450 Rally Maintenance manuals

First Edition (February 2023)

This maintenance manual is copyrighted by TIBET NEW

SUMMIT MOTORCYCLE CO.,LTD.

The contents and pictures of this maintenance manual are for

reference only, please refer to the actual.

English
version

1
 Introduction
This motorcycle manual provides the reader with a detailed introduction to the basic

structure, operating principles, disassembly and overhaul, and troubleshooting methods

of the 450 Rally motorcycle. It also introduces the technical specifications, performance

parameters and maintenance adjustment data of this model. It is hoped that this manual

will provide technical support and guidance to the users and after-sales service personnel

of Kaiyue motorcycles.

The technical specifications, performance parameters and maintenance adjustment

data indicated in this manual are based on the latest status. Please note that any

subsequent improvements made by the Company to this model may not be in

accordance with this manual without prior notice. We sincerely hope that you will give us

your valuable opinions and suggestions on the design, manufacture and quality of this

model, and inform us for timely improvement.

All the information, charts and various data and performance indexes published in

this manual are available until the printing of this manual. Please understand that TIBET

NEW SUMMIT MOORCYCLE CO.,LTD., reserves the right to make changes to this manual

without prior notice. Any part of this manual is the copyright of TIBET NEW SUMMIT

MOTORCYCLE CO.,LTD. Otherwise, they will be held criminally and legally responsible.

Due to the limited level of the editor, there are inevitably errors and omissions in this

manual, so please criticize and correct

TIBET NEW SUMMIT MOORCYCLE CO.,LTD.

Address: No. 2, Xiangyu Road, Shuangfengqiao Street, Yubei District, Chongqing

Customer service hotline :023-67842884

English
For more information, please visit our website at www.colovemotor.com
version

2
 Contents
Introduction
Chapter 1 Overview ....................................................................................................... 1
Chapter 2 Basic information ....................................................................................... 3
Chapter 3 Regular maintenance and adjustment .............................................. 28
Chapter 4 Frame, body trim, exhaust system ...................................................... 72
Chapter 5 EFI ................................................................................................................... 89
Chapter 6 Fuel System .............................................................................................. 124
Chapter 7 Cooling System ........................................................................................ 139
Chapter 8 Engine ......................................................................................................... 150
Chapter 9 Cylinder head assy ................................................................................ 158
Chapter 10 Cylinder block and piston ................................................................. 169
Chapter 11 Clutch, driving gear, overrunning clutch, oil pump, gearshift
mechanism ..................................................................................................................... 175
Chapter 12 Magneto and balance driving and driven gear ......................... 187
Chapter 13 Crankcase, crankshaft, variable speed drive, balance shaft ... 193
Chapter 14 Front wheels, suspension, steering ................................................. 199
Chapter 15 Rear wheel, suspension........................................................................ 216
Chapter 16 Hydraulic brake system ....................................................................... 223
Chapter 17 ABS ............................................................................................................. 234
Chapter 18 Electrical parts ........................................................................................ 249
Chapter 19 Circuit schematic diagram ( factory ediion)..................................272
Chapter 20 Circuit schematic diagram (regular edition)..................................273

English
version

3
 Chapter 1
How to use this manual

This manual describes the maintenance procedures for the 450 Rally.

Chapter 2 and 3 apply to the entire motorcycle. Chapter 4 describes the procedures for removing/installing

components that may be used to perform the services described in the following sections. Chapter 3--

Chapter 19 describe the motorcycle's components, grouped by location. If you are not familiar with this

motorcycle, please read the technical characteristics in Chapter 2. Follow the recommendations of the

maintenance schedule (Chapter 3) to ensure that the motorcycle is in optimum operating condition and that

emission levels meet domestic environmental requirements, then go to the table of contents on the first

page of that section. Most sections begin with program sets or system descriptions, maintenance

information and troubleshooting. Detailed procedures are given on the next few pages. Refer to each section

for troubleshooting based on the fault or symptom.

Your safety and the safety of others is very important. To help you make informed decisions, we have

provided safety information and other information in this manual .

You must use your own good judgment. You will find important safety information in various forms,

including.

*Safety labels

*Safety Message - Precede the safety warning symbol with one of three signal words,

i.e., DANGER, WARNING, or CAUTION. The meaning of these signal words is:

If you do not follow the instructions, death or serious injury will result.

Failure to follow instructions may result in death or serious injury.

If you do not follow instructions, you may be injured.

Instructions - How to properly and safely service this vehicle

English
version

1
 Symbol

The symbols used in this manual represent specific repair procedures. If additional information

related to these symbols is required, it will be explained in detail in the text without using these

symbols

Replace parts with new parts before assembly

Use recommended oils unless otherwise explanation

Use molybdenum oil solution (oil and molybdenum grease

mixed in a ratio of 1:1)
Use multi-purpose high temperature extreme pressure
compound lithium base grease (Youlicheng Grease SU-
T330G/F or equivalent grease)

Molybdenum disulfide grease

Use molybdenum disulfide paste (40% or more

molybdenum disulfide, NLGI #2 or equivalent).
For example: G-n paste made by Dow Corning USA
Honda Moly 60 (USA only). Rocol paste from Sumico
Lubricants, Japan, manufactured by Rocol Ltd.

Use of silicone grease

Apply sealant. Use a medium strength sealant unless

otherwise specified
Application of sealants

Use DOT4 brake fluid. Use recommended brake fluid unless

otherwise stated

Use shock absorbing fluid

English
version

2
 Basic information
1 Maintenance rules ................................................................................................. 4
2 Model identification .............................................................................................. 5
3 Basic information ................................................................................................... 6
4 Torque value - engine part ............................................................................... 13
5 Torque value - body part .................................................................................. 15
6 Lubrication and sealing point - Engine part................................................ 26
7 Lubrication and sealing point - body part................................................... 27

English
version

3
 Maintenance rules
1. Please use genuine or KOVE recommended parts and lubricants or their
equivalents for the KUVE. Parts that do not meet KOVE's design
specifications may damage the motorcycle.
2. Use special tools designed for this product to avoid damage and
incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts
and bolts are not interchangeable with imperial fasteners.
4. Use new gaskets, O-rings, cotter pins and locking plates when
reassembling.
5. When tightening bolts or nuts, start with large diameter or inner bolts.
Then tighten in diagonal increments to the specified torque, unless a
specific sequence is specified.
6. Clean parts with cleaner when disassembling. Lubricate all sliding surfaces
before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all wires as shown in the cable and cableway wiring.
9. Do not bend or twist control cables. Damaged control cables will not
work properly and may become stuck or tangled.

10.Abbreviations
Throughout this manual, the following abbreviations are used to identify
the respective components or systems.

Abbreviation Full Name

ABS Anti-lock braking system (450Rally factory version
without ABS)
CKP sensor crankshaft position sensor
DLC Data link connector
DTC Direct Torque Control
ECU Engine control unit
ECT sensor Engine coolant temperature sensor
EEP ROM Electrically Erasable Programmable Read - Only Memory
EOP switch Engine oil pressure switch
EVAP Evaporative Emission Control System
IAT sensor intake air temperature sensor
MAP sensor ManifoldAbsolutePressureSensor
MCS Motorcycle communication system
MIL Malfunction Indicator Lamp
English
O2sensor oxygen sensor
version
SCS Service connector Service connector
TP sensor throttle position sensor
VS sensor vehicle speed sensor
4
 Model identification
factory edition-⑴ regular edition-⑵

English
version

5
 Basic information
items specification
Total lenght 2190 mm
Total Width 830 mm
Total height 1487 mm
Axle distance 1475 mm
Load free seat height 960 mm
Size No load pedal height 360 mm
No load ground clearance 300 mm
Dry weight 155 kg
Permissible maximum front axle load 150 kg
Permissible maximum load on rear axle 210 kg
Permissible maximum weight 150 kg
Frame type Cradle type frame
Front Suspension Inverted telescopic fork
Front shock absorber stroke 305 mm
Rear Suspension External spring hydraulic
Rear shock absorber stroke 117 mm
Front tire size 90/90-21M/C
Rear tyre size 140/80-18M/C
Frame
Front tyre brand Zhengxin
Rear tyre brand Zhengxin
Front Brake Hydraulic single disc 298mm
Rear Brake Hydraulic single disc 240mm
Caster angle 28°
Towing distance 122 mm
Fuel tank capacity 31L
1 cylinder inline, 18° vertical
Cylinder alignment
tilt
Cylinder diameter and stroke 94.5x64mm
Displacement 499cm3
Compression ratio 12.5:1
Double overhead camshaft
Air distribution system four-valve chain drive
intake -5°BTDC -5°BTDC
valve 35°ABDC 35°ABDC
exhaust 33°BBDC 33°BBDC
Engine valve -13°ATDC -13°ATDC
Forced pressure lubrication +
lubricating system splash lubrication
Oil pump type Oscillating type
Cooling system water cooling
Paper cartridge，oil-based
Air filltration sponge
English

Engine dry weight 37kg version

Ignition sequence /
Number of cylinder single cylinder
6
 items specification
The Fuel Type Bosch EFI
Supply
Throttle valve hole 46mm
System
Clutch system Wet multichip type
Clutch operating
Cable operation
system
Normal mesh two-stage
Gearbox
transmission, 6-speed
Primary drive 2.286（69/34）
Final drive 3.769
Drive system
1th 2.357（43/15）
2th 1.824 (46/14)
3th 1.474 (40/19)
Gear Ratio
4th 1.181(32/20)
5th 1.000(26/20)
6th 0.846(23/20)
Gear Shift Mode international 1-N-2-3-4-5-6
Ignition system electron ignition
Starting system electric starter
Electricity Charging system Three-phase output magnetic motor
Regulator/rectifier Three-phase full-wave rectification
Lighting System Battery
EFI specification Measurement units：mm

items specification
Engine idle 1600±100rpm
ECT Sensor resistance（40°C/104°F
1.0-1.2kΩ
）
IAT Sensor resistance（20°C/68°F
2-4kΩ
）
Fuel injector resistance（20°C/68°F
11-13Ω
）
Oxygen sensor heater resistance（
10-40Ω
Ignition system specification Measurement units：mm
20°C/68°F）
items
Idle motor resistance（25°C/77°F specification
Sparking plug 110-150Ω
CR8E（NGK）
）
Spark Plug Clearance 0.80-0.90
Spark plug resistance 5-8 KΩ

Electric starter specifications Measurement units：mm

English items Standard value limit value

Start motor brush
version 12.0-13.0（0.47-0.51） 6.5（0.26）
length

7
 Start motor brush length
items specification
hrottle body identification number 450R
Fuel pressure at idle 380Kpa±10kpa
Fuel pump flow (12V, 380kpa) ≥30L/h
Type Bosch EFI/
Fuel oil supply system Throttle valve hole 46mm

cooling system
items specification
Cooling capacity radiator tank 1.2 L
The radiator cap releases pressure 108-133 kPa
Start turning on the
temperature
82±2℃
Thermostat Fully open temperature 92°C
valve lift Not less than 8 mm
Alcohol-free silicate coolant
Recommended Antifreeze
(Dongfeng Castrol LEC-II-25)）
Standard coolant concentration 1:1 mixture with distilled water
Lubrication system specification
items Standard value limit value
After oil change 1.4 L -
engine After changing
oil 1.6 L -
the oil filter
capacity After removing
1.8 L
the engine
Recommended SG10W-
50API service
classification:SG or higher
(except for oils marked as
Recommended engine oil energy efficient on the -
round API service
label)JASO T903
standard:MA viscosity:SAE
10W-50

English
version

8
 Engine cylinder head/valve specification Measurement units：mm

items Standard value limit value

Outside diameter Intake φ5.472-φ5.487 φ5.46
of valve stem Exhaust φ5.46-φ5.475 φ5.44
Valve tube Intake φ5.505-φ5.515 φ5.535
valve diameter Exhaust φ5.505-φ5.515 φ5.535
Valve stem and Intake 0.018-0.043 0.07
tube clearance Exhaust 0.03-0.055 0.08
Valve seal tape width 1.2 ----
Cylinder Planeness 0.05 0.06
Head Width of valve seat working surface 0.8 ----
items Standard value limit value
Valve spring free length outer:47.5 inner:38.1 outer:47.35 inner:37.95
Intake:0.1-0.15 Intake＞0.17
valve clearance
Exhaust:0.15-0.2 Exhaust＞0.22
Camshaft base circle run-
0.02 0.04
out
Cylinder body and piston specifications Measurement units：mm
items Standard value limit value
cylinder bore φ94.5-φ94.52 φ94.528
cylinder Out of roundness 0.05 0.01
Flatness of cylinder
0.03 0.05
surface
piston outside diameter φ94.453-φ94.467 φ94.43
Inner diameter of piston
φ20.004-φ20.01 φ20.015
pin hole
Piston pin and piston pin
0.004-0 .018 0.025
bore clearance
top ring/second
Piston Piston ring
ring 0.2-0.35 0.5
closing
Piston ring clearance oilring 0.2-0.7 1.4
Piston pin Piston ring
and piston
top ring 0.03-0.07 0.08
ring groove
clearance
second ring 0.02-0.06 0.08
Clearance between cylinder
and piston
0.033-0.067 0.07
Outside diameter of piston
English pin
φ19.992-φ20 φ19.99
version
Small end of inner diameter φ20.015-φ20.025 φ20.04
connecting Clearance between small
rod end of connecting rod and 0.015-0.033 0.05
9 piston pin
 Shift fork/shift fork shaft/crankshaft/balance shaft specifications
Measurement units：mm

items Standard value limit value

Internal diameter of the right fork of the
secondary shaft / Internal diameter of the φ12.016-φ12.043 φ12.045
left fork of the secondary shaft
Shift fork Spindle fork inner diameter φ12.016-φ12.043 φ12.045
Jaw thickness 4.8-4.9 4.8
Spindle fork shaft outer diameter φ11.973-φ12 φ11.95
shift fork Outside diameter of countershaft fork shaft φ11.973-φ12 φ11.95
shaft cylindricity 0.006 ----
Connecting rod small end inner diameter φ20.015-φ20.025 φ20.04
Big end clearance of axial direction 0.15-0.4 0.7
crankshaft connecting rod radial direction 0.008-0.016 0.02
balance Shaft diameter φ19.98-φ19.993 φ19.96
shaft
Clutch/oil pump specifications Measurement units：mm

items Standard value limit value

10-20（0.4-0.8
Clutch handle free clearance -
）
Free spring length 25 25
Friction plate free
2.95 - 3.05 2.85
thickness
Clutch Clutch driven plate
0.1 0.14
flatness
Clutch cover and friction
0.1 - 0.3 0.6
plate clearance
Radial clearance between
0.06 - 0.15
outer and inner rotors
oil pump End clearance between
rotor assembly and cover 0.04 - 0.1
plate

English
version

10
 Front wheel/suspension/steering specifications
items Standard value limit value
Vacuum tire（regular
Tire 200kPa(2.0kgf/cm³，29 psi) -
edition）
Pressure
Inner Tire（regular edition） 100kPa(1.0kgf/cm³，15 psi) -
Shaft Runout ≤ 0.8 1.0
radial direction ≤ 0.8 1.0
Rim Runout
end face ≤ 0.8 1.0
Wheel dynamic balance - Max 60g
Free spring length/regular
edition/factory edition
475 mm -
Recommended shock Special shock absorbing oil KHL
Front shock absorber oil 5W
-
absorber
shock absorberoil refill 260ml in the damper, 300ml in the
amount damping cylinder, total 560ml
-

Rear wheel/suspension specifications

items Standard value limit value
Tire Vacuum tire（regular edition） 200kPa(2.0kgf/cm³，29 psi) -
Pressure
Inner Tire（regular edition） 100kPa(1.0kgf/cm³，15 psi) -
Shaft Runout ≤ 0.8 1.0

Rim radial direction ≤ 0.8 1.0

Runout axial direction ≤ 0.8 1.0
Wheel dynamic balance - Max 60g
Free spring length/regular
215mm/225mm
edition/factory edition
Rear Recommended shock Special shock absorbing oil
shock absorber oil KHL 5W
absorber shock absorberoil refill
380ml
amount
Cylinder nitrogen volume 1.2mpa

driving Size/link AFAM520C2/114

chain Looseness 30-55 mm

Battery/charging system specifications

items specification
type MTX4L-FPP
capacity 12V/4AH
It can be stored at 25℃
Electrical leakage value
for more than 1 year
Battery
fully charged >13.2V
voltage（28℃、68℉）
need to be charged <12.8V
normal 2A
English Charge Current
quick 10A
version charging capability 280 W/9,000 rpm
Magnetor
Charging coil resistance（20°C/68°F） 0.1-1.0Ω

11
 Hydraulic brake specification Measurement units：mm
items Standard value limit value
Specify brake fluid DOT 4 -
Brake disc wear indicator - To groove
Brake disc thickness 4.0-4.01 3.5
Front Brake disc warped - 0.15
Brakes Main piston outer diameter 11.000-11.050 11.060
Caliper piston cylinder outside
diameter
27.000-27.050 27.06
Caliper piston cylinder outside
diameter
30.200-30.250 30.260
Specified brake fluid DOT 4 -
Brake disc wear indicator - To groove
Rear Brake disc thickness 4.0-4.01 -3.5
Brakes Brake disc warped - 0.15
Main piston outer diameter 9.000-9.050 9.060
Caliper piston outside diameter 22.620-22.670 22.680
灯/仪表/开关规格
Light/meter/switch specification
items specification
Automatic headlight (high/low light) LED
Front turn signal/position light LED
Rear turn signal light LED
Brake/taillight LED
License plate lamp LED
Meter Light LCD
Light Turn Signal Light LED
Neutral indicator light LCD
Engine oil pressure indicator LCD
Coolant temperature high indicator LCD
Malfunction Indicator Lamp（MIL） LCD
ABS indicator LCD
Spare fuse 15A,10A
Oil pump fan 15A
FI 10A
IGN fuse 15A
Headlights start fuse 15A
ABS2 fuse 10A
Fuse ABS1 fuse 15A
The above are regular edition fuse specifications, the following
are factory edition fuse specifications
Spare fuse 10A，10A
FI 10A
Starting and horn 10A English
HEAD 10A version
FAN 10A
ECT 40°C (104°F) 1.0-1.3KΩ
Sensor
100°C (212°F) 0.1-0.2KΩ 12
resistance
 Torque value - engine part

· Listed below are the specifications apply to the specified torque fasteners. Other should
tighten to the above standard torque values.
· The standard torque value

Type of fastener Torque N.m Type of fastener Torque N.m

5mm screw bolt and nut 6 5mm bolt 5
6mm screw bolt and nut 12 6mm bolt 8
6mm flange bolt(8mm head，Small
8mm screw bolt and nut 22 flange）
10
6mm flange bolt（8mm head，big
10mm screw bolt and nut 60 flange）
12
6mm flange bolt（10mm头）and nut 12
8mm flange screw bolt and nut 22
12mm screw bolt and nut 80
10mm flange screw bolt and nut 60

Engine torque value

diameter of
items QTY Torque N.m Note
screw mm
spark plug 1 10 14
Large visual hole cover 1 30 5
Small visual hole cover 1 14 10
Engine oil bolt 1 16 24 aluminium backing
Apply proper amount of
Oil filter cover bolt 2 6 7-19 oil to the sealing ring
Apply proper amount of
Oil strainer assembly bolt 2 20 11-13 oil to the sealing ring
Cooling system torque value
Diameter of
items QTY Torque N.m Note
screw mm
Drain bolt 1 6 10 Copper Gasket

Thermostat cover bolt 2 6 10

Pump chamber bolt 3 6 10

water temperature sensor 1 7 5-8

Cylinder head and valve torque

Diameter of
items QTY Torque N.m Note
screw mm
Oil on thread and end
cylinder head stud 4 10 55-60
face
cylinder head stud 4 6 11-13

Camshaft support bolt 8 6 11-13

English Cylinder head bolt 6 6 10-12
version
Tensioner bolt 2 6 11-13

Tensioner bolt plug 1 8 7-9

13 Exhaust camshaft pressure
1 6 10
reducing valve bolt
Clutch and shift mechanism torque
Diameter of
items QTY Torque N.m Note
screw mm
Clutch fastening nut 1 18 80-90 Thread fastening glue

Clutch spring bolt 4 6 8-10

Drive gear fastening nut 1 10 115-125 Thread fastening glue

Shift mechanism
1 6 11-13
positioning plate assembly
Right crankcase cover bolt 11 6 11-13

Five star plate bolt 1 6 11-13

Magneto and starting clutch torque

Diameter of
items QTY Torque N.m Note
screw mm
Magneto rotor fastening
1 10 80-90
nut
Magneto stator bolts 2 5 7-9

Trigger bolt 2 5 7-9

Left crankcase cover bolt 8 6 11-13

Box and driveline torque

Diameter of
items QTY Torque N.m Note
screw mm
Chain plate 2 6 11-13

Tensioning plate bolt 1 6 10

Oil, replace the new
Crankshaft bolts on both
12 6 11-13 bolt, fastening method
sides of closing case
see the following text
Fastening bolt for cover
3 5 7-9
plate of left oil pump

Torque value of crankshaft, piston, cylinder block and

balance shaft Diameter of
items QTY Torque N.m Note
screw mm
Balancing shaft driven tooth
1 80-90
fastening nut
Balancing shaft drive tooth
1 115-125
fastening nut

English
version

14
 Torque value - body part
Note: The following standard parts are for regular edition models
only
Specificati
Installation area Torsion N.m Note
on
Self-tapping nails for the connection of the front brake fluid
pipe pressure plate and the front shock absorbing trim
ST4.8 1
Self-tapping nails for connecting rear fender liner and rear
fender rear section
ST4.8 1
Self-tapping nails for the connection between OBD and
electrical bracket
M4.2 1
Screws for connecting the lower cover plate of the rear
mudguard rear section to the tail trim
M5 3
Screws connecting the rear mudguard lower cover to the rear
section of the rear fender
M5 3
Internal six-flower countersunk head screws for connecting the
fuel tank connector mounting plate to the left and right rear M5 5
fuel tank
Oil level sensor mounting plate and the left fuel tank
connected to the internal six flower countersunk head screws
M5 5
Phillips pan head screw connecting oil pump to fuel tank M5 5
Phillips pan head screws for instrument and cowl bracket
connection
M5 4
Phillips pan head screw connecting the position light to the
rear trim
M5 4
Phillips pan head screw for connecting tail light to rear fender
rear section
M5 4
Inner six-flower step screw connecting rear tailcap to rear fuel
tank
M5 4
Inner six-flower step screw connecting the front fender to the
front trim of the fuel tank
M5 4
Internal six-flower countersunk head screw connecting the Threading
front gear ring to the front wheel drum
M5 5
glue
Crossed pan head screws for the rear brake pipe clamp to the
flat fork
M5 5
Inner six hexagonal flange face bolts connecting the rear
harness clamps to the rear fuel tank
M5 4
Inner six flower countersunk head screws for rear gear ring to Threading
rear drum connection
M5 5
glue
Crossed large pan head screws for the fuel filter mounting
bracket to the fuel tank
M5 4
Hexagon socket head cap screws for connecting headlight
M5 4
bracket pressure plate to headlight bracket
Phillips pan head screw for connecting the roll sensor to the
M5 5
electrical mounting bracket
Crossed large pan head screws connecting ECU to rear fuel
M5 4
tank
Internal hexagonal countersunk head screw connecting the
M6 8
seat cushion locking seat to the rear fuel tank
Hexagonal pan head step screw for front shock trim to front
M6 5
shock absorber
Crossed half-round head screws for the chain guard and flat
M6 8
fork connection
Hexagon socket flower pan head screws for connecting rear
M6 8
English brake master cylinder to frame
Inner hexagonal countersunk head screws for connecting the
version M6 8
rear fuel tank protection plate to the rear fuel tank
Inner six hexagonal flange face bolts for connecting electrical
M6 12
bracket to fuel tank reinforcement bracket
Inner six flower hexagonal flange face bolts connecting the
M6 8
electrical bracket to the rear fuel tank
15 Inner hexagonal flower pan head step screws for connecting
M6 8
headlight trim parts to headlight mounting brackets
Hexagon socket pan head step screws for connecting the
M6 8
water reservoir to the frame
 Specifica
Installation area Torsion N.m Note
tion
Hexagon socket flower-shaped pan head screws for connecting
side bracket flameout switch to side bracket
M6 8
Hexagon socket head screws for connecting the left and right
front fuel tanks to the tank mounting bracket
M8 22
Hexagon socket head screws in front of the left and right front
fuel tanks connected to the frame
M8 22
Hexagon socket head bolts connecting ignition lock to upper
coupling plate
M8 22
Inner hexagonal flange bolts connecting the left and right cowl
brackets
M5 5
Inner hexagonal flange bolts connecting the oil cooler grille to
the lower shield
M5 5

Inner hexagonal flange bolts connecting radiator grill to radiator M5 5

Inner hexagonal flange bolts connecting the shield mounting
bracket to the left and right front fuel tanks
M5 5
Inner hexagonal flange face bolts of the rear brake pedal Threading
M5 3
connected to the rear brake rocker arm glue
Inner hexagonal flange bolts of headlight and headlight
M5 5
mounting bracket
Inner six hexagonal flange face bolts connecting the side
M5 5
bracket hook bracket to the rear fuel tank
Inner hexagonal flange bolts of the front brake main pump
M6 10
connected to the steering handle
Inner hexagonal flange bolts of the oil cooler connected to the
M6 12
frame
Hexagonal flange face bolts connecting the small sprocket cover
M6 8
to the engine
Inner hexagonal flange face bolts of muffler mounting bracket
M6 10
connected to rear fuel tank
Hexagonal flange face bolts with inner six flowers for connecting
M6 12
the lower shield to the frame
Hexagonal flange face bolts with inner six flowers connecting
M6 12
the hood bracket to the headlight bracket
Inner six hexagonal flange face bolts connecting the regulator to
M6 10
the electrical bracket
Inner hexagonal flange bolts of the radiator connected to the
M6 12
frame
Inner six hexagonal flange face bolts connecting the
M6 10
front brake fluid pipe clamp to the lower coupling plate
Inner six hexagonal flange face bolts connecting the Threading
M6 12
front disc to the front wheel hub glue
Inner hexagonal flange face bolts of front fender to
M6 8
lower coupling plate
Inner hexagonal flange bolt for front ABS sensor
M6 10
mounting
Inner hexagonal flange bolt for connecting injector cap
M6 8
to throttle
Inner hexagonal flange bolt for clutch handle mounting
M6 10
and connection
Inner hexagonal flange bolt for connecting horn to
M6 12
frame
Inner six hexagonal flange face bolts connecting the air
M6 12
filter to the frame
English
Inner six hexagonal flange face bolts connecting the
lower rear fuel tank mounting bracket to the rear fuel M6 10 version
tank
Inner six hexagonal flange face bolts connecting the rear
M6 10
fuel tank reinforcement bracket to the rear fuel tank
Inner hexagonal flange bolts connecting the rear brake 16
M6 10
caliper trim to the rear brake caliper
 Installation area Specification Torsion N.m Note
Inner six flower hexagonal flange face bolts for the Threading
M6 12
connection of the rear disc brake disc to the wheel drum glue
Inner hexagonal flower pan head step bolts for the
M6 10
connection of the rear water skin to the rear fuel tank
Hexagonal flange face bolts for rear ABS sensor bracket
M6 12
to rear caliper bracket connection
Inner six flower hexagonal flange face bolts for the rear
M6 8
ABS sensor connected to the bracket
Inner six flower hexagonal flange face bolts for chain
M6 10
guide connection to flat fork
Inner hexagonal flange face bolt of headlight bracket
M6 12
connected to headlight module
Inner six hexagonal flange face bolts connecting the shift
M6 12
lever to the engine
Inner hexagonal flange surface bolts of ABS and ABS
M6 12
bracket
Inner hexagonal flange bolts of the left and right hood Threading
M8 22
brackets connected to the frame glue
Hexagonal bolts connecting left and right chain
M8 10
adjustment
Hexagonal bolts with inner hexagonal flange for
M8 22
connecting the middle part of the muffler to the frame
Hexagonal bolts with inner hexagonal flange for
M8 22
connecting the rear part of muffler to the frame
Hexagonal bolts with inner hexagonal flange for
connecting the lower coupling plate to the shock M8 22
absorber
Rear bag mounting bolts connecting rear end cover and
M8 22
rear fender to rear fuel tank
Inner hexagonal flange bolts connecting the upper
M8 35
suspension plate to the frame
Inner hexagonal flange bolts of the upper coupling plate
M8 22
to the shock absorber
Inner six hexagonal flange face bolts connecting the
M8 22
upper mount to the lower mount
Inner hexagonal flange face bolts of the front brake Threading
M8 32
caliper connected to the front shock absorber glue
Inner hexagonal flange face bolts of the front shock
M8 22
absorber connected to the front axle
Brake arm bolts for the rear brake arm connected to the Threading
M8 22
frame glue
Rear fuel tank mounting bolts connecting the rear fuel Threading
M8 22
tank to the frame glue
Hexagonal flange face bolts connecting the rear section
M8 22
of the rear fender to the rear fuel tank
Inner hexagonal flange face bolts of the front engine
suspension plate connected to the fuel tank mounting M8 15
bracket
Hexagonal flange face bolts of the front engine
M8 22
suspension plate connected to the frame
English Sprocket bolt connecting sprocket to U-shaped rocker M8 22
version Hexagonal bolt connecting oil level sensor to mounting
M10 22
plate
Hexagonal bolts with inner hexagonal flanges connecting Threading
M10 35
the lower mount to the upper coupling plate glue
17 Flat head bolts connecting the rear shock to the
M10 44
triangular rocker
Hexagonal bolts with inner hexagonal flange for
M10 44
connecting the rear shock absorber to the frame
Hexagonal flange face bolts connecting the lower engine
M10 54
suspension to the engine
 Installation area Specification Torsion N.m Note
Hexagonal flange face bolts of the engine upper
M10 60
suspension connected to the bracket
Hexagonal flange face bolts connecting the
M10 54
front engine suspension to the engine
Special bolts for side brackets connected to the
M10 2
frame
Hexagonal flange face bolts for connecting the
M10 60
U-shaped rocker to the frame
Flat head bolts for connecting triangle rocker to
M12 60
flat fork
Flat head bolts for connecting the U-shaped
M12 60
rocker to the triangular rocker
Lubricate
Hexagonal flange surface bolts connecting
M14 80 with
upper coupling plate to steering column
grease
Hexagonal flange face nut connecting the rear
license plate light to the rear part of the rear M5 5
fender
Hexagonal flange face self-locking nut for
connecting the rear section of muffler to the M8 22
bracket
Hexagonal flange face self-locking nut
connecting the front engine suspension plate to M8 26
the frame
Hexagonal flange face self-locking nut of the
chain guide wheel and chain guide wheel bolt M8 22
connection
Hexagonal flange face self-locking nut of the
rear shock absorber connected to the triangle M10 60
rocker
Hexagonal flange face self-locking nut of the
lower engine suspension connected to the M10 54
engine
Hexagonal flange face self-locking nut of the
front engine suspension connected to the M10 54
engine
Front wheel axle nut M16 88

Flat fork axle nut M16 88

Rear axle nut M22 128

40N-m,
4-slot adjusting nut for steering column locking loose again
M25
connection 10N-m back
1/4 turn

English
version

18
 Note: The following standard parts are for factory edition models only
Installation area Specification Torsion N.m Note
Front brake oil pipe pressure plate and
ST4.8X12 3N·m
front shock trim attachment screw
Rear mudguard lower cover and tail
ST4.8X15/16 2N·m
trim attachment screw
Front and rear oil cup filler cap
M4 3N·m
fastening screws
OBD and electrical bracket connecting
M4.2X13 1N·m
bolts
Front brake upper pump oil cup cover
M4x12 3N·m
fastening screw
Small instrument and road book
M5X0.8X5*8 4N·m
bracket connection nut
Instrument indicator and road book
M5X0.8X5*8 4N·m
bracket attachment nut
Rear position light/tail light mounting Crossed pan head screws
6N·m
screw M5X12
Oil pump and fuel tank connecting
M5X20 6N·m
bolt
Headlight adjustment controller and
M5x10 10N·m
handlebar connection bolt
Battery positive and negative cable
M5X10 4N·m
bolts
Oil pipe fitting mounting plate and left
TC4 titanium
and right rear fuel tank connecting M5X10 6N·m
alloy
bolts
Oil level sensor mounting plate and TC4 titanium
M5X10 2N·m
left fuel tank connection screw alloy
Hand windshield and hand windshield M5X10(Step diameter 8X
5N·m
bracket height 3.5)
(Threading
Brake pedal and brake arm connecting glue)TC4
M5x12 5N·m
bolt titanium
alloy
Oil-cooling grille and lower shield TC4 titanium
M5x12 5N·m
connecting bolt alloy
Rear brake card oil pipe clamping TC4 titanium
M5X12 5N·m
screw alloy
Fuel filter bracket and left fuel tank TC4 titanium
M5X12 4N·m
attachment screw alloy
Side bracket hook bracket and fuel TC4 titanium
M5X12 5N·m
tank mounting bolts alloy
Front fuel tank guard trim bracket left
TC4 titanium
and right and fuel tank connecting M5X12 6N·m
alloy
bolts
Road book and road book bracket TC4 titanium
M5X16/25 4N·m
connecting bolts alloy

English
version

19
 Installation area Specification Torsion N.m Note
Air filter cotton and air filter
M5X78 4N·m
housing fastening bolts
Throttle cable adjusting nut M6 5N·m

Clutch handle adjusting nut M6 2N·m

Starter relay nut and main line
M6 5N·m
connecting bolt
Main wire tower wire and
M6 10N·m
engine connection bolt
Chain retainer and flat fork TC4 titanium
M6*12，Head diameter10.5 8N·m
attachment screw alloy
Front windshield and windshield
M6,self-locking nut 12N·m
mounting bolts
Front reduction trim cover and
TC4 titanium
front reduction attachment M6X10,stepping 8.5X3.5 8N·m
alloy
screw
Threading
Front brake disc and wheel hub
M6x12 12N·m glueTC4
attachment bolt
titanium alloy
Headlight module and cowl TC4 titanium
M6x12 12N·m
bracket attachment bolts alloy
Air filter and frame attachment TC4 titanium
M6X12 10N·m
bolts alloy
Horn and frame attachment TC4 titanium
M6X12 12N·m
bolts alloy
Lower guard and emergency TC4 titanium
M6x12 12N·m
water bottle connecting bolt alloy
Bolts connecting the front brake
TC4 titanium
oil pipe clamp to the upper and M6X12 10N·m
alloy
lower coupling plate
Rear fuel tank protective cover
TC4 titanium
with rear fuel tank mounting M6X12 6N·m
alloy
screws
Rear ABS sensor and bracket
mounting screw TC4 titanium
M6X12 8N·m
Head cover bracket and road alloy
book bracket attachment bolt
Head cover bracket and road
M6X12 nut M6X10.4 8N·m
book bracket attachment bolt
Chain guide rear bolt and flat TC4 titanium
M6X12，pan 11 10N·m
fork connecting bolt alloy
Rear water barrier rubber with TC4 titanium
M6X12,stepping8.5X3.5 8N·m
rear fuel tank connecting bolt alloy
Headlight cover trim with
TC4 titanium
headlight mounting bracket M6X12,stepping8.5X3.5 8N·m
alloy
attachment bolt
Bolts connecting the secondary TC4 titanium
M6X12,stepping8.5X3.5 8N·m
water bottle to the frame alloy
Head cover bracket and road TC4 titanium
M6x13 10N·m
book bracket 1 connecting bolt alloy English
Muffler mounting bracket and TC4 titanium
M6X13 10N·m version
rear fuel tank connecting bolt alloy
Bolts connecting the lower TC4 titanium
M6x13 12N·m
shield to the frame alloy

20
 Torsion
Installation area Specification Note
N.m
Headlight mounting bracket and cowl bracket TC4 titanium
M6X13 10N·m
attachment bolt alloy
Rear brake disc trim and flat fork attachment TC4 titanium
M6X13 10N·m
bolts alloy
Rear brake caliper trim and rear caliper TC4 titanium
M6X13， 10N·m
attachment bolt alloy
Rear fuel tank mounting bracket and rear fuel TC4 titanium
M6X13，pam14 10N·m
tank attachment bolt alloy
Rear fuel tank lower mounting bracket and rear TC4 titanium
M6X13，pan14 10N·m
fuel tank attachment bolt alloy
Steering damper bracket and frame attachment TC4 titanium
M6x16 12N·m
bolt alloy
Rear brake master cylinder to frame attachment TC4 titanium
M6x16 12N·m
bolt alloy
Rear brake disc and rear wheel hub attachment TC4 titanium
M6X16 12N·m
bolts alloy
Hand windshield bracket and clutch handle
M6X20 8N·m
bracket/brake handle bracket attachment bolts
Bolts connecting steering damper to upper TC4 titanium
M6x20 10N·m
connecting plate alloy
Front brake pump and brake handle mount TC4 titanium
M6x20 10N·m
attachment bolt alloy
TC4 titanium
Fuel filler and handle bolts M6x20 10N·m
alloy
TC4 titanium
Clutch handle mount bolt with handlebar M6x20 10N·m
alloy
Instrument operation switch and handgrip TC4 titanium
M6x20 10N·m
connecting bolt alloy
TC4 titanium
Shifter and engine connecting bolt M6X20 12N·m
alloy
Front mudguard and lower connecting plate TC4 titanium
M6X20 10N·m
connecting bolt alloy
TC4 titanium
Injector cap and throttle fastening bolt M6X20 8N·m
alloy
Seat cushion lock and rear fuel tank mounting TC4 titanium
M6X20 8N·m
bolts alloy
Electrical mounting bracket and frame TC4 titanium
M6X20，pan11 12N·m
attachment bolt alloy
TC4 titanium
Oil cooler and frame bolts M6X25 12N·m
alloy
Bolts connecting the left and right radiators to TC4 titanium
M6X25 12N·m
the frame alloy
Bolts connecting the regulator to the electrical TC4 titanium
M6X25 12N·m
bracket alloy
TC4 titanium
Left and right radiator lower bolts to frame M6X25 12N·m
alloy
TC4 titanium
Small sprocket cover and engine mounting bolts M6X30 10N·m
alloy
Chain guide box front bolt and flat fork TC4 titanium
M6X48，pan 11 10N·m
English attachment bolt alloy
Head cover bracket and road book bracket GB/T 6187 self-locking
version 8N·m
fastening nut nut，M6

21
 Installation area Specification Torsion N.m Note

Rear tank vent fitting screws Screw thread with M6 4N·m

Headlamp bracket and head cover Rubber bolt M6X12 nut
8N·m
bracket connection bolt (rubber) M6X10
Frame and air filter housing connection Rubber bolt M6X12 nut
8N·m
bolt M6X10
The left and right sides of the front fuel
tank are connected to the underframe Rubber bolt M8X20 nut M8 22N·m
nut
Guide sprocket self-locking nut and
self-locking nut，M8X1.25 22N·m
guide sprocket connecting bolt
Connection bolts under front fuel tank Inside M8, outside TC4 titanium
22N·m
to frame M16*1*11, length 35.5mm alloy
Tail trim piece with tank 2 mounting Hex shaped Step Bolt TC4 titanium
22N·m
bolts M8X15 Step 5.5 alloy
Flat fork chain adjustment lock nut M8 22N·m

Clutch cable lower adjustment nut M8 8N·m

Muffler collar M8 22N·m

Oil cooler overoiling bolt installation M10/copper packing 25N·m

Threading
Brake arm bolt to frame connection M8 x 16 Step 18.2 Hex glue TC4
22N·m
bolt Socket Step Bolts titanium
alloy
A cap nut for connecting the front
M8X1.25X14 22N·m
muffler segment to the engine
Front tank mounting bracket bolts left TC4 titanium
M8X10 15N·m
and right alloy
TC4 titanium
Rear tank mounting bolts M8X11 stepping 25mm 22N·m
alloy
The front engine suspension is bolted TC4 titanium
M8x115 26N·m
to the frame alloy
Engine suspension with frame TC4 titanium
M8x16 36N·m
connection bolt alloy
Mounting point on front tank with TC4 titanium
M8X20 22N·m
frame connection bolt alloy
Front bottom reduction barrel locking TC4 titanium
M8x25 22N·m
bolt alloy
Bolts are connected to rear oil tank in TC4 titanium
M8X25 22N·m
rear block alloy

English
version

22
 Installation area Specification Torsion N.m Note
Front tank side mounting point TC4 titanium
M8X30 22N·m
with frame connection bolt alloy
Upper connecting plate and TC4 titanium
M8x35 22N·m
damping fastening bolt alloy
(Threading
Front brake caliper with bottom
M8x35 32N·m glue)TC4
barrel bracket connection bolt
titanium alloy
Muffler middle section and TC4 titanium
M8X35 22N·m
frame connection bolt alloy
Lower connecting plate with TC4 titanium
M8x40 22N·m
damping fastening bolt alloy
Muffler rear section and bracket TC4 titanium
M8X45 22N·m
connection bolt alloy
Hand windscreen bracket left
TC4 titanium
and right handlebar connection M8X45 22N·m
alloy
bolts
Fasten the upper and lower TC4 titanium
M8x50 22N·m
bracket bolts in the direction alloy
Head cover bracket and frame TC4 titanium
M8x50 22N·m
connection bolt alloy
Connecting bolt between guide
TC4 titanium
sprocket and U-shaped shake Inner hole M10, length 61, 60N·m
alloy
frame
Triangle shake frame and rear M10 x 45 flat head bolt
60N·m
reducer lower connection bolt Shaped bolt Ducro
Front engine suspension with TC4 titanium
M10x1.25x115 54N·m
engine connection bolts alloy
Lower engine rear suspension TC4 titanium
M10x1.25x130 54N·m
with frame connection bolts alloy
U-shaped shaking frame and
M10x1.25x130 60N·m
frame connection bolt
Lower engine front suspension TC4 titanium
M10x1.25x145 54N·m
with frame connection bolts alloy
Brake tubing to front brake TC4 titanium
M10x1.25x22 30N·m
caliper connection bolt alloy
The brake tubing is bolted to TC4 titanium
M10x1.25x22 22N·m
the front brake upper pump alloy
Brake tubing and rear brake TC4 titanium
M10X1.25x22 22N·m
pump, caliper connection bolt alloy

