Royal Alloy GP125S Maintenance Manual
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Royal Alloy GP125S Maintenance Manual

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  • Page 3 Dear users: Thank you for choosing your Royal Alloy GP125S/GP200Sscooter. In order to make you drive more safe and comfortable, please read carefully and fully understand the contents of this manual. This manual explains the main information, such as the structure, characteristic, basic inspection and maintenance, and the structure and maintenance of EFI etc for your scooter, so that you can carry out regular maintenance operations on your vehicle.

  • Page 4: Table Of Contents

    Contents CHARACTERISTICS................................4 TOOLING....................................18 ELECTRICAL SYSTEM..............................54 REMOVE ENGINE FROM VEHICLE..........................61 ENGINE DISASSEMBLY..............................83 EFI SYSTEM..................................122 BRAKING SYSTEM................................145 COOLING SYSTEM................................160 FINAL INSPECTION................................. 165...

  • Page 5: Characteristics

    CHARACTERISTICS Maintenance rules Vehicle identification Specifications Transmission system description Lubrication system description Fuel system description Cooling system description Chassis and suspensions system Front and Rear wheel description Braking system description Electrical system description Tightening torque...
  • Page 6 Maintenance rules 1. Use the spare parts and lubricants of our company or recommended by our company, the spare parts and lubricants that are not in conformity with the design specifications of our company may damage the motorcycle. Recommended brand model: MOTOREX scooter semi synthetic 4 stroke SAE 10W/40. 2.

  • Page 7: Vehicle Identification

    Vehicle identification Chassis number is stamped on the frame right side frame rail. Engine number is stamped on the rear of the crankcase assembly.

  • Page 8: Specifications

    CAUTION These numbers are necessary for vehicle registration identification, and changing the identification number may be severely punished by the law, especially if the revision of the chassis number will be invalid even if the warranty is invalid Specifications Vehicle data Engine data GP125S 1P58MI(125CC) Model Engine model GP200S 1P63ML-4(200CC) 1900±100rpm...
  • Page 9 58*47(125CC) Saddle height (mm) Bore × stroke (mm) 63*58(200CC) Minimum ground 124.2(125CC) Total displacement (mL) clearance (mm) 181(200CC) 12±0.5:1(125CC) Net weight (kg) Compression ration 11.6±0.5:1(200CC) 10/8000(125CC) Max net power, rate Max loading weight (kg) (kW/r/min) 13/8250(200CC) 12/7500(125CC) Max net torque, rate Fuel tank capacity (L) 10.5 (Nm/r/min)
  • Page 10 Exhaust:0.20～0.25 Rear brake Disc brake Lubrication type Pressure/splash Battery capacity 12V 9Ah Spark plug NGK PMR9B Automatic centrifugal dry Horn 90-100dB(A) Clutch clutch Variator Continuous, automatic Transmission system description Item Standard Transmission CVT with V belt + final reduction unit 2.9～0.89:1(125) CVT ratio 2.4～0.86:1(200)
  • Page 11 Lubrication system description Item Standard Change Engine oil 900ml Engine oil 1000ml Brand name: APL SJ Change Engine 950ml SAE10W-40 engine oil filter Dismantle engine, inject oil 1000ml Change transmission oil 180ml Transmission oil 200ml Brand name: 75W-80 Dismantle engine, inject oil 200ml Fuel system description Item...
  • Page 12 Cooling system description Item description Coolant liquid When change 1.15L capacity When dismantle 1.20L The coolant or the same quality ethylene glycol antifreeze Recommended antifreeze is mixed with distilled water according to 1:1. The freezing point reaches -40℃ and boiling point to 108℃. Chassis and suspensions system Item Standard...
  • Page 13 Front suspension travel 104mm Rear suspension Hydraulic double-acting shock absorber and adjustable preloading Rear suspension travel 80mm Front and Rear wheel description Item Standard Wheel Rims material Aluminium alloy Front tyre Tubeless 110/70-12 Rear tyre Tubeless 120/70-12 Front tyre inflation pressure 32/220(Psi/kPa) Rear tyre inflation pressure 34/234(Psi/kPa)
  • Page 14 Braking system description Item Standard Braking system Front brake Ø220mm disc brake with hydraulic transmission Rear brake Ø220mm disc brake with hydraulic transmission Brake fluid FMVSS DOT4+ Electrical system description Item Standard Battery capacity 12V-9Ah Fuses 20-15-15-15A (Permanent-magnet) Alternator 12 V - 330W at 8000 rpm Spark plug NGK PMR9B...
  • Page 15 Bulbs/ High-/low-beam bulb Square lamp:12V 35/35W warning Round lamp:LED lights Front position lamp Tail light bulb License plate light bulb Brake lamp Front and rear turn indicator bulbs Speedometer Instrument panel lighting bulb Turn indicator warning light High-beam warning light Engine oil pressure warning light Low fuel warning light EFI check warning light...

