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49X Maintenance Manual

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1. 12 5 12 1 Preparing documents Work Instructions The cylinder cover bears large bolt pretension to ensure sealing between the cylinder cover and the cylinder body Pretension 50Nm All components must be cleaned and dried with high pressure air before check Function of the cylinder cover the cylinder cover is used to seal the cylinder and form the combustion chamber with the piston It bears HPHT gas and achieves air intake and exhaust through distribution mechanism 12 2 Failure diagnosis When the vehicle is running there is gas leakage or too high combustion pressure between the cylinder cover and the cylinder body Cylinder cover gasket is broken Bent bottom surface of the cylinder cover Too much carbon fouling in the combustion chamber 12 3 Cylinder cover 12 3 1 Disassembly Loosen fixing bolts for the fan cowl Remove the fan cowl LOSS Fan cowl Loosen fixing nuts and spark plug remove the cylinder cover ai a i a S Cylinder N _ Fixing nut2 1 over 12 4 Cylinder cover check Check whether cylinder cover is broken Check flarness of cylinder cover bottom surface Limit for use 0 04mm 12 5 Installation of cylinder cover Install it in reverse order 106 Cylinder block and piston Note all parts shall be cleaned and blown by high pressure air before check 1 piston 2
2. flywheel WAST screw Fix the flywheel with the universal spanner and tighten fixing n Torque force 9 0 Ne m Install the left body guard 46 J L rm X L K Ignition System H ja E BLe wc SPORE PLUG s ri 6 ip GNET sk T AMO Q HLEAMENT EATTERY O JGNITION COIL ia A _ Pi Me cI 1 Annunciator 2 Relay 3 C D I igniter 4 Ignition coil 5 power lock assembly 6 rectifier 7flasher 8 battery 9 right amp left combination switch 10 start motor 47 2 Ignition System Preparing documents 2 1 CDI Group 2 4 Failure diagnosis 2 2 Ignition coil 2 5 Ignition system check 2 3 Trigger 2 6 2 1 Preparing documents Work Instructions 1 Check the ignition system following the sequence listed in the table of failure diagnosis 2 This ignition system is an electronically and automatically angling device It is solidified in the CDI group and you don t have to adjust the ignition time 3 Check the ignition system following the sequence listed in the table of failure diagnosis 4 Do not make CDI of the ignition system fall down or hang down or hammer it with strong force primary causes for failure Pay special attention during disassembly 5 Failure of the ignition system is mostly caused by poor contact of the socket Check whether each connector is in good condition 6 Chec
3. Remove the primary lead of the ignition coil Remove the fixing bolts and then the ignition coil Install the ignition coil in reverse order Note Install the primary coil with black white terminal 2 5 2 Check the primary coil Measure impedance between terminals of the primary coil 5 Standard 0 6N 10 20 C Kk AI Ignition Coil Drawing It shows good if the impedance is within the range of standard values Relplace the primary coil if the impedance shows ce which indicates that the coil breaks 2 5 3 Secondary coil Attached with spark plug Measure the impedance between the wiring side of the spark plug cap and the terminals Standard 5 11KQN 20 C It shows good if the impedance is within the range of standard values The impedance cs indicates that the coil breaks Remove the spark plug cap Measure the impedance between the primary side wire of the ignition coil and the negative terminal Standard 0 5 5 5KQ 20 C 2 6 Trigger Note Check the trigger on the engine Check Remove the body guard Remove the trigger terminal Measure the impedance between the blue white terminals of the side wire of the engine and the body GND Standard 100 500QN 20 C 4 4 white green amp H blue white Replace the magnetor if the measured value exceeds the standard value
4. fe FA L422 A N ms S WT pJ7031 2 8 21 DJ621 2 80 5 53 54 2 FE WL4 1 magnetor interface black 2 Z green red white Startup System BRAKE SWITCH BRAKE SWITCH BATTERY m STARTER SWITCH one OR MOTOR E m al Ao TEN U U UU aS gt gt S j AG W A o A gt O Y A i k Era di Ja SANSA 1 storage battery 2 relay 3 alarm 4 C D I igniter 5 ignition coil 6 startup motor 7 power lock assembly 8 right left combination switch HZI Startup Schematic Diagram K K 3 Startup System Preparing docuemnts 3 1 Failure diagnosis 3 2 Startup motor 3 3 Starter relay 3 4 3 1 Preparing documents Work Instructions Disassemble the startup motor on the engine For the disassembly of the startup clutch please comply with related regulations Preparing principles mm Length of the brush of the startup 6 2mm 3 motor Bushing of the startup idler shaft Outer diameter of the startup idler shaft Tightening torque force Bolts for the clutch cover of the startup motor 12 Ne m Retaining nut for the clutch of the startup motor 95 N m Tools Spanner for retaining nuts Universal fixing spanner
5. 14 3 Left crankcase cover Disassembly Remove fixing bolts soacer and locating pin Fixing bolt Note Left cover Fixing bolts should be removed in staggered sequence Remove the locating pin 14 4 Drive face 14 4 1 Disassembly Remove fixing nuts for drive face and the left half drive face Remove the triangle belt from the drive face VG Check whether the triangle belt is cracked and whether rubber or cotton yarn falls down or is abnormally abrasive Measure the width of the triangle belt Limit for use 16mm Note Apply original parts from our company for replacement Remove the right half drive wheel assembly aH Check abrasion of the ball Measure the outer diameter of the ball Limit for use 14 4mm Measure the inner diameter of the right half driving wheel Limit for use 26 06mm z gt Right half drive wheel Measure the outer diameter of the sliding sleeve Limit for use 25 94mm 14 5 Clutch driven wheel 14 5 1 Disassembly Install the clutch sleeve with the fixer and remove fixing nuts Remove the clutch sleeve clutch driven wheel Ma e driven wheel AAE clutch sleeve AcE as fixer 22 fajtx F socket spanner 14 5 2 Breakdown of clutch Remove the retainer ring and break down the clutch Note Do not stain the clutch facing with any grease during breakdown sare Ds Nis GHE retainer ring PRPS Er clutch fa
6. After loosening grip the nut upon the top of the shock absorber After loosening grip the nut upon the bottom of the shock absorber Disassemble the back shock absorber set bolt G Take down back shock absorber 4 8 4 2Inspection and adjustment Note The preload value of every shock absorber shall always be adjusted to the same set value No uniform adjustment will worsen the operating performance and thus the stability is lost Adjust spring preload turn the adjustment device to direction or direction To direction turn to spring and increase preload to 6 direction turn to and preload value decreases Adjust device position standard position is 2 minimal position is 1 maximal position is 5 8 4 3 Installation Install rear shock absorber Torque force Upper set bolt 37 44 N m Lower set bolt 22 29 N m Installation of rear shock absorber Install back handrail back mud guard plate 88 Install cushion left right protective plate Fuel tank cushion Note when disassembling fuel tank fuel switch must be turned to OFF When disassembling and installing body cover must not be damaged When disassembling hook claw upon the car must not be damaged Align the panel upon the car cover and respective slots When assembling the installment of hook claw parts correct 1Icushion assembly must be 2left protective plate 6rightpedal 7righ
7. No 71 n 1 cylinder shaft Weight kg Curb weight Splash lubrication Rear rim Capacity of gasoline 6 0 5L Clutch Dry centrifugal clutch tank iia type Transmission Variable gear speed gear Se a Idle speed 1800 100rpm min Belt transmission Max torque 3 0N mA250rpm Battery 12V 4AH capacity type Performance Total Front outer ire 120 70 12 Tyre Front rim 3 50x12 Size Rear outer 130 70 12 tyre Backshaft dry charged Max Hp 1 90kW 6500 rpm Magnetor 90W 8000rpm capacity Compression devices Spark plug NGK BR7ES Spark plug 0 6 0 7mm gap Braking Front brake system disk Dia 6190mm mm 15 Rear brake disk Dia Specification 49X Cross country Model Unleaded petrol Length mm 1780 Fuel type tent E 92 95 Total displacement Forward shaft Weight kg Curb weight Total Lubrication Splash lubrication F ront outer 120 90 10 tyre Tyre Front rim 2 5X10 i Air filter 3XG Size Rear outer 130 90 10 tyre Rear rim 3 0x10 Capacity of 6 0 5L gasoline tank Dry centrifugal clutch Carburetor type JB 2G Variable Transmission Stepless gear speed gear Idle speed rom 1800 100rpm min Belt transmission Max torque 3 0N m 44250rpm Battery 12V 4AH capacity type dry charged Performance Magnetor devices Spark plug NGK BR7ES oa Max speed 45km h S eile 0 6 0 7mm gap Braking Front brake disk svat l 6190mm col A pi i 16 Rear
8. 56 3 2 Failure diagnosis Startup failure Weak in rotation No rotation of RE rotary engine of the startup motor of the startup motor e Fuse blow e Low battery e Poor startup clutch e Low battery e Poor wiring contact e Reversal rotation of the startup motor e Poor main switch e Gear seized e Low battery e Poor startup clutch e Poor brake switch e Poor starter relay e Poor wiring contact e Poor startup motor 3 3 Startup motor 3 3 1 Disassembly Note Before the startup motor is disassembled turn off the main switch remove the GND wire of the battery and then power on to check whether the startup motor works for ensuring safety Remove the wire clip of the startup motor Remove the fixing bolts of the startup motor and dismantle the startup motor 4 5 4 commutator Roll the waterproof rubber case and dismantle the connector of the startup motor 3 3 2 Breakdown Remove screws in the shell front cover motor housing and other parts 3 3 3 Check Check other components Replace any part with abraded damaged or burnt sureface Clean the commucator sureface if there is metal power Bf attached to it Check conduction between the surfaces of other components Ensure non conduction between armature shafts of the commutator Check the conduction of the shell of the startup motor Ensure non conduction between the conduction terminal and the startup motor shell Check conduction be
9. Charging state closed circuit voltage inspection Open the cushion Remove the cover of battery container First remove the negative wire and then remove the positive wire Take out the battery Measure the voltage between battery terminals Full charge 13 1V Under charge 12 3V Keep the battery idle for 1 hour Not Charge state examination must use a voltmeter operation Charge Connection method Connect the battery charger positive pole and battery positive pole together Connect the battery charger negative pole and 30 battery negative pole together Warning e Battery should be far away from fire source eTurn off the charger switches when starting or completing charging in order to prevent spark of the connections resulting in explosion e You must follow the required current time when charging IRRE voltage meter Note e Except emergencies you should not use emergency charge e Measure the voltage for every other 30 minutes Charging current standard 0 4A Rapid 4 0A Charging time standard 10 15 hours Rapid 30 minutes Charging complete closed circuit voltage Above 12 8V Carburetor Idle soeed adjustment Note Idle speed adjustment is carried out when the engines warms up HEIR solenoid valve It is carried out when the engines warms up T D i p i fi T ten a Operate the engine and connect the engine rotary meter Adjust the adjusting screws of the
10. The fuel pump assembly shall be parallel with the ground during inspection Headlamp Remove the front shield Disconnect the connector of the headlamp Remove the headlamp Clutch Start the engine and increase its speed gradually to check the work condition of the clutch If the motorcycle fails to run or the engine flames out you should check the clutch block 34 Replace it if necessary Front rear suspension system Front Pull the front brake tight compress the front absorber upwards or downwards for check Check whether there is oil leakage in the front absorber and whether any component is damaged or loosened Rear Compress the rear absorber upwards or downwards for check Check whether each part of the rear absorber is damaged or loosened Suspend the rear wheel and check shimmy Check whether the suspension bushing of the engine is loose or not Bolt nut fastener Check whether each bolt nut and fastener is loose If yes tighten it to required torque Rim tyre Check whether tyres or rims have any crack nail or any other damage Check tyre pressure 35 Note Check tyre pressure when it is cold Required pressure Unit Kpa Specification Tyre specification Specification Road 130 70 12 Check whether the locking nut of the front wheel spindle is loose Check whether the fixing nut of the rear wheel is loose Tighten it to the
11. 10 Do not use electrolyte added batteries when interchanging batteries 11 Use a voltmeter to check charging condition of the battery 39 Preparing principles Capacity Type 12V 4AH dry charged Fully charged 13 1V Voltage x ecessar Battery 20 C 4 12 3V not working for 1h charging Charging current Standard 0 4A quick 4A Charging time Standard 10 15 hours quick 30 mins s0w 8000rpm Impedance of lighting coil Between green red black 2 0 2 50 Magnetor 20 C Impedance of charging coil Between white black 1 5 2 00 20 C Type Single phase semiwave SCR charging SCR semiwave short circuit Voltage Lighting limit 14 0V 0 4V 5000rpm regulator Limited 13 5V 5000rpm voltage Charging one 14 8V 0 4V 5000rpm imi Tightening torque force Tools Rectifier bolt 5 0 Nem Universal fixing spanner High voltage coil fixing bolt 9 0N m Flywheel remover Flywheel fixing nut 5 0 N m Test instrument Body guard bolt 9 0N m Multimeter 1 2 Failure diagnosis Power supply dead Interrupted current Battery overdischarge Poor contact of the charging wire Unconnected battery wiring Poor contact of the charging system Fuse blow Poor contact or short circuit of the lighting system Poor switch Low voltage Poor charging system Poor battery charging Poor contact short circuit or open circuit of wire terminals Poor contact Poor voltage current regulator Poor charging system Poor magnetor Poor voltage current regulato
