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Fault Diagnosis - Generic Motor Danmark

1. 7 4 4 Actuation Inspection Connect starting relay with battery and connect terminal of starting motor with multimeter Connect fully charged battery between black wire and green yellow wire of relay A tap sound of operation can be heard on the relay and resistance displayed by multimeter is zero Bl VIII Bulbs Switches Instruments Preparatory data 8 1 Fault Diagnosis 8 2 Headlamp Bulb Replacement 8 3 Front Turn Signal Lamp Bulb Replacement 8 4 Taillight license plate lamp rear turn lamp bulb replacement 8 5 Instrument 8 6 Master switch 8 7 Horn 8 8 Handle switch 8 9 8 1 Preparatory Data Precautions on operation Remove switches from the motorcycle and perform continuity test 8 2 Fault Diagnosis ON lamp of Ignition switch is not on e Bulb burnt e Defective switch e Poor contact of connector or broken wire 82 8 3 Headlamp Bulb Replacement 8 3 1 Removal Disassemble pod Disassemble blot to disassemble headla
2. 4 3 Rear shock absorber rear swing arm 4 4 Chain drive assembly 4 5 4 1 Preparatory Data Precautions on operation Do not contaminate braking shoe ad brake disc with oil Basic preparatory data Item Standard Value mm Service Limit mm Rear wheel Longitudinal 20 gt Tightening torque Rear shat locknut 100 113 N m Rear shock absorber top nut 37 44 N m Rear shock absorber bottom nut 37 44 N m 54 4 2 Fault Diagnosis 4 2 1 Shimmy Rear Wheel Distorted wheel rim Worn rear bearing Troubled tyre Worn or injured swing arm pivot bush Improper adjustment of drive chain adjuster Unbalance of tyre and wheel Tyre pressure is too low Bent frame or swing arm 4 2 2 Inflexible Wheel Rotation Flexible rear liquid brake plate Worn rear bearing Too tight drive chain 4 2 3 Soft suspension Q000o0o D Insecure damping spring with shock Incorrect front suspending regulator Oil leakage of shock absorber Tyre pressure is too low 2 4 Hard suspension Damage of assembly axle on shock absorber Bending shock absorber pipe Damage of rear rocking arm pivot bearing Bending rear rocking arm pivot bearing Incorrect suspending regulator Tyre pressure is too high 4 2 5 Operation with one side only or not taking straight line Bending rear axle Arrangement of axle of both sides incompetent chain regulator 5 4 3
3. Whether the oil supply line and return line are damaged 3 Pressure is amp Check whether the nozzle control circuit is normal normal Whether the glib should be cleaned 150 e Determine whether the cylinder is submerged e Fully open throttle connected to the starter after a few seconds the engine should begin to work f Whether the crankshaft position sensor clearance is too large 16 4 3 3 Fault phenomenon unable to start and accompanied by a tempering a Check whether high voltage lines of the ignition coil high voltage are tightened b Whether the timing gear ring is loose 16 4 3 4 Fault phenomenon unstable idle aio coniugi Check whether idle speed bypass bolt of the is screwed too tight or loose usually 2 laps Fuel supply Whether there is leakage for tubing pipe system 16 4 3 5 Fault phenomenon the idle is too high or too low idle speed does not match obviously Idle speed When the water temperature is below 68 degrees the system will increase the idle to is too high accelerate the warm up process which is a normal phenomenon Except for that make inspection according to the following steps Check whether the idle bypass holes are too big Valve clearance especially whether the exhaust valve clearance is too large Idle speed Check the fuel tank fuel filter oil pressure and nozzle is too low Check whether the idle bypass holes are too small Check the valve clearanc
4. 78 7 2 Fault Diagnosis Starting motor will not run Starting motor runs weakly Starting motor runs but the engine does not Broken Fuse Low battery Defective starting clutch Low battery Poor connecting wire contact Starting motor counter rotate Defective ignition switch Starting motor gear stuck by Low battery Defective starting clutch foreign substances Defective braking switch Defective starting relay Poor connecting wire contact Defective starting motor 7 3 Starting Motor 7 3 1 Removal Attention Before removing starting motor the ignition switch must be set at OFF position Disconnect battery grounding wire and then turn on the power supply to check if starting motor runs to confirm your operation is safe First remove the lead wire clip of starting engine Remove starting motor pinch bolt and take down the starting motor Roll up the rubber waterproof jacket and remove starting motor connector 7 3 2 Disassembly Disassemble housing screw front cover motor housing and other Electric brush parts a 7 3 3 Inspection Inspect other component assemblies Replace with a new one when there is surface partial friction injuries or burn The commutator shall be cleaned when there is metal particles 79 adhered to its surface Inspect for continuity between contact surfaces of other assemblies Confirm the discontinuity of armature shaft among surfac
5. Check whether engine oil volume in 27777777T bent axle tank is over or polluted Bh See hee Run or travel in increased speed 10 Fault Cause Block of air filter Unhealthy gasoline Pipeline block in evaporation controlling system of fuel tank Block of exhaust pipe Unhealthy auto choke Unhealthy air damper Unhealthy CDI Group Unhealthy trigger Unhealthy cylinder plunger packing ring Staleness cylinder cushion Cleaning pollutions Cleaning pollutions Spark plug heat value is not agreeable Engine oil volume is over Engine oil volume is less No change of engine oil Piston and cylinder wear Mixed air is too thin Unhealthy of gasoline Coal in combustor is over Ignition time is too early Coal in combustor is over Unhealthy of gasoline Slipping of clutch Mixed air is too thin Ignition time is too early Rotation unsmooth especially in low speed Fault Diagnosis Adjustment Check Fault Cause Ignition time adjustment A Unhealthy CDI group Normal Abnormal Unhealthy trigger Air damper restriction Beta ahs fa a screw adjustment Gas mixture 1s too thin loosen bolt Adjust well Gas mixture is too strong tighten bolt k e e e ee m l a Loose restrictor fixed nut No air in Broken shim Broken negative pressure pipe _ eee og KES Disassemble spark plug to check the flashover Spark plug not well or polluted CDI n
6. Hemispherical Have spark plug hemispherical combustion chamber combustion placed in middle to seek the safety of burning Combustion Combustion t hamb system chamber Te Exhaust Catalyst Catalyst Have canned oxidation catalyst put in central exhaust system device converter pipe to oxide CO HC and NOX Parameters and the recommended settings can be adjusted Idling adjustment Engine speed 1400 100rpm min Concentration of CO 0 5 1 2 130 15 4 Catalyst conversion system 15 4 1 Construction ser 15 4 2 Instructions 1 The function of conversion catalyst is to convert the waste gas HC CO NOx into H O CO N and other harmless gas before release 2 Conversion catalyst contains platinum rhodium and other rare metals restricted unleaded petrol X Note that leaded petrol will make catalyst failure e General notes for inspection and maintenance of vehicles exhaust pipes filled with catalytic converters 1 gt Vehicles filled with the conversion catalyst cannot be touched when the engine is running or turned off for only a short time because of the too high temperature 2 gt Vehicles filled with the conversion catalyst cannot be close to combustibles 3 gt Exhaust pipe contains carbon monoxide which is harmful to health so do not run the engine in a confined space 4 gt Vehicles filled with the conversion catalyst cannot use leaded petrol To prevent catalyst poisoning 5 gt Engine cannot be lau
7. Pollution of liquid brake plate of brake shoe units 1 2 2 Brake reaction slowly or handle is tight amp Brake without adjustment well Abrasive wear of brake shoe units and liquid brake plate Improper installment of brake shoe units 1 2 2 Brake with abnormal sound Abrasive wear of brake shoe units and liquid brake plate amp Pollution of liquid brake plate of brake shoe units 1 2 4 Braking handle footstep is soft or light Air in hydraulic system Leakage of hydraulic system Braking footstep plate is dirty Sealing abrasive wear of caliper piston Abrasive wear of braking footstep plate Caliper is dirty Caliper can not slide well Lack of brake fluid Block of brake fluid pipe Bending incompletion of caliper piston Bending incompletion of master cylinder piston Master cylinder piston is dirty Braking handle footstep is curving 1 2 5 Brake gets stuck or is pulled to one side amp Braking footstep plate is dirty 585 Deviation of wheels Block or restriction in brake hose joints Bending incompletion of braking plate Caliper slides abnormally 1 2 6 Brake drag amp Braking footstep plate is dirty Deviation of wheels Abrasive wear of braking footstep plate Bending incompletion of braking plate Caliper slides abnormally 1 2 7Brake handle footstep is hard Block or restriction of brake system Adhere abrasive wear of caliper piston Caliper slides abnormally Block restriction of brake fluid pipe
8. DESIGN m AUSTRIA Service Manual SCANDINAVIAN MACHINERY IMPORT ApS Holtvej 8 10 H ruphav 6470 Sydals Telefon 45 73 15 11 00 Fax 45 73 15 11 01 E mail info scanmi dk www scanmi dk CVR 27 73 31 07 Maj 2013 Two wheel Motorcycle QJ125GY 16A Instruction and Maintenance Manual ZHEJIANG QIANJIANG MOTORCYCLE CO LTD Contents HE RT EE TE Te Preparatory Data EEE NR ET EE NM aoe Ker ace ee Re E Se ws E tee eine ee ere Zs 2 Inspection Adjustment Geis phe Rate SEE tae Sidon oe age leah E eta KR Gg ie eee eee Tare a eae tt ac amine oars 7 15 Check and Maintenance of Body ae E E Cape E TE 430 I Braking System ee Gi se TN dead _ 34 a 1 1 Maintenance Instruction cote een ene Een ea eS 3A 1 2 Fault diagnosis tettet tette erverve raven neon rar a ren rr kven rav ra teen teen erent es 95 1 3 Front Hydraulic Og lt n 36 1 4 Back liquid brake gt tette tt eten renter arne entre nr nen renten tren 598 II Vehicle Housing gt gt gt gt gt gt gt gt gt gt ttt ster nre narr ran renne narr nn renne norr norr renten renn _42 III Front Wheel Front Suspension EEE TERESE AON Ak Oe ed ENE NE OER ONES DOR EO eae 45 3 1 Preparatory Data EEE 45 3 2 Fault diagnosis t tettet tet ten renere ener ar anr ee Eee _ 45 3 3 Front Wheel tt tt EEE EE EEE EEE EEE EEE EEE EEE EEE Eee eee eee aS SAF 3 4 Direction handle aE Sa Sle os GS a a ea le alg a Aaa nt as A eta esas EE
9. Sealing gasket abrasive wear of caliper piston Adhere abrasive wear of master cylinder piston Braking handle footstep is curving 1 3 Front Hydraulic Brake 1 3 1 Removal Attention Replace braking shoe assembly e If a braking shoe assembly will be used again please mark it on the side before removal so as to re install it to its original place Loosen brake cylinder units and fix bolts Disassemble brake cylinder units from front damper Disassemble the following units from front damper Front liquid brake block 1 Braking shoe 2 Front brake block oil pipe 3 Brake cylinder units 36 Attention Please do not contaminate braking shoe assembly with oil while assembly or disassembly Please use specified detergent to clean the braking assembly or it may reduce braking performance Disassemble front axle Take down front axle Disassemble front liquid brake block from front wheel 1 3 2 Check Mn Check the abrasive wear condition of brake shoe Replace it when necessary Measure brake shoe brake plate and then write down the maximum number Measure the thickness of brake shoe Use limits brake shoe 4 5mm Specification Diameter of front liquid brake plate 0280mm Attention Wipe brake plate with 120abrasive paper if it rusts e Micrometer is the only choice for measurement If the thickness of brake plate and brake shoe are less than maintenance value o
10. XVI EFI System Description er 3134 16 1 Introduction to EFI System of finished enginecycle s rrtttrt etree ttt 134 16 2 EFI system parts irri ee nee reer rane 134 16 3 Troubleshooting diagnosis EE RENEE SEE NE EE Se anita aa 146 16 4 Common troubleshooting EEE EEE P REE OD KE RR ee mon oat ance eed 153 16 4 3 Concise troubleshooting ETEN ite it ees cela ase EEE AEE Ne NN 154 QJ125GY 16A circuit diagram sakedik raned kens trer iesea ERE a Rew a we Ores 1 Preface The Instruction and Maintenance Manual contains an introductory description of maintenance on QJ125GY 16A motorcycle Preparatory data include attentions that shall be paid on all the maintenance operations in the Instruction and Maintenance Manual Please read the manual carefully before operation Check and adjustment contains main aspects for inspection and adjustment safety of the vehicle performance and maintenance of each component This shall be started from the time of periodical inspection The parts following Chapter One demonstrate the main point of disassembly installation and check of electrics parts finished vehicle engine and other components System diagrams breakdown drawings fault diagnosis maintenance and other explanatory contents are presented before each part Note The parts which are not explained separately in the manual apply to both of the motorcycles For any pattern and structure change of the
11. 1Okpa 30 Change a new tyre when decorative pattern depth on tyre middle reaches the degree of the right picture Minimum decorative pattern depth Warning Do not try to mend damaged tyre because wheel balance and tyre reliability may be worsen To inflate tyre in a wrong way will cause unusual tread abrasive wear and threaten safety To inflate tyre less may cause slipping or casting and cause tyre deflate When tyre is abrased over it is dangerous to drive and goes against ground adhesion and driving Check if lock nut of front shaft is loosened Check if lock nut of rear shaft is loosened If loosened tighten it to specified torque Torsion force Front shaft 100 113N m Back shaft nut 100 113N m Steering Stem Bearing and Handle Fixation Move the left and right handle and check if lead wires disturb it Rotate front wheel and confirm handle can move smoothly If the handle does not move smoothly and is loosened check steering stem bearing Check of left right action Alte Check and Maintenance of Body Front liquid brake block Thickness of brake shoe se limits 3 8mm Torsion force to Install Bolt 1 22 34N m Torsion force to Install Bolt 7 30 35N m DE tamil 5 10N m 2 5N m 5 10N m spt 2 1 1 Inner hexagon screw M8 35 2 Gasket 8 3 Front liquid brake block units 4 Brake cylinder units 5 Brake shoe units 6 Sealing gasket 7 Erection bolt in
12. 3 3 2 Inspection 3 3 2 1 Shaft Bow Inspection Place the shaft onto a V block and measure its eccentricity with a dial gauge Service limit When the measured value exceeds 0 2mm replace it 3 3 2 2 Wheel Shimmy Inspection Service limit Longitudinal replace it when it is over 2 0mm Transversal replace it when it is over 2 0mm 47 3 3 2 3 Front Bearing Inspection Disassemble front wheel central lining and take down oil seal a fH Front wheel intermediate bushing Grease seal Check the rolling condition of bearing Clearance gt lg If not rolling or the bearing is worn or loose replace with a new one 3 3 3 Bearing Replacement Disassemble front wheel front axle and axle sleeve and then disassemble oil seal with oil seal stripping attachment and bearing with bearing stripping attachment Note Removed bearing shall be replaced with a new bearing Apply some lubricating grease on the bearing at installation And then press the bearing in with bearing installer Attention e The bearing must be pushed in parallel e Bearing oil seal sleeve must be pressed in from the out 3 3 4 Installation Oil seal on front wheel should be spread with lubricating grease Autometer gearing mesh and moving parts should be spread with lubricating grease Fold odometer wheel gear units and then install brake disc 48 Attention Without folding and locking odometer wheel gear
13. Clearance between valve 0 02 0 042 0 075 stem and valve guide 0 03 0 057 0 082 Valve race width Intake alve sprin ree len Fit clearance between the cam shaft and Cam shaft 0 02 0 054 0 08 the cylinder head 97 11 2 Fault Diagnosis Low compression pressure Noisy cylinder head Improperly adjusted valve clearance Improperly adjusted valve clearance Valve burnt or bent Valve spring hurt Poorly sealed valve race Over high compression pressure Air leakage at cylinder head Too much carbon deposited in the combustion chamber Improperly installed spark plug 11 3 Cylinder Head Removal Loosen the fastening bolt and remove the cylinder head cover rocker arm rocker arm shaft Bolt Cylinder head cover Remove the tensioner loosen the chain and remove the can shaft Cam shaft Tensioner Cam shaft measurement Measure the size of the cam matching journal Admission can shaft Allowable limit 024 957 mm Exhaust cam shaft Allowable limit 024 957 mm Measure the height of the cam shaft Allowable limit Intake 36 9 mm Exhaust 35 9 mm Admission cam shaft Exhaust cam Remove the bolt nut and the cylinder head cover Nut shaft Matching Bolt as Tas eel nm OL J l omy TOU O Remove the tappet compress the valve spring with valve spring compressor remove the valve lock clamp Remove the gas distribution adjustment gasket v