  • Page 16: Tightening Torque

    Tightening torque Vehicle part: Fastening parts Number Thread specification Torque Nm Nut fixing engine hanger Nut fixing engine Front wheel axle nut Rear wheel axle nut Upper screw fixing rear shock absorber Lower screw fixing rear shock absorber Upper screw fixing front shock absorber Lower screw fixing front shock absorber...
  • Page 17 Locking nut fixing direction column Nut fixing handlebar Screw fixing front brake disc Fastening bolt fixing rear wheel Screw fixing rear brake disc Reference bolts for other specifications: GB1231-2006 bolt torque standard Engine part: Fastening parts Number Thread specification Torque Nm Cylinder head screw A 24～26 Cylinder head screw B...
  • Page 18 Combined box screw 9～12 Intake manifold fixing screw 9～12 Crankcase oil releasing screw 33～38 Gear box oil releasing screw 23～27 Pressure regulating valve screw 33～38 Front clutch nut 70～80 Rear clutch nut 55～65 Generator rotor fixing screw 23～27 Water temperature sensor 20～24 Spark plug 9～11...

  • Page 19: Tooling

    TOOLING Special tools (The following tools are restricted to professional technicians only,consumers must not operate without authorization) Name Tool number Picture Valve spring compressor Threaded bolt for locking crankshaft at...
  • Page 20 Clutch driving wheel locator Shaft bearing punch Z06.1---Z06 Oil seal punch Z07.1--Z07.
  • Page 21 Flywheel extractor Spark plug sleeve Fault diagnosis instrument Shock absorber adjusts handle...
  • Page 22 2. General tools Name Picture “T” sleeve: 8#. 10#. 12#. 14# Tool case 1...
  • Page 23 Tool case 2 Spring pliers Screwdriver...
  • Page 24 Pliers Nylon hammer Multimeter...
  • Page 25 MAINTENANCE Precautions for Maintenance Maintenance cycle Basic maintenance 1. Spark plug 2. Check and replace the gear oil 3. Check and replace the engine oil 4. Throttle grip adjustment 5. Clean the air filter 6. Check and top-up the coolant 7.
  • Page 26 Precautions for Maintenance 1. Before the maintenance, put the motorcycle on the ground and support the main stand. 2. Ensure that the maintenance environment is well ventilated. 3. Prepare the worktable (under the engine) and tools. 4. For threaded fasteners or seals, if not specified, counterclockwise should be loosened and clockwise should be tightened.
  • Page 27 mileage 1000km. mileage 1000 5000 10000 15000 20000 25000 30000 lubrication Engine oil New 300R system Engine oil filter New 300R Gear oil New 300R Fuel Fuel filter net Air intake Air filter /CVT sponges system Intake manifold and fixed bolt Air lines Electric injection...
  • Page 28 Water temperature sensor Oxygen sensor Ignition coil CVT/ Drive belt clutch Clutch system Front and back Belt fixed, moving plate PuLiZhu Braking Brake Liquid system Brake tubing Brake disc Cooling Coolant system Valve gap...
  • Page 29 Spark plug Control Throttle line, brake line drawing line Front and rear shock absorption Wheels / tires Head tube bearing Battery Safety fastener of important bolt and nut of car body Basic maintenance 1. Spark plug A. Removal and cleaning WARNING In order to avoid the risk of ignition, please let the engine and silencer cool down before...
  • Page 30 performing the following operations. (1)Park the vehicle on its main stand, unscrew and remove the 3 screws of right side cover (shown no.1), remove the right side cover (shown no.2),and find the spark plug suppressor cap (shown no.3). (2)Remove the spark plug suppressor cap (shown no.3).
  • Page 31 (3)Clean off any trace of dirt from the spark plug base by using compressed air. Then unscrew it using the spanner supplied in the toolkit and remove it from the engine, being careful not to let dust or any other substance enter into the cylinder.
  • Page 32 (5)Check the electrode gap with a feeler gauge. This gap should be 0.7 - 0.8 mm, adjust it if necessary by carefully bending the ground electrode. B. Assembly fastening (1)Make sure that the washer is in good conditions. Once the washer is fitted, manually screw the spark plug using spark plug sleeve (Z05).
  • Page 33 C. Technical data Standard spark plug: NGK PMR9B Spark plug electrode gap: 0.7 - 0.8 mm Locking torques: 10Nm (7.38 lb ft) CAUTION 1. If spark plug insulation material is broken and electrode corrosion is serious, spark plugs need to be replaced. 2.
  • Page 34 A. Check (1)Park the vehicle on its main stand (shown no.1), unscrew and remove the plug (shown no.2), unscrew and remove the screw (shown no.3), then drain off the oil (get a collecting container before carrying out these operations). (2)Check that the quantity is within the specified limits (SEE TECHNICAL DATA), top-up with the necessary quantity if required.
  • Page 35 CAUTION In the case of insufficient lubrication (less oil), oil deterioration (long running time), and no use of recommended oil, it will accelerate the wear of moving parts, and produce irreparable harm. B. Replacement The operation steps are the same as the above A inspection process. 3.
  • Page 36 (4)Clean the oil of oil cap/dipstick (shown no.1), insert the oil cap/dipstick (shown no.1) into the injection port, but do not screw in. Remove again and check for the correct oil level, it must be between the reference mark “H” and “L”. Visual oil color, if black or iron filings, please immediately change the oil.