English
version

23
 Installation area Specification Torsion N.m Note
Brake tubing and rear brake TC4 titanium
M10X1.25x22 22N·m
upper pump connection bolt alloy
Engine sprocket fastening nut M10X22 45N·m
Engine suspension with engine TC4 titanium
M10x30x1.25 54N·m
connection bolt alloy
Direction handle lower holder TC4 titanium
M10x35 34N·m
connection bolt alloy
First 10N·m,
then loosen
Side bracket and frame 1/3 turn, TC4 titanium
M10x42.3
connection special bolt clamping alloy
bolt and nut
60N·m
Connecting bolt to frame above TC4 titanium
M10x52 44N·m
rear shock absorption alloy
U-shaped shaking frame and
M12X105 Flat head bolt shaped TC4 titanium
triangle shaking frame 60N·m
bolt alloy
connection bolt
Connecting bolt between flat
M12X85 Flat head bolt shaped TC4 titanium
fork and triangular rocking 60N·m
bolt alloy
frame
Upper coupling plate and （Thread
M14x1.5x30 80N·m
direction column fastening bolt oiling）
The front oil tank is fitted with
TC4 titanium
hexagonal nuts and connected M16X1，3mm thickness 35N·m
alloy
to the frame
TC4 titanium
Front axle lock nut M16x1.5 88N·m
alloy
TC4 titanium
Flat fork shaft fastening nut M16x1.5 88N·m
alloy
Oxygen sensor and muffler front
M18 44N·m
section connection bolt
Rear axle lock nut M22X1.5 128N·m
40N·m first,
10N·m
The directional post locks the
M25x1 loose, and
four-slot nut
then a
quarter turn

English
version

24
 Installation area Specification Torsion N.m Note
TC4
Headlamp bracket press plate
M5X12 4N·m titanium
mounting bolt
alloy
TC4
Headlight and headlight bracket
M5X12 5N·m titanium
mounting bolts
alloy
TC4
ECU to rear tank connection
M5X12 4N·m titanium
bolt
alloy
TC4
Radiator grille with radiator
M5X12 5N·m titanium
connection bolt
alloy
TC4
Rear tail cover with fuel tank 1
M5X13,stepping 8X3.5 5N·m titanium
Mounting screws
alloy
Connecting screw between side TC4
guard plate and windshield M5X13,stepping 8X3.5 4N·m titanium
glass alloy
Roll sensor and electrical TC4
mounting bracket connection M5X16 4N·m titanium
bolt alloy

English
version

25
 Lubrication and sealing point - Engine part
Materials Location Note
1596 Crankcase coupling surface
seal gum
1590 Magneto outlet
The whole surface of the inner and
outer rotors of the oil pump
Valve rod sliding face and rod end
Timing chain the entire surface
Camshaft rolling surface
Inner surface of cylinder bore
Piston outer surface, piston pin hole
and piston ring groove
Outer surface of piston pin
The whole face of the piston ring
Clutch friction disc entire surface
Clutch pull rod sliding surface
engine oil Shift shaft rod part and dial plate
Double gear shaft whole face
Start clutch whole face
The entire surface of the fork shaft
Crankshaft connecting rod big end
bearing inner surface
Crankshaft connecting rod small
end hole
Gear teeth (primary drive, crankcase,
starting reduction)
Disk tooth sliding surface
Each bearing rotation area
Surface of each O-ring seal
tappet column
Molybdenum disulfide oil Camshaft surface
Cylinder head CAM shaft hole
Starter motor seal ring

Multi-purpose grease Speed sensor seal ring

Large and small decorative cover
seals
Degreasing agent All joint surfaces

English
version

26
 Lubrication and sealing point - Body part
Materials Location Note
Lithium base multi- 3-5 grams each（
Steering bearing ring sliding surface
purpose extreme pressure 0.1-0.2oz）
grease NLGI2# Dust seal for steering bearing
Side support rotating shaft sliding area
Seat latch sliding area
Throttle door handle pull slot and roll up area
Clutch lever slide area
Front axle rod and wheel dust ring rotation area
Rear axle rod and dust ring rotation area
Rear wheel hub left O-ring
Multi-purpose grease
Rear shock absorber upper slip area
U-shaped frame rotation area and needle roller
bearings
Tripod rotation area and needle roller bearings
Rear flat fork shaft rod and plane bearing,
needle roller bearing
Guide sprocket mounting stud sliding face
Brake arm bolt rotation area
Front brake caliper rubber sleeve sliding area
Front brake caliper bracket pin sliding area
Front brake caliper piston dust-proof oil seal
contact area
Front brake handle mounting bolt contact area
Silicone grease Rear brake caliper bracket pin sliding area
Rear brake caliper rubber sleeve sliding area
Contact area between rear master cylinder push
rod and main piston
Rear brake pump dust jacket pushrod mounting
area
Rear brake caliper dust ring contact area
Brake main piston and leather bowl
Front and rear main pump hose connector O-
ring
Brake fluid Brake caliper piston oil seal
Brake clamp piston outer surface
Brake pipe joint nut thread
Clutch cable
Cable lubricant
Seat lock cable
Front damping oil seal lip
Special damping fluid
Front damping and dust proof seal lip
KHL 5 W
Front shock absorbing end cover O ring
KOVE special chain lube
English Whole surface of chain
or equivalent
version Driving tooth fastening nut
Clutch fastening nut
Sealant (Loctite 263
Balanced driven tooth fastening nut
Made by Loctite)
Balancing drive tooth fastening nut
27
Magneto rotor fastening nut
Front and rear brake pad mounting bolts
Rear and rear ABS ring mounting bolts
Low strength locking
agent Brake arm and brake pedal mounting screws
Front engine suspension left and right with
Rubber bolt
 Regular maintenance and adjustment
1 Overview ............................................................................................................................ 30
2 Maintenance interval schedule (factory edition) ................................................ 31
3 Maintenance interval schedule (regular edition) .............................................. 32
4 Fuel Line Inspection .................................................................................................... 33
5 Spark plug inspection ................................................................................................... 33
6 Inspection and adjustment of valve clearance..................................................... 35
7 Engine oil change............................................................................................................ 39
8 Throttle valve body intake pipe inspection ......................................................... 40
9 Inspection of exhaust gas pipe assembly ............................................................. 40
10 Inspection of evaporative emission activated carbon canister and dump valve ..
41
11 Air filter sponge element replacement / check hose cleaning .................... 42
12 Exhaust system inspection ....................................................................................... 43
13 Adjustment of clutch free travel ............................................................................ 44
14 Inspection of brake operation ................................................................................ 45
15 Inspection of front and rear brake pads.............................................................. 45
16Inspection of front and rear brake fluid lines...................................................... 46
17 Emission of air from hydraulic brake system .................................................... 47
18 ABS gear ring clearance inspection ...................................................................... 48
19 Inspection of brake fluid level ................................................................................ 49
20 Brake fluid addition ................................................................................................... 49
21 Adjustment of headlight beam .............................................................................. 50
22 Inspection of side brackets ...................................................................................... 50
23 Lubrication of side brackets .................................................................................... 50
24 Inspection of side stand flame out switch ......................................................... 50
25 Check of cooling fluid quantity .............................................................................. 51
26 Inspection of cooling system .................................................................................. 52
27 Coolant change ............................................................................................................ 53 English
28 Lubrication of front brake handle ......................................................................... 54 version

29 Lubrication of the rear brake arm ......................................................................... 54

30 Lubrication of the clutch handle ............................................................................ 54
28
31 Lubrication of foot pedal .......................................................................................... 54
 32 Steering damper inspection and adjustment ................................................... 55
33 Steering Head Inspection and Adjustment ....................................................... 56
34 Inspection and lubrication of front and rear wheel seals .......................... 56
35 Lubrication of steering head bearings ............................................................. 57
36 Inspection and lubrication of the triangular rocker .................................... 57
37 Inspection and lubrication of the flat fork shaft ........................................... 57
38 Inspection and lubrication of U-shaped rocker ............................................ 57
39 Inspection of wheel tires ....................................................................................... 58
40 Inspection of wheel rim damage and runout ................................................ 58
41 Replacement of tires .............................................................................................. 59
42 Inspection of cushion body assembly .............................................................. 59
43 Inspection of chain guide box ............................................................................ 60
44 Inspection of chain guard card ........................................................................... 60
45 Inspection of chain guide wheel ........................................................................ 60
46 Inspection and adjustment of transmission chain tightness ..................... 61
47 Inspection cleaning and lubrication of the drive chain ............................... 62
48 Transmission chain replacement ........................................................................ 63
49 Inspection of the master/follower sprocket .................................................... 63
50 Inspection of Front Shock Absorber and Rear Shock Absorber ................ 64
51 Front shock absorber air pressure, compression and rebound damping adjustment ....... 65
52 Rear Shock Absorber Spring Preload Adjustment ....................................... 66
53 Rear shock absorber high speed, high and low speed compression damping adjustment .............. 67
54 Rear Shock Absorber Rebound Damping Adjustment ............................... 68
55 Front Shock Absorber Wear Ring Inspection ................................................ 68
56 Vehicle locking torque inspection .................................................................... 69
57 Inspection of brake light switch ........................................................................ 69
58 Inspection of Switches, Light and Signals ..................................................... 69
59 Adjustment of throttle free travel .................................................................... 70
English 60 inspection and damage lubrication of steel cable ...................................... 71
version
61 Inspection of the battery ...................................................................................... 71

29
 Maintenance information
Overview：
This chapter contains all relevant information for the recommended
inspections and adjustments. If these maintenance procedures are carried
out regularly, they will result in smoother running, longer life and lower
maintenance costs. The information in this chapter applies to motorcycles
already in use and not yet for sale. All maintenance technicians should be
familiar with all the information in this chapter.

English
version

30
 Maintenance interval schedule
The table below for the factory only edition :
during each regular maintenance, to check before driving. I: if necessary for inspection and
cleaning, adjustment, lubrication or replacement. C: clean. R: replacement. A: adjust. L:
lubrication.
Every
TIMES Every three About 15 Every nine Every 12
time use
games or hours or games or games or
NOTE or about
about 7.5 every six about 22.5 about 30
2.5
ITEM hours
hours games hours hours

Fuel line （note 6） I R，*

Fuel pump filter （note6） R，*
Throttle adjustment I
Air filter element （note1） C R
Crankcase snorkel I
Spark plug I
Valve clearance （note4） I，*
（note3）
Engine oil I R
（note5）
Engine oil filter （note3） R
Piston piston ring R，*
Piston pin R，*
Radiator coolant （note2） I
Cooling system I
Drive chain I，L R
Drive chain slider I
Drive chain roller I
Driving sprocket I
Driven sprocket I
Brake fluid （note2） I
Brake pads are worn I
Braking system I
Clutch system （note5） I
Control cable I，L
Exhaust pipe/muffler I
Friction ring I
Horizontal fork/shock
absorber linkage L，*
mechanism
Front fork oil front
（note3） R，*
shock absorber oil
Nut bolt fastener I，*
Wheel/tire I
Steering head bearing I，*
We recommend referring to the official KOVE maintenance manual to repair these items.
This maintenance schedule is based on average riding conditions. Frequent use of the vehicle
requires more frequent maintenance.
English
Note: 1. Clean the motorcycle promptly after each ride.
version 2. Replace every 2 years to replace needed mechanical parts. Marked * items For safety
3. Replace after the first break-in. reasons, we recommend that
4. Check after the first break-in. these items be repaired by the
5. Replace the engine oil if the clutch friction plate is replaced. dealer only.
31 6. Replace every year.
 Maintenance interval schedule
The following table is for regular edition only:

The motorcycle should be serviced within the specified time, and to ensure safety, it should
only be serviced by the special repair store of KOVE.
The meaning of each symbol in the table is as follows.
I: Inspection, cleaning, adjustment, lubrication or replacement if necessary; C: Cleaning; R:
Replacement; L: Lubrication.

Odometer km (note 2)
times
period 3000km/6 5000km/6
ITEM 1000km/3M 7000km/6M 9000km/6M
M M
* Fuel system oil circuit I I I
* Fuel filter R 10000km/1year
* Throttle operating system I I I I I
1000km or every 1 month for replacement, daily for venue or desert
* Air filter element note 1
rides
* Spark plug I I I
** Exhaust valve clearance I 2000km/30H
** Intake valve clearance I 2000km/30H
Replace it every 500km for the first 2000km and every 2,000 km after
* Engine oil
that
* Oil filter element Change the oil together when you change it
* Timing chain tension A A A A A
** EFI system I I I
* Drive chain I、L I、L I、L I、L I、L
* Battery monthly I I I
* Brake pads are worn I I I I I
** Braking system I I I I I
* Headlight light I I I
* clutch I Paved 5000km/ non-paved 20 hours
** fastener I I I I I
** Directional bearing I I、L I I、L I
** coolant R 30000km/2 year
** Shock absorber oil R 5000km/100H
*: This item is repaired by the personnel of KOVE locomotive special repair store. If
the user has special tools, repair parts and repair ability, he can also repair by himself, and
the repair knowledge can refer to this instruction manual.
**: To ensure safety, this item can only be repaired by the personnel of KOVE
locomotive special repair store.
Remarks.
1. When driving in dusty areas, such as deserts or grounds need to change or clean
the air filter element daily.
2. When the odometer reading exceeds the given maximum figure, its maintenance
interval is still repeated at the mileage interval specified in the table.
3. When the vehicle is often used under harsh conditions again, the vehicle
maintenance interval should be shortened by 50%.
English
version

32
 P1 ※Fuel line inspection
[1]
Before and after the tank inspection before
remove the following content: - fuel tank
vent;
- seat cushion assembly;
- before tank decoration or so;
- remove the engine protection plate
[2] assembly;
- disconnect the fuel pump power supply 2 p
P2 (black) joint.

[1] Inspection
If the quick-connect fitting and its
surroundings are dirty, clean them.
1: Check (P1) Fuel tank front and rear vent hoses
[1], [2].
Cracked / damaged → Replace.
[2]
[6] Hang the front left fuel tank on the left side of the
frame.
[3] 2: Check (P2) fuel pump to throttle supply hose
[2] for damage or leakage and quick connect joint
[1], for loose, damaged or leaking connections.
[4] 3: Check whether the fuel supply hose [3]
[1] connected to the fuel tank on the left and right
sides of (P2) is extruded, damaged or leaking and
[5] whether the quick connect joint [4] is loose,
damaged or leaking and other connections.
4: Check (P2) whether the fuel tank connection
supply hose [3] on the left and right sides and the
double-hole fuel tank bolts on the left and right
sides [1] and P3 [1] are loose or leaking.
5: Check (Fig. 2) whether the fuel filter [6] and
P3 [1] [2] [3] the rubber sleeve mono-ear induction clamp are
loose, damaged or leaking.
6: Check (P3) whether the fuel check valve [2]
and mono-ear induction clamps are loose,
damaged or leaking.
Whether the fuel supply hose connecting the rear
fuel tank and the front right fuel tank is accurately
stuck into the wire hook bracket [3].
7: Check (P4) whether the fuel supply hose [3]
connecting the rear fuel tank and the front right
fuel tank is extruded, damaged or leaking and
whether the quick connect joint [1] is loose,
P4 damaged or leaking and other connections.
8: Check (such as the right P3) whether the rear
fuel tank connection hose and the double-hole
[1] over fuel bolt [2] are loose or leaking and other
connections.
Check for the following conditions
English Cracked/damaged → Replace.
version Extrusion / damage / leakage / looseness →
Connect correctly.
[2] Caution.
[3] -Be careful not to damage fuel supply hoses,
33 fittings and fuel lines. Do not use tools.
※Spark plug inspection
[2] [1]
The following procedure applies to all spark
plugs.

Remove the following components.

- Removal of the seat cushion assembly.
- The front trim assembly.
- The front fuel tank vent pipe.
- Front left and right side fuel tanks.
- Air filter assembly.
- Ignition coil pressure plate screw M6x12 [1].
- Ignition coil pressure plate [2].
- Spark plug [3].
[2]
Caution.
-Blow around the spark plug base with an air
gun before removing the spark plug, and also
make sure no dust has fallen into the cylinder.

1. Check.
● Spark plug type
Error → Replace.
Manufacturer / Model
NGK/LMAR8A-9CR8E
2. Check.
- Electrode "1"
Damaged/consumed → Replace the spark
plug.
- Insulator "2"
Abnormal color → Replace the spark plug.
Normal color should be tan or light tan. 3.
3. Cleaning.
- Spark plug
(Use spark plug cleaner or wire brush)
4. Measure.
- Spark plug gap "a"
(Measured by thickness gauge)
Out of specification → Adjust the gap.
Spark plug gap
0.80-0.90 mm (0.031-0.035 in)
5. Installation.
- Spark plugs
Install spark plugs tightened to specified
torque.
13 N-m (1.3 kgf-m, 9.6 lb-ft)

Note: before installing the spark

plug, first clean the spark plug
with the gasket surfaces.

English
version

34
 ※Check of valve clearance
Note: in cooler conditions, please
[1]
check and adjust the valve clearance.

Remove the following parts:

- cylinder cover;
[2] - inspects a hole cover and o-rings [1];
- depending on the hole cover and o
-rings [2];
1. installation status: use a 17mm
[3] socket wrench to rotate the magneto lock
nut, while observing whether the timing
mark line "Ⅰ" [2] on the magneto rotor
and the timing mark slot [1] on the left
front cover are aligned through the small
sight cover screw hole on the left front
cover.
2. After the above timing marks are
aligned, make sure that the [5] exhaust
cam timing line is flush with the end face
[4] of the cylinder head at the same time.
The timing point is facing directly above
the cylinder head. The [6] intake cam
timing line is flush with the end of the
EX IN cylinder head with the timing point facing
[5] [6]
directly above the cylinder head.
If this is not the case, turn the crankshaft
another 360 degrees.

☆: The engine is in the correct timing

position only if both 1,2 are satisfied.

Check valve clearance by inserting

a thickness gauge [1] between the
cam and tappet.
Valve clearance.
[1] Intake: 0.10-0.15mm
Exhaust: 0.15-0.20mm
Notes:
-Record each valve clearance for
easy reference of shim selection
Thickness gauge when valve clearance needs to be
English
adjusted.
version

35
※ Inspection and adjustment of valve
clearance EX IN
Disassemble the following components. [1] [2]
- Tensioner.
- Camshaft bracket.
- Chain press.
1. Turn the timing driven sprocket to the
engine timing position: the positive time
line mark of the timing driven sprocket is
flush with the cylinder head end face [1],[2];
The inlet and exhaust camshafts are directly
above the cylinder head at the correct time
point [2],[1].
[1]
2. Remove the tensioner assembly; [1]
Remove the following parts: - remove
the two bolts fastening tensioner M6 x
20 [1]; - remove the tensioner
combination [2] and tensioner gasket.

[4] [5]
3. remove the camshaft bracket and [3]
timing chain pressure plate. [1]
Remove the following components.
- Remove the 2 M6×40 [1] and 6 M6×35
bolts [2] fastening the camshaft bracket [2] [2]
in the order of 1→2→3→4→5→6→7→8,
then remove the timing chain pressure
plate [3] and the camshaft bracket [5].
[1]

[6]
[5]
4. Remove the timing chain and
intake and exhaust camshaft shaft;
Remove the following parts: -
remove the set of timing on the
timing driven sprocket chain [4], the
remove the intake camshaft parts [5]
[6] and exhaust CAM shaft parts.

[1]

Note: remove the valve lifter, [1]

English
and according to the order in
place after the gasket, completes version
the corresponding identification
respectively.
36
 [1] The thickness of the gasket [1] was measured
and recorded. Note: gaskets to choose from,
there are 69 different thickness is 0.025 mm
from adjacent thickness (1.200 2.900 mm) with
the following equation calculating the new
gasket thickness: A = B (C) + D
A: B: new gasket thickness record of valve
clearance value
C: regulation valve clearance value of
D: Removed the shim thickness with inside
diameter micrometer measuring instrument to
ensure that the correct gasket thickness.
Apply the oil to the valve rod end; Install the
new gasket [1] to the valve spring seat; Apply
the oil to sliding zone of the valve lifter, thrust
surface; According to the corresponding logo
to install valve lifter.

1. Inlet and exhaust camshaft shaft and

[1] timing chain installation Installation:
[1] Apply appropriate amount of oil to the
inlet and exhaust camshaft and axle
diameter parts, install the timing chain [4]
on the timing driven sprocket, and the
positive time line mark of the timing
driven sprocket is flush with the cylinder
EX IN head end face [1],[2]; Inlet and exhaust
[1] [2]
camshaft is point [1], [2] the cylinder
head.
2. Camshaft bracket mounting
Then install the camshaft support [5],
spark plug seal ring and chain press plate
[3] on the cylinder head, and tighten the
8 cylinder head support bolts [1] [2] to
the specified torque.
[4] [5] The fastening bolt order 1-2-3-4-5-6-7-8;
[3] Torque: 11 ~ 13 n. m
[1]
3. Combination installation of tensioner
Press down the eccentric wheel of the
[2] [2] tensioner [1] by hand, push the tensioner
plunger [2] into the tensioner to make the
plunger of the tensioner shrink, then align the
tensioner gasket [3] and the tensioner
[1] combination to the cylinder body mounting
hole, and tighten 2 M6x20 bolts to the
[1] specified torque; Torque: 11 ~ 13 n. m. The
[6] tensioner spring again [4], [5] flat gasket,
tensioner plug [6] [7] in turn into the tensioner
[5] ontology, fastening tensioner plug, make the
tensioner plunger pop-up, tighten bolts [6] to
[4] specified
English torque. Torque: 7 ~ 9 n. m
version
[7]
Note: in time to check if timing
chain tensioner, again make sure
37 [2] [3] engine is point is correct.
4. Installation of cylinder head [5] [6]
cover
Assemble the cylinder head cover
sealing ring [1], spark plug hole sealant [4]
pad [2], head cover bolt buffer washer [4] [4]
in the designated position of the cylinder [3]
head cover. Will three cylinder [2]
epicranium fixed bolt M6 x 22.8 [5] and 3
[1]
cylinder epicranium fixed bolt M6 x 50.7
[6], in the cylinder head assembly,
fastening, in turn, according to the
diagonal, and tighten bolts to specified
torque.
Torque: 10 ~ 12 n. m

5. Installation of large and small

visual hole covers [1]
Replace o-rings and blotted out
the oil, and assembly left decorative
cover [1]. Replace o-rings and install
hole cover bolts [2]. Tighten the left
[2]
decorative covers and depending on
the hole cover to specified torque.
Torque inspects a hole cover: 6 N.m
(0.6 KGF. J m, LBF. 4.4 ft) depending
on the hole cover: 15 N.m (LBF. 1.5
KGF. J m, 11 ft)

English
version

38
 [1] ※Engine oil change
After starting the engine for a few minutes,
turn off the engine and place a container under
the oil drain bolt. Remove the following parts: -
engine oil fuel cap [1]; - the oil discharge bolt
and aluminum spacer; - the oil filter cover [2]
[3] and mesh, the right combination mesh bolts [3];
On the left side of the engine oil filter
[4]
combination bolts [4].
[2]
Oil change fine filter, the required
amount of engine oil: 1.6 L
engine removal after reassembling,
P1 左 engine oil quantity required: 1.8 L

Installation of oil filter：

①. Installation of the left case oil screen (e.g. P1)
Put 1 oil screen combination [1], apply a small
amount of engine oil to its O-ring [2], and fit it
[1] into the corresponding oil screen hole. Install
the oil screen bolt 0-ring onto the oil screen
[2] bolt, put an appropriate amount of grease in the
[3] inner hole of the oil screen bolt [3] and tighten
it on the case to the specified torque.
Torque: 11~13 N-m
P2 [5] [4] 右 ②Installation of the right body oil screen (e.g.
[6] P2)
● Put one oil screen combination [1], apply a
small amount of oil on its O-ring [2], put it into
the corresponding oil screen hole, put the oil
[8] screen bolt 0-ring on the oil screen bolt, put an
[1] appropriate amount of grease in the inner hole
of the oil screen bolt [3], and tighten it on the
[2] box, and tighten it to the specified torque.
Torque: 11 to 13 N-m.
[3] ● Put the oil filter parts [4] , into the
[7]
corresponding holes of the right case.
● Put the fine filter spring [5] on the oil filter
part, put the fine filter cover 0-shaped seal [6]
[1] [2] into the fine filter cover [7] seal groove, take two
small disc bolts M6×16 [8], put them into the
corresponding mounting holes of the fine filter
cover, and tighten them to the specified torque.
Torque: 7～9 N-m
Paper filter element [1] The right OUT letter is
marked to install outward [2] The open end
faces the left box when installed.
[1] [2]

Inspection of oil filter element and

oil screen
English
"Check the oil filter (filter) [2]
version damage to replace, no damage to
cleaning. "Check the oil filter, oil filter
(fine filtration) [1] in oil filter [1]
39 must be replaced every time.
※Throttle valve body intake pipe
inspection

1. Remove the following components.

- Seat cushions.
- Front trim parts.
- Fuel tank vent pipe.
- Lower engine guards.
- Front left and right side fuel tanks.
- Air filter assembly.
- Throttle valve body.
2. Inspection： [1]
• Throttle valve body intake pipe [1];
Crack/damage → replacement.
The installation sequence is opposite
to Inspection
※ the disassembly sequence.
of exhaust gas pipe
assembly

Remove the following components：

- Remove seat cushion assembly;
- remove the decoration before the
assembly; Around before [1]
- remove the fuel tank, ventilation tube;
- remove the guard plate assembly; -
disconnect around tank before fuel line;
- disconnect the fuel pump 2 p (black)
joint;
- remove the front left tank. [2]
The installation sequence is opposite
to the disassembly sequence.

Note: throttle fully open or motorcycle

in the rain should be more frequently
after cleaning or reverse for
maintenance, if you can see the
sediments in the transparent tube [2],
you need to clean up. Remove the
crankcase vent plug [1], the sediment
discharge into the appropriate
containers, and then reinstall the
congestion in a reliable way. Check the
crankcase ventilation hose [1]
crack/damage and replacement. Loose
connection parts to correct connection. English
Note: confirm exhaust pipe assembly, version
hose is configured correctly.

40
 ※Inspection of evaporative emission
activated carbon canister and dump
valve

Disassemble the following

components.
[1] - Removal of the seat cushion
assembly.
[2] - Removal of the front trim assembly.
- Removal of the front left and right
fuel tank-vent pipes.
- Removing the lower shield assembly.
- Disconnecting the front left and
right fuel tank connection fuel lines.
- Disconnect the fuel pump 2P (black)
fitting.
[1]
- Remove the front left fuel tank.
[2]
The installation order is the reverse of
the disassembly order.
Inspect.
- Evaporative emission activated
carbon canister and rubber sleeve.
- Evaporative emission activated
carbon tank connecting hose.
- Dump valve and rubber sleeve.
- Dump valve practice connection
hose.

Cracked / damaged → Replace.

Loose connection part → Connect
correctly.
Also, check if the hose is kinked or
crushed.

English
version

41
※Air filter sponge element
replacement / check hose cleaning Figure1 [1]
Remove the following components.
- Removal of the seat cushion assembly.
- Removal of 2 profile bolts [1].
- Remove the air filter sponge [2].
Install in the reverse order of disassembly.

1. As shown in Figure 1:
Depending on the maintenance interval or any
time the air sponge element is too dirty / [2]
damaged → Replace.

The air filter sponge is removable, so please

Figure2 [3]
clean it each time with a special cleaner for oil-
based sponges, dry it, and spray it with special air
filter oil for maintenance.
If the motorcycle is used in an unusually humid
or dusty place, more frequent inspection is
required.
Caution:
[1] [2]
-Because gasoline or low flash point solvents
are very flammable, it is prohibited to use them to
clean the air filter sponge cartridge. Figure3 [1]
Do not use engine oil on the sponge cartridge.
2. As Figure 2:
Check if the nuts [1], [2] in the air filter box are
loose. Loose → tighten.
Clean the inside of the housing [3] of dust or
foreign matter.
3. As in Figure 3.
Check whether the air filter case and frame
mounting screw [1]/[2] are loose, loose → tighten.
4. As in Fig. 4:
Check if the inlet hose is intact.
[1]
Cracked/broken → Replace.
Check if the clamp is installed in the correct Figure4
position [1].
Incorrect adjustment → Perform correct
installation.
Position [2] screw with limit tighten to the limit.
5. As shown in Figure 5:
Check the air filter box leak tube.
Cracked/broken → Replace.
Clean the water inside the leak tube.
Torque.
Air filter sponge anisotropic bolt [2] [1]
4 N.m (0.4 kgf.m, 0.3 lbf.ft)
Air filter box and frame mounting bolts
12 N.m (1.2 kgf.m, 8.9 lbf.ft) Figure5
Rubber bolt to air filter box
8 N.m (0.8 kgf.m, 6.0 lbf.ft)
English
version
[1]

42
 ※Exhaust system inspection
[4] [7] [8] 1. Remove the following components.
- Seat cushion assembly.
- Front trim parts assembly.
- Lower engine guard assembly.
Install in the reverse order of disassembly.

Caution.
-Wait for the muffler to cool down before
checking to avoid hand burns.
Figure 1,2 shows the regular edition model.
[1] [5] 2. Check.
- Exhaust pipe front section [1];
[11] [6] [9] [2] - Middle section of exhaust pipe [2];
- Exhaust tail section [3];
Cracked / damaged → Replace.
[12] - Seal gasket and gasket [4], [5], [6];
Exhaust air leakage → Replace.

3. Check.
Locking torque
- Exhaust front section nut [7];
- Exhaust pipe mid-hugger bolt [8];
[3] [10] [12] - Exhaust pipe middle bolt [9];
- Exhaust tail section clamp bolts [10];
- Exhaust tail section and bracket bolts [11].
- Exhaust air anti-scalding trim cover bolts
[12].
P3 [7] P3,P4 is factory edition
[4] 1. Check.
- Exhaust pipe front section [1];
- Middle section of exhaust pipe [2];
- Exhaust tail section [3];
Cracked / damaged → Replace.
- Seal gasket [4];
Exhaust air leak → Replace.
[1] [10]
2. Check.
P4 [9] [3] [12] [8] Lock to specified torque
- Exhaust front nut [7];
- Exhaust pipe middle section bolt [8];
- Exhaust tail section and bracket bolts
[9];
- Exhaust anti-scald trim cover bolts
[11] [12].
English
version 3. Check.
Exhaust tension springs [10], [11] for
[2] loosening and damage.
43
Broken/damaged → Replace.
Loose → Connect correctly.
Exhaust mounting bolt torque：

1. Exhaust front section to engine connection nut: 22 N.m (2.2 kgf.m, 16 lbf.ft)
2. Exhaust middle section to frame attachment bolt: 22 N.m (2.2 kgf.m, 16
lbf.ft)
3. Exhaust rear section and bracket attachment bolts: 22 N.m (2.2 kgf.m, 16
lbf.ft)
4. Exhaust hoop bolts: 22 N.m (2.2 kgf.m, 16 lbf.ft) (regular edition only)
5. Muffler anti-scald trim cover mounting screw: 8 N.m (0.8 kgf.m, 6 lbf.ft)
※Adjustment of clutch free travel 10-20mm（0.4-0.8in）

Check the clutch cable for kinks or

damage.
Lubricate the pull cable if necessary.
Check the free play [1];
Free play: 10-20mm (0.4-0.8in).
If necessary, adjust to the specified range.
Improper adjustment of the free play can
lead to premature clutch wear.

1. The usual use of fine adjustment at the clutch

cable end adjustment knob Turning the
adjustment knob [1] in the (+) direction will
increase the free play, and turning it in the (-) （-）
direction will decrease the free play.
(+) increases free play;
(-) decreases free play;
Adjustment knob [1] is 1/4 turn in one position;
If the correct free play is not obtained even if [1]
the adjustment knob exceeds the adjustment （+）
limit, select the adjustment knob fully in and turn
it out 5 turns, then make more adjustments on
the left box side.

2. Use the lower adjusting bolt [1] on the

clutch tappet arm for the main adjustment.
Loosen the locknut [2] and turn the adjusting
nut as necessary to reach the specified free [2] [3]
clearance, tighten the 2 nuts [2] while holding
the adjusting nut [1], and tighten the nut over （-）
the rubber sleeve to press the clutch tappet
anti-release plate [3].
Lock nut [2] Torque.
8.0 N.m (8.0 kgf.m, 6.0 lbf.ft)
[1]
3. Start the engine, pull down the clutch
handle and put it in gear, making sure the English
engine does not stall and the motorcycle does （+） version
not run.
Gradually release the clutch handle, open the
throttle, and drive the vehicle smoothly to
ensure the clutch is working properly. 44
 ※Inspection of brake operation
FRONT：
1. Check: • brake brake operation is
not normal to check the brake
system.
Note: in dry road driving, and
brake, before and after operation
respectively to check the brake is
working correctly.

※Inspection of front and rear brake

pads

REAR： Check the liner. If any one liner wear

to 1.0 mm (0.04 in), both pad must
be replaced.
Note: wear identification [1], the
width of 1.0 mm (0.04 in) if the brake
pads wear limit to maintenance,
replacement of brake pads.

•Brake disc check

visual check brake disc is damaged
or crack. Brake disc limit wear value
3.5mm, if the brake disc wear to the
maintenance limit please replace the
brake disc.

English
version

45
※Inspection of front brake fluid
lines [2] [3] [1]
1. Check: • brake tubing [1];
Crack/damage to replace. 2. Review: [2]
• brake pipe fixed [2]; Loose - > lock
tighten bolts reservation. • brake
tubing (bolt) [3]; Loose - > lock bolt.
3. Keep upright, vehicle braking
action several times. 4. Check: •
brake tubing [1]; The brake fluid
leak to replace damaged brake
tubing. [3]

[3] [3]
※Inspection ofrear brake fluid
lines
1. Check: • brake tubing [1];
Crack/damage to replace. 2. Review:
• brake pipe clamp [2]; Loose - >
lock tighten bolts reservation. Loose
brake tubing (bolt) and tighten bolts. [1] [2] [2]
3. Keep the vehicle upright, will be
the rear brake function several times.
4. Check: • brake tubing [1]; The
brake fluid leak to replace damaged
tubing.

English
version

46
 A ※Emission of air from hydraulic
brake system （ABS）
The following process applies only to
factory edition vehicles

• After removing brake related parts, be

sure to exhaust the brake system air.

Note: in the following order,

discharge the air brake system. Step
[1][2]
1: before the brake calipers. • step 2:
after the brake calipers.

Release the brake system the state of

B the air: • brake pump decomposition. •
brake tubing loose, remove or replace.
• brake fluid level is lower than the
minimum scale. • brake operation
failure.

d. Place the other end of the hose in the container.

e. Slowly apply the brake several times.
f. Fully pull up on the brake handle, or fully depress
the brake pedal to hold it in place.
g. Loosen the vent screw.
[1][2] Note
Loosening the exhaust screw will vent the air and
bring the brake handle into full contact with the
throttle grip or brake foot pedal.
Note h. Lock the exhaust screw and release the brake
- Be careful not to spill brake fluid or allow handle or brake pedal before releasing the brake.
the brake master cylinder reservoir or brake i. Repeat steps (e) through (h) until the brake fluid
caliper reservoir to overflow. in the plastic hose is free of any air bubbles.
j. After operating the ABS, repeat steps (e) through
- When releasing air from the hydraulic brake
(i), then add the brake master cylinder reservoir or
system, always make sure the brake fluid is brake fluid reservoir to the correct level using the
adequate before applying the brakes. specified brake fluid.
Neglecting this precaution will allow air to k. Lock the exhaust screw to the specified torque.
enter the hydraulic brake system and cause
the air venting procedure to take significantly Brake Caliper Exhaust Screw [1].
longer. 6 N-m (0.6 kgf-m, 4.4 lb-ft)
m. Using the specified brake fluid, fill the brake
master cylinder or brake fluid reservoir to the
- If venting is difficult, it may be necessary to correct fluid level.
allow the brake fluid to settle for several
hours first. Wait for the small air bubbles in
the fluid line to disappear before repeating
the venting procedure.
1. Evacuate.
a. Using the specified brake fluid, add the
brake fluid reservoir to the correct level.
b. Install the diaphragm (brake master
English cylinder reservoir or brake fluid reservoir).
c. Tightly connect the clear plastic hose [1] to
version the drain bolt [2]. After the hydraulic brake system is
A.Front、 emptied, check the operating
B.Rear、 condition of the brake.
47
The following are regular edition models: Air Emissions Operation Procedures (ABS)
After the repairer has finished installing the ABS, there must be no gas in the line to ensure
the ABS works properly. In this case, you need to use the diagnostic instrument to perform
manual exhaust operation on the ABS. Note: Please use the manufacturer's recommended type
of brake fluid and do not mix them.

The following is an example of exhausting the front ABS system.

Open the upper pump brake fluid cap, add sufficient brake fluid, and open the lower pump
drain bolt.

2. Connect the diagnostic instrument, double-click the routine: front wheel exhaust stage 1, at
this time the maintenance personnel while squeezing the handbrake, while adding brake fluid.
The handbrake frequency is about 1 time/s. The process lasts about 25s.

3. After the front wheel exhaust stage 1 is executed, there will be a prompt in the diagnostic
instrument interface indicating that the execution is complete. At this point, double click on the
routine: front wheel exhaust stage 2, the process still requires the maintenance personnel to
squeeze the handbrake while adding brake fluid. The process lasts about 90s.

4. After front wheel bleed stage 2 is completed, squeeze the handle and close the lower pump
drain bolt. Then, repeatedly squeeze the front brake handle several times and feel the strength
to determine if the exhaust is complete.

Exhaust precautions.
Do not repeat the exhaust procedure 2 or more times in a short period of time! If you need
to repeat the exhaust procedure, please wait for 5 minutes to cool the solenoid valve to protect
it from overheating!

ABS gear ring clearance inspection

Firmly support the motorcycle using a FRONT REAR
crane or equivalent and lift the wheel off
the ground.
Slowly turn the wheel and measure the
clearance [1] between the sensor and
the gear ring at multiple points (air gap).
Must be within specifications.
Standard: 0.4-1.2mm (0.02-0.05in)
Clearance (air gap) cannot be
adjusted. If not within specification,
check each part for deformation, [1] [1]
looseness or damage.
Check if the wheel speed sensor is English
damaged and replace if necessary Check
version
if the gear ring is deformed or damaged
and replace if necessary.
-Front gear ring
-Rear gear ring 48
 ※Inspection of brake fluid level
Note: do not use different types of brake
front： rear： fluid mixing are incompatible with each
other. Filling liquid storage tank, don't let
the foreign matter to enter.

Liquid level check:：

Check the liquid level of the storage
tank of the front and rear brake master
pump. If the liquid level is close to liquid
level line [1], check the brake wear. If brake
[1] [1] piece did not wear and liquid level is low,
please check for leaks of the whole system,
and then use the brake fluid filling liquid
storage tank.

•Spilled brake fluid can damage spray paint, plastic or

rubber parts.
※Brake fluid addition

1. Front brake upper pump.

[4] [1] Remove the front brake master cylinder
reservoir cover screw [1], reservoir cover [2] and
diaphragm [3].
Fill the reservoir to the upper level [4] with the
recommended brake fluid.

Recommended brake fluid: DOT4 brake fluid

Install the diaphragm and reservoir cap.

Install the front brake master cylinder
[2][3] reservoir cover screw and tighten to the
specified torque.
Torque: 1.0 N.m (0.1 kgf.m, 0.7Ibf.ft)

Check the front brake hydraulic system for

leaks.

2. Rear brake upper pump.

Remove the rear brake master cylinder
reservoir cover bolt [1], reservoir cover [2],
[1] [5] gasket plate [3] and diaphragm [4].
[2] Fill the reservoir to the upper level line [5]
[3] using the recommended brake fluid.
Recommended brake fluid: DOT4 brake fluid
[4] Install diaphragm, gasket and cap.
Install the rear brake master cylinder reservoir
cover bolts and tighten to the specified torque.
English
Torque: 2.0 N.m (0.2 kgf.m, 1.5Ibf.ft)
version
Check the front brake hydraulic system for
leaks.
49
※Adjustment of headlight beam

Caution. .
-Adjust the headlight to the light according to
the local laws and regulations.
Support the motorcycle vertically on the
horizontal plane.
By turning the adjustment screw [1].
Turn clockwise to move the beam downwards.
Turn counterclockwise to move the beam
upward.
[1]

※ Inspection of side brackets

Check: check the side stand [1] whether

the activities of the smooth; Activity is not
smooth, repair or replacement.

[1]

※Lubrication of side brackets

Lubricate the pivot points of the side
brackets [1], the moving parts between
metals and the spring contact points [1].
Recommended lubricant.
Unisun Grease SU-T330G
Caution.
-Align the switch pin with the hole in the [1]
side pedal.
-Aligning the switch slot with the return
spring pin.
-Replace the switch bolt with a new one.
※ Inspection of side stand flame
out switch
To check if the side stand ignition cut-
off is normal.
1. sitting across the motorcycle with the
side stand retracted. [1]
2. starting the engine with the gearbox in
neutral, then putting the gearbox into
gear while holding the clutch lever.
3. lowering the side stand completely.
4. the engine should stop when the side English
stand is lowered.
version
If the vehicle is not stopped when the side
stand is lowered → Replace.
50
 a ※Check of cooling fluid quantity
1. Stand up the vehicle on a flat surface.
Caution.
-Place the motorcycle on a suitable stand.
-Make sure the motorcycle remains upright.
2. Check.
- Coolant level
The coolant level should be between the
lowest level mark "a" and the highest level
mark "b".
b Lower than the minimum level mark → Add
the recommended coolant to the correct
level.
3. Start the engine, warm it up for a few
minutes and then turn it off.
4. Check.
-Coolant level
Caution.
Before checking the coolant level, wait a few
minutes for the coolant to settle.

Note:
• water instead of the cooling fluid
can reduce coolant antifreeze
concentration. If water is used
instead of coolant, check and
correct the antifreeze concentration
of coolant if necessary. • only use
distilled water. But if distilled water
is not available, soft water can be
used instead.

English
version

51
※Inspection of cooling system
[2]
1. Check: radiator [1]; About the
radiator, connecting hoses [2]; The [1]
radiator water hose [3]; • radiator
inlet hose [3]; Crack/damage to
replace. [3]
[1]

[4]

[2] [1]

2. Review: oil cooled radiator [1];

Gives oil, oil cooled radiator hose [2];
• oil cooled radiator inlet hose [3];
Crack/damage to replace.
[3]

Check whether the air channel of

the heat sink is blocked or damaged.
Straighten the bent heat sink using a
flat-mouth screwdriver, and use
compressed air or low water pressure
to remove insects, dirt, or other
obstacles. If restrict air flow rate is
more than 20% of the heat
dissipation surface, the change of the
radiator.