12. 14 016 14 034 14 06 13 2 Failure diagnosis Low compression pressure White smoke from the exhaust pipe Abrasive burnt or ruptured piston Abrasive or damaged piston ring Abrasive or damaged cylinder or piston Abrasive or damaged cylinder or piston Damaged spacer or crankcase leakage Over high compression pressure Abnormal noise of the piston Too much carbon deposit in the combustion chamber Damaged cylinder piston or piston ring Abrasive piston pin hole and piston pin 13 3 Cylinder block 13 3 1 Disassembly of the cylinder block Remove the cylinder cover and then the cylinder block 13 3 2 Cylinder block check Check the abrasion of the inner wall of the cylinder If it is serious replace it Check the flatness of the cylinder block Limit for use 0 05 A Logs 13 4 Piston 13 4 1 Disassembly Remove the retainer ring of the piston Note during disassembly do not make the retainer ring fall into the crankcase Remove the piston pin and the piston Check the piston piston pin and piston ring Remove the piston ring Note Do not rupture or damage the piston ring Eliminate carbon deposit in the groove of the piston ring Remove the piston ring and install each piston ring on the cylinder bottom Note Press the piston ring into the cylinder with piston head Measure the joint
13. Prepanne dOCUMEN rerne e testiactnoossandiuneaaaintediead lactate Gonnndivaane 108 123 2 Failure diog ho iS anien ana a E E TT TT 109 13 3 Cynder DIOCK ak aia ati a a aa aa tons 109 DD A PI SUO MN EITAN EA ENA O A A A A EE A A AA cnaatnin enn 110 DD STIS CONS Call lic Ul OMA aea E NN 112 14 Drive Face Clutch Driven Wheel Kickstart Mechanism cccssseccccssececcsececcusececeeccceceuececeucececsuseceesaness 115 1A 1 Preparing GOCUMEM S tannie a a avidacdea eee yaeeee te avieda iets 115 AZ FAM UIE SVU I Os Sates is see ei sic elec sr cnet ecw gloat iene aslon ee urea eas clone Reames Meanen aa 116 TA eener anKCa S OCON ae N a a a T 116 TAA DVE TI E ai A A T E OA T races E OTA 116 T45 Cluteh driven WHEE lier atch dicta a a a a 118 14 6 Breakdown of clutch and driven wheel eossennssssseessssseesssseeersssseerssssrrrssssrressssrerossseeressseeresseeeressss 120 TEA aaO ae E N 123 14 8 Kickstart mechani S eeror n an a E TE O O A TeDe rO ai a N anid ahd ae aon eas eee Mls PRCA e CLO CUIVGIIES oe tra snrhs cera succtarzns festa aeacetaccea te A tian matamnetae De E eE AO EEE EENEN SEINE IT OTENE NE ENEE EENE AENEASE NT TENENT AITA EESENE N Ta e DOE E E T T TET E TE T TE TEO E E O TS A ASSEmMDI yen a a a A A N LOCF IKC AS ea E E E A NN TO LPreparnne COCUMEN S ensenen a a Tossuacdnoaginadtesguacdncomieadtaciaaqoouieeieaeie 162 Faluredidgnho iS anakina a A OET OT to o Crank SE
14. a A A AN EAAS SEME cessed a A Inspection and Maintenance of Exhaust Emission SYSTEM ccccccssseecccceeesececcceeseccecsaeaeceeseuaueeceesauaeeeeeseaees EF SEXMAUSTEMISSION Ge CONTON SV SUI cascaaesanciendareancaderasncacaweincadlonaiaguc seeanduseansnnus cceundadeamonnus A T 17 1 Warranty on the exhaust emission amp control system ccccccssssseeccceeeseeccccaessececeesaeeceessuaeeceesaeaasees 17 2 MASEL CTIONS ON penodi Midi NLC IAI CO ciiai ann aA AT A R 17 3 Mechanical function of the exhaust control SYSTEM cccccccsssseccccceeseccecceeeseceeseaeueeeessaaaeeeeesauaasees 174 Catalytic conversion Syste mM osrin a aA A ETOO TO OOTO 17 5 Measures when the idle speed emission value exceeds the standard Two Stroke cccccssseeeees Preface This manual is an introduction to the maintenance of 49X Preparing Documents include all the contents needed so read it carefully before operation Inspections introduce how to check and maintain your motorcycle which needs to be done regularly After the first chapter the manual will explain parts of the engine entire motorcycle electrical parts and how to disassemble and reassemble these parts Each chapter has decomposition map and system diagrams failure diagnosis and maintenance instructions This manual does not separate the two motorcycles when they are described in common parts The pictures and content are just for your reference Please be subject to t
15. and where cables may be clamped during moving Cables along the handlebar shall be neither too tight nor too loose and do not interface with any neighboring parts at steering positions Cables shall be properly deployed without twist or knot Check whether the connector jacket is damaged and whether the connector is over stretched before mounting connectors Adopt adhesive tape or hosepipe to protect cables if they are positioned at sharp point or corner Bind cables with tape after repairing Control cables shall not be bent or twisted Clumsy operation may be caused in light of damaged control cables QO CORRECT X INCORRECT Identification 1 The identification number of motorcycle frame is marked at ye The motorcycle code indicated as The 9 10 digital and 11 digital respectively indicate test code year code and factory code 2 The engine serial number 1 is printed on the shell of crankcase QJ1E40QMB 4 OH H HUHHHHH See Figure 1 2 Figure1 2 Significant Notes 1 Please apply valid Qianjiang parts and accessories Any part or accessory not in accordance with the design specification of Qianjiang Company may cause damage to engine 2 Only metric tools are valid for maintenance and repair Metric screws bolts and nuts can not be exchanged with imperial fasteners 3 New gaskets O rings cotter pins and locking pieces shall be applied for re assembly 4 Bolts with large diameter or positi
16. assembly tools Oil seal remover Handle for dismantling tools Piston pin pulling device Piston pin pliers Socket spanner for spark plug Clutch thickness measuring device Cylinder diameter measuring device Dial indicator Measuring the inner diameter of piston pin Fig 1 16 Table 1 2 continued Clearance gauge Fig 1 5 Fig 1 6 10 ne Fig 1 15 Fig 1 16 2 Tools for repairing the chassis Table and drawing 1 17 1 18 of ordinary tools and special tools for disassembling assembling chassis parts are as follows Table 1 17 Remark Torque spanner Inner hexagon spanner Socket spanner Micrometer Magnetic rack V block Dial indicator Vernier calipers Circlip pliers Screwdriver with striking cap Tool for assembling oil seal of front fork Tool for hammering seal of front fork Steering nut spanner 1 Ordinary tools for repairing the chassis Table 1 18 continued Fig 1 19 Fig 1 20 4a Aua i i bg R ejo 4 connecting rod Fig 1 27 Fig 1 28 2 Special tools for repairing the chassis tool for hammering seal of front fork Fig 1 29 Fig 1 30 3 Tools for electric parts Table and drawings 1 31 1 32 of special tools for testing electric parts are as follows Table 1 31 Multimeter Fig 1 33 Ignition tester Fig 1 34 Table 1 32 continued Fig 1 33 14 Specification 49XHighway Model Unleaded petrol Length mm 1780 Fuel type 92 95
17. axle 6201 2RS 6 front wheel middle axle sleeve 10 front wheel left axle sleeve 8 Calcium soap base grease is recommended as a lubricant Install front wheels 2 front wheel axle 1 pinion stand assembly 4 nut M12X1 25 5 When installing pinion stand assembly 4 attentions must be paid to ensure it is well folded if the odometer pinion stand assembly has not folded and locked the front wheel axle odometer the pinion stand assembly will deform Install brake cylinder assembly 3 upon the front wheel hub Screw up the front wheel axle seen in the right hand picture note 49X front wheel assemble and disassemble picture is seen in P72 in the manual Torque force Front wheel axle locknut 55 62 N m 7 4 Handlebar 7 4 1 Disassemble Disassemble rear view mirror assembly Disassemble left right combination switch assembly Disassemble oil pump assembly Take down the left handle bar throttle operation handle assembly Loosen steering column bushing and set screw Disassemble steering column fixed seu A5p se cee ym REI M101 26X RO sleeve tft M10X1 25 Take down the handle bar ABEE steering column fixed sleeve HAE ANZA Foil pump assembly B44 crash bar HHAH right combination switch assembly JWE steeringbar ZHARAR left combination switch mounting base WEEE nut WET screw 8 amp 8 7 4 2 Installation note 49X steering bar disassemble and assemble picture is seen in P74 in th
18. brake disc 190 R On road Dia of rear brake disc 180 Dia of front brake disc 190 Off road Dia of rear brake disc 180 5 1 2 Torque force Fixing bolts for fuel pump assembly 5 9N m Mounting boltsfor front brake cylinder assembly 22 29 N m Rear brake rocker arm bolt 5 9N m Fixing nuts for rear wheel 85 98N m 5 2 Failure diagnosis Brake Poor brake performance Slow reaction or tight lever 68 1 Improper adjustment of the brake 1 Improper adjustment of the brake 2 Abraded brake shoe friction disc or brake drum 2 Abraded brake shoee friction disc or brake drum 3 Improper installation of brake shoe 3 Improper installation of brake shoe or friction disc assembly or friction disc assembly 4 Stained brake shoe or friction disc assembly of the brake disc Abnormal noise 1 Abraded brake shoe friction disc or brake drum 2 Stained brake shoe or friction disc assembly of the brake disc 5 3 Front disc brake 5 3 1 Disassembly Note e Replace the friction disc assembly e f the friction disc will be used again mark it before disassembly so as to reinstall it at the original place Remove the following assemblies from the right grip and the front absorber Front brake 1 fuel pump assembly 2 front brake disc 3 brake cylinder assembly 4 friction disc assembly 5 brake hose Note for breakdown details see P63 Note e Do not stain the brake assembly with oil spots during installation or
19. disassembly e Clean it with required cleaning agent to maintain the brake performance Loosen fixing bolts for the brake cylinder assembly Remove the brake cylinder assembly from the front absorber Remove the front wheel spindle and take down the front wheel Remove the brake disc from the front wheel 5 3 2 Check Check whether the friction disc assembly is abraded Replace friction disc if necessary Measure the friction disc assembly and the brake disc Record maximum values 69 Specification 49X on road off road ff Diameter of the front brake disc 190mm Thickness of the front brake disc 4 0mm Thickness of the friction disc 6 0mm Note e Measure with micrometer Measure the thickness of the friction disc assembly If the thickness of the front brake disc or the friction disc assembly is below the required value for maintenance or it is stained with grease please replace it Limit for use friction disc 3 0mm Brake disc 3 0mm Note Replace friction disc in pair 5 3 3 Installation Install the brake disc and the front wheel Install the front brake hose assembly and the brake cylinder assembly Do not stain the friction discs and the front brake disc with grease Note Any grease on friction discs will reduce the brake performance and even lead to failure Tighten bolts and nuts to the required torque force Torque force Fixing bolts for fuel pump assembly 5 9 Nm Mounting bolts f
20. function After the carburetor is disassembled block the intake manifold with cloth in case that any foreign matter enters If not used for more than one month gasoline in the float chamber of the carburetor shall be drained out since it may block the idling jet after deterioration which affects idle speed Carburetor functions Carburetor is a critical component in the fuel supply system of the engine its work condition directly affects the stability as well as the dynamic and economic indicators of the engine It atomizes certain amount of gasoline into small oil drops and evenly mixes it with different quantities of air to form combustible vaporific mixed gas of different concentration upon different working conditions of the engine The mixed gas will be supplied to the engine to ensure continuous and normal operation Preparing Principles Unit mm Item Standard value Main jet 47 5 Main metering jet SO Idle metering jet 15 Oil needle BO5 2 11 2 Failure diagnosis Abnormal startup Difficulty in startup flameout after 100 startup No fuel in the carburetor Blocked oil filter Blocked oil pipe Adhesive needle valve Oil level maladjustment Too much fuel in the engine Oil spilling Secondary air suction into the fuel system Fuel deterioration Abnormal enrichment valve Blocked idle speed system or choke system Too dense mixed gas Abnormal enrichment valve Abnormal needle valve Over high oil le
21. handle 3 left rear view mirror assembly 4 nut bolt M5x20 5 left combination switch mounting base 6 left combination switch 7oil pump body 8 nut M10x1 25 9 screw M10x1 25x50 10 bolt M6x23 11 right combination switch 12 right handle assembly 13 screw M5x25 14 tight rear view mirror assembly 15 coupling bolt 16 fluid brake cable clamp 17 carrier ring 18 screw M6x20 19 carrier ring 20screw M6 21 nut bushing 22 nut M6x12 23 cable clamp assembly 24 crash bar 25 steering column bushing 26 handle bar 27 handle bar cover 28 right combination switch mounting base 29 right crash bar mounting base 30 left crash bar mounting base lt 7 Front wheel Front suspension Preparing documents 7 1 Failure diagnosis 7 2 Front wheel 7 3 Handlebar 7 4 Front fork assembly 7 5 7 1 Preparing documents Work Instructions Before disassembling the front wheel use lifting jack to support the chassis and see to it that the front wheels must not rotate reversely In operation see to it that no fat sticks to the stop brake friction disc and fluid brake plate Motorcycle Standards Measurement points tem Standard mm Limit for use mm Rim Vertically ie 2 0 Front wheel l i TE shimmy Horizontally Within 1 0 2 0 49X road 49X SUV Torque force tools Handle bar set screw 40 60 Nm axle bearin
22. j A CDI 2H CDI group black f blue white Connection positive pole to blue white negative pole to GND Minimum voltage above 1 7V Note Never touch any metal part of the test rod with your finger to avoid electric shock When the maximum voltage measured at the terminal of CDI Group is abnormal dismantale the right body guard and the magnetor connector Connect th trigger blue white to the shunt e f the voltage of CDI is measured to be abnormal while the voltage at the magnetor terminal is normal it is caused by poor contact or disconnected wiring e If the voltage at both CDI and magnetor terminal appears El white 4k green Hi blue to be abnormal it is caused by poor trigger Please refer to the table of failure diagnosis 5 2 4 CDI group 2 4 1 System check Check the system Remove the CDI Group andcheck componentys of the ignition system at the terminal black 24 H black red 2 H green white W Fl blue white 54 20 black red 2 4 2 Check Remove CDI Group and check whether the terminal is loose or corrosive Red red white Conduction when the main switch is OFF Primary coil of the ignition coil Black white black 0 60410 Secondary coil of the ignition coil Black spark plug cap excluding 0 5 5 5KO the spark plug 2 5 Ignitin coil 2 5 1 Disassembly Remove the body guard Remove the spark plug cap
