RK6 Service Manual PDF
RK6 Service Manual PDF
RK6 Service Manual PDF
0
Contents
Preface .............................................................................................................................................................. - 1 -
Preparing Documents ....................................................................................................................................... - 2 -
General Safety .......................................................................................................................................... - 2 -
Maintenance Rules ................................................................................................................................... - 3 -
Specification ........................................................................................................................................... - 13 -
Failure Diagnosis.................................................................................................................................... - 15 -
Inspection/Adjustment ........................................................................................................................... - 22 -
Inspection and Maintenance of the Electrical System .................................................................................... - 43 -
1. Battery/Charging System ........................................................................................................................... - 44 -
1.1 Preparing Documents ....................................................................................................................... - 44 -
1.2 Failure Diagnosis.............................................................................................................................. - 45 -
1.3 Battery .............................................................................................................................................. - 46 -
1.4 Charging System .............................................................................................................................. - 47 -
1.5 Voltage/Current Regulator ................................................................................................................ - 48 -
1.6 Magnetor Charging Coil ................................................................................................................... - 48 -
1.7 Magnetor Disassembly ..................................................................................................................... - 49 -
2. Ignition System .......................................................................................................................................... - 52 -
2.1 Preparing Documents ....................................................................................................................... - 52 -
2.2 Failure Diagnosis.............................................................................................................................. - 53 -
2.3 Ignition System Check ..................................................................................................................... - 54 -
2.4 ECU Group....................................................................................................................................... - 55 -
2.5 Ignition Coil ..................................................................................................................................... - 56 -
2.6 Sensor of the Crankshaft .................................................................................................................. - 56 -
3. Startup System............................................................................................................................................ - 58 -
3.1 Preparing Documents ....................................................................................................................... - 58 -
3.2 Failure Diagnosis.............................................................................................................................. - 59 -
3.3 Startup Motor ................................................................................................................................... - 59 -
3.4 Starter Relay ..................................................................................................................................... - 61 -
4. Bulbs/ Switches / Meters ............................................................................................................................ - 63 -
4.1 Preparing Documents ....................................................................................................................... - 63 -
4.2 Failure Diagnosis.............................................................................................................................. - 64 -
4.3 Replacement of Headlamp Bulbs ..................................................................................................... - 64 -
4.4 Replacement of Front Position Lamp Bulbs .................................................................................... - 65 -
4.5 Replacement of Tail Lamp ............................................................................................................... - 66 -
4.6 Replacement of Rear Registration Plate Lamp Bulbs ...................................................................... - 67 -
4.7 Replacement of Front Steering Lamp Bulbs .................................................................................... - 68 -
4.8 Replacement of Rear Steering Lamp Bulbs ..................................................................................... - 68 -
4.9 Meters ............................................................................................................................................... - 68 -
4.10 Main Switch ................................................................................................................................... - 69 -
4.11 Horn ................................................................................................................................................ - 69 -
4.12 Handlebar Switch ........................................................................................................................... - 70 -
Inspection and Maintenance of the Motorcycle Body .................................................................................... - 71 -
5. Brake .......................................................................................................................................................... - 74 -
1
5.1 Maintenance Instruction ................................................................................................................... - 74 -
5.2 Failure Diagnosis.............................................................................................................................. - 75 -
5.3 Front Disc Brake .............................................................................................................................. - 76 -
5.4 Rear Disc Brake ............................................................................................................................... - 80 -
6. Body ........................................................................................................................................................... - 84 -
6.1 Disassembly ..................................................................................................................................... - 84 -
6.2 Assembly .......................................................................................................................................... - 84 -
7. Front Wheel/Handlebar/Front Suspension ................................................................................................. - 88 -
7.1 Preparing Documents ....................................................................................................................... - 88 -
7.2 Failure Diagnosis.............................................................................................................................. - 89 -
7.3 Front Wheel ...................................................................................................................................... - 90 -
7.4 Steering Handlebar ........................................................................................................................... - 95 -
7.5 Front Fork ......................................................................................................................................... - 97 -
8. Rear Wheel/Rear Suspension ................................................................................................................... - 101 -
8.1 Preparing Documents ..................................................................................................................... - 101 -
8.2 Failure Diagnosis............................................................................................................................ - 101 -
8.3 Rear Wheel ..................................................................................................................................... - 102 -
8.4 Rear Absorber................................................................................................................................. - 106 -
8.5 Chain Drive .................................................................................................................................... - 108 -
8.6 Rear Swinging Arm ........................................................................................................................ - 110 -
9. Fuel Tank .................................................................................................................................................. - 113 -
9.1 Preparing Documents ..................................................................................................................... - 113 -
9.2 Failure Diagnosis............................................................................................................................ - 113 -
9.3 Fuel Tank ........................................................................................................................................ - 114 -
10. Disassembly and Installation of Engine ................................................................................................. - 116 -
10.1 Preparing Documents ................................................................................................................... - 116 -
10.2 Disassembly of Engine ................................................................................................................. - 116 -
10.3 Installation of the Engine ............................................................................................................. - 122 -
Inspection and Maintenance of Engine ........................................................................................................ - 123 -
11. Lubricating System................................................................................................................................. - 124 -
11.1 Preparing Documents ................................................................................................................... - 124 -
11.2 Failure Diagnosis .......................................................................................................................... - 124 -
11.3 Fuel Pump..................................................................................................................................... - 125 -
12. Cylinder Head ........................................................................................................................................ - 130 -
12.1 Preparing Documents ................................................................................................................... - 130 -
12.2 Failure Diagnosis.......................................................................................................................... - 130 -
12.3 Cylinder Head .............................................................................................................................. - 132 -
13. Crankcase ............................................................................................................................................... - 140 -
13.1 Preparing Documents ................................................................................................................... - 140 -
13.2 Failure Diagnosis.......................................................................................................................... - 143 -
13.3 Upper Box .................................................................................................................................... - 144 -
13.4 Piston ............................................................................................................................................ - 145 -
13.5 Lower Box .................................................................................................................................... - 150 -
13.5 Lower Box .................................................................................................................................... - 151 -
13.6 Clutch ........................................................................................................................................... - 154 -
2
13.7 Gearshift Mechanism ................................................................................................................... - 157 -
13.8 Crankshaft Connecting Rod Assembly Chamber and Variable Speed Chamber .......................... - 161 -
14. Cooling System ...................................................................................................................................... - 167 -
14.1 Preparing Documents ................................................................................................................... - 167 -
14.2 Failure Diagnosis.......................................................................................................................... - 168 -
14.3 Water Pump .................................................................................................................................. - 168 -
Inspection and Maintenance of Exhaust Emission System .......................................................................... - 171 -
15. Exhaust Emission & Control System ..................................................................................................... - 172 -
15.1 Warranty on the Exhaust Emission & Control System ................................................................. - 172 -
15.2 Instructions on Periodic Maintenance .......................................................................................... - 173 -
15.3 Mechanical Function of the Exhaust Control System .................................................................. - 173 -
15.4 Catalytic Transfer System ............................................................................................................ - 174 -
15.5 Measures When the Idle Speed Emission Value Exceeds the Standard ....................................... - 176 -
Inspection and Maintenance of Electronic Fuel Injection (EFI) System ...................................................... - 177 -
16. Electronic Fuel Injection System ........................................................................................................... - 178 -
16.1 Introduction of Electronic Fuel Injection System......................................................................... - 178 -
16.2 Components of Electronic Fuel Injection System ........................................................................ - 178 -
16.3 Methods for Fault Diagnosis and Maintenance ............................................................................ - 192 -
16.4 Common Fault Removal Techniques ........................................................................................... - 202 -
RK6 Circuit Diagram ........................................................................................................................................... 0
3
Preface
RK6.
Inspection & Adjustment states how to check and adjust your motorcycle. All
safety rules and maintenance regulations shall be carried out from the beginning of
periodic inspection.
Except for Chapter I, the rest chapters explain the disassembly/ assembly/
electrical equipment.
Please note that photos, pictures or instructions are for your reference only.
The actual object may differ from what is mentioned here. We will not make
- 1 -
Preparing Documents
General Safety Maintenance Rules
Specification Table Inspection/Adjustment
General Safety
Carbon monoxide
Note
Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human.
Start up engine in an open place. The exhaust cleaning system shall be adopted if engine is started up in a
closed area.
Petrol
Ventilation is required for working places. Fire is strictly forbidden in any working place or where petroleum is
stored.
Battery
Battery emits explosive gas. Therefore, it shall be far away from fire sources, naked flame or smoking places.
Make sure good ventilation during charging.
Battery contains sulfuric acid (electrolyte). It will burn your skin or eyes when contacted. Therefore, wear
protective clothing and mask.
—— Clean with fresh water immediately if electrolyte splashes on the skin.
—— Clean with fresh water at least for 15 minutes immediately and then go to the doctor if electrolyte
splashes on eyes.
Electrolyte is poisonous. Drink a large quantity of fresh water, milk, milk of magnesia (laxative antacid) or
mineral oil if electrolyte is swollen accidentally. Then go to the doctor. It shall be unreachable for children.
Machine Oil
It may trigger cancer if repeatedly expose the hands in the air after contacting with oil. Although there is little
possibility for you to contact with oil in the daily life, wash hands thoroughly with water and soap if you have
contacted. And it shall be unreachable for children.
Thermal Energy
Parts of the engine and cooling system produce heat, which can last for some time before the engine gets
started. Deal with these parts with gloves or after the engine and cooling system cools down.
- 2 -
Maintenance Rules
Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage.
Clean up the surface of components or assembly parts before removing or opening the shield for maintenance,
which can prevent dirt from falling into the engine, the chassis or the braking system.
Wash and dry parts with air compressor after disassembly and
before measurement of attrition value.
套:boot
- 3 -
Bolts and screws with different length shall be separately used for
different assembly parts and shields, and they shall be correctly
mounted. Insert a bolt into a hole to check whether it is proper if
you are confused.
Fill the groove with grease before mounting an oil seal. Check
whether the oil seal is smooth or damaged during assembly.
- 4 -
Loose cables threaten electrical safety. Check each cable
after it is clamped to another for electrical safety;
Wire clamps are not allowed to bend towards welding
point;
Bind cables at the designated place;
Do not deploy cables at the end of frame or at sharp point;
Do not deploy cables at the end of bolts or screws;
Cable deployment shall be far from heat source and where
cables may be clamped during moving;
Cables along the handlebar shall be neither too tight nor
too loose, and do not interface with any neighboring parts
at steering positions;
Cables shall be properly deployed without twist or knot;
Check whether the connector jacket is damaged and
whether the connector is over-stretched before mounting
connectors;
Adopt adhesive tape or hose to protect cables if they are
positioned at sharp point or corner;
Bind cables with tape after repairing;
Control cables shall not be bent or twisted. Clumsy
operation may be caused in light of damaged control
cables.
- 5 -
Identification
Frame Number
Frame
2.Rivets of the frame sign and the frame, see figure
Significant Notes
1. Please apply valid Qianjiang parts and accessories. Any part or accessory not in accordance with the design
specification of Qianjiang Company may cause damage to engine.
2. Only metric tools are valid for maintenance and repair. Metric screws, bolts and nuts can not be exchanged
with imperial fasteners.
3. New gaskets, O-rings, cotter pins and locking pieces shall be applied for re-assembly.
4. Bolts with large diameter or positioned inside shall be fastened first and then diagonally screw down until
reaching required torque, otherwise there is special instruction.
5. Wash disassembled parts with cleanser. Lubricate all sliding surface before assembly.
6. Check whether all the parts and accessories are correctly mounted and operated after assembly.
7. Clean and remove oil before measurement. Add recommended lubricant to the lubricating areas during
assembly.
8. Apply lubricant to the surface of engine and driving system if they are dismantled for long-term storage,
which can prevent rust and dirt.
- 6 -
Special Tools
Special tools refer to tools which are specially designed for assembling or disassembling some
motorcycle parts on special positions. Applicable special tools are necessary for precise adjustment and
installation. With them, parts and accessories can be mounted safely, reliably and rapidly, which improves
efficiency and saves energy.
1.Tools for repairing the engine
Special tools are required for properly disassembling/assembling some engine parts.