14. Engine oil Oil filter screen Headlamp Gasoline filter Clutch Check Adjustment of accelerator stay wire Front Rear suspension system Air cleaner Bolt Nut Fastening part Spark plug Wheel rim Tyre Battery Tyre specification Restrictor Steering stem bearing and handle fixation Cylinder pressure Driving chain Preparatory Standard General Warning Before running the engine please make sure the area you are working in is well ventilated You shall never run the engine in an enclosed site Gas exhausted from the motorcycle contains carbon monoxide which may lead to loss of consciousness and result in death e Under certain conditions gasoline is highly volatile Work in well ventilated site Fire and smoking are forbidden in working site or gasoline storage place _15 Specifications Engine Idle speed 1 700 100rpm min Spark plug clearance 0 7 0 8mm 1 2L oil changelL Spark plug type NGK CR8E Cylinder compression 1 1 1 3Mpa pressure Ignition time BTDC12 degrees ldegree 1 700 100rpm Frame Clearance of front brake 10 20mm handle Clearance of rear brake pedal 10 20mm Pneumatic pressure unit of Front wheel 100 80 17 225kpa tyre Kpa QJI2Z5GY 16A 130 80 17 225kpa Front shaft locknut 75 88 N m Torque Rear shaft locknut 100 113 N m 16 Periodic Maintenance Schedule Mileage and Every Every Every Every Every as 3000 Be ee interval 300 KM KM three Twelve Fifteen Vehicle mo
15. Muffer decorative board 17 Socket head cap screw M8 30 18 Washer 8 19 Socket head cap screw M8 40 20 Washer P20 08 1 5 21 Socket head cap screw M8 20 22Exhaust protective shield 23 Combination screw M6 12 7 28 XV Emission Control System Emission control system guarantee 15 1 Periodical maintenance instructions ensure emission standard 152 Emission control system mechanical function 15 3 Catalyst conversion system 15 4 Solutions to Idle exhaust exceeding specified value 15 5 15 1 Emission Control System Guarantee 1 The emission control system of the enginecycle is up to the EC 97 24 5 I and 2003 77 EC Stage B The company will guarantee it in its effective service life under normal use and specified maintenance 2 Scope of Guarantee 1 gt Emission control system function guarantee The company guarantees that the system meets regular or irregular exhaust emission inspection carried out by relevant government authorities within 15 000km drive 3 The guarantee article is not applicable to the following situations but local dealers or service departments of the company are still willing to provide maintenance service for the customers at a reasonable price 1 gt Not performing regular maintenance according to the time and traveled distance specified by the company 2 gt Users not perfor
16. When a valve guide is replaced surface of valve seat retainer shall be fixed and adjusted Put the valve guide into the freezing chamber of refrigerator for one hour to freeze it Heat with electric furnace or oven the cylinder head to 100 150 C Fix the cylinder head and remove the valve guide from upper side of cylinder head with a special valve guide remover Install a new O ring onto the new valve guide Install the valve guide from the top of cylinder head Attention Please do not hurt cylinder head while installing valve guide OL Testing Opener When the valve guide is inserted fix and adjust it Valve reamer with a valve guide reamer Attention When a reamer is used to cut please apply some amount of cutting lubricant onto it Rotate the reamer in clockwise direction Remove carbon deposited in combustion chamber and valve and clean thoroughly intake and exhaust valves Inspect width of contact surface of valve seat width of valve race Allowable limit intake exhaust 1 6mm surface Valve Race Fixing and Adjustment Remove hackly and ragged parts on the valve race Hackly part with a 45 angled milling cutter Note Apply a layer of transparent or Prussian blue film onto the valve race so that it can be observed clearly JOS Remove 1 4 of external edge of valve race with a 30 angle milling cutter Remove 1 4 of bottom of
17. flicker for 10 times again on behalf of 0 after an interval of 1 2 seconds and after an interval of 1 2 seconds flicker for 7 times on behalf of 7 namely P0107 it is thus clear that other figures from 0 to 9 are expressed by the times of the flicker of the fault light except that figure 0 is expressed by flicker for 10 times If there are other fault codes such as fault P0201 which means there is a fault in the front cylinder injector the fault light will continue to flicker P0201 fault code in 3 2 seconds after finishing P0107 if there is no other fault the fault light will flicker P0107 and P0201 circularly and then check the fault code table for related faults While using PCHUD software the software will use the decimal number to report fault code and in fault code table decimal system is corresponding with hex one to one so the corresponding fault can be found according to the correspondence between them For example in software MULFCURR current fault 263 and it corresponds to P0107 in the fault code table namely the intake air pressure sensor fault 16 3 2 Make use of diagnostic equipment for fault diagnosis Operational approach 1 Locate the 6 hole diagnostic interface on the enginecycle 2 Connect the connecting wire and diagnostic equipment interface 147 3 Open the key for diagnosis 16 3 3 Use diagnostic software PCHUD on the laptop to check fault PCHUD software is used to detect and record engine o
18. gt E Batt ie Power Ground E Pin DIAGHOSTIC COW HECTOR Baii rnrariirnmas aiiai EE eh ate SND ra es as FOWER 16 2 1 5 Note for use of ECU 1 Do not place ECU in the high temperature parts such as a muffler or engine 2 The ECU cannot be placed near the water droplets oil or any liquid 3 Do not let the mud or other contaminants cover the ECU affecting the ECU cooling 4 Use the M8 bolt for connection and ensure that the tightening torque is about 3 9Nm installation surface must be flat to prevent bending the circuit board caused by external forces to ECU 5 The ECU normal DC power supply and voltage range is 9 to 16V and the ECU does not produce permanent damage if working under no more than 26V DC voltage for one minute and so Is it if working under the condition that the reverse voltage does not exceed 13V DC voltage within one minute will not cause permanent ECU damage J30 16 2 2 Oil Injector 16 2 2 1 Working principle of oil injector Inside the injector surrounding the iron core there is an electromagnetic coil which leads to the two electrodes namely the injector input control interface When the electromagnetic coil is energized the generated electromagnetic force makes the ball valve rise by overcoming the spring force of the ball valve and fuel pressure so the high pressure fuel 250Kpa inside the fuel pipe can pass through the injector valve seat hole flowing through the spray orif
19. measure the clearance between the cam base circle and tappet with the testing gauge Inlet valve 0 15 0 2mm Exhaust valve 0 2 0 25mm Special cylinder head cover Testing gauge 2 SE Cylinder Block and Piston XII Cylinder Block and Piston Preparatory data 12 1 Fault diagnosis 12 2 Cylinder block 12 3 Piston 12 4 12 1 Preparatory Data Function of cylinder block Cylinder block provides the space for gas compression combustion and expansion and guides piston movement It also transfers part of heat in the cylinder to surrounding coolant Function of piston 1 Piston can bear the pressure generated by combustion of mixed combustible gas in the cylinder and transmit the pressure to connecting rod to drive crankshaft to rotate 2 It forms a combustion chamber with cylinder head Precautions on Operation All the components shall be cleaned before inspection and test and purged with high pressure air Table of standard values of baseline projects and allowable limit Piston ODGmeasuring pon 35994590 Joint clearance of piston ET o o Clearance between linkage rod and piston 0 011 0 024 0 092 pin TOLE 12 2 Fault Diagnosis Low compression pressure White smoke from exhaust pipe Worn burnt or broken piston Worn or damaged piston ring Work or damaged cylinder and piston Worn or damaged cylinder and piston Broken washer air leakage between crankcase and gas Higher compression pressure
20. when items are proved normal No high voltage power supply or Defective ignition coil high voltage power is sporadic Defective charging coil Inner impedance is too small Use appointed tester to test l i Crankshaft rpm is too low When high voltage power supply is pe DE i i Tester is disturbed it is normal when more than one time s measured too low Trigger voltage is above the basic Trigger is bad when items are proved normal No high voltage power supply or Bad ignition coil high voltage power is sporadic Bad trigger 72 Avometer 6 3 Ignition System Inspection Attention e When the spark plug is not sparking check if components of wiring are loosened or badly contacted and make sure if all the s i voltage values are normal High voltage shunt e There are many brands of multimeters with different interior impedance The values they measured are not the same Connect a high voltage shunt or an ammeter with input impedance higher than 1OMQ 10CV to the multimeter 6 3 1 Primary voltage of ignition coil If an old spark plug is removed and replaced with a good one ground it with engine Attention Test when wirings of all the circuits are correct Normal cylinder compression pressure means to test with spark plug installed on the cylinder head Disassemble central cover Connect lead wir
21. 2 Charging Connection method Positive pole of battery charger is connected to battery positive lead wire Negative pole of battery charger is connected to battery negative lead wire 64 Warning Battery shall be away from fire e Shut off charger switch first before or after charging in case sparks may be generated at connection parts which may result in explosion During charging please take the current time labeled on the battery as basic time Attention e Battery quick recharging is not recommended except in case of emergency e After recharging wait at least 30minutes and then measure the battery voltage Recharging current Standard 0 4A Quick charging 4 0A Recharging time Standard 10 15hours Quick recharging 30minutes Recharging completed Open circuit voltage over 12 8V 5 4 Charging System 5 4 1 Short circuit test Disconnect the grounding wire from the battery and use a voltmeter to connect battery negative lead wire with grounding wire Set the switch at OFF position and check if it 1s shorted Attention Positive lead wire of multimeter is connected to negative lead wire of battery If abnormality found check if there is short circuit on ignition switch and main wiring 5 4 2 Charging state inspection While inspection battery shall be fully charged and a multimeter be used for the test Warm up the engine and then install fully charged battery onto the mot
22. 9 a yee Front wheel 4 Front wheel I Front wheel axleM14 1 5 219 2 Odometer wheel gear units 3 Front wheel sealed units 8 Liquid brake plate middle shaft sleeve 5 Cycle valve6 vacuum tyre 100 80 17 7 Front wheel ring erection bolt 9 Front wheel left shaft sleeve 10 Antifriction bearing 6202 2RS 11 Front brake plate 44 IHI Front Wheel Front Suspension Preparatory data 3x1 Fault diagnosis 3 2 Front wheel 3 3 Control assembly 3 4 Front fork assembly 3 5 3 1 Preparatory Data Precautions on operation Before removing the front wheel lift and support the bottom of motorcycle with a jack or other available device The front wheel is off the ground Take care not to rotate the wheel reversely Attention Please do not let oil contaminate braking shoe Basic data of the motorcycle as a whole Measuring position Standard value mm Service Limit mm Front wheel Wheel shimmy Within 1 0 2 0 Tightening torque Tools Direction handle fixed screw 22 29 N m Bearing disassembly pole Front axle 37 44 N m 3 2 Fault diagnosis 3 2 1 Direction handle moves hard amp Direction handle is out of order or damaged Bearing failure of direction handle Faucet bearing rating nut is too tight Tire pressure is not enough 3 2 2 Wobbly Direction Handle Damaged handle bearing Not enough tyre pressure Front fork bent front w
23. EN Sew oe ah ce hats wie wane Be ele nee whe _ 49 a NR ee ee ee ee 49 IV Rear Wheel Rear Suspension gt gt gt gt gt 2 ester renten renne nen rn rn raner arna rn rrn rn _ 54 41 Preparatory Data EEE 254 4 2 Fault Diagnosis EE TE TE NE EE EE NE E EE EE RE eae re eer 55 eg RR NR EE _ 56 4 4 Rear Shock Absorber ict ttt EEE EEE EERE EEE EEE enn e nen EE ES se Ta 4 5 Rear Swing Arm ttteetetetteretetreresttrrrrttererenteretrererereererereererenerrerenrererettn 58 LOD PN 59 V Storage Battery Charging System SEP ED NTE JE DEE ENTEN ee 62 te Preparatory Data ETTER 62 5 2 Fault Diagnosis KE STR SET RT E A E E A TAE E EE 63 5 3 Storage Battery Ee DR DE EE Re Se ee ae ee ey meee rey 64 5 4 Charging System EE EE TE ly am NE EN EEE E ET EE gr geen ama ENE EE T kere 65 7 5 5 Voltage current Regulator SATT EEE SPSS ah SEL PEDER ENE EFE EG EE ENE BS Glee ON ae ants 66 5 6 Alternator Charging Cojl EEE EEE 67 5 7 alternator light Le ERE 67 5 8 disassembly Of alternator EEE EEE Eee nee nen eee nee ees 68 VI Ignition System ee SM eT Ee TT Ce ee CC eee ee eee Cee ee eee L ee re ce ee EES ra ee 6 1 Preparatory IDE EEE SF PP 6 2 Fault Diagnosis DE EEE ENE EE EE EE NE TET OE EN EE DE REE eae eer me oe 6 3 Ignition System Inspection NES ett AE mag ce 6 4 CDI Assembly gt t tettere eter era rar rak rare ee nee et 6 5 Ignition Coil srs errr rte rte rrr eee TE 6 6 Trigger t ttt terte rer terre
24. Voltmeter shall be used for charging inspection Charging Connection method Positive pole of battery charger is connected to battery positive lead wire Negative pole of battery charger is connected to battery negative lead wire Warning e Battery shall be away from fire e Shut off charger switch first before or after charging in case sparks may be generated at connection parts which may result in explosion e During charging please take the current time labeled on the battery as basic time Attention e Battery quick recharging is not recommended except in case of emergency e After recharging wait at least 30minutes and then measure the battery voltage Recharging current Standard 0 4A Quick recharging 4 0A Recharging time Standard 10 15hours Quick recharging 30minutes After recharging Closed circuit voltage over 12 8V Restrictor Idle speed adjustment Attention Perform idle speed adjustment when the engine is warm Warm up the engine and then adjust idle speed Run the engine and connect engine tachometer Adjust the throttle cable lock screw to specified RPM Idle speed RPM 1 700 100rpm min Fr If idle speed RPM is unsteady or idle speed is not smooth when gently raise engine speed adjust idle speed adjusting screw again Cylinder pressure Operation when engine is warming Disassemble spark plug Install roof cylinder pressure gage Fully open accele
25. alternator joint is in bad contact or wiring is broken eThat both are abnormal indicates badness of charging coil Please refer to the check of charging coil meter 6 3 3 Trigger Attention Inspect when spark plug is installed on the cylinder head and compression pressure is normal Disconnect connector 4P from CDI assembly A peak voltage shunt is indirectly connected to the 4P connector black terminal and 4P wiring terminal connector of trigger blue white terminal Press starting motor button or kick pedal level to measure primary peak voltage of trigger Connecting method positive to blue white negative to black Min voltage higher than 1 7V Ty ee ANE E TA A N Attention Nl ne Please do not touch the metal parts of testing probe with your fingers while measuring the voltage or you will be shocked Please take care When the peak voltage measured at connector of CDI assembly is abnormal take down the protecting plate on the right side of 74 vehicle and remove connector of alternator Trigger blue white is connected with a shunt e When the measured voltage at CDI assembly terminal is abnormal but measured voltage at alternator terminal is normal it indicates that the connector is of poor contact or wiring 1s broken e When measured results at both sides are abnormal the trigger is damaged Please refer to items listed in Diagnosis Table and check 6 4 CDI Assembl
26. blocked for example foreign body presents in the exhaust passage excessive oil consumption resulting in clogging catalytic converter and blockage resulting from the internal fragmentation of the catalytic converter and it will cause this value is too high d Number of cycles of the oxygen sensor values too little number of cycles indicating the oxygen sensor failure 16 4 3 Concise troubleshooting Please repair fuel injection systems according to the following sequence of steps if troubleshooting can be finished in some step the follow up steps may be omitted And then with use of diagnostic equipment make inspection and erase the fault code according to 14 4 2 In use of diagnostic equipment the battery voltage is not less than 8 5 volts 154 16 4 3 1 Daily use and maintenance Petrol should be such high quality unleaded petrol as 924 or 95 ECU has a moisture barrier but its shell may not be washed with water cannon 3 Replace the fuel filter every 7 000 10 000km Under normal conditions of use clean the throttle body once every 10 000 km or 1 year 16 4 3 2 Fault phenomenon unable to start a Make the ignition switch at ON file to check whether the engine fault light is on If not on Check the fuse and earth wire Check whether the ECU s patch plug is securely connected Diagnostic apparatus may also be used to execute agency check function to check whether the light and line are normal Che