23. l l l l the battery voltage l Voltage The voltage rises_to the don t rise normal level and is back to original after switch off the bike _ Voltage exist No voltage Check whether the voltage adjuster is loose or not Check the socket of the voltage adjuster Connect the read wire and positive terminal of the multimeter together Connect the negative terminal and tHe body together Measure the coil impedance of the I alternator I I Start the engine Connect the read I I I I wire and positive terminal of the I multimeter together Connect the Higher than Normal Tesan hte ca oak tc eves han een ay alos l normal voltage Check whether the contact voltage adapter is good or not Spark plug cannot jump Failure diagnosis Measure the impedance of the Voltage adapter Adjustment and inspection 22 Life of the battery is over Bad battery Poor contact of the plug Open circuit of the red wire Voltage adjuster Open circuit of the white wire Bad coil Poor contact of the connection Broken white wire of the alternator Bad battery Poor contact of the connection or wire Bad voltage adjuster Source of trouble No jump spark or Intense little jump spark spark Old spark plug is bad Loose spark plug cap Check whether the CDI plug is loose or not Poor plug contact Bad main switch Bad charging coil Ba
24. of cylinder body link plate BENELLI EX M2 1 exhaust pipe assembly 45KM 2 muffler hoop 3 bolt M6x16 4 bolt M6x16 5 muffler tube assembly 6 tube assembly 7gasket 8 screw M6x20 9 screw M6x25 17 Exhaust Emission amp Control System Warranty on the exhaust emission amp control system 17 1 Instructions on the periodic maintenance compliance with standards 17 2 dio s Mechanical function of the exhaust control system 17 3 Catalytic conversion system 17 4 Measures when the idle soeed emission value exceeds the standard 17 5 17 1 Warranty on the exhaust emission amp control system 1 The exhaust emission amp control system of this motorcycle is in conformity with the revision of EC 97 24 5 I and 2002 81 EC B issued by the EU We warrant that the exhaust emission amp control system works normally during its effective period provided that users completely comply with all operation and maintenance requirements 2 Warranty range 1 Function warranty of the exhaust emission amp control system We warrant that it satisfies all periodic or non periodic exhaust emission inspection by the related government authorities within riding of 15000 kilometers 3 This provision is not applicable under any following condition However our distributor or service store would like to provide maintenance or re
25. on the left half driven wheel Guide pin Oil seal EB ES Fe LO 4 elastic retainer ring ASVHIZAK rolling bearing Apply grease evenly to the outer rolling bearing and then place it into the sleeve Note Place the outer rolling bearing into the sleeve with its Bearing screwdriver marked side outwards Then fill the sleeve with 8 9g grease Install the elastic retainer ring Install the needle bearing Press the needle bearing in with the equipment shown in the picture 14 6 2 Combination of clutch and driven wheel Eliminate any grease on the surface of the driven wheel Install the oil seal in the sliding sleeve of the left half driven wheel Apply grease evenly on the O ring and install it on the sliding sleeve of the left half driven wheel JA 7H Ha lubricating grease Ff oil seal O 44 fal o ring Combine the left half and the right half driven wheel Apply grease evenly to the guide pin and then install it into the guide groove Sals Guide pin Guide groove Install the spring guard Eliminate the leaked grease GXI E spring guard Install the clutch spring and the clutch on the driven wheel Compress the set with the clutch spring Install locking nuts after compression Note Properly compress the spring to avoid damage to the spring WF ZIARE spanner locking nut AAEE clutch spring compressor 14 7 Installatio
26. piston pin 3 cylinder block 4 cylinder gasket 5 cylinder cover 6 nut 7 spark plug 105 13 Cylinder Block and Piston Preparing documents 13 1 Piston 13 4 Failure diagnosis 13 2 Piston installation 13 5 Cylinder block 13 3 13 1 Preparing documents Work Instructions All parts shall be cleaned and blown by high pressure air before check Function of the cylinder block cylinder block provides space for gas compression combustion and expansion and also guides piston movement It also transfers part of heat energy in the cylinder to cooling medium around Function of the piston Piston bears pressure arising from mixed gas combustion inside the cylinder and transfers such pressure to the connecting rod for driving the crankshaft It forms combustion chamber along with the cylinder cover It acts as slide valve for air inlet stop periodically compresses fresh mixed gas from the crankcase into the cylinder and discharges exhaust gas after combustion in the cylinder Preparing Principles Unit mm Item Standard Linit or use Top ring 0 015 0 05 0 09 Piston ring groove gap Ring 2 0 015 0 05 0 09 Piston 0 1 0 25 0 5 Joint gap Piston 0 1 0 25 0 5 Outer diameter of piston ring 11 994 12 11 96 Clearance between piston pin hole and piston pin 0 002 0 014 0 02 Inner diameter of the smaller end of the connecting rod
27. required torque value if it is loose Torque value locking nut of the front wheel spindle 55 62 Nm fixing nut of the rear wheel 100 113 Nm Fixing steering stem bearing and handlebar Move the handlebar to confirm there is no wire interference Rotate the front wheel and move the handlebar freely for check If the handlebar moves difficultly release it and then check the bearing of the fixing steering stem 36 Inspection and maintenance of electrical system Torque force list of fixing parts in electrical system Rectifier bolt High tension coil fixing bolt Flywheel Fixing bolt Body Shield Bolt Clutch cover bolt of starting motors Set screw nut of clutch cover of starting motors 37 Charging System W GYR R GYR W 10A GYR W 3 BLSYW G h IN gt ue BATTERY Ps R MAGNE 1 HF RMI MEN 1 Announciator 2 Ignition coil assembly 3 Power locking assembly 4 horn 5 C D I igniter 6 relay 7 Flasher 8 Rectifier 38 1 Battery Charging System Preparing documents 1 1 Failure diagnosis 1 2 Battery 1 3 Charging system 1 4 Voltage current regulator 1 5 Charging coil of magnetor 1 6 Disa
28. speed or with high mileage shall be maintained frequently Engine oil filter Oil level Note e The motorcycle should be parked on a flat ground when checking its oil level e After the engine runs for 2 3 minutes or stops running for about 2 3 minutes check the oil level Check the oil level Check the oil level Add oil to the upper limit when there is an alarm from the oil level sensor 1Oil Tank 2 Rubber Cushion at Oil Tank 3 Oil Tank Cover Component 4 Oil Sensor Assembly 5Bolt M6x16 60il Tank Assembly 7Clamping Bnad Oil replacement Note It will be easier to change oil when the engine is warming up iH Be HE POMBE Oil bolt Turn off the engine Remove the drain bolt at the bottom of the crankcase and discharge oil When oil is discharged completely you can install the drain bolt and packing washer after they are cleaned Add oil to the required level Check oil leakage when the engine operates at its idle speed for minutes Check the oil level again Throttle cable inspection adjustment Check whether the throttle cable works smoothly Check the free stroke of the throttle cable Free stroke 5 10mm Adjustment shall be made when improperness exist Adjust the free tavel of accelerator Fisrt loosen the locked nut 1 fix or loosen the adjusting device util the free travel meet the standard value Then fix the locking nut 4 Air filter Filter replacement Remove the body shield R
29. the startup motor Install the wire clip for rear brake 58 3 4 Starter relay 3 4 1 Check Remvoe the body guard When the main switch is ON check there is click sound at the time of pressing the startup motor With click sound it is normal Without click sound echeck voltage of the starter relay e check the GND loop of the starter relay e check the movement of the starter relay 3 4 2 Check voltage of the starter relay Set up the main stand and measure voltage between the negative pole of the green yellow wire of the starter relay terminal and the body groung connection When the main switch is ON hold the brake lever HZ 4kH4s starter relay The battery voltage shall comply with regualtiosn When there is no voltage at the starter relay terminal check the conductin of the brake switch and leads 3 4 3 Check GND loop of the starter relay Remove the starter relay connector Check conduction between the black wire of the lead terminal and the body ground connection When the startup button is pressed it shall show good conduction between the black wire of the terminal and the body ground connection Check conduction of the startup but
30. 49X Maintenance Manual Contents GO MU CIIUS coach eheee seat a eae ect areata atari arc tote as EE EE den dsabeectacemeneaaes 1 FPG Tl So ders Sareea sane dena Perea ergs tare dati teeta E oan dunn dea Poaceae E A tesa dunee atadtuneadostendtatseediai 4 PEED arING DOCUMEN ce sadaeadusecsencvsadenadensyceadoqedaexd pansies EAEN EE view dean deat oie nce sedan taeenws chs teaatootidaeases 5 SPE CTIONy Ad us UIC INU eaaa A A 24 Inspection and maintenance of electrical system csccccccsssssecccceeeeccessueececesaeseccecsauaeceessuausecesseaaeecessauansees 37 k Batterv Chars INe SY StI nornen REE E N TEA TET 39 REPE DANN docum ENS nense aaea Er EAEE EE E ENEA EO RE 39 1 2 Fall re diag MOSIS sersan aeara s E E AE TE E A A 40 j AULT sate hatha dada E EA Shad fede atta Meter ETE T A A tented E tel E E T ns oi Ye A E E detente 41 PEERI EME SV aU CN weds seen teauenrestcouesutestweeruistesuens a tartrinutithedel tetennkliguartemener 42 1S Voltage ANG Current AG IUSLON vj atsscsoctucesacandsnndeo tesa naeyadcaades te smaasendsuades on ecaaca aseniegn iasacn suena mecasu aaa neces 43 LO Magnet t Chareing COM susinetinsativierseg ease ersaiarseas biasaets vearaas aaa ee Pes ata Saw TR TI 44 t Disassembly OF MaABNETOR arinaa aa sen eaeeesapegin ease amen ae ease ee ae 45 2E AONE SVS LOW i trscwneleeectnaseo acme E E E otegtieawalsseeracsatiexeatesancuesatiauactesserweiseteceees 48 ZAPPED AIMS COCUINE
31. L ON eet eae E AEE EOE AEN A EE E EEE E EE E EE ieee white Guan udey beatae Gusa ude saute 64 FO COMMON ALI ONS WC h enana adanada aa aaa aa aaa 64 Inspection and Maintenance Of the CHASSIS sssssccccccccsessseececcceseaeesseeececcesseaeseeeeeceessuueeseeeceeessauaaseeeeeeeesaaaaees 65 Bf BEING oaa aed sae aaemiatea aueanenenaed ata tes yr ateneane a cee eRe 68 VANES AA Ce MISE UE ON en oracle bastante r sain onceauectedts sags EA ENI E OAE tures 68 S2 MUN CGA NO SIS a tas naaceceta eves teed EAE E ape ante teataas a aberol 68 53 Front disc Dra kO naen a Mariner oan nen Meri ae oan eeu peas 69 DBA Rear CISC Drake orses n baie seasasetantacdeiastadebartacd a a aa 70 7 PRONE WINECl Front SUSPENSIO Moia uti cia teca vile wat acai ae ET iat al ag iat alae 78 Peale a e eE EE agli alice Center AAE meen A a rrr A tint tn A OA rn inte tery try irene te te iter 78 ToD WES IN O6 16 aaiganeaasusensccugausaaas uaa snd asa sedan aah oacsacanedageaatuusdigaascagenat vaedanata aden antssuasnaasadassatuancugaauunessoanccaas 79 A TONE WINS CIS ac aE E E Dau aie cess eerla ese nse asd ei ecb nda acl Saco wrk cae Sua ETO OTO 79 FAs ANGIE DAN oenina hatha ae asian a a aioe ade eee eee 81 Te STON CON na a este aces sits setae deste eee esa es tees ee mice ek sted dee so ee GS ase ee 82 8 Rea WMEEIZFC ar SUSPENSION 2 css casecstccans 48 a E N E E E E 86 Bal PRED are document Sariini E E AEA O OE OA E
32. M ES orae a E E EE ENTE E E A O 48 22 Falura diagnosis sirnaan A 49 2 3 lenition system ChNECKkensennan iaaa A eas aneancaptaaancesceadeatadcaieeeansy 50 Zee SOUS soos oat titan es oh cu tow te Suan dew bin wh oc Shee uae E ules Charedeebinwtaitheaaone eta 52 PMI N OW aarden Ardara ae AE A ae tence dee tae toeduag tae AEN 52 Zs VVC Fs ws aces sry asa ane hires vases ns we Saw aH pg SRS E EUR T a E E E S 53 De ArU D SYSTE Mienna A E EEE AE 56 Dl PREDALIMNG COCUMICELS aarne a I E N AT EEG 56 22 Faurc dide NOSIE ra e a EE ENA E 57 DS SNUP MOO aasar eor EEA EEE EREE cies arse A EEE E ORES 57 SA aer Trela e a a a a aa 59 Yale Bub AS I VE TRE G Ska IV 21 aoe ete nee ae mate a Beats Bt TIC Pee ew ee OE eae en Pr eee eR 61 At Prepanne CLOG UW ld biatch eserscecondenaant EA decades E evanaue deste A OEE AA ES 61 Ai 2 Failure Cla BIOSIS oerrinne wea taana ues v cays kep Wana ai Saas yea uaa aa wats eas Guanwkea Vaan vas Gama aa eww way UNA eT aes 61 4 3 Replacement Of heddlamp DulbSusscancennsssni antaa ania aa A E eee 61 4 4 Replacement of front steering lamp cccccccsssssccccccesececccaeecceccseeseccceeeuaeeceessuaseceesseaaecessuuaeceessensees 62 4 5 Disassembly Replacement of tail lamp and rear left rignt steering laMp ssssssssssssssssssssseseseeees 62 A O MOTOT aSa caste wna ects cc ni Gaels sn aa cline T T I I TA A A eine S 63 Ae ALANA SWI Cia a AEE OAE AEAEE GO 63 OE c
33. O OOA O 86 SZ aU Ca INO SIS shart ea aati alaet Cadet aaterud ated eaaaeeei ahaa easeenties sed varaatsa eae ae 86 rl NMI AEA estate acetate te eect er ect carne cachet cert acetate eee caudate staan nea EE AE A A TE ES 87 SA Rear SNOK a0 SO hOCK eona a a A a 88 S E E a1 ALOIS 011 a EAE E ANE AE ANEA AAE IEE ANA E OAA E E E E E TE 92 91 Prepar ne GOCUMICIES ai e a a R A 92 92 Fal ure diagnosis anaia a aa a a a a a E ones 92 gS UN bat CUERO Men a 93 Inspection and Maintenance Of ENgine rennene oa a OO OEA EAO TO E 94 LO UDEICALION Vystoma a a a el ear ea a a wae 96 JIO t Prepa OE a a R 96 IG AF Aue CAS Os EE TEETE EE TTE E ENEE EENE ENE EENE NTA EENE NTE N E 96 1O 3 UC DUN De eee Mere ere te fe rise Ar T TE E A EE E OE T O T O TEE 97 TI Cap OuUnerOl on iea n a a a 100 MDs VP SAE CLO CUI US nonas EE E E A 100 TE Fae dae Oss e e a a a a canned toomateeeaae 100 11 3 Carb retor disassembly sccsicestavaniinaderawsedevanwaadeawens daeacwmadeanwas davadumaduawmnsdavadweandrunen TOO 101 12 CVIT COV EC ute eae eee a Geek 105 DEM PWS AVIV COC EVV INES ccs acetate Recerca est rcpt to a ce wre ba delta R A a demon ne 105 AP PH AMS Cl ASO A E A AEE NEN E NE ama EAE ENNEN NTN NE AEE 105 DZS CVM Er COVE ana E E EEEE OAE E AO OOTA 105 124 Cynder COVEL check coii a e N A E bhaetastesoen 106 12S psta lation or cylinder COV OM nanii a N EE E A AG 106 IS E