Table and drawing (1-1, 1-2) of special tools for disassembling/assembling engine parts are as follows:
Table 1-1
Name Remark
Special socket spanner Used for assembling/disassembling bolts for flywheels, Fig. 1-3
Clutch clamp holder Fig.1-4
Flywheel puller Fig. 1-4
Feeler gauge Fig. 1-5
Bearing disassembly tools Fig. 1-6
Bearing assembly tools Fig. 1-7
Oil seal remover Fig. 1-8
Handle for dismantling tools Fig. 1-9
Piston pin pulling device Fig. 1-10
Piston pin pliers Fig. 1-11
Socket spanner for spark plug Fig. 1-12
Clutch thickness measuring device Fig. 1-13
Cylinder diameter measuring device Fig. 1-14
Dial indicator Fig. 1-15
Dial indicator, V-block Measuring the inner diameter of the piston pin, Fig. 1-16
Dial indicator For measuring the bending of the valve rod,Fig. 1-17
Assembly/disassembly tool for valve catheter For measuring the external diameter of the valve rod,Fig. 1-18
Assembly tool for valve catheter Fig. 1-19
Adjustment tool for valve space Fig. 1-20
Assembly/disassembly tool for valve spring Fig. 1-21
Valve catheter reamer Fig. 1-22
Disassembly tool for crankcase Fig. 1-23
Fig. 1-24
Table 1-2 (continued)
- 7 -
Fig. 1-5 Fig. 1-6 厚度规(塞尺)
:feeler gauge
- 8 -
Fig.1-13 Fig.1-14
- 9 -
Fig. 1-23 Fig. 1-24
2.Tools for repairing the chassis
Table and drawing (1-25, 1-26) of ordinary tools and special tools for disassembling/assembling chassis
parts are as follows:
Fig. 1-25
Name Remark
Torque spanner Fig. 1-27
Inner hexagon spanner Fig. 1-28
Socket spanner Fig. 1-29
Micrometer Fig. 1-30
Magnetic rack, V-block Fig. 1-31
Dial indicator Fig. 1-32
Vernier calipers Fig. 1-33
Circlip pliers Fig. 1-34
Screwdriver with striking cap Fig. 1-35
Tool for assembling oil seal of front fork Fig. 1-36
Tool for hammering seal of front fork Fig. 1-37
Steering nut spanner Fig. 1-38
(1) Ordinary tools for repairing the chassis
Table 1-26 (continued)
- 10 -
Fig. 1-31 Fig. 1-32
Fig. 1-37
(3) Steering nut spanner
Fig. 1-38
3.Tools for electric parts
- 11 -
Table and drawings (1-39, 1-40) of special tools for testing electric parts are as follows:
Fig. 1-39
Name Remark
Multimeter Fig. 1-41
Ignition tester Fig. 1-42
Fig. 1-40 (continued)
Fig. 1-41
Fig. 1-42
- 12 -
Specification
Brake
Fuel Dia. of rear
consumption ≤5.2L/100km liquid brake 240mm
limit disc(mm)
- 13 -
RK6
- 14 -
Failure Diagnosis
- 15 -
Check if petrol
pump is working No petrol in the tank
properly Oil tube of fuel injector blocked
Oil tube of petrol pump blocked
Tube of combustion chamber’s
Oil provided to fuel No petrol Evaporation Control System
injector is sufficient provided to blocked
and smooth fuel injector Petrol air filter blocked
Low oil pressure of petrol pump
Disassemble spark Abnormal spark plug
plug into its cap, Polluted spark plug
ground it with engine Abnormal CPU group
to check if it can spark Abnormal trigger
Open circuit or short circuit of
ignition coil’s wire
Spark-over Weak sparks
No Open circuit or short circuit of
ignition coil
Abnormal main switch
Test compression pressure Abnormal charging coil
Abnormal clutch for startup
- 16 -
Unsmooth gyration (No speed or weak speed)
Failure diagnosis Adjustment specification Causes of failure
Start engine with
soft refueling Air filter blocked
Abnormal petrol
accelerated Engine can not Tube of combustion chamber’s
gyration speed fully speed up Evaporation Control System
of engine blocked
Exhaust pipe blocked
Adjust ignition timing and Abnormal automatic choke
use ignition timing light Abnormal throttle valve
Correct
Incorrect ignition Abnormal CPU group
ignition time
time
Abnormal trigger
Test compression pressure
- 17 -
Unsmooth gyration(especially in low speed)
Failure Diagnosis Adjustment & Inspection Causes of Failure
Normal Abnormal
Abnormal trigger
- 18 -
Unsmooth gyration (high speed)
Failure Diagnosis Adjustment & Inspection Causes of Failure
Adjust ignition time
Normal Abnormal
Abnormal trigger
No Blocked Remove
- 19 -
Poor battery charging (over discharge or over charge)
Failure Diagnosis Adjustment & Inspection Causes of Failure
Test the voltage of
battery’s two ends, and
stat engine
Battery used up
Abnormal coil
Normal Abnormal Poor connection of the joint
Open circuit of alternator’s
white wire
Poor battery
Poor battery charging
Overcharging Start the engine, connect the red wire of the
voltage regulator’s socket to the multimeter,
while anode and cathode wire to the voltage
between parts of the body
- 20 -
No spark-over of the spark plug
Failure Diagnosis Adjustment & Inspection Causes of Failure
Normal Abnormal
Bad connection of the plug
Check conduction between terminals
of CDI group’s plugs, and test
resistance value
Abnormal main switch
Abnormal charging coil
Normal Abnormal
Abnormal trigger
Abnormal ignition coil
Check relevant parts
Normal Abnormal
Breakage of main wire
Bad connection of the plug and
socket
Use CDI tester to check CDI group
Abnormal
Abnormal ignition coil
- 21 -
Inspection/Adjustment
Bolt/nut/fastener Rim/tire
Components lubrication
Preparing Principles
General
Warning!
• Make sure that it is well ventilated before starting the engine. It is forbidden to start it in a closed area.
Exhaust gas, which contains monoxide, may cause unconsciousness or even death of human being.
• Petrol is liable to volatile or exploded under certain condition. Ventilation is required and no any fire exists in
working places. Fire is strictly forbidden in working areas or where oil is stored.
- 22 -
Specification
Engine
ID × stroke 65.0×45.2
Total displacement 600cc
Ignition TLI
Spark plug gap 0.6-0.7mm
Spec. of spark plug CR9E(NGK)
Type of combustion chamber spherical
Frame
- 23 -
Periodic Maintenance & Inspection Table
Service cycle and time Per Per Per Per Per Per
300 1000 3000 6000 12000 14500
Inspection item Km Km Km Km Km Km Tools
One Three Six Twelve Fifteen
New month months months months months
* Air filter I C C R C Ordinary tools
* Petrol filter I I R Ordinary tools
* Fuel filter C C C Ordinary tools
Replacement of engine
R Replacement every 1000KM Ordinary tools
fuel
Tire pressure
Tire pressure I I I I I I
gauge, inflator
Densimeter,
Battery inspection I I I I I I
multimeter
Actuation gap inspection I I I I I I Ordinary tools
Inspection of steering
I I I Ordinary tools
handle fastening
Absorber working
I I I Ordinary tools
inspection
Screw fastening
I I I I I I Torque spanner
inspection
Oil leakage inspection for
I I I I I I Ordinary tools
gearbox
Inspection or replacement
* I I R R I Ordinary tools
of spark plug
Replacement of gearbox
* I Replacement every 5000KM Ordinary tools
oil
Lubrication of each part L L Lubricator
Muffler I I I I I I Ordinary tools
* Ignition timing I I I I I I Timing lamp
* Carburetor A I A A A A
Tachometer, CO
Exhaust gas inspection at HC analyzer
* A I A A A A
idle speed
* Throttle inspection I I I I I Ordinary tools
Fuel pipeline inspection I I I I I Ordinary tools
Lighting/metering/electric
I I I I I I Visual multimeter
devices
Main stand bracket I I I Ordinary tools
Absorber I I I I Ordinary tools
Torque force of engine
* I I I I I Torque spanner
bolts
Front/rear brake I I I I Ordinary
Drive chain I I I I A Ordinary
Clutch I I I I Ordinary
* Valve I I I I I Feeler
- 24 -
Anticipated Inspection
1 Ignition system—obviously continuous ignition abnormality, engine fire or overheating, which requires
inspection and maintenance.
2 Carbon fouling elimination—obviously insufficient horsepower, which requires carbon fouling removal
from cylinder head, piston head and exhaust system.
3 Piston & cylinder—excessive abrasion; replace cylinder if it is blocked.
Please have your motorcycle inspected and adjusted periodically at Qianjiang distributors for being in best
condition.
The above table is established under the presupposition of 1000 km/month.
I—Inspection A—Adjustment R—Replacement C—Cleaning L—Lubrication
Note: 1. “*” Regulations on exhaust emission made by the State Environmental Protection Agency shall be
complied with. Maintenance must be carried out in accordance with the instruction manual supplied by the
company. We are not responsible for any loss rising from private adjustment or maintenance.
2. Increase frequency of washing air filter if your motorcycle runs on the sandy/gravel road or under
heavily polluted environment so as to extend its service life.
3. Motorcycles which often run at high speed or with high mileage shall be maintained frequently.
Engine Oil/Filter
Oil level
* Note
• The motorcycle should be parked on a flat ground when
checking its oil level.
• After the engine runs for 2-3 minutes or stops running for
about 2-3 minutes, check the oil level.
*Note
Check the O-ring.
Assemble the dipstick.
Oil Replacement
* Note
It will be easier to change oil when the engine is warming up.
- 26 -
Cooling Liquid
Remove the front shield on the right side. Find the filler mouth
of radiator water tank①.
Open the filler cap and inject a right amount of cooling liquid.
Re-install the cap after injection.
Check the cooling liquid of the expansion kettle after the
engine has been turned off and cooled down.
While checking, make sure the motorcycle is on the flat ground
and its body upright.
Observe the capacity of the cooling liquid in the expansion
kettle through the frame hole from the right side of the
motorcycle.
Keep the capacity between the mark of H and L. If the liquid is below H, remove the cap of the expansion
kettle② and then add cooling liquid.
Warning:
Add the cooling liquid after the engine is turned off
and cooled down. In case of burns, do not open the filler
cap before the engine has cooled down. The cooling
system is under pressure. In some cases, the cooling
liquid contains substances that are combustible, and
there will be visible flame when ignited. Avoid the
leakage of cooling liquid on hot motorcycle parts,
because it can cause serious burns if combust.
Avoid contact to and inhalation of the cooling
liquid, because it is highly toxic. And keep it away from
the children and domestic animals. If inhaled, seek
medical advises immediately, and if the skin or eyes
have accidentally contacted the cooling liquid, they
must be cleaned with water instantly.
- 27 -
Assembly and Disassembly of the Clamp of the Radiator’s Conduit
卡箍:clamp
- 28 -
Adjustment to the Steel Rope of the Throttle
*Note
Adjust the idle speed of the engine right before adjusting
the stroke of the steel rope of the throttle.
Check the free stroke of the steel rope of the throttle, and it
should be 3-5mm.
Adjust if it does not conform to the specified value.
Adjust the free stroke of the steel rope of the throttle.
Air Filter
Filter Replacement
Open the rear seat cushion with the key, and remove it.
钥匙:key
Pull the seat steel rope, open the front seat and take it off.
- 29 -
座垫钢索:seat steel rope
Disassemble the shield of the fuel tank and its front fixing
bolt, and open the fuel tank.
Replacement Time
Replace it as early as possible if the motorcycle is always running on rainy days or on rugged road.
*Note
- 30 -
Do not start engine when disassemble the cartridge of the air filter, otherwise, the engine will intake unfiltered
air, which may lead to rapid abrasion of other components, and the damage of the engine too.
In addition, rotation without cartridge will cause sequential malfunctions of the carburetor, and it may lead to
overheat of the engine.
Spark Plug
Check
Whether the insulator is cracked or damaged
Whether the electrodes are abrasive
The combustion condition and color
The condition is good in light grey
Combustion color of pale indicates that the ignition system
gets a breakdown or the mixed air is too thin.
The condition of wet or there is black carbon deposition
indicates that the mixed air is too thick.
If there occur any cases mentioned above, please remove with spark
plug cleaner or steel brush, and replace if necessary.
Check the spark plug visually.
Replace the cracked or abrasive insulator if necessary.
Replace the spark plug after 8000 kilometers of each driving.
Check the spark plug gap.
Gap: 0.6-0.7mm
Model: CR9E(NGK) 火花塞间隙:spark plug gap
*Note
Re-install the spark plug to the cylinder head, and screw tight with a specified torque.
Torque value: 20-25N.m
Manually install the spark plug first, and then tighten with the spark plug sleeve.
Do not make the spark plug too tight or the threads staggered, so as not to damage the threads of the cylinder
head.
When remove the spark plug, avoid impurities from entering into the engine through it.
- 31 -
Battery
Battery Disassembly
Disassemble the front seat.
Remove the mounting plate of the battery.
*Note
Charging
Connection: Connect the positive pole of the charger to the positive pole of the battery.
Connect the negative pole of the charger to the negative pole of the battery.
- 32 -
Warning!
• The battery should be far away from fire source.
• Turn off the charger before or after charging to avoid
explosive danger caused by spark which may exist in any
connection.
• Comply with the current and time requirements for charging
as stated on the battery.
* Note
• Except emergencies, you should not use emergency charging.
• Measure voltage in 30 minutes after the battery is charged.
伏特表:voltmeter
Charging current: standard: 0.3A
quick: 3.0A
Charging time: standard: 10-15 hours
quick: 30 minutes
charging accomplished:open-circuit voltage: above 12.8V
Fuse Replacement
The fuse is under the driver’s seat, and near the battery.
The main fuse is set on the starter relay, and the fuse box is
near the fuse. As shown in the figure ① refers to the fuse,
model: 40A, ② refers to the spare fuse of the main fuse, model:
40A, ③ refers to the fuse box, the configuration of the fuse is
shown in the figure:
Frequent fuse blowout indicates that there is short circuit or
circuit overload.
Note:
Before check or replace the fuse, set the ignition switch to “off
”, in case of short circuit or damage to other electrical
components.
Use the specified fuse only, or it will cause serious affect to the
electric system, and it can even burn the lamps of the
motorcycle or cause a fire or loss of engine traction, which is
very dangerous.
- 33 -
Cylinder Pressure
Looseness: 10-20mm
Warning:
It is the maximum interval for adjustment as
recommended; in fact, you should adjust the chain
before every drive. Over loosened chain may
cause the accessory chain off the drive chain or
serious damages to the engine.
- 34 -
(1)Put up the motorcycle with the support frame.
(2)Loosen the rear axle nut①.
(3)Loosen the locking nut②.
(4)Turn right or left the adjustment bolt③ to adjust the looseness of the chain, and keep the centers of the
rear and back sprockets into a straight line. There are benchmarks on the swinging arm and each chain
adjuster to facilitate your adjustment, and they can be aligned with each other and the reference from
one side to the other. Align and adjust the looseness of the chain to 10—20mm, and then fix again the
rear axle nut for the final check.
Note:
The two sprockets of the newly replaced
chain should be checked to make sure whether
they are abrasive or not, replace if necessary.
If the chain has defects as mentioned above, then there is a high possibility that the sprocket will damage the
chain. So the following items should be check to the sprocket:
(1)Excessively abraded gear tooth
(2)Broken or damaged gear tooth
(3)Loose fixing nut of the sprocket
*Note
Do not assemble new drive chain to abraded sprocket or vice versa.
The sprocket and the chain should all be in good conditions, or it will cause quick abrasion of the newly
replaced chain or sprocket.
- 35 -
Free Stroke of the Front Brake
- 36 -
If specified value has not been met, it should be adjusted.
Adjust the free stroke of the brake pedal.
First open the nut 1.
Screw in or out nut 2 to adjust the free stroke of the brake pedal.
Screw in 2 to reduce the free stroke;
Screw out 2 to increase the free stroke.