27. displayed value of coolant temperature sensor intake air temperature sensor intake manifold absolute pressure sensor and oxygen sensor is normal f Operating range of the throttle position sensor that it cannot be fully opened or fully closed may affect engine dynamic performance and some system functions 16 4 2 2 Step 2 Whether the ECU power supply is turned off communication between the diagnostic apparatus and system 1s terminated after the key switch is turned off 16 4 2 3 Step 3 a Coolant temperature and coolant temperature cycling indicates whether the thermostat is working properly b Battery voltage indicates whether the generator is working properly Too high It may be the generator regulator failure Too low It may be the improper generator connection or generator failure c Intake manifold pressure may indicate whether there is leakage in inlet air and problem for valve clearance Valve clearance is too small this value is on the high side it may affect the power of the engine and because of the exhaust valve too early to open that the exhaust temperature increases greatly shortens the life of the oxygen sensors and catalytic converters The valve clearance is too large it will cause the intake manifold pressure is on the low side and impact judgment of the system on the engine operating state resulting in idling exception while warming up the enginecycle In addition if the exhaust system 1s
28. inner diameter of the shifting fork hole Allowable limit 10 05mm Testing gauge 124 Measure the thickness of the shifting fork SE Vernier caliper Allowable limit 4 6mm Measure the outer diameter of gearshift drum Allowable limit 41 75mm Measure the width of the locked groove of the j Width of locked gearshift drum va BrOOYVE Allowable limit 5 7mm 13 7 Variable speed chamber Layshaft assembly Remove the spindle assembly WAS Oo N 2 pa MST Remove the layshaft assembly R TIT MAS gt der Nat Lae ai Spindle assembly 20 Exploded view of variable speed gear shift assembly 1 Gearshift stop pin 2 Stop collar 3 Gearshift shaft combination 4 Gearshift running board 5 Gearshift running spring 6 Gearshift shaft return spring 7 Gearshift plate pin 8 Plastic sleeve 9 Gearshift shaft assembly 10 Gearshift changeover contact 11 Contact spring 12 Gearshift drum 13 Gearshift positioned assembly 14 Washer 15 Bolt M6X25 16 Positioning wheel return spring 17 Star wheel positioning plate assembly 18 Gearshift positioning roller arm axis 19 Shifting fork shaft 20 Shifting fork II 21 Shifting fork II 22 Shifting fork 23 Nut 24 Spline pad 25 Output chain wheel 26 Output chain wheel space bush 27 O shape ring 19 1 8 28 Layshaft 29 Layshaft second gear 30 Spline pad 31 Shaft collar 32 Layshaft sixth gear 33 Layshaft fourth gear 34 Washer 35 Layshaft third gea
29. motorcycle or any difference between the product and pictures drawings and instructions in the manual the product shall prevail The product is subject to changes without prior personal notice ZHEJIANG QIANJIANG MOTORCYCLE CO LTD Finished Automobile Institute Preparatory Data General Safety Maintenance Rules Specification Table Fault Diagnosis General Safety Carbon monoxide CO When it is necessary to start the engine please make sure the operation area is well ventilated Never run the engine in an enclosed place Attention Gas exhausted from the motorcycle contains harmful carbon monoxide which may lead to loss of consciousness and death It is necessary to run the engine in an open area To run the engine in an enclosed site ventilation system shall be used Gasoline Operate in well ventilated site No fire or smoking is allowed in operation site and gasoline storage place Storage Battery Electrolyte in the storage battery has sulfuric acid so leave eyes skin and clothes away from it Once got electrolyte on our skin or clothes you will have to wash them by fresh water thoroughly once into our eyes to see a doctor immediately is necessary Special Tool When disassembly and installation is in process general tools and special tools should be selected correctly When it is time to use the special the general can not be substitution Besides appropriate power 1s welcomed to avoid the damag
30. the running state of the engine through various sensors to control the output device through rational calculation and self learning which can optimize the drive of vehicles under various conditions and also ensures the vehicle emissions and fuel economy When the system is out of order the engine controller can be awakened to self diagnosis This system needs two ECU working together 134 16 2 1 2 Appearance of ECU 16 2 1 3 The ECU pin definitions System ground pin ma ms ivi commiato pin ma fm4 i potential pin ofthe erat signal usd estore J1 8 Intake air temperature sensor signal pin J1 17 Oil pump control signal pin J2 17 Oxygen sensor signal pin J1 18 Neutral switch pin J2 18 Battery power battery 12V positive power supply Note J1 means the gray plug in the ECU while J2 means the black plug in the ECU J1 1 means the Ist pin in ECU gray plug 10 16 2 1 4 EFI circuit diagram FUSE fie WTSI sR i Fride Twisted a TARGET WHEEL EyYCIom n dde at Gable Par ssa a i mdapsn eney fume SY T 5 MEAT 23X VF Sensor J XX me T LAIGYLE grttan Col i ce 4 IGRAN Sploh aiot ST FER f E E S i i E Spars Flog OHO 4 ko POWER _ Venite m L Power 12W 1 ANALOG NPUTE p FPRs Clr 11 47 Irjecan WA KYLE pr mkr fai E E prs ar ode aout oxyger sEreor The pin dePaltlom nt GEN ie diffesrant Ten ira oT OEP VSS Sensor Haji E zemer TBAT
31. 60 Check and maintenance of electrical equipment Charging system R W Bl V Storage Battery Charging System Preparatory data 5 1 Fault diagnoses 5 2 Battery 5 3 Charging system 5 4 Voltage current adjuster 5 5 Alternator charge coil 5 6 Alternator light coil 5 7 Disassembly of alternator 5 8 5 1 Preparatory Data Precautions on operation Attentions 1 The battery can be charged and discharged and used repeatedly If a battery is laid aside after discharging its service life will be shortened and its performance is degraded Performance of a battery is usually reduced after about 2 3 years run Voltage of the performance reduced capacity drops battery can be resumed but the voltage will run down quickly while loading 2 Overcharging of battery Usually overcharging 1s demonstrated by the battery itself If short circuit occurs inside the battery there will be no voltage or very low voltage on the terminals of the battery Adjuster fails it indicates too high voltage on the battery the life span of the battery will be sh
32. FPESTAT FPEAFREN FTRNSAEDCLOAD PNSWTCH FTRNSDEINLOAD DIAGSWTCH FCLCEN2 b ios_MIL_Status 4 Select Parameter File under the Setup click MTOS5common par file select Comm protocol under the Setup select Keyword2000 and then click OK at the same time Device Code selects 17 148 START me 00 00 0 x Le 1 fe ESN 0 00 pctFCNO 0 cellNo MALFCURR 0 NA i Ir Sn mm gt 0 ALDE ma 200 000 25510 1000 HROT lg orem m 0 CA FELMCORZ 0 000 facto 0 000 factor MALFHIST 0 NA e E 0 0 3000 000 2 000 0 10000 VBARO ooo 0 0 CAFBLMCORT 0 000 factor 0 000 factor RUNTIME 0 Sec EE 0 0 TE O Lol 256 0 0 000 2 000 0 10000 MAP aac aaa a AE A countFBLMCOR2 0 000 factorlUndefined Parameter a H MAPRAW 256 0 TT 3276710 000 2 000 vMAPEXP 0 0 VMAPEXP 0 0 ka FCLCINT2 coun 0 countlARDRPM 0 ARDRPM tom AFCCLNUM 0 cellNo ry ee r res 0 256 0 7 EE 3276710 20000 32 IGN 0 0 5 EE 5 dl 0 00 factor i JE 0 00 factor Y CSPC 0 count SS ee i TT 0 65535 TT 00 2 00 0 00 2 0010 65535 CLTS 0 0 VET B0degliacvDSMe 0 ster 0 step 0 00 mv 0 00 m VTHROTRAW 0 count Sr eee TETT 0 256 0 Lu 25510 00 1023 980 65535 IAT 0 0 degCllACVDSMP 0 step vo2 0 00 mVISTATUSBYTE1 00000000 SS SS sen Pa ae 256 0 256 010 25510 00 1024 00 STATUSBYTE5 00000000 STATUSBYTE2 00000000 STATUSBYTE1 00000000 STATUSBYTEA4 00000000 CYCSENBL CSINSYN IDLCONM FPESTAT FPEAFREN FTRNSAEDCLOAD PNSWTCH FTRNSDEINLOAD DIAGSWTCH FCLCEN2 b ios
33. Noisy piston Too much carbon deposited in the combustion chamber Damaged cylinder piston and piston ring Worn piston pin hole and piston pin 12 3 Cylinder Head Removal Remove cylinder block Inspection Inspect wear of cylinder inner wall If it is seriously worn replace it Cylinder block Remove washer and location pin Gasket Piston pin retainer Locating pin ALG Piston Removal Remove piston pin retainer Attention Please do not drop the retainer into crankcase during removal Take out piston pin and remove piston Remove piston ring Inspect piston piston pin and piston ring Attention Please do not break or hurt piston ring Remove deposited carbon inside the piston ring Install the piston ring PIRIOU Measure the clearance between piston ring and piston Me OG i J org ring groove Push Allowable limit First ring 0 12 mm Second ring 0 12 mm ES Remove piston ring and install all the piston rings LLL Piston onto bottom of cylinder 7 ring Attention Compress piston rings into the cylinder with piston N n Piston ring a head fa Measure the joint clearance between piston rings Allowable limit First ring 0 4 mm Second ring 0 5 mm 109 Measure piston pin hole ID Allowable limit 15 04 mm Tester Measure piston pin OD Allowable limit 014 976mm Measure the
34. Rear wheel 4 3 1 Disassembly Loosen rear axle nut Disassemble rear axle nut and take down chain from chain wheel seat Disassemble rear axle Disassemble rear wheel Rear axle Rear swing arm 4 3 2 Inspection 4 3 2 1 Check the bending of axle Put axle on V style seat and measure its eccentricity ratio with dial indicator Use limits change over 0 2mm 4 3 2 2 Wheel Shimmy Inspection Rotate the wheel by hands and measure its eccentricity with a dial gauge Service limit Longitudinal Replace it when the measured value exceeds 2 0mm Transversal Replace it when the measured value exceeds 2 0mm When rear wheel shimmy exceeds service limit rear wheel bearing is loosened which results in wobbly rear wheel Check and replace rear wheel bearing 56 4 3 3 Installation Install the rear wheel in the reverse order of removal and tighten the nut Rear wheel shaft locknut Tightening torque 100 113N m 4 4 Rear Shock Absorber 4 4 1 Disassemble rear shock absorber Disassemble body guard board Disassemble rear splash guard Disassemble tool box Disassemble air filter Disassemble rear wheel shock absorber fixed bolt Take down rear shock absorber 4 4 2 Rear Shock Absorber Inspection Visual inspection of shock absorber to check whether there is damage Check the following items bending or damage of shock absorber pipe out of shape or oil leakage of shock absorber abrasive w
35. SURE TEMPERATURE EEHLOR pr a iG COOLANT 4 gta lAGSHI Eee FE Fonda ie LEIG ACLI hola aout tuyger s PSOr st OSK Is difterant Treen fei oT Ger POWER GHOD roAa GAD cane Jae sitar AHL Jeep GAN Lo VBAT gt ball Batt E Pin DAGNOSGTIC kr POY AEC TOR WSS Sensor 158 gt XVI EFI System Description EFI system 16 1 EFI system parts 16 2 Fault diagnosis 16 3 Common troubleshooting 16 4 16 1 Introduction to EFI System of finished enginecycle QJI25GY 16A uses the small engine EFI system from Delphi Corporation which makes closed loop control through the oxygen sensor with independent fuel injection and ignition control It uses three way catalytic converters for post processing of the gas after the engine s combustion to make it into harmless gas before emitted into the atmosphere The system uses a closed loop control self learning system which can effectively eliminate the manufacturing difference of the system and related mechanical components improve the consistency of the finished enginecycle and can also eliminate the error caused by the vehicles in actual use due to wear 16 2 EFI system parts 16 2 1 Engine controller MT05 2 ECU 16 2 1 1 Working principle of ECU The engine controller makes real time detection on
36. Sere Impedance value o0 indicates broken wire inside the coil Remove the spark plug cap and measure impedance value between primary side lead wire of ignition coil cap and negative terminal Standard value 4 5 5 5KQ 10 20 6 6 Trigger Magneto interface DI7 068 6 3 21 DJ 623 E6 3A white green Attention Trigger inspection can be performed on the engine Inspection Remove protecting plate of vehicle block Remove lead wire connector of trigger Measure the impedance between blue white terminal of lead wire at engine side and grounding vehicle block Standard value 100 2009 20 i blue white If measured impedance value is beyond the range please replace the alternator 76 Power Lock Ignition Coil Storage Battery Rectifier Starting Relay BRAKE SWITCH BRAKE SWITCH STARTER SWITCH 77 VIL Starting System Preparatory data ol Fault diagnosis Ta Starting motor Td Starting relay 7 4 7 1 Preparatory Data Precautions on operation Starting motor removal can be performed on the engine Starting clutch removal refers to removal instruction Basic data Tightening torque Starting motor clutch cap bolt 12 N m Starting motor clutch locknut 95 N m Tools Locknut wrench Universal un adjustable wrench
37. YNSPRK IDLCONM SATITRIG FPESTAT CATLOENB FPEAFREN If ENGSTATE 3 PNSWTCH NISTBLIDLE DIAGSWTCH FO2REDY2 bVios MIL Status Then it can communicate properly in the MALFCURR displays the current fault code while history fault codes are displayed in MALFHIST ONA 1000 0 NA wae eS eS h Inquire the fault code table for the corresponding fault 149 Attached Table 1 PCHUD software parameters explanations VTHROT throttle position intake air temperature SATITRIG tip in Spark Advance retard trigger FO2REDY2 O2 ready FOSHTREN Oxygen sensor heater enable desired position of idle air control valve 100 STATUSBYTE2 FCLCENI PPDSEBL FPENABL FTRNSAES FTRNSDES FTRNSAEDCLOAD FTRNSDEINLOAD FCLCEN2 STATUSBY TE2 151 Attached Table 2 Fault code table The MTO05 fault code table The fault description code 0107 Open circuit for intake pressure sensor or signal end pins shorted to battery negative P0108 P0112 Intake air pressure sensor signal end pins shorted to battery positive Intake air temperature sensor signal end pins shorted to the battery negative P0113 Open circuit for Intake air temperature sensor or signal end pins shorted to battery positive PO117 Cylinder head temperature sensor signal end pins shorted to battery negative PO118 Open circuit foe cylinder head temperature sensor or signal end pins shorted to the battery positive P0199 Open circuit foe throttle pos
38. _MIL_Status 5 If the software interface cannot display real time communication data in the case of power it needs to continue the following work under Setup check whether there is problem with COM port connection settings and the usual settings are COM Port 4 the Baud Rate 10400 do not Select the DTR High at the Startup Tira od a0 00 00d ET De ve 5 Les RPM 0 rpm FVE1 0 00 NE SINT ING 0 cellNo MALFCURR 0 N E gt EES 200 00 0 25510 1000 vo NG 0 GT ETTE 0 000 factorMALFHIST 0 N EK r F lt gt SS nm COM Port Baud Rate 300 0 000 2 000 0 10000 VBAR oa 0 0 2 a 0 000 factor RUNTIME 0 Sec HA Tu a lt r re eee 0 0 256 010 000 2 000 0 10000 YMAP sms 0 000 factorUndefined Parameter E HMA PRAW 0 0 og 0 000 2 000 MAPEXP i IARDRPM 0 51505 TTT AFCCLNUM 0 cellNo a I DTR High at Startup Cancel 0 0 EAA 0 32 VIGN 0 0 ATT AFCMULT 0 00 factor VOUT 1 00 eco 0 00 factor CSPC 0 count SS tee S E 0 0 65535 0 0 00 2 00 0 00 2 00 0 65535 VCLTS 0 0 degCIIACYDSMP 0 2 a 2 EE 0 00 mYNTHROTRAW 0 count es ee Ss EE ER 256 0 256 0 0 255 0 00 1023 98 0 65535 0 0 degCIIACYDSMP 0 LE SS i 0 00 m STATUSBYTE1 00000000 Ti ETE __ ss 256 0 0 255 0 00 1024 00 STATUSBYTE5S 00000000 STATUSBYTE 2 00000000 STATUSBYTE1 00000000 STATUSBYTEA4 00000000 CYCSENBL CSINSYN AFCMET BAROCMET CSINS
39. ace it when below 2 5mm Check the flatness of the driven friction plate with the plug gauge Allowable limit Replace it if above 0 2mm Driven friction Plug gauge plate measure the thickness of the surface needle roller bearing Allowable limit Replace it when it is below 1 8 mm Needle bearing maa OG ce Crankshaft connecting rod combination and variable speed chamber Crankshaft ee connecting rod p Cys I a Left crankcase Left crankcase Layshaft assembly Main shaft assembly Gearshift drum EG 13 5 Gearshift mechanism Disassemble Remove the stop arm Stop arm Remove the gearshift locating plate Remove the gearshift shaft combination Remove the parts Gearshift Please refer to the exploded view of the locating plate variable speed shift assembly Gearshift shaft combination Inspection The gearshift plate should be pulled back flexibly without clamping stagnation before being disassembled Check whether the gearshift plate and the gearshift shaft combination are worn If badly worn replace it Check whether the gearshift locating plate is worn If badly worn replace it Check whether the gearshift shaft 1s bent If excessively bent replace it Check whether the force of the return spring is weakened and replace it if necessary Loosen the nuts and washer of the right crankshaft to remove the clutch drive gear using electric or pneumatic too
40. aft 14 Oil pump cover 15 Inner rotor 16 Outer rotor 17 Gasket 18 Oil pump transition gear 19 Transition gear shaft Attention After assembly inner and external rotors shall rotate smoothly and be out of nimbleness Installation Install the oil pump in the reverse order of removal 92 X Cooling system Preparatory data 10 1 Fault diagnosis 10 2 Water pump 10 3 10 1 Preparatory data Functions of cooling system It can build some channels which can allow liquid circulation inside the cylinder and the inner wall of the cylinder cover a special radiator is set outside the engine body so that the forced circulation of cooling water can be made through water pump and pipeline and then the heat of the engine can be released to cool it through air blowing the surface of the cooling fin of the radiator at high speed 10 2 Fault diagnosis Water leakage Seal ring damaged Pimp body broken Water pipe breakage Over high temperature of cylinder body Water pump impeller damaged Radiator fan broken Lack of cooling liquid Temperature sensor damaged 93 10 3 Water pump Disassemble Loosen the fastening bolt remove the crankcase right cover and remove the gasket Bolt Right cover Remove the water pump gear loosen the Fastening bolt and remove the water pump cover and the gasket Bolt Water pump cover Wa