English
version

52
 ※Coolant change
[3]
When adding coolant to the tank
radiator or sub-tank or checking the
coolant dosage, the motorcycle
should be placed on level level and in
an upright position. Remove/install
remove the following parts: - remove
the front guard board under the right
side of the tank and assembly; -
[1] [2] remove the water pump drainage
bolt washer [2] [1] peace; - remove
• Wait for the motorcycle to cool down the radiator cap [3], the drainage of
after the engine is turned off. Perform the coolant. After emptying coolant: -
the following operations to avoid the risk
to replace the new flat washer, fitted
of burns caused by excessive coolant
temperature. with water will drain bolt tighten to
specified torque. 10 N.m torque:
[1] water pump drainage bolt: (1.0 KGF. J
m, 10 LBF. Ft.)
Disconnect the siphon hose from
the radiator [1] Pull the siphon hose
from the clamp, place the hose low
outside the engine frame, and drain
the coolant from the storage tank.
Emptying of coolant, wash with
water storage tank, install the hose
into the pipe clamp and radiator.
Fill the cooling system up to the
neck with the recommended coolant
through the water injection hole [2].
Not recommended with antifreeze:
including ethanol containing silicate
cooling fluid.。
The air in the cooling system
[2]
discharge: according to the following
rule out the air in the system: 1. Put
the engine into neutral, start the
engine and idle for 2-3 minutes. 2.
Open closed throttle for three to
four times, will all the air in the
radiator system. 3. Shut down the
engine, if necessary, need to refill
• Wait for the vehicle to cool down coolant. 4. Install the radiator cover,
English after the engine is turned off. fill store kettle with recommended
version Perform the following operations coolant to standard scale, covering
to avoid the risk of burns caused water storage lid.
by excessive coolant temperature.
53
Lubrication of front brake handle [1]
Lubricate the pivot point of the
handle and the contact part of the
metal [1]. [1]

Recommended Lubricants
Use of silicone grease

Recommended Lubricants
Lithium-based multi-purpose
grease

※Lubrication of the rear brake arm [2]

The pivot point of the lubricating [1]
foot and the contact part of the
metal [1].

Recommended Lubricants
Lithium-based multi-purpose
grease
Recommended Lubricants
Use of silicone grease

※Lubrication of the clutch handle

Lubricate the pivot point of the
handle and the contact part of the
metal [1].
Recommended Lubricants
Lithium-based multi-purpose
[1]
grease
※Lubrication of foot pedal

The anti-slip teeth of the pedal can be

repaired by filing the grooves between the
teeth with a triangular file, but be careful,
filing too much will reduce the life of the boot
sole. Filing only the tips of the anti-slip teeth
and filing the grooves too deeply will weaken
the footrest. Make sure the pins are free to
rotate and keep the cotter pin pivot in good
condition. English
Lubricate the pivot points and metal
contact areas of the footrest [1]. version

Recommended Lubricants
Lithium-based multi-purpose
grease
[1] [1] 54
 ※Steering damper inspection and
[1] adjustment

1. Stand up the vehicle on a flat surface.

Caution.
-Make sure the motorcycle remains upright.
2. Check that.
- whether the front end dampers are working
properly by holding the handlebars and
turning them left and right [1].
Improper damping/stalling → Adjust.
[2] [3] - The steering damper is leaking oil and
damping is not working → Repair.
- Steering damper and bracket mounting
(bolts) [1], [4].
Loose → Lock the bolt.
Caution.
-Check the reference valve setting before each
ride.
1. The reference valve [3] can adjust the size of
resistance you feel when you rotate the direction
handle from left to right, and increase the "hardness"
of the damper when you rotate the button clockwise
(to the right); The damper softens when the button is
turned counterclockwise.

2. High speed valves [2] are primarily resistant to

[4] large, unexpected impact forces (such as hidden
roots and pits). Adjust knob located just below the
black lid, the lid was built is tight, adjust when you
need to take off the lid. Factory default for high-
speed valve from fully rigid position to turn out a
circle, we suggest you in cycling for a period of time
to adjust it. Adjust in units of 1/8 turns.

3. Sweep control valves [5] are located on both sides

of the damper, machined bevels on the grooved head
recess side. The distance of the resistance sweep is
controlled to extend from the center line to both sides,
and then the damper is free to move to the steering
gear, allowing the motorcycle to turn easily in tight
turns.
[5] [5] ☆Specific adjustment → Instruction manual.

English
version

55
※Steering Head Inspection and
[1]
Adjustment
1. Set up the bike on a flat surface.

•The bike must be firmly supported and

there is no danger of tipping over
Notes.
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
1. Check.
- Upper and lower dust rings [1].
Cracked/broken → Replace.

2. Check.
- Steering head
Hold the front shock absorber bottom barrel
and rock the front fork gently. [2]
Sticking/loose → Adjust the steering head.

3. Disassembly.
- Steering handle
- Upper linkage plate

4. Adjustment.
- Steering head
a. Loosen the steering column retaining four-
slot nut [2].
b. Then use a torque wrench to lock the nut to
the specified torque.
Notes.
Use a torque wrench perpendicular to the
four-slot nut sleeve. •Do not over-lock the steering
Steering column four-slot nut (locking torque) column four-slot nut.
Hit 40N.m first, loosen and hit 10N.m, then
back off 1/4 turn

c. After installing the upper coupling plate and

handlebars, turn the front shock absorber to
the end on both sides and check if there is any
looseness or jamming in the steering head. If
there is a feeling of dry stalling, please
disassemble the lower coupling plate steering
column assembly and check the upper and front rear
lower bearings.

※Inspection and lubrication of

front and rear wheel seals
Clean, inspect and lubricate seals regularly
especially when wet, muddy or dusty roads are often
encountered.
Ensure that all dust seals are in good condition. Apply
a very small amount of grease in the groove between English
the main and secondary lips of the seal during
installation. version
Lubricate with high temperature lithium complex
grease (Unisun Grease SU-T330G/F or equivalent).

56
 ※Lubrication of steering head
bearings

Regularly clean, inspect and lubricate

steering head bearings especially on wet,
muddy or dusty surfaces. Using high
temperature extreme pressure lithium complex
base grease (optimal sheng SU - T330G grease
or similar grease) lubrication.
Recommended Lubricants
Lithium-based multi-purpose
grease

※Inspection and lubrication of the

triangular rocker
Clean, inspect and lubricate the triangular
rocker bearings regularly. Make sure all dust seals
are in good condition. Install and apply a very
small amount of grease in the groove between
the main and secondary lips of the oil seal.
Lubricate with high temperature extreme
pressure lithium complex grease (Unisun Grease
SU-T330G/F or equivalent).
Recommended Lubricants
Lithium-based multi-purpose
grease

※Inspection and lubrication of the

flat fork shaft
Clean, inspect and lubricate the flat fork bearings
regularly. Make sure all dust seals are in good condition.
And apply a very small amount of grease in the groove
between the main and secondary lips of the oil seal.
Lubricate with high temperature extreme pressure
lithium complex grease (Unisun Grease SU-T330G/F or
equivalent).
Do not attempt to weld or repair damaged flat forks,
welding will weaken the fork strength.

Recommended Lubricants
Lithium-based multi-purpose
grease

※Inspection and lubrication of U-

shaped rocker
Clean, inspect and lubricate the U-shaped
rocker bearings regularly. Make sure all dust
seals are in good condition. And apply a very
small amount of grease in the groove between
the main and secondary lips of the oil seal.
Lubricate with high temperature extreme
pressure complex lithium grease (Unisun
Grease SU-T330G/F or equivalent).
English Recommended Lubricants
Lithium-based multi-purpose
version grease
Caution.
-For lubrication in the groove between the primary and
57 secondary lips of the oil seal, use Unisun Grease S-UT330G.
※Inspection of wheel tires
Check the tires for cuts, embedded nails or other
damage.
Check that the front and rear wheels are
properly mounted and check the tire pressure with
a tire pressure gauge when the tires are cold.

Regular edition tire pressure (vacuum tires).

Front side: 200kPa (2.0kgf/cm³, 29 psi)
Rear side: 200kPa(2.0kgf/cm³, 29 psi)
Regular edition tire pressure (inner tube)
Front side: 100kPa(1.0kgf/cm³, 15 psi)
Rear side: 100kPa(1.0kgf/cm³, 15 psi)

☆ Adjust the tire pressure appropriately according

to the actual usage.

Support the motorcycle firmly and lift the front

wheel off the ground.
Hold the front fork and move the front wheel
sideways with force to see if the wheel bearing is
damaged.
Support the motorcycle firmly and lift the rear
wheel off the ground.
Hold the rear flat fork and move the rear wheel
with force laterally to see if the wheel bearing is
damaged.
If excessive wear occurs on the wobble bearing,
replace the front/rear wheel bearing.
Contact your local dealer for bearing replacement.
[4] [2]

※Inspection of wheel rim damage

and runout
Limit values.
Front wheel: Radial: 0.8mm
Axial direction: 0.8mm [1]
Rear wheel：Radial：0.8mm
Axial direction: 0.8mm
Check the wheel rim [1] and spokes [2] for
damage.
Use a spoke wrench [3] to tighten any loose
spokes to the specified torque. Tighten the
wheel bead clamp nut [4] to the specified
torque.
Tools
Front wheel: spoke wrench, 6.0mm
Rear wheel: spoke wrench, 7.0mm
Torque.
Front/rear wheel spokes. English
6 N-m (0.6kgf-m, 4.4lbf-ft)
Front/rear tire clamp lock nut.
[3] version
12 N-m (1.2 kgf-m, 9.0 lbf-ft)

58
 ※Replacement of tires
450rally factory edition tire：

front 90/90-21M/C 54R KOVE tires provide excellent

tire handling, braking, durability and
Zhengxin/CST EX02F comfort in all riding conditions.
rear 140/80-18M/C 70R
tire Zhengxin/CST EX02R • Installing the wrong tires on a motorcycle
can affect handling and stability. This can
type Sponge inner tube result in a crash, serious injury or death. In this
manual, be sure to use the recommended size
and type of tyre.
450rally regular edition tire：
• When replacing, use the original tire or
front 90/90-21M/C 54R its equivalent of the same size. Decorative
pattern, rated speed and load range is the
tire Zhengxin/CST EX01 same as the original tire replacement tires,
please replace the new tube. Old tube may
rear 140/80-18M/C 70R be stretched, if within the new tires may fail.
tire Zhengxin/CST EX01
vacuum tire Note:
• ROTATON - labeled tire rolling
type Normal tyre (with inner direction. In tire lateral wall delta
tube) these id and the center of the tire
tire wear limit. (only regular edition),
the tire lateral wall delta these id
and the center of the tire tire wear
limit. (factory edition only)

[1] ※Inspection of cushion body

assembly
1. Check.
- Buffer body [1].
Cracked / damaged → Replace.
- Buffer rubber [2].
Damage / wear → Replace.

[2]

English
version

59
※Inspection of chain guide box
[1]
Check the chain guide box [1] for
deformation and damage.
Damage/deformation and
replacement.
Note: if the chain guide box of
metal framework, impact
transmission chain, fall off, lead to [2]
transmission chain worn or noise.
Check the transmission chain guide [3]
rail sliding block [2] for wear. If the
leading chain slider wear to the limit
of [3] position, change the
transmission chain guide slide block.
Torque: chain guide box installation
bolt; 10 N.m (1.0 KGF. Ft, 7. 0 LBF.
Ft.)

※Inspection of chain guard card

Check the chain guard for excessive

wear.
The wear limit does not exceed:
3mm on the upper side
Lower side 2mm
Caution.
-Replace the chain guard when it
exceeds the wear limit.
If the chain guard is worn to the limit
or damaged, the chain will damage the
rear flat fork or drive chain.
Torque.
Chain retainer mounting screw x3 [1].
8.0 N.m (0.8 kgf.ft, 6.0 bf.ft)

※Inspection of chain guide wheel

Check the lower guide sprocket [1]

for excessive wear or guide sprocket
bearing stuck. If necessary, replace
the timely replacement. Wear limit: 2
mm (millimeter) note: remove, be English
sure to use the new bolt and nut. version
Fastening torque: the side guide
sprocket nut: 22 N.m (2.2 KGF. J m, [1]
18 LBF. Ft.) 60
 ※Inspection and adjustment of
transmission chain tightness

•Do not check or adjust the engine while

it is running
Inspection.
Lift the drive chain at the position shown and
measure the distance from the upper surface
Tightness of the rear flat fork.
diagram Standard: 35-55mm
If the measured value exceeds the standard,
please adjust the drive chain.

Driving chain sag: 35-55 mm if sag

more than 55 mm, cannot continue to
drive motorcycle.

Drive chain tightness adjustment：

note：
-The scale lines for the drive chain
adjustment are provided on the rear flat
[3] fork. The left and right adjusters must be
aligned at the same tick mark position. If
they are not aligned, the wheels are not
[1] aligned and the handlebars may pull to
one side.

Loosen the rear axle nut [1],

Loosen the drive chain adjuster lock nut
[2] and turn the adjusting bolt [3] to
adjust the drive chain clearance.
Check that the indexing marks [4] are
[4] [2] aligned at the same position on the
marked scale.

Tighten the rear axle nut [1] to the

specified torque.
Torque: 128 N.m (12.8 kgf.m,94 ibf.ft)
Recheck the drive chain for slack and
make sure the rear wheels turn smoothly.
English Tighten the adjuster to the adjustment
plate and tighten the drive chain adjuster
version
lock nut [2] to the specified torque.
Torque.
12 N.m (1.2 kgf.m, 8.9 lbf.ft)
61
※Inspection cleaning and
lubrication of the drive chain
[1]
Note: • to ensure the service life of the
chain and the intensity of single truncation
chain is prohibited. For maximum service
life, after each driving should be clean and
smooth transmission chain.
Service
1: measuring the height of the limit
transmission chain (plate) : 15.0 mm. Using
the limit measure the distance between
the 17 pins (16 pitch) from the center of
the pin to the center of the pin, the chain
stays taut, and any kinked joints
straighten. Use limit: 257 mm if measured
values more than maintenance limit,
please change the transmission chain.
2: check your sprocket kink or damage,
whether to replace if necessary.

cleanning

3: clean with non-flammable or high flash

point solvent cleaning chain [1] and wipe
dry. Make sure the chain is completely dry [1]
before lubrication. Wipe and dry

[1]

4: lubrication with transmission chain

lubricant [1] [2] lubrication transmission
chain. Recommended lubricants: use a
chain lubricant or SAE# gear oil wipe off English
excess oil, 80-90 or chain lubricant. version

[2]
62
 ※Transmission chain replacement
Disassembly/Installation
[2] [4] [5] Remove the following parts.

- Remove the chain guide box [1];

- Remove the small sprocket trim cover [2];
- Remove the triangle rocker and flat fork
attachment bolts [3];
- Remove the lock nut of the flat fork shaft
and take out the flat fork shaft [4];
- Remove the chains from the large and small
sprockets respectively [5];
[6] [3] [1] - Separate the flat fork [6] from the frame to
remove the chain completely.

The order of installation is opposite to the

order of disassembly.
-After replacing the chain, adjust the slackness
of the drive chain to the specified range.

Standard chain link: 114 links (AFAM)

Replacement chain: A520 XC-3 (X-type oil
seal)

Caution.
-Never use a new drive chain on a worn
sprocket.

Both the chain and sprockets must be in

good condition or the new replacement drive
chain will wear out quickly.
When replacing the drive chain, check the
sprockets as well.
※ Inspection of the
Wear sprocket
master/follower sprocket
Damaged teeth Remove the drive sprocket cover
sprocket teeth
Inspect the drive sprocket teeth and
replacement
driven sprocket teeth for wear or damage
replacement and replace them if necessary. Consult
your dealer to replace the master and
driven sprockets.

Normal sprocket Never use a new drive chain on a worn

is good sprocket.
The chain and sprockets must be in good
condition, otherwise the newly replaced
drive chain will wear out quickly.
Check the bolts and nuts on the active
and driven sprockets.
If there is any looseness, tighten to the
specified torque value.
Torque.
English Drive sprocket nut.
version 45 N.m (4.5 kgf.m, 34 lbf.ft)
Slave sprocket bolt.
37 N.m (3.7 kgf.m, 28 lbf.ft)
63
※Inspection of Front Shock Absorber

Front Shock Absorber

1. Stand up the vehicle on a flat surface.

•The bike must be firmly supported

without the risk of tipping over.
2. Review: • tube damage/scratch and
replacement. , between the bottom of
the shock absorber tube tube and
appearance before the spill to replace oil
seal.
3. Keep the bike upright, before applying
the brake.
4. Check: • shock absorber before action
force to press down, steering handle
several times, check whether before the
shock absorber can smooth the
springback. The activity is not smooth -
maintenance.
※Inspection of Rear Shock Absorber
Rear Shock Absorber
1. Stand up the vehicle on a flat surface.

The bike must be firmly supported

without the risk of tipping over.

2. check：
- Rear shock absorber inner rod
Bent / damaged → Replace the rear shock absorber.
- Rear shock absorber
Oil leakage → Replace the rear shock absorber.
- Spring
Damage/wear → Replace the rear shock absorber.
- Bolt
Bend/damage/wear → Replace. 3.
3. Check.
- Rear shock absorber action English
Press down the rear of the vehicle seat cushion several version
times to check whether the rear shock absorber can
rebound smoothly.
The movement is not smooth → Repair. 64
 ※Front shock absorber air pressure
adjustment

[1] The pressure inside the shock acts as a

progressive spring, affecting the front reduction
throughout its travel.
Air is an unstable gas and his pressure increases
when he does his work (inside the shock cavity),
so the front shock on this motorcycle will become
stiff as the race progresses.
After a race or practice, release the accumulated
air pressure in the front shock in time.
Make sure the front shock is fully extended,
the front wheel is off the ground and the front
shock bleeder bolt is fully loosened [1].
Check the bleeder bolt O-ring for damage and
replace if necessary.
Apply the recommended grease to the O-ring.
Install and tighten the front damper bleeder bolts
to the specified torque: Torque
1.3 N.m (0.1 kgf-m, 1.0 Ibf.ft)

※Front shock absorber compression

damping adjustment
The compression damping adjustment affects
the speed of the front shock compression. There
are 22 segments of front damper compression
damping. Each segment is 1/4 turn. By turning
the compression damping adjustment bolt one
full turn, the adjuster will turn 4 segments.
[1] Turn the adjusting bolt clockwise (H) to make
the compression damping harder, and
counterclockwise (S) to make the compression
damping softer.

To set the standard compression damping.

1. turn the compression damping adjusting
bolt clockwise until it stops turning.
2. Then turn the adjusting bolt
counterclockwise (lighter), the standard
compression damping is from the hardest
position to turn 10 segments and hear the click
position.
You can adjust accordingly according to your
weight and riding conditions, make sure that in
each adjustment, the adjustment bolt stops at
the click position and the left and right ends are
adjusted to the same position.

Note:
• don't rotate the adjusting bolt is
English beyond the given position, otherwise
version it may damage the adjusting device.
Adjusting torque shall not exceed
0.5N·m.
65
※Front reducer rebound damping
adjustment

The rebound damping adjustment affects the speed of

the front shock rebound. The front shock rebound
damping has 22 segments. Each segment is 1/4 turn. By
turning the rebound damping adjustment bolt one full
turn, the adjuster will turn 4 segments.
Turn the adjusting bolt clockwise to increase the
rebound damping (hard) and counterclockwise to
decrease the rebound damping (soft).
To set the standard rebound damping. [1]
1. turn the rebound damping adjusting bolt clockwise
until it stops turning.
2. Then turn the adjusting bolt counterclockwise
(lighter), the standard rebound damping is 10 segments
from the hardest position, and hear the clicking sound
position.
You can adjust accordingly according to your weight
and riding conditions, make sure that in each
adjustment, the adjusting bolt stops at the click position
and the left and right ends are adjusted to the same
position.
Caution.
-Do not rotate the adjusting bolt beyond the given
position, otherwise the adjusting device may be
damaged. The adjusting torque should not exceed 0.5N-
m.
-Compression damping and rebound damping can both
be increased by turning the adjusting bolt clockwise.

※Rear shock absorber adjustment

The rear shock assembly includes a shock gas
cylinder containing high-pressure nitrogen gas. Do
not attempt to disassemble, repair or dispose of
the unit; puncture or exposure to flame may also
cause an explosion resulting in serious injury. gas
Repair or disposal should be done by an bottle
authorized service store. Spring lock nut
Spring Preload Adjustment
Spring preload should be adjusted while the
engine is cool by turning the damper spring lock
nut and adjusting nut to adjust the spring preload.
Adjustment method. spring adjusting screw
1. Firmly support your motorcycle with a length
maintenance stand or crane and lift the rear wheel
off the ground.
2. Check that the spring preload is at the
standard length.
3. Loosen the shock spring lock nut and rotate
the adjusting nut. For every turn of the adjusting
nut, the spring length will change by 1.5mm.
4. Adjust accordingly as needed.
English
5. After the adjustment is completed, hold the
adjusting nut and tighten the shock spring locking version
nut. (Torque: 44N-m)

66
 High seat version.
Increase spring preload.
Loosen the shock spring lock nut with an active wrench, turn the adjusting nut and
shorten the spring length, the shortest should not be less than: 215mm.
Decrease the spring preload.
Loosen the locking nut of the damper spring with an adjustable wrench, turn the
adjusting nut and increase the spring length up to a maximum of: 230 mm.
Each turn of the adjusting nut will change the spring length and spring preload.
Low seating version.
To increase the spring preload.
Loosen the damper spring locknut with an adjustable wrench, turn the adjusting nut
and shorten the spring length by a minimum of: 205 mm.
Decrease the spring preload.
Loosen the locking nut of the damper spring with an adjustable wrench, turn the
adjusting nut and increase the spring length up to a maximum of: 225 mm.
Each turn of the adjusting nut will change the spring length and spring preload.

High speed compression ※Rear reduction compression

damping adjustment bolt
damping adjustment
Compression damping can be adjusted
individually by adjusting the bolt for 2
stages of high speed compression
damping and low speed compression
Low speed compression damping, you can adjust accordingly
damping adjustment bolt
according to your weight and riding
conditions.
When adjusting the compression
damping adjustment bolts, be sure to use
the right size tool to avoid damage.
1. High-speed compression damping
adjustment
High-speed compression damping
adjustment bolt is effective when damping
adjustment is needed for high-speed
operation. High-speed damping can be
adjusted by turning the hexagonal part of
the compression damping adjustment bolt,
and the high-speed compression damping
adjuster is adjusted in increments of 1/4
turn. Make sure that the high speed
compression adjuster is firmly in the brake
position and not in between positions.

To adjust to the standard position.

1. Turn the adjusting bolt clockwise (H)
English until it no longer turns in the position
version (hardest).
2. Turn the adjusting bolt
counterclockwise 2 turns from the hardest
67 position, then ± 1/4 turn.
2. Low-speed compression damping adjustment
When damping adjustment is required at High speed compression
damping adjustment bolt
relatively low speeds, the low-speed compression
damping adjustment bolt should be used. The
low-speed compression damping adjustment bolt
has 16 segments, each segment is 1/4 turn.
The dampers become stiffer after turning
clockwise (H) and softer after turning
counterclockwise (S). The adjusting torque does Low speed compression
damping adjustment bolt
not exceed 0.5N-m.

Adjust to the standard position as follows.

1. Turn the adjusting bolt clockwise (H) until it
no longer turns in the position (hardest).
2. Turn the adjusting bolt 8 sections
counterclockwise from the hardest position and
hear a clicking sound at the position.

3. Rebound damping adjustment

The rebound damping adjusting bolt is located
at the lower left end of the rear shock absorber.
Turn the adjusting bolt clockwise to increase the
rebound damping (hard) and counterclockwise to
decrease the rebound damping (soft).
To set the standard rebound damping.
1. turn the rebound damping adjusting bolt
clockwise (H) until it no longer turns in position.
2. Then turn the adjusting bolt
counterclockwise (S, a little lighter), the standard Springback damping
rebound damping is from the hardest position to adjustment bolt
turn 10 sections, and hear the click position.

Note:
• gently turn adjusting bolt, prevent [2]
damage after shock absorbers.
Adjustment rebound damping
adjustment bolt, be sure to use the size of
the right tools, to avoid damage. Every
time adjustment, ensure the fixed
position of the adjusting bolt is firm. No
more than 0.5 N · m torque adjustment.
※ Front Shock Absorber Wear Ring
Inspection [1] [1]
Check front shock action by operating the front
brakes and compressing the front shocks a few
times.
Check the entire front shock assembly for signs [1]
of leaks, damage or loose fasteners Check the
front shock trim protection plate and dust seal for
cleanliness. No dirt or dust remove any dirt that
has collected on the bottom of the front shock
seals. English
Inspect the wear ring [1] for wear or damage.
If the wear ring is less than 1.7 mm or flush with version
the outer tube, replace the wear ring [2].
Ensure that the wear ring end gap [3] faces
backwards. 68
[3]
 ※Motorcycle locking torque inspection
Check that all nuts, bolts and screws are properly locked (every 3 months
or 1000km). Torque values - 1-13 pages of "moment of torque value - the
engine, car body parts".

P1 ※ Inspection of brake light switch

Brake light switch inspection

1. Checking.
- Front brake light switch operation
[2] - Rear brake light switch operation
[1]

2. Check.
- Brake switch cable.
Crack / damage → Replace.
- Brake switch (bolt).
Loose → Lock the bolt.

P2 Make sure the brake light comes

on when operating the brake handle
and brake pedal.

If P1: for regular edition brake

switch vehicle mounting position.
- Front caliper fuel line into ABS
[3] main pump connect (FW), FM out
connect to rear front upper pump
and brake switch [2].

Such as P2.3: [3], [4] for factory

edition brake switch vehicle
P3 installation position;
[4]
※Inspection of Switches, Light
and Signals

1. Check that all switches operate

English properly and all lights are on.
version

69
※Adjustment of throttle free travel
2-6 mm (0.08-0.24 in)
Check that the throttle cable is not aged, damaged or
kinked.
Turn the throttle handle and check that the throttle
opens smoothly and closes automatically in any steering
position.
If the throttle handle does not turn smoothly and
smoothly, check that the cable is properly routed, that
the throttle lever is clean and lubricated with the
recommended lubricant (engine oil or appropriate cable
lubricant), and that the throttle drum is turning properly.
If there are no abnormalities, but the throttle does not
turn smoothly, replace the throttle cable (oil feed, return
cable).
Measure the free clearance at the throttle handle flange.
Free clearance: 2-6mm (0.08-0.24in)

1. Fine adjustment on the throttle side P1

Loosen the locknut [1] and turn the adjuster
[2].
Turning the adjuster in the (-) direction will （+）
decrease the free play and turning it in the (+)
direction will increase the free play.
After adjustment, hold the adjuster and [2] [1]
tighten the lock nut.
If the correct free clearance is not obtained （-）
even after turning the adjuster to the bottom,
return it to the (+) direction until it gently
touches the bottom and turn it one turn to
the (-) direction, then make more adjustments
on the throttle side.
Nut [1] Torque. P2
5.0 N.m (0.5 kgf.m, 3.7 lbf.ft)
（+）

Note: P1 is factory edition, P2 is regular

edition.
[2] [1]
（-）
2. Throttle body side for significant
adjustment
Loosen the intake throttle cable adjuster lock
nut [1] and turn the adjuster [2] in the (-)
direction to reduce free play and in the (+)
direction to increase free play.
After adjustment, hold the adjuster and tighten
the inlet throttle cable adjuster lock nut to the （-）
specified torque. [2]
Torque.
4.0 N.m (0.4 kgf.m, 3.0 lbf.ft)
(The oil inlet cable and the oil return cable are
adjusted the same) （+） English

Caution. version
-Re-check that the throttle handle turns
smoothly with no sticking. [1]

70
 ※Inspection and damage lubrication of steel cable

The following procedures apply to all steel cables.

1. Inspection.
- Outer steel cable
Damage → Replace.
2. Check.
- Cable operation
Uneven movement → Lubrication.
Recommended lubricants
Engine oil or suitable steel cable
lubricant

Note: the end of a rope self-reliance, the number will

be lubricant drops into the wire, or using the
appropriate lubrication equipment.

•Damaged outer cables can cause

corrosion and affect their operation.
Replace the damage wire as soon as
possible.

※Checking of the battery

Before operation.

The battery must be disconnected

from the negative cable first, otherwise it
will lead to short circuit of the battery.

Charging
Turn off all electrical appliances and
engines.
Remove the battery.
Connect the charger to the battery and
switch on the charger.
Turn off the appliance after charging and
disconnect it from the battery.
Caution.
-If the vehicle is not in use, re-charge its
battery every 3 months.
Battery model: MTX4L-FPP
Fully charged voltage: >13.2V
Required charging voltage: <12.8V
Charging current: Standard 2A Max 10A
English Working temperature -20℃-60℃
version Battery capacity: 12V/4Ah
Overall Dimension LxWxH:
113x69x85(2mm±)
71
 Frame, body trim, exhaust system
1 Maintenance information ........................................................................................ 73
2 Body trim location/removal diagram ................................................................. 74
3 Seat cushion assembly ............................................................................................ 75
4 Front trim assembly (left and right), front windshield ................................. 76
5 Front headlight housing, front fender .............................................................. 77
6 Front shock absorber trim parts (left and right), front brake fuel line
pressure plate ................................................................................................................ 78
7 Rear fuel tank protection cover, rear wheel water shield ......................... 79
8 Rear tail cover, rear fender rear section (competition version) ............... 80
9 Rear tailgate, rear fender liner, rear fender rear section (civilian version)
............................................................................................................................ 81
10 Engine small sprocket, chain guide assembly ............................................. 82
11 Chain guide sprocket ........................................................................................... 82
12 Chain guard, rear brake caliper trim, rear disc brake trim ..................... 83
13 Hand windshield (left and right) ..................................................................... 84
14 Lower engine guard assembly ......................................................................... 85
15 Rear view mirror assembly ................................................................................ 86
16 Footrest assembly, side bracket assembly .................................................. 87
17 Exhaust system ...................................................................................................... 88

English
version

72
 Maintenance information
Overview.
-This section describes the removal and installation of body trim and
exhaust systems.
-When removing, mark and store the installation fasteners to ensure that
they are reinstalled in their original locations.
-When installing the valve cover, ensure that the mating areas are properly
aligned before tightening the fasteners.
-Be sure to replace the exhaust system with a new gasket after disassembly.
-When installing the exhaust system, loosen all fasteners first. Be sure to
tighten the exhaust fitting nuts first, then the mounting bolts.
-Be sure to check the exhaust system for leaks after installation
Troubleshooting Excessive exhaust noise.
-Damaged exhaust system.
-Exhaust gas leaks Poor performance.
-Deformation of the exhaust system.
-Exhaust gas leakage.
-Clogged muffler.

English
version

73
Body trim location/removal diagram

[17] [18] [19] [20] [21]

[1]

[2]
[16]

[3]
[15]
[4]

[5]

[6] [7] [8] [9] [10] [11] [12] [13] [14]

（15）muffler rear
（1） Front decoration assembly (8)engine lower guard plate
section
（16）Rear position
（2）Headlight (9) Shift arm
light
（17）Road book
（3）Front fender (10)Footrest
box
（4）front shock absorber (11) Side stand （18）Clutch handle
（5）Front shock absorber （19）Front oil tank
(12) rear flat fork
decoration (left and right) left
（20） Seat cushion
（6）Front brake disc (13) guide chain box
assembly
（7）Front brake caliper (14) Rear sprocket and chain （21）Rear oil tank

After the bike is powered off, disassemble it in this order:

Seat cushion → front trim parts assembly → front fender → front brake oil pipe pressure
plate → front shock absorber trim parts (left and right) → engine lower guard → hood
bracket → lamps → handlebar → front left and right fuel tank → rear fuel tank → whole
vehicle wiring harness → vehicle electrical → front brake caliper → front wheel → front
English

shock absorber → upper linkage plate → lower linkage plate and steering column
version

assembly → rear wheel → rear brake caliper → rear suspension assembly → flat fork →
exhaust full section → radiator left and right → oil cooling radiator → air filter assembly →
74
throttle assembly → engine.
 ※Cushion assembly

Disassembly/Installation
Remove the following components.

Pull down on the seat pull cable

while pulling the rear end of the seat
Seat lock up and out of the lock, then remove
latch the seat diagonally upward to the rear.

Install the seat cushion：

1. Snap the front and rear pins of the

saddle assembly into the frame slot
respectively.
seat 2. Align the saddle locking pin with
cushion
the locking hole and press down on
the rear of the saddle, the locking pin
will be inserted into the saddle
locking hole and automatically locked
by the latch. Gently pull upward to
ensure the cushion is firmly locked in
place.
3. When the seat cushion is closed,
the seat cushion lock will
automatically lock.

English
version

75
 Fig [1]
※Front trim assembly
1
Disassembly/Installation
Remove the following parts.

- Remove Fig. 1, Fig. 2 - 3 left and

right 1/4-turn quick-lock bolts at
position [1].
- Removal of the front trim of the
fuel tank.

Install in the reverse order of

disassembly.

Fig2 [1]

※Front windshield

Disassembly/Installation
Remove the following parts.

- Remove the 6 hexagon socket

step screws [1];

Install in the reverse order of

disassembly. English
version
Caution.
-Insert the tabs sequentially from the
front, taking care not to remove the [1]
washers. 76
 ※Headlamp cover
Disassembly/Installation
Remove the following components.

- Remove the 4 hexagon socket step

pan head step screws [1];

Install in the reverse order of

disassembly.

[1]

※Front fender

Disassembly/Installation
Disassemble the following parts.

- Remove 4 inner hexagonal flange

bolts [1] and 4 flat washers 4 flanged
bushings;

[1] Install in the reverse order of

disassembly.

English
version

77
※Front shock absorbing trim parts
(left and right)

Disassembly/Installation
Disassemble the following [1]
components.

- Removal of 3 hexagonal flower

head step bolts [1].
- Removal of the front shock
absorber trim right.
- Removal and installation of the left
shock absorber trim member as
above.

The installation order is the reverse

of the disassembly order.
※Front brake tubing press plate [2]

Disassembly/Installation
Remove the following parts.

- Remove 2 x M5x10 internal

hexagonal screws [1];
- Remove the oil tube clamps [2];

Install in the reverse order of [1]

disassembly.

English
version

78
 ※Rear tank protective cover
[2]
Disassembly/Installation
Remove the following components.

- Remove the 5 hexagonal

countersunk head screws [1].
- Removal of the rear fuel tank
protective cover [2].
[1]
Install in the reverse order of
disassembly.

※Rear wheel water barrier leather

Disassembly/Installation
Disassemble the following parts.

- Remove the 2 inner hexagonal

[1] flange bolts [1];
- Remove the rear wheel water barrier
skin [2];

Install in the reverse order of

disassembly.

[2] Caution.
-The rear wheel water barrier is a
rubber product, if it is deformed and
damaged, replace it in time.

English
version

79
※Rear tail cover (factory edition) [1] Figure1

Disassembly/Installation
Remove the following components.

- Removal of 2 hexagonal pan head

bolts [1] in the position of Fig. 1.
- Removal of 2 tailpack mounting
step bolts [2] in the position of figure
1. [2] [4]
- Removal of 3 cross slotted large pan
head self-tapping bolts [3] in position
Figure 2.
Figure 2
- Removal of the rear tailcap [4] in
position Figure 2.

The installation order is the reverse of

the removal order.

[3]

※Rear fender back section (factory

edition)

Disassembly/Installation [2]
Remove the following components.

- Disconnect the taillight wiring harness.

- Removing the four inner hexagonal
flange bolts [1].
- Remove the rear mudguard rear
section [2].

Install in the reverse order of [1]

disassembly.
English
Torque.
version
Rear mudguard rear section and rear
fuel tank attachment bolt
M8x25
15 N.m (1.5 kgf.ft, 11 lbf.ft) 80
 ※Rear tail cover（regular edition）
[1] [4]
Disassembly/Installation
Disassemble the following parts.

- Remove 2 hexagonal pan head bolts [1];

- Remove 2 tail pack mounting step
bolts [2];
- Remove 3 self-tapping nails [3];
[2] - Remove the rear tailcap [4];

The installation order is the reverse of

the disassembly order.

※Rear fender liner（regular edition）

[3] Disassembly/Installation
Disassemble the following parts.

[2] - Remove 4 self-tapping nails [1];

- Remove the rear fender liner [2];

Install in the reverse order of removal.

※Rear fender back section（regular

edition）
[1]
Disassembly/Installation
Remove the following components.
[2]
- Disconnect the tail harness;
- Remove the four inner six flower
hexagonal flange bolts [1];
- Remove the rear mudguard rear
section [2];

Install in the reverse order of

[1] disassembly.
English
Torque.
version Rear mudguard rear section and rear
fuel tank attachment bolt
M8x25
81 15 N.m (1.5 kgf.ft, 11 lbf.ft)
※Engine sprocket cover
[2]
Disassembly/Installation
Remove the following parts.

- Remove the 2 small sprocket cover bolts [1];

- Remove the small sprocket cover [2];

The installation order is the reverse of the

disassembly order.
※Chain guide box
[1]
Disassembly/Installation
Disassemble the following parts.
- Remove 2 x M6x55 hexagonal socket head cap [1] [2]
screws [1];
- Remove 1 x M6x12 hexagonal bolt [2];
- Pull out the drive chain guide slider [3];
- Remove the empty chain guide box [4];

The installation order is the reverse of the

disassembly order.
[3]
Torque.
Chain guide box mounting bolts [1]. [4]
Chain guide box mounting bolts [2].
10 N.m (1.0 kgf.m, 7.0 lbf.ft)

Check the chain guide box [1] for deformation

damage. [1]
Damage / deformation → Replace.
Caution.
If the metal frame of the chain guide box is
deformed and hits the drive chain, it causes the
drive chain to fall off, wear or noise.
Check if the drive chain guide slider [2] is worn.
If the chain guide slider is worn to the position of
the limit mark [3], replace the drive chain guide
slider. [2]

※Chain guide sprocket [3]

Check whether the lower guide

sprocket [1] is excessively worn or the
guide sprocket bearing is stuck.
If necessary, replace promptly.
Wear limit: 2mm (mm)
Caution.
When disassembling, be sure to use new
bolt nuts. English
Torque.
Lower side fastening guide sprocket nut. version
22 N.m (2.2 kgf.m,18 lbf.ft)
[1]
82
 ※Chain Guard
upper lower
Disassembly/Installation
[3] Disassemble the following parts.

- Remove 2 Phillips half-round head screws

[1] [1], [2] from the upper part of the flat fork;
- Remove 1 Phillips half-round head screw
from the lower part of the flat fork [3];
- Remove the chain guard [4];
[1] [2]
The installation order is the reverse of the
disassembly order.
Torque.
Chain retainer mounting screw x3 [1].
8.0 N.m (0.8 kgf.ft, 6.0 lbf.ft)
Check the chain guard for excessive wear.
The wear limit does not exceed:
3mm on the upper side
Lower side 2mm

Caution.
-Replace the chain guard when it exceeds
the wear limit.
-If the chain guard is worn to the limit or
damaged, the chain will damage the rear
flat fork or drive chain.

※Rear brake caliper trim/rear disc

brake trim
[2]
Disassembly/Installation
Remove the following parts.

- Remove 2 screws [1] to remove the

caliper trim [2];
- Remove 2 screws [3] to remove the rear
disc brake trim [4];
[1]

[3] [4] The installation order is the reverse of the

disassembly order.

Note: Regular edition does not

have rear disc brake trim.

English
version

83
※Hand windshield-(left and right)
[2]
（factory edition）

Disassembly/Installation
Remove the following components.

- Removal of 3 hexagon socket step screws

[1].
- Removal of hexagon socket countersunk
head screws [2].
- Removal of 2 inner hexagonal socket [1]
head flange bolts [3].
- Remove the hand windshield bracket [4].
[3] [4]
- Remove the hand windshield bushings [5].
- Disassemble in the same manner as left
and right.

The installation order is the reverse of the

disassembly order.

Note: -regular edition without hand

windshield
[5]

English
version

84
 ※Engine lower guard assembly

Disassembly/Installation
Disassemble the following parts.

- Removal of 5 inner hexagonal flange

bolts [1].
- Remove the lower shield assembly [2].

Install in the reverse order of disassembly.

[1] [2]
※Oil cooling grille

Disassembly/Installation
[1] Remove the following components.

- Removal of 2 hexagonal screws [1].

[2] - Removal of the oil cooling grille [2].

Install in the reverse order of disassembly.

※Emergency water bottle (regular

edition without emergency water
bottle)

[1] Disassembly/Installation
Remove the following components.

- Removal of the lower shield [1].

- Removal of the five inner hexagonal
flange bolts [2].
- Removal of the emergency water bottle
[3].

Install in the reverse order of disassembly.

[2]

[5] ※Tool box cover

Disassembly/Installation
Disassemble the following components.

- Unscrewing the 1/4 turn quick-lock

English bolt [4].
- Removal of the tool box cover [5].
version
[3] [4]
Install in the reverse order of
85 disassembly.
※Rearview mirror assy (regular
edition)

Disassembly/Installation
Disassemble the following parts. [2]

- Loosen the nuts [1].

- Rotate the rearview mirror until the
mirror [2] is removed. [1]
- Removal and installation of the right
side mirror as for the left.

The installation order is the reverse of

the removal order.
Note: factory edition does not have this mirrors.

English
version

86
 [2] ※Left and right side of foot pedal
assembly

Disassembly/Installation
[3] [4] Disassemble the following parts.
- Removing the cotter pin and flat pad [1].
- Removal of the main foot pin [2].
- Removing the foot pedal [3] and torsion
spring [4].
[1] - Installing and disassembling the same left
and right.

The installation order is the opposite of the

disassembly order.
Factory edition and regular edition
disassembly and assembly are the same as
[1] [2] above.
※Side stand assembly（factory
edition）

Disassembly/Installation
Remove the following components.

- Removal of side bracket tension springs

and side bracket mounting pegs [1].
[3] - Removal of the nut [2] to remove the
special bolt for the side bracket.
- Removal of the side bracket [3].

The installation order is the reverse of the

disassembly order.
※Side stand assembly（regular edition）
[1] [3] [4]
Disassembly/Installation
Remove the following components.

- Disconnect the side bracket flame

failure switch harness [1].
- Removing the flame failure switch
fastening bolt [2].
- Removing the side bracket tension
[2] [5] spring [3] and the side bracket mounting
peg.
- Remove the nut [4] to remove the
English special bolt for the side bracket.
version - Removing the side bracket [5].

The installation order is the reverse of

87 the disassembly order.
 ※exhaust assembly（regular edition）
[2] [6] [4]
1. Exhaust mid-section, tail section
Removal/Installation
Remove the following components.
- Removal of the hoop locking bolt [1].
- Remove the exhaust tail section locking bolt
[2].
- Removing the exhaust tail section [3].
- Remove the exhaust mid-section bolt [4].
- Loosen the hoop locking bolt [5].
- Removing the middle section of the exhaust [6].
The installation order is the reverse of the [3] [1]
removal order.front section
2. Exhaust
Disassembly/Installation
Remove the following components. [8] [5] [7]
[9]
- Disconnect the oxygen sensor harness
connector [7].
- Remove the exhaust front section fastening
nut [8].
- Remove the front section of the muffler [9].
1. Check.
-Exhaust seal, gasket.
Exhaust air leakage → Replace.
-Exhaust pipe front middle end section
Cracked / damaged → Replace.

