensor
B/BL
Y
A
W
Front left turn
signal lamp
BL/Y
.A
S
S
Head lamp
R/W
im
D
-
LG/W
Diode
Front right turn
signal lamp
CODE
Black
N/O
LR/G
LR/N
W
LR/W
B/W
R/BL G/B R/W B/N R/W G/Gr
Gr/R
B
Gr G/W BL
N/B O/B
COLOR
Instrument gear indication
s
o
i
r
it
ABS
Headlight
Y/R
Idle stepping motor
Ka
Fuse box
ABS
R/W
is
n
ra
k
-d
Circuit Diagram of BJ400-8 (electronic injection version, exported)