34. R 0001095 Sport E4 75R 000487 1 handle bar 2 nutM12x1 25 3 front wheel middle axle sleeve 4 pinion stand assembly Saxle bearing 6201 2RS_ 6 tyre 120 90 10 7 front wheels 8 inhaul cable assembly 9 front wheel grease seal assembly 10 front wheel left axle sleeve 11 front brake disc 12 front axle T5 Front Suspension Bolt 6 in the picture installation torque force 37 44 N m Bolt 2 7 in the picture installation torque force 5 9 N m Upper steel ball number 21 C Lower steel ball number 21 1 bolt 2 bolt M6x16 3 nut 4 odometer cable clamp 5 front right shock absorber assembly 6 bolt M10x1 25x30 7 bolt M6x12 8 fluid brake cable clamp 2 9 dust ring 10 steel cable baffle ring 11 grease seal assembly 12 compression nut 13 compression nut 14 coupling steel bowl 15 dust proof cover 16 steel balls 3 16 17 lower axle bearing and upper steel bowl 18 lower axle bearing and upper steel bowl 19 lower axle bearing and upper steel bowl 20 lower yoke plate welding assembly 21 front mudguard bracket 2 22 front mudguard bracket 1 23 fluid brake cable clamp 1 24 front left shock absorber assembly _ 76 Handlebar Bolt 9 in the picture handling bar set bolt installation torque force 40 60 N m Front brake handle free travel 10 20mm Rear brake handle free travel 10 20mm Throttle operating handle picture 12 free travel 5 10mm Rear view mirror3 identification number L E4 005 1 left handle cover 2 left
35. R ALARM SYSTEM c zI SS Lz i a w GA Cas O OIL SWITCH UEL LEVEL GAUGE MAGNETO
36. Unsmooth rotation Cunder speed Failure diagnosis Adjustment and inspection Source of trouble 19 Air filter plugs up Engine speed Not enough Bad petrol T engine speed Pipeline of the Evaporative Emissions Control System plugs up Vent pipe plugs up Bad automatic choke Cracked vacuum module for the carburetor Bad automatic oil control ring Bad CDI Bad trigger Bad piston and piston ring of the cylinder Air leakage of the cylinder ring Clear up dirt Clear up dirt Heat value of spark plug is not appropriate Too much oil Check the cylinder for Insufficient oil lube condition Unchangeable oil Cylinder wear Mixed gas is too thin Bad petrol Too much carbon distribution in the firebox Too early ignition time Too much carbon distribution in the firebox Bad petrol Clutch slip Mixed gas is too thin Too early ignition time Unsmooth rotation especially high speed Failure diagnosis adjustment and inspection Source of trouble 20 Bad CDI Abnormal a Bad trigger Insufficient petrol in the petrol tank Petrol filter plugs up Normal Abnormal Pipeline of the Evaporative Emissions Control System plugs up Bad automatic oil control ring Unblocked Blocked Clear up Good Spring has no Bad spring elasticity Bad battery Cover discharged or overcharged Failure diagnosis Adjustment and inspection Source of trouble 2 4 Start the engine and measure l
37. attery Note e Except emergencies you should not use emergency charging e Measure voltage in 30 minutes after the battery is charged Charging current standard 0 4A quick 4 0A Charging time standard 10 15 hours quick 30 minutes Charging completed open circuit voltage above 12 8V 1 4 Charging system 1 4 1 Short circuit test Remove the batter ground wire and connect the voltmeter between the negative terminal and ground wire Turn off the switch and check whether it is short circuit Note Connect the positive terminal of the multimeter and the negative terminal of the battery together Check whether the main switch and main wire are short circuit under abnormal conditions 1 4 2 Charging inspection Use the multimeter to checking the fully charged battery Mount the battery after the engine warming up Connect the voltmeter between terminals Remove the fuse and connect the ammeter between its terminals JHHEX avometer 42 Start the engine slowly and measure the limiting voltage and current Limiting voltage rotating speed 14 15V 2500rpm If the limiting voltage is not within the required range check the voltage adjustor Check the limiting voltage of the lighting system Note choose AC voltage of the multimeter Limiting voltage 13 1 0 5V 2500rpm If the limiting voltage is not within the required range check the current adjustor 1 5 Voltage and current adjus
38. axle nut 55 62 Nm force Rear axle nut 100 113 Nm value Certification for Related Parts twe ne careno OO ema Front E4 75R 0001095 Highway outer tyre Marked with DOT Model Rear E4 75R 0001096 outer tyre Front E4 75R 000487 Cross country outer tyre Marked with DOT Model Rear E4 75R 000488 outer tyre Tail lamp E9 50R 001498 Double lens Front steering lamp E9 50R 001499 LED Rear steering lamp E9 50R 001500 Front position lamp E9 50R 001501 LED Tail lamp E9 50R 001498 Rear number plate lamp E9 50R 001493 Rearview mirror rearview mirror L E4 005 Side reflector E11 020614 Reflector Rear reflector E4 023272 Vent pipe e9 BENELLI EX M2P Muffle Body hanging board e9 BENELLI EX M2 25 Periodic Maintenance amp Inspection Table x x x x service cycle and time Inspection item Petrol filter Fuel filter Replacement of engine fuel handle fastening inspection inspection Oil leakage inspection for gearbox Inspection or replacement of spark plug oil idle speed Lighting metering electri c devices Main stand bracket Torque force of engine bolts Per 300 KM New C A A Per 1000 KM One month Per Per Per Per 3000 6000 12000 14500 KM KM KM KM Tools Three Six Twelve Fifteen months months months months ae LL oraes Pre oe FP ortinary too Replacement every 1000KM Ordinary tools Tyre pressure gauge inflator Dens
39. bly Loosen the screw and disassemble the top cap Take out spring and pommel assembly Screw Top cap Plunger Oil needle Pomme Check the wearing of pommel If any change Check the wearing of oil needle If any change Loosen the screw and take down the Oil needle compression cap floating chamber Disassemble the floating assembly floater sheath and needle valve assembly 11 3 3lnspection a LOZ To inspect the damage of needle valve assembly needle seating and floater assembly If needle valves rush pith is worn or damaged change If needle seating is worn change the carburetor body If the floater tongue piece is worn change Inspect whether the carburetor oil needle is worn out if any change the main spray nozzle Inspect if the idling orifice main orifice and main spray nozzle are worn or dirty if any change Inspect if the pommel is worn if any change Inspect if the carburetor and oil tube are dirty and clean according to the instructor C g Floatin call ng chambe e Needle valiy c Floater sheath _ amp Ye nozzle Main eae 103 Cylinder cover 1 spark 2 cylindercover set bolt 3 culinder cover 4 cylinder cushion 5 cylinder 12 Cylinder Cover Preparing documents 12 1 Failure diagnosis 12 2 Cylinder cover 12 3 Cylinder cover check 12 4 Installation of cylinder cover
40. box assembly 17 front cover 18 shield of left foot pedal 19 left guard 20 decorating panel of left guard 21 connecting bracket of left guard 22 left foot pedal 23 rearfender 24 odometer shade 25 foot protection board 26 fuel tank cover plate 27 rear fender 28 fuel tank 29 frame 30 front fender II 31 left right guard 73 6 Body Disassemble the car according to the following order Speed indicator sun shield gt front cover panel gt front cover left right plate gt front cover bracket cup headlamp gt NY Seat assembly storage cell gt left right rear pedal assembly gt rear mudguard assembly gt rear lower mudguard right plate Vv Right plate decorating plate right plate gusset plate left plate left plate decorating plate left plate gusset plate gt foot plate left right foot pedalSoil tank cover note The body cover must not be damaged when disassembling The hook claw upon the body cover must not be damaged Align the panel and cover plate and respective slots upon the body cover Correctly install the hook claw of respective parts when assembling The accessories must not be damaged when installing the cover parts 74 Front Wheel A Tyre dimensions Cover tyre 120 90 10 Bolt in the picture 2 front axle set bolt installation torque force 55 62 N m Rim run out extreme vertical 2 0mm horizontal 2 0mm Front wheel axle camber extreme Front wheel cover tyre identification number Highway E4 75
41. brake disc 3 0mm Note Replace the friction discs in pair 71 5 4 3 Installation Install in the reverse order Note Install the brake disc and the rear wheel Install the rear brake hose assembly and the brake cylinder assembly Do not stain the friction disc or brake disc with grease Note Any oil spot on friction disc will reduce the brake performance and even lead to failure Tighten bolts and nuts to the required torque force Torque force Fixing nuts for rear wheel 85 98 N m Do not stain friction discs with oil spots Use brake cleaning agent to clean the friction discs with oil spots Note Any oil spot on friction disc will reduce the brake performance Note for breakdown details see P64 72 Covering parts Note Do not damage any body part during disassembly Do not damage any hook or claw in the body during disassembly Aim panels in the body at each corresponding groove Ensure correct installation of each hook or claw part during assembly Do not damage any part during assembly 1 seat assembly 2 helmet box 3 rear fender assembly 4 right guard 5 decorating panel of right guard 6 connecting bracket of right guard 7 right foot pedal 8 shield of right foot pedal 9 right guard of front shield 10 bottom board of front shield 11 front fender 12 front shield 13 left guard of front shield 14 odometer shade 15 left right storage box 16 left right storage
42. brake disk 180 Dia mm ie 49X 1090 Failure diagnosis Hard to start hard or can not start Failure diagnosis Adjustment and inspection Source of trouble 4 ____ Loosen the bolt of the No petrol in the petrol tank Oil pipe of carburetor plugs up I I I I I I I I carburetor to check whether I I i there is enough fuel i I I Oil pipe of float chamber plugs up Enough fuel for Not enough fuel for Pipeline of the Evaporative Emissions Control the carburetor the carburetor System plugs up Petrol filter plugs up Remove the spark plug and Bad automatic oil control ring put it into its cap check Bad spark plug whether it is work with Polluted spark plug the engine ground Bad CDI Bad trigger Sparkp lug Little or no Open circuit or short circuit of the lead of has a Jump spark ignition coil Open circuit or short circuit of ignition coil Bad main switch compression Bad charging coil pressure Bad starting clutch Enough Not enough Bad piston and piston ring of the cylinder pressure pressure Air leakage of the cylinder ring Fail to ignite Close to ignite Bad automatic choke the engine the engine but also fail Air in induction manifold Incorrect duration of ignition Bad governing screw of the carburetor Overtopped oil lever of carburetor Bad automatic choke Dry spark plug Wet spark plug o Oversized throttle opening
43. cing Check abrasion of the clutch sleeve Measure the inner diameter of the clutch sleeve Limit for use 118 5mm Check abrasion of the clutch facing Measure the thickness of the clutch facing Limit for use 1 5mm 14 6 Breakdown of clutch and driven wheel Clutch spring compressor must be used for disassembling the clutch spring Note Spring compressor must be used for disassembly to avoid damage to spring Fix the spring compressor and remove fixing nuts of the clutch Loosen the compressor and disassemble the clutch and the driven wheel GRF spanner WA eset akaz clutch spring compressor Remove the spring guard FSET spring guard Remove the guide pin Remove the weldment on the left half driven wheel Remove the oil seal on the left half driven wheel Check the free length of the clutch spring Limit for use 68mm AHKE free length Check abrasion of the driven wheel Measure the outer diameter of the bushing on the right half driven wheel Limit for use 32 94mm Measure the inner diameter of the sliding sleeve on the left half driven wheel Limit for use 33 06mm 14 6 1 Replacement of the bearing on the right half driven wheel Remove the needle bearing from the right half driven wheel Remove the elastic retainer ring and the outer rolling bearing Note Removed bearing cannot be used any more CRER needle bearing 5 o Weldment
44. d rotor and support Take down the worm wheel from crank axle and take down lubricating oil pump assembly Assemble lubricating oil pump Lubricating o 07 Seen in the following chart Lubricating oil pump axle Lubricating oil pump Plunger spring omme Lubricating oil pump cover Gear 10 3 2 Installation To be operated according to the reverse order of disassemble 10 3 3 Inspection Does the tooth flank of worm wheel have damage Does his key seat have damage Measure pommel external diameter allowed extreme 2 61mm Carburetor 98 Note gasoline is very dangerous and open flame is forbidden is working sites After disassembling the carburetor stuff the induction manifold with clothing to prevent the introduction of foreign matter 1 screw 2 float chamber 3 needle valve assembly 4 floater 5 floater sheath 6 main jet 7 idling let 8 main foam tube 9 idling adjusting screw 99 11 Carburetor Preparing documents 11 1 Failure diagnosis 11 2 Carburetor disassembly 11 3 Carburetor installation 11 4 Carburetor adjustment 11 5 11 1 Preparing documents Work Instructions Gasoline is very dangerous Fire is strictly forbidden in workplace Pay special attention to spark Forcibly pulling and bending of wires is not allowed Distortion and damage will affect their
45. d trigger Bad ignition coil Broken main wiring Poor contact of the socket Bad CDI Check the ignition coil using I CDI tester I Abnormal Bad ignition coil 23 Inspection Adjustment Preparing information Cylinder pressure Check list for periodical maintenance Gear oil Engine oil Oil filter screen Gear oil change Petrol filter Drive chain Cable accelerator inspection adjustment Front Rear travel clearance Air cleaner Front brake shoe wear Spark plug Headlight Battery Clutch Carburetor Front Rear suspension system Electronic spark timing bolt nut mounting block Rim tire tire type Preparation Principles In a general way Warning eStart the engine in a well ventilated place not a confined one Exhausted gas contains poisonous carbon monoxide which may cause people unconscious and even death eUnder certain condition petrol is easy to volatile and explode so its workplace should be ventilated and it should be stopped Flames are prohibitive in its workplace and fuel storage place 24 Specification Engine Idling speed 1800 100rpm min Plug gap gauge 0 6 0 7mm Spark plug type BR7ES NGK Frame Front brake lever free stroke 10 20mm Rear brake pedal free play 10 20mm Specification Tire pressure 49X Front wheel 120 70 12 170 Highway Rear wheel ns 130 70 12 195 Tire pressure unit Kpa type cross country Rear wheel 130 90 10 195 type Torque Front