  • Page 37 (5)If the level is not close to the mark “H”, pour a small quantity of oil and wait approximately five minutes. Then check the oil level by step (4) until it close to the mark “H”, screw and tighten the oil cap/dipstick (shown no.1). (6)Wipe the oil of the engine surface with a rag to confirm no leakage.
  • Page 38 (2)Unscrew and remove the oil release bolt of right crankcase (shown no.2), remember not to dismantle the bolt (shown no.3), drain off the oil (get a collecting container before carrying out these operations).
  • Page 39 CAUTION Figure 3 is pressure and pressure relief devices. Remember not to open the drain. If the oil is released accidentally, remember to mark the spring 5 and mark the marbles 6, and restore the original state according to the order shown.
  • Page 40 (4)Screw and tighten the screw (shown no.2). (5)Pour approx. 950mL engine oil through the fill opening of oil cap/dipstick (shown no.1). (6)Screw and tighten oil cap/dipstick (shown no.1). (7)Start the engine and let it run for several minutes. Stop the engine and let it cool down. (8)Check engine oil level again whether to meet the requirements.
  • Page 41 4. Throttle grip adjustment The empty travel of the throttle grip (shown no.4) should be 2-3mm, measured at the throttle trim. If this is not so, proceed as follows: (1)Slide off the protection cover(shown no.1). (2)Loosen the lock nut(shown no.3). (3)Turn the set screw (shown no.2) so as to obtain the specified value.
  • Page 42 5. Clean the air filter The air filter element used in this scooter is a polyurethane foam element. If the filter element has become clogged with dust, intake resistance will increase with a resultant decrease in power output and increase in fuel consumption due to the richer fuel/air mixture.
  • Page 43 (2)Unscrew and remove the 5 screws (shown no.2) and the 2 screws (shown no.3). (3)Remove the filter box cover (shown no.4) together with the filtering element (shown no.5). (4)Check the filtering element (shown no.5), and replace it if necessary. (5)Washing filtering element (shown no.5) ...
  • Page 44 the oil.  Reinstall the cleaned air filter element in reverse order of removal. Be absolutely sure that the filter element is securely in position and is sealing properly. Filter element Non-flammable cleaning solvent Filter element Engine oil...
  • Page 45 CAUTION Without the filter element, running the engine will increase engine wear. 6. Check and top-up the coolant WARNING In order to avoid the risk of ignition, please let the engine and silencer cool down before performing the following operations. Undo the 3 screws (shown no.1) to remove the left side cover (shown no.2).
  • Page 46 A. Fluid level inspection of coolant tank (1)Loosen (turning it anticlockwise) but do not remove the coolant tank cap (shown no.2). (2)Wait for some seconds so that possible pressure may be purged. (3)Remove the coolant tank cap (shown no.2) (4)Check the coolant level. If you do not see the liquid level or the liquid level is deep, top-up until liquid level close to the coolant tank cover.
  • Page 47 Top-up (1)Remove the filler cap (shown no.4) from the expansion tank (shown no.3). (2)Top-up with coolant until the fluid level is close the ''MAX'' reference mark. Do not exceed this level. Otherwise, the coolant will spill out when the engine is running. (3)Refit the filler cap (shown no.4).
  • Page 48 CAUTION If the coolant transition loss or expansion tank is empty, check whether there is any leakage in the cooling system. 7. Braking system A. Check and top-up the brake fluid (1)Park the vehicle on its main stand. (2)Check that the level in the reservoir is over the mark “LOWER”. If the fluid does not reach the mark “LOWER”, check brake pads and disc for wear.
  • Page 49 Top-up (a)Undo the2 screws (shown no.1) to remove the brake pump cover (shown no.2). CAUTION In order to avoid the risk of brake fluid overflow, the brake handle cannot be held after the 2 screws are removed and the pump cover is removed mainly. (b) Top-up the fluid to reach the mark “MAX”.
  • Page 50 CAUTION 1. Only when the friction shoe is new, the liquid level reaches the mark "MAX", the liquid level of the brake fluid will gradually decrease with the wear of the friction shoe. 2. WHEN TOPPING-UP, DO NOT EXCEED THE “MAX” LEVEL MARK WHEN BRAKE PADS ARE WORN AS YOU RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS.
  • Page 51 If the ABS indicator is not light or the front and rear wheels move at the same time, the ABS lamp will not extinguish: 1. Check the gap between the front wheel hall sensor (shown no.1) and the front wheel counting gear tray (shown no.2) and the clearance should be 1.0--1.6mm.
  • Page 52 2. Check the gap between the rear wheel hall sensor (shown no.3) and the rear wheel counting gear tray (shown no.4) and the clearance should be 0.5--1.6mm. If there is an excess, check and adjust the position of hall sensor (shown no.3).
  • Page 53 8. Headlight inspection and adjustment A. For a quick inspection of the correct aiming of the front light beam (1)Place the vehicle 10 m from a vertical wall and make sure the ground is level. (2)Turn on the low beam light, sit on the vehicle and check that the light beam projected to the wall is a little below the headlight horizontal straight line (about 9/10 of the total height).
  • Page 54 B. Adjust the light beam Unscrew and but not remove the screw (shown no.1), push the bolt (shown no.1) to the R direction to lower the light beam, push the bolt (shown no.1) to the F direction to raise the light beam.