※exhaust assembly（factory
edition）

Exhaust front section mid section,

[2] [3] [4]
tail section
Disassembly/Installation
Remove the following parts.
- Removal of exhaust tail section tension
spring [1].
- Remove the exhaust tail section bolts [2].
- Removing the exhaust tail section [3]. [1]
- Removal of the exhaust mid-section bolts [4].
- Removal of the exhaust mid-section and
front section tension springs x2 [5].
- Removal of the middle section of the muffler
[6].
- Removal of the muffler front section
[6]
fastening nut [7].
- Removal of the front section of the muffler [7]
[8].
1. Check.
-Exhaust gasket.
Exhaust air leakage → Replace.
-Exhaust pipe front middle end section
English
Cracked / damaged → Replace.
-Exhaust tension spring version
Broken / damaged → Replace.
Caution.
-Wait for the muffler to cool down
[8] [5] 88
before disassembling to avoid hand burns.
 EFI
1. Overview ...................................................................................................... 90
2 System Location ........................................................................................ 91
3 EFI System Related Components ....................................................... 92
4 Introduction to System Troubleshooting Functions ................. 105
5 Inspection and Diagnosis Process ..................................................... 109
6 Troubleshooting based on fault codes .......................................... 109
7 Troubleshooting based on fault phenomena ............................. 118
8 Fault Code List....................................................................................... 123

English
version

89
1. Overview:
-This section introduces the EFI system service of MSE8.0, which is equipped
with self-diagnostic function, when troubleshooting, please check and
troubleshoot according to the fault diagnosis code and fault phenomenon.
-EFI system failure is usually related to poor connector connection or
connector corrosion, please check the connector before troubleshooting.

Caution.
- During the repair process, it is prohibited to disassemble the parts of the EFI
system.
- Repair process, take electronic components (electronic control unit, sensors,
etc.), be very careful not to let them fall, and do not touch the electrical
components pin parts to avoid damage caused by electrostatic breakdown.
- Do not arbitrarily remove any parts of the EFI system plug-in from its
installation position to avoid accidental damage or water, oil and other
foreign objects into the plug-in, affecting the normal work of the EFI system.
- When disconnecting and connecting the plug-in, be sure to put the ignition
switch in the off position, otherwise it will damage the electrical components.
- As the idle speed adjustment is completely completed by the EFI system, no
manual adjustment is required. The throttle limiting screw of the throttle body
has been adjusted at the factory, and the user is not allowed to change its
initial position at will.
-The car adopts the trigger signal of 24-2 teeth to identify the speed.

The following color codes used are indicated through this section

Bl=black G=green Lg=light green R=red Y=yellow

Br=brown Gr=gray O=orange V=violet
English
Bu=blue Lb=light blue P=pink W=white
version

90
 2. System location

Racing version
Ignition coil
spark plug
ECU

Throttle Oxygen
Assembly Sensor

Civilian version
Ignition coil
spark plug
ECU Control Unit

Throttle Oxygen
English Assembly Sensor
version

91
3. EFI system-related components

3.1 ECU electronic control unit

The electronic control unit is the brain of

the entire EFI system and electrical
appliances. It analyzes and processes the
various information provided by the
sensors and sends the resulting
conclusions in the form of commands to
the actuators so that the engine runs in ECU Form Factor
an optimal state.
Caution.
-Do not allow to add load to the
housing or to the cover: take it
gently and do not allow to drop it
on the ground.

Function of each ECU pin. ECU Connector Outline View

PIN- PIN-
SIGNAL FUNCTION SIGNAL FUNCTION
NO NO

Upstream oxygen sensor 1

1 A_P_LSVK 18 A_S_MIL MIL灯
heating

Headlight relay
2 A_P_STPA Stepper motor A 19 A_S _IIIR
(competitive version)

Speed signal input (civilian Upstream oxygen

3 E_F_ VSIN 20 E_A_LSVK1
version) sensor 1

4 U_U_UBD UBD continuous power supply 21 E_A_DKG Throttle position sensor

5 E_F_DGA Engine speed sensor A terminal 22 NC Reserved

6 E_F_DGB Engine speed sensor B terminal 23 NC Reserved

7 M_M_GND1 Power ground 1 24 A_P_STPC Stepper motor C

8 E_A_DS Intake pressure sensor 25 A_P_STPB Stepper motor B

9 A_P_NMOT Engine speed output 26 E_S_KL15 Ignition Switch

10 M_M_GND2 Power ground 2 27 M_R_SEN Sensor ground

11 A_P_ZUE1 Ignition coil 1 28 A_S_REL Oil Pump Relay

12 A_P_EV1 Injector 1 29 A_S_MR Main Relay

13 A_P_STPD Stepper motor D 30 E_A_DUMP Dump switch DUMP

14 E_S_NGEAR Neutral switch 31 E_S_RES1 Side support switch

Engine coolant English

temperature sensor
15 A_U_5V1 5V power supply1 32 E_A_TMOT version
(water temperature
sensor)

Intake air temperature

16 B_D_CANL CAN communication line low 33 E_A_TANS
sensor

17 B_D_CANH CAN communication line height 92

 Ignition coil shape drawing 3.2 Ignition Coil

The ignition coil converts the low

voltage electricity from the primary
winding to the high voltage
electricity from the secondary
winding, which is discharged
through the spark plug to produce
Fig. 1
a spark that ignites the fuel mixture
in the cylinder.

Definition of the function of each pin.

Power: connects to the main relay (violet)

Signal: connect to ECU pin 11 (black and
yellow)

Figure 1: shows the wiring diagram

of the ignition coil and ECU.

Measure the secondary ignition

voltage.

Connecting the engine according to the

EFI schematic.
Connecting the peak voltage measuring
instrument according to the diagram.
Start the engine.
After starting, the secondary ignition
voltage should be >22,500V.

Ignition coil parameter table

1. Static parameters
Primary resistance: 1.3±10%Ω
Secondary resistance: 8.7±10%KΩ
Primary inductance: 3.0±15%mH
Secondary inductance: 16±15%H
2.Dynamic parameters.
Supply voltage: 14±0.5V
English Primary current: 7±0.9A
Ignition pulse width: 2.05±0.5msec
version Peak voltage Secondary high voltage: MIN22.5KV at
1 measuring 3 Battery 25pF load
instrument Ignition energy：MIN21.5mj
93 Operating temperature: -35℃-125℃
2 ECU 4 Spark Plug
3.3 Spark plug
[2] [1]
Caution.
-Before removing the spark plug use
an air gun to blow and clean the spark
around the plug base and also make
sure that no dust has fallen into the
cylinder.
1. Check.
● Spark plug type
Incorrect → Replace.
Manufacturer / Model
NGK/LMAR8A-9CR8E [2]

2. Check.
- Electrode "1"
Damaged / depleted → Replace the
spark plug.
- Insulator "2"
Abnormal color → Replace the spark
plug.
Normal color should be tan or light
tan.

3. Cleaning.
- Spark plugs
(Use spark plug cleaner or wire brush)

4. Measurement.
- Spark plug gap "a"
(Thickness gauge measurement)
Out of specification → Adjust the gap.
Spark plug gap
0.80-0.90 mm (0.031-0.035 in)

5. Installation.
- Spark plugs
Install spark plugs tightened to
specified torque of
13 N-m (1.3 kgf-m, 9.6 lb-ft)

Caution.
-Clean the spark plug and gasket English
surfaces before installing the spark version
plugs.

94
 Injector profile drawing 3.4 Injector
One end of the injector is mounted
on the injector holder, and the other
end is connected to the fuel pipe
through the injector cap. It injects fuel
within the specified time according to
the instruction of ECU, by which fuel is
supplied to the engine and atomized.
This injector adopts four-hole injection
and shall not be rotated after fixing the
card spring.

Definition of the function of each pin.

1: Positive (+) connected to the main relay
(purple)
2: Negative (-) connects to pin 12 of ECU
(orange and black)
factory edition wiring diagram

Fig1 Injector resistance: 12.5Ω±5%

Fig 1: shows the wiring diagram of
the injector and ECU
Tips 1. in order to avoid contamination
of the injector injection area, the injector
inlet end should always be located
above the outlet end (at the injector
installation location on the entire
vehicle).
2. In order to achieve the best injector
assembly, clean silicone-free engine oil
must be used to lubricate the upper and
lower O-ring circumference; lubricant
must not contaminate the injector
regular edition wiring diagram interior and spray holes;
3. Removal and reassembly of the
Fig1 injector must be replaced when the O-
ring, the operation does not allow
damage to the sealing surface.
Injector installation.
Injector installation by hand,
prohibit the use of hammer and
other tools to knock
O-ring must be replaced when
removing and installing the injector.
when disassembling the injector, if
English
necessary, first carry out pressure
version relief treatment.
After installing the injector, carry out
the sealing test to ensure that there
95 is no leakage.
3.5 Fuel Pump
The fuel pump assembly and the wiring Fuel pump outline drawing
diagram of the connection with the fuel
pump relay ECU.
This fuel pump assembly integrates a
fuel pump, a plastic holder coarse and fine
filter and a regulator, which works to pump
fuel from the fuel tank to the engine at a
certain oil pressure and flow rate.

Function definition of each pin.

1: connected to the fuel pump relay
output (+) (brown-green)
2: Connected to the negative terminal of
the battery (-) (green)
Performance parameters.
Regulator opening pressure:
0.33±0.01mpa
When the flow rate is 40L/h, the Fig1
corresponding rated pressure value
330±10 kPa
This fuel pump assembly is installed at
the bottom of the fuel tank on the left
front side of the vehicle.
Do not run the fuel pump assembly in the
no-load, no-oil condition to avoid
damage.
Hold it gently when installing or
disassembling, and do not drop it to the
ground.

Measuring oil pressure

Connect the oil pressure
gauge to the fuel pump
assembly outlet, and lock it
with clamps to ensure that Figure 1: shows the wiring
there is no leakage at the diagram of the fuel pump and
combination Press the ignition ECU.
off switch, the fuel pump will
work for 5 seconds and then
stop rotating.
Fuel line pressure relief treatment
The fuel supply pressure of the EFI system is high, and all fuel lines
are made of high-pressure resistant fuel lines, so even if the engine is
not running, the fuel line also maintains a high pressure, so only
English
during the repair process, note: do not easily disassemble the fuel line:
when repairing the fuel system in need of repair, remove the fuel line version
before the fuel system should be unpressurized, as follows: remove
the fuel pump relay, or remove the fuel pump harness connector 2P
( Black), start the vehicle and idle until the engine turns off on its own.
96
 3.6 Throttle Body Assembly
Fig1 [3] [3]
Connects the air filter and engine,
controls the opening and closing
angle of the throttle plate by the
throttle cable, and sends the turning
[1] angle signal to the ECU by the
throttle position sensor.
[4] As shown in figure 1 on the right
[2] [4]
sensor locations.
If not for maintenance 1. intake air temperature, intake air
disassembly is prohibited pressure, throttle position [1];
Three in one sensor mounting screw 2. Idle speed stepper motor [2];
specifications.
M4x12 screw Sensor installation precautions.
Screw tightening torque at position [3]: 1. The terminals must not be sticky with
2.0±0.4N.m water, oil and other liquids.
Stepper idle motor mounting screw 2. Do not contact with harmful gases (Cl,
specification: M4x12 screw SO₃, etc.).
M5x14 spring pad combination screw 3. Do not use falling parts.
Screw tightening torque at position [4]: 4. Do not use external force to deform
4.0±0.4N.m or break the parts.
5. Do not allow direct contact with the
Fig2 terminals (to prevent static electricity).
6. When cleaning the throttle, the
pressure channel must be blocked.
[3] [2]
As in Fig 2 idle speed limit screw [1]
is not allowed to be adjusted.

[1]
-Engine idle speed is completely
adjusted by EFI system, manual
NO disassembly adjustment of idle speed limit bolt is
not allowed.
-It is not allowed to add load on the
Specification for installation of the pull shell or cover.
wire bracket: M5×10 screws. -Take it lightly when disassembling
Screw tightening torque at position [2] and do not allow it to fall on the
3.5±0.5N.m
ground.
Screw tightening torque at position [3]
4.5±0.3N.m

Throttle valve body inspection.

1. flexible movement of the throttle plate, no stalling.
2. throttle body and the oil and gas channel without foreign matter
English (foreign particles size <0.34mm).
version 3. Each product without omissions, misgrouping, under-products,
internal parts installed securely without falling off.
4. Throttle screw fastening reliable, no loose.
97
3.7 Three-in-one sensor
Intake air temperature
The intake air temperature sensing
element is a negative temperature
coefficient (NTC) resistor, the resistance
of which varies with the intake air
temperature.
This sensor delivers a voltage to the
ECU controller that indicates the change
in intake air temperature.
Three-in-one shape drawing
Intake Pressure
Monitors intake tube pressure to Fig1
provide the ECU with information on
engine load.
Throttle Position
This sensor is used to provide throttle
angle information to the ECU. Based on
this information, the ECU can obtain
engine load information, operating
condition information (e.g., start, idle,
reverse tow, part load, full load), and
acceleration and deceleration information.
Function definition of each pin.
Fig 1: shows the wiring diagram of 1. Intake air temperature signal output (GND)
the 3-in-1 sensor and ECU. (pink and black)
2. Intake air pressure signal output (TPS VOUT)
(pink-green)
Characteristic parameters of intake 3. Connected to 5V power supply (VCC) (pink 1)
air temperature sensor 4. Throttle position signal output (PB VOUT)
Operating temperature: -40C°/+130C° (pink white)
5. Ground (TA VOUT) (green-black 1)
Rated voltage: pull-up resistor 1 k
operating at 5V or at a constant Installation.
current of 1mA The permissible installation range, which
20C° rated voltage: 2.5 kΩ ± 5% ensures that condensation does not form inside
the sensor, as condensation can damage the
Characteristic parameters sensitive components inside the sensor.
of pressure sensors
value
Parameters Unit
Minimum Typical Maximum
Pressure test range 10 115 kPa
Operating temperature -40 130 C
Supply Voltage 4.75 5.0 5.25 V
Throttle position sensor characteristics parameters
English
value version
Quantity Unit
Minimum Typical Maximum

Total resistance (pins 1-2) 1.6 2.0 2.4 KΩ

Supply voltage 5 V 98
 3.8 Idle stepper motor
Control the flow of bypass airflow,
stepper motor by the ECU according
to the engine load, through the
engine sensor to control the stepper
motor in different operating
conditions, the injection volume is
also different, so the stepper motor is
needed to make up the air intake, so
it should be connected according to
the specified connection, otherwise it
Idle stepper motor may cause unstable idle speed.
profile drawing
Function of each pin.
Fig1 Stepper motor pin A / connected to
the ECU's 2 (gray-yellow)
Stepper motor pin B / connected to
the ECU's 25 (yellow-green)
Stepper motor pin C / connected to
the ECU's 24 (brown-blue)
Stepper motor pin D / connected to
the ECU's 13 (gray-blue)
Fig 1: The wiring diagram for the idle
stepper motor and ECU.

Fig2
Fig 2: The circuit diagram for the idle
stepper motor.
The following table shows the
characteristic parameters of the
idle stepper motor.
Characteristic parameters
NO Item Spec Terms
1 Rated Voltage 12V DC
Mini/maxoper
2 7.5V-14V
ating voltage
3 Phase Resistor 53±5.3Ω 27℃
Operating -40℃-
4
temperature 125℃
English
version

99
3.9 Oxygen sensor

This sensor is used in the feedback

system of the electronically controlled
fuel injection device to achieve
closed-loop control and improve the
accuracy of the ECU's control of the
air-fuel ratio, which is installed on the
front section of the exhaust pipe to
determine the oxygen content in the Oxygen Sensor Outline Drawing
exhaust gas to determine whether the
gasoline and air are completely
combusted to ensure that the three- Fig1
way catalytic converter has the
maximum conversion efficiency of HC
CO and NOx in the exhaust.

Fig 1: shows the wiring diagram of

oxygen sensor and ECU.

Definition of each pin

function.

English
version

100
 3.10 Engine water temperature
sensor

This sensor is two sets of negative

temperature coefficient (NTF)
thermistor, its resistance value
decreases with the increase of coolant
temperature, but not a linear
relationship. One group is provided to
the ECU to monitor the thermal status
of the engine, and A group is
provided to the ECU for the water
Water temperature profile temperature signal.
A: Temperature sensor signal +
C: Signal ground- Definition of the function of each
pin.
Fig1 A:Signal + connected to ECU pin 32
(grey-green)
C:Signal - connect to ECU pin 27
(green and black 1)

Fig 1: The wiring diagram for the

water temperature sensor and ECU.

ECU resistance value parameter

Tempera Resistance value（kΩ）

ture
range The table on the left shows the
Min Standard Max
°C±1 characteristics of the temperature and
the signal is transmitted to the ECU.
-20 13.65 14.93 16.33

20 2.286 2.435 2.591

80 0.306 0.316 0.327

100 0.178 0.183 0.187

English
version

101
3.11 Sway sensor

The role of this sensor for the

side tilt protection, that is, when the
car side tilt angle exceeds the
allowable angle (65 ° ± 10 °), OUT
pin signal to the ECU, the ECU
control engine off, so as to achieve
the protection of the driver and the
vehicle.

Fig1
As Fig 1: Install with the UP logo
facing up.

Racing version pin function definition.

VDD: connected to the negative battery
terminal - (green)
OUT: connect to ECU30 # pin (yellow 4)
GND: connected to the main relay
(purple)

Pin function definition for civilian

version.
VDD: connected to the negative battery
terminal - (green)
OUT: connect to ECU30 # pin (yellow 4)
GND: connected to the power supply
(purple)
regular edition wiring diagram
factory edition wiring diagram

English
version

102
 3.12 Side bracket switch

Check
Disconnect the side stand switch
[1] 3P (white) connector [1].
Check the switch side connector
[2] terminal.
The vehicle can be started normally
when the side stand is lowered, and
automatically turns off after
shifting.
When the side stand is retracted,
the vehicle can be started and
Fig1 driven normally in gear.
Removal/Installation
Remove the following parts.
- Disconnect the side bracket switch
connector and remove the side
bracket wiring harness from the
frame.
- Remove the bolt [1] and side
switch [2].
Install in the reverse order of
removal.
Fig 1: shows the wiring diagram of Caution.
the side bracket switch and ECU. -Align the switch pin with the hole
in the side sill.
-Align the switch slots with the
return spring pins.
-Replace the switch bolt with a new
one.

English
version

103
3.13 Trigger

Provide the engine speed signal

to the ECU, and the ECU determines
the ignition angle, injection phase,
etc. based on this signal.

Trigger profile drawing

Fig1
Fig 1: The wiring diagram of the
trigger and ECU

Measure the resistance value of the

trigger.
Multimeter hit in 1X100Ω file.
Trigger coil resistance: 100Ω-160Ω
(20 °)
If the trigger resistance value is
not in the above range, replace a
trigger.
Measure the peak voltage of the
trigger
Connect the multimeter and peak
voltage adapter according to the
magneto
diagram as follows.
+ probe: green and white (B) lead Trigger
+ probe: blue and white (A) lead resistance

With the multimeter in AC gear. Peak Voltage Meter

Put the gear in neutral and hold
the start button to let the engine turn
for a few seconds, then measure the
peak voltage of the trigger coil:.
Repeat the measurement several
times and measure the highest magneto
trigger coil peak voltage. English
Trigger coil peak voltage: ≥ 2V Trigger peak
version
voltage
(300r/min)

If the trigger peak voltage is not in

the above range, replace a new 104
trigger.
 4. System fault diagnosis function introduction
On-board diagnostic system (OBD system) is a diagnostic system
integrated in the engine control system that can monitor the status of
components affecting exhaust emissions and the main functions of the
engine. It has the function of identifying and storing EFI faults.
When repairing a vehicle with OBD system, the repairer can quickly and
accurately locate the malfunctioning parts through the diagnostic
instrument, which greatly improves the efficiency and quality of repair.
OBD technology involves many brand new concepts, the following is the
first introduction to some basic knowledge related to OBD technology, in
order to facilitate a better understanding of the subsequent content.
4.1 Fault information logging
The electronic control unit constantly monitors sensors, actuators,
associated circuits, fault indicators, battery voltage, etc., and even the
electronic control unit itself, and performs confidence checks on sensor
output signals, actuator drive signals and internal signals (e.g., closed-
loop control, coolant temperature, idle speed control, etc.). As soon as a
fault is detected in a link or a signal value is outside the normal range, the
electronic control unit immediately records the fault information in the
fault memory of the RAM. The fault information is stored in the form of
fault codes and is displayed in the order in which the faults appear.
Faults can be divided into "current faults" and "historical faults" according
to the time of their occurrence.

EFI system Error diagnosis schematic

4.2 Fault Lamp Description and its Control Strategy
Failure Indicator (MIL): Used to indicate the failure of an emission-related
component or system, a MIL light is generally an indicator that can be displayed
on the instrument panel and is shaped in accordance with regulatory
requirements.
The MIL light is activated according to the following principles.
1) In normal mode and with empty fault memory

The ECU is initialized immediately when the ignition is switched on and the
English ignition is switched off. From initialization on, the MIL light is on. The MIL light
goes off immediately after the engine starts.
version 2）In normal mode, and the fault memory is already fault
From the time the ECU is initialized with the ignition switch on, the MIL light is on
continuously; if the fault manager requires the MIL to be on in fault mode, the MIL
105 light is on during the subsequent driving cycle; if the fault manager does not
require the MIL to be on in fault mode, the MIL light is off after starting.
4.3 OBD Interface Introduction
Pin 4, 7 and 16 on the OBD diagnostic connector are used for EMS
with engine management system. Pin 4 of the standard diagnostic
connector is connected to the negative terminal of the battery; pin 7 is
connected to pin E3 of the ECU, which is the "K" wire of the ECU; pin 16
is connected to the positive terminal of the battery

ISO9141-2 standard diagnostic interface pin number

The diagnostic device communicates with the ECU via the "K" wire and can
read the following information.

-Version information display

ECU hardware number, ECU software number.

-Fault code display

Intake pressure sensor, intake temperature sensor, engine temperature
sensor, throttle position sensor, oxygen sensor, oxygen sensor heating line,
air-fuel ratio correction, fuel injector, fuel pump relay, speed sensor, carbon
canister control valve, speed signal, idle speed, idle speed regulator, system
voltage, ECU, fault light and other fault information.

-Engine parameter display

Battery voltage, engine speed, target idle speed, vehicle speed, engine
temperature, engine temperature sensor signal voltage, intake air
temperature, intake air temperature sensor signal voltage, intake air pressure,
intake air volume, stepper motor target position, throttle position sensor
signal voltage, throttle opening, relative throttle position, carbon canister
control valve duty cycle, charge time, injection pulse width, ignition advance
angle, oxygen sensor Short-term correction, oxygen sensor voltage, oxygen
sensor long-term correction, relative engine load, carbon canister control
relative fuel injection, carbon canister purge rate, carbon canister load, idle
actuator TEV opening, ambient pressure, altitude correction factor, injection
phase, and other parameters.

English
version

106
 4.4 Maintenance tools

Tool.
EFI system diagnostic
instrument
Function.
Read/clear EFI system
fault codes and observe
data flow.

Tool:
EFI system adapter
Function.
Check the electrical
signal of each pin of the
electronic control unit,
check the wiring
condition, etc.

Tool:
Ignition Timing Light
Function.
Check engine ignition
timing, etc. .

Tool:
Digital multimeter
Function.
Check the voltage,
current, resistance and
English other characteristic
parameters in the EFI
version
system.

107
Tool:
Vacuum table
Function.
To check the pressure in
the intake manifold.

Tool:
Cylinder pressure gauge
Function.
Check the cylinder
pressure of each cylinder.

Tool:
Fuel pressure gauge
Function.
To check the pressure of
the fuel system
to determine the fuel system
pump and fuel pressure
regulator in the fuel system.
Operation.

English
version

108
 5. Inspection and diagnosis process

5.1 How to use the diagnostic instrument

1. Connect the diagnostic instrument to the diagnostic

interface.

2. Turn on the "ignition switch".

3. Read fault-related information (fault codes, freeze frames, etc.);

check the repair manual to confirm the defective parts and types;
develop a repair plan based on fault-related information.

4. Troubleshoot.

5. Turn on the ignition again, start the vehicle to read the fault
information, and confirm that the fault has been removed.

5.2 Preliminary check

Before starting the troubleshooting steps based on engine fault codes, a
preliminary check should first be made to.
1. confirm that the engine fault indicator is working normally.
2. confirm that the fault phenomenon complained by the owner exists and
confirm the conditions under which the fault occurs.
Then conduct an external inspection to.
-Check if there is any leakage in the fuel line.
-Check whether the vacuum line is broken, kinked and connected correctly.
-Check for blocked, leaking, crushed or damaged air intake lines.
-Check if the high-voltage wires of the ignition system are broken or aging,
and if the ignition sequence is correct.
-Check if the wiring harness joints are clean and firm
-Check whether the sensors and actuators joints are loose or have poor
contact.
Important: If the above phenomena exist, the repair work will be carried out
for the fault phenomenon first, otherwise it will affect
Otherwise, it will affect the later troubleshooting and repair work.

6. Troubleshooting according to fault codes

English This section introduces the meaning of the fault codes used in the current
version MSE6.0 system, the corresponding diagnostic strategy and possible causes of
the faults, as well as the handling strategy of the faults, which can be referred
to during the vehicle maintenance process.
109 All ECU pins mentioned below are based on the actual wiring harness
diagram of the project.
6.1error code: P0030 oxygen sensor heating control circuit open circuit or P0053
oxygen sensor heating unreasonable
Repair Tips. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems (1) Measure the resistance of the line
(1) Open circuit between the circuit between the ECU connector pin and the
connected to the ECU pin and the upstream oxygen sensor pin 2 and
upstream oxygen sensor pin 2. determine if it is normal.
(2) Open circuit between the circuit (2) Measure the resistance between the
connected to the main relay at pin 1 of upstream oxygen sensor pin 1 and the
the upstream oxygen sensor. main relay to determine if it is normal.
(3) Open circuit between upstream (3) Measure the resistance between the
oxygen sensor pin 1 and pin 2. upstream oxygen sensor pin 1 and pin 2
to determine if it is normal.
6.2 error code: P0031 oxygen sensor heating circuit short circuit to ground
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the resistance of ECU pin to
1) The circuit connected to the ECU pin is ground is normal.
shorted to ground.

6.3 error code: P0032 oxygen sensor heating circuit short circuit to the
power supply
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the ECU voltage to see if it is
1) Short circuit between the circuit normal.
connected to the ECU pin and the 2) Measure the resistance between the
upstream oxygen sensor pin 1 circuit. ECU pin and the upstream oxygen sensor
2) Short circuit between the circuit pin 1 circuit.
connected to the ECU pin and other
power circuits.
6.4 error code: P0107 Intake pressure sensor circuit voltage is too low

Repair Tip. Repair Tip.

The fault has been identified as possibly Check the following items
having the following problems 1) Resistance between ECU pin and
1) The ECU has detected a short to ground.
ground in the sensor signal circuit.

6.5 error code: P0108 Intake pressure sensor circuit voltage is too high
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Voltage of ECU pin.
1) The ECU has detected a short circuit in
the sensor signal circuit to the power
supply.

6.6 error code: P0105 intake pressure sensor circuit signal stuck
Repair Tip. Repair Tip. English
The fault has been identified as possibly Check the following items version
having the following problems 1) The presence of serious air leaks in the
1) The ECU detects that the sensor signal intake system.
is jumping too much in the intake 2) Clogged intake air pressure sensor
pressure during normal engine operation sampling port.
is too small. 3) Pressure sensor picking. 110
 6.7 Error code: P0106 Intake pressure sensor circuit signal untrustworthy

Repair Tip. Repair Tip.

The fault has been identified as possibly Check the following items
having the following problems 1) The presence of a serious air leak in the
1) The intake pressure sampling value intake system.
used for load calculation exceeded the 2) Intake air pressure sensor sampling
limit value. port is blocked.
6.8 error code: P0112 intake air temperature sensor signal voltage is
too low
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the resistance between the
1) The sensor signal circuit connected to sensor signal circuit of ECU pin and
the ECU pin is shorted to ground. ground.

6.9 error code: P0113 Intake air temperature sensor signal is too high
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the voltage of the sensor
1) The sensor signal circuit connected to signal circuit at the ECU pin to see if it is
the ECU pin is shorted to the power normal.
supply.

6.10 error code: P0111 Intake air temperature out of range

Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure whether the voltage of the
1) There is a break, short to 5v or ground sensor signal circuit at the ECU pin is
in the engine intake air temperature normal.
sensor. 2) Check whether the temperature sensor
model corresponds to the inventory.

6.11 error code: P0114 intake air temperature signal stuck

Repair Tip. Repair Tip.
The fault has been confirmed that there Check the following items
may be the following problems (1) whether the intake air temperature
1) The engine temperature starts below sensor installation position to
40℃, the engine runs with a certain load position.
for more than 30min, and the rise in (2) Whether the ECU PIN pin corresponds.
intake air temperature is still less than 3℃.

6.12 error code: P0117 Engine coolant temperature sensor circuit

voltage is too low
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the resistance connected to
English
1) Short circuit between the circuit the ECU pin to ground.
version connected to the ECU pin and ground.

111
6.13 error code: P0118 Engine coolant temperature sensor
circuit voltage is too high
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the voltage connected to the
1) Short circuit between the circuit ECU pin to see if it is normal.
connected to the ECU pin and other
power circuits.

6.14 error code: P0116 engine temperature over range

Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure whether the voltage of the
1) There is a break, short to 5v or ground sensor signal circuit at the ECU pin is
in the engine temperature sensor. normal.
2) Check whether the temperature sensor
model corresponds to the parts list.
6.15 error code: P0126 Engine temperature signal stuck
Repair Tip. Repair Tip.
The fault has been identified as 1) Check whether the engine temperature
possibly having the following sensor installation position is in place.
2) Whether the ECU PIN pin corresponds.
problems
1) As the engine runs, the engine
temperature rise performance is not
consistent with the actual engine
temperature.
6.16 error code: P0122 Throttle position sensor circuit voltage is too
low fault
Repair Tip. Repair Tip.
The fault has been identified as possibly having Check the following items
the following problems 1) Measure the resistance connected to
1) ECU pin is shorted to ground. the ECU pin to ground.

6.17 error code: P0123 Throttle position sensor circuit voltage is too
high fault
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the voltage connected to the
1) Short circuit between the circuit ECU pin to see if it is normal.
connected to the ECU pin and other
power circuits.
6.18 error code: P0130 Oxygen sensor signal unreasonable fault
Fault cause introduction: The system judges that the oxygen sensor
signal is unreasonable when the following conditions occur The
oxygen sensor signal circuit is coupled with the heating circuit.
English
Repair Tip. Repair Tip：
The fault has been identified as possibly version
having the following problems
1) Check whether the oxygen sensor
connector is correct and normal.
2) Check whether the oxygen sensor
signal circuit is coupled with the heating 112
circuit.
 6.19 error code: P0131 Oxygen sensor circuit voltage is too low
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the resistance between the
1) The signal circuit connected to the ECU signal circuit connected to the ECU pin
pin is shorted to ground. and ground.

6.20 error code: P0132 oxygen sensor circuit voltage is too high
Cause of failure: When the ECU measures the oxygen sensor circuit
voltage after the engine starts, when the signal voltage is higher than
1.5 volts for a long time, it is judged that the oxygen sensor signal
circuit is short-circuited to the power supply failure.
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the resistance between the
1) Short circuit between the signal circuit signal circuit connected to the ECU pin
connected to the ECU pin and oxygen and the oxygen sensor pin 1.
sensor pin 1. 2) Measure the voltage of the signal
2) Short circuit between the signal circuit circuit connected to the ECU pin.
connected to the ECU pin and other
power circuits.
6.21 error code: P0133 Oxygen sensor response is slow
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Replace the oxygen sensor and fix the
1) The oxygen sensor has aged and the fault.
sensing element is poisoned and
contaminated.
6.22 error code: P0134 oxygen sensor signal circuit open circuit fault"
Fault cause: When the ECU measures the oxygen sensor circuit voltage
after the engine is started, the system judges that the oxygen sensor
signal circuit is open-circuit fault when the signal voltage is always
above 1.2 volts.
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the resistance from the ECU
1) an open circuit in the circuit connecting connector to oxygen sensor No.4.
the oxygen sensor to the ECU pin.
2) poor connection of the oxygen sensor
connector (oxidation of the pin).

6.23 error code: P0201 One-cylinder injector control circuit open circuit
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems
1) whether the injector coil is open circuit.
2) whether the injector connector pin to
English
the ECU pin is well connected.
version (3) whether the injector connector pin to
the main relay connection is good.

113
 6.24 error code: P0261 One-cylinder injector control circuit short
circuit to ground
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the resistance of the circuit
1) Each drive circuit circuit connected to connected to the ECU pin to ground.
the ECU pin is shorted to ground.

6.25 error code: P0262 One-cylinder injector control circuit short-

circuit to the power supply
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the voltage of the circuit
1) The circuit connected to the ECU pin is connected to the ECU pin.
shorted to another power source.

6.26 error code: P0322 No tacho sensor pulse signal (open or short circuit)
Fault cause: When the engine is started the ECU monitors both the tacho
sensor signal and other signals.
By the signal reasonableness system is judged to be the loss of tacho
sensor signal.
Repair Tip. Repair Tip.
The fault has been identified as possibly
having the following problems
1) an open circuit in the circuit connecting
the tacho sensor to the ECU.
2) Short circuit in the circuit connecting
the tacho sensor to the ECU.
3) Open circuit in the tacho sensor coil.

6.27 error code: P0444 carbon canister control valve control circuit
open circuit
Repair Tip. Repair Tip.
The fault has been identified as possibly
having the following problems
1) Open circuit between the circuit
connected to the ECU and the carbon
canister control valve pin 2.
2) An open circuit between the carbon
canister control valve pin 1 and the main
relay.
3) Open circuit in the solenoid coil
between pin 1 and pin 2 of the carbon
canister control valve.

6.28 error code: P0458 carbon canister control valve control circuit
voltage is too low
Repair Tip. Repair Tip. English
The fault has been identified as possibly Check the following items
version
having the following problems 1) Measure the resistance to ground
1) The circuit connected to the ECU is connected to the ECU pin to see if it is
shorted to ground. normal.

114
 6.29 error code: P0459 carbon canister control valve control circuit
voltage is too high
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the voltage at the ECU pin to see
1) Short circuit between the circuit if it is normal.
connected to the ECU and the carbon 2) Measure the resistance between the ECU
canister control valve pin 1 circuit. pin and the carbon canister control valve pin
2) Short circuit between the circuit 1 circuit.
connected to the ECU pin and other power
circuits.

6.30 error code: P0508 stepper motor drive pin shorted to ground
Fault code: P0509 stepper motor drive pin short circuit to power
Fault code: P0511 stepper motor drive pin open circuit or overload
Cause of failure: When the circuit control module in the ECU after the
engine is started to continuously monitor the voltage of the idle stepper
motor drive circuit, when any of the four circuits have a short circuit to
ground/short circuit to power supply/open circuit/overload, the system
determines that the stepper motor circuit corresponds to a fault.
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the resistance or voltage
1) Any of the stepper motor drive circuits between each stepper motor drive circuit
connected to the ECU is shorted to ground connected to the ECU and ground.
to the power supply short/open circuit.

6.31 error code: P0560 system battery voltage signal is not reasonable
Fault code: P0562 system battery voltage is too low
Fault code: P0563 system battery voltage is too high
Repair Tip. Repair Tip.
Check the following items
The fault has been identified as possibly 1) Check generator power generation capability (measure generator
voltage after starting).
having the following problems
1) the generator has been damaged unable
to generate electricity or battery leakage.
2) An open circuit in the generator excitation
circuit.
3) generator regulator has been damaged
can not control the amount of power
generation resulting in high generation
voltage.
6.32 error code: P0627 oil pump relay control circuit open circuit
Fault code: P0628 Oil pump relay control circuit short-circuit to ground
Fault code: P0629 oil pump relay control circuit short-circuit to power
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the resistance or voltage of the
1) open circuit/short circuit to ground/short fuel pump relay control circuit connected to
circuit to power supply between the oil the ECU.
English pump relay control circuit connected to the 2) The resistance between the relay to the
ECU and the oil pump relay. main relay.
version 2) Open circuit between the relay 3) The resistance between the two legs of
connection to the main relay. the relay.
3) Open circuit in the solenoid coil of the
relay.
115
6.33 error code: P0650 MIL lamp driver stage circuit failure
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Measure the resistance or voltage of
1) open circuit/short circuit to the MIL lamp driver circuit connected to
ground/short circuit to power supply in the ECU.
the MIL lamp drive circuit connected to
the ECU.
2) Open circuit between the MIL
connection to the main relay.
3) MIL lamp burned out.

6.34 error code: P2300 Ignition coil short to ground

Repair Tip. Repair Tip.

The fault has been identified as possibly Check the following items
having the following problems 1) Measure the resistance and voltage of
1) The ignition coil drive circuit is shorted the ignition coil drive circuit connected to
to ground. the ECU.

6.35 error code: P0301 engine misfire fault

Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems
1) abnormal ignition coil drive circuit
drive.
2) Abnormal injector circuit drive.
3) Wire harness interference exists in the
DG signal.

6.36 Error code: P0507 Engine idle speed is too high

Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems
1) Air leakage from the air intake system.
2) stepper motor plug jammed at a large
opening.
3) Large air leakage from the valve body.

6.37 Error code: P0506 Engine idle speed is too low

Repair Tip. Repair Tip.
The fault has been identified as possibly
Check the following items
having the following problems
1) abnormal stepper motor drive and
plug jammed at a lower opening.
2) blockage of the air intake system.
3) Small air leakage from the valve body.
English
version

116
 6.38 Error code: P2177 Non-idling mixture is too lean
Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Whether the fuel pressure regulating
1) Low oil supply pressure. valve (3.5 bar) is normal.
2) Insufficient oil supply. 2) The fuel supply line is bent and
blocked.

6.39 Error code: P2178 Non-idling mixture is too rich

Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems 1) Is the fuel pressure regulating valve
1) The oil supply pressure is high. (3.5 bar) normal.

6.40 Error code: P2187 Idle speed mixture is too lean

Repair Tip. Repair Tip.

The fault has been identified as possibly Check the following items
having the following problems 1) Whether the fuel pressure regulating
1) Low oil supply pressure. valve (3.5 bar) is normal.
2) Insufficient oil supply. 2) The fuel supply line is bent and
blocked.

6.41 Error code: P2188 Idle speed mixture is too rich

Repair Tip. Repair Tip.

The fault has been identified as possibly Check the following items
having the following problems 1) Is the fuel pressure regulating valve
1) The oil supply pressure is high. (3.5 bar) normal.

6.42 error code: P0501 speed signal break

Repair Tip. Repair Tip.
The fault has been identified as possibly Check the following items
having the following problems (1) Check whether the speed sensor
(1) The vehicle is coasting, the speed connector is loose and
signal is less than 5km/h, and the whether the sensor installation position is
duration is greater than 10s. facing the signal plate.
(2) The distance between the sensing part
of the speed sensor and the signal plate
is less than 1.8mm.

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117
 7. Troubleshooting according to the fault phenomenon
This section introduces the meaning of the current fault phenomenon, the
corresponding diagnosis strategy and possible causes of the fault, as well as
the treatment strategy of the fault, which can be referred to during the
vehicle maintenance.
7.1 When starting, the engine does not turn or turns slowly.
General fault parts: 1, battery; 2, starter motor; 3, wiring harness or ignition switch; 4,
engine mechanical parts.
General diagnostic process.
No. Procedure Testing Following Steps
results
Use a multimeter to check the voltage between Y Next setp
1 the two terminals of the battery when the
engine is started whether
around 8-12V. N Battery replacement
Keep the ignition switch in the starting position Y Next setp
2 and use a multimeter to check if the positive
terminal of the starter motor has a voltage of 8V Repair or replace wiring
N
or more. harnesses
Disassemble the starter motor and check the Repair or replace starter
Y
3 working condition of the starter motor. Focus on motor
checking if it has a broken circuit or is stuck due
to poor lubrication. N Next setp
If the fault occurs only in winter, check whether Change the appropriate
the resistance of the starter motor is too high Y
4 grade of lubricant
due to improper selection of engine lubricant。
N Next setp
Check if the internal mechanical resistance of Checking internal engine
5 Y
the engine is too large, resulting in the starter resistance
motor not turning or turning slowly. Repeat the above
N stepsRepeat the above
steps
7.2 When starting, the engine can be towed, but cannot be started successfully.
General fault parts: 1, no oil in the fuel tank; 2, fuel pump; 3, speed sensor; 4, ignition coil;
5, engine mechanical parts.
General diagnostic process.
No. Procedure Testing Following Steps
results
Connect the fuel pressure gauge (access point Y Next setp
1 injector inlet pipe front), turn on the ignition
switch, repeat several times if necessary, or start
Inspection and repair of
the engine and check whether the fuel pressure N
the oil supply system
is around 300kPa.
Connect the EFI system diagnostic instrument, Y Next setp
2 observe the "engine speed" data item, start the
engine, and observe whether there is a speed Repair of speed sensor
N
signal output. wiring
Pull out the ignition high voltage wire, connect Y Next setp
3 the spark plug, make the spark plug electrode
from the engine body about 5mm, start the Inspection of ignition
engine, check whether there is blue and white N
system
high voltage fire.
Check the pressure condition of the engine Troubleshooting engine English
Y
4 cylinder and observe whether there is insufficient mechanical problems version
pressure in the engine cylinder.
N Next setp
Connect the EFI adapter, turn on the ignition Y Diagnostic Help
5 switch, and check whether the power supply of
Inspection of the
pins 4# and 15# is normal; check whether the N
overlap of pins 7# and 10# is normal. corresponding wiring 118
 7.3 Difficult to start when cold and hot.
General fault parts: 1, fuel containing water; 2, fuel pump; 3, engine temperature sensor;
4, injectors; 5, ignition coil; 6, throttle body and idle bypass airway; 7, engine mechanical
parts.

General diagnostic process.