46. documents Work Instructions Remove the switch from the vehicle to measure its conduction 4 2 Failure diagnosis Main switch ON not light Dim light of the headlamp e Poor bulbs e Generator failure e Poor switch e Voltage stabilizer failure e Bad contact or broken wires e Commutator failure 4 3 Replacement of headlamp bulbs 4 3 1 Disassembly 6 Remove the odometer shade and the panel of front shield Remove fixing screws for dismantling the headlamp Disconnect the headlamp connector Remove the headlamp Remove the glass of the headlamp Fix the headlamp and rotate the socket clockwise to remove the bulb 4 3 2 Installation Install the bulb in reverse order 4 4 Replacement of front steering lamp 4 4 1 Disassembly Remove the left right side guard of the front shield Loosen the fixing screws of the steering lamp Remove the left right steering lamp D Note The front steering lamp is LED lamp Change the whole lamp if replacement is required 4 4 2 Installation Install the left right steering lamp in reverse order 4 5 Disassembly Replacement of tail lamp and rear left rignt steering lamp 4 5 1 Disassembly Remove the seat and body guard Remove the fixing screw G to dismantle the tail lamp and the rear left right steering lamp 2 Disconnect the tail lamp and rear left right steering lamp connector 62 Remove the tail lamp and the rear left right stee
47. e cylinder 19gasket 20 front brake clip 21 gasket 22 connecting bolt 23 friction plate assembly 24 link plate 25 bolt M8x32 26 front brake disc mounting bolt 66 Rear disc brake Dia of rear brake disc 180mm Thicknes of rear brake 4 0mm Limit for us 3 0 Thickness of friction disc Limit for us 3 0mm 10 20mm Torque of mounting bolt 2 22 29 N m 1 rear brake disc 2 mounting bolt M8X20 for brake disc color zinc 3 left bushing for rear wheel 4 cycle valve 5 rear brake cylinder assembly 6 friction disc assembly 7 rear fender bracket 8 muffler clevis 9 gasket 10 coupling bolt 11 bolt M8X40 12 bolt M8x16 13 bolt M8X20 14 gasket 8 15 nut M14x1 5 16 outer bushing guide pin 18 check ring 19 deep groove ball bearing 6302 2RS 67 5 Brake Maintenance instruction 5 1 Failure diagnosis 5 2 Front disc brake 5 3 Rear disc brake 5 4 5 1 Maintenance instruction Work Instructions Note e Do not stain the brake assembly with oil spots during installation or disassembly e Clean it with required cleaning agent to maintain the brake performance Check the brake before riding 5 1 1 Specification Item Standard mm Limit for use mm Brake fluid DOT3 or DOT4 Thickness of front brake disc 4 0 3 0 Thickness of front friction disc a 60 3 0 Dia of front
48. e locking bolt 10 12 Cooling fan blade locking screw 10 12 Flywheel locking bolt 45 50 Locking screw for the magnetor stator coil 10 12 Right crankcase locking bolt 10 12 Bearing plate locking bolt 10 12 Double end stud for cylinder double head 15 18 Motor fixing bolt 10 12 Locking screw for the crankcase left cover shade 10 12 Locking bolt for the crankcase left cover 10 12 Locking nut for the drive wheel 40 45 Locking nut for the driven wheel 40 45 Locking nut for the driven wheel clutch 55 60 Locking screw for the overrunning clutch outer ring 10 12 Locking screw for the electric starter idler plate 10 12 Locking bolt for the gearbox cover 10 12 Locking bolt for the oil drain hole of the left crankcase 18 22 Locking nut for the locating pin shaft of left crankcase 18 22 94 Lubrication system ee hy A Notice worm and worm wheel shall be turned flexibly without stagnation and one side clamping While worm wheel shall have slight end play lubricating oil pump O shape circle has no scrap edge End caps of oil pump have no leaking and gaskets are well in condition H Soon e 2 1 of L i v 2 i 4 3 sii s R Tor J Bee lt Fo lea Icrankcase 2carbureter 3fuel tank Alubricating oil pump 95 10 Lubrication system Preparing documents 10 1 Failure diagnosis 10 2 Fuel pump 10 3 10 1 Prepar
49. e manual Install according to the reverse order of disassemble Steering bar set screw Torque force 40 60 N m 7 5 Front fork 7 5 1 Disassemble Disassemble body plate Disassemble front wheels Disassemble meter headlamp braking flexible tube odometer conductor Disassemble steering bar Disassemble compression nut in order 12 dust proof cover 15 compression nut 13 connecting steel bowl 14 steel balls 16 lower axle upper steel ball 17 Take down front fork Disassemble lower axle and upper steel bowl 18 19 and steel balls 16 Disassemble front shock absorber set bolt 6 Disassemble front shock absorber assembly 10 Tools Steering bar set bolt wrench Extracting tools reserved for axle steel bowl note Use rag to clean the peristome of body plate Use extracting tools reserved for axle and steel bowl to disassemble the upper lower axle steel bowl 7 5 3 Installation Smear the bottom axle steel bowl with grease and confirm the steel ball numbers 21 Handle bar is irreversible to prevent the steel balls from falling and install the steering bar Support the steering bar and smear the top axle steel bowl with grease and confirm the steel ball number 21 Turn the handle bar right and left to press the steel balls tightly together Tool Set nut spanner Turn the front fork right and left to confirm it is smooth and not loosened steps Front sh
50. e the following periodic inspection table for exhaust emission in consideration of different 134 use by customers Users shall carry out periodic inspection adjustment or maintenance according to the schedule to ensure normal emission For any problem please contact Qianjiang distributors or Qianjiang service center Relevant emission provisions are shown as follows The latest national regulation shall prevail if there is any change We are not responsible for any problem due to failure in periodic maintenance at our distributor or service center Please carry out necessary inspection to ensure its best condition Note 1 Clean the air filter frequently if the motorcycle runs in sandy road or under seriously polluted condition to extend the service life of the engine 2 Increase maintenance if the motorcycle often runs at high speed or frequently Pay attention to following items to ensure compliance with emission standards 1 Please use lead free gasoline 92 or 95 2 Please use fuel with stipulated specification 3 Please comply with periodic maintenance requirements 4 gt For the exhaust control system it is forbidden to make any adjustment or replacement at random including use of spark plug adjustment of idle speed ignition timing carburetor adjustment etc 5 Notes Since any problem in the ignition system the charging system or the fuel system has significant effect on the catalytic device pl
51. e the middle shaft and the middle gear 15 3 2 Check the Output Gearbox Cover Check abrasion and damage of the clutch spindle gear and bearing Exchange gearbox cover bearings Press the clutch spindle when the clutch spindle bearings are exchanged remove it from the gearbox cover Note Removed bearing cannot be used any more It shall be replaced Use special tools to dismantle the bearing and the oil seal Remove the oil seal from the gearbox and knock the bearing out Note Removed bearing cannot be used any more It shall be replaced Use special tools to dismantle the bearing and the oil seal 15 4 Assembly Assemble it in reverse order Note Use special tools to assemble the bearing and the oil seal to avoid any damage PPO Crankcase RoR los Note The crankcase is thin section casting thus shall not suffer impact during operation which may cause deformation or fracture All components must be cleaned and blown with high pressure gas before test Lubricant in the crankcase should be drained out before operation 16 Crankcase Preparing documents 16 1 Failure diagnosis 16 2 Crankcase 16 3 Assembly 16 4 16 1 Preparing documents Work instructions The crankcase is thin section casting thus shall not suffer impact during operation which may cause def
52. ease go to our designated distributor or service center for inspection adjustment or repair immediately when there is any problem found in the engine Please use lead free gasoline 92 or 95 Otherwise the catalytic conversion device two stroke system will be affected 6 The exhaust control system of this motorcycle is in accordance with the national regulation For replacement of any component please use our original parts and have our designated distributor or service center carry out such replacement 17 3 Mechanical function of the exhaust control system General This system adopts two stroke single cylinder engine carburetor and air conduction device to maintain qualified exhaust gas Meanwhile active carbon canister is used for exhaust gas evaporated from fuel X Engine improvement Aoo X As the semicircle combustion chamber with spark plug inside compression ratio ignition time exhaust system and other engine components are improved as well as the intake exhaust efficiency is enhanced the combustion efficiency is raised X Air induction device Induce air into the exhaust pipe to react incompletely combusted CO and HC into harmless gas Division Constitution Function Canned oxidized catalyst installed in the Catalytic device Catalytic converter center of the exhaust pipe is able to oxidize CO HC and NOx Exhaust system 17 4 Catalytic conversion system 17 4 1 Structure eo OO 17 4 2 Ins
53. ecially note important connections before disassembly Replace parts which will not be in use before disassembly Bolts and screws with different length shall be separately used for different assembly parts and shields and they shall be correctly mounted Insert a bolt into a hole to check whether it is proper if you are confused Fill the groove with grease before mounting an oil seal Check whether the oil seal is smooth or damaged during assembly When installing a hose fuel vacuum or cooling agent insert its end into the bottom of the connector so that the hose clip can properly fix the connector Rubber or plastic dirt proof boot shall be mounted at the original design position Ki groove YF clip 22k connector During dismantling ball bearings one or two inside amp outside bearing rollers shall be supported by tools Ball bearings may be damaged during disassembly and have to be replaced if only one roller either inside or outside is imposed with force D EAEE Sh KAKA Bearings will be broken under either occasion as mentioned 4 CA _E A PRS 1 BH eK a Loose cables threaten electrical safety Check each cable after it is clamped to another for electrical safety Wire clamps are not allowed to bend towards welding point Bind cables at the designated place Do not deploy cables at the end of frame or at sharp point Do not deploy cables at the end of bolts or screws Cable deployment shall be far from heat source
54. ed at the No or interrupted high voltage maximum voltage Side 6 Poor trigger measured at the maximum voltage voltage 7 Poor terminal of high voltage wires 8 Poor CDI group when item D O is checked to be abnormal or there is no spark for spark plug Poor spark plug or secondary leakage of the Normal high voltage but no spark ignition coil Poor ignition coil 1 The inner resistance is too small and it should be tested by required tester 2 Low speed of the crankshaft Notienwettage 3 Interfered tester It 2 normal that voltage is Charging always beyond the required value upon several coil measurements 4 Poor charging coil Item 1 is checked to be normal 1 Poor ignition coil No or interrupted high voltage D Poor aiana ceil Too low high voltage 49 1 The inner resistance is too small and it should be tested by required tester 2 Low speed of the crankshaft 3 Interfered tester It is normal that voltage is always beyond the required value upon several measurements 4 Poor trigger Item 1 is checked to be normal 1 Poor ignition coil No or interrupted high voltage Poor ripsat Too low high voltage Trigger 2 3 Ignition system check HHK O QO Note eWhen there is no spark check whether there is loose wiring or poor contact and make sure all voltage values are normal eThere are kinds of multimeters w
55. emove the set bolt 2 on the air filter Remove the pipe clip Remove the air filter Remove the the set bolt G on the upper cover of air filter Remove the filter element 4 on the filter Check weather the filter element is polluted or damaged And replace it with a new element if necessary Remove the pipe clip Remove the filter Check weather the filter is polluted or damaged And replace it with a new one if necessary 28 Replacement time Replace it as early as possible if the motorcycle is always running on rainy days or on rugged road Note e Make sure the air filter cap is well installed before installing the filter WAKE bolt pipe clip A AwaeT tapping screw 2 YEA AM air filter assembly Y filter element MAJE rear brake line clip RKE bolt Spark plug Disconnect the connecting wire of plug cap 1 Lateral electrode 2 Central electrode 3 Insulator Note Clean the spark plug by compressed air thus to guarantee that no shatter is exist in the firebox Remove the spark plug by special spanner or other tools 1 Inspection Carry out the following inspection and make replacement when necessary whether the insulator is damaged whether the electrode is worn Burning condition and color Light grey indicates a good burning condition Paleness indicates any error in ignition system or any diluted air mixture Humidity or black indicates carbon distribution or over r
56. er 8 4 8 1 Preparing documents Work Instructions The surface of the brake drum and brake shoes shall not be stained with oil spots Preparing Principles Item Standard mm Limit for use mm Locking torque force Rear wheel grip nut 85 98 Nem Rear shock absorber top bolt 37 44N m Rear shock absorber bottom bolt 22 29 Nem 8 2Failure diagnosis 8 2 1 Rear wheel swing Rim deformation Tyre failure Back wheel not gripped Tyre low pressure 8 2 2shock absorber over soft Spring elastic fatigue 8 amp 6 8 3 Rear wheel 8 3 1 Disassemble Disassemble the silencer assembly Disassemble back inner mud guard plate Disassemble the rear wheel axle grip nut Take down the rear wheel 8 3 2 Inspection 8 3 2 1 Rim swing test Use hands to turn the wheels and measure the eccentricity with dial gauge Allowed extreme Vertical change when above 2 0mm Horizontal change when above 2 0mm When the back wheel wobble goes beyond the available extreme the loosening of back wheel will lead to the swing of back wheel Change the back wheel axle after inspection 8 3 3 Installation Install the back wheel according to the reverse order of disassembling and grip the nut Back wheel grip nut Torque force 100 113 N m note 49X back wheel disassembling picture is seen in P80 81 49X Rear wheel 8 4 Rear shock absorber 8 4 1 Disassembling Disassemble cotter pin 2