41. alve spring the upper and lower seat of valve spring valve 99 Valve disassembling Valve Lower seat of ve NE app valve spring Valve lock clamp BRE aA Upper seat of valve Valve spring spring Inspection Clean carbon deposition on the cylinder cover Ruler Measure flatness of junction surface of cylinder cover Allowable limit 0 05mm If flatness of junction surface of cylinder cover exceeds the service limit put a piece of fine sandpaper on the ERT sl flat plate and fit the sandpaper with junction surface of cylinder cover and then push the sandpaper to grind in figure of 8 way Testing gauge 7 OO Measure the free length of the valve spring Allowable limit Spring 37 mm Measure the outer diameter of the valve stem Allowable limit Intake 04 455 mm Exhaust 4 448 mm Check valve guide Please eliminate the carbon deposition in the valve guide with a reamer before inspection Attention Rotate the reamer in clockwise Please do not rotate the reamer in counterclockwise OL Valve reamer Measure valve guide ID Allowable limit Intake Exhaust 04 53mm Clearance between valve and valve guide Allowable limit Intake Valve 0 08m Exhaust valve 0 1mm Valve Guide Replacement Attention When the clearance between valve and valve guide exceeds service limit value please replace the valve guide
42. aner on the internal wall of the throttle body and brush gently off the dust coke etc make sure no dirt clogging the side channel 16 2 4 cylinder head temperature sensor 16 2 4 1 Working principle of cylinder head temperature sensor The engine cylinder head temperature sensor is used for air cooled engine to measure the engine cylinder head temperature within the temperature range of the sensor its resistance varies with engine temperature and its temperature characteristic is the negative temperature coefficient resistance characteristics It is a part which is not maintainable 16 2 4 1 Appearance of cylinder temperature sensor Cylinder head temper al senson 150 16 2 5 Intake air temperature sensor 16 2 5 1 Working principle of intake air temperature sensor It is used to measure the temperature of incoming air and its resistance will vary with the temperature of the intake air its characteristic is also negative temperature coefficient resistance characteristics It 1s also a part which cannot be repaired 16 2 5 2 Appearance of intake air temperature sensor 140 16 2 6 Intake air pressure sensor 16 2 6 1 Working principle of intake air pressure sensor The sensor is used to measure the absolute pressure of intake air elbow to reflect different inlet pressure according to the resistance value and the inlet pressure can be thus indirectly converted into calculation of the size of th
43. ative SLS Corresponding to the decimal number 263 264 274 275 219 280 290 291 305 306 N a 513 514 560 562 822 823 849 850 1378 1379 1616 STP 5780 311 312 N WT WM oO 16 4 Common troubleshooting 16 4 1 Maintenance tools a Disassemble of the electronic control system components withdrawal tools of automotive mechanical parts are often used b Electronic control system circuit and system signals digital multimeter with buzzer c Fault diagnosis of electronic control system and detection of engine s working condition Electronic control system malfunction diagnostic apparatus recommended Failure diagnostic software PCHUD and interface connection wire conditional use d Electronic control system failure fault code table emergency use e Fuel pressure gauge range 0 300kPa 16 4 2 Diagnostic apparatus displays engine operating data stream Use the engine operational data stream the diagnostic apparatus displays to analyze and determine the engine failure 16 4 2 1 Step 1 a Engine wiring harness and vacuum tube may affect the system to control air flow and fuel supply 153 b Whether the oxygen sensor installation is in place may affect system s judgment of the air fuel ratio c Engine fault indicator impacts system failure alarm d Battery voltage to determine the adequacy of battery power e According to experience to judge whether the
44. check if plug of voltage current regulator is of poor contact and measure impedance value between terminals of voltage current regulator itself Attention e Do not touch the metal part of multimeter probe with your finger e Check with a multimeter If impedance values measured by different multimeters are not the same it perhaps the inspection is not correct When impedance value between terminals is abnormal replace voltage regulator 66 Unit MQ wet mo No 013 1090 Ei EEE ret fors me Ses fora SE Me fe Jr 5 6 Alternator Charging Coil Attention Inspection of alternator charging coil can be performed on the engine Inspection Disassemble alternator 4P joint Measure Alternator white coil and impedance between bodies with multimeter Standard value 0 6 10 20 If measured value exceeds the standard the alternator coiling shall be replaced 5 7 alternator light coil Attention Inspection of alternator charging coil can be performed on the engine Inspection Measure Alternator white coil and impedance between body bondings with multimeter Standard value 0 6 10 20 If measured value exceeds the standard the alternator coiling shall be replaced 67 5 8 disassembly of alternator 5 8 1 Disassembly Disassemble fixed bolt and bolt Take down left cover Fix flywheel with universal fixed wrench Disassemble flywheel fixed nut Take down fly
45. ck and repair the bulb and its line Use another ECU to determine Connect the diagnostic equipment to the system diagnostic socket b Whether the diagnostic apparatus can connect and communicate with the system Check the fuse and earth wire Check whether the ECU s patch plug is securely connected Check whether the diagnostic apparatus in another normal vehicle is working properly Use another ECU to determine According to the fault indicated by the diagnostic apparatus for troubleshooting c Check the ignition system failure whether the spark plug is normal ignition Check whether the high voltage lines and spark plug patch firmly or are damaged Use another ignition coil assembly to judge Use another ECU to determine Check whether the high voltage lines is properly connected to the ignition coil and spark plug d Check the fuel supply system failure Whether the fuel pump is working working of pump can be hears near the tank when starting the engine Check whether the fuel pump relay is working properly Check whether the crankshaft position sensor is connected and work is normal Use another ECU to determine Check the fuel pump lines 1 Whether the supply pressure is greater than 220Kpa 2 Pressure is Check the fuel tank if there is sufficient oil insufficient Check the fuel filter whether it should be replaced Note The EFI dedicated fuel filter 1s replaced once every 7000 to 10000 km
46. cle can not walk or engine shuts down check clutch block Replace a new one when necessary Free travel of clutch 10 20mm Please adjust free travel of clutch in the following way 1 Loosen mandrill to lock nut 2 Twist in or out the mandril2 to adjust free travel of front brake handle after adjusting free travel to 10 20mm 3 Install mandrill tight and lock nutl Front Rear Suspension System Pressure up and down Front suspension Grasp the front brake handle and compress upward and downward the front shock absorber to check its actuator Check if the front shock absorber leaks oil and if the components are loosened 29 Rear suspension fh Pressure up Compress upward and downward the rear shock absorber to ta and down check its actuator Check if components on the rear shock absorber are loosened or injured Lift and support the rear wheel and swing the wheel to check if engine suspension bushing is loosened Bolt Nut Fastening Part Inspect bolts nuts and fastening parts at every part of the motorcycle for looseness If it is loose tighten it to specified torque Wheel Rim Tyre X C x Check if there is crack nails and similar sharp objects and other injuries on the tyres Inspect pneumatic pressure of tyres Attention Measure cold inflation tyre pressure Specified air pressure Unit Kpa Tyre specifications Front tyre 100 80 17 225 10kpa QI125GY 16A 130 80 17 225
47. clearance between piston pin hole and pis Allowable limit 0 064mm Measure piston OD o ee A Attention 90 A YD Measuring position forms a 90 angle with piston RES 27 pin about 11mm below piston skirt AK Ar AS SK a z ty rn I r re al Allowable limit 059 93mm AT NG pa sn ii T7 110 Inspect wear and scratch on inner wall of cylinder Attention Measure cylinder ID at three positions i e upper intermediate and lower positions The position forms a 90 angle with piston pin Allowable limit 60 063mm Measure the clearance between cylinder and piston Take the maximum clearance as standard Allowable limit 0 07mm Measure the roundness of cylinder inner wall internal diameter difference between X direction and Y direction Allowable limit 0 01mm Measure the cylindricity of inner wall of cylinder internal diameter difference of three positions upper intermediate and lower along X direction or Y direction Allowable limit 0 01mm Check flatness of cylinder surface Allowable limit 0 05mm Testing gauge IMicrreate K Ruler gt DE Cylinder Measure Connecting rod small end ID Allowable limit 15 068mm Installation of piston Install location pin Apply engine oil evenly on each piston ring and piston Install piston to its place with bev
48. connect wire to the electric horn Connect lead wire of horn with the battery When the electric horn sounds it indicates the horn is in good condition 8 9 Handle switch Remove protecting plate of steering handle Screw off mounting bolt on the brake lever and take down the bracket Remove bracket for the rear brake lever Yellow ay Red White Remove throttle handle and bolts Ei EE Take down throttle handle from the handle and remove the s throttle cable H i Eai AE aN Remove locknut on the handle and take down the handle Wiring Diagram Dimmer Switch Turnning Switch Hom Button Dvertaking Button Black Red Dark Green Green Yellow 86 Engine Inspection and Maintenance Table of tightening torque for fastening parts used in engine Table of tightening torque for fastening parts Cylinder head cover screw M6 Cam cover fastening screw M5 Cylinder head cover screw M6 Cylinder head cover acorn nut M8 Cylinder stud bolt M8 Tensioner fastening screw M6 Chains leading fastening screw M8 Oil pipe set bolt M8 Thermostat fastening screw M6 Induction manifold fastening bolt M6 Flywheel locking hexnut M12 Starting engine set bolt M6 Clutch transmission gear jam nut M16 Clutch jam nut M16 Gearshift star wheel fastening screw M6 Gearshift positioning wheel rocker arm fastening screw M6 Mould assembling screw M6 Left and right crankcase cap bolt M6 Cylinder head cover fastening screw M6 Water pump
49. cover fastening screw M6 Machine oil strainer cover M6 Engine cover fastening screw M6 Machine oil strainer plug screw M20 Oil pump cover fastening screw M6 Coil fastening screw M6 Output sprocket nut M18 Spark plug M10 Water temperature sensor M12 Magnetic bolts M12 87 Lubricating System Chart GF Cam bearing 3 CC Orifice A Connecting rod bearing o Plunger orifice Oil pump 2 Oil filter Li Oil pump I 88 IX Lubricating System Preparatory data 9 1 Fault diagnosis 9 2 Oil engine pump 9 3 9 1 Preparatory Data Function of lubricating system Function of engine lubricating system is to supply lubricating oil to friction surfaces of engine parts so that dry surface friction will turn to liquid friction between plasmids of lubricating oil It is used to reduce wear of component cool components of higher heat absorb impact from bearing and other parts weaken noise increase tightness between piston ring and cylinder wall clean and take away impurities from surface of component etc Precautions on Operation When engine oil pump is removed clean carefully all the components and purge them with high pressure gas During engine oil pump removal and installation pay attention not to drop anything into the crankcase Table of standard values of baseline projects and allowable limit Radial clearance between Oil pressure pump 0 025 0 175 inner and external
50. d the oxygen sensor are in normal state in a normal water temperature if the reading 1s always greater than 500 mV check whether the injector spills Attentions amp Most of the EFI parts are not repairable so it is usual to replace the damaged parts after confirmation amp When starting the engine do not operate any organization on the engine including the throttle do not pull the throttle to start If the engine fault light is on in the engine running make sure to identify the cause as soon as possible and to debug it Leaded gasoline must be used because lead can damage the oxygen sensors and three way catalytic converters For oil consumption anomalies it should be resolved as soon as possible Some substances in the oil will damage the oxygen sensor and three way catalytic converters amp The valve clearance should not be too small if the exhaust does not close well it will make the exhaust temperature too high and shorten the life of three way catalytic converters amp When temperature below 10 C if the finished enginecycle and engine run at low speed for too long the exhaust pipe may have a coke and go black which is a normal phenomenon It would disappear after a high speed operation for some time or take appropriate means to make the engine coolant temperature maintained at the specified temperature range OE QJ125GY 16A circuit diagram
51. discharged Lead wire of battery is poorly contacted Lead wire of battery is not connected Discharging system is of poor contact Fuse is broken Lighting system is of poor contact or short circuit Power switch is poorly contacted Low voltage Poor charging system Battery is poorly recharged Wire connector is of poor contact short circuit or short line Poor contact Defective voltage and current adjuster Poor charging system Magneto does not work well Bad voltage and current adjuster 63 5 3 Storage Battery 5 3 1 Battery Removal Open seat cushion Disassemble left guard board Disassemble negative guide line first and then the positive guide line Take out storage battery Warning During positive lead wire disconnection be sure to prevent the tools being used from touching the frame or it will result in short circuit sparks which may ignite gasoline and damage battery It is dangerous Install the battery in the reverse order of removal Attention To avoid short circuit please connect positive lead wire first then the negative lead wire Check of charging situation open circuit voltage Open sear cushion Open air filter s cover and disassemble storage battery joint guide line Measure voltage between terminals of the battery Fully charged 13 1V Undercharged 12 3V battery does not work for 1hour Attention A voltmeter shall be employed to check recharged battery 5 3
52. djustment bolt3 to right or left to adjust the looseness of chain When adjusting chain make sure front and back chain wheel should aim at centre as a line In order to help you adjust there is reference mark on swing arm and every chain adjuster They can aim at each other and become as the reference from out to out After aiming at and adjusting the looseness of chain to 10 20mm fix back axle nuts again and then check as the last time Attention When changing the new chain the wear of the two chain wheels should be checked Replace them when necessary Check the following situations of chain in periodic inspection 1 Loose pin 2 Damaged idler wheel 3 Dry out and rusting chain 4 Twisting or seizing chain 5 Excessive damage 6 Adjust the loose chain If chain is in the above conditions chain wheel is likely to be damaged Check the chain wheel as following 1 Over wearing gear teeth 2 Breaking off or damaged gear teeth 3 Fix nuts with loose gear teeth Lubrication of drive chain Use drive chain grease first buy drive chain grease or engi joint to make grease through link plate melt lining and rollin Attention Don t install new chain on the damaged chain wheel or install chain wheel should be in good condition or the changed chain a Chain wheel Driving chains 25 Clearance of Front Rear Brake Front brake clearance Measure the clearance of front brake at the tip of front bra
53. e whether the clearance is too small 16 4 3 6 Fault phenomenon instable idle speed with deceleration flameout a Check the valve clearance b Check whether the idle bypass holes and throttle body are too dirty 16 4 3 7 Fault phenomenon inability to accelerate a Whether the parameters are normal during Idle and high idle b Check the fuel tank fuel filter 1150 c Check whether the exhaust system is blocked for example whether the three way catalytic converter is blocked due to burning oil or broken d Check oil pressure and nozzle e Check whether the fault lights are normal or whether it is because only one cylinder can make normal ignition 16 4 3 8 Fault phenomenon slight fire phenomenon Check whether the spark plug clearance is in line with the specification 0 7 I mm 16 4 3 9 Fault phenomenon fault lights on but code and fault do not match Maybe the system ground wire connection is not solid and reconnects the ground wire reconnect it in 3 minutes after disconnecting the battery power leads and start the engine 16 4 3 10 Fault phenomenon abnormal high fuel consumption a Check whether the oxygen sensors of both cylinders are installed in place if in loose state the oxygen sensor makes wrong judgment that there is oil combustion in the cylinder resulting in abnormally high fuel consumption b Observe the oxygen sensor readings in running of the engine after the engine mechanical parts an