No. Procedure Testing results Following Steps

Connect the fuel pressure gauge Y Next setp

1
(access point for the front of the
injector inlet pipe), start the Inspection and repair of
engine, and check whether the fuel N
oil supply system
pressure is around 300kPa.
2 Pull out the ignition high-voltage Y Next setp
wire, connect the spark plug, so
that the spark plug electrode is
about 5mm from the engine body, Inspection of ignition
N
start the engine, check whether system
there is blue and white high-
voltage fire.
Dial off the engine temperature
3 Repair the wiring or
sensor connector, start the engine, Y
replace the sensor
and observe whether the engine
starts successfully at this time. (Or
connect a 2500 ohm resistor in
series with the engine temperature
sensor connector instead of the
engine temperature sensor, and N Next setp
observe whether the engine starts
successfully at this time.
start.)
Throttle and idle airway
4 Pull the throttle gently and observe Y
cleaning
if it starts easily.
N Next setp
Disassemble the injector and check Y Replacement of faults
5 whether there is leakage or
blockage in the injector with the
special cleaning analyzer for N Next setp
injectors.
Check the fuel condition and Y Fuel Replacement
6
observe whether the failure
phenomenon is caused by just N Next setp
after refueling.
Check the pressure condition of Troubleshooting engine
Y
7 the engine cylinder and observe mechanical problems
whether there is insufficient
pressure in the engine cylinder. N Next setp
Connect the EFI adapter, turn on Y Diagnosis Help
8
the ignition switch, and check
whether the power supply of pins
4# and 15# is normal; check Inspection of the
English N
whether the overlap of pins 7# and corresponding wiring
version 10# is normal.

119
7.4 Start normally, but idle speed is unstable at any time.
General fault parts: 1, fuel containing water; 2, injector; 3, spark plug; 4, throttle body and
idle bypass airway; 5, air intake; 6, idle speed regulator; 7, ignition timing; 8, spark plug; 9,
engine mechanical parts.

General diagnostic process.

No. Procedure Testing results Following Steps
Check if the air filter is clogged and Inspection of air intake
Y
1 if there are air leaks in the air system
intake tract. N Next setp
Check if the idle speed regulator is Y Cleaning or replacement
2
stuck. N Next setp
Check the spark plug of the Y Next setp
cylinder and observe whether its
3 Adjustment or
model and gap meet the N
replacement
specification.
Check the throttle body and idle Y Cleaning
4
bypass airway for carbon buildup. N Next setp
Disassemble the injector and use Y Faulty replacement
the special cleaning analyzer for
5 injectors to check whether there
are leaks, blockage or flow rate N Next setp
over-performance.
Check the fuel condition and Y Fuel Replacement
observe whether the failure
6
phenomenon is caused by just N Next setp
after refueling.
Check the pressure of the engine Troubleshooting engine
Y
cylinders and observe whether mechanical problems
7
there is a large difference in the
N Next setp
engine cylinder pressure.
Check whether the mechanical Y Next setp
8 ignition timing of the engine meets
N Checking ignition timing
the specification.
Connect the EFI adapter, turn on Y Diagnostic Help
the ignition switch, and check
whether the power supply of pins
9 Inspection of the
4# and 15# is normal; check N
whether the overlap of pins 7# and corresponding wiring
10# is normal.

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version

120
 7.5 The speed does not go up or stalls when accelerating.
General fault parts: 1, fuel containing water; 2, intake pressure sensor and throttle
position sensor; 3, spark plug; 4, throttle body and idle bypass airway; 5, intake airway; 6,
idle speed regulator; 7, injector; 8, ignition timing; 9, exhaust pipe.
General diagnostic process.
Testing
No. Procedure Following Steps
results
Inspection of air intake
Y
1 Check the air filter for blockage。 system
N Next setp

Connect the fuel pressure gauge (access Y Next setp

point for the front of the injector inlet pipe),
2
start the engine, check the fuel pressure at Inspection and repair of
idle speed in about 350kPa. N
oil supply system

Check the spark plug of the cylinder and Y Next setp

3 observe whether its model and gap meet Adjustment or
the specification. N
replacement
4 Remove the idle speed regulator, check Cleaning of related
Y
the throttle body, idle speed regulator and parts
4
idle speed bypass airway for carbon
accumulation. N Next setp

Check whether the intake pressure sensor, Y Next setp

5 throttle position sensor and its wiring are Repair the wiring or
normal. N
replace the sensor
Disassemble the injector and check whether Y Faulty replacement
there is leakage or blockage in the injector
6
with the special cleaning analyzer for N Next setp
injectors.
Check the fuel condition and observe Y Fuel Replacement
7 whether the failure phenomenon is caused
by just after refueling. N Next setp

Check whether the engine ignition Y Next setp

8 sequence and ignition timing meet the Checking ignition
specifications N
timing
Y Next setp
9 Check the exhaust pipe for smooth exhaust. Repair or replace
N
exhaust pipes
Connect the EFI adapter, turn on the Y Diagnostic Help
ignition switch, and check whether the
10 power supply of pins 4# and 15# is normal; Inspection of the
check whether the overlap of pins 7# and N
corresponding wiring
10# is normal.

English
version

121
7.6 Slow response during acceleration.
General fault parts: 1, fuel containing water; 2, intake pressure sensor and throttle
position sensor; 3, spark
plug; 4, throttle body and idle bypass airway; 5, air intake; 6, idle speed regulator; 7, fuel
injector; 8.
Ignition timing; 9, exhaust pipe.

General diagnostic process.

No. Procedure Testing results Following Steps
Inspection of air intake
Y
Check the air filter for clogging. system
1
N Next setp
Connect the fuel pressure gauge Y Next setp
(access point for the front of the
injector inlet pipe), start the engine
2 and check whether the fuel
N Inspection and repair of
pressure is around 350kPa at idle
oil supply system
speed.

Check the spark plug of the cylinder Y Next setp

and observe whether its model and
3 Adjustment or
gap meet the specification. N
replacement
Remove the idle speed regulator, Y Cleaning of related parts
check the throttle body, idle speed
4 regulator and idle speed bypass
N Next setp
airway for carbon accumulation。
Check whether the intake pressure Y Next setp
5 sensor, throttle position sensor and Repair the wiring or
its wiring are normal. N
replace the sensor

No. Procedure Testing results Following Steps

Disassemble the injector and Y Faulty replacement
check whether there is leakage or
blockage in the injector with the
6 N Next setp
special cleaning analyzer for
injectors.
Check the fuel condition and Y Fuel Replacement
observe whether the failure
7 phenomenon is caused by just N Next setp
after refueling.

Check whether the ignition Y Next setp

sequence and ignition timing of Checking ignition
8 N
the engine meet the specification. timing
Y Next setp
Check the exhaust pipe for
9 smooth exhaust. Repair or replace
N
exhaust pipes
Connect the EFI adapter, turn on Y Diagnostic Help
English
the ignition switch, and check version
whether the power supply of pins
10 4# and 15# is normal; check Inspection of the
N
whether the overlap of pins 7# corresponding wiring
and 10# is normal.
122
 8. Annexes:
•-List of error codes (PCODE)
No. Error Instructions（ UAES）
Code
1 P0030 Oxygen sensor heating control circuit open circuit
2 P0031 Oxygen sensor heating control circuit shorted to ground
3 P0032 Oxygen sensor heating control circuit shorted to power supply
4 P0053 Oxygen sensor heating unreasonable
5 P0107 Intake pressure sensor shorted to ground
6 P0108 Intake pressure sensor circuit voltage is too high
7 P0106 Intake pressure sensor signal exceeds limit
8 P0105 Intake pressure signal stalling
9 P0112 Intake air temperature sensor signal voltage is too low
10 P0113 Intake air temperature sensor signal voltage is too high
11 P0114 Intake air temperature signal stalling
12 P0111 Intake air temperature signal exceeds limit
13 P0117 Engine coolant temperature sensor circuit voltage is too low
14 P0118 Engine coolant temperature sensor circuit voltage is too high
15 P0126 Engine coolant temperature sensor signal stalling
16 P0116 Engine coolant temperature sensor overrun
17 P0122 Throttle position sensor circuit voltage is too low fault
18 P0123 Throttle position sensor circuit voltage is too high fault
19 P0130 Oxygen sensor signal unreasonable fault
20 P0131 Oxygen sensor circuit voltage too low
21 P0132 Oxygen sensor circuit voltage is too high
22 P0134 Oxygen sensor signal circuit open circuit failure
23 P0133 Oxygen sensor deterioration
24 P0201 One-cylinder injector control circuit open circuit
25 P0261 One-cylinder injector control circuit shorted to ground
26 P0262 One-cylinder injector control circuit shorted to the power supply
27 P0322 No speed sensor pulse signal (open circuit or short circuit)
28 P0444 Carbon canister control valve control circuit open circuit
29 P0458 Carbon tank control valve control circuit voltage is too low
30 P0459 Carbon tank control valve control circuit is too high voltage
31 P0508 Stepper motor drive pins shorted to ground
32 P0509 Stepper motor drive pins shorted to power supply
33 P0511 Stepper motor drive pin open circuit or overload
34 P0560 System battery voltage signal is not reasonable
35 P0562 System battery voltage is too low
36 P0563 System battery voltage is too high
37 P0627 Oil pump relay control circuit open
38 P0628 Oil pump relay control circuit shorted to ground
39 P0629 Oil pump relay control circuit shorted to the power supply
40 P0650 MIL lamp driver stage circuit failure
41 P0501 Speed signal disconnection fault
42 P2300 Ignition coil shorted to ground
43 P0301 Engine Misfire Failure
English 44 P0507 Engine idle speed high fault
45 P0506 Low engine idle speed fault
version
46 P2177 Lean mixture at non-idle speed
47 P2178 Thick mixture at non-idle speed
48 P2187 Lean mixture at idle speed
123
49 P2188 Thick mixture at idle speed
 Fuel System
1 Maintenance information .................................................................................... 125
2 Parts Location .......................................................................................................... 126
3 Fuel Line Inspection .............................................................................................. 127
4 Fuel Pressure Relief ............................................................................................... 127
5 Quick Connect Removal ..................................................................................... 128
6 Quick Connect Head Installation ..................................................................... 129
7 Increasing Fuel Pressure ..................................................................................... 130
8 Fuel pump unit ....................................................................................................... 130
9 Fuel pump filter ....................................................................................................... 131
10 Front side fuel tank and rear fuel tank mounting fuel line connection check ............. 132
11 EFI (evaporative fuel emission) carbon canister/dump valve ............... 133
12 Air filter assembly ............................................................................................... .134
13 Throttle Free Travel .............................................................................................. 135
14 Throttle assembly and air intake hose ......................................................... 136
15 Throttle Valve Body .............................................................................................. 137
16 Oil rail assembly .................................................................................................... 138

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124
 Maintenance information
Overview
-Bending or twisting control cables can interfere with smooth operation and
can cause cables to stick or become tangled, which can cause loss of vehicle
control.
-Work in a well-ventilated area. Smoking or allowing flames or sparks in the
work area or where gasoline is stored can cause a fire or explosion.
-Release fuel pressure in the system before disconnecting the fuel supply
hose.
-Don't open the throttle from fully open to fully closed after removing the
throttle cable. It may result in improper idle operation.
-Seal the air inlet with a piece of tape or clean cloth to prevent dirt and
debris from entering the engine after the throttle body is removed.
-Do not damage the throttle body. This may cause the throttle to operate
incorrectly.
-Prevent dust and debris from entering the throttle bores and air passages
after the throttle body is removed. Clean them out using compressed air if
necessary.
-Do not loosen or tighten the white painted nuts and bolts on the throttle
body. Loosening or tightening them will cause throttle valve and idle speed
control failure.
-Do not apply commercial carburetor cleaner to the inside of the throttle
bore.
-Throttle body parts not shown in this manual should not be removed.
-For injector and idle air control valve repairs, throttle body
removal/installation is required.
-For checking the fuel level sensor.

English
version

125
Parts Location

Dumping valve
Throttle Valve

fuel pump carbon tank

English
version

126
 P1 ※Fuel Line Inspection
Before and after the tank inspection before
remove the following content:
- fuel tank vent;
- seat cushion assembly;
[1] - before tank decoration or so; - remove
the engine protection plate assembly.
Inspection.
[2] Hang the front left fuel tank on the left side of
the frame
1. Check (as right P1) the connection
condition such as aging damage of the left and
right fuel tank connecting hose quick connect
connector [1].
2. Check (as right P1, 2) whether the left and
right fuel tank connecting hoses and double-
P2 [1] [2] [3] hole over fuel bolts [1], [2] are loose, damaged
or leaking.
3. Check (such as right P2) whether the fuel
check valve [2] and single-ear induction clamps
are loose, damaged or leaking.
Is the rear fuel tank and front right fuel tank
connection hose accurately stuck into the wire
hook bracket [3].
4. Check (e.g. right P3) whether the
connection condition of the rear tank and the
front right tank connecting hose quick-connect
fitting [1] is damaged by aging.
5. Check (e.g. right P3) whether the rear fuel
P3 tank connecting hose and the double-hole
over-fuel bolt [2] are loose, damaged or leaking.
If the quick connect fitting and its
[1] surroundings are dirty, clean them.
Replace them if necessary.

Contact your dealer for replacement of the

injector fitting/oil supply hose assembly.
Caution.
[2] -Be careful not to damage the fuel supply hose
fitting and fuel line. -Do not use tools.

※Fuel Pressure Relief

Caution.
-Before disconnecting the fuel supply
hose, relieve system pressure as follows.
1. remove the lower engine shield
assembly.
2. disconnect the fuel pump 2P (black)
English
fitting [1].
version 3. start the engine and allow it to idle until
the engine stalls.
4. Turn off the ignition switch.
[1]
127
※ Quick Connect Removal

Disassembly
Caution.
-Before disconnecting the fuel
supply hose, clean around the quick
disconnect and make sure no dirt
enters the fuel system.
Do not bend or twist the fuel supply
hose. This may cause a fuel leak.
1. relieve fuel pressure. [1][2]
2. Remove the seat cushion assembly.
3. Remove the front trim assembly.
4. Remove the lower engine shield.
5. remove the battery terminal bolt [1]
disconnecting the negative (-) battery
cable [2].
6. remove the front side 2 fuel tanks
and air filter assembly waste gas pipe,
leaky water pipe.
6. Press and hold the fuel connector
release button [3], [4] respectively,
[3]
and disconnect the quick connect
connector from the fuel pump unit
connector and the injector connector. [4]
Caution.
-Drain the remaining fuel from the
fuel supply hose into a suitable
container.
-Wipe off any spilled fuel immediately.
-Be careful not to damage the slide
retainer and hose. Do not use tools.
7. To prevent damage and entry of
foreign objects, cover the
disconnected connector [1] and fuel
fitting end [2] with a plastic bag.

English
[1][2] version

128
 ※ Quick Connect Head
Installation

Caution.
-Do not bend or twist the fuel supply
hose, this may cause fuel leaks.
-Do not reuse kinked or damaged fuel
supply hoses.
-Do not use gloves or rags when
installing quick-connect couplings.
[1]
1. Connect quick-connect fittings [1],
[2] to the fuel pump unit connector
[2] and injector connector, respectively,
while holding the quick-connect
housing until you hear a "click".

Caution.
-Be careful not to damage the sliding
ring and fuel supply hose.
-Do not use tools.
If connection is difficult, apply a
small amount of oil to the fuel fitting
end.
Make sure the connection is secure
and the quick connect coupling is
locked firmly in place; visually inspect
and pull on the connector housing [1].
2. Connect the negative (-) battery
cable [1].
Install and tighten the battery
terminal bolts [2] to the specified
torque.
[1][2] Torque.
2.0 N-m (0.2 kgf-m ,1.5 lbf-ft)

English
version

129
※Increasing Fuel Pressure

1. Connect the fuel pump power supply wire

quick plug connector (black) 2p[1]; 2.
Temporarily left before the fuel tank is installed
on the frame; 3. In the case of throttle fully
closed, pull the clutch handle to the bottom,
and press the starter switch; The engine will
increase the fuel pressure to start; 4. Turn off
the engine check whether there is a leak in the
fuel line.
※Fuel pump unit [1]
Removal/Installation
- Disassemble the front trim assembly [1];
- Disassemble the front fuel tank vent pipe [2]; [5] [2] [7]
- Disassemble the seat cushion assembly [3];
- Remove the lower engine shield assembly [4];
Before removing the fuel tank, disconnect the fuel [3]
pump supply line speed connector fuel line quick [1]
release fitting.
Remove the front fuel tank upper connecting bolts
[5] and left and right side fuel tank connecting
bolts [6], the left and right 3 of the turn over
bushing [7] and the left and right fuel tanks [7].
The installation order is opposite to the [4]
disassembly order. [2] [3]
(The left and right side fuel tanks are installed in
the same way)

Front fuel tank upper connecting bolt and side

connecting bolt installation
Torque.
Fuel tank mounting nut. 22 N-m (2.2kgf-m, 16
lbMt)
Disassembly/Installation
Remove the following components.
Remove the fuel tank and clean around the
fuel pump. Cross loosen the 4 mounting bolts
[1] and remove them in several steps as shown
in Figure 1. Remove the fuel pump and rubber [5] [6]
seal [2].
Install in the reverse order of removal.
Caution.
-Be careful not to damage the fuel pump unit. [1] [2]
Drain the remaining fuel from the fuel pump
unit into a suitable container and wipe off the
spilled fuel immediately.
Replace the rubber seal with a new one [2].
-Clean the rubber seal seating area of the fuel
tank and fuel pump base plate to ensure that
there are no foreign objects.
-Place the rubber seals with the tabs facing the English
fuel line.
-Tighten the 4 mounting nuts to the specified version
torque in the order shown. Torque.
Fuel pump mounting bolts. 图1
8 N-m (0.8 kgf-m, 6.0 lbf.ft)
130
 ※Fuel pump filter
[3]
Remove/check/installation dismantling the
[1]
pump unit disconnect pump motor wiring
[2] harness connector [7], [8]. As shown, open
fuel pump bracket left and right sides of the
card buckle [1], [2], remove the fuel pump
bracket. Note: • don't use tools in order to
avoid damage to the pump unit.

Disassemble the fuel pump unit as shown in

the figure on the right.
- Fuel pump base [1].
- O-ring x3 [2].
[2] [2] [4] [6] [9]
- Rubber seal [3].
- Fuel filter (screen) [4].
- Fuel pump [5].
- Fuel pump unit bracket [6].
- Fuel pressure regulating valve [9].
[2]
[5] Caution.
[7] [8] -Check the fuel filter for clogging, damage or
deterioration, and replace it if necessary.
-Lay the black wire [7] and red wire [8]
[1] [3] correctly.
-Align the rubber seal with the fuel pump
base unit recess.
Install in the reverse order of removal.

※Installation
[3]
Apply engine oil to the new rubber seal [1].
[1]
Install the following components.
[2] - 4 x M5x16 fuel pump unit mounting bolts.

Caution.
-Make sure the rubber seal [1] is located in
the fuel pump base recess [2].
[4] Install the fuel pump bracket and fuel pump
图1 onto the fuel base.
-Align the fuel pump plate slots with the fuel
pump unit lugs.
Install the fuel pump assembly so that the fuel
fitting [3] is toward the left front of the fuel
tank.
-Be careful not to damage the fuel pump unit.
English Tighten the fuel pump unit mounting bolts [4]
to the specified torque in the order shown in
version Figure 1.
Torque.
8.0 N-m (0.8kgf-m , 6lbf-ft)
131
※Front side fuel tank and rear
P1
fuel tank mounting fuel line
connection check
Disassembly/Installation
Remove the following.
Before installing the fuel tank, disconnect the
fuel pump supply line speed connector fuel line
quick release connector.
-Check the P1 rubber screw bolt [1] for looseness,
breakage, and deterioration.
and tighten the bolts to the specified torque.
Torque: rubber screw [1] [1] [2] [3] [3]
22N-m (2.2kgf-m, 16 lbMt)

-Check P1 bolt [1] for looseness adjust tank

mounting bracket to proper angle and tighten bolt
to specified torque.
P2 [left] [right]
Torque: front fuel tank mounting bracket bolts [2];
15N-m (1.5kgf-m, 11 lbMt)

-Adjust the Figure 1 hexagonal nuts [3] to the

proper position and tighten the bolts to the
specified torque before installation. [2]
Torque: front fuel tank mounting hex nut to frame
connection [3];
15 N-m (1.5 kgf-m, 11 lbMt)
(Left and right side fuel tank mounting bolts are
adjusted with the same locking torque)

As P2. [1] [1]

first hang the right side tank on the frame and
tighten the bolt through the turning over inch P3
sleeve to the specified torque.
Torque: fuel tank mounting screw [1]
22N-m (2.2kgf-m, 16 lbMt)
and connect the tank vent hose [2].
The installation order is the reverse of the
disassembly order.
(The left and right side tanks are installed in the
same way)
[1] [2]
As in P3.
Connect the right side tank fuel hose [1] P4 [1]
through the engine and frame lower beam to the
left side tank quick plug [2] and check for
looseness, damage or leaks.
Replace if necessary.

As in P4.
The rear tank fuel hose is connected to the front
right side tank using the quick plug [1] then check
for looseness, damage or leaks. English
The rear fuel tank and front right side fuel tank version
connection hose is accurately seated in the wire
hook bracket.

132
 [1] ※EFI (evaporative fuel emission)
[3]
carbon canister/dump valve
（regular edition only）

Disassembly/Installation
Disassembly of the following.
- Disassembly of the dump valve and
carbon tube.
- Removal of the lower engine guard
[2] assembly.
- Removal of the left front fuel tank.
- Disconnecting the fuel tank
connecting dump valve hose [1],
connecting dump valve carbon tube
hose [2] removing the dump valve [3].
- Disconnect the carbon canister
discharge connection throttle hose [4]
[4] Remove the carbon canister [5] from
the carbon canister retaining rubber
sleeve [6].
[6] [5]
Install in the reverse order of
removal.

English
version

133
 ※Air filter assembly
[4]
Remove the air filter housing assembly
from the frame by loosening the air intake
hose [1] toward the rear and from the
throttle side.
Install in the reverse order of removal.
Caution.
- When placing the assembly into the frame,
carefully install the crankcase breather hose
[2], making sure it is not kinked or deformed. [1] [3]
-Tighten the intake hose holding screws [3]
with a distance of 10 ± 1.0 mm between the
band ends.
-When connecting the injector 2P (gray)
fitting [4 [2]
Align the notch with the lug of the injector
fitting.
Torque.
Air filter assembly mounting bolts.
10N-m (kgf-m, lbMt)
Throttle cable attachment bolt (at throttle
body).
3.0 N-m (0.3 kgf-m, 2.2 lbf-ft)
Adjust throttle handle free play If the
sensor unit has been removed, perform the
throttle position sensor reset procedure.

- Anisotropic bolt M5X78 [1].

- Air filter sponge [2].
- Air filter housing [3].
- Rubber bolt X4 [4].
-Air filter element leakage pipe [5].
-Air filter end of intake tube assembly [6]. [1]
-Intake duct assembly clutch X2 [7].
-Injector [8].
- Injector O-ring X2 [9]; - Injector O-ring [9].
[2]
- Injector clamps [10].
-Oil rail [11].
- Three-in-one sensor [12].
- Idle motor valve body [13]. [3]
- Engine side air intake hose [14]. [10]
[4] [11]

[8] [6]
[9]
[7]
[5] [14] [12]
English
[13] version

134
 2-6 mm (0.08-0.24 in)
※Throttle Free Travel
Check that the throttle cable is not aged,
damaged or kinked.
Turn the throttle handle and check that the
throttle opens smoothly and closes automatically
in any steering position.
If the throttle handle does not turn smoothly
and smoothly, check that the cable is properly
routed, that the throttle lever is clean and
lubricated with the recommended lubricant
(engine oil or appropriate cable lubricant), and
that the throttle drum is turning properly.
If there are no abnormalities, but the throttle does
not turn smoothly, replace the throttle cable (oil
feed, return cable).
Measure the free clearance at the throttle handle
flange.
Free clearance: 2-6mm (0.08-0.24in)
P1 1. Fine adjustment on the throttle
side
（+） Loosen the locknut [1] and turn the
adjuster [2].
Turning the adjuster in the (-) direction
[2] [1] will decrease the free play and turning it in
（-） the (+) direction will increase the free play.
After adjustment, hold the adjuster and
tighten the lock nut.
If the correct free clearance is not
obtained even after turning the adjuster
to the bottom, return it to the (+)
P2 direction until it gently touches the
bottom and turn it one turn to the (-)
（+） direction, then make more adjustments on
the throttle side.
Nut [1] Torque.
[2] [1] 5.0 N.m (0.5 kgf.m, 3.7 lbf.ft)
（-）
Note: P1 is factory edition and P2 is
regular edition.

2. Throttle body side for significant adjustment

Loosen the intake throttle cable adjuster lock nut
[1] and turn the adjuster [2] in the (-) direction to
（-） reduce free play and in the (+) direction to increase
[2] free play.
After adjustment, hold the adjuster and tighten the
inlet throttle cable adjuster lock nut to the specified
torque.
Torque.
（+）
4.0 N.m (0.4 kgf.m, 3.0 lbf.ft)
English
(The oil inlet cable and the oil return cable are
version adjusted the same)
[1] Caution.
-Re-check that the throttle handle turns smoothly
135 with no sticking.
※Throttle assembly and air [1] [2]
intake hose

①. Throttle

Removal/Installation
Remove the following parts.
- Remove the fuel line quick coupling [3]
[1]; [4]
- Remove the fuel rail cap mounting
screw [2] and the fuel rail mount
injector;
- Disconnect the triple sensor plug 5p [6]
[3];
- Disconnect the stepper motor
motor plug 4p[4];
- Loosen the throttle cable
adjustment nut [5]; [5]
- Remove the throttle cable from the [6]
[5]
turntable [6]; [11]
- Remove the intake pipe clamp
fastening screws at both ends [7]; [11]
- Remove the throttle valve body [9]
and intake pipe [10].
[7]
The installation order is the reverse
of the disassembly order.

Caution.
-Installation of intake pipe clamps
should be in the limit point [11],
[7]
intake pipe and engine connection
aligned with the limit tab [8] within.

Torque.
M6x20
Injector cap and throttle connecting
bolt
8.0 N.m (0.8 kgf.ft, 6 lbf.ft) [9]

Note. Throttle inlet pipe mounting [8]

clamps can be screwed to the limit. English
version
[10]

136
 Throttle Valve Body
Removal/installation
note: • throttle body, is the factory assembly
good way to remove the outside not shown
in this manual. , throttle pull don't will
throttle after removed from open to close,
which may lead to damage of throttle. Don't
damage the throttle body; This may cause
the throttle to not work properly. • don't
loosen or tighten the nuts and bolts, coated
Prohibit disassembly with torsion logo loosen or tighten they
lead to throttle body malfunction.
Disassemble the idle motor / triple sensor
Inspect the idle motor air passage in the
throttle body for carbon buildup.
Inspect the O-ring on the idle motor/triple
sensor for deterioration or damage.
Prohibit disassembly

Remove the following parts.

maintenance
if not for

- 2 screws [1];
- Remove the 3-in-1 sensor unit [2];
- 2 screws [3];
- Idle speed motor valve body [4];
Clean the throttle body and idle motor valve
body piping with compressed air.
Caution.
-Cleaning with a wire ball will damage the
[1] [1] [2] throttle valve body.

The installation order is the reverse of the

removal order.

Caution.
-Replace new rubber seals
[3] [4] -Install each clamp in the intake tube
assembly with the screw head [5] facing the
[3] right side and align the left side band hole [6]
with the locating tab.
-Install each clamp with the "UP" mark facing
up
Facing the throttle body and aligning the
notch [7] with the lug.
-Tighten the clamp screws so that the
[6] distance between the two ends is
10±1.0 mm (0.4±0.04 in)
Install the tightening bolts to the specified
[7] torque.
English Torque.
3-in-1 sensor mounting screws.
version 3.4 N-m (0.3 kgf-m, 2.5lbf.ft)
[5] Idle motor valve body mounting screw: 3.4 N-
m (0.3 kgf-m, 2.5lbf.ft)
137 3.4 N-m (0.3 kgf-m, 2.5lbf.ft)
※Oil rail assembly
[2]
Removal/Installation
Remove the oil rail assembly from the
throttle assembly. [1]
Remove the following parts.
- 1 bolt [1];
- 1 wire harness connector [2] ;
- Remove the oil rail [3];
- Remove the injector clips [4];
- Remove the injector [5];
- Remove the injector O-ring [6].

Check each part for wear or [4] [5]

damage and replace if necessary.

Install in the reverse order of

disassembly.

Caution.
-Apply oil when replacing the new O-
ring and seal.
-Be careful not to damage the O-rings [3] [6]
when installing the injectors.
-Insert the injector fitting in line with
the fuel fitting.

Torque.
Fuel rail assembly connecting bolt
12 N-m (1.2 kgf-m, 8.9 lbf.ft)

English
version

138
 Cooling System
1 Maintenance information ............................................................................... 140
2 Cooling System Flow Chart ........................................................................... 141
3 Cooling System Test ........................................................................................ 142
4 Coolant change................. ................................................................................ 143
5 Thermostat .......................................................................................................... 145
6 Water reservoir, radiator grille .................................................................... 146
7 Fans, water pipes, radiators ........................................................................... 147
8 Water pump ........................................................................................................ 148
9 Oil-cooled radiators ........................................................................................ 149

English
version

139
 Maintenance information
Overview

Do not remove the radiator cap before the engine and radiator cool
down to prevent the coolant from splashing out and scalding people
NOTE
The use of coolant with silicate inhibitors can lead to premature wear of
water pump seals or blockage of radiator passages.
Using tap water can cause engine damage.
l - Add coolant to the reservoir; do not remove the radiator cap except to
add or drain coolant.
Do not remove the engine from the frame when servicing the cooling
system.
-Avoid leakage of coolant to painted surfaces.
Check for leaks with a cooling system tester after system maintenance.
Check the coolant temperature indicator/water temperature sensor.
Check the fan control relay.
Troubleshooting
Engine temperature is too high
-Coolant temperature indicator/water temperature sensor failure
-Throttle valve not open
-Faulty radiator cap
-Insufficient coolant
-Blocked radiator passages, hoses, water pipes
-Circulation system air intake
-Failure of cooling fan motor
-Fan control relay failure
-Faulty water pump
Engine temperature too low
-Faulty coolant temperature indicator/water temperature sensor
-Throttle valve open
-Fan control relay failure
Coolant leakage
-Defective water pump mechanism
-O-ring deterioration
-Radiator cap failure
-Damaged or deteriorated cylinder head gasket
-Hose connection is loose or not clamped
-Damaged or deteriorated hoses
-Damaged radiator
English
-Thermostat cover, water pump cover pipe joint is loose
version

140
 Cooling System Flow Chart
[3] [4] [5] [6]

[7]

[8]
[2]

[1]
[9]

[1
0]

[1
1]
[1
2]

[1
3]

[1 [1 [1 [1
4] 5] 6] 7]
Oil Cooled
1 Radiator fan left 6 Siphon Tube 11 Thermostat 16
Radiators
Engine Intake
2 Water reservoir 7 Radiator cap 12 17 Radiator grille
Hose
Engine outlet
English 3 Radiator left 8 13 Water pump
pipe
version
Radiator left and right Radiator fan Oil-cooled radiator
4 9 14
connecting pipes right inlet pipe
Oil-cooled radiator
5 Overflow pipe 10 Radiator right 15
141 discharge pipe
※Cooling System Test
[1]
Radiator system pressure check.
Disassembly/Installation
Removal of the following components.

- Removal of the front trim assembly.

- Remove the radiator cap [1].

Lubricate the sealing surface of the [2]

cap [1]; then install the cap on the
tester [2].
Use the tester to pressurize the
radiator cap.
Replace the radiator cap if it does not
hold pressure or if the release
pressure is too high or too low.
The radiator cap must hold the
specified pressure for at least 6 [1]
seconds
Radiator cap release pressure.
108-133Kpa
Note. This operation is performed
Connect the detector to the radiator. when the bike is running cold.
Use the tester to pressurize the
radiator, engine and hoses to test
their airtightness.

Caution.
-High pressure can damage cooling
system components, do not exceed
133kPa.
-If the system does not maintain the
specified pressure for at least 6
seconds, repair or replace the
components.
English
version

142
 [3] ※Coolant change

When adding coolant to the tank

radiator or sub-tank or checking the
coolant dose, the motorcycle should
be placed on a level flat surface and
in an upright position.

Disassembly/Installation
[1] [2] Remove the following components.

- Removal of the front right side fuel

tank and lower guard assembly.
• After motorcycle shuts off, wait - Removal of water pump drain bolts
for the car to cool down for a [1] and flat washers [2].
while, and then perform the - Remove the radiator cap [3] and
following operations to avoid drain the coolant.
the risk of burns due to
excessive coolant temperature. Drain the coolant :

-After replacing the flat washer with

a new one, install the drain bolt.
Tighten the drain bolt to the correct
torque.
Torque.
Water pump drain bolt.
10 N.m (1.0 kgf.m, 10 lbf.ft)

English
version

143
 Disconnect the siphon hose from [1]
the radiator [1] and pull the siphon
hose out of the hose clamp.
Place the hose in a lower position
outside the engine frame and drain
the coolant from the storage tank.
Drain the coolant, flush the inside of
the storage tank with water, and
install the hose into the hose clamp
and over the radiator

Fill the cooling system up to the

neck with the recommended coolant
through the water injection hole [1].
Not recommended with antifreeze:
including ethanol containing silicate
cooling fluid
[1]

※Air is discharged from the radiator

• After motorcycle shuts off, wait
Recommended antifreeze. for the car to cool down for a while,
Remove air from the system as and then perform the following
follows. operations to avoid the risk of
1. Shift the engine to neutral, start the burns due to excessive coolant
engine and allow it to idle for 2-3 temperature.
minutes.
2. Open and close the throttle three
to four times to remove the air from
the radiator system.
3. Turn off the engine and fill it with
coolant if necessary. 4.
4. Install the radiator cap. English
Fill the reservoir with the version
recommended coolant to the
standard scale and close the reservoir
cap.
144
 [2] ※Thermostat

Remove/install
- emptying of coolant.
- remove the bolts [1] and [2]
thermostat cover.

Remove the thermostat from the

[1]
cylinder head [1].
Install in the reverse order of removal.
Torque.
[1]
Thermostat cover bolts.
12 N.m (1.2 kgf.m, 9.0 lbf.ft)
Caution.
-When installing the thermostat, be
careful to install the thermostat seal
properly and snap it into the round
recess in the waterway of the middle
cylinder.

[1] [2] Inspection：

Thermostat [1] appearance whether

there is damage. If the thermostat
valves are open at room temperature,
need to change. Check whether the
seal [2] is damaged, if you need the
replacement.

Heat the water to operating

[1] temperature for 5 minutes with an
electric heating element.
Suspend the thermostat [2] in hot
water and check its operation.
Thermostat starts to open at.
English
82±2°C (176-183°F)
Valve ramp-up.
version
92°C (197.6°F) not less than 8 mm
If the thermostat responds at a
[2]
temperature other than that specified,
145 replace the thermostat.
※Water reservoir
[3] [2]
Disassembly/Installation
Remove the following components.

Drain the sub kettle coolant .

- Remove the sub kettle mounting
bolts [1];
- Remove the siphon hose clamps
[2].
- Remove the sub kettle [3]. [1]

Install in reverse order of removal.

Torque :
Reservoir mounting bolts.
10 N-m (1.0 kgf-m, 7.4 lbf.ft)

※Radiator grille

Disassembly/Installation
Remove the following components.

- Remove the front trim assembly;

- Remove the lower engine shield
assembly; [2]
- Remove the front left and right side [1]
fuel tanks; [3] [4]
- Disconnect the fuel line and fuel
pump harness connector 2P (black);
- Remove the radiator grille mounting
bolts [1][2];
- Remove the radiator left and right
grilles [3][4].

The installation order is the reverse of

the removal order.

Torque:
Radiator grille mounting bolts.
8 N-m (0.8 kgf-m, 6.0 lbf.ft)
English
version

146
 ※Fans
Disassembly/Installation
Disassemble the following components.
- Drain radiator tank coolant;
- Disconnect the radiator fan motor 2P
(white) wire harness connector;
- Remove the radiator fan left and right side
mounting 6 bolts [1];
- Remove the radiator fans on the left and
right sides.

The installation order is the reverse of the

[1] removal order.

Torque :
Radiator fan cover mounting bolts.
8 N-m (0.8 kgf-m, 6.0 lbf.ft)
Fan motor check.
Battery voltage 12V Motor running at full
speed with amperometer current not
exceeding 3A, if motor does not rotate or
current exceeds specified then replace fan
motor.

[1]
※Water pipes
Disassembly/Installation
Remove the following parts.
[2] [4] [3] - Loosen the pipe clamps [1] and loosen
the water pipe above the radiator [2];
- Loosen the pipe clamp [3] and loosen the
[5] [8] water pipe [4] on the right side of the
radiator;
- Loosen the clamp [5] and loosen the
[6] [7] water pipe [6] on the lower left side of the
radiator;
- Loosen the pipe clamp [7] and loosen the
water pipe [8] on the lower right side of
the radiator.
The installation sequence is the reverse of
[1] the removal sequence.
[2]
※Radiator
Disassembly/Installation
Remove the following parts.
- Remove the radiator left and right side
mounting bolts [1], [2];
- Remove the left and right radiator
English assemblies;
version Install in the reverse order of disassembly.
Torque:
Radiator do superior both sides mounting
bolts
147 12 N-m (1.2 kgf-m, 8.8 lbf.ft)
※Water pump
End face seal inspection. [5] [2]
Make sure there is no continuous coolant
leakage when starting the engine. [3]
If necessary, replace the water pump as an [2] [4]
assembly.

Caution.
Place a clean oil pan under the engine, coolant [6]
will flow when the water pump body is removed.
[1]
After installation, add the specified coolant.
Keep the motorcycle in an upright position on
level ground.

Removal/Installation
Remove the following parts.
- Water drain bolt and gasket [1]; [2]
- Remove the lower radiator hose clamp [2], [3];
- Remove the water inlet pipe [4], [5];
[1]
- Install the water pump valve body cover bolts [6].

The installation sequence is the reverse of the

disassembly sequence.

Torque:
Water pump body cover mounting bolts.
12 N-m (1.2 kgf-m, 9.0 lbf.ft)
Water pump discharge bolt.
10 N.m (1.0 kgf.m, 7.5 lbf.ft)

※Water pump impeller

Disassembly/Installation
Remove the following components. [5]
- Remove the right side cover of the
crankcase;
- Remove the water pump valve body
cover [1] and gasket [2] from the right side
cover of the crankcase;
- Remove the C-clamp [3] and retaining
pin [4] at the rear of the crankcase side
cover;
- Remove the water pump impeller [5].
Inspect.
Whether the water pump cover gasket is
broken If broken, replace it in time. [3] [4]
Replace the water pump impeller in time if
it is broken. English
version
The installation order is the reverse of the
disassembly order.

Crankcase side cover mounting bolts.

10 N.m (1.0 kgf.m, 7.5 lbf.ft)
148
 ※ Oil-cooled radiator

[2] Make sure there is no continuous oil

leakage when starting the engine.
If necessary, replace the oil cooled
radiator as an assembly.
[3]
Caution.
Place a clean oil pan under the
engine where oil will escape when the
[1] oil cooled radiator is removed. After
installation, add the specified oil.

Keep the motorcycle in an upright

position on level ground.

Removal/Installation
Remove the following parts.

- Remove the inlet and outlet oil pipe

overflow bolts [1];
- Remove the oil-cooled radiator
mounting bolts [2];
- Remove the oil cooled radiator [3];

The installation order is the reverse of

the removal order.

Torque:
Mounting oil-cooled radiator over-oil
bolt.
12 N-m (1.2 kgf-m, 8.8 lbf.ft)

English
version

149
 Engine removal/installation
1 Maintenance information ....................................................................................... 151
2 Parts Location ............................................................................................................. 152
3 Engine Removal ......................................................................................................... 153
4 Engine Installation .................................................................................................... 157

English
version

150
 Maintenance information
Overview
Removing and installing, you need to use professional table
or equivalent to support the motorcycle. You need to use a jack
or other adjustable bracket to support and control the engine

English
version

151
Parts Location
[1][1] [1][1]

[2] [2]
[3] [4]

[5] [9] [9] [6]

[5] [6]
[12]

[10] [11]
[7] [8]

Engine upper suspension and Engine and front suspension

[1] 36N.m [7] 54N.m
frame attachment bolts x4 connecting bolts
Self-locking nuts for engine
Engine upper suspension
[2] [8] and front suspension 54N.m
bracket left and right
connection

Engine upper suspension and Engine front suspension

[3] 54N.m [9]
engine connecting bolt left bracket left and right

Engine lower front, lower

Engine upper suspension and
[4] 54N.m [10] rear suspension and frame 54N.m
engine connecting bolt right
connecting bolt x2
Engine lower front, lower
Frame and front suspension rear suspension and frame
[5] 26N.m [11] 54N.m
attachment bolts x2 attachment self-locking nuts
x2
Frame and front suspension
Flat fork axle fastening nut
[6] connecting self-locking nut 26N.m [12] 88N.m
and flat fork axle
x2

English
version

152
 ※Engine Removal
- Removing the seat cushion assembly.
- Disconnecting the negative battery
terminal.
- Removing the front trim assembly.
- Removing the lower engine guard
assembly.
- Removing the fuel tank vent pipe.
- removing the front left and right side fuel
tank and fuel pump connector fuel line quick
release fittings.
[1] [2] - Drain the engine oil.
- Evacuate the coolant.
Caution.
-Let the vehicle stand still for a period of time
to avoid high temperature burns when
draining the engine coolant.
Remove the following components.
[1] [2] - Fuel evaporation system and associated
components [1].
-①Exhaust
Clutchgas pipe assembly [2].
cable
Install in the reverse order of removal.
Installation / Disassembly
Remove the following parts.
- Loosen the travel adjustment bolt [1]
and disengage the clutch safety plate [2].
Then disconnect the clutch pull cable [3]
from the clutch tappet arm [4].

[3] [4] The installation sequence is the reverse of

the disassembly sequence.
[1] [2] ② Engine flywheel cover/shift lever
assembly
Installation / Disassembly
Remove the following components.
- Removal of bolts [1].
- Removal of the small flywheel cover [2].
- Remove the bolts [3].
- Remove the gearshift lever assembly [4].

The installation order is the reverse of the

[3] [4] disassembly order.

[2] ③ Small engine driven flywheel

Installation / Disassembly
Remove the following parts.
- Disengage the drive small flywheel
English fastening nut locking tab [1] and remove
version the small flywheel fastening nut [2].
- Remove the drive small flywheel.

The order of installation is the reverse of

153 the order of disassembly.
[1]
④ Air filter assembly
[1] [2]
Installation / Disassembly
Remove the following parts.