57. g disconnect rod Front wheel axle locknut 55 62 Nm grip nut wrench Front shock absorber set bolt 40 60 Nm 78 7 2 Failure diagnosis 7 2 1 Difficulty in turning the handle bar 7 2 2 unsteady steering Handle bar axle failure Dandle bar axle breakdown Handle bar axle breakdown Insufficient tyre pressure Low tyre pressure Front fork winding front wheel axle winding Tyre blowing Front wheel tyre deformation oblique 7 2 3 Shimmy of front wheels 7 2 4 Difficulty in turning the wheels Rim deformation Wheel axle bearing failure or pinion stand failure Front wheel axle bearing loosened Bad tyre 7 2 5 Front shock absorber abnormal sound Shock absorber plate fricative Bolts of various parts of shock absorber loosened 7 3 Front wheels 7 3 1 Disassembly Note The monocycle must be supported firmly Loosen the brake cylinder assembly assembling bolt 4 Take down the brake cylinder assembly 2 Place a suitable pedestal under the engine so as to lift the front wheels Loosen the front wheel axle grip nut 5 take down front wheel axle 1 front wheels Take down the pinion stand assembly Dismantle the fluid brake plate 3 Dismantle the front wheels oil seal assembly front wheel left axle bushing axle bearing 6201 2RS front wheel middle axle sleeve note 49X front wheel assemble and disassemble picture is seen in P72 in the manual 79 7 3 2 Inspection 7 3 2 1 Axle bending inspec
58. gap of the piston ring SS SY Limit for use 0 5mm Piston fing Measure the inner diameter of the piston pin hole Limit for use 12 04mm LI Measure the outer diameter of the piston pin Limit for use 11 96mm Clearance between the piston pin holr an the piston pin Limit for use 0 02mm Measure the outer diameter of the piston Note The measuring point shall be at 90 with the piston pin and at 11 5mm below the piston skirt Limit for use 39 9mm Check whether cylinder inner wall is scratched or abraded Note It is at 90 degree with the piston pin Measure the inner diameter of the cylinder at the top middle and bottom points Limit for use 40 05mm Measure the maximum clearance between the cylinder and the piston Limit for use 0 1mm Measure the roundness of the inner wall of the cylinder inner diameter difference at X direction and Ydirection Limit for use 0 05mm Measure the cylindricity of the inner wall of the cylinder inner diameter difference at the top middle and bottom a Tester points of X direction and Y direction Limit for use 0 05mm Measure the inner diameter of the smaller end of the connecting rod Limit for use 14 06mm Smaller end of the connecting rod 13 4 2 Piston Installation Install the locating pin Apply fuel to each piston ring and pist
59. h multimeter Standard 1 5 2Q 20 C Replace the magnetor coil when the measured value exceeds the standard value 1 7 Magnetor lighting coil Note Check the magnetor lighting coil on the engine Check Remove the 3p connector of the magnetor Measure impedance between the green red coil of the magnetpr and the body with multimeter Standard 2 0 2 50 20 C 44 Replace the magnetor coil when the measured value exceeds the standard value REE bolt AAA cooling fan 1 8 Disassembly of magnetor 1 8 1 Disassembly Remove the body guard Remove the right body guard Remove the fixing bolts and screws dismantle the fan cover CA eE universal fixing spanner Remove four fixing bolts of the cooling fan dismantle the cooling fan Fix the flywheel using the universal spanner Remove fixing bolts of the flywheel Remove the flywheel using the flywheel remover Remove the solid key Remove the conductor joint Remove the stator KSEE flywheel remover 1 8 2 Installation Kae flywheel AAA coolingfan JX 3iti fan cover Install the stator on the body of the engine Connect the magnetor joint 45 Clean up the crankshaft and the taper part of the flywheel Install the solid key into the groove above the upper crankshaft key and confirm it Aim the groove in the flywheel at the solid key on the shaft Note Ensure there is no any bolt in the inner magnetic side of the
60. he actual products if anything is different or updated Please forgive me for not informing you in advance Preparing Documents General safety Maintenance rules Specification table Failure diagnosis General Safety Carbon monoxide Start the engine in a well ventilated place not a confined one Note Exhausted gas contains poisonous carbon monoxide which may cause people unconscious and even death Do use the exhaust removal system when starting the engine in a confined place Petrol Work in a well ventilated place Open flames are prohibited at places for storing oil and its workplace Maintenance rules In the maintenance of this bike metric tools should be used as much as possible otherwise the bike will be damaged using the improper tools Clean up the dirt of the parts or the assembly parts before removing or opening the motorcycle shield in the maintenance work to prevent dirt falling into the engine chassis or braking system After dismounting the parts wash and blow the parts with compressed air machines at last measure wear values Solvent or oil can easily damage aging rubber articles Check rubber before reassembly and replace rubber if necessary When loosening assembly parts please start from outside to inside Small assembly parts shall be loosened first Complex assembly parts such as gearbox shall be stored in proper order for facilitating installation in the future Please sp
61. heel 14 5 Failure diagnosis 14 2 Breakdown of clutch and driven wheel 14 6 Left crankcase cover 14 3 Installation 14 7 Drive face 14 4 Kickstart mechanism 14 8 14 1 Preparing documents Work Instructions During operation the surface of the triangle belt cannot be stained with any grease that must be removed It helps avoid slipping between the triangle belt and the belt pulley as much as possible Function Drive face clutch and driven wheel constitute stepless transmission The triangle belt transfers torque between the drive face and the driven wheel Preparing Principles Unit mm Item Limit for use Inner diameter of right half driven wheel 26 06 Outer diameter of the sliding sleeve 25 94 Width of the triangle belt 16 Thickness of the clutch facing 1 5 Inner diameter of the clutch sleeve 118 5 Free length of the clutch spring 68 Outer diameter of the bushing on the right half driven wheel 32 94 Outer diameter of the sliding sleeve on the left half driven Outer diameter of the ball 14 4 los 14 2 Failure diagnosis No run after engine startup Insufficient horsepower Vibration during driving Abrasive triangle belt Abrasive triangle belt Ruptured clutch facing spring Damaged driven wheel Distorted clutch spring Broken or damaged clutch facing Abrasive ball Ruptured clutch spring Stained surface of the driving pulley
62. ich air mixture Visual inspection of spark plug Replace the spark plug if and crack or wearing is detected The following spark plug is recommended Standard CSHSA NGK C6HSA NGK C7HSA NGK 2 Reuse of spark plug Clean the electrode of spark plug by scratch brush or special tools Check the distance between the central electrode and lateral electrode of spark plug by steel feeler gauge If necessary carefully bend the lateral electrode to adjust the distance Distance of spark plugs 0 60 0 70mm Installed the spark plug onto the cylinder and fix it to specified torque Torque 18 N m Note Fix the spark plug by hand and then by special spanner thus to protect the cylinder cover 29 3 Replacement of spark plug Adjust the spark plug distance by steel feeler gauge until it meets the specified value Note Do not fix the spark plug too light Install the new spark and sealing cushion and fix them by hand After contact the spark plug hole continue fixing by 1 2 circle Battery Battery disassembly Open the seat cusion Remove the battery box cover Remove the negative wire and then the positive wire Remove the battery Warning The tools for removing the positive electrode should not contact the flame otherwise it will be very dangerous that the damaged battery will cause fire Install the battery following the opposite sequence Warning First positive and then negative to prevent short circuit
63. imeter multimeter ni Replacement every 5000KM Ordinary tools ee a a re ee Tachometer CO A HC analyzer A A A pop 1 1 1 f ordinary tools a a a Cetin tt ordinary tools if 1 1 ordinary toots 26 gt gt b gt gt f Anticipated Inspection Ignition system obviously continuous ignition abnormality engine fire or overheating which requires inspection and maintenance Carbon fouling elimination obviously insufficient horsepower which requires carbon fouling removal from cylinder head piston head and exhaust system 3 Piston amp cylinder excessive abrasion replace cylinder if it is blocked Please have your motorcycle inspected and adjusted periodically at Qianjiang distributors for being in best condition The above table is established under the presupposition of 1000 km month I Inspection A Adjustment R Replacement C Cleaning L Lubrication Note 1 Regulations on exhaust emission made by the State Environmental Protection Agency shall be complied with Maintenance must be carried out in accordance with the instruction manual supplied by the company We are not responsible for any loss rising from private adjustment or maintenance 2 Increase frequency of washing air filter if your motorcycle runs on the sandy gravel road or under heavily polluted environment so as to extend its service life 3 Motorcycles which often run at high
64. ing documents Work Instructions Worm gears and worm wheels shall rotate flexibly without being seized or imbalanced tightening A little axial movement shall be allowed for worm wheels Fuel pump O ring shall not cut the edge Machine oil pump plugs shall not leak and sealing gaskets shall be in good condition After installation remove bolt 3 during engine trial running and lock it when machine oil runs out continuously Function of the lubricating system the lubricating system of the engine is to provide lubricating oil to the frictional surface of each part which transforms dry friction into liquid friction between lubricating oil particles and also reduces abrasion of parts It also cools components with high thermal load absorbs shock from bearings and other parts reduces noise increases sealing between piston ring and cylinder wall and cleans and removes particles in the surface Preparation criteria Item Fuel volume 10 2 Failure diagnosis Fuel decreasing Lube natural consumption Lube leaking Piston ring worn out bad installation When disassembling 0 11L Engine burning no lube or lube pressure too low lube passage blocking absence of lube utilization 96 10 3 Fuel pump 10 3 1 Disassembly Loosen the bolt and disassemble the wind scooper Z assembly A Loosen the screw on the fan take down the fan Take down magnetor determinant and rotor and support Magnetor
65. ion Install the piston ring with inclined side upward Note Do not scratch the piston or break the piston ring After the piston ring is installed it shall be able to rotate freely in the piston ring groove Remove any residual spacer attached to the crankcase Note Do not make any object fall into the crankcase Install the piston piston pin and retainer ring Note The notch side of the piston skirt shall face the air intake channel for installation 13 5 Piston installation Install the spacer on the crankcase Apply fuel to the inner wall of the cylinder piston and piston ring Carefully install the piston ring into the cylinder eZ Note Do not damage the piston ring Drive face clutch driven wheel Lie Note During operation the surface of the triangle belt can not be stained with any grease which must be removed It helps avoid slipping between the triangle belt and the belt pulley as much as possible Kickstart Mechanism Note During operation the surface of the triangle belt can not be stained with any grease which must be removed It helps avoid slipping between the triangle belt and the belt pulley as much as possible 1 snap spring 2 startclaw 3 idle gear 4 idlershaft 5 start shaft assembly 6 kickstart shaft spring 114 14 Drive Face Clutch Driven Wheel Kickstart Mechanism Preparing documents 14 1 Clutch driven w
66. ith different impedances and different test values Connect a high pressure shunt or an ammeter with an input impedance above 10MQ10CV to the multimeter HHK multimeter 2 3 1 Primary voltage of the ignition coil If you replace the original spark plug with a better one make ground connection with the engine Note Make sure all wiring is correct before test Cylinder compression pressure normally refers to the test value when the spark plug is installed on the cylinder head Connect the lead of the ignition coil and also the shunt between the primary coil terminal black white and the GND 50 Press the startup motor or step the actuating lever to measure the maximum primary voltage of the ignition coil Minimum voltage above 95V HHE multimeter Note Never touch any metal part of the test rod with your finger to avoid electric shock 2 3 2 Trigger Note Install the spark plug on the cylinder head and carry out measurement when the compression pressure is normal Remove 4P and 2P connectors of CDI group Connect the peak voltage shunt between the trigger blue white with 2P connector and the 4P connector black terminal Press the startup motor or step the actuacting lever to measure the maximum voltage of the trigger
67. k whether the heat value used for the spark plug is proper If not the engine may work abnormally or the spark plug may be burnt 7 Check in this chapter is based on the maximum voltage It also refers to check on the impedance of the ignition coil 8 Check the main switch according to the conduction table 9 Remove the magnetor and the stator according to instructions Preparing principles CSHSAINGK Spark plug cBHSAINGK recommended Cold type C7HSA NGK Spark plug gap 0 6 0 7mm ignition coil 0 60 10 impedance With plug cap 5 11KQO Secondary coil 20 C Without plug cap 0 5 5 5KO Impedance of trigger 20 C 100 5000 Measure the maximum primary voltage of the ignition coil 95 400V Trigger voltage 1 7V LAE Charging coil voltage 95 400V Tools Attachments to the Maximum Voltage Table 48 Multimeter 2 2 Failure diagnosis Non sparking of spark plug 1 The inner resistance is too small and it should be tested by required tester 2 Low speed of the crankshaft Ignition coil 3 Interfered tester It is normal that voltage is always beyond the required value upon several measurements 4 Poor wiring contact of the ignition system 5 Poor ignition coil 6 Poor charging coil measured at the maximum voltage 1 Incorrect connection of the tester 2 Poor main switch 3 Poor contact of CDI terminal 4 Short circuit or poor contact of the GND of CDI 5 Poor contact of charging coil measur