54. e filter Check of degradation and damage of fuel pipe If there is any degradation damage or fuel leakage new products should replace the old ones Warning Check Adjustment of accelerator stay Check the smoothness of accelerator stay wire Check the play of accelerator stay wire Free stroke 2 6mm i Fixed nut Side of the restrictor is the main parts which should be adjusted aie Adjusting nut Loosen the hold down nut and rotate to adjust nuts Air filter Change of air filter Disassemble seat cushion Disassemble backplate of the right fuel tank Disassemble right knee board 19 Disassemble backplate of the left fuel tank Disassemble left knee board Disassemble gusset plate of right and left fuel tank backplate Disassemble air filter cover fix bolts take down the cover Disassemble bolts take down air filter Disassemble filter sponge from air filter Check whether the filter sponge is polluted or damaged If there is pollution or damage please replace a new one If there is pollution please replace and wash 20 How to wash the filter sponge a Wash it in the clean washing oil b Make it fully dry c Soak it in the clean gear oil until soaking well d Squeeze out the extra oil in sponge Replacing Time If driving under dusty condition or in rainy days frequently replace the air cleaner earlier Attention e When installing air filter cover please ma
55. e intake air into the engine combustion chamber It is not the repairable parts 16 2 6 1 Appearance of intake air pressure sensor 141 16 2 7 Oxygen sensor 16 2 7 1 Working principle of oxygen sensor The sensor can be used to detect the amount of oxygen in the exhaust gas in the engine exhaust pipe for the ECU internal fuel closed loop control so that the combustion of engine has always been maintained at the most reasonable proportion of air and petrol 16 2 7 2 Appearance of oxygen sensor 142 16 2 8 Ignition coil 16 2 8 1 Working principle of ignition coil Ignition coil can provide energy to the spark plug and it is the high voltage that connects the ignition coil and spark plug 16 2 8 2 Appearance of ignition coil 143 16 2 9 Idling stepper engine 16 2 9 1 Working principle of idling stepper engine Function of idling control valve is to control the circulation area of the airway next to the throttle body to regulate the amount of air entering the engine to achieve the engine idling control 16 2 9 1 Appearance of idling stepper engine 144 16 2 10 Fuel pump 16 2 10 1 Working principle of fuel pump The electric oil pumps and pressure regulator works together to provide 250Kp gas pressure to the engine installed at the bottom of the fuel tank 16 2 10 2 Appearance of fuel pump 16 2 10 3 Fuel pumps fault diagnosis 1 After the key is tur
56. e net erter 94 XI Cylinder Head eee eee eee eee eee ee ee ee eee eee eee ee 07 11 1 Preparatory Bro TE NE TT EE 97 11 2 Fault Diagnosis EE NE EEN ESEE A TEA EEEE E ETE OEE 98 11 3 Cylinder RR ER ET 98 XII Cylinder Block and Piston s 0ss0vennennnnanenanannanenenanenannnnnenennener 107 12 1 Preparatory BT TT 2107 2 12 2 Fault Diagnosis NNN 108 125 Cylinder ET ET EE 108 XIIL Crankcase 00s00r0nrennnnnnnennennnnnnennnennnnnnennnennnenneennennnnnnennrennnene a ie a 13 Preparatory BO eo TE TT ee eee er 13 2 Fault Diagnosis SETE EE OE E EENS ESEE etl cm ta ere Ax keen NE TE TE 115 keen ENE TT rd ee ree T 116 125 Gearshift mechanism r n ea an ae EE aE EE EAE EEE EEA 121 13 6 Crankcase connecting Frode SSN 199 13 7 Variable speed EE ET RE SE ER 125 Exhaust System Inspection and Maintenance sssstrrreennnnennannennanennnneer 12g XV Emission Control System bss ied eaaa N EGNE EG NA Ea 129 15 1 Emission Control System Er NT 129 15 2 Regular maintenance guidelines NL 129 15 3 Emission Control System Mechanical Functions ttttttttttenenrrrrrrrrrrerenr 130 15 4 Catalyst conversion SYSten gt gt ttttttete rer ee raneren raneren rar a raven ra ra ren rann rene nn afola 15 5 Solutions to Idle Exhaust Exceeding Specified Value tt tt tttrrrrrrrrrrrrrrrrrrr 132 Inspection and Maintenance of EFI System FEET ETT SES E A EEE E E Aw Owe z 133 E
57. e of components High Temperature Burn Tips Do not be burned by engine exhaust pipe silencer and other components with high temperature When operating together with others you d better look after each other and keep a way for safety Maintenance Rules While repairing and servicing use tools of metric system as possible Incorrect tools may damage the motorcycle Before taking down or opening protecting plate for repair work please clean the dirt on the external surfaces of components or combination parts and prevent the dirt from falling into engine chassis or braking system After disassembly and before measuring friction please clean the components and blow them with compressed air Incorrect Incorrect Incorrect operation or advanced damage will be caused a FI I p g 4 O a _ Bending or Warping are forbidden in operation otherwise tough Plastic parts may age and deteriorate which are apt to be damaged by solvent or oil Check before re installation and replace if necessary To loose component with many assembling units it shall start from external to internal and loosen smaller assemblies first The complicated assemblies such as transmission case shall be put in proper assembling order for easy assembly in the future Pay special attention to the key fitting position before disassembly The components that are not used any more shall be replaced on time before disassembly Lengt
58. e of ignition coil a shunt is connected between the terminal black white of primary coil and the grounding vehicle block Press starting motor button or kick starting pedal to measure primary peak voltage of ignition coil Min voltage over 95V Attention Please do not touch the metal parts of testing probe with your fingers while measuring the voltage or you will be shocked Please take care 6 3 2 Charging coil 73 Attention Install spark plug on the head of cylinder Check in the condition of normal compression pressure Disassemble 4P 2P joints of CDI group Connect high pressure shunt between 2P red white side and 4P black side Button start motor or step on actuating lever to measure the maximum voltage of charging coil Connection method connect red white with negative pole and black with black pole Minimum voltage more than 95V Attention Fingers can not touch metal part of test S SS NSS SS AS EANN AW SSN stick when measuring voltage Special attention should be taken when electric NO Ke IN Black ISS 3 NQ lt 5 shock may happen X When the maximum voltage of CDI group terminal is abnormal disassemble alternator joints Connect shunt with charging coil red white eWhen voltage is abnormal in CDI group while normal in
59. ear or damage of block rubber damage of spring Check damage or abrasive wear of other parts Replace shock absorber if necessary 4 4 3 Install Rear Shock Absorber Install the rear shock absorber in the reverse order of removal Install upper locknut and lower mounting bolt on the rear shock absorber Tighten them to specified torque Torsion force Upper hold down nut 37 44N m Bottom hold down nut 37 44N m hf 4 5 Rear Swing Arm 4 5 1 Remove Rear Swing Arm Disassemble chain guard board Disassemble chain tension wheel and rear axle Disassemble rear wheel and rear shock absorber Disassemble rear swing arm installment axle Take down rear swing arm weld assembly 4 5 2 Rear Swing Arm Inspection Check rear swing arm installation shaft Rotate the shaft on a flat surface or measure it with a dial gauge If it is bent replace it Attention Don t attempt to straighten bent shaft Wash in solvent the components for rear swing arm installation shaft Check sleeve assembly and intermediate sleeve of rear swing arm If they are damaged replace them 58 4 6 Drive Chain 4 6 1 Disassembly Lay motorcycle on the flat ground and fasten Disassemble shift lever swing arm left rear cover and drive chain Disassemble rear wheel chain shield and drive chain 4 5 2 Inspection Wash drive chain and put it into kerosene Brush dust and then take it out from kerosene and dry it out Check ra
60. egulations of emission standard of air pollutants Due to different situations the users are in we make the following regular inspection table relating to exhaust emission To ensure normal gas exhaust please inspect adjust or repair your enginecycle in the specified time intervals If you have any other individual problem please contact or call your local dealer or service center of Qianjiang Enginecycle Co Ltd AE Relevant emission specifications Emission Specifications HC NOx lt 1 0g km lt 1 2g km X The latest version shall prevail when emission standard is updated The enginecycle that does not perform regular inspection in local dealer or service center of the company may be prohibited to use The company will not be responsible for that Please have your enginecycle inspected whenever necessary to keep it in best condition Note You shall clean more frequently the air cleaner to extend service life of the engine when your enginecycle is often used on sand gravel roads or in severely polluted environment 2 More frequent services may be required when the enginecycle is often driven at high speed or travels a long distance Pay attention to the followings to ensure standard emission 1 gt Please use only 92 or 95 unleaded gasoline 2 gt Please use only specified type of engine oil 3 gt Please service your enginecycle according to your periodical maintenance table 4 gt Emission control system is forbidd
61. el upward Attention Piston shall not be scratched and piston ring shall not be broken When the piston ring is installed it can rotate freely in the piston ring groove Scrape the washer attached to the crankcase Attention No foreign matters can be dropped into the crankcase Install piston piston pin and piston pin retainer Attention The larger side of the groove at the piston head should be installed towards the intake valve Install Cylinder Install washer and location pin onto the crankcase Connecting rod small end ID care ier a Top ring Second Oil ring Apply evenly engine oil on inner wall of cylinder piston and piston ring Install carefully the piston ring into the cylinder Attention Do not hurt piston ring MD XIII Crankcase Preparatory data 13 1 Fault diagnosis 13 2 Crankcase 13 3 Clutch 13 4 Gearshift mechanism 13 5 Bent axle connecting rod assembly 13 6 Variable speed chamber 13 7 13 1 Preparatory Data Function of crankcase Crankcase is the force bearing part of engine It is mainly used to support crankshaft clutch transmission cylinder block and cylinder head It bears impact from combustion and inertia force from movement of crankshaft connecting rod and forms a partial enclosed space for air and oil Suspension hole is set on the crankcase which can be connected with the suspension hole in the vehicle block so that the e
62. en to be adjusted or replaced including spark plug use idle speed adjustment ignition timing carburetor adjustment etc 5 gt Attentions Improper ignition system charging system or fuel system will have great effect on muffler so please go to your local dealers or service center of the company for inspection adjustment or maintenance when you encounter it Please use only 92 or 95 unleaded gasoline or the muffler device two stroke system may be injured 6 gt Emission control system of the enginecycle meets national standard If you have to replace any component of the system please use the spare parts made by Qianjiang Enginecycle Co Ltd and ask your local dealer or service center to replace it for you 15 3 Emission Control System Mechanical Functions General introduction The emission control system is based on two stroke single cylinder engine and throttle valve It uses air intake device and keep excellent exhaust gas level Activated carbon canister is used for vaporized waste gas process X Engine improved Improvement in the central spark plug with compression ratio combustor duration of ignition and ventilation system is for a commonly accepted intake and exhaust efficient which is also for improvement in combustion efficiency X Air intake device Guide air into exhaust pipe and CO and HC of incomplete combustion will be reacted into harmless gas Classification Equipment Constituted Part Desired Function
63. es of commutator Inspect for continuity of starting motor housing Confirm the continuity between conducting terminal and starting motor housing Inspect continuity between conducting terminal and brush Replace it with a new one if abnormality exits Inspect carbon brush holder for continuity If there is continuity replace it Measure carbon brush length Service limit replace it when it is shorter than 8 5mm Check rotation smoothness of the needle bearing in the front cover and whether it is loosened when it is pressed in If there is abnormality replace it with a new one Check the oil seal for wear and injury 7 3 4 Assembly Apply lubricating grease on the oil seal in the front cover Install brush onto the carbon brush holder Apply lubricating grease on movable parts at both ends of brush shaft Press brush into its holder and install front cover of electrodes Attention e There should be no hurt on the contact surface of brush and armature Take care Installation shaft of armature cannot hurt lip of oil seal Take care Install the new seat cushion ring on the front cover Align and install the boss of motor housing to the recess of front cover Tighten housing screws Attention When assembling housing and front cover armature can work as a magnet to easily pull the front cover up and then gently press it down to complete the assembly 7 3 5 Installation Install lead wire of starting
64. groove of sliding gear are worn resulting a greater axial force in the gear while working Gearshift hub and shifting fork are worn Abnormal sound in the crankcase There are parts scattered or broken inside the crankcase Engine stalling Clutch is stuck Shifting difficulty Separation between the clutches is not complete Poor returning spring of the clutch Locked grove of the gearshift hub worn 114 13 3 Crankcase Disassemble the left cover of the crankcase Starting engine Release the fastening bolts of the starting engine to remove the starting engine Release the fastening bolts of the left cover to remove the left cover Bolt Electric idle gear Release the locking nuts of the flywheel using electric or pneumatic tools Allocate the flywheel assembly including the star wheel to remove the electric idle gear Remove the gasket Flywheel assembly HE Disassemble the right cover of the crankcase Starting engine Loosen the fastening bolts to remove the right cover of the crankcase gasket and locating pin Bolt Right COVE 13 4 Clutch Removal Socket spanner Loosen the five bolts of the pressure plate according to the diagonal cross mode Remove the clutch springs spring washers pressure plate bearing washer surface needle roller bearing and bearing pedestal clutch separation shaft sleeve and so Universal fixer Ne N mf Use a special tool to sc
65. h of bolts and screws are different for assembly components and protecting plates They shall be installed at correct positions If confused just put the bolt in the hole and see if it matches Fill lubricating grease into the groove during oil seal installation Check if the oil seal is smooth and if there is any damage to it Installation of rubber hose fuel vacuum or coolant insert its end into bottom of connector so that there is enough room for the hose clamp to grip the connector Install the rubber or plastic dust cover back to its originally designed position Groove gt Clamp _ Connecto r Disassembly of ball bearing use a tool to push against one or two internal and external bearing races If the force works only on one bearing race whatever internal or external it may be damaged when the bearing is disassembled in which case 1t must be replaced Bearings may be broken If operated inthe above methods as shown Specifications QJ125GY 16A Overall Length mm 2030 Overall Width mm 845 Overall height mm 1120 Wheelbase mm 1385 Front axle 63kg Engine type QJI60MI A 924 or 95 unleaded Mee gasoline Number of cylinders amp 60 mm 44 mm Bore stroke Displacement 124 4 Starting mode Electric Cooling mode Water cooled Vehicle Weight kg axle 76kg Total Force feed and splash lubrication re X z 139kg Lubricating mode Front E
66. heel shaft bent Distorted and crooked front wheel tyre 3 2 3 Wobbly Front Wheel Distorted wheel rim Worn front wheel bearing Defective front tyre Unbalance of tyre or wheel 3 2 4 Difficult Rotation of Wheel Breakdown of front wheel bearing Braking breakdown of brake Breakdown of wheel and axle Bending of front wheel 3 2 5 Noisy Front Shock Absorber 3 2 6 Operated to one side only or walking not in straight line Lack of liquid in shock absorber Friction sound of shock absorber protecting plate Loosened bolts on the shock absorber unbalance of both crosses adjustment bending of shock absorber bending of wheels inaccuracy of wheels installment bending of car frame illness of axle illness of swing arm central shaft units 3 2 7 Front shock absorber is soft lack of liquid in shock absorber insecure of spring in shock absorber tyre pressure is too low 3 2 8 Front shock absorber is hard inadequacy of liquid weight block of shock absorber liquid pipe 46 3 3 Front wheel 3 3 1 Disassembly Support the bottom of body to float front wheel Disassemble bolt and take down front splash guard and odometer guide line Disassemble front brake hose Disassemble front axle jam nut Disassemble front axle Disassemble front wheel Disassemble oil seal with oil seal stripping attachment and bearing with bearing stripping attachment Note dismounting picture is on page 41 of this manual