Tighten the fixture 1 until the specified value is met.
After being adjusted, dragging should not occur to the brake.
Headlamp
- 37 -
Unplug the lamp holder connector③ of the headlamp,
remove the lamp holder, disentwine the snap ring, and take
out the bulb.
*Note
Keep combustible materials and your hands a distance away
from the bulb when it is light. Because the bulb is very hot at
that moment, you should let it cool down before touching it.
Install new headlamp bulb, lamp holder, and screw in the
bulb to the socket.
During the installation, avoid direct touch with the glass of
the bulb, an do not make it oil-stained. Or it will affect the
transparency, life and luminous flux of the bulb.
Once stained with oil, wipe thoroughly with a damp cloth of
alcohol or rubber solution of strong volatility.
Clutch
- 38 -
Front/Rear Suspension System
Front Absorber
Pull the front brake tight; compress the front absorber upwards or downwards for check.
Check whether there is oil leakage in the front absorber and whether any component is damaged or loosened
上下压缩
(上下压缩:compress upwards or downwards)
Rear Absorber
Compress the rear absorber upwards or downwards for check.
Check whether each part of the rear absorber is damaged or loosened.
Suspend the rear wheel and check shimmy.
Check whether the suspension bushing of the engine is loose or not.
上下压缩
Bolt/ Nut/Fastener
- 39 -
Rim/Tyre
Tyre
Specification
pressure
Front tyre 120/70 ZR 17 250±10kpa
RK6
Rear tyre 180/55 ZR 17 290±10kpa
Warning:
Do not attempt to repair the damaged tyre.
The balance and reliability of the tyre is likely to
worsen.
Improper tyre inflation will lead to abnormal
abrasion of the tyre and threat the safety. And
insufficient inflation will cause tyre slip, or
disengage the tyre, or lead to the deflation of tyre
which is out of control. It is dangerous to drive
with excessively abraded tires, and it is adverse to
the adhesion or driving.
- 40 -
Fixing Steering Stem Bearing and Handlebar
Throttle Body
Note:
Do not let impurities block the parichnos nearby.
- 41 -
Components Lubrication
Appropriate lubrication is of great importance to the normal operation of each part of the motorcycle, to an
extended life and to the safety drive. Lubricate the motorcycle after a long time running or exposure in the rain
or after cleaning. As for detailed points for lubrication and maintenance, see the following figure:
Ymotorcycle
□ lubrication □ grease
Z
○ □
1 axis of the rear brake pedal Z ○ □
2 single bracket joint and spring hookZ ○
3 pin of the
gearshift riding rod Z□
4 throttle cableY
○ □ ○
5 pin of the front brake handle Z□ 6 clutch handle(pin)Y
○ □
- 42 -
Inspection and Maintenance of the Electrical System
充电系统
- 43 -
1. Battery/Charging System
Preparing Documents-----------------------1.1
Failure Diagnosis----------------------------1.2
Battery-----------------------------------------1.3
Charging System-----------------------------1.4
Voltage/Current Regulator -------------------1.5
Work Instructions
*Note
1. Battery can be charged or discharged repeatedly. If it is placed after discharge, its service life will be
shortened and performance is undermined. Normally, the battery performance will be degraded after two or
three years. As for battery of degraded performance (reduced capacity), whose voltage will recover temporarily
after charging but decrease sharply when loading.
2. Battery overcharge: normally, overcharge can be judged upon the battery. In the case of short circuit inside
the battery, its terminal is unable to detect voltage or the detected voltage is very low. Regulator failure: over
voltage inside the battery will shorten its service life.
3. The battery will be self-discharged if being stored for a long time, which reduces its capacity. It shall be
charged about every three months.
4. Check the charging system following the sequence listed on the failure diagnosis table.
5. Do not remove the connector when there is current through electrical parts, otherwise it will cause over
voltage and damage to electrical parts inside the voltage regulator. Please operate it after the main switch turns
off.
6. It is unnecessary to check the maintenance-free battery and add electrolyte and distilled water.
7. Check all electric loads.
8. Emergency charging can only be used under emergency situation.
9. Remove the battery from the motorcycle for emergency charging.
10. Do not use electrolyte-added batteries when interchanging batteries.
11. Use a voltmeter to check charging condition of the battery.
- 44 -
Preparing Principles
Item Specifications
Capacity/Type 12V-9AH/ dry-charged
Fully charged 13.1V
Battery Voltage
Necessary
(20℃) 12.3V(not working for 1h)
charging
Charging current Standard: 0.8A, quick:8A
Charging time Standard: 10-15 hours, quick: 30 mins
Impedance of the coil
Magnetor Between white-white 1.5-3.5Ω
(20℃)
Type Three-phase full wave
Voltage
Charging voltage of the
regulator 14.5±0.5V/5.000rpm
battery
- 45 -
1.3 Battery
Warning!
*Note
To prevent short circuit, connect the positive wire
first and then the negative wire.
* Note
Use a voltmeter to check the charging condition.
1.3.2 Charging
Connection method: connect the positive pole of the charger with the positive pole of the battery;
connect the negative pole of the charger with the negative pole of the battery.
Warning!
• The battery should be far away from fire source.
• Turn off the charger before or after charging to
avoid explosive danger caused by spark which
may exist in any connection.
• Comply with the current and time requirements
for charging as stated on the battery.
- 46 -
*Note
• Except emergencies, you should not use
emergency charging.
• Measure voltage in 30 minutes after the battery
is charged.
*Note
Connect the positive terminal of the multimeter
with the negative terminal of the battery.
Check whether there is short-circuit in the main switch or in the main wire in the case of any abnormality.
- 47 -
1.5 Voltage/Current Regulator
*Note
• Do not touch any metal part of the test rod of the
multimeter with your finger for check.
• Check with multimeter. Different multimeters
show different impedance and different results.
Replace the voltage-current regulator when the impedance between terminals is abnormal.
Check
Remove the 6p connector of the magnetor.
Measure the impedance between the three white terminals of the magnetor with the multimeter.
Standard: 1.5-3.5Ω(20℃)
Replace the magnetor coil when the measured value exceeds the standard value.
- 48 -
1.7 Magnetor Disassembly
Left cover and
the magnetic coil
1.7.1 Disassembly
Loosen the fixing nuts on the left cover, and
remove the left cover and the magnetic coil.
Bolt
Bolt
- 49 -
Loosen the locking nuts of the flywheel with
electric, pneumatic tools or torque spanner. Locking nut of
Remove the flywheel assembly. the flywheel
1.7.2 Installation
Fix the flywheel with the universal spanner and tighten fixing nuts.
- 50 -
电源
黑/红2
黑
黑/白2
ECU2
黑/红2
黑
橙/绿2
黑/红1
黑
黑/白1
白蓝
/ /
ECU1 黑/红1
绿白
黑
橙/绿1
触发头
电源
- 51 -
2. Ignition System
ECU Group----------------------------2.4
Trigger ---------------------------------2.6
Work Instructions
1. Check the ignition system following the sequence listed in the table of failure diagnosis.
2. This ignition system is an electronically and automatically angling device. It is solidified in the ECU group
and you don’t have to adjust the ignition time.
3. Check the ignition system following the sequence listed in the table of failure diagnosis.
4. Do not make ECU of the ignition system fall down or hang down or hammer it with strong force (primary
causes for failure). Pay special attention during disassembly.
5. Failure of the ignition system is mostly caused by poor contact of the socket. Check whether each connector
is in good condition.
6. Check whether the heat value used for the spark plug is proper. If not, the engine may work abnormally or
the spark plug may be burnt.
7. Check in this chapter is based on the maximum voltage. It also refers to check on the impedance of the
ignition coil.
8. Check the main switch according to the conduction table.
9. Remove the magnetor and the stator according to instructions.
Preparing Principles
Item Standard value
Spark plug
Standard CR9E(NGK)
recommended
Spark plug gap 0.6-0.7mm
Ignition coil
Primary coil 650±50mΩ
impedance(20℃)
Impedance of trigger(20℃) 100-300Ω
Measure the maximum primary voltage of the ignition coil 14V
Trigger voltage Above 1.7V
Tools
Attachments to the Maximum Voltage Table
Multimeter
- 52 -
2.2 Failure Diagnosis
- 53 -
2.3 Ignition System Check
*Note
• When there is no spark, check whether there is
loose wiring 万用表
or poor contact, and make sure all voltage values
are normal.
• There are kinds of multimeters with different
impedances and different test values.
*Note
Make sure all wiring is correct before test.
Cylinder compression pressure normally refers to
the test value when the spark plug is installed on
the cylinder head.
Connect the lead of the ignition coil and also the shunt
between the primary coil terminal (black/red) and the GND.
Press the startup motor or step the actuating lever to
measure the maximum primary voltage of the ignition coil.
Minimum voltage: above 95V
*Note
Never touch any metal part of the test rod with
your finger to avoid electric shock.
- 54 -
2.3.2 Sensor of the Crankshaft
*Note
Install the spark plug on the cylinder head and
carry out measurement when the compression
pressure is normal.
*Note
Never touch any metal part of the test rod with
your finger to avoid electric shock.
When the maximum voltage measured at the terminal of ECU Group is abnormal; dismantle the shield of the
body and the magnetor terminal.
• If the voltage of ECU is measured to be abnormal while the voltage at the magnetor terminal is normal, it is
caused by poor contact or disconnected wiring.
• If the voltage at both ECU and magnetor terminal appears to be abnormal, it is caused by poor charging coil.
Please refer to charging coil check.
- 55 -
2.5 Ignition Coil
2.5.1 Disassembly
Remove the body.
Remove the spark plug cap.
Remove the primary lead of the ignition coil.
Remove the fixing bolts and then the ignition coil.
Install the ignition coil in reverse order.
*Note
Install the primary coil with black/red
terminal.
*Note
Check the trigger on the engine.
Check
Remove the shield of the body.
Remove the trigger terminal.
Measure the impedance between the blue/white terminal of
the side wire of the engine and the body GND.
Standard: 100-300Ω(20℃)
Replace the magnetor if the measured value exceeds the
standard value.
- 56 -
BATTERY
G/Y
G/Y M
启动示意图
启动示意图:Startup Schematic Diagram
- 57 -
3. Startup System
Starter Clutch--------------------------3.5
Work Instructions
Disassemble the startup motor on the engine.
For the disassembly of the startup clutch, please comply with related regulations
Preparing Principles
Item Standard Limit for use
Length of the brush of the
12.5mm 8.5mm
startup motor
Bushing of the startup idler
8.3mm
shaft
Outer diameter of the startup
7.94mm
idler shaft
Tools
Spanner for retaining nuts
Universal fixing spanner
- 58 -
3.2 Failure Diagnosis
3.3.1 Disassembly
Loosen the two fixing bolts of the startup motor,
and remove the motor.
Bolt
Startup motor
* Note
Before the startup motor is disassembled, turn off the
main switch, remove the GND wire of the battery, and
then power on to check whether the startup motor
works for ensuring safety.
- 59 -
Remove the wire clip of the startup motor.
Remove the fixing bolts of the startup motor, separate
the front cover and the back cover, and dismantle the
startup motor.
Roll the waterproof rubber case and dismantle the
connector of the startup motor.
换向器:commutator
3.3.2 Breakdown
Remove screws in the shell, front cover, motor housing and other parts.
3.3.3 Check
碳刷
Check other components.
Replace any part with abraded, damaged or burnt surface.
Clean the commutator surface if there is metal power attached to it.
Check conduction between the surfaces of other components.
Ensure non-conduction between armature shafts of the commutator.
Check the conduction of the shell of the startup motor.
Ensure non-conduction between the conduction terminal and the startup motor shell.
Check conduction between the conduction terminal and the brush.
Replace any abnormal part.
Check conduction of the brush bracket. Replace it when there is conduction.
Measure the length of the brush.
Limit for use: replace it if lower than 8.5mm
Check smooth rotation of the needle bearing inside the front cover and whether it is loose when press-in.
Replace it if there is any abnormality.
Check whether the oil seal is abraded or damaged.
碳刷:carbon brush
- 60 -
3.3.4 Assembly
Lubricate the oil seal inside the front cover with grease.
Install the brush on the bracket.
Lubricate moving parts at two ends of the brush shaft
with grease.
Press each brush into the bracket,
* Note
• Pay special attention that the contact surface between
the brush and the armature shall not be damaged.
• Pay attention that the armature shaft shall not damage
lips of the oil seal.
3.3.5 Installation
Install the lead of the startup motor and the dustproof boot.
And then install the startup motor.
Install the wire clip for rear brake.
3.4.1 Check
When the main switch is “on”, check there is “click” sound at
the time of pressing the startup motor.
With click sound, it is normal.
Without click sound: • check voltage of the starter relay;
• check the GND loop of the starter relay;
• check the movement of the starter relay.
启动继电器:starter relay
- 61 -
3.4.2 Check Voltage of the Starter Relay
Set up the main stand, and measure voltage between the
negative pole of the green/yellow wire of the starter relay
terminal and the body ground connection. Ω
When the main switch is “on”, hold the brake lever. The
battery voltage shall comply with regulations.
When there is no voltage at the starter relay terminal,
check the conduction of the brake switch and leads.
启动继电器:starter relay
3.4.4 Check
Connect the starter relay to the battery, and the
terminal of the startup motor to the multimeter.
Connect the fully charged battery between the black
wire and the green/yellow wire of the relay. The relay
shall sound “click” and the multimeter shall indicate
resistance of “zero”.
- 62 -
4. Bulbs/ Switches / Meters
Meters--------------------------------------------------------------------------------4.9
Horn ---------------------------------------------------------------------------------4.11
Work Instructions
Remove the switch from the vehicle to measure its condition.
All plastic connectors have clamping jaws,
lift the clamping jaws and clamps before disassembly,
and make sure that the clamping holes aim at the clamping jaws when installing.
When looking up for electric faults,
check the continuity of the circuit passing through the electronic devices.
The state of the battery must be confirmed before carrying out any inspection,
including the voltage, to confirm that whether it is normal or not.