68. lan Measure idle emission note 1 Adjust Carburetor note2 Qualified for Remove and clean the carburetor eG delivery SJ MJ SAJ MAJ etc Replace the carburetor Dismantle and repair engine Satisfactory Valve leakage Piston abrasive aK eCombustor cleaning Note 1 measure it with the idle soeed measurement program Note 2 adjust the engine speed with stop screws to live up to requirements and measure CO HC at the idle speed 130 MOUSE a Cia wana Maanne SIDE INDICATOR LIGHT 2W DT ATOR BEAM INDICATOR LIGHT 2W STARTOR SWITCH FUELMETER ELECTRIC CLOCK BRAKE SWITCH ats Es B G BL i OIL SIDE INDICATO TURN SIGNAL INDICATOR LIGHT 3W ep RIGHT TURN LIGHT a G W G W a SIDELIGHTS 5W al DIPPED HEADLIGHT 35W SIDELIGHTS 5W aS HIGH BEAM 35W l LEFT TURN LIGHT HORN FLASHER o HORN SWITCH S ots CIGHT SWITCH TURN SWITCH FLAMEOUT SWITCH asd argi F r LBL AE S H ra HE A IGNITION SWITCH al IGNITION COIL ca BATTERY se TTN y X aed MV SPARK PLUG U A RELAY e a fg gt PU RIGHT TURN LIGHT BRAKE LIGHT TAIL LIGHT P x P oOo 3 ee Idl di didid Idl di didid Id di didid OW ee ee ee R W Y LICENSE PLATE LIGHT 5W LEFT TURN LIGHT G B it G B 5 rT R ce Es Ss M vo a ad Ge M M G C TET _ fe THERMO ELEMENT ALARM HORN STARTOR MOTO
69. locating pin Remove the crankshaft from the crankcase Remove any spacer on the joint surface of the crankcase Note Do not damage the joint surface of the crankcase soba gs Remove the oil seal from the left crankcase Remove the oil seal from the right crankcase 16 3 2 Check Measure the left right clearance of the larger end of the connecting rod Limit for use 0 6mm JEFF AK mW Ey CEI K mM EMA measuring point at the larger end of the connecting rod Measure the clearance of the larger end of the connecting rod X Y direction Limit for use 0 05mm Check whether crankshaft bearing makes noises or is loosen when it rotates If yes replace the crankshaft assembly Note Crankshaft bearing Removed oil seal cannot be used any more Special tool should be used when removing the oil seal 16 4 Assembly Assemble the crankcase in reverse order Note Install the oil seal with special tools to avoid any damage to it at Inspection and Maintenance of Exhaust Emission System Muffler ses Torque for fastening fixing screw 15 of the muffler connecter 5 9 N m Torque for fastening fixing bolt 3 of the muffler 22 99 N m Torque for fastening fixing bolt 8 of the muffler decorative board assembly 22 99 N m Certification number of exhaust pipe BENELLI EX M2P Certification number
70. motorcycle upright for checking the oil level Disassemble the dipstick after the engine stops It is good if the oil level at the lower limit of the dipstick Add gear oil when the oil level is too low Install the dipstick CTH WAKE drain bolt BUH BRE Note 32 Make sure whether the bolt is well sealed slippery or damaged Gear oil replacement Remove the dipstick Remove the drain bolt and gear oil is drained Install the drain bolt Note Make sure whether the bolt is well sealed slippery or damaged Add gear oil 7 Check whether there is oil leakage in any part E ETT Install the dipstick OHIE drain bolt Drive belt Remove the cover of left crankcase Check whether the drive belt is ruptured or abraded Periodically maintenance shall be guaranteed and replace the drive belt if necessary IKZI r drive belt Free stroke of front rear brake Free stroke of front brake Measure the free stroke of front brake at the tip of the brake lever Free stroke 10 20mm 33 Free stroke of rear brake Measure the free stroke of rear brake at the tip of the rear 10 20mm brake lever Free stroke 10 20mm Inspection of brake fluid level Brake to the maximum and check the oil level through the oil sight glass In case the brake fluid level is at or below the arrow in the picture certain brake fluid DOT3 DOT4 shall be added until it reaches the upper limit Note
71. move the right grip assembly and the left steering grip 2k AA green white amp orange 2 24 green black 2 A red white k brown 2x ZL green red Remove the left right combination switch DJ7021 1 5 41 AX CAW assembly 2 purple 22k dark green Pe are 2 ti green yellow 5 black 5 25 SE 64 Inspection and maintenance of the chassis Torque Force Table of Chassis Fasteners Name of fastening parts and fasteners Tightening torque N m Fuel pump assembly fixing bolt Mounting bolt of front brake cylinder assembly Rear brake rocker arm bolt Handlebar fixing screw Front wheel spindle locking nut Front absorber fixing bolt Rear wheel fixing nut Rear absorber top nut Rear absorber bottom nut Exhaust pipe joint bolt Exhaust pipe fixing bolt 65 Front disc brake Dia of front brake disc 190mm Thicknes of front brake disc 4 0mm Limit for use 3 0 Thickness of friction C disc 6 0mm Limit for use 3 0mm Torque for mounting bolt 1 and 22 35 N m Torque of mounting bolt 11 5 9 N m Free stroke of brake handle 10 20mm 1 connecting bolt 2 front brake clip 3gasket 4nutM6 Sbrakehandle 6screwM4x12 7 oil cup cap 8 fuel pump gasket 9 oilcup pad 10fuelpump 11 bolt M6x23 12 retaining cap of handle seat 13 round pin 14 plunger assembly 15 handle return spring 16 handle screw M6 17 front brake 18 brak
72. n Install the drive face clutch driven wheel in reverse order 14 8 Kickstart mechanism Disassembly Check Remove the left crankcase cover Loosen the screw and remove the guard Remove the start claw assembly Remove the start shaft assembly Check abrasion of the start shaft Check abrasion of stress area of the start shaft sleeve and the idler shaft Check abrasion of idle gear Measure clamping force of the snap spring Normal standard 8 12N Note 1 snap spring 2 start claw 3 idle gear 4 idler shaft 5 start shaft assembly 6 kickstart shaft spring Decelerator Le ow en Function transfer torque and decide final output torque and rotational speed 124 15 Decelerator Preparing documents 15 1 Failure diagnosis 15 2 Gearbox 15 3 Assembly 15 4 15 1 Preparing documents Function transfer torque and decide final output torque and rotational speed 15 2 Failure diagnosis No run after engine startup Broken driving gear Burnt driving gear Leaked gear oil Too much gear oil Damaged oil seal 15 3 Gearbox 15 3 1 Disassembly Remove the drain bolt and drain out gear oil inside the gearbox Loosen the bolt and remove the gearbox cover AAD Remove the spacer and the locating pin Remove the clutch spindle and gear of output shaft Remov
73. ock absorber assembly installation Handle bar headlamp braking flexible tube odometer conductor meter installation Body plate installation Front wheel installation Front shock absorber set bolt Torque force 40 60 Nm note 49X front fork disassemble picture is seen in P73 in this manual 83 Rear wheel rear suspension In the picture 6 back wheel grip nut torque force 85 98 N m In the picture bolt8 installation torque force 37 44 N m In the picture bolt7 installation torque force 22 29 N m 18 ag 8 3 f 1back rim assembly 2back braking plate 3back shock absorber 4silencer assembly 5silencer hanging board 6nut M14x1 5 7bolt M8x40 8bolt M10x1 25x40 9back wheel left axle sleeve 10back fluid braking cylinder assembly 84 Rear wheel 5 Tyre dimension 130 90 10 In the picture 8bolt torque force 22 29 N m In the picture 3bolt torque Back wheel outer tyre ID No E Highway F4 75R 0001096 Sport E4 75R 000488 1back rim assembly 2back braking plate 3fluid braking plate installation bolt M8X20 coloring zinc Aback wheel left axle sleeve 5back fluid braking cylinder assembly 6friction disc assembly 7back mud guard support 8bolt M8X20 9coupling bolt amp 5 8 Rear wheel rear suspension Preparing documents 8 1 Failure diagnosis 8 2 Rear wheel 8 3 Rear absorb
74. oned inside shall be fastened first and then diagonally screw down until reaching required torque otherwise there is special instruction 5 Wash disassembled parts with cleanser Lubricate all sliding surface before assembly 6 Check whether all the parts and accessories are correctly mounted and operated after assembly 7 Clean and remove oil before measurement Add recommended lubricant to the lubricating areas during assembly 8 Apply lubricant to the surface of engine and driving system if they are dismantled for long term storage which can prevent rust and dirt Special Tools Special tools refer to tools which are specially designed for assembling or disassembling some motorcycle parts on special positions Applicable special tools are necessary for precise adjustment and installation With them parts and accessories can be mounted safely reliably and rapidly which improves efficiency and saves energy 1 Tools for repairing the engine Special tools are required for properly disassembling assembling some engine parts Table and drawing 1 1 1 2 of special tools for disassembling assembling engine parts are as follows Table 1 1 Special socket spanner Used for assembling disassembling bolts for flywheels Fig 1 3 Fig 1 4 Fig 1 5 Clutch clamp holder Flywheel puller Feeler gauge Fig 1 6 Fig 1 7 Fig 1 8 Fig 1 9 Fig 1 10 Fig 1 11 Fig 1 12 Fig 1 13 Fig 1 14 Fig 1 15 Bearing disassembly tools Bearing
75. or front brake cylinder assembly 22 29 N m Do not stain friction discs with oil spots Use brake cleaning agent to clean friction discs with oil spots Note Any oil spot on frictin discs witll reduce brake performance 5 4 Rear disc brake 70 5 4 1 Disassembly Remove the muffler 4 Remove the fixing nut 6 of the rear wheel and fixing nuts 7 and 8 of rear absorber Remove the rear right absorber 3 and the clevis Remove the brake cylinder assembly 10 Note e Replace the friction disc assembly e t the friction discs will be usd again mark it before disassembly so as to reinstall it at the original place Remove following assemblies from the rear wheel Rear brake 1 front brake disc 2 mounting bolts for brake disc 3 rear brake cylinder assembly 4 friction disc assembly 5 muffler clevis Note for breakdown details see P64 5 4 2 Check Check whether the friction disc assembly is abraded Replace it if necessary Measure the friction disc assembly and brake disc Record the maximum values Specification 49X on road off road Diameter of rear brake disc 180mm Thickness of rear brake disc 4 0mm Thickness of friction disc 6 0mm Note e Measure with micrometer Measure the thickness of friction disc assembly If the thickness of the brake disc and the friction assembly is below the required value for maintenance or it is stained with grease please replace it Limit for use friction disc 3 0mm
76. ormation or fracture All components must be cleaned and blown with high pressure gas before test Lubricant in the crankcase should be drained out before operation Function of the crankcase The crankcase is the load bearing part of the engine Its main function is to support the crankshaft clutch gearbox cylinder block and cylinder cover sustain combustion shock and inertia force from the movement of the connecting rod and form part of closed space oil sealing gas sealing Suspension holes in the crankcase are linked with suspension holes in the body which connects the engine to the frame and other parts Preparing Principles Item connecting rod Tools Universal holder Clutch spring compressor Screwdriver lever Socket spanner Guide rod Bearing screwdriver Slo Left right clearance of the larger end of the connecting rod Crankshaft Radial clearance of the larger end of the Unit mm Standard Limit for use 0 25 0 40 0 55 0 015 0 025 0 05 0 1 16 2 Failure diagnosis Noise in crankcase Loose or broken parts inside the crankcase Loose crankshaft bearing Loose crankpin bearing Seized clutch 16 3 Crankcase 16 3 1 Crankcase disassembly Loosen the bolts and remove the start driving gear Remove the start wheel block gear Remove the fixing bolts of the crankcase Remove the left and right crankcase Note Do not damage the spacer Remove the spacer and the
77. pair services at reasonable prices 1 Users fail in periodic maintenance within the required period or kilometers 2 Periodic maintenance adjustment or repair is not carried out at our distributor or service center or there is no evidence of maintenance record 3 Overload or improper operation 4 Refit the motorcycle remove original parts or replace with other devices in private 5 Ride the motorcycle on race tracks or on any non motorized vehicle lane frequently 6 Damage to the motorcycle due to extreme weather such as typhoon or flood or damage or failure due to negligence crash or impact 7 Users fail in periodic maintenance since it is out of service for a long time 8 The odometer is not repaired immediately after being damaged or it is refit stopped or replaced in private 9 Users fail in periodic exhaust inspection at the station every three months All new motorcycles delivered by our company have satisfied the noise test and comply with EC 9724 9 implemented by the EU 17 2 Instructions on periodic maintenance It is the national requirement that all motorcycles produced domestically shall comply with exhaust emission standards to lessen environmental pollution We strictly accord with these exhaust emission standards and also make great effort in purifying air and reducing pollution This motorcycle has been strictly examined before delivery and is in conformity with all exhaust emission standards We provid
78. r 40 1 3 Battery 1 3 1 Battery disassembly Remove the storage battery lid Remove the platen assembly of the storage battery Remove the negative wire and then the positive wire Remove the battery HMA location of the storage battery Warning When the positive wire is disassembled do not make the tool contact with the frame Otherwise it may cause short circuit spark which may ignite gasoline and damage the battery It is dangerous Install it in reverse order Note To prevent short circuit connect the positive wire first and then the negative wire Check the charging condition open circuit Open the lid of the storage battery and remove the platen assembly of the storage battery Remove the connector wire of the storage battery Measure voltage between battery terminals Fully charged 13 1V Insufficient charging 12 3V storage battery is off working for 1 hour Note Use a voltmeter to check the charging condition 1 3 2 Charging Connection the positive pole of the charger to the positive pole of the battery The negative pole of the charger to the negative pole of the battery 4 Warning e The battery should be far away from fire source e Turn off the charger before or after charging to avoid explosive danger caused by spark which may exist in any connection e Comply with the current and time requirements for charging as stated on the b