67. ice board and forming a conical mist sprayed into the intake valve When the injector is in outage electromagnetic coil s electromagnetic force disappears and the ball valve of the injector closes automatically under the action of return spring to make fuel injection action of the injector stop 16 2 2 2 Appearance of oil injector JG gt 16 2 2 2 Note for use of injector 1 Inside the injector there is a filter but it is not a serviceable part because it is only designed to filter out the accumulated impurities between the fuel filter and injector of the oil line The impurities can cause injection bonding flow offset and leakage and other faults so the fuel filter is very important 2 Only the injector of the same parts number can be replaced 16 2 3 Throttle body 16 2 3 1 Working principle of throttle body Throttle body is mainly made up of principle cast body return spring throttle cable throttle body position sensor and idle speed adjustment screw and throttle body position sensor is to provide throttle opening to the ECU idle adjustment screw to control the idle speed and stability Clockwise reduces the bypass gas and reduces the idle speed while counterclockwise increases the bypass gas and increases the idle speed in general it requires about two laps 16 2 3 2 Appearance of throttle body 136 16 2 3 3 Clearing of throttle body Use throttle cleaner to clean the throttle body spray the cle
68. ition sensor or the signal end pins shorted to battery negative P0123 P0131 P0132 P0031 P0032 P0201 P0202 P0230 P0232 P0336 P0337 P0351 P0352 P0562 P0563 P0560 P1693 P1694 P0137 P0138 P0038 P0037 Throttle position sensor signal end pins shorted to battery positive Front cylinder oxygen sensor signal end pins shorted to battery negative Front cylinder oxygen sensor signal end pins shorted to battery positive Front cylinder oxygen sensor heating end pins shorted to battery negative Front cylinder oxygen sensor heating end pins shorted to battery positive Front cylinder injector fault Back cylinder injector fault such as fuel injector plug is not plugged in Pump open or short circuit to the battery negative Pump short circuit to battery positive Crankshaft position sensor interference Crankshaft position sensor without signals Front cylinder ignition coil fault Back cylinder ignition coil fault EFI system voltage is too low EFI system voltage too high Fault for fault lamp bad filament or plug in board is not plugged in Tachometer line short circuit to the battery negative Tachometer line short circuit to the battery positive Back cylinder oxygen sensor signal end pin shorted to the battery negative Back cylinder oxygen sensor signal end pin shorted to the battery positive Back cylinder oxygen sensor heating end pins shorted to battery positive Back cylinder oxygen sensor heating end pins shorted to battery neg
69. ke handle Clearance 10 20mm Please adjust free travel of front brake handle in the following way 1 Loose mandrill to lock nut1 2 Twist in or out the mandril2 to adjust free travel of front brake handle after adjusting free travel to 10 20mm 3 Install mandrill tight and lock nut1 JG Rear brake clearance Measure the clearance of rear brake at the tip of front brake hanc Clearance 10 20mm Please adjust free travel of back brake footstep in the following way 1 Loose mandrill to lock nut1 2 Twist in or out the mandril2 to adjust free travel of front brake handle after adjusting free travel to 10 20mm 3 Install mandrill tight and lock nut1 Ta Front back brake shoe s abrasive wear Front brake shoe s abrasive wear When braking exactly check oil level from oil immersion _ Oil pump lens If liquid level of brake fluid is below the arrow position in the right picture brake shoe should be replaced immediately by a new one Oil immersion lens Back brake shoe s abrasive wear When braking exactly look oil cup to check oil level of brake fluid If the level is below MIN brake shoe should be replaced as soon as possible Headlight Adjustment Optical axis adjustment of headlight is loosening headlight spinning adjusting bolt and then rotating S R Clutch Start engine and increase rotation speed gradually to check running condition of clutch If motorcy
70. ke sure that it is finished well Spark plug Pull out head of spark plug Disassemble spark plug with spark plug sleeve vA Check the burning pollution and carbon deposit of spark plug If the conditions above happen please clear with spark plug scavenger or steel brush Clearance inspection of spark plug Gap 0 7 0 8mm Spark plug type CR8E NGK Spark plug gap Attention When installing spark plug you d better install with hands and then use spark plug sleeve to tighten Storage battery Disassembly of storage battery Open seat cushion Disassemble gusset plate of right and left fuel tank backplate Disassemble air filter cover Disassemble negative wire first and then the positive one Take out storage battery Warning Storage battery During positive lead wire disconnection be sure to prevent the tools being used from touching the frame or it will result in short circuit sparks which may ignite gasoline and damage battery It is dangerous Install the battery in reverse order of removal Warning To avoid short circuit please connect positive lead wire first then the negative lead wire Check of the charging state closed circuit voltage Open seat cushion Open roof cover of air filter disassemble joint wire of storage battery Measure the battery voltage using a voltmeter Fully charged 13 1V Undercharge 12 3V Attention 99 2
71. ls Clutch drive gear Remove the nuts of the countershaft to remove the sprockets and bushings ZL Loosen the mould assembling bolt Separate the crankcase Attention There should be no damage on joint case surface Remove the left case Chain gear a PD SP 13 6 Crankcase connecting rod combination Disassemble Remove the trunnion shaft combination and crankcase connecting rod combination from the right crankcase Attention There should be no damage on joint case surface Trunnion shaft combination Crankcase connecting rod combination Inspection Measure the clearance between the big ends of Plug gauge connecting rod Allowable limit 0 5 mm a L Measure the clearance in the X Y direction of the big ends of connecting rod Allowable limit 0 008 0 018mm Position for measurement in the big ends of connecting rod Testing point Measure the jumping of the crankshaft Allowable limit 0 03 mm Check whether there is abnormal sound or loose for the revolution of the crankshaft bearing If any replace the crankshaft assembly Crankshaft On Set aside the shifting fork shaft Remove the gearshift drum Remove the gearshuft fork Shifting fork Shifting fork shaft Gearshift drum Inspection Measure the outer diameter of the shifting fork shaft Allowable limit 9 96mm Measure the
72. lthy coil Connector contact undesirable Wiring white line disconnected Charging bad charging EEE EE EEE I Start the engine the voltage regulator socket red line connects with electric 1 meter by three anode and ed body in I I electricity Voltage EEE EEE TEEN higher than voltage normal EE Check whether the voltage regulator wiring contact undesirable Joint contact undesirable wiring The voltage regulator grounding is poor monomer test impedance Unhealthy storage battery The voltage regulator is poor ae be ae Spark plug without flashover Fault Diagnosis Adjustment Check Fault Cause PETERS TEN ENR ee E 1 p Replace new spark pe plugs to check The spark plug Hot spark jump weak or no fire jump Spark plug the bad Check the spark plug check again Spark plug cover relaxation Check whether the plug CDI group flabby Plug contact undesirable Examination of each terminal wire plug CDI between conduction resistance value measurement The Lord switch bad Charging coil bad Trigger bad Ignition coil badly Related parts inspection The Lord wiring broken Joint socket contact undesirable Use the check CDI group CDI test Unhealthy CDI group Use the test CDI 1 ignition coil check Ab l Unhealthy ignition coil 14 Inspection Adjustment Preparatory data Front Rear brake free stroke Periodic maintenance schedule Front Rear brake shoe s abrasion
73. ming regular inspection adjustment or maintenance at local dealer or service center of the company or unable to provide evidence of maintenance record 3 gt Overloading or improper use 4 gt Remounting the enginecycle removing original spare parts or install extra devices on to the vehicle at will 5 gt Using the enginecycle as a racing vehicle or driving on the roads not suitable for it 6 gt Damages because of typhoon flood or other natural disasters or injuries or trouble caused by gross negligence traffic accident or subject to impact by external objects 7 gt Stopping use for a long time without regular maintenance 8 gt Odometer is damaged and no prompt repair or the odometer 1s artificially altered stopped or replaced 9 gt Please come to the inspection station every three months for regular exhaust gas inspection The new enginecycle delivered by the company has passed noise inspection and is up to EC 97 24 9 and 2003 77 EC 15 2 Regular maintenance guidelines To reduce environment pollution it is required by the country that all the engine vehicles manufactured by each company shall meet the regulations of emission standard of air pollutants Besides the production process is up to the regulations of emission standard of air pollutants the company is also devoted to purifying air and reducing air pollution Strict inspection is performed on the enginecycle delivered from the company all the specifications can meet the r
74. motor and be sure to install the dust seal Then install starting dynamo Install rear brake wire clip 80 7 4 Starting Relay 7 4 1 Actuation Inspection Take down the protecting plate of vehicle block When the ignition switch is set at ON position press starting motor and a Click sound can be heard Click sound indicates normal No sound Check starting relay voltage e Check starting relay ground wire loop Inspect starting relay actuation 7 4 2 Starting relay voltage inspection Lift and support the main stand Measure the voltage between negative pole green yellow of starting relay connector and vehicle ground wire Set ignition switch at ON position and catch the brake lever Battery voltage shall meet the specified When there is no voltage at wire terminal of starting relay inspect braking switch continuity and lead wire 7 4 3 Starting relay ground loop inspection Remove starting relay connector Inspect continuity between grey wire of connector terminal and vehicle ground wire When the starting button is pressed continuity between grey wire of connector and vehicle ground wire shall be fine If there is no continuity inspect starting button continuity and lead wire
75. mp Disassemble sheet glass of headlamp Fix headlamp and rotate socket in clockwise to disassemble bulb 8 3 2 Installment Install bulb back in the verse order of disassemble 83 8 4 Front Turn Signal Lamp Bulb Replacement 8 4 1 Removal Loosen turn signal lamp fixed bolt Take down bulb from bulb socket 8 4 2 Installation Left right turn signal lamps Install bulb back in the verse order of disassemble 8 5 1 Disassembly Disassemble bolt and taillight shade Disassemble bulb from socket 8 5 2 Installment Install bulb back in the verse order of disassemble 8 5 3 Rear turn signal lamp replacement 8 5 3 1 Disassembly Disassemble bolt and taillight shade Disassemble bulb from socket 8 5 3 2 Installment Install bulb back in the verse order of disassemble 84 8 6 Instrument Remove rear mirror Take down the handle hood and pull out waterproof connector Remove the bolts Remove meter housing Remove the instrument Install the instrument orderly in the reverse order of removal 8 7 Main Switch 8 7 1 Inspection Disassemble front guard board Disassemble master switch guide line joint Break over test of joint side Wiring Diagram 8 7 2 Master switch replacement Disassemble body front guard board Disassemble fixed bolt and take down master switch fixed seat Disassemble fixed bolt and replace master switch 85 8 8 Horn Inspection Dis
76. nched by use of carts If it must rely on carts to starting the engine carts can also not be used until the temperature of the engine and the catalytic converter is lowered 6 gt Do not use gear up and way of shut down in going downhill 7 gt Do not drive the vehicle of bad ignition 8 gt when in maintenance of engine ignition do not disassemble the spark plug Start the engine and use the method to check if there is any sparks If necessary however a long time of spark plug removal is not allowed lol 15 5 Solutions to Idle Exhaust Exceeding Specified Value Qualified Qualified Qualified Qualified For Delivery Qualified Qualified Perform regular inspection Repair and maintenance plan Measure Idle exhaust Note 1 Adjust carburetor Note 2 Unpick and wash fuel injector Replace fuel injector Disassemble and repair engine e Valve Leak Qualified e Piston Worn e Combustion chamber clean Attention 1 Make the measurement with idling testing procedure 2 Adjust the engine idle speed within the provisions and measure the idle speed CO HC ap ae Inspection and Maintenance of EFI System QJ125GY 16A EFI circuit diagram MPRA ramper Twisted Cable Pal 25xv sHi Vg 23X ka sems H SOC somme TARGET WHEEL GOLAICGYLEN hgr ton Col wethout GET FF eng at Spars Flog Fuel 7 5 1 1 i Fump en FFRS Clr MPR p A injeciom MASFOLT PREZ
77. ned on the pump will operate for about 3 seconds or so if you can hear the pump running please go directly to 4 2 Disconnect the pump connector detect whether the supply voltage of the pump is about 12V 3 If there is no problem for step 2 make external connection to battery to provide 12V DC to test whether the pump 1s operating well 4 If the pump is operating normally use petrol pressure gauge to test the tubing pressure of the front end of engine is about 250Kpa during idling of engine 5 If the line pressure is lower than 220Kpa check if there is leakage for the oil pipeline if oil pump is inverted or if there is blockage for filter 16 2 10 4 Common problems for fuel pump 1 The fuel pump assembly plug is reversed resulting in the reversal of the fuel pump so it cannot provide sufficient fuel pressure to the engine causing the engine does not work 2 Pump cannot rotate because of damage 16 2 10 5 Notes for use of fuel pump 1 There is no petrol in the fuel tank for the new enginecycle at the beginning and there is much air in the fuel oil pipeline after the petrol is filled so it needs to move the engine for a lot to let the air out completely and the engine can work properly this is normal being unable to start for a long time will not appear in the following Start up 2 Because petrol can cool the fuel pump do not let the pump work with little oil or no oil otherwise it will burn the fuel pump 16 3 Tr
78. ng system before driving your motorcycle 1 1 1 Specifications Available project Standard value Available limits project Standard value limits Dedicated brake DOT4 Dedicated brake DOT4 i fluid fluid hickness of liquid hickness of liquid thickness of brake Ga en thickness of brake omm EE shoe shoe diameter of liquid diameter of liquid brake block pe nm brake block scala i Jump of liquid Jump of liquid front brake block Oom back brake block oe Inner diameter of Inner diameter of mercury oil 12 70 mm mercury oil Q147 mm cylinder cylinder Outer diameter of 12 72 mm Outer diameter of D14 mm mercury oil piston il mercury oil piston Inner diameter 25 mm Inner diameter D30 mm caliper cylinder caliper cylinder Outer diameter of D252 mm Outer diameter of D25 mm caliper piston caliper piston 1 1 2 Torsion force Former brake disc retaining bolt 5 10N m 34 Under the brake fluid before pump installation bolt 22 34N m Liquid brake oil pump before installation bolt 5 10N m Front wheel spindle 100 113N m Front wheel head bolt 5 10N m The brake disc retaining bolt 5 10N m Liquid brake pump installation after the bolt 22 34N m Back oil pump installing bolts liquid brake 5 10N m Back wheel spindle 100 113N m 1 2 Fault diagnosis 1 2 1 Brake in ill performing services amp Brake without adjustment well Abrasive wear of brake shoe units and liquid brake plate Improper installment of brake shoe units
79. ngine can be linked together with frame and other parts Precautions on Operation Crankcase is a thin wall casting part Avoid impact on it during operation in case it may be distorted or broken Clean carefully all the components before inspection and test and purge them with high pressure gas Drain the lubricating oil from crankcase before working on it ap oa Table of standard values of baseline projects and allowable limit Unit mm Clearance between the left and the right of the big end of the 0 1 0 35 0 5 connecting rod Connecting rod big end radial 0 008 0 018 clearance mp pr 008 Bent axle Jump connecting rod assembly clutch Thickness oy eten pile 2 8 2 9 Length of pressure spring 30 4 31 6 Thickness of surface needle roller 1 88 2 GE Outer diameter of shifting fork axis 9 98 9 995 006 Diameter of bore of shifting fork 10 10 018 10 05 Gearshift Thickness of shifting fork 4 8 4 9 mechanism Outer diameter of gearshift hub 41 8 42 41 75 Width of gearshift hub locked 5 45 555 groove 13 2 Fault Diagnosis Low compression pressure Crankcase air leakage Engine overheat Clutch clipping Poor lubrication Failure in gear Gear shift fork broken or deformation Shifting fork guide pin broken Wheel gear convex claw worn Auto off gear The joint claw is worn with the edge into a fillet Force of return spring of the speed shifting mechanism is weakened The spline tooth of spline shaft and the spline