- 63 -
4.2 Failure Diagnosis
- 64 -
The figure below shows the bulb of the dipped
headlight③, and the bulb of the headlight on full
beam④, remove the power cord socket, bulb snap,
fixing bolts and the bulb snap buckle of the dipped
headlight and the headlight on full beam that need to
be replaced, and finally remove the damaged bulb.
*Note
Keep combustible materials and your hands a distance
away from the bulb when it is light. Because the bulb
is very hot at that moment, you should let it cool
down before touching it.
Install the bulb in reverse order.
During the installation, avoid direct touch with the
glass of the bulb, an do not make it oil-stained. Or it
will affect the transparency, life and luminous flux of
the bulb.
Once stained with oil, wipe thoroughly with a damp cloth of alcohol or rubber solution of strong volatility.
Install headlamp devices.
- 65 -
4.5 Replacement of Tail Lamp
- 66 -
4.6 Replacement of Rear Registration Plate Lamp Bulbs
(2) Take off the damaged bulb, and replace on a new one
of the same specification.
- 67 -
4.7 Replacement of Front Steering Lamp Bulbs
4.9 Meters
- 68 -
4.10 Main Switch
4.10.1 Check
Remove the front shield.
Remove the main switch lead terminal.
Check the conduction of the terminal.
POWER LOCK
ON
OFF
LOCK
R R/W
4.11 Horn
Check
Remove horn wires.
It shows good when the horn wire is connected to the battery.
- 69 -
4.12 Handlebar Switch
Switch classification:
1. Light changing switch (变光开关)
2. Start switch
3. Steering switch (转向开关)
4. Horn switch (喇叭开关)
5. Turn off switch (熄火开关)
6. Warning switch
接线原理图
变光开关 转向开关
兰 黄/红 浅兰 绿/黑 橙 绿/白
喇叭按钮
黑 棕
- 70 -
Inspection and Maintenance of the Motorcycle Body
- 71 -
Front Disc Brake
Dia. of the front left/right brake
A
disc:320mm
Thickness of the front left/right brake
B disc:4.0mm
Limit for use: 3.6mm
Thickness of the brake shoes:7.8mm
C
Limit for use:3.8mm
Torque for mounting bolt 4 in the
D
figure:5-10N·
m
Torque for mounting bolt 5 in the
E
figure:30-35N·
m
Torque for mounting bolt 11 in the
F figure:
5-7N· m
Torque for mounting bolt 12 in the
G
figure:30-35N·
m
Torque for mounting bolt 14 in the
H
figure:37-55N·
m
Torque for mounting bolt 17 in the
I
figure:22-34N·
m
1. handlebar assembly of the front brake disc 2.handlebar screw 3.fixing cover 4.bolt M6×23 5.hexagon
flange screw 6.brake switch 7.screw M4×12 8.nut M6 9.brake hose assembly 10.11. bleed nipple
12.mounting bolt of the oil tube 13.gasket 14.bolt M10×1.25×55 15.front left brake cylinder assembly
16.brake shoes 17.bolt M8×16 18.D.320front brake disc 19.front right brake cylinder assembly
- 72 -
Rear Disc Brake
A Dia of the rear disc brake: 240mm
Thickness of the rear disc brake: 5.0mm
B
Limit for use: 4.5mm
Thickness of the brake shoes: 7.0mm
C
Limit for use: 3.7mm
Torque for mounting bolt 15 in the
D
figure:30-35N· m: 22-34 N· m
Torque for mounting bolt 14 in the
E
figure:30-35N· m: 5-10 N· m
Torque for mounting bolt 10 in the
F
figure:30-35N· m: 30-35 N· m
Torque for mounting bolt 8 in the
G
figure:30-35N· m: 30-35 N· m
1.pin 2.joint M6 3.cotter 4.nut M6 5.pushrod 6.rear fuel pump assembly 7.gasket 8.rear brake
indicator 9.rear brake hose assembly 10.mounting bolt of the oil tube 11.rear brake cylinder assembly
12.brake shoes 13.rear disc brake 14.screw M6×20 15.bolt M8×1.25×20
- 73 -
5. Brake
Work Instructions
*Note
A stained brake disc or protective gasket will reduce brake force, so discard
stained gasket and clean the brake disc with quality brake degreaser.
Check the brake system through the brake lever and pedals.
Spilled brake liquid is harmful to the focusing and paint of the equipment,
and the rubber parts too. So be careful whenever you remove the cap of the
oil cup, and the first thing you should do is to make sure that the liquid in the
cup is aclinic.
Never let the earth, water or other dirt into an open cup.
Use the DOT4 brake liquid taken out from a sealed container when doing
maintenance, and do not mix it with other type of liquid, since they can not
coexist.
5.1.1Specification
Item Standard Limit for use Item Standard Limit for use
Special brake liquid DOT4 - Special brake liquid DOT4 -
Thickness of the left/right
4.0mm 3.6mm Thickness of the brake disc 5.0mm 4.5mm
brake disc
Thickness of the left/right
7.8mm 3.8mm Thickness of the brake shoe 7.0mm 3.7mm
brake shoe
Dia. of the left/right brake disc Φ320mm - Dia. of the brake disc Φ240mm -
The jump of the brake surface The jump of the brake
Front 0.1mm - Rear 0.1mm -
of the left/right brake disc surface of the brake disc
I.D. of the pump oil cylinder Φ16+0.043
0 mm - I.D. of the pump oil cylinder Φ11+0.027
0 mm -
O.D. of the oil-pumping O.D. of the oil-pumping
Φ16-0.032
-0.059 mm - Φ11-0.032
-0.059 mm -
piston piston
I.D. of the caliper cylinder Φ34+0.08
+0.03 mm - I.D. of the caliper cylinder Φ32+0.08
+0.03 mm -
O.D. of the caliper piston 32-0.032
-0.065 mm - O.D. of the caliper piston Φ32-0.032
-0.065 mm -
- 74 -
5.1.2 Torque Force
Fixing the front wheel spindle 100-140N·m
Mounting screw of the front left brake cylinder assembly 37-55N·m
Mounting screw of the front right brake cylinder assembly 37-55N·
m
Fixing nut of the rear wheel spindle 130-150N·m
Mounting screw of the rear brake cylinder assembly 22-34N·m
5.3.1 Disassembly
*Note
Replace the brake shoes assembly.
If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place.
Remove following assemblies from the right grip and the front absorber.
Front brake:
Nut of the rearview
1. brake handle mirror
2. fuel pump assembly
3. brake hose assembly
4. left/right brake cylinder assembly Fixing screw of
5. left/right brake disc the fuel pump
*Note
Do not stain the brake assembly with oil spots during
installation or disassembly.
Clean it with required cleaning agent to maintain the brake performance.
- 76 -
Fixing screw of the handle
Brake hose
Bleed nipple
Bleed nipple
- 77 -
Remove the front wheel spindle.
Remove the front wheel.
Remove the disc brake off the front rim.
前轮:front wheel
前轮轴:front wheel spindle
前左液刹:front left disc brake
固定螺钉:fixing screws
5.3.2 Check
Check whether the brake shoes assembly and the brake
disc are abraded. Replace brake shoes if necessary.
Measure the brake shoes and the brake disc. Record
maximum values.
Specification
Diameter of the front brake disc Φ320mm
Thickness of the front brake disc 4.0mm
*Note
Measure them with micrometer.
- 78 -
Measure the thickness of the brake shoes.
If the thickness of the brake disc or the brake shoe is
below the required value for maintenance or it is stained
with grease, please replace it.
5.3.3 Installation
Install the brake disc and the front wheel.
Install the front brake hose assembly and the brake cylinder assembly.
Do not stain shoes and the brake disc with grease.
* Note
Any grease on brake shoes will reduce the brake performance and even lead to failure.
Torque force:
Fixing the front wheel spindle 120N·m
The bolt of the brake disc 28N·m
The fixing bolt of the fuel pump assembly 8N·m
Mounting bolt of the front brake cylinder assembly 50N·m
*Note
• Do not stain the brake assembly with oil spots during installation or disassembly.
• Clean it with required cleaning agent to maintain the brake performance.
- 79 -
5.4 Rear Disc Brake
5.4.1 Disassembly
*Note
Replace the brake shoes assembly.
If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place.
Remove the following assembly off the frame and the rear swinging arm.
Rear disc brake:
(1) Fuel pump assembly
(2) Brake hose assembly
(3) Brake cylinder assembly
(4) Brake discs
Fuel pump
assembly
Fixing screws
- 80 -
Loosen the fixing screws of the brake cylinder assembly.
Remove the brake cylinder assembly off the rear
swinging arm.
Fixing bolt
Brake cylinder
assembly
Fixing screw
5.4.2 Check
Check whether the brake shoes assembly and the brake
disc are abraded. Replace brake shoes if necessary.
Measure the brake shoes and the brake disc. Record
maximum values.
Specification
Diameter of the rear brake disc Φ240mm
Thickness of the rear brake disc 5.0mm
*Note
• Measure with micrometer.
- 81 -
Measure the thickness of the brake shoes.
If the thickness of the brake disc or the brake shoe is
below the required value for maintenance or it is
stained with grease, please replace it.
5.4.3 Installation
Install the rear brake disc.
Install the rear wheel.
Install the brake cylinder.
* Note
Any grease on brake shoes will reduce the brake performance and even lead to failure.
Torque force:
Fixing the rear wheel spindle 120N·m
The bolt of the brake disc 28N·m
The fixing bolt of the fuel pump assembly 8N·
m
Mounting bolt of the rear brake cylinder assembly 50N·m
*Note
• Do not stain the brake assembly with oil spots during installation or disassembly.
• Clean it with required cleaning agent to maintain the brake performance.
- 82 -
Body
*Note:
Do not damage any body part during disassembly.
Do not damage any hook or claw in the body during
disassembly.
Aim panels in the body at each corresponding
groove.
Ensure correct installation of each hook or claw
part during assembly.
Do not damage any part during assembly.
1. right air deflector mounting plate 2. windshield 3. left air deflector mounting plate 4. 5. right front shield 6.
right shield of the tank 7 bottom right shield 8. right shield 9. trim-cover of the right muffler 10. decorative
cover of the right muffler 11. back seat assembly 12. right rear handrail 13. left rear handrail 14. 16. left
assembly of the rear fender 17. right assembly of the rear fender 18. left shield 19. battery box 20. bottom left
shield 21. front seat assembly 22. middle shield of the tank 23. left shield of the tank 24. left front shield 25.
front shield of the tank 26.connecting board of the left/right shield
- 83 -
6. Body
6.1 Disassembly
back seat assembly→ front seat assembly → front shield of the tank→ left shield
of the tank→ right shield of the tank→ left front shield→ right front shield →
rear connecting board of the left/right shield → left rear handrail → right rear
handrail → bottom left shield→ left shield→ bottom right shield → right shield →
trim-cover of the right muffler → decorative cover of the left muffler → trim-cover
of the left muffler → barrel assembly of the muffler → rear fender assembly →
battery box
6.2 Assembly
- 84 -
Front Suspension
Torque for mounting the
fixing bolt 20 of the steering
A
column in the figure:
50-70N·m
Torque for mounting the
fixing bolt 16 of the upper
B
base of the steering handlebar
in the figure: 22-34N·m
Torque for mounting the
fixing bolt 13 of the upper
C
connecting board in the
figure: 22-34N·m
Torque for mounting the
fixing bolt 5 of the front
D
absorber in the figure:
5-10N·m
Torque for mounting the front
E wheel spindle 1 in the figure:
100-140N·m
Torque for mounting the
locking bolt 28 of the head of
F
the front wheel spindle in the
figure: 5-10N·m
1. front wheel spindle 2. bolt M5×0.8×14 3. screw M6×15.2 .4. front right absorber assembly 5. bolt
M6×20 6. screw M5×0.8×12 7. bolt M6×1×14 8. suspension bush 9. mounting base under the
headlamp 10. spacer bush 11. screw M6×1×16 12. mounting base above the headlamp 13. bolt
M8×1.25×25 14. upper connecting board 15. upper base of the steering handlebar 16. bolt M8×1.25×25
17. locking screw of the inner hexagon flat end M4×6 18. pin 19. column 20. fixing screw of the upper
connecting board 21. nut 22. locking nut of the upper connecting board 23. steering bearing 24. screw
M6×8 25. fixing wire clip of the front brake tube 26. bottom connecting board 27 front left absorber
assembly 28. bolt M6×30 29. left spacer bush of the front wheel
- 85 -
Handlebar
1. balance piece assembly 2. throttle lever 3. mounting base of the balance piece 4. front cover of the throttle
cable 5. screw 6. right switch group 7. handlebar 8. left switch group 9. cover of the left handlebar 10.
handle combination of the clutch 11. clutch cable assembly 12. throttle cable assembly I 13. throttle cable
assembly II
- 86 -
Front Wheel
1. bolt M8×16 2. front brake disc 3. bearing 6005-2RS/1-C3 4. middle spacer bush of the front wheel 5. front
rim 6. vacuum tyre 120/70 ZR17 7. front brake disc 8. valve
- 87 -
7. Front Wheel/Handlebar/Front Suspension
Preparing Documents--------------------------7.1
Failure Diagnosis-----------------------------7.2
Front Wheel-----------------------------------7.3
Handlebar--------------------------------------7.4
Front Suspension-----------------------------7.5
Work Instructions
Before removing the front wheel, you should use jack to support the body bottom and suspend the front wheel
which shall not be reversely rotated.
Pay attention that the brake shoes and the brake disc shall not be stained with grease during operation.
A stained brake disc or brake shoe will reduce brake force, so discard stained gasket and clean the brake disc
with quality brake degreaser.
Motorcycle Standards
Standard
Measurement points Item Limit for use (mm)
(mm)
Front wheel spindle Bending 0.2
Rim Vertically 2.0
Front wheel
shimmy Horizontally Within 1.0 2.0
- 88 -
7.2 Failure Diagnosis
7.3.1 Disassembly
Note:
Support the motorcycle firmly.