  • Page 55: Electrical System

    ELECTRICAL SYSTEM Components arrangement...
  • Page 57 1. Headlamp 2. Horn 3. Front turning lamps 4. Speed sensor 5. ABS unit 6. H2O temperature sensor 7. Fan 8. Side stand switch 9. Engine oil pressure sensor 10. Rear turning lamps 11. Taillight 12. Control unit / throttle body 13. Spark plug 14. Battery 15. Left grip switch 16. Buzzer 17. Injector 18.
  • Page 58 Instrument Panel Indications 1. Engine RPM Indicator 2. Fuel gauge 3. LH Direction Indicator 4. High beam/ Low beam indicator...
  • Page 59 5. Engine fault indicator warning light: If this warning light appears during running please consult your dealer. 6. “MODE” button functions (See below)，With the ignition key turned to the on position. A. TRIP METER to ODOMETER to change between displays: Press the “MODE” button then release “MODE” button.
  • Page 60 Harness diagram...
  • Page 61 Conceptual diagram...

  • Page 62: Remove Engine From Vehicle

    REMOVE ENGINE FROM VEHICLE CAUTION Before dismantling the engine associated parts, clean the engine thoroughly with a suitable cleaner. Remove the left and right side cover 1. Undo the 6 screws (shown no.1), remove the right side cover (shown no.2) and left side cover (shown no.3).
  • Page 63 Remove the main cover 1. Unscrew and remove the 2 screws (shown no.2), take down the cushion (shown no.1), unscrew and remove the 2 screws (shown no.3). 2. Unscrew and remove the screw (shown no.4), take down the battery cover (shown no.5), unscrew and remove the 2 screws (shown no.6).
  • Page 64 4. Unscrew and remove the 2 nuts (shown no.8), take down the taillight (shown no.9), unscrew and remove the 2 screws (shown no.10), take down the main cover (shown no.11).
  • Page 65 Remove the Fuel evaporation system 1. Loosen the clamp (shown no.1), pull out the trachea (shown no.2). 2. Unscrew and remove the screw (shown no.3), take down the air valve (shown no.4), dump valve (shown no.5) and bracket (shown no.6).
  • Page 66 3. Cut the tie band (shown no.7), loosen the clamp (shown no.8), pull out the trachea (shown no.9) and remove the carbon canister (shown no.10).
  • Page 67 CAUTION The trachea of the system should not be disassembled. If it is disassembled, attention should be paid to the dumping valve (shown no.5). The arrow direction should be connected with "TANK" port of the carbon tan (shown no.10).
  • Page 68 Connecting Fuel Tank Connecting Canister Remove the Fuel tank 1. Disconnect the oil pump plug (shown no.18) and the oil level sensor plug (shown no.19) 2. Take down the 3 relays (shown no.16), unscrew and remove the 2 screws (shown no.17), 2 screws (shown no.20), and 2 screws (shown no.21).
  • Page 70 3. To open the fuel cap, insert the ignition key (shown no.22) into the cap (shown no.23) and turn the fuel cap tab clockwise, undo the screw fixed to ABS (shown no.24), pinch and pull out the fast joint of the high pressure oil pipe (shown no.25) with the hand, remove the fuel tank.
  • Page 71 Remove the air filter 1. Remove the clamp (shown no.1 and no.3), separate the trachea (shown no.4) and take down the return valve (shown no.2). CAUTION Reassemble and remove the oil in the return valve (shown no.2). The "UP" arrow points to the air filter.