79. ring lamp 4 5 2 Installation Install the tail lamp and the rear left right steering lamp in reverse order Note Both the tail lamp and rear left right steering lamp are LED lamps Change the whole lamp if the replacemen is required 4 6 Meter Remove the odometer shade Remove the left and right side boards of the front shield Remove the panel of the front shield Remove the meter Install the meter in reverse order 4 7 Main switch 4 7 1 Check Remove the front body guard Remove the main switch lead terminal Check conduction of the terminal HE as 27 et a ALA aR OK h Toun So SS Ho ari A electrical logic diagram 3fz gears R color of wire 2L red 2 H red white 74 black 2 green JK grey Haiii keyinsert fE no Ae yes ZAHA wire seal 4 7 2 Replacement of main switch Remove the front body guard Remove the fixing bolts and the fixing seat of the main switch Remove the fixing bolts and relace the main switch 4 8 Horn Check Remove horn wires It shows good when the horn sounds after connecting the wires to the battery 4 9 Combination switch Remove the left right rearview mirrors Revome the fixing screws of the left right combination switch Loosen the left right combination switch Re
80. ssembly of magnetor 1 7 1 1 Preparing documents Work Instructions Note 1 Battery can be charged or discharged repeatedly If it is placed after discharge its service life will be shortened and performance is undermined Normally the battery performance will be degraded after two or three years For battery with performance degradation reduced capacity voltage will recover temporarily after charging but decrease sharply when loading 2 Battery overcharge normally overcharge can be judged upon the battery In the case of short circuit inside the battery its terminal is unable to detect voltage or the detected voltage is very low Regulator failure overvoltage inside the battery will shorten its service life 3 The battery will be self discharged if being stored for a long time which reduces its capacity It shall be charged about every three months 4 Check the charging system following the sequence listed on the failure diagnosis table 5 Do not remove the connector when there is current through electrical parts otherwise it will cause overvoltage and damage to electrical parts inside the voltage regulator Please operate it after the main switch turns off 6 It is unnecessary to check the maintenance free battery and add electrolyte and distilled water 7 Check all the electric load 8 Emergency charging can only be used under emergency situation 9 Remove the battery from the motorcycle for emergency charging
81. t foot protective plate 8left foot protective plate protective plate 14helmet bucket 3right protective plate 9frontmud guard plate II 10front cover 89 4fuel tank cover 11fuel tank 12frame 5leftpedal 13foot Fuel tank fuel tank gasoline volume 6 0 5L In the picture bolt13 fuel tank set bolt torque force 5 9 N m Note when disassembling fuel tank the fuel switch must be turned to OFF 1fuel tank assembly 2oil level sensor assembly 3filter assembly 4steel wire hoops g9 Soil pipe V g11x2x270 6steel wire hoops 8 7oil pump S8screw M6x16 9oil pipe I 9x2x190 100i pipe IV 8 5x2x163 1loil pipe g9x2x192 12o0il pipe Il 9x2x80 13fuel tank set bolt 90 Cushion N In the picture bolt5 torque force 5 9 N m In the picture bolt13 torque force 5 9 N m 1strap assembly 2main cushion assembly 3side cushion assembly 4storage battery box cover 5screw M6x16 6helmet bucket 7helmet bucket bottom cover 8screw 9pad 10card 11storage battery box 12nut inserts M6 13cushion lock assembly set bolt 14cushionlockassembly 15nut Qj 9 Fuel tank cushion Preparing documents 9 1 Failure diagnosis 9 2 Fuel tank cushion 9 3 9 1 Preparing documents Work Instructions It shall be dismantled far from fire sources Turn the fuel switch to OFF when the fuel tank is dismantled Tighten all the bolts and screws to the required torq
82. throttle cable Idle speed 1800 100rpm min When it rotates unstably at idle speed or it is unsmooth during oil filling slightly adjust the idle soeed adjusting screw Ignition timing Warm up the engine for 3 5 minutes Connect the timing light to the lead of spark plug after the engine is off Note carefully read the instruction of timing light before 3 carry out any operation Remove the body shield Start the engine and it idle running Inspect the ignite timing In case the F mark and the mark on the right cover of crank case is in a line the ignition time is correct Speed up the engine and check out if the F mark start to move Idle Speed 1800 100rpm min PW shield Cylinder pressure Operate it when the engine warms up Remove the seat the body guard Remove the spark plug Install the cylinder pressure gauge At full throttle measure the cylinder pressure by starting the engine Following items shall be checked in case of extra low pressure whether the spacer of cylinder cover is damaged whether piston ring is damaged whether piston ring is worn whether the piston or the cylinder is worn iL 77 measure the cylinder pressure When compression pressure is too high please check whether there is too much carbon fouling inside the combustion chamber and at piston head Gear oil Inspection Note Set the middle kickstand on the flat ground and keep the
83. tion Place the axle upon the V shape seat and use dial gauge to measure the eccentricity Available limit change when above 0 2mm 7 3 2 2 Inspection of rim shimmy Place the rim upon a precise pedestal and inspect the rim wobble Use hands to turn the wheels and read the value of wobble available limit Vertical change when above 2 0mm Horizontal change when above 2 0mm 7 3 2 3 Front wheels axle bearing inspection Disassemble the front wheel axle fluid brake plate Take down the front wheel left axle sleeve and disassemble the front wheel oil seal assembly Disassemble axle bearing 1 Inspect the rolling of axle bearing If rolling is absent axle wearing or loosened replace with new products JRE clearance tHe axially 4 amp 5 radially 7 3 3 Axle bearing replacement Disassemble the front wheel axle front wheel and front wheel left axle sleeve front wheel middle axle sleeve Use oil seal puller and axle puller to respectively disassemble the oil seal and axle Note The disassembled axle shall be replaced with new axles The axle shall be smeared with grease when installing Then use the axel installation tool to press in the axle note ethe axle must be pressed in parallelly 80 7 3 4 Installation To be operated according to the reverse order of disassemble The following are to be noted Lubricate the front wheel axle 1 pinion stand assembly 4 oil seal 7 mouth
84. ton and leads when it is not conducted GaAs starter relay 2R f green yellow black 3 4 4 Check Connect the starter relay to the battery and the terminal of the startup motor to the multimeter Connect the fully charged battery between the black wire and the green yellow wire of the relay The relay shall sound click and the multimeter shall indicate resistance of zero 59 Bulbs switches meters Iden No of double headlamp lens E9 50R 001498 Iden No of front position lamp E9 50R 001498 Iden No of front steering lamp E9 50R 001500 Iden No of rear steering lamp E9 50R 001501 Iden No of tail lamp rear position lamp L E9 50R 001499 Iden No of rear registration plate lamp E9 S5OR 001493 LED LED ED 1 storage battery 2 tail lamp assembly 3 right left combination switch 4 meter 5 headlamp assembly 6 power lock assembly 7 flasher 8 rear steering lamp assembly 4 Bulbs Switches Meters Preparing documents 4 1 Meters 4 6 Failure diagnosis 4 2 Main switch 4 7 Replacement of headlamp bulbs 4 3 Horn 4 8 Replacement of front steering lamp bulbs 4 4 Handlebar switch 4 9 Disassembly replacement of tail lamp and right left steering lamps 4 5 4 1 Preparing
85. tor 1 5 1Main wiring inspection Remove the adjustor s 4p plug Check the conducting state of the terminals of the main wiring Between Battery red and l With battery voltage GND of the body Between GND wire black i With lead and GND of the body Between charging coil Resistance in the coil white and the GND of of the magnetor the body Between lighting cable green red and the GND of the body resistor plug Resistance in the coil automatic side starter of the magnetor plug remove the lighting switch and check it at the OFF position 43 White seen Black CE jell pnts MQ a 24 25 19 23 1 5 2 Voltage current regulator check red L When the main cable is inspected to be normal check Red B 10 50 0 n 19 21 whether the plug of the voltage current regulator is in good S NS contact Measure impedance between terminals of the CE voltage current regulator Note e Do not touch any metal part of the test rod of the multimeter with your finger for check e Check with multimeter Different multimeters show different impedance and different results Replace the voltage current regulator when the impedance between terminals is abnormal 1 6 Magnetor charging coil Note Check the magnetor charging coil on the engine Check Remove the 6p connector of the magnetor Measure impedance between the white coil of the magnetor and the body wit
86. truction 1 The function of convertible catalyst is to converse exhaust gas HC CO and NOx after complete combustion to harmless gas such as H20 CO2 and N before emission 2 Convertible catalyst contains rare metal such as platinum and rhodium Only lead free gasoline can be used X Note that lead gasoline may invalidate catalyst e General instructions for maintaining motorcycles exhaust pipe with catalytic converter 1 For motorcycles with catalytic converter when the engine is running or just closes down it shall not be touched for a while because of high temperature 2 Motorcycles with catalytic converter shall not be near flammable material 3 There is CO inside the exhaust pipe which is harmful to health So do not run the engine in closed space 4 Lead gasoline can not be used for motorcycles with catalytic converter to prevent catalytic poisoning 5 Do not push the motorcycle to start the engine If it is necessary please wait until the temperature of the engine and the catalytic converter lower down 6 Do not make gear up or flame out when descending 7 Do not drive the motorcycle with bad ignition 8 Do not remove spark plug and start the engine to see whether there is spark when repairing the ignition system of the engine If it is necessary it shall be finished in a short time 137 17 5 Measures when the idle speed emission value exceeds the standard Two Stroke Periodic inspection maintenance p
87. tween the conduction terminal and the brush Replace any abnormal part Check conduction of the brush bracket Replace it when there is conduction Measure the length of the brush Limit for use replace it if lower than 3mm Check smooth rotation of the needle bearing inside the front cover and whether it is loose when press in Replace it if there is any abnormality Check whether the oil seal is abraded or damaged 3 3 4 Assembly Lubricate the oil seal inside the front cover with grease Install the brush on the bracket Lubricate moving parts at two ends of the brush shaft with grease Press each brush into the bracket and install the electrode front cover Note e Pay special attention that the contact surface between the brush and the armature shall not be damaged ePay attention that the armature shaft shall not damage lips of the oil seal HANLYbSc motor shell O p o ring Install the new o ring into the front cover FAX armature Hilti front cover Aim the screw hole of the motor shell at the screw hole of the front cover for installation Lock screws in the shell Note When the shell and the front cover are assembled it is easy to pull the front cover with magnet to attract the armature Press it gently for assembly 3 3 5 Installation Install the lead of the startup motor and the dustproof boot Replace any damaged or abnormal o ring Lubricate o ring with fuel and then install it on
88. ue value for assembly After assembly check whether all the parts are correctly installed and operated Preparing Principles Item Gasoline tank capacity Lock torque force 5 9N m 5 9N m Fuel tank set bolt Helmet barrow set bolt 9 2 Failure diagnosis Gasoline reduction Natural gasoline consumption Gasoline leaking 902 Standard Limit for use 6 0 5L 9 3 Fuel tank cushion 9 3 1 Disassemble Open the cushion 1 Disassemble the machine oil pot cover Open the storage battery cover Disassemble the storage battery Disassemble the cushion helmet bucket set screw Disassemble the cushion and helmet bucket Disassemble the plate assembly 2 3 Disassemble the foot plate protective cover 7 8 left and right pedal 5 6 Disassemble the fuel tank set screw Take down fuel tank Turn the fuel switch to OFF Disrupt the fuel flexible tube Take down the fuel tank from the car shelf Note Disassemble and assemble in detail are seen in P85 86 87 9 3 1 Installation To be operated according to the reverse order of disassemble Installation torque force Fuel tank set bolt 5 9N m Helmet bucket set bolt 5 9N m 93 Inspection and Maintenance of Engine Table of Torque Force of Engine Fasteners Name of fastening parts and fasteners Tightening torque N m Fan cowl locking bolt 10 12 Cylinder cover locking nut 15 18 Spark plug 22 25 Air intake pip
89. vel Oil spilling from the carburetor Blocked air channel Dirty air filter 11 3 Carburetor disassembly 11 3 1 Disassembly Turn fuel switch to OFF Remove the oil inlet pipe and loosen the throttle cable Remove the plug of the oil drain pipe and discharge fuel in the float chamber into another box ii N connecte Remove the connector of electric enrichment valve Cee Loosen the screws of carburetor to the engine connector lt A ek AN and the air filter connector remove the carburetor between two connectors 11 3 2 Carburetor breakdown unstable idle speed Blocked carburetor Too dense or dilute mixed gas Secondary air suction into the air intake system Idle speed maladjustment Oil volume maladjustment Blocked idle speed system or electric enrichment valve Too dilute mixed gas Blocked oil jet Blocked needle valve Low oil level Blocked fuel system Abnormal plunger Secondary air suction into the air intake system Interrupted spark at acceleration Too dilute mixed gas Lf LA lectric A feame interface Ss LOL Throttle cable Oil inletpipe te A t vatve Loose screws of the electric enrichment valve and remove the electric enrichment valve assembly Electric enrichment S IXiINg screw valve Fixing flange i hment valve Check abrasion of electric enrichment valve and oil needle Oil needle If it is severe replace the electric enrichment valve assem

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