Bleed nipple
- 90 -
Bleed nipple
- 91 -
Disassemble the front wheel assembly①
Remove the left spindle sleeve of the front wheel②
Note:
Do not operate the brake controlling lever after the removal of the brake caliper.
- 92 -
7.3.2 Check
车轴:axle
- 93 -
7.3.2.4 Check the front wheel bearing
Remove the bearing①, and the middle sleeve of
the front wheel②.
Note:
Replace dismantled bearings with new ones.
Lubricate the bearings with grease during installation.
Then press the bearings in with bearing installation
tools.
*Note
• Bearings must be pressed in horizontally.
游隙 clearance 轴向 axially 径向 radial
7.3.4 Installation
Install it in reverse order.
Note:
Lubricate the front wheel spindle, left spindle sleeve of the front wheel, bearing 6005-2RS/1-C3, and the
middle spindle sleeve.
Albany grease is suggested.
When tighten the front wheel and the caliper assembly of the disc brake, make sure that the brake disc is
between the brake pads.
The free stroke of the front brake lever can not be adjusted.
*Note
Torque of fixing the front wheel spindle: 100-140N· m
- 94 -
7.4 Steering Handlebar
7.4.1 Disassembly
Remove the left/right rearview mirror assembly.
Fixing screw
- 95 -
Remove the left handle assembly.
Remove the left switch group.
Left handle
assembly
Fixing screw
7.4.2 Installation
Note:
Fixing screw of the upper base of the steering handlebar
Torque: 22-34N· m
- 96 -
7.5 Front Fork
7.5.1 Disassembly
Support well the middle bracket of the motorcycle.
Disassemble the front wheel.
Disassemble the brake caliper and the brake pipe clamp.
Remove the steering handlebar.
- 97 -
Tools:
Fixing nut spanner.
Special disassembly tool for bearing cup.
*Note:
The opening of the body guard shall be cleaned with cloth.
The upper/lower bearing cup shall be dismantled with a special disassembly tool for bearing cup.
7.5.3 Installation
Note:
Make sure that the hole of the front wheel spindle is concentric when installing the left and right
absorber.
Note:
Fixing screws for the bottom connecting board: 10N.m
Fixing screws for the upper connecting board: 28N.m
- 98 -
Rear Wheel/Rear Suspension
Tyre size: rear tyre: 180/55 ZR
A
17
Pressure of the rear tyre:
B
290±10kpa
Minimum non-skid depth:
C
2.0mm
Rim run-out limit:
D Vertically: 2.0mm
Horizontally: 2.0mm
Torque for mounting the bolt 2 in
E
the figure: 5-10N·m
Torque for mounting nut 19 in the
F
figure: 37-55N· m
Torque for mounting nut 20 in the
G
figure: 130-150N· m
1. rear wheel spindle 2. screw M6×20 3. right spacer bush of the rear wheel 4. DIA.240 disc brake 5.
bearing 6006-2RS1-3C 6. spacer bush of the rear wheel 7. valve 8. rear rim 9. vacuum tyre 180/55 ZR17 1.
bearing 6006-2RS1-3C 11. buffer bushing 12. left spindle sleeve of the rear wheel 13. bearing 30×62×23.8
14. spindle sleeve of the sprocket wheel 15. fixing bolt of the sprocket wheel 16. sprocket wheel rim 17.
sprocket wheel 18. retaining ring Φ62 19. self-locking bolt M10×1.25 20. self-locking bolt M24×1.5
- 99 -
Rear Suspension/Rear Absorber
Torque for mounting bolt 1
A
in the figure: 70-105 N·
m
Torque for mounting nut
T 10 in the figure: 37-55
N· m
Torque for mounting nut
C 10 in the figure: 37-55
N· m
1. screw 2. mounting sleeve of the rear swinging arm 3. rolling bearing 61905-2RS 4. straight pin 4×8 5.
middle spacer bush 6. mounting sleeve of the rear swinging arm 7. sleeve 8. rear absorber assembly 9.
mounting gasket of the rear absorber 10. fixing spindle of the rear absorber 11. nut M10×1.25 12. supporting
board of the brake clamp 13. rear chain cover 14 bolt M6×8 15. bolt M6×1×14 16. chain protecting block 17
bolt M6×1×14 18 front chain cover 19 bolt M6×1×14 20 fixing spindle of the rear absorber
- 100 -
8. Rear Wheel/Rear Suspension
Chain Drive--------------------------------8.5
Work Instructions
The surface of the disc brake and the brake shoes shall not be stained with oil spots.
Preparing Principles
Item Standard (mm) Limit for use (mm)
Rear wheel Vertically 2.0
shimmy Horizontally 2.0
- 101 -
Abraded or damaged bearings of the swinging arm spindle
Incorrect adjustment of the drive chain
Unbalanced tires and wheels
Too low of the tyre pressure
Bending frame or the rear swinging arm
8.3.1 Disassembly
Support the motorcycle firmly with the rear
wheel above the group.
- 102 -
Caliper of the rear disc brake
Remove the nuts of the rear wheel spindle and left adjusting block of the chain.
Remove the rear wheel spindle and the right adjusting block of the chain.
后轮:rear wheel
后液刹盒:rear disc brake box
固定螺钉:fixing screws
后轮轴:rear wheel spindle
Chain
Big sprocket
wheel
- 103 -
Remove the rear wheel assembly.
- 104 -
8.3.2 Check
When the rear wheel indication goes beyond the limit for
use, the rear wheel bearing is loosened leading to the rear
wheel shimmy. Replace the rear wheel bearing after check.
8.3.3 Installation
Install the rear wheel in reverse order, and lock the nuts.
- 105 -
8.4 Rear Absorber
- 106 -
Fixing bolts
Torque force: 37-55 N·
m
- 107 -
8.5 Chain Drive
8.5.1. Disassembly
Put the motorcycle on level ground, and firmly support it.
Remove the left rear cover.
8.5.2 Check
- 108 -
* Note:
• Measure after stretching the chain by hand.
• Range from chain link roller (1) to the inside of roller (11).
• Measure the length of ten chain links.
• Measure the length of ten chain links of different parts 2-3 times.
- 109 -
Check the drive sprocket and driven sprocket.
8.5.4. Installation
Install it in reverse order.
Fixing nuts
Torque force: 37-55 N·
m
Note:
Adjust the laxation degree of the drive chain and the free stroke of the brake pedal.
If the laxation degree of the chain is too small, engine and other vital parts will be overloaded.
The laxation degree of the chain should be kept within the prescribed limit value.
Arm
Put the motorcycle on level ground, and firmly support it.
Disassemble the rear wheel.
Disassemble the lower fixing nut of the absorber.
Disassemble the bolt and drive chain shade.
- 110 -
Disassemble the rear swinging arm spindle bearing and the
rear swinging arm spindle
Clean the parts of the rear swinging arm mounting spindle Rear swinging arm
in the solvent.
Check the sleeve of the rear swinging arm and the middle
sleeve, if damaged, replace them.
Note:
Bolts for the rear swinging arm spindle
Torque force: 70-105N· m
- 111 -
Fuel Tank
Gasoline capacity of the
A gasoline tank:
15±0.2L
Torque force of bolt 3:
B
5-10N·m
Torque force of bolt 6:
D
5-10N·m
Torque force of bolt 9:
E
5-10N·m
Torque force of bolt 12:
F
5-10N·m
图中螺栓 16 的扭力值:
G
22-37N·m
1.fuel tank body assembly 2.gasket 6.4×12.5×1.6 3.bolt M6×70 4.fuel pump seal gasket 5.fuel pump
assembly 6.petrol pump screw 7.fuel pipe assembly 8.filter assembly 9.bolt M6 10.gasket 5,3×10×1
11.oil level sensor assembly 12.bolt M6×25 bolt M6×25 13. rubber gasket tube 14.fuel tank front
mounting pad 15.fuel tank front mounting board 16.bolt M8×1.25×20 17.fuel tank cover support
assembly 18.fuel tank lock 19.socket head cap screw M5×30 20.socket head cap screw M5×14 21.fuel
tank cover seal gasket
- 112 -
9. Fuel Tank
Work Instructions:
It shall be dismantled far from fire sources.
Tighten all the bolts and screws to the required torque value for assembly.
After assembly, check whether all the parts are correctly installed and operated.
Preparing Principles
Item Standard Limit for use
- 113 -
9.3 Fuel Tank
9.3.1 Disassembly
Remove the rear seat and the front seat
Remove the upper body of the fuel tank.
Fuel pump
- 114 -
Remove the rear fixing bolt of the fuel tank.
9.3.2 Installation
Install it in reverse order.
- 115 -
10. Disassembly and Installation of Engine
Work Instructions
It shall be dismantled far from fire sources.
Tighten all the bolts and screws to the required torque value for assembly.
After assembly, check whether all the parts are correctly installed and operated.
- 116 -
Unscrew the clamp of the engine water pump
inlet/outlet, remove the cooling water-pipe and
exhaust the coolant
Note:
Confirm the left and right limits are set at
positions when installing the front seat.
- 117 -
Disassemble the fuel tank assembly
See 9.3.1 Disassembly of the fuel tank
Note:
The stepper motor of the throttle body should be
set well to position when installing the air filter.
Note:
Confirm the throttle cable assemblyI and throttle
cable assemblyII are set at positions;
Confirm the oil pipe is connected well to place
without oil leakage after the correct installation of
the throttle body assembly.
Confirm the electric components are connected at
positions;
- 118 -
Disassemble the canister assembly
Canister assembly
Battery wire
- 119 -
Disassemble the anterior segment of muffler exhaust
pipe
- 120 -
Disassemble gearshift lever swing arm and the left cover of
the engine
Disassemble the small sprocket and detach the chain from the
sprocket
- 121 -
10.3 Installation of the Engine
Note:
Place an appropriate holder under the frame in case of rollover when disassembling the engine.
Engine fuel: 3.2L when assembling.
Start the engine and check it for abnormal vibration, noise and engine lubrication.
After the engine works properly at idle speed for a period of time, turn the throttle handle to maximum
level, then completely relax the throttle handle, at this time if the idle speed changes, it shows that the
throttle cable hasn’t been regulated well. Therefore, attention should be given to the regulation in this
regard prior to the testing the engine.
- 122 -
Inspection and Maintenance of Engine
- 123 -
11. Lubricating System
Work Instructions:
Clean all parts carefully and blow the parts surface clean with high-pressure gas after disassembly of the fuel
pump.
Foreign matter shall not fall into the crankcase when the carburetor is disassembled
- 124 -
11.3 Fuel Pump
11.3.1 Disassembly
Remove the clutch cover, loosen the fuel pump fixing bolt, take down
the fuel pump drive sprocket and the fuel pump drive chain.
Screw
螺钉
Fuel pump drive sprocket
Screw
Remove the screw, take down the fuel pump cover, and decompose
the fuel pump. Screw
- 125 -
Check the radial clearance between inner and outer rotors
Limit for use: 0.15mm.
Gauge
Check the clearance between outer rotor and fuel pump cover
Limit for use: 0.15mm. Gauge
- 126 -
11.3.2 Assembly of Fuel Pump
As shown below Fuel pump
drive sprocket
Inner rotor
Pump shaft
Note: After the combination, the inner and outer rotors should rotate flexiblely without stagnation.
Installation
Install it in reverse order.
- 127 -
11.3.3 Lubricating Systematic Drawing
Piston cooler
- 128 -
- 129 -
12. Cylinder Head
Work Instructions:
The cylinder cover bears large bolt pretension to ensure sealing between the cylinder head and the upper
cylinder block. Pretension: 12 N·
m, torque force: 60 N· m. All components must be cleaned and dried with
high-pressure air before check.
Standard of benchmark items and table of limit for use Unit: mm
Item Standard Limit for use
Flatness of cylinder cover 0.03 0.05
Intake 013-0.19 __
Valve gap
Exhaust 0.19-0.25 __
Intake 3.97-3.98 3.96
Outer diameter of valve stem
Exhaust 3.97-3.98 3.96
Valve Intake 4.03-4.04 4.07
Inner diameter of valve catheter
Valve catheter Exhaust 4.03-4.04 4.07
Clearance between valve stem Intake 0.05-0.07 0.11
and valve catheter Exhaust 0.05-0.07 0.11
Intake 1.0-1.1 1.5
Width of valve seat
Exhaust 1.0-1.1 1.5
Intake 38.8 37.3
Valve spring Free length
Exhaust 41.6 40.1
Fitting clearance between camshaft and
Camshaft 0.041-0.054 0.08
cylinder head
- 130 -
Burnt or bent valve Damaged valve spring
Poor air-tightness of valve seat Over high compression pressure
Cylinder head gasket leaks gas Too much carbon fouling in the combustion chamber.
Poor installation of spark plug
- 131 -
12.3 Cylinder Head
12.3.1 Disassembly
Remove the ignition coil.
Loosen six locating bolts, remove the gasket and cylinder cover shade.
Cylinder
cover shade
Locating bolt
Fastening bolt
Gauge
- 132 -
Loosen the camshaft holder.
Camshaft holder
Camshaft
Camshaft chain
Camshaft sprocket
Guide chain
plate
Cylinder
cover
Loosen the cylinder cover locking bolt.
Remove the cylinder cover.
Remove the top stem, compress the valve spring with valve
spring compression tools, and remove the valve block.
Remove the valve adjusting gasket, valve spring, valve spring
upper/lower seat and valve.
- 133 -
12.3.2 Cam Assembly Breakdown
Camshaft
Seal cover D13 Bolt
Camshaft sprocket
Valve spring
Valve spring upper seat Valve adjusting
gasket
Ruler
Gauge
Check
Eliminate carbon deposit in the cylinder cover.
Measure the flatness of the joint surface of the cylinder cover.
Limit for use: 0.05mm.
When the flatness of the joint surface of cylinder cover
exceeds the limit for use, place the fine-sand paper on the flat
plate, with the joint surface of cylinder cover fitting the sand
paper, and mill it according to 8-shape.
- 134 -
Vernier calipers
Tester
- 135 -
Screwdriver
- 136 -
12.3.5 Trim of Valve Seating
Remove the rugged or ragged parts of the valve seating Rugged part
surface with a milling cutter at 45°angle.