  • Page 72 2. Loosen the clamp (shown no.5) and separate the air filter outlet pipe (shown no.6). 3. Unscrew and remove the 2 screws (shown no.7 and no.8).
  • Page 73 4. Unscrew and remove the 2 screws (shown no.9). 5. Take down the air filter and front fender.
  • Page 74 Remove the exhaust system 1. Undo but not remove the two Hoop screws (shown no.3). 2. Undo and remove the screw (shown no.4). 3. Undo but not remove the two screws (shown no.5), remove the exhaust system (shown no.6).
  • Page 75 CAUTION Check the graphite sleeve (shown no.6.1) every time after removing the muffler, and replace it when the inner hole is damaged or broken. 4. Loosen the clip (shown no.7), disconnect the oxygen sensor connector (shown no.8), and remove the oxygen sensor (shown no.9).
  • Page 76 5. Unscrew the 2 nuts (shown no.10), remove the exhaust pipe (shown no.11). CAUTION When reassembled, the 2 nuts (shown no.10) and bolt (shown no.4) are first swirled but not locked, when the clamp bolt (shown no.3) is locked, then lock the 2 nuts (shown no.10) and bolt (shown no.4).
  • Page 77 Emptying coolant 1. Unscrew the screw of clamp (shown no.4) and slide out the water pipe (shown no.5), so that the coolant is collected in the well prepared container. CAUTION Remove the expansion box cap to help the coolant evacuate. Rising the front wheel at least 55cm, can make the coolant in the system loop empty.
  • Page 78 Remove the connection plug 1. Pull out the spark plug cap (shown no.36). 2. Disconnect water temperature sensor plug (shown no.37). 3. Disconnect oil temperature sensor plug (shown no.38). 4. Disconnect the start motor line plug (shown no.39). 5. Disconnect the ECU plug (shown no.40). 6.
  • Page 79 7. Loosen the clamp (shown no.1) and remove the throttle body (shown no.2). Remove the rear wheel 1. Unscrew and remove the screws (shown no.7 and no.8), take down the right rear shock absorbers (shown no.9). 2. Unscrew and remove the 2 screws (shown no.10) and nuts (shown no.11) , take down the rear fork (shown no.12).
  • Page 80 3. Hold the left brake lever (shown no.1), unscrew and remove the 5 screws (shown no.13), and take down the rear wheel (shown no.14).
  • Page 81 CAUTION When reassembling, the bolt thread part of Figure 13 is coated with Loctite 243 thread adhesive, and the tightening torque is 60Nm. 4. Hold the left brake lever (shown no.1), unscrew and remove the 5 screws (shown no.16). CAUTION When reassembling, the bolt thread part of Figure 13 is coated with Loctite 243 thread adhesive, and the tightening torque is 25Nm.
  • Page 82 6. Unscrew and remove the screw (shown no.28), take down the sensor (shown no.29). CAUTION After the sensor 29 is removed, fix it with the strap temporarily to the appropriate position of the frame to avoid damage.
  • Page 83 Take down the engine 1. Unscrew and remove the engine fixed shaft nut (shown no.43), do not remove the fixed shaft (shown no.43). 2. Reconfirm that the connection of the engine has been removed, remove the fixed shaft (shown no.43), and take down the engine.