- Remove the air filter assembly left

and right 2 side bolts [1], [2];
- Remove the air filter assembly
connecting the throttle intake pipe
holding hoop [3];
- Remove the air filter assembly [4].
[3] [4]
The installation order is the reverse of
the disassembly order.

⑤ Throttle assembly

Installation / Disassembly
Remove the following parts.

- Remove the intake pipe clamps [1];

- Unplug the fuel injector [2];
- Unplug the triple sensor [3];
- Unplug the stepper motor motor [1]
[4];
- Remove the throttle assembly [5];
- Loosen the adjustment nut [6];
- Remove the throttle wiring harness
[7].
[7]
The installation sequence is the [6]
[2]
reverse of the disassembly sequence .
[3]
[4] [5]

English
version

154
 ⑥ Oil-cooled radiator

Keeps the motorcycle upright on

level ground. [2]

Disassembly/Installation
Remove the following parts.
[3]
- Removal of the inlet and outlet oil
pipe over oil bolts [1], [4].
- Remove the oil-cooled radiator
[1]
mounting bolts [2].
- Remove the oil-cooled radiator [3].

The installation order is the reverse of

the disassembly order.

Torque :
Installation of oil-cooled radiator
over-oil bolt.
12 N-m (1.2 kgf-m, 8.8 lbf.ft)
[4]

English
version

155
⑦ ABS pump
[1] [1]
[2] [2]
Disassembly/Installation
Disassemble the following
components.
Drain the brake fluid from the front
and rear brake hydraulic system.

- Seat cushion assembly.

- Air filter assembly. [3] [3]
- ABS pump bracket.
Disconnect the ABS pump 18P (black)
connector
Remove the brake hose brake light
switch nut [1] and the upper and
lower 2 sealing washers [2].
removing the ABS nut [3] to
disconnect the brake hose [4].
- Removal of ABS bracket mounting
nut [5].
- Remove the ABS bracket ABS pump
[6]
[6].

Install in reverse order of removal. [5]

Note: factory edition do not have

an ABS pump.

Remove the two mounting bolts [1]

and the ABS pump 2] from the [2]
bracket.
Torque.
ABS pump to bracket attachment
bolts.
12 N.m (1.2 kgf.m, 8.8 lbf.ft)
Brake hose oil bolt.
22 N.m (2.2 kgf.m, 16 lbf.ft)

English
version
[1]

156
 ⑧ Engine

Disassembly/Installation
Remove the following parts. [4] [2]

- Removal of bolts [1] engine outlet

pipe hugger [2]. [1]
- Remove the rear flat fork shaft nut [3]
[3] to remove the rear flat fork shaft
[6] and spacer.
- Remove the engine upper
suspension left and right attachment
bolts [4] and [5].
- Removing the front engine
suspension attachment nuts [7],
washers and bolts.
- Removing the lower engine front [5]
and rear attachment nuts [8][9], bolts. [10]
- Removal of the engine assembly [10].
[7]
The installation order is the reverse of
the disassembly order. [6]

[8] [9]

Engine Installation
Caution.
-Not applicable to oil filters as jacking points.
-Jack height must be constantly adjusted to relieve pressure for bolt-on
installation.
-Carefully align the mounting points with the jack to prevent damage to the
engine, frame, radiator, hoses, wires and cables Raise the rear of the
motorcycle so that the rear wheel is 150mm off the ground
placing the engine on a jack or other adjustable bracket under the frame.
aligning the front engine suspension bolt holes with the frame mount, then
installing the bolts and bushings.
lifting the engine while rotating it upward at the rear to install the other
hanger bolts and bushings.
Installing the rear engine suspension nuts with washers.
Tighten the bolts and nuts to the specified torque in the order indicated.
English
version

157
 Cylinder head and valve
1 Maintenance information .......................................................................... 159
2 Troubleshooting ............................................................................................ 160
3 Cylinder head assembly drawing .............................................................. 161
4 Disassembly of cylinder head cover .......................................................... 163
5 Disassembly of cylinder head ...................................................................... 163
6 Disassembly of the cylinder head ............................................................... 164
7 Inspection of valves and valve springs ..................................................... 164
8 Inspection of valve tappet, camshaft, cylinder head ........................... 165
9 Assembly of cylinder head components ................................................. 166
10 Installation of cylinder head ....................................................................... 167
11 Engine Timing Adjustment Method ....................................................... 167
12 Installation of cylinder head cover ......................................................... 168

English
version

158
 Maintenance information
Overview
-This chapter covers maintenance and inspection of cylinder heads, valves, camshafts,
and tappets.
-When repairing the cylinder head, camshaft and tensioner, judge whether the
engine needs to be removed from the frame according to the model and shade;
when repairing the cylinder head and valve, the engine must be removed from the
frame.
-When disassembling, mark the disassembled parts and put them away to ensure
that they are correctly placed when reassembling.
-Before inspection, clean all disassembled parts with a cleaning agent and blow
them dry with compressed air.
-Camshaft lubricant is injected through the oil lines in the cylinder head and
camshaft bracket, so the oil lines should be cleaned before assembling the cylinder
head and camshaft bracket.
-When removing the cylinder head and cylinder head cover, be careful not to
damage the joint surface.

Cylinder head/valve specification

Maintenance limit value
item standard value mm
mm
Valve spring free length inner:47.5 outter:38.1 inner:47.35 outter:37.95
intake＞0.17 exhaust＞
valve clearance intake :0.1～0.15 exhaust:0.15～0.2
0.22
Camshaft base circle runout 0.02 0.04

Maintenance limit
item standard value mm
value mm
Outside diameter intake φ5.472～φ5.487 φ5.46
of valve stem exhaust φ5.46～φ5.475 φ5.44
Valve tube inner intake φ5.505～φ5.515 φ5.535
valve diameter exhaust φ5.505～φ5.515 φ5.535
Valve stem and intake 0.018～0.043 0.07
tube clearance exhaust 0.03～0.055 0.08
Valve seal tape width 1.2 ----
flatness 0.05 0.06
Cylinder Head
Width of valve seat face 0.8 ----

English
version

159
1.Troubleshooting

Low air pressure in the cylinder.

1. valves.
Incorrect adjustment of valve
clearance.
Poor valve sealing.
incorrect air distribution timing.
Broken valve springs.
2, cylinder head
The spark plug is not tightly
connected to the cylinder head.
Damaged cylinder head gasket.
Cracks or sand holes in the cylinder
head.
3、cylinder block, piston, piston ring
Piston ring gap is too large or
fracture.
cylinder block pulling.

Exhaust with black smoke.

1, valve guide wear.
2, oil shield leaking or damaged.
3、Leakage of cylinder head gasket.
4, piston ring gap is too large.

Excessive warm-up noise or

strange noise
1、Incorrect valve adjustment.
2, valve stuck or broken valve spring.
3, excessive wear of the tappet.
4、Incorrect timing of air
distribution.
5, camshaft wear.
6、Fracture of the pressure reducing
valve dump block.

English
version

160
 A. Cylinder head assembly drawing.
(1) Small plate bolt M6×40_7 grade
24h.
(2) Small plate bolt M6×35_7 grade
24h.
(3) NC450S camshaft bracket.
(4) NC450S chain pressure plate.

(5)Small plate bolt M6×16_7 grade

24h.
(6)NC250S camshaft stopper.
(7)NC450S camshaft pressure
reducing valve.
(8)NC250 cam pressure reducing
valve reset torsion spring (2#).
(9) NC450S exhaust camshaft
components.
(10) NC450S intake camshaft
components.
(11)Derbi125 spark plug hole seal.

(12)NC450S valve tappet (DLC

coating).

English
version

161
(13) NC450S valve spring upper seat.
(14)CB125 foot valve locking clip
(improved type).
(15)NC450S valve inner spring.
(16)NC450S valve outer spring.
(17)CG125D oil shield combination.
(18)CG125D inner valve spring seat
(lower).
(19)NC450S outer valve spring seat
(20)NC450S intake valve (rod
diameter φ5.5)
(21)NC450S exhaust valve (rod
diameter φ5.5)

(22)Bolt M6×25
(23)NC450S thermostat cover
(24)NC450S thermostat (2#_vent hole
φ2)

English
version

162
 Disassembly of cylinder head cover
heteroshape
heteroshape 1、Remove the 3 NC450S cylinder
head cover fixing bolts (shaped
M6×22.8) and 3 NC450S cylinder
head cover fixing bolts (shaped
M6×50.7).
fixing bolts (shaped M6×22.8), 3
NC450S cylinder head cover fixing
bolts (shaped M6×50.7).
2、Remove the head cover and the
head cover gasket.

Disassembly of cylinder head

1、Turn the timing sprocket to the

engine timing position.
The timing sprocket timing line mark
is flush with the end face of the
cylinder head, and the intake and
exhaust camshaft timing point is
facing the top of the cylinder head.
Tensioner
combination
2、Remove the 2 bolts of tightening
tensioner M6×20.
then remove the tensioner
combination and tensioner gasket.

3、Remove the 2 bolts M6×40 and 6

bolts M6×35 that fasten the camshaft
bracket in the order of
1→2→3→4→5→6→7→8; then
remove the chain pressure plate and
camshaft bracket, remove the timing
chain on the timing driven sprocket,
and remove the intake camshaft parts
and exhaust camshaft parts.

4. Remove the four M6×25 cylinder

head bolts first.
in removing 4 cylinder double-
headed bolts AB (M10×152), in the
English order of 1→2→3→4, and then remove
version 4 AB bolts flat washers.

5, remove the cylinder head.

163
Disassembly of cylinder head valve lifter

1, remove the four pieces of valve

tappet, respectively, a good
corresponding mark.

2. Remove the 2 NC450S thermostat

cover fastening bolts M6×20 and
remove the NC450S thermostat
cover and the NC450S thermostat.
thermostat cover
3、Use the valve remover to press thermostat
down the valve spring and remove
the valve locking clip; then relax the
valve remover and remove the
upper seat of the valve spring, the
inner and outer valve springs and
the lower seat of the inner and
outer valve springs as well as the
intake and exhaust valves,
respectively, to make the
corresponding
Caution. markings.
-In order to prevent permanent
deformation of the valve spring, the valve
spring should not be overly compressed,
only the valve locking clip should be able
to be removed.
-All parts removed should be marked to
ensure that they reach their original
assembly position during assembly.
Inspection of valves and valve springs
1, check whether the valve is bent or the valve stem has abnormal wear, measure the valve
stem outer diameter. Maintenance limit value.
Intake: φ5.46mm
Exhaust: φ5.44mm
2、The width of the contact surface maintenance limit value: 1.5mm

Caution.
-If the valve contact surface is very
rough, uneven abrasion or contact
with the valve seat is not normal, can
not guarantee the sealing
performance, should be replaced
valve. English
3、Check the valve spring for version
abnormal wear and measure the
free length. Repair limit value.
Outer spring: 47.35mm
164
Inner spring: 37.95mm
 Inspection of valve tappet

Check the front and side of the

tappet for abnormal wear. If the wear
and tear is serious or the clearance is
large after installation, a new tappet is
required.

Inspection of camshaft

1. Check whether the camshaft surface

is worn and destroyed. If the wear is
serious, replace the camshaft parts
with new ones.

Inspection of cylinder head

1、Check whether the cylinder head is

well sealed, if the cylinder head is
poorly sealed, replace the cylinder
head or valve with a new one.
2、Check whether the cylinder head is
deformed, and check the flatness of
the cylinder head with a knife edge
ruler and a plug ruler.

Check the flatness of cylinder head with a stopper

Combustion chamber leak
detection test: Inflation 0.3Mpa,
leakage ≤6000pa/10sec.
Testing parameters: Inflation time
5S, balance time 3S, detection time
2S, deflation time 0.5S, upper limit of
English pressure detection 320Kpa, lower
version limit of pressure detection 290Kpa,
judgment value 1.2Kpa.

165
Assembly of cylinder head components
1, the valve spring lower seat (3, 4), oil shield
(5) installed on the valve guide.
2, the intake valve rod (1), exhaust valve rod
(2) coated with a small amount of lubricant,
installed into the valve guide, installed the
valve outer spring (6), valve inner spring (7),
valve lock clip (8) and valve spring upper
seat (9).
3, then use the valve remover to press down
the valve spring, and then install the valve
lock clip into the valve spring upper seat.
Note:
• to prevent valve spring produce permanent
deformation, not overly compression spring, to
load the valve lock clamp.
4、Check whether the valve lock clip assembly is in
place.
valve lifter
5, the assembled cylinder head combination for gas
tightness testing, if the cylinder head combination
gas tightness testing qualified then you can
proceed to the next step (according to the cylinder
head composition diagram assembly).
6, the valve tappet surface lubrication oil into the
cylinder head corresponding position.
7、In the intake and exhaust camshaft parts
completed by the department, grease the journal
surface and assemble them in the camshaft groove
position of the cylinder head, and take the spark
Exhaust valve CAM unit
plug hole seal and install it into the camshaft intake valve CAM unit
bracket.
8. then assemble the camshaft bracket and chain Spark plug seal ring
pressure plate at the designated position in the
cylinder head, and fasten the chain pressure plate
and camshaft bracket with two M6×40 and six
M6×35 bolts, in the order of
1→2→3→4→5→6→7→8.
Tightening torque: 11~13N.m.
9. After rotating the intake and exhaust camshafts
until the timing line is flush with the cylinder head
and the timing point is facing upwards, check the CAM
intake and exhaust valve clearance with a stopper; support
intake valve clearance 0.1mm~0.15mm, exhaust
valve clearance 0.15mm~0.2mm. chain
plate
Attention. English
-Camshaft should rotate flexibly without version
interference and stalling
-When adjusting the valve lash, make the camshaft
in the timing position and torque the camshaft
bracket tightening bolt to 10N.m before measuring. 166
 Cylinder stud AB(M10×152) Assembly of cylinder head components
1、Remove the camshaft bracket that has been
flat washer
adjusted for the valve clearance cylinder head, and
then remove the intake and exhaust camshaft parts.
2、Remove the old cylinder head gasket, install the
new cylinder head gasket, and then install the
cylindrical pin (∅6×12).
3, put the cylinder head on the cylinder body, then
round pin Cylinder put the A and B bolts flat washers on the NC450S
head cylinder double-head bolt AB, then put the NC450S
gasket cylinder double-head bolt AB into the cylinder head,
cylinder body connection hole and tighten it.

Caution.
-The cylinder head gasket must be replaced
with a new one.
A, B bolt nut tightening need to be done
diagonally, the first time for 20N.m pre-
tightening, the second time for 40N.m
tightening, and finally the third tightening
torque: 55 ~ 60N.m.
4、First put 2pcs M6×25 bolts into the
cylinder body, box
Body connection hole and tighten, then put
2 M6×25 bolts into the connection hole of
cylinder head and body and tighten.
Tightening torque: 11~13N.m.
5. First check whether the engine is in the
timing position, if not, readjust the engine
timing position; then install the intake and
exhaust camshaft parts so that the camshaft
timing line is flush with the end surface of
the cylinder head and the timing point is
directly above the cylinder head, then install
the timing chain to the intake and exhaust
camshaft.

Small viewport NC450S engine timing adjustment

covergasket (1) Remove the large viewport cover and small
viewport cover of the left front cover.
(2) Rotate the magneto lock nut with a special tool
big viewport covergasket
and observe whether the timing mark line "Ⅰ" on
the rotor of the magneto and the timing mark slot
Left cover timing marker slot
on the left front cover are aligned through the
screw hole of the small sight hole cover on the left
front cover.
(3) After the above timing mark is correct, continue
to install the intake and exhaust camshaft parts so
that the timing line of the intake and exhaust
camshaft parts is flush with the end surface of the
cylinder head and the timing point is facing the
English
upper part of the cylinder head, and then install
version the timing chain to the intake and exhaust cam
timing driven sprocket.
☆: Only if (2)(3) is satisfied at the same time, the
engine is in the correct timing position.
167 Magneto rotor timing marker line
6、After adjusting the timing position,
assemble the large viewport cover and
small viewport cover to the left front
cover.
7. Then install the removed camshaft
bracket, spark plug seal and chain
pressure plate onto the cylinder head,
and tighten 8 bolts of the cylinder
head bracket, tightening bolts in the
order of 1→2→3→4→5→6→7→8.
Tightening torque: 11~13N-m

8, press down the tensioner eccentric

wheel by hand, press the tensioner
plunger into the tensioner, make the
tensioner plunger in a contracted
state, then align the tensioner gasket,
tensioner combination to the cylinder
mounting hole, and fasten with 2
M6×20 bolts.
Tightening torque: 11 ~ 13N-m

9, and then the tensioner spring, flat

washer, tensioner screw plug in turn
into the tensioner body, tighten the
tensioner screw plug, so that the
tensioner plunger pops out.
Tightening torque: 7~9N-m.
10、Check whether the timing chain is
tensioned and confirm again whether
the engine timing point is correct.

Installation of cylinder head

1、Take NC450S cylinder head cover
seal, head cover bolt cushion washer,
assemble in NC450S cylinder head
cover specified position.
2、Take 3 pieces NC450S cylinder
head cover fixing bolt M6×22.8, 3 English
pieces cylinder head cover fixing bolt version
M6×50.7, assemble in cylinder head,
tighten diagonally in turn.
Tightening torque: 10~12N-m. 168
 Cylinder block and piston

1 Maintenance instructions .................................................................................. 170

2 Assembly drawings .............................................................................................. 171
3 Disassembly of the cylinder .............................................................................. 172
4 Inspection of the cylinder .................................................................................. 172
5 Disassembly of piston ......................................................................................... 173
6 Inspection of pistons and piston rings ......................................................... 173
7 Installation of piston rings ................................................................................ 174
8 Installation of piston ........................................................................................... 174
9 Cylinder installation ............................................................................................. 174

English
version

169
 Maintenance instructions

Caution.
-The cylinder head lubricating oil goes to the cylinder head through the
small oil hole next to the left body AB pin of the engine, make sure the
small oil hole next to the left body AB pin is clear before installing the
cylinder. Do not put the cylinder solid locating pin into the oil passage hole.

Cylinder, piston, piston ring, piston pin, specification parameters

Maintenance
standard values
item limit values
mm
mm
Cylinder bore diameter φ94.5～φ94.52 φ94.528

cylinder deroundness 0.05 0.01

Flatness of cylinder surface 0.03 0.05

Piston outside diameter φ94.453～φ94.467 φ94.43

Piston pin bore bore diameter φ20.004～φ20.01 φ20.015

Clearance between piston pin and piston
0.004～0 .018 0.025
pin hole
Top ring/second
0.2～0.35 0.5
Piston ring closing ring
Piston
clearance
Piston ring Oil ring 0.2～0.7 1.4
piston pin
Top ring 0.03～0.07 0.08
Piston ring groove
clearance
Second ring 0.02～0.06 0.08

Clearance between cylinder and piston 0.033～0.067 0.07

Outside diameter of piston pin φ19.992～φ20 φ19.99

Small end Inside diameter φ20.015～φ20.025 φ20.04

of
connecting Clearance between small end of
rod 0.015～0.033 0.05
connecting rod and piston pin

English
version

170
 Assembly drawings

1、NC450S piston ring assembly.

2、NC450S piston.
3、NC450S piston pin.
4、NC450S piston pin retaining ring.
5、NC450S timing chain assembly
(5×134_tooth chain).
6、NC450S chain tensioning plate
combination (2#).
7、NC450S chain guide plate combination.
8、Cylinder pin φ6×12.
9、NC450S cylinder block parts (cylinder
standard 449_passivated by shot blasting).
10, NC450 cylinder block gasket (foam
metal rubber composite plate).

English
version

171
Disassembly of the cylinder
1、Take off the chain guide plate, Chain
remove the two cylinder block and guide
plate
box connecting bolts M6×25, remove
the cylinder block.

2、Scrape the remaining gasket on

the cylinder surface with a scraper.

Inspection of the cylinder

1、Check whether the cylinder block

is worn or destroyed.
2、Measure the cylinder bore, should
measure three positions, namely the
top, middle and bottom of the piston
stroke, the measurement should be
made in two directions at right angles
to each other.
Repair limit value: φ94.528mm English
version

172
 Disassembly of piston

Remove the piston pin retainer

with sharp nose pliers and take off
the piston pin and piston.

Caution.
-The piston pin retainer should not be
dropped into the crankcase when
removing the retainer.
Inspection of pistons and piston
rings
1、Remove the piston ring.
2、Measure the clearance between
the piston ring and the piston ring
groove, repair limit value.
First ring: 0.08 mm
Second ring: 0.08 mm
Oil ring: 0.08 mm
3、Check whether the piston is worn
or cracked, and whether the piston
ring groove is worn.

4、Insert the piston ring into the

cylinder, then measure the piston
ring closing gap.
Repair limit value.
The first ring: 0.5mm
Second ring: 0.5mm
Oil ring: 1.4 mm
5. Measure the outside diameter
located at a height of 7 mm from the
piston skirt.
Repair limit value: φ94.43 mm
6、Figure out the clearance between
the cylinder and the piston.
Repair limit value: 0.1mm

7、Measuring the outer diameter of

the piston pin.
Repair limit value: φ19.99 mm
English
8、 Calculate the clearance between
version the piston and the piston pin.
Repair limit value: 0.025 mm
173
Installation of piston rings
1, the piston ring groove will be thoroughly
cleaned.
2、Fit the piston ring.

Caution.
1, in the installation, should prevent the piston
and piston ring from being destroyed.
2、When installing the piston ring, the first ring
and the second ring should not be installed
wrongly, and the side of the first ring and the
second ring with the mark should face the top of
the piston.
3、After installation, the piston ring should rotate
flexibly.
3、The gap between each ring in the oil ring
should be matched with the gap of the
spacer ring; when installing the oil ring, the
spacer ring should be installed first, and then
the side guide.
Installation of piston
Install the piston ring, piston pin and new
piston pin retainer on one side. The larger
side of the
Attention. concave
1. when installing the piston, the smaller side of transverse
is the
the skirt should face the intake side of the engine,
direction of
or the larger side of the top groove should face the intake
the intake side. valve
2. the opening of the piston pin retaining ring end
gap should be facing downward.
3. the piston pin retaining ring must be replaced
with a new retaining ring if the deformation is The smaller side of the skirt is the direction of
serious. the intake valve
4. Do not let the piston pin retainer fall into the
crankcase.

Cylinder installation
1, install the cylinder block locating pin, new
cylinder block gasket.
2, in the cylinder block, piston and piston ring
surface evenly coated with a layer of oil;.
3、First stagger the openings between the
piston rings 120° from each other, then gently English
assemble the cylinder block in place. version
4、Assemble the chain guide plate in place.

Note: When installing the cylinder block,

avoid destroying the piston rings. 174
 Clutch, driving gear, overrunning clutch, oil pump, gearshift
mechanism
1 Maintenance instructions ........................................................................................... 176
2 Water pump cover, right crankcase cover, impeller water pump shaft water
seal oil seal removal ........................................................................................................ 177
3 Disassembly of clutch, active gear, overclutch, starter gear, right body oil
pump ................................................................................................................................... 178
4 Disassembly and inspection of starter motor .................................................. 179
5 Disassembly of duplex gear, gearshift mechanism ........................................ 181
6 Inspection of right crankcase cover, impeller, water pump shaft, water seal
oil seal, clutch active friction plate .......................................................................... 182
7 Inspection of clutch cover, overclutch, right body oil pump ..................... 183
8 Gearshift mechanism, assembly of right body oil pump ............................ 184
9 Installation of starter gears and overclutch, active gears .......................... 185
10 Installation of clutch, starter motor, right crankcase cover ..................... 186

English
version

175
 Maintenance instructions
Instructions
After removing the right crankcase cover, the disassembly, installation and
maintenance work concerning the clutch, oil pump and gearshift
mechanism can be carried out without removing the engine.

Clutch oil pump specifications

standard values Maintenance
item
mm limit values mm
Free spring length 25 25

Friction plate free thickness 2.95～3.05 2.85

Clutch
Clutch driven plate flatness 0.1 0.14
Clutch cover and friction plate
0.1～0.3 0.6
clearance
Radial clearance between
0.06～0.15 ----
outer and inner rotors
Oil pump
End clearance between rotor
0.04～0.1 ----
assembly and cover plate

English
version

176
 Water pump cover removal
Remove the water pump cover
drain bolt, release the cooling water
from the engine at the drain bolt,
and remove the water pump cover
and the water pump cover gasket
when there is no water flowing from
the drain bolt.

water pump
nut cover

Right crankcase cover removal

1、Drain the engine oil first (remove
the two fastening bolts (1) M6×16
of the oil filter cover (2) on the right
side, remove the oil filter cover (2),
remove the oil filter spring (4),
remove the oil filter parts (5),
remove the oil filter cover (6) of the
left and right box, remove the oil
filter combination (8) in the box, and
wait until the oil in the box is
finished; when removing the oil filter
cover. pay attention to the oil screen
cover O-rings (3), (7) are not
damaged.
2. Remove the connecting bolts and
take off the right crankcase cover.

Note: When taking the right cover,

remove the two locating pins
together and keep the locating pins
in a safe place.

Impeller, water pump shaft, water

seal assembly and oil seal removal
1、Remove the pump impeller (9)
and remove the pump shaft (12).
English 2、Take off the water seal assembly
version (10) and oil seal (11) in the pump
shaft hole.

177
Disassembly Clutch
gland bolt locknut
1、Remove the clutch pressure plate
bolt and spring, note that when
twisting and loosening the clutch
pressure plate bolt, it should be
twisted and loosened in a cross way in
two or three times.
2、Remove the clutch pressure plate
and clutch top lever.
3、Remove the clutch lock nut and
thrust spacer.
needle bearing
4、Remove the clutch center sleeve,
outer cover, needle bearing and
washer
spacer.
5、Take out the clutch push rod in the
center hole of the main shaft.

Disassembly active gear, overclutch,

starter gear
washer
1、Remove the active gear lock nut and
lock nut washer.
2、Take off the active gear, overrunning
clutch and starting large disc gear.
Note:
when you start down the big gear
combinations, will start the big gear the
washer below to be removed, and
properly keep the gasket. check ring washer

Disassembly right body oil pump gear

1、Remove the oil pump over-bridge
gear and oil pump gear combination
Oil
retaining ring with expansion pliers. pump
2、Remove the oil pump over-bridge gear
gear gasket, oil pump over-bridge
gear, oil pump gear combination.
3, remove the right oil pump cover Oil pump cover assy
plate of three bolts M5 × 18, take off
the oil pump cover plate combination
and oil pump inside and outside rotor
combination.
Attention. English
The oil pump over-bridge teeth have 1 version
oil pump over-bridge teeth washer on
top and bottom, the removed retaining
Oil pump pin
ring, washer and oil pump pin should be
properly stored to avoid loss. 178
 Disassembly starter motor

Remove the fastening screw M6x25

of the starter motor and remove the
starter motor.

[1] Remove the o-ring [1]. The installation

sequence and remove the reverse
order. Note: the replacement of a new
o-ring and coated with engine oil.

Caution.
[6] [4] [3] Install the armature [1] into the
motor housing from the housing slot [2]
side
body so that the commutator lever is
facing the rear side.
Install the front cover [3] with the tabs
aligned with the recesses (index line [8]
[5] [1] [2] aligned).
Install the carbon brush assembly [4]
onto the motor drive shaft [1] The wire
harness [5] is threaded into the rear
cover hole [6] while the rear cover [7] is
[11] [10] installed.
Caution:
Prevent damage to the oil seal lip
with the armature shaft aligned with
English the rear cover index line [8] and the
groove [9] on the motor housing.
version
Install the front and rear cover
attachment bolts [11] harness positive
179 [7] [8] [9] fastening nuts [10].
※Inspection of starter motor [1] [2]

Front cover

Check whether the oil seal [1] in the front

cover is deteriorated, worn or damaged.
Turn the inner ring of the bearing [2] with
your finger, the bearing should rotate
smoothly, and also check whether the outer
seat ring fits tightly with the front cover.

Rear cover
[1]
Check the bushing [1] in the rear cover for
wear or damage.
Check the carbon brush for damage and
measure the length of the carbon brush [1].
Operating limit: 6.5 mm
Check the conductivity of the rear cover as
follows.
-Conductivity should be maintained
between positive brushes [2] and cable
terminals.
-Between the cable terminal and the back
cover: should not be conductive.
[1]
Rotor

Remove any metal debris from the

commutator rod [1].
Check commutator bar for discoloration.
Check for conduction on the rotor as
follows.
-Between a pair of commutator bars;
[2]
there should be conduction.
-Between each commutator bar and the
armature shaft [2].
There should be no conductivity. [1] [2]

English
version

180
 duplicate
duplicate gear shaft
duplicate Disassembly of duplex gear
gear 1 gear 2
Remove the duplex gear shaft
first, then remove the duplex
gear one and duplex gear two.

shift arm
5-star
parts
plate
Disassembly of gearshift
mechanism

1、Remove the five-star plate

fastening screw M6×35 and remove
the five-star plate.
2、Remove the shift arm parts.
3、Remove the positioning plate
combination fastening screw M6×20,
remove the positioning plate washer
and positioning plate combination.

Positioning
plate assembly

English
version

181
 Inspection of right crankcase cover NJK
1, check whether the right crankcase cover
crankshaft oil seal is broken, if the oil seal is found
to be broken then it needs to be replaced with a
new oil seal.
Two points should be noted when
replacing crankshaft oil seal:
1. Make sure the state of oil seal is correct, the end
face of NC450S crankshaft oil seal should be
marked with "NJK".
2. The marked side should face outward during
assembly.
Inspection of right crankcase cover,
impeller, water pump shaft, water seal water pump impeller
oil seal

1、Check whether there are cracks in the impeller

of the water pump and whether the inserts of the
impeller of the water pump are loose, if there is
the above phenomenon, it is necessary to replace
the impeller of the water pump with a new one.
2、Check whether the water seal component and
oil seal are broken, check whether the water pump
shaft is abnormally worn and bent, if so, replace
the water seal component, oil seal and new water water pump shaft
pump shaft.
When replacing the water seal assembly,
oil seal and pump shaft, attention should
be paid to.:

1. Apply an appropriate amount of oil in the

NC450S water pump shaft hole and press the
NC450S water pump shaft oil seal into place with
special tooling, with the oil seal end mark facing
outward.
2. Press the NC450S water seal into place with
special tooling, 0.5mm below the end face, with
the water seal end mark facing outward when
assembling the water seal.
3. Apply an appropriate amount of lubricant to
the main lip of the water seal.
4. Press the new water pump shaft into place with
special tooling.
5. The assembled water pump shaft should be
flexible in rotation.
Inspection of clutch active friction
plate

1. If the clutch friction plate shows signs of

abrasion or discoloration, it should be replaced.
Measure the thickness of each clutch friction plate. English
Repair limit value: 2.85mm version
2、Check the surface of the clutch follower plate
for distortion, and use a gap gauge for the
inspection (flatness).
Repair limit value: 0.14 mm 182
 3. Check the gap between the clutch
cover and the friction plate.
Maintenance limit value: 0.6 mm

Inspection of clutch cover

Check whether the groove on the

drum of the outer cover is notched
and scarred by the friction of the
clutch disc. If serious, the outer cover
needs to be replaced.

Overreach clutch Overreach clutch block Inspection of overclutch

housing
Remove the ring on the end face of
the overrunning clutch, and check
whether the wedge of the
overrunning clutch is worn and
damaged, and whether the wedge
spring is stretched or broken.

Oil pump plate Oil pump inner and outer Inspection of Right body oil pump
rotor combination

1. Check whether the rotor inside and

outside the oil pump is worn and
damaged. If the wear and damage are
serious, it is necessary to replace the
new oil pump rotor assembly;
2, check the gear oil pump across the
bridge and oil pump gear
Oil pump gear Oil pump gear combinations have burst phenomenon,
assembly there is need to replace the new
machine oil pump gear and gear oil
pump combination
3 bridge, inspect right oil pump cover
English
for wear and damage phenomenon, if
version has the need to change new oil pump
cover board right.
183
Assembly of shift mechanism

1、Install the positioning plate

combination (4) and flat washer (6), snap
the positioning plate spring (3) into the
corresponding position of the
positioning plate and fasten it with the
M6×20 bolt (5).
2, put the five-star plate combination
(1) on the shift drum, take a M6 × 35
bolt (2), apply 3 to 4 teeth thread
fastening adhesive on the threads, and
tighten the bolt.
3. Take the NC250 shift arm part (7)
and put it into the corresponding
position (note: the shift arm return
spring is stuck into the right body shift
arm positioning bolt (8)).
4. test whether the gearshift is correct
and smooth.
5、Take the shift arm oil seal (9) and
assemble it in the left body shift arm oil
seal hole position with tooling.

Assembly of right body oil pump

1、Put the oil pump shaft (1) through

the corresponding hole in the case.
Note: there are 2 pin holes on the shaft
facing the right box
2, put the oil pump pin (2) through the mark
oil pump shaft (1), and then put the oil
pump rotor assembly (4) into the
corresponding oil pump hole in the right
body (the marked face of the oil pump
rotor assembly should face the same
direction), and
3, then install the oil pump cover
assembly (5) to the oil pump and fasten
it with 3 bolts (6) of M5×18.
4、Put the oil pump pin (3) through the English
oil pump shaft, then put the oil pump version
gear combination (7) onto the oil pump
shaft, and finally put the retaining ring (8)
onto the snap ring groove of the oil
pump shaft. 184
 Attention.
1. when installing the oil pump rotor,
the marked surface of the inner and
outer rotor should face the same
direction.
2. tightening torque of the oil pump
cover bolts: 7 to 9 N.m.
3. After assembling the cover plate,
make sure that the oil pump shaft is
flexible in rotation.。

4. Install the oil pump over-axle gear

washer (9) on the oil pump over-axle
gear shaft, install the oil pump over-
axle gear (10) on the oil pump over-
axle gear shaft, then install the oil
pump over-axle gear washer (11) on
the oil pump over-axle gear, and finally
install the retaining ring (8) on the snap
ring groove of the oil pump over-axle
gear shaft.。
Caution.
Apply oil evenly on the inner hole of
the starter large disc teeth before
installing the starter large disc teeth. Installation of starter gears and
overclutch

1、Install the starter large disc tooth

washer (12) onto the right crank.
2、Install the starter large disc tooth
(13), needle bearing (14) and
overrunning clutch (15) on the right
crank.
Installation of active gears

1、Fit the active tooth (16) to the

right crank
2、Fit the active tooth lock nut
washer (17) to the active tooth.
3、Apply 3~4 teeth thread fastening
English adhesive to the active tooth lock nut
version (18), install it on the right crank and
fasten it.
Tightening torque: (115 ~ 125) N - m
185 Thread fastening adhesive name:
Loctite 263
Installation of clutch
1. Install the clutch cover washer (19),
needle roller bearing (20), clutch cover
(21) and clutch center sleeve washer
(22) on the spindle;
Note: The clutch needle rollers are
evenly coated with engine oil.
2, first clutch center sleeve
combination (23), clutch lock nut
washer (24) installed on the spindle,
clutch lock nut (25) coated with 3 to 4
teeth thread fastening adhesive will
be installed on the spindle and
tightened. Note: Clutch lock nut tightening
torque: 80～90N.m
3, then put the clutch push rod (26) into
the center hole of the main shaft, then
put the clutch top rod (27) into the
center hole of the main shaft, then put
the thrust bearing (28) and top rod
washer (29) onto the top rod.
4. Install the clutch pressure plate (30),
clutch pressure plate spring (31), and
pressure plate screw (32), and tighten
the pressure plate screw with a torque
wrench, tightening torque: 8 to 10 N-m.
Installation of starter motor start motor
Assemble the starter motor in
place after evenly applying oil to the
slotted end of the starter motor and
fasten it with 2 bolts M6×25 with a
tightening torque of 11 to 13 N.m.
Installation of right crankcase
cover
1, the two locating pins (1) to the box
locating pin hole, remove the old right
crankcase gasket (2), install the new
gasket, the right crankcase cover (3)
assembly in place and 11 bolts M6 × 35
tightening, tightening torque: 11 ~ 13N.m
2、Fit the water pump impeller (4) to the English
water pump shaft and tighten it,
version
tightening torque: 2～4N-m.
3、Fit the pump cover gasket (5) and
assemble the pump cover (6) in place and
fasten it with 2 bolts M6×45 and 2 bolts 186
M6×25.
 Magneto, balance driving and driven gear
1 Repair instructions ................................................................................................. 188
2 Disassembly of the left crankcase cover, magneto stator and rotor ... 189
3 Disassembly of balancing master and slave gears, left body oil pump ... 190
4 Inspection of the left crankcase cover, magneto stator and rotor ........... 190
5 Balancing master and slave gears Inspection and installation of the left
body oil pump .............................................................................................................. 191
6 Installation of magneto stator and rotor, left crankcase cover ............... 192

English
version

187
 Repair instructions

The removal and installation of the magneto and balanced master and
slave gears described in this section
This can be done by simply removing the left crankcase cover without
removing the engine.

English
version

188
 Disassembly of the left
crankcase cover

Remove the left front cover 8

fastening bolts and remove the left
crankcase cover.

Disassembly of magneto
stator

1、Remove the 2 bolts M5×10

fastening screws of sensing.
2、Remove the 2 bolts M5×40
fastening screws of the stator coil, and
then remove the magneto stator
combination from the left crankcase
cover.
Magneto stator assy

Disassembly of rotor

Remove the magneto rotor lock nut

and remove the magneto rotor with
special tools.

Attention.
1. magneto rotor disassembly can
only be disassembled with special
tools, do not allow knocking magneto
rotor.
2. The magneto rotor should be
replaced with a new magneto rotor if
English the rotor is subjected to accidental
version impact during disassembly and
assembly, such as if the magneto
rotor falls to the ground or is struck
189 by a foreign object.
Disassembly of balancing master
and slave gears
1、Remove the balance active gear lock
nut (1) and active gear lock nut washer
(2), respectively.
2、Remove the crankshaft timing active
sprocket (3) and balance active gear (4).
3、Remove the balance follower gear
lock nut (5) and disc washer (6).
4、Remove the balance tooth driven
wheel (7), crankshaft sleeve and balance
shaft flat key.
Disassembly of left body oil
pump

1、Remove the 3 bolts M5×1 2 that

fasten the left oil pump cover plate.
2、Remove the oil pump cover plate,
remove the left oil pump rotor assembly, Balance shaft
the oil pump pin should be properly oil seal
stored to avoid loss.

Inspection of the left

crankcase cover

Check the balance shaft oil seal of

the left crankcase cover for damage.
If so, replace the balance shaft oil seal.

Inspection of magneto Magneto rotor Magneto stator

stator and rotor
1、Check whether the magnetic motor
rotor tile is cracked or broken, if so, it
needs to be replaced with a new
magnetic motor rotor.
2, check whether the magneto stator
coil is black, if there is a need to replace
the new magneto stator.

English
version

190
 Balance driving gear Balancing master and slave
gears Inspection
1、Check whether the balance master and
driven gears are worn or damaged.
2、Balance driven gear buffer spring is
broken, if there is broken need to replace
the new gear.
Inspection of the left body oil
pump
1、Check the left body oil pump rotor
assembly for wear and damage.
oil pump plate oil pump rotor assy 2、Check the left body oil pump cover plate
for wear and damage.

Installation of the left body oil

pump
1、Fit the left body oil pump pin (1) into the
corresponding hole of the oil pump shaft,
and then fit the left body oil pump (2) into
the corresponding hole of the left body.
2、Fasten the oil pump left cover (3) with 3
bolts M5×1 2 (4).
Attention.
1. when installing the oil pump rotor, the
marked surface of the inner and outer rotor
should face the same direction.
2. tightening torque of the left oil pump
cover bolt: 7 to 9N-m.
3. Check whether the oil pump shaft rotates
flexibly after tightening.
Inspection of the left body oil
pump
1、First install the crankshaft sleeve (5) to
the balance shaft, then install the balance
shaft flat key (6) into the keyway of the
balance shaft, and finally install the balance
driven gear combination (7) to the balance
shaft.
2. first install the balance active gear (8)
onto the left crank, then install the balance
shaft flat key (6) into the keyway of the
crankshaft, and then install the crankshaft
timing sprocket (9) onto the left crank.
English Attention.
version When loading the balanced master and
driven teeth, the timing marks of the
balanced master and driven teeth should
be corrected, i.e. the teeth with timing
191 marks of the balanced master and driven
teeth should be engaged with each other.
(10) and disc washer (11) onto the crankshaft
timing active sprocket (9) and balance driven Balance shaft Balance shaft
gear combination (7), and put 3 to 4 teeth of driven tooth driving tooth
thread fastening adhesive on the balance timing mark timing mark
shaft active tooth lock nut M24×1 (12) and
balance shaft driven tooth lock nut M16×1
(13) and then put them onto the crankshaft
and balance shaft and fasten them.
Balancing driven tooth lock nut tightening
torque.
80～90N.m.
Balancing active tooth locking nut tightening
torque
115~125N-m.
Installation of magneto rotor
1, magneto semi-circular key (14) a, installed
in the crankshaft semi-circular key slot.
2, the magneto rotor (15) will be installed on
the left crank, and then the magneto nut (17)
will be installed on the left crank and
fastened with the washer (16) after applying
3 to 4 teeth of thread fastening adhesive.

Note: the magneto rotor lock nut

tightening torque: 80-90 n. m

Installation of magneto rotor

Fasten the magneto stator assembly (18)

to the left crankcase cover with 2 screws
M5×10(20) and 2 screws M5×40(19),
tightening torque: 7 ~ 9N·m.

Installation of magneto left

crankcase cover
1, remove the old gasket (21), install
the new gasket;.
2, the two locating pins (22) will be
installed to the box body.
3, then the left crankcase cover (23)
assembly in place and two M6 × 35
bolts (24) fastened, six M6 × 30 bolts
(25) fastened, tightening torque: 11 ~
13 N .m. English
version
Note: One of the M6 × 30 bolts (26), the
disk part coated with three and glue, set
into the flat washer (27), inserted into the
corresponding position shown in the figure 192
 Crankcase, crankshaft, variable speed drive, balance shaft
1 Maintenance instructions ..................................................................................... 194
2 Crankcase Disassembly, Crankshaft/Balance Shaft/Main shaft and Co-Shaft
Disassembly....................................................................................................................... 195
3 Inspection of crankshaft and left and right case bearings ............................ 195
4 Inspection of fork jaws/shift drum/ main and subshaft assembly/oil filter
parts, oil screen ............................................................................................................... 196
5 Transmission/crankshaft/balance shaft assembly/combined box ............ 197
6 Assembly of oil screen ........................................................................................... 198

English
version

193
 Maintenance instructions

This section introduces the installation and testing of transmission,

crankshaft and balancing mechanism. When carrying out the above work, the
crankcase should be separated first, and the disassembly of other parts about
the engine should be carried out before the crankcase is separated.