Note: Coat a transparent or prussian-blue cladding on the
valve seating to get a better view.
25°
60°
45°
- 137 -
If the contact is the part where the valve is too high, please
lower the valve seating with a flat milling cutter at
25°angle. High contact surface
If the contact is the part where the valve is too low, raise
the valve seating with a inner milling cutter at 60°angle. 25°
Refine the valve seating again with a refining milling cutter
at 45°angle to meet the specifications required. Low contact surface
After grinding the valve seating, please coat the polish on
the surface of valve to gently polish the valve.
60°
12.3.6 Installation
Note:
When installing the valve spring, the end with smaller pitch of the spring shall be installed towards the
combustion chamber.
When installing the valve collet, install it by compressing the valve spring with valve spring compression
tools
When installing the valve, the surface of the valve stem shall be coated with proper amount of fuel prior
to installing to the valve catheter.
- 138 -
- 139 -
13. Crankcase
Preparing Documents------------------------------------------------------13.1
Failure Diagnosis-----------------------------------------------------------13.2
Upper Box-------------------------------------------------------------------13.3
Piston------------------------------------------------------------------------13.4
Lower Box------------------------------------------------------------------13.5
Clutch-----------------------------------------------------------------------13.6
Variable Speed Gear Transmission---------------------------------------13.7
Camshaft Connecting Rod Assembly-------------------------------------13.8
The cylinder block in the upper box provides space for gas compression, combustion and expansion, and also
guides piston movement.
It also transfers part of heat energy in the cylinder to cooling medium around.
1. It bears pressure arising from mixed gas combustion inside the cylinder and transfers such pressure to the
connecting rod for driving the crankshaft.
2. It forms combustion chamber along with the cylinder cover.
The crankcase is the load-bearing part of the engine. Its main function is to support the crankshaft, clutch,
gearbox, cylinder block and cylinder cover, sustain combustion shock and inertia force from the movement of
the connecting rod, and form part of closed space (oil sealing, gas sealing).
Suspension holes in the crankcase are linked with suspension holes in the body, which connects the engine to
the frame and other parts.
Work Instructions:
- 140 -
All components must be cleaned and blown with high-pressure gas before test.
The crankcase is thin-section casting thus shall not suffer impact during operation which may cause
deformation or fracture.
Lubricant in the crankcase should be drained out before operation.
- 141 -
Standard of benchmark items and table of limit for use
Limit for
Item Standard
use
Cylinder I 65 (0.025, 0.03) 65.100
Diameter of the cylinder
Cylinder II 65 (0.03, 0.035) 65.110
Cylindricity of the cylinder 0.008 0.050
Roundness of the cylinder 0.006 0.050
Flatness of the cylinder 0.03 0.05
Piston I 65 (-0.03, -0.025) 64.90
Outer diameter of piston (measured in piston skirt)
Piston II 65 (-0.025, -0.02) 64.91
Inner diameter of piston pin hole 16 (0.002, 0.008) 16.04
Outer diameter of piston pin 16(-0.008, 0) 15.96
Clearance between piston pin hole and piston pin 0.002-0.016 0.04
Upper box
Clearance between piston ring Ring 1 0.05-0.09 0.11
and ring groove Ring 2 0.04-0.08 0.11
Ring 1 0.15-0.30 0.5
Joint gap of the piston ring Ring 2 0.25-0.45 0.65
Fuel ring 0.20-0.70 1.0
Inner diameter of the smaller head of connecting rod. 16 (0.016, 0.034) 16.04
Clearance between connecting rod and piston pin 0.016-0.042 —
Thickness 1.5 (0-0.09) 1.48
Connecting-rod Clearance between the
bearing connecting-rod bearing and 0.025-0.05 0.065
crankshaft
Left-right clearance of the larger
0.1-0.25 0.5
end of the connecting rod
Connecting rod
Radial clearance of the larger
0.008-0.016 0.05
end of the connecting rod
Thickness 1.5 (0-0.012) 1.44
Main-shaft
Clearance between main shaft
bearing 0.03-0.05 0.07
and crankshaft
2.8 (-0.05, +0.05) 2.45
Thickness of friction disc
Lower box 3(-0.1, 0) 2.6
Clutch
24.3(-0.15, +0.15) 22.8
Length of pressure spring
23.5(-0.2, +0.2) 22.4
Outer diameter of fork shaft 11.973-11.984 11.96
Diameter of fork inner hole 12-12.018 12.03
Variable
Thickness of fork 5.80-5.90 5.75
speed gear
Outer diameter of gearshift drum 41.9-42.1 41.5
transmission
Width of gearshift drum lock
5.45-5.55 5.65
groove
- 142 -
13.2 Failure Diagnosis
- 143 -
13.3 Upper Box
Upper box
Check
Check the abrasion of the inner wall of the cylinder.
If it is serious, replace it.
Spacer
Locating pin
- 144 -
13.4 Piston
13.4.1 Disassembly
Remove the retainer ring of the piston pin.
Note: during assembly, do not make the retainer ring fall
into the crankcase.
Remove the piston pin and the piston.
Piston pin
Note:
Do not rupture or damage the piston ring.
Eliminate carbon deposit in the groove of the piston ring.
Piston ring
Gauge
- 145 -
Remove the piston ring, and install each piston ring on the
cylinder bottom.
Note:
Press the piston ring into the cylinder with piston head.
Measure the joint gap of the piston ring.
Limit for use: ring 1: 0.5mm.
ring 2: 0.65mm. Piston ring
Gauge
Tester
- 146 -
Measure the outer diameter of the piston I and piston II.
Note:
90°
The measuring point shall be at 90°with the piston pin, and
at the piston skirt.
Limit for use of the piston I: 64.90mm. 11mm
Limit for use of the piston II: 64.91mm.
Tester
- 147 -
Check the flatness of the cylinder surface..
Limit for use: 0.05mm. Ruler
Gauge
Upper box
Tester
Connecting-rod bearing
- 148 -
Measure the clearance between main shaft bearing and crankshaft.
Limit for use: 0.07mm.
Plastic gauge
- 149 -
Remove any residual spacer attached to the crankcase.
Note:
Do not make any object fall into the crankcase.
Install the piston, piston pin and retainer ring.
Note:
The dot mark on the top of the piston shall be installed
towards the intake valve.
Dot mark
- 150 -
13.5 Lower Box
Starter motor
Flywheel assembly
- 151 -
13.5.2 Disassembly of the Clutch Cover
Loosen the fixing bolt, and remove the clutch cover.
Bolt
Clutch cover
Right cover
Remove the fixing bolt, clutch, gearshift arm assembly and fuel pump sprocket.
Remove the spacer and locating pin.
Clutch assembly
Driven gear
- 152 -
Loosen the locking nut with the electric or pneumatic
tool, and remove the clutch.
Loosen the fuel pump screw, and remove the fuel pump
gear.
- 153 -
13.6 Clutch
13.6.1 Disassembly
Unscrew the four bolts of the release plate in diagonally staggered sequence.
Loosen the clutch nut.
Remove the sleeve, bearing, release plate
and the clutch spring.
See the breakdown drawing for the disassembly of parts.
.
Clutch nut
Unscrew the clutch locking nut with the special tool, and remove the locking nut and gasket.
Remove the center holder of clutch.
Remove the clutch disc and friction disc.
Remove the clutch pressure plate.
See the breakdown drawing for the disassembly of
parts.
Remove the spline gasket.
Remove the shell assembly.
Universal holder
Shell assembly
- 154 -
13.6.2 Clutch Breakdown
- 155 -
13.6.3 Check
Check the shell groove for burrs and brakeage, if
trimmed excessively by the file, replace it.
Check the pressure plate and the tooth profile of the
center holder for damage, if damaged, replace it.
Drive hub assembly
Driven hub
Free length
- 156 -
13.7 Gearshift Mechanism
13.7.1 Disassembly
Remove the gearshift shaft assembly.
Remove the bolt and gearshift locating plate.
Remove the bolt, stop arm and spring.
Remove the locating pin.
See the breakdown drawing for the disassembly of
parts.
Gearshift shaft assembly
Pressure plate
Gearshift drum Gearshift drum bearing Ratchet
13.7.2.1 Check
Before the breakage, the gearshift plate should flexibly return without being seized.
Check the gearshift plate and gearshift shaft assembly for abrasion. If heavily abrasive, replace the assembly.
Check the gearshift locating plate for abrasion, If heavily abrasive, replace the assembly.
- 157 -
Check whether the gearshift shaft is bent, if excessively bent, replace it.
Check the return spring for decreasing elasticity, if necessary, replace it.
- 158 -
Loosen the crankcase bolt.
Separate the crankcase. Upper box
Note: Do not damage the spacer and crankcase surface.
Remove the upper box.
Crankcase bolt
Lower box
Countershaft assembly
Loosen the pressure plate bolt, and remove the pressure plate.
Pull the fork shaft.
Remove the gearshift drum.
Remove the gearshift fork.
Gearshift drum
Fork
Fork shaft
- 159 -
13.7.2.2 Check
Measure the outer diameter of the fork shaft. Fork shaft
Micrometer
Limit for use: 11.96mm.
Tester
Vernier calipers
- 160 -
13.8 Crankshaft Connecting Rod Assembly Chamber and Variable
Speed Chamber
Depository for
the main shaft
Depository for the
crankshaft connecting rod Depository for
the countershaft
Gearshift chamber
变档室
- 161 -
Countershaft assembly
Main shaft
assembly
Gearshift drum
assembly
Gearshift arm
Fork shaft
assembly
- 162 -
13.8.1 Crankshaft Connecting Rod Assembly
13.8.1.1 Disassembly
Remove the upper box.
Remove the spacer and locating pin.
Remove the crankshaft connecting rod assembly from the lower box.
- 163 -
13.8.1.2 Check
Measure the left-right clearance of the larger end of the connecting rod.
Limit for use: 0.5mm.
Measure the clearance of the larger end of the connecting rod (X-Y
direction).
Limit for use: 0.05mm.
- 164 -
13.8.1.3 Assembly
Assemble in reverse order of breakdown and disassembly.
Remove the main shaft assembly
Remove the countershaft assembly.
- 165 -
Countershaft assembly
13.8.2.2 Check
Check the abrasion of gear surface and driving-claw point of the gear respectively.
If it is seriously abraded or damaged, replace it.
Gear surface
Check whether the bearing and oil seal are damaged, If yes,
replace it.
Driving claw
Note:
Removed bearing cannot be used any more. It shall be
replaced.
Use special tools to dismantle the bearing and the oil seal.
Note:
Lubricate all gears and shafts with grease when assembling.
Ensure all gears without being seized after assembling.
Note:
Install the crankcase in reverse order.
- 166 -
14. Cooling System
- 167 -
dissipate heat, and transfers heat to the outside air with the help of radiator’s fin.
Water leakage
Damaged seal ring
Broken pump assembly
Broken water pipe
Over high temperature in cylinder block
Damaged blade of the water pump
Blocked water pipe
Damaged cooling fan
Damaged water temperature switch
Disassembly
Loosen the bolt, and remove the water pump sub assembly.
Bolt
- 168 -
Water pump sub assembly
Bolt
Loosen the bolt, and remove the water pump cover.
Check
Check the abrasion of the blade assembly.
If it is serious, replace it.
Note: Don’t damage the spacer and the joint surface of box
during operation.
Installation
Install it in reverse order.
- 169 -
Cooling Systematic Drawing
Reservoir
465 cooling system piping drawing
thermostat
t
Cylinder cover Thermostat
Pressure valve
Oil
cooler
Water direction
- 170 -
Inspection and Maintenance of Exhaust Emission System
1 exhaust pipe gasket assembly 2 screw M8×30 3 gasket 8 4 spring gasket 8 5 muffler assembly 6
muffler buffer rubber 7 muffler decorating panel 8 heat-insulating spacer 9 combined screw M6×10
- 171 -
15. Exhaust Emission & Control System
Measures When the Idle Speed Emission Value Exceeds the Standard ---------15.5
15.1.1 The exhaust emission & control system of this motorcycle is in conformity with the GB 14621-2011,
GB 14622-2007, GB 19758-2005 and GB 20998-2007 standards prescribed by the state. We warrant that the
exhaust emission & control system works normally during its effective period provided that users completely
comply with all operation and maintenance requirements.
15.1.3 This provision is not applicable under any following condition. However, our distributor or service store
would like to provide maintenance or repair services at reasonable prices.
(1) Users fail in periodic maintenance within the required period or kilometers.
(2) Periodic maintenance, adjustment or repair is not carried out at our distributor or service center, or there is
no evidence of maintenance record.
(3) Overload or improper operation.
(4) Refit the motorcycle, remove original parts or replace with other devices in private.
(5) Ride the motorcycle on race tracks or on any non-motorized vehicle lane frequently.
(6) Damage to the motorcycle due to extreme weather such as typhoon or flood, or damage or failure due to
negligence, crash or impact.
(7) Users fail in periodic maintenance since it is out of service for a long time.
(8) The odometer is not repaired immediately after being damaged, or it is refit, stopped, or replaced in
private.
·All new motorcycles delivered by our company have satisfied the noise test and comply with the GB
4569-2005 and GB 16169-2005 standards prescribed by the state.
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15.2 Instructions on Periodic Maintenance
It is the national requirement that all motorcycles produced domestically shall comply with exhaust
emission standards to lessen environmental pollution. We strictly accord with these exhaust emission
standards and also make great effort in purifying air and reducing pollution.
This motorcycle has been strictly examined before delivery and is in conformity with all exhaust emission
standards. We provide the following periodic inspection table for exhaust emission in consideration of
different use by customers. Users shall carry out periodic inspection, adjustment or maintenance
according to the schedule to ensure normal emission.
For any problem, please contact Qianjiang distributors or Qianjiang service center.
Relevant emission provisions are shown as follows:
Emission regulation CO HC NOX
Emission standard ≤2.0g/km ≤0.3g/km 0.15g/km
We are not responsible for any problem due to failure in periodic maintenance at our distributor or service
center. Please carry out necessary inspection to ensure its best condition.