  • Page 84: Engine Disassembly

    ENGINE DISASSEMBLY CAUTION Before the engine is disassembled, clean it thoroughly with a suitable cleaner to prevent impurities from entering the engine. Basic principle 1. Replacement of rubber parts In principle, the engine has been used more than 2 years should replace the rubber parts, such as oil seal, O ring and so on.
  • Page 85 When the bearing is replaced, the principle that the new shaft is pressed into the bearing hole or shaft is not to force the bearing outer ring and inner ring at the same time. otherwise the bearing may damage or produce murmurs again. Press the bearing into the hole Press the bearing into the shaft Working surface...
  • Page 86 Disassemble intake manifold 1. Remove the screw (shown no.1) and take down the fuel injector (shown no.2). 2. Remove the 3 screws (shown no.3) and take down the intake manifold (shown no.4). Discharge oil，fill oil 1. Discharge oil from gear box Unscrew and remove gear box oil discharge screw (shown no.3), release oil (prepare suitable containers in advance to collect gear oil).
  • Page 87 Reassembly attention: (1). Rear gear box: Add 200CC lubricating oil of 75W/80. (2). The tightening torque of the oil discharge screw (shown no.3) is 25Nm. 2. Discharge oil from crankcase Unscrew and remove crankcase oil discharge screw (shown no.2), release oil (prepare suitable containers in advance to collect engine oil).
  • Page 88 CAUTION Figure 3 bolt is a pressure maintaining and voltage regulating device, and cannot be easily disassembled. The release of waste oil is handled in accordance with the relevant laws of the state. Reassembly attention: (1). Crankcase: Add 1000CC lubricating oil of 10W/40，it is recommended to use the grade APL SJ above。 (2).
  • Page 89 Disassemble CVT cover 1. Remove the air duct (1) Unscrew and remove the 2 screws (shown no.1) and 3 screws (shown no.2), remove the air duct. (2)Unscrew and remove the screw (shown no.4), take down the air-box cover (shown no.5) (3)Clean or replace the air filter.
  • Page 90 2. Remove the CVT cover (1)Unscrew and remove the screw (shown no.1), Take down the CVT cover (shown no.2) by using screwdriver (shown no.3).
  • Page 91 Disassemble front and back clutch 1. Take down the plastic cover (shown no.10). 2. Remove the 2 nuts counter clockwise (shown no.8). 3. Take down the figure 7—4—3—9—5. 6—2—1 in turn.
  • Page 92 Reassembly attention: (1). Figure 6 and 9 are components. When Install 5 to 6, hard and counter clockwise rotation of the upper sheet of 6. (2). When you install belt (shown no.5), pay attention to direction, arrow forward. (3). The gasket (shown no.1) is mounted on the side of the box according to the direction of the picture, that is, the chamfering of the inner hole.
  • Page 93 Reassembly attention: (1). Check sealing gasket. If oil immersion, damage and folding occur, it must be replaced. (2). Check whether the locating pin is on the gear box cover or the left box body, and then place the sealing gasket. Disassemble water pipe and sensor 1.
  • Page 94 CAUTION 1. The water temperature sensor (shown no.1) and the oil pressure switch (shown no.2) are high quality goods. No knocking or beating is allowed during demolition or assembly. 2. The water pipe clamp (shown no.4) is disposable parts, and it is not reused as far as possible after dismantling. Reassembly attention: (1).
  • Page 95 Disassemble generator cover 1. Remove the generator cover screws in turn and Take down the generator cover and gasket.
  • Page 96 2. Remove the 5 screws and Take down the stator components. If not necessary, it will not be disassembled. Reassembly attention: (1). Check sealing gasket. If oil immersion, damage and folding occur, it must be replaced. (2). Check whether the locating pin is on the gear box cover or the left box body, and then place the sealing gasket. (3).
  • Page 97 Disassemble generator rotor 1. Removing the starter motor Unscrew and remove the two screws, take out the starter motor. 2. Rotate the crankshaft to make the piston reach the TDC and lock the crankshaft with the special tool below.
  • Page 98 3. Remove the screws of the generator rotor, undo the generator rotor with special tools, take off the rotor assembly, and take out the semicircle key (if the crankshaft is not replaced, do not take out).
  • Page 99 4. Remove the intermediate gear; Reassembly attention: (1). If the semicircular key has been removed, please tap lightly with the copper hammer, and the upper plane is parallel to the centerline of the crankshaft. (2). The key slot on the rotor is aligned with the upper half key of the crankshaft. (3).
  • Page 100 Disassemble engine oil pump 1. Unscrew and remove the 4 screws, Take down the Oil baffle. 2. Unscrew and remove the 2 screws, take off the chain, sprocket and engine oil pump.
  • Page 101 Disassemble heat engine 1. Remove the cylinder head cover (1). Remove the screw (shown no.4). Figure 5 is a seal sleeve. (2). Remove cylinder head cover (shown no.1), gasket (shown no.2) and sealing ring (shown no.3) All 2, 3 and 5 of the drawings are rubber seals. If they are damaged or increased, they should be replaced.