80. nth months months months months mwe Sn Engine oil replacement Once every 1000KM Common tool Tyre pressure Tyre pressure gauge air inflator Densimeter Actuating clearance l l I I Common tool inspection Shock absorber actuating inspection Inspection of looseness of bolts at all positions Inspection of steering I Common tool handle bar looseness Check if gearbox leaks Common tool oil Spark plug inspection gin C ECE Lubrication of all the Lubricant places on the vehicle TT injector mme fr fr fr fi fi fr mme een fr fr fr fr fr fr mener je Resin gt Aa Jr Aa JA A A tachometer eertain Aa 1 A A A A come Throttle inspection ee ee a Fuel hose inspection Light instrument and Visual multimeter electric apparatus 317 Expected Inspection Ignition system perform maintenance inspection on obvious and continuous ignition malfunctions engine on fire overheated back burning and others Carbon deposit removal obvious underpowered get rid of carbon deposit at cylinder head piston head and air exhaust system Piston and cylinder when cylinder is over worn or stuck please replace it Please go to your local Qianjiang Motorcycle dealer periodically for inspection and adjustment to keep your vehicle in best conditions In above table monthly 1000km travel is employed as reference I Inspect A Adjust R Replace C Clean L Lub
81. oe brake plate and then write down the maximum number Measure the thickness of brake shoe Use limits brake shoe 4 5mm Specification Diameter of front liquid brake plate p280mm Attention e Wipe brake plate with 120abrasive paper if it rusts e Micrometer is the only choice for measurement If the thickness of brake plate and brake shoe are less than maintenance value or polluted by grease please replace them Attention e Micrometer and vernier caliper are the only choices for measurement 1 4 3 Installment Install front wheel Install front liquid brake oil pipe and brake cylinder units Do not get grease on brake shoe Attention If there is grease on brake shoe brake ability will reduce and cause brake failure Fasten bolts to the setting torsion force Torsion force Former brake disc retaining bolt 5 10N m Under the brake fluid before pump installation bolt 22 34N m Liquid brake oil pump before installation bolt 5 10N m 39 Front wheel spindle 100 113N m Front wheel head bolt 5 10N m No oil stain shall be on brake shoe and brake disk If any use brake cleaner fluid Attention Oil stain on brake shoe will eliminate braking performance 40 Body outer panels D Eh eae al I Front and right turn light 2 Front and left turn light 3 Front night light fixed position 4 Pod 5 Right mounting plate of pod 6 Left mounting plate of pod 7 Headlight 8 Instrument assembl
82. oil tube 8 Brake house units 9 Oil pump units 0 Handle QD Thin nut M6 2 Handle screw 3 Fixed cover 4 Bolt M6 25 5 Brake switch units Countersunk flat Phillips heads for exposed screws M4 12 Mandrill Self locking nut M6 ar Back liquid brake block Thickness of brake shoe 7 0mm Use limits 3 7mm Torsion force to Install Bolt 3 5 10N m Torsion force to Install Bolt 4 5 10 N m Torsion force to Install Bolt 7 30 35 N m Torsion force to Install Bolt 12 22 34N m Torsion force to Install Bolt 23 30 35 N m Rear liquid brake block units Gasket 6 Inner hexagon screw M6 16 Inner hexagon screw M6 16 Gasket6 Oil pump assembly Brake switch assembly Seal ring LiningI Lining H Connecting plate Inner hexagon screw M8 20 Gasket 8 Brake cylinder B Friction plate units Nut M6 Draw bar Draw handle Brake hose unit Oil tube 21 Hoop 22 Oil cup units 23 Hexagon flange head tapping screw 24 Protecting spring ae ae I Braking System Maintenance instruction 1 1 Fault diagnosis 1 2 Front hydraulic disc brake 1 3 Rear drum brake 1 4 1 1 Maintenance Instruction Precautions on operation Attention e Please do not contaminate braking assembly with oil while assembly or disassembly e Please use specified detergent to clean the braking assembly or it may reduce braking performance Please check braki
83. ools T Accessory for voltmeter with maximum range Multimeter 6 2 Fault Diagnosis Spark plug not sparking Symptom Possible causes Determine the cause from I in sequence Inner impedance is too small Use appointed tester to test Crankshaft rpm is too low RA Tester is disturbed it is normal when more than one time s measured Ignition coil When the high voltage power is too voltage is above the basic low o o o Wiring of ignition system is poorly contacted Ignition coil is no good Charging coil is bad Peak voltage measurement Tester is wrongly connected Poor ignition switch Connector of CDI assembly is poorly contacted l Ground wire for CDI assembly is shorted or poorly contacted While no high voltage power supply Poor charging coil Peak voltage measurement Secondary high voltage power is sporadic l l Defective trigger Peak voltage measurement side voltage pe Connector of high voltage wire is not good Inferior CDI assembly after items are tested and proved abnormal or spark plug no sparking High voltage power is normal spark Inferior spark plug or secondary leakage of the ignition coil plug no sparking Bad ignition coil Inner impedance is too small Use appointed tester to test Crankshaft rpm is too low No high voltage power supply Tester is disturbed it is normal when more than one time s measured Charging coil voltage is above the basic Charging coil is bad
84. orcycle Connect voltmeter between terminals of the battery Remove the main fuse and connect ammeter between the two terminals Start engine and slowly raise RPM Measure limited voltage and current Limited voltage rpm 14 15V 5 000rpm If limited voltage is beyond the specified range check voltage regulator Inspect limited voltage in lighting system Attention 65 Set multimeter to position of AC voltage Limited voltage 13 1 0 5V 5 000rpm If limited voltage is beyond the specified range check voltage cuttent regulator 5 5 Voltage current Regulator 1 5 1 Loop inspection on main wiring terminals Disconnect the 6P plug on the voltage current regulator Check continuity between main wiring terminals in the following way Battery red and ground of vehicle It is battery voltage block Output fie ae ss Black Line AC In Ground wire black DN To ee and ground of vehicle There is a lead wire Inspection block NER p Charging coil white HH A ACI No power flowing between EN ce and ground of vehicle Qutput TT magneto coil and ground Red yt YU LU block S Between charging l There is resistance between coils while 1 and white 2 coils 5 5 2 Voltage current regulator inspection When main wiring terminal is normal
85. ortened 3 When the battery is not be used for a long period it will self discharge and its capacitance will drop The battery should be recharged every three months 4 Charging system inspection please perform inspection in the sequence listed in the fault diagnosis table 5 If there is current going through the electric part please do not remove the connector or the voltage will be very high and electronic components inside the voltage adjuster will be damaged Set ignition switch at Off position and then begin your operation 6 It is not necessary to inspect maintenance free dry charged type battery You don t need to add electrolyte and distilled water for it 7 Inspect the entire electric load 8 Quick charging is forbidden except in emergency 9 During quick recharging the battery must be removed from the motorcycle and recharged 10 While battery is exchanged please do not use liquid feeding battery 11 A voltmeter shall be employed to check recharged battery 602 Preparatory Standard Batey 20 Recharging time Standard 10 15hours Quick 30minutes 10038000 Magneto mr Coiling impedance value 20 White white 0 5 10Q regulator Battery recharging voltage 14 5V 0 4V 5 000rpm Tightening torque Tools Rectifier bolt 5 0 N m Universal non adjustable spanner High voltage coil pinch bolt 9 0 N m Flywheel remover Testing device Multimeter 5 2 Fault Diagnosis No power unstable power Battery over
86. ot well Spark plug Spark plug flashover flashover not well well Ignition coil not well Spark plug guide line open circuit or short circuit Master switch not well mm Heat filter not well Negative pressure pipeline damage me Air circulation hole blocked N aIle Rotation unsmooth especially in high speed Fault Diagnosis Adjustment Check Fault Cause Ignition time i ANE adjustment CDI group not well Trigger not well Gasoline is little in gasoline box Gasoline pipe filter block Block of fuel tank evaporation control system pipe Automatic oil ring not well Well Spring breaks with weak elastic force Unhealthy spring A 4192 Unhealthy charging storage battery over discharge or over charge Fault Diagnosis Adjustment Check Fault Cause Measurement on pee ee both ends of the battery voltage I I started the engine Battery life has come Battery voltage Battery voltage up no rise to normal restore the original voltage after flameout Unhealthy storage battery Check the voltage regulator plug is loose I I Normal Abnormal Plug contact undesirable The red lines open circuit wiring Check voltage regulator by the multi purpose socket red line electric meter of anode and connected body in Have voltage No voltage Voltage adjuster Wiring white line disconnected Ac generators coil impedance values determined i I I Normal Abnormal Unhea
87. oubleshooting diagnosis Fault light is located on the dashboard with a FI mark below Under normal circumstances open the key the fault light will be on which means that the EFI system is in power state and can work the fault light are not on which said EFI circuit is out of power supply and will not work and it needs to check the fuse and the battery positive and negative connections After the engine is started the fault light is off which means there is no fault conversely if the engine is started the fault light is still on for long which said the EFI system is not working properly and there is a failure needing to troubleshoot At present there are three ways to detect fault 146 16 3 1 Directly use fault light F1 flashing on the instrument for diagnosis After confirming there is a fault if open and close the key for three times switch three times namely open close open close open the key the fault light will come to a flash code corresponding to the fault And then through the fault code table identify the corresponding fault With fault light reading fault the rules of the flash code are as follows for example if the fault is the intake air pressure sensor is disconnected or the signal side pin shorts to battery negative after the key is opened and closed for three times the fault light will first flicker for 10 times on behalf of 0 flicker for 1 times on behalf of I after an interval of 1 2 seconds
88. over in spark plug Unhealthy spark plug Pollution of spark plug Unhealthy CDI Group Unhealthy trigger Open circuit short circuit of ignition coil There is Weak spark or no flashover in spark is in spark spark plug plug Open circuit or short circuit in ignition coil Unhealthy master switch Unhealthy charge coil Compression pressure test Unhealthy start clutch Compression Compression Unhealthy cylinder plunger or packing ring pressure is pressure is too normal low or none Air leakage of cylinder head gasket Unhealthy automatic choke No Ignition With outbreak outbreak phenomenon phenomenon without start of engine Air in induction manifold Incorrect ignition time Disassemble spark plug to check again Bad adjustment of restriction adjustment screw Oil injection volume of fuel injector is over Spark plug is Spark plug is Unhealthy automatic choke dry wet Accelerator opens too much A Rotation unsmooth No speed or low speed Fault Diagnosis Adjustment Check Start engine and add oil eee EE l Speed of rotation of engine arises Engine speed can not arise completely EEE Adjust ignition correct time and use ignition 1 correct time light test I Compression Compression pressure normal pressure too low EEE EE EE EEE AE aa ak cic 1 Carburetor block test i I D pe KN A eens No pollution Pollution discotorattor discoloration
89. perating data and it needs to connect the laptop with the six hole diagnostic port of the engineccyle through K line prior to the use It needs to install the driver software for the K line in the laptop before use Instructions to PCHUD software use 1 Use the K line to connect the 6 hole diagnostic port of the enginecycle and the notebook computer and open the key 2 Click HUD EXE icon to start PCHUD software 3 On the software interface select File click the Open to select PCHUD HAD and select OK to confirm dd File ear Gauge etup Playback Slew jelp Time 00 00 00 000 2 fv Pase me f M RPM EA SE D 00 pctFCNO 0 cellNo MALFCURR 0 N Le 200 00 0 255 0 1000 0 CAFBLMCOR2 0 000 factor MALFHIST 0 NA E E 300 0 000 2 000 0 10000 Folders OK me Ems ce 0 0 Cancel ev 0 0 CAFBLMCOR1 0 000 factor RUNTIME 0 Sec Es MTOS P1 Network EE CF 256 0 0 000 2 000 0 10000 E Manual Ca PLYLOG vi HMAPRAW 0 000 2 000 HE vist files of type Drives Hu TT r rrn EEE 0 HUD File CHUD amp Local Disk 0 2000 0 32 IGN 0 factor YAFCMULT 0 00 factor CSPC 0 count SSeS EEE 0 0 65535 0 S 65535 CLTS 0 0 degC IACYVDSMP 0 step Y02B 0 00 m VTHROTRAW 0 count E a eT IAT 0 0 degCIACYVDSMP 0 step 02 0 00 mYISTATUSBYTE 1 00000000 Hs a T ee 00000000 STATUSBYTE2 00000000 STATUSBYTE1 00000000 STATUSBYTE4 00000000 CYCSENBL CSINSYN IDLCONM
90. r Install front wheel 50 Rear Wheel Rear Suspension Bl Real Shock Absorber Real Rocker Arm 1 Self locking nutM14 1 5 2 Dust ring units 3 Multi roll bearing HK2020 4 Real rocking arm axle sleeve 5 Oil seal 6 Real rocking arm installment axle 7 Chain tension axle sleeve 8 Chain tension wheel units 9 Bolt M6 50 10 Chain guide plate 11 Self locking nut M6 12 Guide plate lining 13 Bolt M6 45 14 Rear rocking arm weld assembly 15 NutM8 16 Chain upper shield 17 Inner hexagon screw M5 15 18 Gasket 5 19 Bracing sheet weld assembly 20 Spacer bush 2 21 Chain fence 22 Group bolt M6 12 23 Rear rocking arm left decorative plate 24 Bolt M8 60 25 Bolt M6 1 14 26 Liquid brake cable clamp 27 Rear rocking arm right decorative plate 28 Chain tensioner axle 29 Chain tension wheel 30 Chain tension wheel lining 31 Gasket 16 32 2 52 Rear wheel 2 Rear wheel plate pinch 3 front wheel oil seal assembly 4 Rolling bearing 6003 2RS 5 1 Rear axle Chain erection bolt M8 22 6 Rear wheel central axle sleeve units 7 Self locking nutM16 1 5 8 Chain wheel 9 Chain 428HG 1 132 10 Rear brake disc 11 Vacuum tyre 130 80 17 12 Cycle valve 13 Rear wheel left axle sleeve 14 Rear wheel ring 15 Liquid brake plate erection bolt 53 IV Rear Wheel Rear Suspension Preparatory data 4 1 Fault diagnosis 4 2 Rear wheel
91. r 36 Spline pad 37 Shaft collar 38 Layshaft fifth gear 39 Layshaft first gear assembly 40 Layshaft assembly 41 Thrust washer inner 15 42 Spindle second gear 43 Spline sleeve 44 Spline pad 45 Shaft collar 46 Spindle sixth gear 47 Spindle third and fourth gear 48 Spline pad 49 Spindle fifth gear 50 Spindle 51 spindle sleeve 52 Spindle assembly 126 Inspection Check respectively whether the tooth surface of the wheel gear and the drive claw are worn Tooth If badly worn or damaged replace it surface Remove the bearings and oil seals of the left and right crankcase Check whether they are damaged if there is any replace it Attention The bearing that is knocked out can not be used again replace it Disassemble the bearing and oil seals using special tools Combine spindle and layshaft Attention Apply lubrication oil evenly onto each gear and shaft while combining Make sure that there is no jamming for each gear after combination Attention Assemble the crankcase in accordance with the reverse order of the removal de Exhaust System Inspection and Maintenance Muffler 1 Socket head cap screw M8 30 2 Spring washer 8 3 Washer 8 4 Exhaust gasket 5 Exhaust pipe assembly 6 Graphite gasket 7 Clip assembly 8 Muffer cylinder assembly 9 Cylinder liner installation 10 Bolt M6 19 11 Rubber space bush 12 Fasten space bush 13 Card nut M6 14 Heat insulation rubber gasket 15 Washer 98 927 2 16
92. r polluted by grease please replace them Brake shoe Attention e Micrometer and vernier caliper are the only choices for measurement 1 3 3 Installment Ta Install front wheel Install front liquid brake oil pipe and brake cylinder units Do not get grease on brake shoe Attention If there is grease on brake shoe brake ability will reduce and cause brake failure Fasten bolts to the setting torsion force Torsion force Former brake disc retaining bolt 5 10N m Under the brake fluid before pump installation bolt 22 34N m Liquid brake oil pump before installation bolt 5 10N m Front wheel spindle 100 113N m Front wheel head bolt 5 10N m 1 4 Back liquid brake 1 4 1 Disassembly Disassemble back brake oil pump units Disassemble back brake cylinder units EE Ay F s Vi H i Disassemble back wheel AT Disassemble bake disc from back wheel hub ker Og Note Generally speaking brake disc can not be disassembled If needs heat it Attention e Change of brake shoe e If using brake shoe again mark it on its side before disassembly to make it available back to the original position Disassemble the following units from back wheel Back brake 1 Back liquid brake units 2 Brake shoe units 3 Lining 4 Connection plate AR 1 4 2 Check Check the abrasive wear condition of brake shoe Replace it Thickness measurement when necessary Measure brake sh
93. rator start engine to measure cylinder pressure az N N ko et an Compression pressure 1 1 1 3Mpa 1 400rpm When compression pressure is too low check the following items Damage of cylinder head gasket Measure cylinder pressure Damage of piston ring amp Piston ring scuffing amp Piston and cylinder scuffing Check when compression pressure is too high or carbon deposit is too much in combustor or the head of piston Drive Chain Slackness Service life of drive chain relies on proper lubrication and adjustment If not maintained in a proper way advanced abrasion will come out in drive chain or chain wheel In the harsh using conditions maintain frequently is necessary Stand vertically the motorcycle on the flat ground and check drive chain slackness 0 a Drive chain slackness 10 20mm Adjustment of drive chain Adjust drive chain to keep the deflection of chain is 10 20mm per 1000km According to users driving conditions drive chain likely need to be adjusted often Warning This advice is the maximum adjustment time gap In fact chain should b checked and adjusted every time before driving If chain is too loose accident caused by chain dropping may happen or serious damage of engine may be caused 24 Please adjust chain as the following methods 1 Put up motorcycle with carriage 2 Loosen the back axle nut1 3 Loosen the locking nut2 4 Turn the a