Note: ①Clean the air filter frequently if the motorcycle runs in sandy road or under seriously polluted
condition to extend the service life of the engine.
②Increase maintenance if the motorcycle often runs at high speed or frequently.
General
This system adopts four-stroke single-cylinder engine, EFI and air conduction device to maintain
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qualified exhaust gas. Meanwhile, active carbon canister is used for exhaust gas evaporated from fuel.
※ Engine improvement
As the spark plug, spherical combustion chamber, compression ratio, ignition time, exhaust system and
other engine components are improved, as well as the intake/exhaust efficiency is enhanced, the combustion
efficiency is raised.
15.4.1 Structure:
触媒:Catalytic
15.4.2 Instruction:
(1) Function of transfer catalyst is to transfer completely burnt HC, CO and NOX to harmless gas such as H2O,
CO2、and、N2 for discharge.
(2) Transfer catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used.
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※ Note that lead gasoline may invalidate catalyst.
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15.5 Measures When the Idle Speed Emission Value Exceeds the
Standard
Qualified
Qualified
Measure idle emission (note 1)
Qualified
Adjust Carburetor (note2)
Qualified
Replace the carburetor
Notes:
1. Measure it with the idle speed measurement program.
2. Adjust the engine speed with stop screws to live up to requirements and measure CO/HC at the idle speed.
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Inspection and Maintenance of Electronic Fuel
Injection (EFI) System
- 177 -
16. Electronic Fuel Injection System
RK6 adopts the small-scale engine electronic fuel injection system manufactured by Delphi Company, which
is controlled with four oxygen sensors within a closed loop. Besides, it is equipped with four-cylinder
independent fuel injection and ignition control functions. The three-way catalytic converter would go through
treatment with the gas after combustion in the engine, turn it into harmless gas and discharge it into the air.
This system adopts the closed-loop independent function that can efficiently eliminate the manufacturing
differences within the system and the other corresponding components, highly improving the integrity of the
motorcycle, which can also reduce the deviations of the motorcycle after a some time of actual using.
The engine controller can test the operation conditions of the engine with various sensors at any time and
guarantee the emission and economy of fuel by proper computing and self-study control output mechanism
with the driving performance optimized. Once failures are found within the engine, the control would go
through automatic diagnosis. The normal working of the system requires two ECU.
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16.2.1.1 ECU Appearance
ECU 12 is located on the left of battery and ECU 34 is behind the battery.
1) ECU 12:
J1-1 J2-1 Pin for activating 1-cylinder ignition coil
J1-3 Pin for trouble light J2-3 Pin for K line communication
Pin for signal 2-cylinder oxygen Pin for activating 1-cylinder fuel injector
J1-5 J2-5
sensor
J1-6 Connector pin for tachometer J2-6 Pin for activating 2-cylinder fuel injector
J1-7 CAN line low signal 1 pin J2-7 Pin for heating 1-cylinder oxygen sensor
J1-8 CAN line high signal 1 pin J2-8 Pin for intake temperature sensor signal
Pin for activating 2-cylinder ignition Pin for 5V system reference voltage grounding
J1-10 J2-10
coil
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J1-14 Dump switch (efficient at low) J2-14 Signal pin for water temperature sensor
J1-16 J2-16
J1-18 Pin for neutral gear switch J2-18 Battery power supply (battery 12V positive voltage)
Remarks:
J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey
connector.
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2) ECU34:
J1-1 Idle speed stepper motor high A pin J2-1 Pin for activating 4-cylinder ignition coil
J1-2 Canister solenoid valve pin J2-2 Pin for system grounding
J1-3 Pin for trouble light J2-3 Pin for K line communication
Pin for signal 3-cylinder oxygen Pin for activating 4-cylinder fuel injector
J1-5 J2-5
sensor
J1-7 CAN line low signal 2 pin J2-7 Pin for heating 4- cylinder oxygen sensor
J1-8 CAN line high signal 2 pin J2-8 Pin for intake temperature sensor signal
J1-9 Pin for system grounding J2-9 Pin for oil pump control signal
Pin for activating 3-cylinder ignition
J1-10 J2-10 Pin for 5V system reference voltage grounding
coil
J1-11 Idle speed stepper motor low A pin J2-11 Pin for intake pressure sensor signal
J1-12 Idle speed stepper motor high B pin J2-12 Pin for throttle position sensor signal
J1-13 Idle speed stepper motor low B pin J2-13 Pin for crank signal low potential
J1-14 Dump switch (efficient at low) J2-14 Signal pin for water temperature sensor
J1-15 Pin for vehicle speed sensor J2-15 Ignition power (12V positive voltage after key)
J1-18 Pin for neutral gear switch J2-18 Battery power supply (battery 12V positive voltage)
Remarks:
J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey
connector.
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16.2.1.3 Circuit Diagram of Electronic Injection System
Notes:
a) Keep ECU away from places of high temperature, like muffler or engine;
a) Keep ECU away from water, engine oil or any places of liquid;
b) Keep ECU away from mud or other dirt that would affect the heat dissipation function of ECU;
c) Connect with M8 bolts and make sure the tightening torque is around 3.9Nm, keep the surface neat to
prevent outside force to ECU in case of circuit board bending;
d) The DC power supply voltage of ECU of normal working is between 9V and 16V. when it's working
under a voltage not over 26V for one minute, permanent damage would not happen to ECU, neither when the
backward voltage is not over 13V.
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16.2.2 Fuel Injector
The fuel injector is designed with magnet coil surrounding iron core inside. Two electrodes from magnet
coil are input control connectors of the fuel injector. When magnet coil is energizing, electromagnetic
attraction generated by magnet coil will conquer spring force and fuel oil pressure of ball valve to uplift the
ball valve. Then high pressured fuel oil (250Kpa) in fuel pipes can inject cone-shaped fuel oil to the air inlet
through value seat hole and orifice plate. After power of the fuel injector, magnetic force of the magnet coil
will automatically disappear. The ball valve closes by the action of return spring and fuel injection stops.
16.2.2.2 Appearance:
注意事项:
Fuel injector is designed with a filter which is not a repairable component because it is designed for only
filtering impurities between fuel filter to fuel injector. The impurities may cause failures such as injector
bonding, flow deviation and leakage. Thus, fuel filter system is very important.
Replace the fuel injector with parts of the same models.
- 183 -
16.2.3 Throttle Body
The throttle body assembly is comprised of the main casting valve body, return spring, throttle position
sensor system and idle adjusting screws.
Throttle position sensor system offers accelerograph opening for ECU; idle adjusting screws controls and
idle speed and the stability by clockwise reducing the ventilation to lower the idle speed and anticlockwise
increasing the ventilation to higher the idle speed, which is normally required around 2 circles.
16.2.3.2 Appearance:
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16.2.3.3 Cleaning
Clean the throttle body assembly with carburetor cleanser by spraying it on the inner wall of the throttle
body and brush the dusts and carbons away gently.
Notice:
Make sure the side channel is not blocked by the dirty.
This sensor is used on the air cooled engine for measuring the engine cylinder head temperature. Within
the temperature scope of the sensor, the electric resistance would vary with different temperature of the engine,
which is a negative temperature coefficient resister. It is a not a repairable part.
- 185 -
16.2.4.2 Appearance
It is used for measuring the temperature of the intake air. Within the temperature scope of the sensor, the
electric resistance would vary with different temperatures of the engine, which is a negative temperature
coefficient resister. The intake air temperature sensor is not a repairable part.
16.2.5.2 Appearance
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16.2.6 Intake Pressure Sensor
This sensor is mainly used for measuring the absolute pressure of the intake bend tube, which, in
compliance with the change between the resistance value and the intake pressure, can measure the air input of
the engine's combustion chamber indirectly.
16.2.6.1 Appearance
Oxygen sensor is mainly used for measuring the oxygen content within the exhaust pipe of combustion
engine and for the fuel closed loop controlling in the engines, which can make sure the combustion of the
engine is maintained at a reasonable air-gasoline ratio (14.7).
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16.2.7.2 Appearance
The ignition coil can provide energy to the spark plug. The high voltage wire is used to connect the
ignition coil and the spark plug.
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16.2.8.1 Appearance
The idle speed control valve is used to control the ventilation circulation area aside the throttle body so as
to adjust the intake air to the engine, realizing controlling of the idle speed of the engine.
- 189 -
16.2.9.1 Appearance
The electric pump would work together with the pressure regulator to provide 250Kpa fuel pressure for
the engine. It is installed under the gasoline tank.
16.2.10.2 Appearance
- 190 -
Back side:
Front side:
a) Turn on the key and run the fuel pump for about 3 seconds. If the fuel pump starts to run, refer to
step d).
b) Cut off the connector of the fuel pump and check whether the power supply voltage is 12V or so.
c) If there is nothing wrong with the second step, supply 12V DC to the fuel pump with an external
storage battery. Check whether the fuel pump runs or not.
- 191 -
d) If the fuel pump runs normally, check the oil pressure gauge to see whether the front supply pressure
of the nozzle is about 250Kpa when the engine is idling.
e) If the pipe pressure is lower than 220Kpa, check if there is a leakage in the oil pipe, if the fuel pump
runs backwards, or if the filter is blocked.
a) The reverse connection of the connector of the fuel pump assembly causes the fuel pump run
backwards, thus leading to inadequate fuel pressure for the engine. As a result, the engine
cannot work normally.
b) The fuel pump is damaged and cannot run.
Note:
1. Since a new motorcycle has no gasoline in its fuel tank at the very beginning, much air remains in the
fuel line after the tank is fueled up. Therefore, it is necessary to turn the motor over for several times to
discharge all the air in the fuel line so that the engine can operate normally. This is a normal process,
which will avoid the engine from taking a long time to start but still in failure in the later startup.
2. The gasoline can cool down the fuel pump, so do no run the pump with little or no fuel, or the fuel
pump will be overheated and damaged.
The trouble light is on the instrument panel, with a sign of FI down blew. In a normal circumstance, when
turning on the key, the trouble light will turn on to indicate the electronic control injection system is power-on
and is ready to work. If the trouble light is off, it indicates that there is no power supply in the electronic
control injection circuit and thus it cannot work. In this case, check the fuse and the connection of both
positive and negative electrodes of the storage battery. After the engine has been started, if the trouble light
turns off, it indicates that there is no fault; otherwise, if the trouble light is still on, it indicates that the
electronic control injection system is abnormal and it is necessary to remove the faults.
When any fault is confirmed, by switching the key for three times, i.e., turning the key on-off-on-off-on,
the trouble light will flash in corresponding fault code. Then check the fault code list for the breakdown in
correspondence.
In case of reading faults with the trouble light, the rules of flash codes are illustrated as below. Take the
open circuit of intake pressure sensor or short circuit of signal end pin to the negative electrode of the battery
as an example, after the key has been switched for three times, the trouble light will flash 10 times standing for
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0, flash once after 1.2 seconds standing for 1, flash 10 times after another 1.2 seconds standing for 0 and flash
7 times after another 1.2 seconds standing for 7, that is P0107. It shows that, except the number 0 is
represented by flashing for 10 times, other numbers from 1 to 9 will flash as the number itself shows. If there
are other fault codes, such as fault P0201, a fault in the fuel injector of front cylinder, the light of fault code
P0201 will flash in 3.2 seconds after the flashing of P0107. The trouble lights of P0107 and P0201 will flash
circularly in case of no other fault. Then faults can be checked according to the fault code list.
Decimal number will be adopted to show the fault code in PCHUD software. The decimal number in the fault
code list is corresponded to the previous hexadecimal, thus faults can be found out in correspondence. If
MULFCURR (current fault) =263, the corresponding fault code in the fault code list is P0107, i.e., a fault of
intake pressure sensor.
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MT05 Fault Code List
Corresponding
Fault code Description decimal number
open circuit of intake pressure sensor or short circuit of signal end
P0107 pin to the negative electrode of the battery 263
short circuit of signal end pin of the intake pressure sensor to the
P0108 positive electrode of the battery 264
short circuit of signal end pin of the intake temperature sensor to
P0112 the negative electrode of the battery 274
open circuit of intake temperature sensor or short circuit of signal
P0113 end pin to the positive electrode of the battery 275
short circuit of signal end pin of the cylinder end temperature
P0117 sensor to the negative electrode of the battery 279
open circuit of cylinder end temperature sensor or short circuit of
P0118 signal end pin to the positive electrode of the battery 280
open circuit of throttle position sensor or short circuit of signal
P0122 end pin to the negative electrode of the battery 290
short circuit of signal end pin of the throttle position sensor to the
P0123 positive electrode of the battery 291
short circuit of signal end pin of the front cylinder oxygen sensor
P0131 to the negative electrode of the battery 305
short circuit of signal end pin of the front cylinder oxygen sensor
P0132 to the positive electrode of the battery 306
short circuit of heating end pin of the front cylinder oxygen sensor
P0031 to the negative electrode of the battery 50
short circuit of heating end pin of the front cylinder oxygen sensor
P0032 to the positive electrode of the battery 49
P0201 fault of for fuel injector front cylinder 513
fault of for fuel injector rear cylinder (plug-in device of the fuel
P0202 injector is not plugged) 514
open circuit of oil pump or short circuit to the negative electrode
P0230 of the battery 560
P0232 short circuit of oil pump to the positive electrode of the battery 562
P0336 signal interference of crank shaft position sensor 822
P0337 no signal of crank shaft position sensor 823
P0351 fault of ignition coil for front cylinder 849
P0352 fault of ignition coil for rear cylinder 850
P0562 voltage below level of electronic control injection system 1378
P0563 overtension of electronic control injection system 1379
P0560 fault of trouble light (damage of filament or plug-in device) 1616
P1693 short circuit of tachometer line to the negative electrode of the 5779
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battery
short circuit of tachometer line to the positive electrode of the
P1694 battery 5780
short circuit of signal end pin of the rear cylinder oxygen sensor
P0137 to the negative electrode of the battery 311
short circuit of signal end pin of the rear cylinder oxygen sensor
P0138 to the positive electrode of the battery 312
short circuit of heating end pin of the rear cylinder oxygen sensor
P0038 to the positive electrode of the battery 56
short circuit of heating end pin of the rear cylinder oxygen sensor
P0037 to the negative electrode of the battery 55
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16.3.2 Fault Diagnosis by Diagnostic Apparatus
Operation steps:
a) Find the 6-hole diagnostic port on the motorcycle.
b) Connect the connecting line to the port on the diagnostic apparatus.
c) Turn on the key to diagnose the faults.