  • Page 102 2. Rotate the crankshaft to make the piston reach the TDC and lock the crankshaft with the special tool below. 3. Remove the tensioner Unscrew and remove the screw (shown no.1), close the spring, remove the screw (shown no.2) and remove the tensioner.
  • Page 103 4. Remove the timing sprocket To facilitate assembly, mark the chain and 2 sprockets before removing, remove the screws (shown no.3), and Take down the washers (shown no.2) and sprockets (shown no.1).
  • Page 104 Reassembly attention: (1). First, install 1, 2, 3 of the drawings, then install 4, 5, and 6 of the drawings. (2). The gasket (shown no.2) has a direction, and the inner hole chamfering faces to the head of the bolt (shown no.3). (3).
  • Page 106 Reassembly attention: (1). The valve tappet (shown no.1) must be placed according to the early marking position; if once forgotten, use the tape measure to measure the gap one by one and replace the valve tappet, with a thickness mark on the inside, until the requirement is met.
  • Page 107 (3).When using the bolt (shown no.6) to fix the camshaft cover (shown no.5), it should be observed that first install the inner ring and reload the outer ring. The tightening torque is 9--11Nm. 7. Remove the 2 bolts (shown no.4) and 4 bolts (shown no.5, no.6), take down the head of the cylinder (shown no.3) and seal (shown no.2), and the positioning pin (shown no.1) connected to the head of the cylinder (shown no.3).
  • Page 109 Reassembly attention: (1). Check the sealing gasket (shown no.2). If oil immersion, damage and folding occur, it must be replaced. (2). After cleaning and maintenance of the components, install the locating pin (shown no.1) and the gasket (shown no.2), tighten the bolt (shown no.6) first and then tighten the bolt (shown no.4). The operation is as follows: A.
  • Page 110 (2). Use special tool to compress valve spring and take out valve lock clip.
  • Page 111 (3). Take down the relevant parts connected with the valve in turn. If there is no need, do not Take down the valve oil seal.
  • Page 112 Reassembly attention: After the above procedure is assembled, the tightness of the valve seat must be tested. Import gasoline from intake and exhaust port, observe leakage from intake and exhaust valve seat, do not leak too much.
  • Page 113 9. Disassemble cylinder Remove the cylinder (shown no.7) and the seal pad (shown no.6). 10. Disassemble piston Remove the retaining ring (shown no.3) and remove the piston pin (shown no.2) and take down the piston (shown no.1).
  • Page 114 Reassembly attention: (1). Routine installation: A little lubricant is applied to the parts before assembly. (2). The piston pin should be missed out of the piston gap. The piston top arrow points to the exhaust direction. (3). If you only need to replace the gasket (shown no.6), you must measure its thickness by using the vernier caliper and then choose the same thickness gasket (shown no.6).
  • Page 115 (5). If replacing the cylinder or / and piston, it must be replaced by the next table group: Cylinder & piston diameter grouping Engine capacity Grouping mark Cylinder diameter piston diameter Tolerance clearance 58.01～58.017 57.963～57.970 0.04～0.054 58.017～58.024 57.970～57.977 0.04～0.054 125CC 58.024～58.031 57.977～57.984 0.04～0.054...
  • Page 116 Grouping Mark Grouping Mark (6). The letter of the piston ring top ring and the second ring must point to the top of the piston, and the opening of each ring is stagger 90 degrees. See the following figure:...
  • Page 117 Disassemble crankcase (1). Remove the 3 bolts. (2). Tapping the right crankcase with a nylon hammer and separating the right crankcase.
  • Page 118 (3). Tapping the left crank with a nylon hammer and taking the crankshaft out. (4)It is not recommended to remove the bush.
  • Page 119 WARNING The axle bush is selected by special equipment and is assembled with special tools. If the crankshaft and crankcase are replaced, the user may not disassemble and replace it without authorization. It is suggested to return to the seller or the production plant for maintenance. Reassembly attention: (1).
  • Page 120 Disassemble engine oil filter Remove the 2 bolts (shown no.6). Remove the oil filter cover (shown no.5), O circle (shown no.4) and filter element (shown no.3).
  • Page 121 Reassembly attention: 1. When installing the driving shaft oil seal (shown no.1) and the crankshaft oil seal (shown no.2), pay attention to lip protection, the inner ring is coated with butter. 2. During the maintenance and cleaning of the filter (shown no.3), pay attention to the O ring (shown no.4) not to be damaged.
  • Page 122 (2)Starting the engine, the oil pressure detection data are as follows: When the idle speed is 1700 ± 100rpm, the oil pressure is more than 0.18MPa. When the speed is 6000rpm, the oil pressure is 0.35～0.65MPa. (3)If the engine oil pressure is not within the specified limits, check oil quantity, oil filter, oil pressure regulating valve and oil pump in turn.