94. renta vea vera e arena tne nee 76 VII Starting System gt gt gt gt gt gt gt sttersrensransrenarnn een nett teeter tne enn _ 78 7 1 Preparatory Data corr EEE Eee EE Cee EEE EEE EEE Eee eee eee EES ITR 7 2 Fault Diagnosis EEE AEE E E EA E E E EE E E E E E E E E EE E S NER EAS 79 7 3 Starting Motor gt gt gt stteer trenerne aner eee anbe roar entrer rentene _79 74 Starting Relay EEE to cease see a pte E EE E E EEE A N E OE TE AD E E E E 81 VILL Bulbs Switches Instruments lt ete eette EEE en eee tenn eee 82 g1 Preparatory Da aa A NE E A ae 82 g2 Fault Diagnosis SN 82 83 Headlamp Bulb Replacement EEE TREE AE KE bel epee Nkr Re ET a 83 8 4 Front Turn Signal Lamp Bulb Replacement ws edad coed EE RE EE NN E 84 8 5 Taillight license plate lamp rear turn lamp bulb replacement tttttttttttrrrrrrrrn 84 TANG EE EE 85 EES e E TT E 85 RE EE 86 Og Erle TE ETE ET EEE ee rere 86 Engine Inspection and Maintenance 0vs0nennannananennennnanennnnnennnnnunanennener 87 IX Lubricating System REDERE PEER AEE ER EE SD Sk re HER EA 80 9 Preparatory DAA ee TT TETTE 89 9 2 Fault Diagnosis EE SE dts can eh cece A tap nt coe ose Tess ERE tee ecu a Baste ALAN ES VERE 89 93 Oil Pump EE EN ESS ae 90 X Cooling SYStem MARARA 20 10 1 Preparatory ae EE RE ET 407 10 2 Fault diagnosis ENE EE NE EN E E ER NERE ewes 93 10 3 Water PUMP gt gt gt tt tettere rear era e
95. rew off clutch locknut Remove 8 locknut and washer Remove clutch center bracket Remove clutch drive and driven friction plates Removed components refer to exploded view a oa Six TUG Housing fis Remove the thrust washer Pm ee ail a a i Le ar she pe i I assembly Remove housing assembly Install clutch in the reverse order of removal ALLO Disassemble Clutch 5 Bearing washer 6 Surface needle bearing 10 Friction plate assembly 11 Driven I Bolt 2 Spring washer 3 Clutch spring 4 Pressure plate 7 Clutch separation shaft sleeve 8 Jam nut 9 Locking washer plate 12 Clutch driven hub 13 Thrust washer 14 Clutch driving drum assembly 15 Internal separation mandrill 16 Needle roller bearing 17 Bushing 18 Internal separation mandril 19 Separation drag bar weld assembly 20 Clutch assembly LE Inspection Check if there are burs or broken parts on the housing groove of clutch If there are fix and adjust with a file If there is a lot for fix and adjustment replace it TE hd I Sd a I i Housing assembly Check 1f teeth of pressure plate and center bracket are injured If they are replace them center bracket pressure plate Measure the free length of pressure spring Allowable limit replace it if below 29 7mm Free Length 118 Measure the thickness of friction plate with a vernier caliper Thickness Allowable limit Repl
96. ricate Note 1 for items involved in exhaust gas which meets regulations of national environmental protection Normal maintenance shall be performed according to specifications on the user s manual unauthorized repair and adjustment are forbidden We will not be responsible for the results 2 You shall clean more frequently the air cleaner to extend its service life when your motorcycle is used on sand gravel roads or in severely polluted environment 3 More frequent servicing may be required when the motorcycle is often driven at high speed or travels a long distance Engine Oil Filter Engine oil level Attention e Motorcycle shall stand on the flat ground while checking engine oil level Inspect engine oil level when the engine has run for 2 3mintues or stopped for 2 3muinutes Check engine oil level When the engine oil level sensor alarms refill engine oil to its upper limit Engine oil replacement Attention When the engine is warmed up replace engine oil The oil can flow out easily Shut down engine Screw off the drain plug at the bottom of crankcase to drain engine oil When the engine oil is completely drained put back cleaned drain plug and sealing ring Refill engine oil to specified level Engine oil volume 1 0 1 2L 18 Check if there is engine oil leakage Start the engine and run the engine on idle for a few minutes Check engine oil level again Gasolin
97. rotors Oil suction pump 0 025 0 175 Clearance between external Oil pressure pump 0 11 0 163 Oil pump rotor l i rotor and pump block Oil suction pump 0 11 0 163 Oil pressure pump 0 05 0 11 Clearance of rotor end face A Oil suction pump 0 05 0 11 9 2 Fault Diagnosis Reducing engine oil Natural consumption Oil leakage Engine burnt No oil pressure or too low oil pressure Oil way clogged 89 9 3 Oil Pump Disassembly Remove the right cover the clutch and the retaining ring and then remove the oil pump gears and oil pump transition gear Oil pump transition gear Retaining ring Oil pump drive gear Remove the fixed pin the screw and the pup cover and disassemble the oil pump on A oS o Oil suction _ pressure pump Bolt Fixed pin E Oil pump pU Xo A 90 Check the radial clearance between the inner and outer rotor hm Allowable limit 0 15 mm Testing gauge Testin Check the clearance between the outer rotor 8 and pump body Allowable limit 0 15 mm Check the clearance between the rotor ends Allowable limit 0 15 mm 9 Assemble Engine Oil Pump As shown in the following figure I Oil suction pump assembly 2 Oil pressure pump assembly 3 Retaining ring 4 Gasket 5 Oil pump gear 6 Fixed pin 7 Oil suction pump shaft 8 Pin 9 Bolt M6x16 10 Oil pump cover 11 Inner rotor 12 Outer rotor 13 Oil pressure pump sh
98. tem inspection please perform inspection in the sequence listed in the fault diagnosis table 2 Ignition system uses electronic type automatic timing device which is solidified in the CDI assembly so it is unnecessary to adjust the ignition time 3 Ignition system inspection please perform inspection in accordance with the sequence listed in the fault diagnosis table 4 Ignition system CDI shall not be dropped and hung or heavily knocked this is also the main reason for its failure Pay special attention to this while removing it 5 Most of the ignition system problem due to poor contact of sockets Please check first if parts of the connector are well contacted 6 Check if heat value of spark plug is proper Improper spark plug may result in unsmooth engine running or burn of spark plug 7 The maximum voltage is taken to introduce inspection items in this Part Inspection methods for impedance value of ignition coil are also recorded and judged 8 Check ignition switch according to the continuity test table 9 Remove alternator and stator on operation instructions Preparatory data CSHSAINGK Recommending C6HISAINGK spark plug Cold type C7HSA NGK Spark plug gap 0 5 0 7mm Ignition coil 0 40 10 value 20 coil Without spark plug cap 4 5 5 5KQ Impedance value of trigger 20 100 2009 Ignition coil primary peak voltage 95 400V Trigger voltage ABOVE 1 7V impedance Secondary With spark plug cap 8 I11IKQ T
99. ter pump gear Remove the impeller the water pump shaft the water seal assembly etc Impeller 94 Inspection Check whether the parts wear If badly worn replace it Note No damage should be made to the gasket and the box joints in operation Installation Installation should be made in accordance with the reverse order of the removal Water pump disassembling I Hexagon socket cylinder bolt 2 Gasket6 3 Water pump cover 4 Water cover seal gasket 5 Pin 6 Impeller 7 Water seal assembly 8 Water pump shaft 9 Pin3 22 10 Water pump gear 11 Gasket 95 Cylinder head XI Cylinder Head Preparatory data 11 1 Fault diagnosis 11 2 Cylinder Head Valve 11 3 11 1 Preparatory Data Function of cylinder head Cylinder head is used to seal cylinder and form a combustion chamber with piston to hold high temperature and high pressure fuel gas It accomplishes air intake and exhausting operation with valve mechanism Precautions on Operation To ensure sealing between cylinder head and cylinder body there is a great bolt pretension on the cylinder head Pre tightening force value 12 N m Locking force value 30 N m All the components shall be cleaned before inspection and test and purged with high pressure air Table of standard values of baseline projects and allowable limit Unit mm Valve clearance Intake Intake 4 47 4 48 4 455 Valve stem OD Intake 4 455 4 47 4 448 Valve guide ID
100. ttleerland side panel2 replace drive chain when damaged or abrased Lubricate drive chain Buy it from store Check drive chain Wash lubricate and replace it if it is hard 59 Check drive chain and driven chain wheel Replace chain wheel when 1 4 gear teeth are worn Replace it when gear teeth is bending Check wheel axle Replace when there is bearing gap in hub or unbalance of rotation Check oil seal and replace when there is abrasive wear or damage 4 5 3 Drive Chain Slackness Adjustment Stand vertically the motorcycle on the flat ground and check drive chain slackness O a Drive chain slackness 10 20mm Adjustment with Not fulfill quality requirements Screw off rear axle nut1 Adjust the slackness of drive chain The adjustment steps are as follows Screw off erection nut2 screw in or back adjusting device3 until fulfilling quality requirements Screw in slackness increases Screw back slackness reduces Attention Make sure the rotation cylinder number of adjusting device is the same to install axle correctly At last screw down locking nut 4 5 4 Installment Do the verse steps as disassembly Install drive hull rear shock absorber left rear wheel and drive chain sleeve Adjust slackness of drive chain and free travel of brake footstep If p the slackness is too small engine and other important parts will overload Make sure the slackness in the scope of limit value
101. units to front axle odometer wheel gear units will be out of shape After installment of axle rotate it to make sure the rotation condition of autometer drive shaft Install front axle and then lock tight Note the dismounting picture is on page 41 of this manual Torsion force Front axle 37 44 N m 3 4 Direction handle 3 4 1 Disassembly Disassemble direction handle sheath and rearview mirror units Disassemble front brake handle and left handle units Take down accelerator seats units and right grip units Take down accelerator cable units Take down left direction handle cover Take down clutch line units and ventilation door line units Take down handle fixed bolt and handle 3 4 2 Installment Install in the order which is against disassembly Fixed bolt Torsion force 22 29N m 3 5 Front fork 3 5 1 Disassembly Disassemble front splash guard Disassemble front wheel Disassemble brake hose and autometer wire Disassemble front shock absorber Disassemble diversion fixed nut 49 9 Mag 4 ME Disassemble direction handle Tools Direction handle fixed bolt wrench Fixed nut wrench Attention e Clean the opening part of protecting plate of motorcycle block with a cloth 3 5 3 Installation Tools Locknut wrench Rotate the front fork left and right to be sure of its smoothness and there shall be no looseness Steps Install direction handle Install front shock absorbe
102. valve race with a 70 angle milling cutter Remove the milling cutter and check the places processed 70 Grind and cut valve race with a 45 angle precise milling cutter till it gains a proper width All the dents and ragged parts must be removed A Standard valve race width Intake 0 9mm Exhaust 1 0mm 45 104 30 If contacted place is the higher part of valve please use a 32 angle plain milling cutter to lower the valve race If contacted place is the lower part of valve please use a 60 angle internal milling cutter to raise the valve High contact fen gt a JR race Low contact face Grind and cut valve race with a 45 angle precise milling cutter till it meets the required specification please apply some polishing agent on the surface of After completion of valve race grinding and cutting valve Polish the valve gently Installation Install the cylinder head in the reverse order of removal Attention While installing valve spring the end with short spring links heads combustion chamber While installing valve collet please compress valve spring with a valve spring compressor and install the valve collet While installing valve please apply appropriate amount of engine oil on the surface of valve stem and then install it into valve guide Valve clearance adjustment With a special cylinder head cover for valve clearance adjustment installed
103. wheel with flywheel puller Disassemble solid key Disassemble alternator guide line joint Disassemble alternator stator 68 5 8 2 Installation Install the alternator stator onto the engine box Connect lead wire connector alternator Clean crankshaft and conical part of flywheel Make sure the fixation key is installed into the key slot on the crankshaft Align the groove on the flywheel to the fixation key on the crankshaft Attention There is magnetism on the inner surface of flywheel ensure there is no bolt on it Fix the flywheel using a universal non adjustable spanner and then tighten the locknut Torque value 9 0 N m Install protecting plate on the left side 69 Power Lock Ignition Coil Storage Battery Rectifier Starting Relay W C a SW B W B W G SPARK PLUG BL W R W S FUSE a gt IGNITION COIL BATTERY 70 VI Ignition System Preparatory data 6 1 Ignition coil 6 5 Fault diagnosis 6 2 Trigger 6 6 Ignition system inspection 6 3 Charging coil 6 7 CDI assembly 6 4 6 1 Preparatory Data Precautions on operation 1 Ignition sys
104. xternal 100 80 17 Rear External 130 80 17 Wet multi plate Clutch type friction type Manual 6 gear Fuel tank capacity 1 2L Oil change1L Wheel Specification Air cleaner Filter sponge Fuel tank capacity TSLE02L Top speed 110 km h Maximum climbing angle POE EE en 20 degrees Gear shift pattern Idle speed 1700 100rpm min Drive Train Clutch type Battery 12V 6AH YUASA capacity type TT27SL Alternating current Max torque 12 18N m 7500r min ursu Max power 11 Kw 9000 r min 12 0 I Compression ratio permanent magnetic motor Generator type Spark plug NGK CR8E opak pug 0 7 0 8mm clearance Ignition type CDI Pressure of cylinder 8 5Mpa Diameter of front brake disc Diameter of rear brake disc 280mm 240mm QJ125GY 16A G Fault Diagnosis Start difficultly or start failed Fault Diagnosis Adjustment Check Fault Cause p Check if petrol ee a renee i pump work well No fuel in gasoline box Pipeline block in fuel injector of gasoline box meme il Block in the pipeline of gasoline pump Oil supplying No fuel for fuel injector supplies to is enough and fuel injector smooth Pipeline block in evaporation controlling system of fuel tank Block in the gasoline filter Oil pressure of gasoline pump is not enough Disassemble spark plug and put it into spark plug cover connect engine to check whether there is flash
105. y Blue White 6 4 1 System Inspection System inspection Remove CDI assembly and check components related to the ignition system at wiring terminal 6 4 2 Inspection Remove CDI assembly and check if connectors are loose or corrosive Main switch Red Red White On continuity when main switch is OFF Red Machine short cut 100 2000 Primary coil of ignition coil Black White Black 0 4Q 10 Secondary coil of ignition coil Black spark plug cap not 4 5 5 5KQ 10 including spark plug SS 6 5 Ignition Coil 6 5 1 Removal Remove vehicle block cover Ignition coil a Remove spark plug cap Pf Remove primary lead wire of ignition coil mA 2 Remove locknut of ignition coil and take out the ignition coil Install it in the reverse order of removal Q Attention The primary coil is installed with black white wire connector eee ae V Th 6 5 2 Primary coil inspection Measure the impedance between terminals of primary coil Standard value 0 4Q 10 20 Impedance value within the range is good Impedance value o0 indicates broken wire inside the coil The coil shall be replaced 6 5 3 Secondary coil Attached with the spark plug and measure the impedance Wat Ro ae LY RE between lead wire side of spark plug cap and terminal Copies NY NG s Na Standard value 8 11KQ 20 NE e Impedance value within the range is good be ne E
106. y 9 Front splash guard 10 Right and left oil tank guard plate gusset piece 11 Right back plate 12 Left back plate 13 Right and left back plate 14 Left dale 15 Back plate of left oil tank 16 Front of back splash guard 17 Right and left guard plate gusset piece 18 Seat cushion 19 Left kneelet 20 Right kneelet 21 Back plate of right oil tank 22 Right decorative plate 23 Back license plate lamp 24 Back and left turn light 25 Back and right turn light 26 Back splash guard 27 Back splash guard 28 Back taillight 29 Back of back splash guard _4 II Vehicle Housing Disassemble body as the following order rearview mirror front pod instrument support instrument back pod front splash guard seat cushion decorating plate of left and right front back plate left and right front back plate front and back junction plate of right and left back plate bottom cover left and right back plate of oil tank right and left back guard board right and left step tread taillight back splash plate back license tag support Attention Do not damage exterior parts during assembly and disassembly Do not damage the jaws on the exterior parts of the vehicle during assembly or disassembly Align built in panel and cover plate to their grooves respectively Correctly install paw of each part during combination Do not damage the fittings during exterior part installation 495 Front wheel front suspension fa

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