PCHUD software is used to inspect and record the operating data of the engine. Before using the software,
connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line. The notebook
computer needs to install the K line driver software before using.
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Instructions of PCHUD Software:
(1)Connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line and turn on
the key.
(2)Click the icon "HUD.EXE" to start PCHUD software
(3)Select "File" on the software interface, click "Open", choose "PCHUD.HAD" and select OK.
(4)Select "Parameter File" within "Setup", click the file MT05COMMON.par, choose "Comm protocol"
within "Setup", then select "Keywork2000" and click OK, meanwhile, choose 17 in Device Code.
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(5)If the real-time communication data fail to display on the soft ware interface when the power is on, check
whether the connection setting of COM port in "Setup". Under the normal circumstance, set COM Port: 4 and
Baud Rate: 10400, instead of DTR High at startup.
Normal communication is ready to make then. Current fault code is displayed in the position of MALFCURR
and historical fault code displayed on MALFHIST.
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Then check the corresponding fault according to the fault code list
- 199 -
Interpretation of PCHUD Software Parameter
VRPM 发动机转速 engine speed
- 200 -
FOSHTREN 氧传感器加热使能 Oxygen sensor heater enable
IF IACV MODE=0 怠速步进电机闭环学习使能 idle airflow control valve close loop correction enable
- 201 -
16.4 Common Fault Removal Techniques
a) Disassembling the parts of the electronic control system- common disassembly tools for auto machinery
parts
b) Circuit of the electronic control system and its electrical signal- digital multimeter (with beep)
c) Diagnosing the faults in the electronic control system and checking the engine's operation
Fault diagnostic apparatus for electronic control system(recommended)
Fault diagnosis software(PCHUD) and port wire( if available)
d) Fault code list of the electronic control system( for emergency)
e) Fuel pressure gauge, range: 0 ~ 300kPa
Analyze and check the faults in engine through the operation data flow of the engine shown on the
diagnostic apparatus.
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16.4.2.1 Step One
a) Engine wire harness and vacuum line- may influence the system in controlling air flow and oil supply.
b) Assembly of Oxygen sensor- may influence the system in judging the air-fuel ratio.
c) Engine trouble light- influences the system in fault warning.
d) Storage battery voltage- judges whether the battery power is adequate.
e) According to the experience, judge whether the readings of coolant temperature sensor, air intake
temperature sensor, manifold absolute pressure sensor and oxygen sensor are normal.
f) Working range of throttle position sensor- Failure in completely turning on or off the sensor may
influence the power performance of the engine and part of system function.
Check whether the power supply of ECU is cut off- the communication between the diagnostic apparatus
and the system halts after turning off the key switch.
a) Coolant temperature and its cycling- indicate whether the thermostat operates normally.
b) Storage battery voltage- shows whether the generator works normally.
Too high: maybe a fault in the generator regulator.
Too low:maybe the inappropriate connection of generator wires or a fault in the generator
c) Manifold air pressure- may indicate whether there is an intake air leak or an air valve clearance
The air valve clearance is too small: the overhigh figure may influence the power performance of the
engine. Meanwhile, because the exhaust valve opens too early, the increased temperature of the exhausted
air will significantly reduce the service lives of oxygen sensor and ternary catalytic converter.
The air valve clearance is too large: may cause the manifold air pressure become low, thus influencing the
system in judging the engine's operation and leading to abnormal idling in the engine's warming-up.
Besides, the clogged exhaust system, e.g., foreign materials in the exhaust passage, or the blocked ternary
catalytic converter caused by the over-consumption of the engine oil, or damaged pieces inside of the
ternary catalytic converter, will lead to an overhigh figure.
d) Cycle number of the oxygen sensor reading- a small cycle number indicates the failure of the oxygen
sensor.
Please take the following steps to repair the electronic control injection system. If the fault is removed in
a certain step, the following steps can be suspended. Then check and remove the fault code by diagnostic
apparatus in compliance with the term 14.4.2.
- 203 -
When using the diagnostic apparatus, the storage battery voltage cannot be lower than 8.5V.
a) Turn the ignition lock to "ON" to check whether the trouble light turns on.
If no: Check the fuse and the ground wire.
Check whether ECU's plug is tightly connected.
Check whether the light and circuit are normal through the inspection function of the
diagnostic apparatus's actuator.
Check and repair the light and its circuit.
Make the judgment with another ECU.
If yes: Connect the diagnostic apparatus to the system's diagnostic port.
b) Whether the diagnostic apparatus can be connected to the system for communication
If no: Check the fuse and the ground wire
Check whether ECU's plug is tightly connected
Check whether the diagnostic apparatus works normally on another normal motorcycle.
Make the judgment with another ECU.
If yes: Remove the fault shown by the diagnostic apparatus.
c) Check the faults in the ignition system- whether the spark plug can ignite normally
If no: Check whether the high-tension cable and spark plug are connected tightly or are damaged.
Make the judgment with another ignition coil assembly
Make the judgment with another ECU.
If yes: Check whether the high-tension cable is connected with the ignition coil and spark plug in a
correct way
d) Check the faults in the oil supply system
Whether the fuel pump is working- the working noise of the fuel pump can be heard in its nearby when
starting the engine.
If no: Check whether the fuel pump relay works normally.
Check whether the connection of crankshaft position sensor and its operation are normal.
Make the judgment with another ECU.
Check the fuel pump circuit
If yes: 1) Whether the supplied oil pressure is above 220Kpa
2) Inadequate Check whether there is enough gasoline in the fuel tank
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pressure: Check whether it is necessary to replace the fuel filter (note: the special
fuel filter for the electronic control injector should be replaced every
7,000-10,000km)
Whether the oil supply line and oil return line are damaged
3) Normal Check whether the nozzle control line is abnormal
pressure: Whether it is necessary to clean the oil nozzle
e) Check whether the cylinder is flooded with oil
If yes: Press the accelerator pedal to the limit and turn on the starter. After several seconds, there
will be a sign showing the engine running.
f) Whether the clearance of crankshaft position sensor is too large
Idle speed control Check whether the idle speed by-pass bolt is too loose or tight. Usually it is necessary to
system: screw 2 turns.
Oil supply system Whether there is an oil pipeline leak
Idle speed When the water temperature is lower than 68℃, the system will increase the idle speed to
is too high: accelerate the warming up. Besides this normal process, check according to the following
steps.
Check whether the idle air bypass hole is too large.
Check whether the air valve clearance, especially the exhaust valve clearance, is too
large.
Idle speed Check the oil amount in the fuel tank, the fuel filter, the oil line pressure and the oil
is too low: nozzle.
Check whether the idle air bypass hole is too tiny.
Check whether the air valve clearance is too small.
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16.4.3.6 Fault Description- Unstable Idle Speed Slowing Down with Flameout
a) Whether the parameters at idle speed and high idle speed are normal
b) Check the oil amount in the fuel tank, and fuel filter.
c) Check whether the exhaust system is blocked, e.g., whether the ternary catalytic converter is clogged
because of burning engine oil or damages.
d) Check the oil line pressure and the oil nozzle.
e) Check whether the trouble light turns on and whether it is because only one cylinder can work normally
to ignite.
Check whether the spark plug gap meets the standard between 0.7-1mm.
The ground wire of the system may be not connected well. Reconnect the ground wire, turn off the
storage battery power line for 3 minutes and turn it on, then start the engine.
a) Check the assembly of the oxygen sensor of two cylinders. If it is in a loose state, the oxygen sensor will
make a wrong judgment of the slight lean burn in the cylinders, and thus add more fuel, leading to
abnormally high oil consumption.
b) When the engine's mechanical parts and the oxygen sensor are confirmed to be normal, start the engine to
check the reading of the oxygen sensor. If the reading is always above 500 mV in a normal water
temperature, check whether there is a leakage in the oil nozzle.
Note
Most parts of electronic control injection system are non-repairable. Once a part is damaged, usually it
needs to be replaced.
When starting the engine, do not run any other organs of the engine (including the throttle, do not push
the throttle in the startup).
- 206 -
If the engine trouble light turns on when the engine is operating, it is necessary to check the reason and
remove the fault as early as possible.
Do not use leaded gasoline for lead will do harm to the oxygen sensor and ternary catalytic converter.
When there is an abnormal consumption of the engine oil, the fault should be removed as soon as possible,
or some substances in the engine oil will also do harm to the oxygen sensor and ternary catalytic
converter.
The air valve clearance should not be too small. If the air valve does not tightly shut off in the exhaust
process, the exhaust temperature will be too high so that the service life of ternary catalytic converter will
be reduced.
When the temperature is lower than 10℃, if the motorcycle and the engine run at a low speed for a long
time, the exhaust pipe may have carbon deposits and appear to be black. This is a normal phenomenon. It
will disappear after the engine operates at a high speed for some time or by adopting appropriate methods
to keep the engine coolant temperature in a specified range
- 207 -
RK6 Circuit Diagram
怠速控制阀
黄/紫 灰/白
白/黄 白/黑
前刹车开关
保险盒 后刹车开关 闪光器 边撑熄火
警示灯二极管
电门锁 左把手 右把手
灯光 燃油泵 风扇 ECU1 电源锁 启动继电器 电瓶正极
ECU2
IN5408 2# Gr ECU J1 2#BLACK ECU J2
10A 10A 15A 15A 10A 15A
保险丝
30A 红/绿
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 黑/橙 节气门传感器
红/白
仪表 马
左 右 右 左
黑/蓝
绿绿 红橙
紫
电瓶正极 绿 橙绿
左 右 右 左
蓝 红红 红 粉绿红 红
达
绿 橙 橙绿 黑 绿 紫 橙 黑 橙
红/白/ / / / 黑
红
红1 / 红1 / / 粉 / 红 / 粉 红 黄 淡蓝黄 绿红 / / / / / / /
/ 红 红 / / 绿 绿棕红 / 绿 棕1
橙 棕
红 红 红 / 红 / 蓝 / / / 蓝黄 黑1白1 白 白 黄
黄 蓝 黄 黄 红 /
白/ 黄
/ / 白 白 蓝黑
红 红 黑白
红 白 白 白
黑/红2
橙/黄 灰/白 黄/紫 灰/红1 橙/红 白/紫 白/橙 黑/蓝 黑/橙 黄/蓝 红/绿 红/黄 黑/黄2
棕/黑 黄/蓝 棕/蓝 黑 橙/绿 黑 蓝/白 黄/绿 3缸氧传感器
白/黑 黑/橙1 棕/红 黑/白 白/黄 蓝/橙 红/灰 白/绿 绿 白/灰 黄/蓝2
黑/黄 红/紫 白/红
灰 黑/蓝
粉红/蓝
绿/蓝
棕/ 灰
红
粉红
白/蓝 绿/黑1 墨绿 灰/红 黑 红/白
/
浅蓝
白 绿/白1
机油开关 棕/白 蓝 红/紫1 棕/黑 橙/黑
黑/红2
碳罐电磁阀
空档 灰 粉红/蓝
橙/红
启动二极管 绿/白 右转向灯
灰 橙/白
绿/白 绿/黑
右转向 左转向灯
橙/白 橙
黑
淡蓝 黑
前大灯 黄 黄 后尾灯
蓝
紫
绿/黑 黄
左转向 橙 牌照灯灯
黑
黑 红/紫
棕/红
诊断仪
离合器开关 棕/蓝
红/黄
黑
橙/红
黑/红2
黑 黄/绿2
4缸氧传感器
白/灰2
喇叭 黑/蓝
黑/蓝
红/灰2 进气压力传感器
红/白
红/绿
风扇继电器 棕/浅绿
红/棕
棕/绿
黑/红2
红/白
白/紫2
大灯继电器 蓝/绿
蓝/黄
喷油器
黄/红
绿/蓝 黑 /红2
白/红2
油泵继电器 黑/红2
红/橙
红/黑
黑 黑/红2
电喷控制继电器2 黑
绿
红/黄 黑/白2
黑/红2
点火线圈
黑 黑/红2
电喷控制继电器1 黑
绿
橙/绿2
红/蓝
黑/红1
红/白
白/橙2
主继电器1 橙/黄 进气温度
红/白 黑/蓝
黑/棕1
红/紫1
红/紫
诊断仪
棕/红1
棕/蓝1
墨绿
红/蓝
棕/黑 黄/蓝1 棕/蓝 黑 蓝/橙 白/红 白/橙 黑/蓝 白/棕 红/绿 红/蓝
蓝/绿 黑/黄 橙/黑 棕/红 橙/绿 黑/橙1 黑/白 黑 蓝/白
橙/红 红/紫 白/紫 黄/绿 红/灰 白/绿 绿 白/灰
电瓶正极
红 红黑 黑 白黄 黑 白蓝 白 黑
黑黑黑黄
黑
红/黑
红 黑 蓝 黑黑黄 白 黑 黑 橙 黑 黑 黑 黑 白 黑 白 墨灰 红 / / / / / / / / / / /
/ / / / / / / / / / / / / / / / / / / 绿/ / 绿1 灰1蓝 蓝 灰1绿1 红1 绿白 橙1 蓝
白 蓝 橙 蓝蓝蓝 棕 红1 绿1 红1 白1 红1 红1 红1 紫1 红1黄 蓝 蓝1 红 浅蓝
白3 白2 白1 电瓶负极
棕 白1白2 白3 黑 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
棕 黑 墨绿 白
/ 黑
/ / 1#Gr ECU J1 1#BLACK ECU J2
浅
绿 蓝
绿 防侧翻传感器 燃油泵 进气压力传感器 1缸氧传感器 触发头 进气温度
2缸氧传感器 速度传感器
水温传感器
103
℃
点火线圈
水温开关 风扇 油位传感器
喷油器