Work before crankcase separation:

-Disassembly of cylinder head
-Cylinder/piston disassembly
-Disassembly of clutch, oil pump, gearshift mechanism, balance gear
-Disassembly of magneto

Shift forks/Shift fork shaft/Crankshaft /Balance Shaft Specifications

standard values Maintenance limit
item
mm values mm
Internal diameter of the right
fork of the secondary shaft /
φ12.016～φ12.043 φ12.045
Internal diameter of the left fork
Shift forks of the secondary shaft
Internal diameter of spindle fork φ12.016～φ12.043 φ12.045

Jaw thickness 4.8～4.9 4.8

Spindle fork shaft OD φ11.973～φ12 φ11.95

Shift fork
Subshaft fork shaft OD φ11.973～φ12 φ11.95
shaft
Cylindricity 0.006 ----
Connecting rod small head inner
φ20.015～φ20.025 φ20.04
diameter
axial
Crankshaft Big end side 0.15～0.4 0.7
direction
clearance of
radial
connecting rod 0.008～0.016 0.02
direction
Balance
diameter of axle φ19.98～φ19.993 φ19.96
Shaft

English
version

194
 Crankcase Disassembly

1. Place the left crankcase of the

engine upward; 2, remove the 3 bolts
M6 M6 x 65 x 70, 3 bolt, six bolt
fastening screws M6 x 45, separate
left crankcase and right crankcase,
remove the two pins.

Crankshaft/Balance
Shaft/Main shaft and Co-
Shaft Disassembly

Remove the crankshaft assembly,

balance shaft, fork shaft, fork, shift
drum, Main shaft and Co-Shaft from
the box.
Caution.
Make sure no parts are left behind
when picking up the Main shaft and
Co-Shaft assemblies.

Inspection of crankshaft

Measure the side clearance of the

big head of the connecting rod with a
thickness gauge.
Repair limit value: 0.7 mm

Inspection of the left and

right box bearings

1, check the left and right box all

bearing rotation is flexible; If the
English rotation is not flexible or there is a
version
card phenomenon, the same type of
bearing should be replaced.

195
 Measure the thickness of the fork
claw. Maintenance limit value: 4.7 mm

Check the variable speed drum

surface and grooves for wear or
damage.

Inspection of main and

auxiliary shaft components
Check whether the gears of the
main and auxiliary shaft components
have excessive or abnormal wear, and
check whether the rings between the
gears have deformation and fall off.。

Inspection of oil filter parts

and oil screen
1、Check the cleanliness of the oil
filter parts and oil screen; rinse the
poorly cleaned oil filter parts and oil
screen with clean gasoline.
2、Check whether the oil filter parts
and oil screen are damaged; if there is
damage, replace the oil filter parts
and oil screen with new ones. English
version

196
 Transmission/crankshaft/balance
shaft assembly
1, the balance shaft (1), (2) the crankshaft to
the corresponding hole in the left body, 2
(3), the main and auxiliary shaft component
to the left the corresponding hole in the
body, then fork (4), (5), (7) assembly to the
corresponding position,
Attention.
1. the fork marked with --R is installed
into the side of the secondary shaft
against the right body.
2. The fork marked with --L is installed
into the side of the secondary shaft
against the left body.
3. The fork marked with --C is mounted
Caution. on the main shaft.
The long fork shaft passes through
the fork marked -R, marked -L, and 3. Install the shift drum (5) into the
the short fork shaft passes through corresponding hole of the left body, then
assemble the other end of the fork into the
the fork marked -C.
corresponding slot of the shift drum, and
finally install the fork shaft (8) and (9) into
the corresponding fork.

combination
1. apply a layer of sealant evenly on the combined box surface of the right box
body, install the positioning pin (10) into the corresponding hole of the left box body,
and then close the right box body on the left box body.
2, take six M6 × 45 screws (15), three M6 × 65 screws (16), three M6 × 70 screws (12),
one M6 × 40 bolts (11), apply 3 to 4 teeth of thread adhesive, then insert them into
the corresponding bolt over hole in the crankcase, and tighten them with a
pneumatic gun.
3、Take the tensioning plate (22), tensioning plate bushing (13) and one M6×105
bolt (14), apply 3~4 teeth thread glue to the bolt, first insert the tensioning plate
bushing into the corresponding hole of the tensioning plate, then fasten the
tensioning plate in the corresponding hole of the left body with a screw;.
English 4、Put the CG125D-2# gear dynamic contact (19) into the corresponding slot of the
version gear drum, then take the gear wire harness (20), put it into the corresponding hole of
the left body, and fasten it with one M6×20 screw (21).
5. Take one M6×12 bolt (17), press the gear display harness under the CB125 foot-2#
block wire piece (18) and fasten it tightly in the corresponding position of the left
197
body.
 Fastening torque: 11 ~ 13 N·m.

Assembly of oil screen

1、Assembly of the left body oil filter

Take 1 oil screen combination (1), apply a
small amount of oil on its O-ring and put it
into the corresponding oil screen hole. Fit
the oil screen cover 0-ring (2) to the oil
screen cover, apply an appropriate amount
of grease to the inner hole of the oil screen
cover (3), and fasten it to the case.
Fastening torque: 11 ~ 13 N-m.
2, the right body oil screen assembly
a. Take 1 oil screen combination (1), apply a
small amount of oil on its O-ring, install it
into the corresponding oil screen hole,
install the oil screen cover 0-shaped seal (2)
onto the oil screen cover, play an
appropriate amount of oil in the inner hole
of the oil screen cover (3), and fasten it on
closed end the box.
Fastening torque: 11~13 N-m.
b. Take the oil filter part (4) and put it into
the corresponding hole of the right box
c. Put the fine filter spring (5) onto the oil
filter parts, set the fine filter cover 0-shaped
seal (6) into the seal groove of the fine filter
cover (7), take 2 small disc bolts M6×16, put
them into the corresponding holes of the
fine filter cover, and fasten them in the
corresponding positions of the right body
Fastening torque: 7 to 9 N-m.

Caution.
When installing the oil fine filter,
opened end The installation should face the open end should face the left
to the left of the box
box

English
version

198
 Front wheel/suspension/steering
1 Overview ............................................................................................................... 200
2 Troubleshooting ................................................................................................ 201
3 Component Location ...................................................................................... 202
4 Handlebar components ................................................................................ 203
5 Handguard ......................................................................................................... 207
6Front wheel ......................................................................................................... 209
7 Front shock absorber .................................................................................... 210
8 Front shock absorber maintenance ......................................................... 211

English
version

199
 Overview
-When servicing the front wheel, front shock and steering column, a special
workbench or equivalent is required to support the motorcycle.
-Do not operate the brake handle after removing the front and rear wheels.
-After installing the front wheel, apply the brake handle to check the brake
operation.
-After installing the front wheel, perform an air gap check.

English
version

200
 Troubleshooting
Hard steering
-Low tire pressure
-Faulty tires
-The steering column adjustment nut is too tight
-Worn or damaged steering runout seat
-Bent steering column
Steering to one side or not straight ahead
-Bent axle
-Wheel not installed correctly
-Wheel bearings worn or damaged
-Steering bearing damaged or loose
-Damaged frame
-Wheel bearing failure
Front wheel shake
-Bent edges
-Faulty tires
-Worn or damaged wheel bearings
-Lax axle
-Tires and wheels are unbalanced
Wheel is difficult to turn
-Faulty wheel bearings
-Bent axle
-Braking resistance
Soft suspension
-Low tire pressure
-Shock absorber spring weakness
-Shock absorber fluid level is low
-Incorrect shock absorber oil specification (low viscosity)
Rigid suspension
-Tire air pressure
-Shock absorber deformation
-High fluid level in shock absorber
-Incorrect shock absorber oil specification (high viscosity)
-Shock absorber oil channel blockage
Front suspension noise
-Loose shock absorber fasteners
-Incorrect shock absorber oil specification (low viscosity)
-Front shock absorber bushing slider worn

English
version

201
Component Location
factory edition
Handelbar

Wheel
front shock
absorber

regular edition

Handelbar

wheel
English
front shock
version
absorber

202
 ※Handlebar-left（regular edition）
[5] [2]
Left rear view mirror/clutch handle/left
handle switch
Disassembly
[1] Remove the following parts.

- Remove the nut [1] to remove the

[4] rearview mirror.
[3] - Clutch switch connector [2].
- Two M6x20 inner hexagonal flange bolts
[3].
- Clutch handle mount [4].
- Clutch handle [5].
[1]
- Removal of the right-hand handle rubber
[1].
- Two self-tapping Phillips screws [2] at the
bottom of the left-hand handle switch.
- Right handle switch housing [3].

Install in the reverse order of removal.

[2] ※Handlebar-right（regular edition）
[3]
Right rear view mirror/front brake
handle/right hand grip switch
Disassembly
[4]
Remove the following parts.
[1]
- Loosen the nuts [1] to remove the rearview
[3] mirror;
- Remove the two M6x20 inner hexagonal
flange bolts [2];
- Remove the brake handle mount [3];
- Remove the brake handle [4].

[2] - Remove 2 screws [1];

- Remove the oiler and handle rubber [2];
- Remove the 2 screws [3] from the bottom of
[3] the right-hand handle switch;
- Remove the right-hand handle switch [4].

The installation order is the reverse of the

[2] disassembly order.
Caution.
-The fuel filler must be installed with the
tab accurately into the truck handle
English restriction hole.
version [1] [2]

203
※Handlebar-left（factory edition）
[3]
Hand guard/clutch handle/left handle
switch
Disassembly
Disassemble the following parts.

- Removal of hexagon socket countersunk

head screws [1]. [1]
- Removal of 2 hexagon socket step
screws [2].
- Remove the inner hexagonal socket [2]
flange screw [3].

- Remove 2 inner hexagonal socket head

flange bolts [1].
- Removing the clutch handle catch [2].
- Removing the left hand guard.
- Remove the 2 inner six-flower hexagonal
[7] [3] [4] [1] [2] [6]
flange bolts [3] behind the combination
button.
- Remove the combination button [4].
- Remove the two hexagonal socket head
bolts [5].
- Remove the left handlebar switch [6].
- Remove the left handlebar rubber [7].

The installation sequence is the reverse of

the disassembly sequence. [5]

※Handlebar-right（factory edition）

Handguard/ Brake Handle/ Starter Switch/

[3] [7] [2]
Throttle Turner
Disassembly
Disassemble the following components.

- Removal of the hand guard as above

(left).
- Removal of 2 inner hexagonal flange
bolts [1].
- Removal of the front brake handle [2].
- Removal of the starter switch screw [3]. [1] [4] [5] [6]
- Removal of the starter switch [4].
- Remove the two inner hexagonal flange
bolts [5]. English
- Remove the throttle handle rubber [6] version
and the throttle filler [7].

The installation order is the reverse of the

disassembly order. 204
 ※Handelbar（factory edition）
[3] [1]
Disassembly
Disassemble the following parts.

- Removal of four internal six-flower

external hexagonal flange screws
M8x50 [1].
- Remove the directional handle
[4] [2] pressure block (ENB bracket) [2].
- Remove the steering handle upper
clamp X2 [3].
- Removing the handlebar tube [4].

The installation order is the reverse of

the removal order.
[2]
※Handelbar（regular edition）

Disassembly
Disassemble the following parts.

[3] [1] - Remove 4 inner hexagonal flange

bolts M8x45 [1]
- Remove the directional upper clamp
[2] X2 [2]
[4]
- Remove the handgrip tube [3]

Install in the reverse order of

disassembly.

※Handlebar installation（factory
edition）

[1] [3] Handlebar [1] and steering handle upper

clamp [2] steering handle pressure block
(ENB bracket) [3] tighten bolt [4], then
tighten bolt [4] to the specified torque.
Torque: 22 N.m (2.2 kgf.m, 16 lbf.ft)

※Handlebar installation（regular
[2] edition）

English Tighten the bolt [3] on the handlebar

[1] and the clip [2] on the steering
version
handle, and then tighten the bolt [3]
Tighten to the specified torque.
[1] [3] Torque: 22 N.m (2.2 kgf.m, 16 lbf.ft)
205
※factory edition
Handlebar installation
installation：
Right handlebar: Throttle lever -
Handlebar rubber - Start button
Clean the sliding surface of the throttle
handlebar rubber [1] and throttle turnbuckle
[2], and apply grease to the top of the
throttle cable and the rolled-up area. Attach
the throttle cable [3] to the throttle
[3] [5] [4] [2] [1]
turnbuckle and install the throttle turnbuckle
cable into the throttle lever [4], install the
start button [5] on the handlebar, and
tighten the bolt. [1] [3]
installation：
Front brake handle

Front brake handle [1] and brake handle

mount [2] then tighten the bolt [3] to the
specified torque.

Torque: 8 N.m (0.8 kgf.m, 6 lbf.ft)

Connect the brake light switch connector [4] [2]
[4].

installation：
Left handlebar: Handlebar adhesive - [1] [2]
Switch button - Instrument button
Clean the surface of the left handlebar
adhesive [1] and the outer surface of the
handlebar tube [2]
Apply handlebar adhesive to the inner
surface of the handlebar and the outer
surface of the handlebar, wait 3-5 minutes,
then install the handlebar adhesive; turn the
handlebar so that the adhesive is evenly
applied, install the instrument button [3] on [3] [4]
the handlebar, install the switch button [4],
and then tighten the rear bolt to the
specified torque.
Torque: 8 N.m (0.8 kgf.m, 6 lbf.ft) [1]

installation ：
Clutch Handle / Handle Bracket
clutch handle [1] and clutch handle [2] English
bracket [2].
Then tighten the bolts [3] version
to the specified torque.
Torque: 10 N.m (1.0 kgf.m, 8 lbf.ft) [3]
206
 ※installation：（regular edition）Handlebar
parts
[2] Right Handlebar: Right Handlebar Switch - Throttle
Turner - Handlebar Rubber

[5] Clean the sliding surface of the throttle handlebar

rubber [1] and the throttle lever, and apply grease to
the top of the throttle cable and the rolled-up area.
Connect the throttle cable [2] to the throttle turner and
install the throttle turner and cable into the throttle
lever [3], then tighten the fuel filler mounting bolts [4].
Install the right hand switch by tightening the screw at
[4] [3] [1]
the bottom of the switch [5].

※installation：（regular edition）Handlebar
parts
[1]
Right handlebar: brake handle - rear view mirror
[4]
Install the brake handle [1] brake handle
bracket/card holder [2] then tighten the bolt [3] to
[2]
the specified torque.
Torque.
10 N.m (1.0 kgf.m, 8.0 lbf.ft)
Install the rearview mirror and tighten the nut [4]

[3] Check the following.

- Connect the brake light switch connector
- Throttle handle free travel
※installation：（regular edition）Handlebar
[1]
parts
Left handlebar: Handlebar adhesive-Left
handlebar switch
Clean the surface of the left handlebar
adhesive [1] and the outer surface of the
handlebar tube apply the handlebar adhesive to
the inner surface of the handlebar and the
[3] outer surface of the handlebar,wait for 3-5
minutes,then install the handlebar adhesive
[2]
turn the handlebar so that the adhesive is
evenly applied,left handlebar switch [2] then
tighten the bottom screw [3].
[1] ※installation：（regular edition）Handlebar
parts
Left handlebar: Clutch handle - Rear view
[4] mirror
Clutch handle [1] and clutch handle bracket
English [2], then tighten the bolt [3] to the specified
version [2] torque.
[3] Torque.
10 N.m (1.0 kgf.m, 8.0 lbf.ft)
207 Install the rearview mirror and tighten the nut
[4].
Check the following.
-Clutch handle free play
-Connect the clutch switch connector
Installation.
[1]
Left and right handlebars:
Handguard (factory edition)
Handguard [1] Install the clutch
bracket/brake handle bracket, install
one end of the handguard bracket at [2]
[3]
the end of the handlebar tube [2]
Handguard [3] Three screws on each
of the 2 sides of the left and right
handguard brackets are fixed, and
then tighten the bolts to the
[1]
specified torque.
Torque.
Hand windshield bracket left and
right and handlebar connection bolts
[2]
22 N.m (2.2 kgf.m, lbf.ft) [3]

Hand windshield and hand

windshield bracket
4 N.m (0.4 kgf.m, lbf.ft)
Hand windshield bracket and clutch
handle bracket/brake handle bracket
attachment bolt
8 N.m (0.8 kgf.m, lbf.ft)

English
version

208
 ※front wheel
[3]
Note.factory edition vehicles front wheels
are removed in the same manner as
below.

Removal/Installation
[2] [1] Remove the following parts.

- Removal of 2 brake caliper bolts [1].

- Front axle lock nut [2] and loosen the
shock absorbing left and right bottom
bucket bolts [3].
- Use a service bench or motorcycle-
specific service bench to prop up the
vehicle and lift the front wheel off the
[1] ground, pull out the axle and remove the
front wheel.

Installation: (regular edition)

Place the wheel between the front
shocks, carefully align the axle holes and
[2] insert the axle from the right side, pre-
tighten the shock bottom barrel axle lock
bolts [1] to a torque of .5 N.m, before
tightening the front axle lock nuts [2] to
the specified torque.
Torque :
Front axle locknut
88 N.m (8.8 kgf.m, 65 lbf.ft)
With the front brakes engaged, move
the front shock up and down several times
to seat the axle and check the brake
operation before tightening the left and
[1] right shock bottom cartridge tightening
bolts [2] to the specified torque.
Torque.
Tightening bolts of shock bottom cylinder
[2]
22 N.m (2.2 kgf.m, 16 lbf.ft)
Brake caliper mounting bolts
27 N.m (2.7 kgf.m, 20 lbf.ft)

Caution.
Install and apply a very small amount of
grease in the groove between the main
Wipe the tip and mounting area of and secondary lip of the wheel bearing oil
the front wheel speed sensor [1] to seal.
Lubricate with high-temperature
English remove any foreign material.
extreme-pressure lithium complex grease
Install the wheel speed sensor and (Unisun Grease SU-T330G/F or equivalent).
version
tighten the bolts [2].
Check the air gap between the wheel
209 speed sensor and the gear ring.
※front shock absorber

Removing the front shock absorber

Disassemble the following
components.
- Front wheels. [4] [1]
- Front brake calipers. [3] [2]
- Remove the brake mounting bolts [1]
[1]
and the front brake caliper [2].
- Remove the front axle lock nut [3]
then loosen the left and right shock
bottom cylinder lock bolts [4] hold the
front wheel and remove the front axle .
Caution.
-Do not hang the brake caliper on the
brake fluid pipe. [1]
-Do not operate the brake handle
before and after removing the brake [3]
caliper.
Loosen the upper connecting plate
locking bolt [1] to firmly support the [2]
shock loosen the lower connecting
plate locking bolt [2] and pull the
shock fork tube [3], then rotate it from
top to bottom to pull out the upper
and lower connecting plate hole part
until all out.

The installation sequence is the

reverse of the disassembly sequence.

Tighten the lower plate locking bolt [1]

to the specified torque. N.m torque:
22 (2.2 KGF. J m, 1 bf. 16 ft) will even
powder on bolt [2] tighten to
specified torque.. N.m torque: 22 (2.2
KGF. J m, 16 1 bf. Ft.) [2] [1]

English
version

210
 * Front shock absorber
maintenance
Place a workbench or equivalent
under the engine to lift the front
wheels off the ground.
Remove the following parts.
[1] - Remove the brake mounting bolts
[2] [1].
- Front brake caliper [2].

Caution.
Do not suspend the brake caliper from
the brake hose.
[5] [2] [3] Do not operate the brake handle
before and after removing the brake
caliper.

- Remove the front axle nut [1].

- Loosen the left shock absorber
bottom barrel locking bolt [2].
- Loosen the right shock absorber
bottom barrel locking bolt [3].
[1] [4] [6] - Removing the front axle by holding
the front wheel [4].
[2] - Removing the front wheel.
[4] - removing the left inch bushing [5]
and the right inch bushing [6] from the
front wheel.
[1] - Remove 2 screws [1];
- brake hose clip [2].
- remove the former subtracter
armor plate bolts [3];
- shock absorber plate [4];
[3]

[2]

- loosen the lock bolt connection

plate [1] if you plan to replace the
[1] former subtracter damping oil,
loosen the damping adjustment on
cover components [2]. Note: do not
remove the subtracter cover before
English
adjusting components.
version

211
Use a special tool to loosen
subtracter before cover
component tools: lock nut wrench,
50 mm note: do not remove the
subtracter inner cavity cover
components.

Hold front shock absorber rod to [2]

loosen the bottom bottom allied
board locking bolt [1] to be
removed before the shock absorber
[2].
[1]

Record compression damping

controller [1] and [2] rebound [1]
damping controller of the current
location counterclockwise rotation
compression and rebound damping
controller, and set it in the most
soft place.
[2]

Removing the front shock absorber [2] [3]

Hold the outer tube [1] and
remove the front shock absorber [4]
upper cover [2] from the outer tube
with the special tool
Tools. English
Locknut wrench, 50 mm [3]
Slowly slide the outer tube down [5] version
until the dust seal [4] is on the [1]
bottom cylinder [5].
212
 [1] [2] Compression pipe outside a few
times, eliminate the outer tube in
[1] from the shock absorber
damping oil remove the o-rings [2].

Pour the recommended damping oil

into the outer tube [1].
Recommended: oil shock absorber
oil (viscosity: 5 w) standard total
capacity of 560 ml + 5 high pressure
oil storehouse 260 ml 300 ml + 5 +
5 / tube

[1]

[1] Apply the recommended shock

[2] oil to the new O-ring [1
Install the O-ring on the front shock
absorber [2].

[3]

[2] Slowly pull up the outer tube [1]

Temporarily tighten the upper
adjustment cap [2] of the shock
absorber into the outer tube using
English
the special tool
version Tool.
[1] Lock nut wrench, 50 mm [3]
213
※Steering damper
Disassembly/Installation [1]
Remove the following parts.
- Screws [1];
-Remove the steering damper [2];
- Screws [3];
-Remove the steering damper bracket [4];

The order of installation is reversed from the order of

removal. [2]
Torque.
Steering damper mounting screws.
10 N.m (1.0 kgf.m, 7.0 lbf.ft)
Steering damper bracket mounting screws.
10 N.m (1.0kgf.m, 7.0 lbf.ft)
Caution.
Installation requires application of (Loctite) low
strength thread adhesive.

The reference valve adjusts the amount of resistance

you feel when you turn the steering handle from left
to right, increasing the "stiffness" of the damper when
[4]
you turn the button clockwise (to the right) and
softening it when you turn the button
counterclockwise.
When you turn the reference valve knob, you will
[3]
feel a "click", with 8 clicks in one rotation.
The starting position of the reference valve is from
clockwise, turn backwards 8 clicks (one full revolution),
we recommend you ride for a while before making
adjustments.
After 20+ clicks of counterclockwise rotation, the
base valve is basically closed, but the high speed valve
is still resisting the resistance shock. The high speed
valve is less effective when the bottom control valve is
turned clockwise (to the right) and more effective
when it is turned counterclockwise (to the left).
Caution.
-Check the reference valve setting before each ride.

Turning the high speed valve clockwise (to the

fast Reference
right) will increase its sensitivity, which means that
less force is needed for the high speed valve to valve valve
respond. Do not set this too "hard" as it may limit The high speed valve resists mainly
your steering response time. large, unexpected impact forces (such as
The high speed valve does not click, each position
hidden roots and potholes).
is a new setting, and adjustments are best made in
1/8 turn increments. The adjustment knob is located under
The high speed valve is less effective when turning the black cover. This cover is tight and
the reference valve clockwise (to the right); it is more you will need to remove the cover when
effective when turning the reference valve to the left. adjusting.
Do not test the high speed valve while the The factory preset is one turn of the English
motorcycle is in the stand. high speed valve from the fully rigid version
Do not turn the valve more than 3 turns from the position, we recommend that you adjust
fully closed position.
it only after a period of riding.
Adjustment is made in 1/8 turn
increments. 214
 As shown on the left: you can think
of each sweep control as the face of a
clock, if set at 3 o'clock, the right valve
will face the front of the motorcycle
and the left valve will face the back of
the motorcycle. Allowing for no
damping in the section.
At 12 o'clock, both valves face up.
Sweep control
At 6 o'clock, both valves face down.
Sweep control
valve valve
The sweep control valve is to be
preset to 12 o'clock direction for off-
road riding and 6 o'clock direction for
road riding.
The sweep control valves are 9 o'clock direction - damping is
located on both sides of the damper, 34 degrees
with machined bevels on the grooved 12 o'clock - damping is 44
head recess side. The distance of the degrees
controlled resistance sweep extends 3 o'clock direction - damping is
from the centerline to both sides, and 54 degrees
then the damper is free to move into 6 o'clock - damping is 90
the steering gear, allowing the degrees
motorcycle to turn easily in tight
turns.

English
version

215
 Rear wheel, suspension
1 Overview ..................................................................................................................... 217
2 Troubleshooting ...................................................................................................... 217
3 Component Location ............................................................................................. 218
4 Rear wheel ................................................................................................................. 219
5 Rear flat fork ............................................................................................................. 221
6 Rear shock/suspension assembly ..................................................................... 222

English
version

216
 Overview
-When repairing the rear wheel and suspension and related parts, you need
to support the motorcycle with a professional workbench or equivalent.
-Do not operate the brake pedal after removing the rear wheel.
-Check the brake operation by depressing the brake pedal after installing the
rear wheel.
-After installing the rear wheel, perform an air gap check.
-All suspension pivots and suspension points can only be replaced with
genuine Escalade bolts and nuts.

Troubleshooting
Steering to one side or not straight ahead
-Drive chain adjuster unevenly adjusted
-Shaft bent
-Flat fork shaft wear
Rear wheel shaking
-Tires have deformation
-Wheel bearings worn or damaged
-Slave flange bearings worn or damaged
-Shaft not properly tightened
-Rear flat fork pivot bearing is damaged
-Suspension assembly bolts not properly tightened
-Tires and rims unbalanced
Wheel is difficult to turn
-Damaged wheel bearings
-Bent axle
-Drive chain too tight
-Braking resistance
Soft suspension
-Low tire pressure
-Incorrect suspension adjustment
-Shock absorber spring weakness
-Shock absorber unit leaking oil
Stiff suspension
-Tire pressure is high
-Suspension incorrectly adjusted
-Shock absorber rod bent
-Damaged suspension or slew pivot bearing
-Slewing pivot improperly tightened
Rear suspension noise
-Loose suspension fasteners.
English -Suspension pivot bearing worn or damaged
version -Shock absorber failure

217
Component Location
factory edition

Rear wheel

Rear fork

regular edition

Rear wheel

Rear fork English

version

218
 ※Rear wheel
[3]
Place a bench or equivalent under the
engine to lift the rear wheels off the
ground.

Disassembly/Installation
Remove the following components.
- 1 bolt [1].
- Rear wheel speed sensor [2].
[2] [1] [4]
- 2 bolts [3].
- Removal of the wheel speed sensor
bracket [4].

Disassembly/Installation
Remove the following components.
- Loosen the rear axle lock nut [1].
- Remove the rear wheel axle [2] by
holding the rear wheel.
- Push the rear wheel forward to
disengage the chain from the large
sprocket [3].
- Remove the rear brake caliper and [1] [4]
caliper bracket [4]
- Remove the rear wheel assembly [5];

Torque. [3]
Rear wheel axle lock nut
128 N.m (12.8 kgf.m, 95 lbf.ft)

Installation is in reverse order of

removal.
Note: after, remove the wheels do not [5] [2]
operate the brake pedal.

Remove the following parts.

Rear wheel T-bush - left side [1];
Rear wheel bushings-right side [2];

English
version

[1] [2]
219
Caution.
-When installing the wheels, be
careful not to let the calipers fall out
of the rear flat fork tabs or damage
the brake pads.
Install the rear axle from the left side.
-Before installing the rear wheel
speed sensor [1], wipe the sensor tip
and mounting area to remove any
foreign material. [1]
-Adjust drive chain slack.
-Check the clearance between the
wheel speed sensor and the gear ring.

Inspection.
Turn the inner ring of each bearing with your finger, and the bearing should
turn smoothly and quietly.
Also check that the outer ring of the bearing fits snugly in the hub.
If the bearing does not turn smoothly, rotate smoothly, or is not securely
installed in the hub, replace the bearing.

English
version

220
 ※Rear fork
[2] [2]
Disassembly/Installation
Remove the following parts.

- Rear brake disc trim [1] factory

edition models.
- Rear caliper trim [2].
- Rear wheel speed sensor [3] regular
edition models. [3] [1]

- Disconnect the wheel speed sensor

2P (black) plug.
- Remove the screw [1] and the wire
clip x2 [2]. [2]
[1]

- Removal of the rear shock absorber [1]

attachment bolts [1].
- Removal of U-shaped rocker
attachment bolts [2].
- Removal of the lower rear shock
absorber and triangular rocker
attachment bolts [3].
- Removing the rear flat fork nut [4].
- Take out the flat fork shaft [5] [2]
[3]
Remove the brake hose, speed
sensor wire and drive chain.
[4] [5]
Install in the reverse order of removal.
Caution.
Install the rear flat fork shaft from the
left side.
Apply grease to the flat fork shaft.
English Torque.
Flat fork shaft nut.
version
88 N.m (8.8 kgf.m, 65 lbf.ft)

221
※Rear shock absorber/suspension
assembly [1] [1]
Rear Shock Absorber
Remove the following components.

- Seat cushion assembly.

- Loosen the rear fuel tank assembly
attachment nut [1].
- Loosen the lower nut [2] of the rear fuel
tank to bracket connection. [2] [2]
- Remove the rear muffler and muffler
bracket attachment bolts [3] lifting the
rear fuel tank assembly.
- Disconnect the wheel speed sensor 2P
(black) connector [4].
Rear shock absorber / triangle
rocker / U-shaped rocker

Disassembly/Installation
Disassemble the following components.
[4]
- Removal of the U-shaped rocker to
triangular rocker attachment nut [1]. [3]
- Remove the rear shock absorber and
triangular rocker attachment nut [2].
- Remove the flat fork and triangular
rocker attachment nut [3]. [3]
- Remove the nut [4] connecting the U-
shaped rocker to the frame and take off
the bolt.
- Removing the bolts connecting the
upper part of the rear shock absorber to
the frame [5].

Install in the reverse order of disassembly.

Caution.
[4] [2] [1]
Install the mounting bolts from the left
side.

U-shape rocker and frame attachment nut.

Flat fork and triangle rocker attachment [5]
nut.
Rear shock absorber to triangle rocker
attachment nut.
U-frame to triangle crankset attachment
nut. English
Torque.
version
60 N-m (6.0 kgf-m, 44 lbf-ft)

Upper rear shock absorber to frame

attachment bolt :
222
Torque: 44 N-m (4.5 kgf-m, 32 lbf-ft)
 Hydraulic brake system
1 Overview ............................................................................................................................ 224
2 Part Location ................................................................................................................... 225
3 Brake fluid level check/addition .............................................................................. 226
4 Brake pad inspection and replacement ............................................................... 227
5 Emission of air from hydraulic brake system (ABS) ......................................... 228
6 ABS Gear Ring Clearance Inspection and Replacement ................................ 229
7 Inspection and replacement of brake discs ....................................................... 230
8 Front brake pump .................................................................................................... 230
9 Rear brake pump/brake pedal ............................................................................. 231
10 Front brake calipers ............................................................................................... 232
11 Rear brake calipers ................................................................................................ 233

English
version

223
 Overview：
-This section describes the maintenance of routine brake components of
the braking system.
-ZF400LS for 2 models of which the civilian version is equipped with ABS,
but the brake fluid change procedure is performed differently than the
exhaust procedure for competitive vehicles.
-Contaminated brake discs or pads can reduce braking efficiency.
-Discard contaminated brake pads and clean contaminated discs with a
good quality brake degreaser.
-When servicing the system, always use fresh DOT 4 brake fluid in a sealed
container do not mix different types of fluids they may not be compatible.
-Never allow contaminants (dirt, water, etc.) to enter an open reservoir.
-Be sure to check brake operation once the hydraulic system is open, or if
the brakes feel loose and the brake system must be drained.
-When removing the wheel speed sensor, be sure to check the clearance
between the wheel speed sensor and the gear ring after installation.
-Spilled brake fluid can severely damage instrument faces and painted
surfaces and rubber parts; be careful when removing the reservoir cap,
making sure the front reservoir is level first.

Troubleshooting
Brake lever/pedal is soft or floppy Brake lever/pedal needs force
-Air in the hydraulic system -Clogged/restricted oil passages
-Hydraulic system leakage -Caliper piston sticking/worn
-Contaminated brake pads/discs -Caliper not sliding properly
-Worn caliper piston seal -Caliper piston seal worn
-Worn main piston bowl -Main piston sticking/worn
-Contaminated brake pads/discs -Bent brake lever/pedal
-Contaminated brake caliper Braking resistance
-Brake pump contaminated -Contaminated brake pads/discs
-Caliper sliding abnormally -Wheel misalignment
-Low brake fluid level -Brake pads/discs severely worn
-Fuel channel blocked -Brake disc twisted/deformed
-Brake disc twisted/deformed -Caliper sliding abnormally
-Caliper piston sticking/worn -Clogged/restricted oil passages
-Main piston sticking/worn -Caliper piston is stuck
-Bent brake lever/pedal

English
version

224
 Parts
Location
Front brake upper pump Front brake caliper

P1 P2

Rear brake upper pump Rear brake calipers

P3 P4

Note: The four figures above are all factory edition

English
version

225
※Brake fluid level check

front： rear：
Spilled brake fluid can damage painted,
plastic or rubber parts.

Caution.
Do not mix different types of brake fluids
that are incompatible with each other.
When filling the reservoir, do not allow
foreign objects to enter.

※ liquid level check

Front and rear brake master cylinder [1] [1]
reservoir level conditions, check the
brake fluid level.
If the level is near the lower level line [1], [4] [1]
check for worn brake pads.
If the brake pads are not worn and the
level is low, check the entire system for
leaks, then refill the reservoir with brake
fluid.
※Brake fluid level addition
-Front brake upper pump.
Remove the front brake master cylinder [2][3]
reservoir cover screw [1], reservoir cover [2]
and diaphragm [3].
Fill the reservoir to the upper level line with
recommended brake fluid [4]。
Use the recommended brake fluid: DOT4 brake fluid
Install the diaphragm and reservoir cap.
Install the front brake master cylinder reservoir cover screws and tighten to the
specified torque. Torque: 1.0 N.m (0.1 kgf.m, 0.7Ibf.ft)
Check the front brake hydraulic system for leaks.

-Rear brake upper pump. [1] [5]

[2]
Remove the rear brake master cylinder
reservoir cover bolt [1], reservoir cover [2], [3]
gasket plate [3] and diaphragm [4]. [4]
Fill the reservoir to the upper level line
using the recommended brake fluid [5]
Recommended brake fluid.
DOT4 brake fluid
Install diaphragm [4] gasket [3] cover [2]. English
Install the rear brake master cylinder
version
reservoir cover bolt [1] and tighten to the
specified torque.
Torque: 2.0 N.m (0.2 kgf.m, 1.5Ibf.ft)
Check the front brake hydraulic system for
226
leaks.
 front： ※Brake pad inspection and
replacement
Check the liner.

If either liner is worn to 1.0mm (0.04in),

both liners must be replaced.

Caution.
[1] The width of the wear mark [1] is
1.0mm (0.04in)
If the brake pads are worn to the
rear： service limit, consult your dealer for
brake pad replacement.

[1] Replacement
-Front brake pads

Removal/Installation
[1] [2] If replacing new brake pads, remove
the hexagonal internal six-talk bolt in
position [1] before removing the
brake pads, remove the caliper [2],
place the tool between the brake
pads, pry left and right to allow the
piston to retract, remove the friction
pads locating pin [3], and you can
[3] remove the brake pads.

Note: After removing the brake pads,

do not operate the brake lever.

•Rear brake pads

Removal/Installation
If replacing the brake pads with new
ones, remove the brake pads by
locating the locating pin in position
English
[1] .
version
Note: Do not operate the brake lever
[1] after removing the brake pads.
227
※Emission of air from hydraulic A
brake systems （ABS）
The following procedure is only applicable to
factory edition

-Be sure to vent the brake system air

after removing brake related parts.
Caution.
- Follow the sequence below to bleed the
brake system air. [1][2]
- Step 1: Front Brake Calipers
- Step 2: Rear Brake Calipers
B

Release of air from the brake system.

- Brake pump disassembled.
- Brake fluid line is loose, disassembled or
replaced.
- Brake fluid level is below the minimum scale.
- Faulty brake operation.
- Be careful not to spill brake fluid or allow [1][2]
the brake master cylinder reservoir or
brake caliper reservoir to overflow. g. Loosen the air vent screw.
- When releasing air from the hydraulic NOTE
brake system, always make sure the brake Loosening the exhaust screw will vent
fluid is adequate before applying the the air and bring the brake handle into
brakes. Neglecting this precaution will full contact with the throttle grip or
allow air to enter the hydraulic brake brake foot pedal.
system, resulting in a significantly longer h. Tighten the air vent screw before
time required for the air venting releasing the brake handle or brake foot
procedure. pedal.
- If venting is difficult, it may be necessary i. Repeat steps (e) through (h) until there
to allow the brake fluid to settle for are no air bubbles in the brake fluid in
several hours first. Wait for the small air the plastic hose.
bubbles in the fluid line to disappear j. Repeat steps (e) through (i), then add
before repeating the venting procedure. the brake master cylinder reservoir or
1. Evacuate. brake fluid reservoir to the correct level
a. Using the specified brake fluid, add the using the specified brake fluid.
brake fluid reservoir to the correct level. k. Lock the exhaust screw to the
b. Install the diaphragm (brake master specified torque.
cylinder reservoir or brake fluid reservoir). Brake Caliper Exhaust Screw [1].
c. Tightly connect the clear plastic hose [1] 6 N-m (0.6 kgf-m, 4.4 lb-ft)
to the discharge bolt [2]. m. Using the specified brake fluid, fill the
d. Place the other end of the hose in the brake master cylinder or brake fluid
container. reservoir to the correct fluid level.
e. Slowly apply the brake several times. English
f. Fully pull up on the brake handle, or
fully depress the brake pedal to hold it in version
After the hydraulic brake system is
place. drained, the operating condition of
the brakes needs to be checked.
A. front、 228
B. rear、
 The following is for regular edition models: Air Venting Operation Procedure (ABS)

After the repairer has finished installing ABS, there must be no gas in the line to ensure the
ABS works properly. In this case, you need to perform manual air venting operation for ABS
with the help of diagnostic instrument.
Note: Please use the manufacturer's recommended type of brake fluid and do not mix them.

The following is an example of exhausting the front ABS system.

Open the upper pump brake fluid cap, add sufficient brake fluid, and open the lower pump
drain bolt.

2. Connect the diagnostic instrument, double-click the routine: front wheel exhaust stage 1, at
this time the maintenance personnel while pinching the handbrake, while adding brake fluid,
handbrake frequency is about 1 times / s. The process lasts about 25s.

3. After the front wheel exhaust stage 1 is executed, the diagnostic instrument interface will be
prompted to indicate that the execution is complete. At this time, double click on the routine:
front wheel exhaust stage 2, the process still requires the maintenance personnel to squeeze
the handbrake while adding brake fluid. The process lasts about 90s.

4. After front wheel bleed stage 2 is completed, squeeze the handle and close the lower pump
drain bolt. Then, repeatedly squeeze the front brake handle several times and feel the strength
to determine if the exhaust is complete.

Note: Do not repeat the exhaust procedure 2 times or more in a short period of time! If you
need to repeat the exhaust procedure, please wait for 5 minutes to cool the solenoid valve to
protect it from overheating!
ABS ring clearance check
Use a crane or equivalent to securely support
front rear the motorcycle and lift the wheel off the ground.
Slowly turn the wheel and measure the
clearance (air gap) between the sensor and the
gear ring at multiple points.
Must be within specifications.
Standard: 0.4-1.2mm (0.02-0.05in)
Gap (air gap) cannot be adjusted or is not
within specifications, check each part for
deformation, looseness or damage.
Check if the wheel speed sensor is damaged, and
replace it if necessary.
Check the gear ring for deformation or damage,
and replace if necessary.
-Front gear ring
-Rear gear ring

[2] [1] Disassembly/Installation

Remove the following parts.
- Remove the screws [1];
- Removal of ABS gear ring.
Install in the reverse order of
disassembly.
English The front and rear gear rings are
installed in the same way.
version
Torque.
Front and rear ABS gear ring screws
4 N.m (0.4 kgf.m, 3.0 lbf.ft)
229 Apply low strength thread adhesive.
 ※Check and replace front and rear [1] [2]
brake discs
Disassembly/Installation
Remove the following components.
- Remove the cable clamps [1].
- Removal of the brake disc [2].
The front and rear brake discs are
installed and removed in the same
manner.
Apply low strength thread adhesive
during installation.
Torque.
Front brake caliper mounting bolts.
12 N.M (1.2 kgf.m, 9.0 lbf.ft)

Brake disc inspection Visually [3]

inspect the brake disc for damage
or cracks. Measure the brake disc
limit wear value of 3.5mm and
replace it if necessary.
[2]
※Front brake pump

Drain the brake fluid from the front brake hydraulic system.
[1]
Disassembly/Installation
Remove the following components.
- Brake light switch connector.
- oil bolts;.
- sealing washers.
- Brake hoses.
- 2 bolts [1].
- Brake handle catch [2].
- Brake pump [3].
The order of installation is the reverse of the order of disassembly.

Caution.
-Replace the seal gasket with a new one.
-Install the brake handle mount with the "UP" mark facing up.
-Align the edge of the master cylinder with the punch mark on the
handlebar and tighten the upper bolt first, then the lower bolt.
-When connecting the brake hose, be sure to place the eyelet fitting into the
groove. English
Torque. version
Brake handle mount.
8 N.m (0.8 kgf.m, 6.0 lbf.ft)
Brake pipe locking bolt.
22 N.m (2.2 kgf.m, 16 lbf.ft) 230
 ※Rear brake pump
Drain the brake fluid from the rear brake
[1] hydraulic system.
Disassembly/Installation
Remove the following components.
- Remove the brake pipe locking bolts [1];
- Upper and lower sealing washers [2];
- Disconnect the brake hoses to loosen the
[3]
rear brake upper pump mounting bolts [3].。
Installation is installed in the reverse order of
disassembly.
[2] Caution.
-When tightening the brake pipe locking bolts,
make sure to place the horizontal limit pins
against the limiters.
Torque.
Rear brake upper pump mounting bolts.
12 N.m (1.2 kgf.m, 9 lbf.ft)
Brake pipe override bolt.
22 N.m (2.2 kgf.m, 16 lbf.ft)
After removing the pushrod, adjust
the pushrod length so that the distance
[1]
[2] from the center of the mounting bolt hole
under the master cylinder to the center of
the connection pin hole is the standard
length If adjusting the length to a longer
position, make sure that the lower end of
the pushrod thread [1] is visible inside the
fitting.
After adjustment, tighten the coupling nut
[2] to the specified torque.
Torque.
Rear master cylinder pushrod joint nut.
6 N.m (0.6 kgf.m, 4.4 lbf.ft)
※Brake pedal
Support the motorcycle firmly with the main bracket.
Disassembly/Installation
Remove the following parts.
[3] [1] - Removal of the 2 hexagonal bolts at position [1].
- Removal of the brake pedal at position [2].
- Removal of the brake return tension spring at
position [3].
- removal of the cotter pin and flat pad at position
[4].
[4] - removal of the rear brake pump pin at position [5].
- Remove the brake arm mounting bolt and spacer
at position [6].

English Install in the reverse order of removal.

[5] [6] [7] [2] Caution.
version Apply grease to the oil seal locations (lubrication
grooves) on both sides of the brake arm pivot shaft.
Torque.
Brake arm mounting bolt: 22N.M (2.2kgf.ft;16lbf.ft)
231 Brake pedal mounting bolt: 8N.
Need to apply (Loctite) low strength thread adhesive
when installing brake pedal.
※Front brake caliper

Drain the brake fluid from the front [1]

brake hydraulic system.
[2]
Note. factory edition is the same as
regular edition disassembly and
installation.
Disassembly/Installation
Remove the following parts.
- Wire clips [1].
- 2 bolts [2].

- brake pad locating pin [1].

- brake pads [2].
- Over-oil bolt [3].
- Fuel line sealing gasket X2 [4].
- Brake hose [5].
- brake caliper [6].
[5]
The order of installation is the reverse
of the order of disassembly .
Caution.
[6]
-Replace a new sealing washer after
disassembling the oil pipe. [3]
-When tightening the brake pipe [2]
locking bolt, be sure to place the
eyelet stop pin against the caliper
[1] [4]
body.
Before installing the wheel speed
sensor, wipe the sensor tip and
mounting area to remove any foreign
material.
Torque.
Front caliper mounting bolts.
22 N.m (2.2 kgf.ft; 16 lbf.ft)
Brake pipe locking bolts.
22 N.m (2.2 kgf.ft; 16 lbf.ft)

English
version

232
 ※Rear brake caliper
[1] [1]
Brake caliper trim cover/wheel speed
sensor bracket
（regular edition）
[2]
Remove/install the brake fluid in the
evacuated rear brake hydraulic system.
[3] [3]
- Locking bolts [1].
[4] - Rear brake caliper trim cover [2].
- 2 locking bolts [3].
- Wheel speed sensor bracket [4].
[1] [1]
Brake caliper decorative cover / brake
disc decorative cover
[2] （factory edition）

Drain the brake fluid from the rear brake

hydraulic system
[4]
Disassembly/Installation
- Locking bolts [1].
[3] [3] - Caliper trim cover [2].
- 2 locking bolts [3].
- brake disc trim cover [4].

[4] [1] [3] Rear brake caliper

Removal/installation of the rear brake

caliper
[5] - Brake pipe over oil bolt [1
[2]
- Seal washer x2 [2].
- Brake hose [3].
- Brake caliper pin bolt [4].
- Brake pads [5].
-Apply 0.4 g (0.01 oz) of grease to the
sliding area of the brake caliper pin bolt.
-When tightening the brake pipe
locking bolt, be sure to lean the eyelet
Note. stop pin against the calibration body.
The rear caliper specification The installation sequence is the reverse
（factory edition） is the same as of the removal sequence.
the（regular edition）. Torque.
Brake pipe over grease bolt: 22N.M
English
(2.2kgf.ft;16lbf.ft)
version Caution.
-Please replace the new sealing gasket
after disassembling the oil tube.
233
 ABS
1 Overview ........................................................................................................................ 235
2 ABS System Function Introduction ...................................................................... 236
3 Mechanical Schematic .............................................................................................. 237
4 Electrical schematic diagram ................................................................................. 237
5 System location .......................................................................................................... 239
6 ABS Master Pump ...................................................................................................... 240
7 Check Diagnostic Process and Troubleshooting ............................................ 242
8 Fault Code Information Table ............................................................................... 243
9 Fault code corresponding treatment measures ............................................. 244
10 Circuit Troubleshooting ....................................................................................... 246
11 ABS Indicator Troubleshooting ......................................................................... 247

English
version

234
 Overview：
-This section covers repair of the anti-lock braking system (ABS). For other
repairs to the brake system (conventional braking), see the section on
hydraulic brakes.
-The ABS control unit is integrated into the regulator. Do not disassemble
the ABS regulator. When the ABS regulator fails, the ABS assembly will be
replaced.
The ABS control unit performs a pre-start self-diagnosis to check if the ABS
is working properly until the vehicle speed reaches 10 km/h (6 mph). After
the pre-start self-diagnosis, the ABS control unit continuously monitors the
ABS function and vehicle operating conditions until the ignition is switched
off (normal self-diagnosis).
-When the ABS control unit detects a fault, it stops the ABS function and
switches back to normal braking operation, and the ABS indicator light
flashes or stays on, so be careful when test driving.
-Read the "ABS Troubleshooting Information" carefully and follow the
troubleshooting flowchart to check and troubleshoot the ABS system. Follow
each step of the procedure individually. Before starting diagnosis and
troubleshooting, write down the diagnostic code and possible fault location.
After troubleshooting, clear the Diagnostic Trouble Code (DTC) and perform
a pre-start self-diagnosis to ensure the ABS indicator is working properly.
-The ABS diagnostic system cannot identify a fault that is not caused by a
faulty ABS (e.g., squealing discs, unevenly worn pads).

Caution.
-If dropped, the ABS regulator may be damaged. In addition, if the
connector is disconnected while current is flowing, excessive voltage may
damage the control unit Be sure to turn off the ignition before servicing.
-Spilled brake fluid can severely damage plastic parts and painted surfaces.
-Be sure to check the air gap when replacing wheel speed sensors and/or
gear rings.

English
version

235
 ABS system function introduction
System Description.
The ABS assembly consists of a hydraulic control unit (HCU), an electronic
control unit (ECU) and a motor, mounted on the frame with a wheel speed
sensor on the front and rear wheels respectively.
The function of the ABS warning light: to indicate whether the ABS is
working properly If the ABS is malfunctioning, the warning light will come on
to warn the driver. When the speed difference between the front and rear
wheels is extremely high under extreme driving conditions, such as when
performing a front wheel off-balance stunt or when the rear wheel skids, the
ABS may fail when riding normally again. To ensure proper ABS function, stop
and turn off the ignition switch. If the vehicle is restarted and the speed
reaches 12km/h, the alarm light will automatically turn off and ABS will be re-
enabled.
After turning on the ignition switch, the ABS alarm light comes on, and
when the first ride speed is greater than 10km, after passing the self-test, the
alarm light goes off after the same ignition cycle if there is no abnormality the
alarm light stays off. If the ABS is always on during driving (≥10km/h), it
means that there is a fault in the ABS. At this time ABS can not be enabled
ABS function failure brake system itself still works only ABS control system
failure.
ABS state switching switch: to disable or turn on the ABS function, please
ensure that the motorcycle has been in the power state; and the speed needs
to be below a certain value to be feasible, it is recommended to switch the
state when the vehicle is stationary. The ABS mode can be set through the
instrumentation whether the ABS function is on or off, after power off and
then re-powered, the ABS automatically becomes on.
ABS braking precautions
Impaired ABS function
If modifications are made, such as shortening or lengthening the shock travel,
using other wheels, other tire sizes, incorrect tire pressure, other brake friction
pads, etc., the ABS may not continue to function optimally. The ABS may not
continue to function optimally, and the optimal function of the ABS can only
be guaranteed when using spare parts and tires approved or recommended
by the supplier on the braking system.

ABS System Braking Recommendations

- The first rule of ABS braking: brake as if you are not equipped with ABS.
- When braking with the brake handle, do not increase the braking pressure
too quickly and violently after the brake pads have fully engaged.
- You can sense ABS intervention by the slight vibration of the brake handle
or rear brake pedal and by a short sound. English
- do not perform full braking operations with gears. version
- Practice braking regularly within the control range of the ABS, which allows
you to use the full potential of the anti-lock braking system in the event of a
serious accident.
236
 Mechanical schematics

English
version

237
Electrical schematic

English
version

238
 System Location

regular edition：

ABS
pump

Front brake, rear brake, ABS

ABS ring gear ring gear

English
version

239
※ABS master pump

Drain the brake fluid from the brake

hydraulic system.
Disconnect the negative (-) battery
connection.
Disassemble the following components.
- Disconnect the ABS regulator 18P
[1]
(black) connector [1]
- Remove the brake fluid line locking
bolt and sealing washer and disconnect
the brake fluid line from the master
cylinder.

Remove the two mounting bolts [2]

and the ABS master cylinder [3] from
[3]
the bracket.
Torque.
ABS bracket and engine attachment
bolts
10 N.m (1.0 kgf.m, 7.4 bf.ft)
ABS bracket to ABS assembly
connection bolt
10 N.m (1.0 kgf.m, 7.4 bf.ft) [2] [2]
Mounting bolts for brake oil pipe.
22 N.m (2.2 kgf.ft, 16 lbf.ft)

English
version

240
 ※Wheel speed sensor
front rear Air gap inspection
Use a crane or equivalent to securely
support the motorcycle and lift the wheel off
the ground.
Slowly turn the wheel and measure the
clearance (air gap) between the sensor and
the gear ring at multiple points.
Must be within specifications.
Standard: 0.4-1.2mm (0.02-0.05in)
Gap (air gap) cannot be adjusted or is
not within specifications, check each part for
deformation, looseness or damage.
Check if the wheel speed sensor is damaged,
replace if necessary Check if the gear ring is
Note: There are no front and rear deformed or damaged, replace if necessary.
wheel speed sensors in the factory -Front gear ring
edition -Rear gear ring

[1] ※Front wheel speed sensor

Disassembly/Installation
Remove the following components.
- Wire clips [1].
- Bolts [2].
- Front wheel speed sensor [3].
The installation order is the reverse of
the disassembly order.
Caution.
[2] [3] After thoroughly cleaning the
sensor tip and sensor mounting area
(caliper bracket) and ensuring that no
foreign objects are allowed to be
installed, check the air gap.

※Rear wheel speed sensor

Disassembly/Installation
[2] Remove the following components.
- Wire clips [1];
- Bolt [2];
- Rear wheel speed sensor [3];

The installation order is the reverse of

the disassembly order.
Caution.
English
Clean the sensor tip and sensor
version [3] [1] mounting area (caliper bracket)
thoroughly to ensure that no foreign
material is allowed. After installation,
241 check the air gap.
 Check Diagnostic Process and Troubleshooting
（1）. How to use the diagnostic meter

1. Connect the diagnostic instrument to the diagnostic interface.

2.Turn on the ignition switch.

3. Read fault-related information (fault codes, freeze frames, etc.); check the
repair manual to confirm the faulty part and type; develop a repair plan based
on fault-related information.

4. Troublehooting

5. Turn the ignition on, start the motorcycle and read the fault information
to confirm that the fault has been removed.

（2）.preliminary check
Before starting the troubleshooting steps based on ABS fault codes, a preliminary
check should first be made to.
1. confirm that the ABS fault indicator is working properly.
2. confirm that the fault phenomenon complained of by the owner exists and confirm
the conditions under which the fault occurs.
Then perform the following checks.
-Check that the sensor gap is normal.
-Check that the ABS gear ring is flat and free of deformation.
-Check if the ABS fuse is normal.
-Check that the wiring harness power and grounding points are clean and firm.
-Check the ABS assembly and each sensor connector for looseness or poor contact.
Important Notes.
If the above phenomena exist, the repair operation will be carried out for the fault
phenomenon first, otherwise it will affect the later troubleshooting repair work.

Troubleshooting - Diagnostics
Troubleshooting needs to be tested in a parked state. The repairer can read the ABS
English
information through the diagnostic instrument, connected to the OBD interface, and
the fault type and treatment measures are shown in the following table. version

242
 （3）.Fault code information

English
version

243
（4）.Fault code corresponding measures

English
version

244
 Note: The C0060, C0061, and C0062 faults will not occur for products that are
configured in software without a brake signal.

English
version

245
※Circuit Check
[2]
1. ABS plug check
Turn off the ignition switch
Remove the ABS regulator cover.
Turn the locking lever [1] to this side
while pressing the locking tab [2] to
release it.
Make sure the lock lever is turned all [1]
the way and disconnect the ABS
regulator 18P (black) connector [3]. [3]
Connection procedure.
Make sure that the lock lever is fully
against the wire side of the connector.
Press straight down in the area shown
(as indicated by the arrow) and
connect the ABS regulator 18P (black)
connector until the latch clicks,
making sure the connector is securely
locked.

-Before disconnecting the connector,

be sure to clean around and away
from any foreign objects on the
connector.
-ABS failures are usually associated
with poor connections or corroded
connections, check these connections
before proceeding.
-On the ABS regulator 18P (black)
connector terminal
(harness side, except terminals 9 and
18), always use a test probe [1]. Insert
the test probe into the connector
terminal and then connect the digital
multimeter probe to the test probe.

English
version

246
 ※ABS Indicator Troubleshooting

ABS indicator light does not light up (when

ignition switch is on)
Note: before you start to check, and check
the initial combination meter operation.
1.Indicator running check
Turn off the ignition switch
Disconnect the ABS regulator 18P (black)
connector.
Turn on the ignition switch with the engine
stop switch " ".
Check the ABS indicator light.
Does the ABS indicator light come on?
YSE - ABS regulator fault
NO - Perform step 2
2.Indicator signal line short circuit check
Turn off the ignition switch
Check harness side ABS regulator 18P (black)
Conductivity between connector [1] terminal
and ground
Tool.
Multimeter
Connection: 16-ground
Is there conductivity?
YES - Purple and white wire shorted
NO - Combination meter fault
ABS light stays on (light does not go off when
motorcycle is running)
1.检修线路开路

关Turn off the ignition switch

Check harness side ABS regulator 18P (black)
Conductivity between connector [1] terminal
and ground
Tool.
Multimeter
Connection: 16-ground
Is there conductivity?
YES - Purple and white wire shorted
NO - Combination meter fault
ABS light stays on (light does not go off
when motorcycle is running)
2.Modulator ground circuit check

Turn off the ignition switch.

Check the conduction between the harness
English side ABS regulator 18P (black) connector [1]
terminal and ground.
version
Connection: 1-Ground / 10-Ground
Is there conductivity?
YES -Go to step 3
247 NO -Green wire open circuit
3.Fuse inspection
Remove the following components.
-Remove the seat cushion by pulling down
the seat cushion pull lock
Remove the fuse box cover from the fuse
box.
Check for a blown ABS main fuse.
Is the fuse blown?
YES -Go to step 4
NO -Go to step 5

4.Power input line short circuit check

With the ABS main fuse (15A/20A)
removed, check the continuity between
the ABS regulator 18P (black) connector
on the harness side and ground
Tool.
Test Probe 07ZAJ-RDJA110
Connection: 9-ground/18-ground
Is there conductivity?
YES - shorted yellow wire / shorted black
and blue wire
N O - Intermittent failure, replace with
new A B S main fuse (15A/20A) and
recheck.
5. Power input line open circuit check
Install ABS main fuse (15A/20A)
Turn on the ignition switch and measure
the voltage between the ABS regulator
18P (black) connector [1] terminal and
ground on the harness side.
Tool
Test Probe 07ZAJ-RDJA110
Connection: 9 (+) - Ground (-) / 18 (+) -
Ground (-)
Is there a battery voltage?
YES-ABS modulation fault
NO-open yellow wire/open black and
blue wire

English
version

248
 Electrical parts
1 Power supply system.................................................................................... 250
2 Switchs................................................................................................................ 254
3 Lights .................................................................................................................. 261
4 Other parts ........................................................................................................ 264

English
version

249
1.Power supply system
Charging circuit diagram

magneto

regulator

Connecting load
(factory edition) battery

※magneto
Magneto coil resistance
Measure the resistance between the
magneto stator coils, the resistance
value is within the specified range, it
means the magneto is good; magneto

otherwise, it means abnormal,

replace immediately.
Normal magneto coil resistance
range.
0.45 Ω - 1.5 Ω (yellow - yellow).
Insulation resistance ∞ Ω (yellow -
ground).
Check the multimeter should be set
at 1x10Ω file.

Magneto performance at load

Start the engine, use a multimeter
to measure the voltage between the
three output lines of the magneto
stator coil has been, if the voltage is
the same size, it means that the
magneto is good; on the contrary, English
abnormal, need to replace. version

250
 ※rectifier
P1 After the engine runs, when the
battery is fully charged at 5000r/min,
use a multimeter to measure the
voltage between 13.5V and 15V at
both ends of the red, red, white, and
Connect magneto input
green lines. If the voltage is not within
this range, replace the rectifier
regulator
For example, P1: is the outline diagram and
pin definition of the factory edition model
regulator rectifier.
P2: is the test wiring diagram of regulator
P2 Test circuit diagram rectifier.

Function definition of each pin:

1：Pick up magnet motor input
(yellow)
magneto regulator 2: Magnetizing motor input (yellow)
3: Connect magneto input (yellow)
4: GND ground (green)
5: Load (black)
6: OUT to power (red and white)

P3
For example, P3: is the regular
edition model regulator outline
diagram and pin definition.
P4: is the test wiring diagram of
Connect magneto input
regulator rectifier.

Function definition of each pin:

1: IN1 connects to magneto input
(yellow)
2: IN2 connects to magneto input
P4 (yellow)
Test circuit diagram
3: IN3 connected to magneto input
(yellow)
4: GND ground (red and white)
regul
magneto
ator 5: OUT connected to the power
supply (green)

English
version

251
※Check and replace the battery
1. Before installing the battery, if the electrode is found to be dirty, please wipe it clean before
installing it, otherwise it may fail to function due to poor contact.
2. If the battery is deformed, abnormally hot, smoking and other abnormal phenomena occur
during use, please stop using it immediately and go to the special maintenance store of Kaiyue
Motorcycle for investigation in time.
3. If the battery is placed in high temperature and humid environment for a long time, the
function may fail and the life may be shortened. Before using it again, please make sure the
appearance and function of the battery are normal before installing and using it.
4. If the whole car can not start, please check whether the battery is charged or damaged, such as
battery power loss, please charge in time, such as battery damage, please replace in time.
If the battery is not used for a long time, please pay attention to the following conditions.
To prevent the occurrence of over-discharge situation, the battery should be charged once every
two months.
When the battery is not in use, it should be placed in a cool and dry environment and prevent the
battery from short-circuiting the positive and negative poles.

[2] [1]
Battery
Disassembly/Installation
Remove the following components.
- Turn off the ignition switch.
- Remove the seat cushion. (+) (-)
- Disconnect the negative (-) battery
cable [1], then the positive (+) cable [2] [3]
by removing the terminal bolt. Remove
the rubber band and the battery [3].

Installation order is the reverse of the

disassembly order
If the displayed value is less than
Caution. the specified value.
The battery must be disconnected from Check the plug from the engine to
the negative cable first, otherwise the the regulator rectifier.
battery may be short-circuited. Check the plug from the regulator
rectifier to the wiring harness.
Charge Check the electronic winding of the
Switching off the ignition. engine.
Removing the battery. If the displayed value is greater
Connecting the charger to the than the specified value.
battery and turning on the charger. Check the battery for overcharge
Turn off the charger and remove protection or replace the regulator
the battery after charging. rectifier.

Check the charging voltage Battery model: MTX4L-FPP

Start the vehicle for voltage testing. Fully charged voltage: >13.2V
Measure the point positive (+), Need charging voltage: <12.8V
English
measure the electrical ground (-). Charging current: Standard 1.5A
Max 12A version
charging voltage Working temperature -20℃-60℃
Battery capacity: 12V/4Ah
5000rpm 13.5V-15.0V
Overall Dimension LxWxH:
252
113x69x85
 Warnings and precautions for battery use

1. It is strictly forbidden to invade the battery into seawater or water, avoid

drenching; when not in use for a long time, it should be placed in a cool and dry
environment.
2. It is forbidden to use or leave the battery next to high temperature sources, such
as open flame, heater.
3. It is strictly prohibited to over-discharge, and when charging, please strictly follow
the requirements for charging.
4. It is strictly forbidden to use the battery by reversing the positive and negative
poles.
5. It is forbidden to connect the battery directly to the positive and negative
terminals for short circuit.
6. Prohibit knocking or throwing or stepping on the battery.
7. It is forbidden to decompose the battery in any way.
8. It is forbidden to weld the battery directly and pierce the battery with nails or
other sharp instruments.
9. It is forbidden to use it in the place of strong electricity and strong magnetic field,
otherwise it will easily destroy the safety protection device of the battery and bring
unsafe hidden danger.
10. If it starts badly, please don't start it frequently, it is recommended to use it after
replenishing the electricity to prevent the battery from over discharging.
11. If the battery emits bad smell, heat, discoloration, deformation or any
abnormality occurs during use, storage or charging, immediately remove the battery
from the vehicle or charger and stop using it.

English
version

253
2.Switchs

※Right combination switch Outline drawing

（regular edition） and pin
Disconnect the plug of the right hand [1]
handle switch harness linked to the main
cable and check the action on/off of each
switch.
[1] Flame-out self-locking button.
① The engine can be started only when the
switch is in the " " (running) position.
② When the switch is in the " " (stop) [2]
position, the engine cannot be started.
[2] Activation of the self-resetting button.
When the emergency flameout switch is
placed in the " " position.

①The engine is in neutral, press this button

to make the engine start.
②If the engine is not in neutral, you need to
retract the side bracket and squeeze the
clutch handle, press this button also can
make the engine start.

Shape drawing and function

※Left combination switch
（regular edition）

Disconnect the connector

connecting the switch harness with
the main cable with the left hand,
and check whether the switch works.

p2

p1

English
version

p1：Wiring diagram for the left hand 254

combination switch.
 ※brake switch
p1
The brake switch working status is
judged by the lighting of the brake light.
1: front brake handle pinch: brake light on.
2: front brake handle release: brake light
off.
[2]
[1] 3: depress the rear brake pedal: brake light
on.
4: release the rear brake pedal: brake light
off.

p1: regular edition Brake switch p1: for regular edition brake switch
installation position mounting position.
p2 - Front caliper fuel line into the ABS
main pump to FW, FM out to the front
upper pump and brake switch [2].
The installation torque is the same as
below.
-Rear caliper fuel line into ABS main
pump to RW, RM out to rear upper pump
and brake switch [1].
[3]
p2.3 : position [3], [4] for factory
edition brake switch mounting
p2: factory edition Brake position.
switch installation position
p3 Torque.
Brake switch mounting
[4] M10X1.25
22N-m (2.2kgf.ft;18lbf.ft)

p3: factory edition Brake switch

installation position
p4 brake switch

p4：Brake switch wiring harness

English definition diagram.
version yellow black2
green

255
 ※Turn signal flasher (flasher)
Attention.
The flasher is equipped with wire
break alarm prompt function and
load overload protection function.
Removal/Installation
- Turn off the ignition switch.
- Removing the seat cushion
assembly.
- Removal of the flasher. Flash profile and pins
Install in reverse order of
disassembly.
P1： wiring diagram for the flasher P1

Relay circuit check

1. Power line open circuit check.

Turn on the ignition switch, measure the
voltage between the black line and the
green line, the normal voltage for the
battery voltage, and vice versa to check
the black and green line open circuit or
fuse blown fault.
2. Output line open circuit check.
Check the connection of the left switch to
the gray line of the flasher
3. Flashing frequency abnormal or not P2
flashing.
Check whether there is damage to each
turn signal.
Check whether the turn signal wire is
shorted to ground, resulting in short
circuit protection for the flasher.

p2：Electrical schematic diagram of

the flasher

1. Rated voltage: DC12.8V;

2. Rated power: LED light, front turn signal, rear turn signal + instrument: English
1.5W*2+0.05W; version
3. Working voltage range: DC11~16V, minimum action voltage: ≤9V;

256
 [3] ※Fan and temperature control
switch

Fan motor check.

Battery voltage 12V motor running
at full speed, amperage meter
current does not exceed 3A, if the
motor does not rotate or the current
[1] [2] exceeds the specified then replace
As shown above. the fan motor.
[1] for fan left.
[2] for fan right.
[3] the temperature control switch.

p1
p1 is the outline drawing of
temperature control switch.

p2
p2:is the pin diagram of the
temperature control switch.
负极-

正极+ Parameters:

Conduction temperature: 93±3℃,

Disconnect temperature: 83±3℃

p3

English p3 is the wiring diagram of the

version
cooling fan and the temperature
control switch.

257
※starting relay
Starting Relay
Load DC12V voltage on the contacts of both Outline
ends of the control circuit coil of the starter relay, Drawing
then use a multimeter to measure whether the B+
and M contacts are connected.
If the relay contacts emit a ticking sound and the
multimeter emits a continuous ticking sound, it
means that the two contacts are connected: the
opposite means that they are not connected: when
DC12V is not loaded at both ends of the coil, the
two contacts are not connected.
The above two can confirm whether the state of the
relay is good, measurement of the multimeter
should be dialed in the on-off file.
p1

-Don't load the voltage on the relay

coil for more than 1 minute,
otherwise it will cause the coil to
overheat and result in burning the
coil.
P1：Wiring diagram for starting
relay
When using a multimeter to
measure the resistance between the
relay coils, if the resistance is not
within the specified range of 3Ω-
5Ω, it is necessary to replace the
new parts
When measuring, the multimeter
should be set to 1x10Ω.

P2: Starting relay schematic.

Auxiliary Relay
Apply DC12V voltage to the control
circuit coil of the auxiliary relay, use a p2
multimeter to measure whether the A B
two contacts are connected,
measurement of the multimeter dialed
in the through file, if the contacts tick
and the multimeter issued a continuous
tick sound, it means that the two
contacts are connected: vice versa: when
the coil is not loaded with DC12V
voltage at both ends, the two contacts English
are not connected. version
The above two items can confirm
whether the relay is in good condition.
The normal coil resistance range is 90Ω-
100Ω 258
 P1

P1：headlamp relay outline drawing and

electrical wiring diagram.

P2

p2,p3：The outline diagram and electrical

wiring diagram of the vehicle relay.

P3

P3
p3：Wiring diagram for factory
edition relay.

P4 p4：regular edition relay wiring

diagram.

English
version

259
※Fuse

To avoid short circuit, be sure to set the

main power switch to "OFF" first when
checking or replacing the fuse.
2. Check.
- Fuse
a. Connect a digital multimeter bit to
the fuse and check for conduction.
b. If it is not conducting, replace the
fuse.
3. Replace.
- Replace the fuse
a. Set main power switch to "OFF".
b. Install a new guaranteed fuse with the P1
correct amperage.
c. Turn on the power switch and check
the circuit for proper operation.
d. If the fuse blows again immediately,
check the circuit.

-Never use a fuse that is not of the

specified amperage. Casual use or
use of fuses with the wrong P1：Wiring diagram for factory
amperage may cause extensive edition vehicle fuse box.
damage to electrical components,
lead to lighting and ignition system
failure, and may cause a fire.

P2：Wiring diagram for regular

edition vehicle fuse box.

English
version

260
 3.Lights

※Headlight assembly and headlight

factory edition
control module
Headlamp
outline drawing The headlights come on
automatically after starting the vehicle
and turn off automatically after the
engine is turned off.
regular edition
Headlamp
outline drawing The headlights do not light up after
starting the vehicle or the high and
P1 low beam cannot switch fault.
Check.
1. switch is damaged.
2. headlight relay damage.
3. plug-in connector abnormal, back
pin, crooked pin, plug in place, etc.

P1：Headlight and headlight control

module wiring diagram.

P2：Wiring diagram for regular

P2 edition headlight assembly

P3

P3：Wiring diagram for factory

edition headlight assembly
English
version

261
※Rear position light, tail light
(factory edition) P1

P1：The rear position light is at position [1]

[1] and the rear tail light is at [2].

When the vehicle is in starting state.

1: the rear position light comes on
after the vehicle starts.
2: After the vehicle is turned off, the
[2]
rear position light goes off.
3: Depress the rear brake pedal: the
rear brake light comes on;
4: Release the rear brake pedal: the
rear brake light goes off.

P2：rear position light, rear tail light

wiring diagram (factory edition).

English
version

262
 P1 ※Front and rear turn signals, rear
taillights, license plate lights
(regular edition)

Turn on the ignition switch.

1: Press the left and right turn signal

[1] [2] buttons respectively, the lights come
on.
P2 2: Press the turn signal centering
[1] [2]
button, the light goes out.
3: the license plate light comes on
automatically.

[4]
P1: Position [1] is front turn signal
right, [2] is front turn signal left.
P2: Position [1] for the left rear turn
[3] [5] signal, [2] for the right rear turn
signal, [3] for the rear taillight, [4] for
the license plate light. [5] rear
reflector .

P3：Wiring diagrams for front and

rear turn signals, taillight plates, and
lights

English
version

263
4.Others parts

※meter (regular edition)

Display check:
When the ignition lock switch is
turned to " " (on), the
instrument is energized to play the
power-on animation, followed by a
self-test, and all function modules and
symbols are displayed; if the display is
missing during the self-test, please Above is the outline of the instrument
refer it to an Escalade locomotive
special repair store for service.

P2

P2：Define for meter pin functions.

※USB charging socket

(regular edition)

Fast charge protocol:

QC2.0/QC3.0/PD3.0 fast charge power ground
protocol is supported. Support
Huawei Fast charge protocol
FCP/SCP; Support Samsung Fast
Charge Agreement AFC; Apple 2.4A, USB
charger
etc.;
USB
(2) Output 5V/3A when the fast charge
charge protocol is not identified;

(3) Output voltage range: DC5V-

12V (automatically adjusted
according to the fast charge
protocol);

(4) Maximum output power: 18W

(5V/3A; 9V/2A; 12 v / 1.5 A) English
version

264
 Oil level sensor ※Oil level sensor (regular edition)
outline diagram
Convert the fuel liquid height
signal into a standard electrical signal
and output it to the indicator light.

p2

P2：wiring diagram of oil level sensor

and TFT meter.

TFT meter oil level displays parameters

＜ 0.2V, ＞5.5V, 8 bars flashing

1
display
2 ＜1.2V，＞0.2V, one 8 grid
3 ＜1.48V，two grids

[1] 4 ＜1.69V， three grids

5 ＜1.97V，four grids
As shown in the figure above, 6 ＜2.6V， five grids
position [1] is 8 grids in the 7 ＜3.18V，six grids
instrument oil quantity display area.
8 ＜3.6V，seven grids
9 ＞3.6V，＜5.5V，eight grids

Note: regular edition oil level

sensor disassembly and installation
is the same as factory edition
English
version

265
※Road book box, speedometer, p1
and directionometer
[1] [2]
(factory edition)

Display check.
Long press the start button " " to the vehicle
start state when the instrument is energized, if the
instrument is not on, you can wake up the
instrument by short press the instrument button.

Such as the left figure 1 position [1] for the

speedometer, [2] for the heading gauge, the
[3] the main body of the pull road book box. [3]
-speedometer
1. Short press any button on the left side of
the speedometer speedometer on. After power on
when there is no button activity or wheel
movement, the speedometer will go to sleep after
20 minutes. When the wheels are turning, the
speedometer will wake up automatically.
2. Press and hold the up and down buttons on
the left side of the speedometer at the same time
to turn off the speedometer.

-Directionometer
1. Short press any button on the left side of
the speedometer to turn on the speedometer.
When there is no button activity or movement after
power on, the speedometer will go to sleep after
two hours. When the wheels turn, the speedometer p2
will wake up automatically.
2. Press and hold the up and down buttons on
the left side of the speedometer at the same time
to turn off the speedometer.

•Wheel speed sensor

Position [1] in p2 on the left is the wheel
speed sensor of the speedometer [1]
component.。
•External GPS receiver

Such as the left figure 2 position [1] for p3

external GPS receiver
Installation.
Use its own double-sided tape to
external GPS stick in the empty space in the
front of the rally car, the vehicle is placed in [1]
the open outdoor space to facilitate GPS
receiving signals.
Attention.
-When the external GPS is powered on for
the first time, or in a new location, it may
take a few minutes to receive the signal, English
please be patient. version
-During this time, a small LED inside the
GPS receiver will remain on. Once a signal is
obtained, the small LED inside the GPS
receiver will start flashing. 266
 ※Left-handle switch
[1] [2] [3] (factory edition)
p1: Position [1] is the control button of
the road book box,[2] is the combination
button of the speedometer,[3] near and far
light switch button,[4] horn button, and [5]
flame out button.

[1] : The thumb button is used to move

forward and backward to control the rolling
p1 [4] [5] of paper books in the book box. After
power failure, the manual mode can be
switched to continue operating the book
box;

[2] : The combination button of the

speedometer is used to set and switch the
p2 [1] function menu in the speedometer;

[3] : Near and far light switch button of

headlamp after vehicle starting.

[4] : vehicle horn button;

[5] : vehicle ignition button.

※Combination button
(factory edition)

p2: Position [1] is the combination

p3 [1] button of the heading table, which is
used to set and switch the function
menu in the heading table.

※Right handle switch

(factory edition)

factory edition do not have ignition lock

and key, press the vehicle start button to
start the vehicle.
p4 Start button:

p3: Button [1] (self-reset)

p4： start button outline and the wire

English harness outlet.
version

267
※meter light
(factory edition) P1

P1：
[1] is the engine fault indicator light.
This light comes on when there is a fault
in the EFI system (after the engine is
powered on, this light is lit. After normal
start, this fault light goes off as normal);
[2]. Fuel indicator.
Display the current fuel level: no light,
indicating sufficient fuel level; green, [1] [2] [3] [4]
indicating normal fuel level; orange,
indicating low fuel level; red, indicating
low fuel level; P2
[3]. High beam indicator.
This light comes on when the high beam
is turned on;
[4]. Neutral indicator.
This light comes on when in neutral.

P2：wiring diagram of METER

indicator light.

P3

P3：the meter indicator function

parameter.

English
version

268
 Oil level sensor ※Oil level sensor
outline drawing (factory edition)

Convert the fuel liquid height signal

into a standard electrical signal and
output it to the indicator light.

power ground
signal
※Oil level sensor
P2 Disassembly/Installation
Remove the following components.
- Disconnect the sensor plug.
- Remove 1 countersunk hexagonal head
bolt at position [1] P2.
- Remove the oil level sensor at position
[2]
[2] P2.
[1]
The installation order is the reverse of the
removal order.

Torque.
Oil level sensor and left fuel tank
mounting bolt:
P3 M10x1.0x36
22 N.M (2.2kgf.ft;16bf.ft)

inspection
Check if the oil level sensor gasket
is deformed, damaged or hardened. If
so, please replace it in time.

P3：the wiring diagram of the oil level

sensor and meter indicator light.

English
version

269
※Horn [1]
Unplug the harness connector on
the horn [1] and connect it to the
12V power supply, the normal
sound of the horn means normal,
otherwise, it needs to be replaced.

※Clutch switch [1]

(regular edition)
When in gear position, pinch the
clutch handle, put away the side
support, you can press the start
button, realize the vehicle start.

Note: The factory edition does not

have a clutch switch.

※ignition lock
Remove the connector connecting
the ignition lock to the main cable,
and check the switch connection
status of the ignition lock.
position function

Use in parking ( power off)

Use when starting or driving

When stopping (including long Electrical logic table

stops), the ignition switch must be color
Key removal
in the " " or "PUSH" position to Gear
red orange and insertion
ensure the safety of the vehicle and
to prevent the battery from "losing NO
power".
Do not push the motorcycle YES English
while the steering mechanism is
locked, otherwise it will lose its version
YES
balance.

Note.factory edition has no 270

ignition lock.
 ※Gear sensor
Check:
Disconnect the plug that connects
[1] the gear sensor harness to the main
[2] cable, check the gear sensor harness
connector, and check the sensor
harness connection status.
Removal/Installation
Remove the following components.
- Small sprocket trim cover.
- Removal of the screw at position [1].
-The gear sensor [2] can be removed.
P1

P1：wiring diagram of the gear sensor

and meter connection.
Gear display on/off relationship
Gear
0 1 2 3 4 5 6
display
resistanc
e（Ω） 0 2K 1K 20K 10K 5.1K 3.3K
（±2%）
Gear control module to meter, analog,
NOTE： resistance value

English
version

271
 Three-in-one sensor
magneto
oxygen sensor H1 intake temperature J3 5V power
ignition coil
G1 throttle position
Rectifier Heating signal 1 K1:intake pressure
injector J1 Sensor ground wire
HV
Oil level Sensor Oil pump
temperature controlled switch fan-left fan-right
stepping motor
right switch color black yellow
Trigger coil Lateral Tilt Sensor
coolant temperature sensor
function red red
yellow
white
yellow black
red
white
green
yellow
gray green

black yellow yellow purple black orange orange green yellow purple
pink
green
pink
black
pink
white
pink 1 green
black 1 grary yellow brown gray blue green green black 1
purple yellow pink

blue white white green white green yellow purple black green
yellow blue blue blue white white purple yellow 4
white green green green
red red black 1 gray green

Connection speedometer
green

Connection Heading meter blue

Connection road book yellow

gray
blue
步进电机D
stepping motor
brown
blue 步进电机C
stepping motor
yellow
green
步进电机B
stepping motor
gray
yellow 步进电机A
stepping motor
green
black 1 Sensor
传感器地 ground wire
pink
5V power
5V电源
Horn 1

pink
white 节气门位置
throttle position
black
red 进气温度
pink
black intake temperature
light
green 进气压力
pink
green intake pressure

yellow
grary 氧传感器-温度信号
Oxygen sensor - Temperature signal
orange
green Oxygen sensor
氧传感器-加热信号 - Heating signal
orange
black injector
喷油器

black
yellow 点火线圈
ignition coil

green ECU
ECU地 ground wire

yellow 4 侧倾信号
Lateral Tilt Signal

gray 水温
water temperature
power blue
yellow
green

green 触发器A端
Trigger temperature A
white
blue
blue white Trigger
触发器B端 temperature B
Meter purple black
purple 发动机故障
Engine Failure
black
Indicator
E F
yellow
white

light
green Neutral
空档信号 signal
light red
green
red neutral switch black
white ignition
点火信号 signal

ground wire green brown oil

油泵 pump
black

yellow head
大灯 light
brown

green 3 ECU地
ECU ground wire
red 12V常电

yellow CAN-L
red

green CAN-H
blue

headlight assembly

tail light
green
yellow

brown

headlight CMOD(control module) green

green

blue
blue
white 1
green

blue brown
yellow

green
green

brown
Rear position light
brown

green

Front brake switch

green
yellow

black 2

Rear brake switch

green
yellow

black 2

yellow ①
blue
② red
yellow white

black ③
red red
white
④
red

red yellow
white red green

fuse box

1.oil pump 10A green

2.head light 7.5A red

color white white

red green
blue green
red function
brown blue
white blue
1 yellow green
yellow
green light black
purple
yellow purple

7
yellow
blue

4
black

7
black

1
white black
7
red

1
3.starting/horn 7.5A
yellow

dimming
4.FI 10A Start Relay green 4

Main Fuse 30A

horn

flameout

left switch
8 3 2 6 6 5
yellow
green
blue
yellow brown
black
brown
green orange
black white
black
green
purple
power Engine hitch

head light oil pump Flame out Main Relay starting motor

Relay
 Three-in-one sensor
magneto Rectifier Ignition coil oxygen sensor
Injector Heating signal 1
HV

color blue black

yellow
Fan-left Fan-right Ignition lock
yellow white temperature controlled switch
function red

switch-right
yellow

yellow red green

white
yellow
yellow yellow white purple black orange
black 1 black white green white green yellow purple green brown

white red blue black black 2 yellow 1

black2 yellow
white
green green
green

Ignition lock

black

stepping
步进电机D motor D

red 步进电机C motor C

stepping
white
步进电机B
stepping motor B
stepping
步进电机A motor A

Sensor
传感器地 ground wire

5V power
5V电源
Horn
节气门位置
throttle position
black 1
进气温度
intake temperature
light
green intake
进气压力 pressure

Oxygen sensor
氧传感器-温度信号 temperature signal

氧传感器-加热信号
Oxygen sensor heating signal

injector
喷油器

点火线圈
ignition coil
Automatic
headlight blue
gray

BAT red green ECU地

ECU ground wire
Starting
current black 2
yellow1 侧倾信号
Lateral Tilt Signal
orange

light
gray
green
Water
水温 temperature
blue
green
' 触发器A端
Trigger A
black 1 white

blue blue
white
Trigger
触发器B端 B

purple purple
black Engine
发动机故障 Failure
black

Meter
E F yellow
white

lighnt
green
red
Neutral
空档信号 signal
light
green
red black
white
点火信号
Ignition signal
pink
red
blue brown
white speed
车速
red

green
black
brown
black oil
油泵 pump

yellow
red 1

white
yellow
green 3 ECU
ECU地 ground wire
yellow
black
red 12VBAT
green 3

red
yellow red CAN-L
yellow

green CAN-H
green
blue blue

Rear wheel speed sensor

white
pink

white
brown

Front turn signal right

Rear turn signal lamp
light light
blue blue

green green

Headlight ASSY.

Tail light
green
yellow

black
1
Headlight control module green

orange
green Rear turn signal left
green
blue
blue
blue
green yello

blue black
yellow 1

green green

brown
License plate light
black 1

green

Front brake switch

green yellow

black2

Front turn signal left Rear brake switch

orange

black ① green yellow

green
blue
② black2
yellow red 1

black 1 ③

Flasher ④
black

black 2
black
2
⑤ red
red
white
grayg
yellow
⑥
blue
reen
red green yellow
white red red

Fuse box

USB charging green

green
green red
black red black yellow
red black white blue`

1 white 3. Headlight, Starting, Horn 10A

black2
color
7 4 7 1 red
blue
blue yellow green light
purple purple white white black green green
red green
blue green
black green green red black function green gray orange light
blue black 1
green green yellow brown pink 2 pink
white
yellow white
blue
white 1 blue yellow green
1 yellow

dimmer
Start Relay green 4

horn 6. Fan, oil pump 10A main relay 30A

Clutch switch
turn light 8 3 2 6 5
purple
purple green
yellow green blue green purple
gray yellow` brown brown
black green
overtake

meter Diodes ground wire FI 油

oil泵pump
switch-left
Headlight Main relay + oil pump

Relay box

Front wheel speed sensor