  • Page 123: Efi System

    EFI SYSTEM The vehicle uses the Magneti Marelli EFI system. The schematic diagram as follows:...
  • Page 124 The fuel supply system consists of oil pump assy (including filter, pressure regulators), high-pressure oil pipe and injector. The ignition system consists of ECU, high voltage coil, high voltage wire, spark plug cap and spark plug.
  • Page 125 Maintenance instructions for EFI system 1. Special Notice: Please use the genuine parts; otherwise it will not be able to ensure the normal operation of the EFI system. Although the installation appearance size of EFI system is similar, the performance parameters are different.
  • Page 126  After complete above operation, the fuel pipe can be disassembled .when the fuel pipe was reinstalled, then the wiring harness connector of the oil pump assembly can reconnected ③ When the fuel pump is removed from the fuel tank, do not turn on the electricity, so as to avoid producing electric sparks and causing fires.
  • Page 127 1. Fault information record The ECU continuously monitors sensors, actuators, related circuits, fault indicator lights and battery voltage, and even the ECU itself, and to the sensor output signal, actuator drive signal and internal signal (such as lambda closed loop control, cylinder temperature / coolant temperature, idle speed control and battery) Reliability detection is carried out by voltage control, etc.
  • Page 128 2. Fault code table P0110 Air temperature sensor Intake Temperature Sensor Engine Coolant Temperature Circuit High P0115 Water temperature sensor Voltage or Open P0120 Throttle position sensor TPS Circuit Low Voltage or Open P0130 Lambda sensor O2 Sensor Circuit P0135 Lambda sensor heater O2 Sensor Heater Circuit P0201...
  • Page 129 3. OBD fault indicator description and control The fault indicator is generally an indicator light that can be displayed on the speedometer and the shape meets the requirements of the regulations. The fault indicator described as follows: ① In the normal mode, no fault code: Turn on the ignition switch, ECU initializes, the fault lights are on, and the MIL lights go out immediately after the engine starts successfully.
  • Page 130 4. OBD diagnostic connect and use: OBD diagnostic function: Read fault code, clear fault code, data flow display, status identification display, etc.
  • Page 131 ①Connect the diagnostic instrument to the diagnostic interface on the vehicle. ②Connect the ignition switch. ③Read fault code; Inquire maintenance manual to confirm the fault parts and types; formulate the maintenance plan according to the query information and experience. ④After troubleshooting, remove the history fault code with the fault diagnostic instrument.
  • Page 132 5. According to the fault, the diagnosis process for maintenance A. Before starting the of fault diagnosis according to the engine fault phenomenon, a preliminary examination should be carried out first. ①. Confirm that the engine fault indicator is working normally ②.
  • Page 133 6. Common fault: (1). When starting, the engine does not turn or turn slowly. General fault parts: 1, battery; 2, starting motor; 3, wiring harness or starting relay and related control circuit; 4, engine mechanical parts. General diagnosis process: Inspection steps Follow steps when the engine start，Check the voltage between the two terminals of the Replace battery...
  • Page 134 (2). When starting, the engine can be towed but cannot start successfully. General fault parts:1, fuel tank without oil; 2, fuel pump; 3, speed sensor; 4, ignition coil; 5, engine mechanical parts. General diagnosis process: Inspection steps Follow steps Connect the OBD diagnostic, observe the data items of the engine speed, start Inspect speed sensor engine, and observe whether there is a speed signal output.
  • Page 135 Remove the injector from the intake pipe (the oil circuit and wiring harness Inspect injector connector is not removed), start the engine and check whether there is fuel circuit, injector injection. (3). Start difficulty General fault parts: 1, fuel has water; 2, fuel pump; 3, coolant temperature sensor; 4, injector; 5, ignition coil; 6, throttle body and idle bypass airway;...
  • Page 136 Remove the spark plug cap, connect the spark plug, let the spark plug on the engine block, start the engine, check whether there was continuous blue and Inspect ignition system white high pressure fire. Cleaning throttle and Softly turning throttle, observe whether easy to start. idle airways Check whether the air filter is clogged, and whether there is a leak in the intake Inspect intake system...
  • Page 137 (4). Starting normal, but idle speed unstable. General fault parts:1, fuel has water; 2, fuel injector; 3, spark plug; 4, throttle body and idle bypass airway; 5, Intake port; 6, idle speed regulator; 7, ignition timing; 8, spark plug; 9, engine mechanical part; 10, coolant temperature (cylinder temperature) sensor.
  • Page 138 check whether engine valve clearance is too small). Check the ignition sequence and ignition timing of the Inspect ignition timing engine. Check whether there is leakage, blockage or excessive replace flow in fuel injector. Idling instability Remove the coolant temperature sensor connector and Inspect the circuit or during the start the engine, observe whether the idle is stable...
  • Page 139 Inspection steps Follow steps Check whether the throttle cable is stuck or too tight, resulting in the throttle adjustment valve not completely closed. Check whether there is air leakage in the intake system. Inspect intake system The idle speed regulator is removed to check whether there is carbon Cleaning the related deposition in throttle body, idle speed regulator and idle bypass.
  • Page 140 General diagnosis process: Inspection steps Follow steps Remark Check whether the air filter is blocked. Inspect intake system Connect the fuel pressure gauge and start the engine to check whether the fuel pressure of the engine is around Inspect fuel system 250kPa at all working conditions.
  • Page 141 ethanol) meets the requirements of the vehicle. Check the ignition sequence and ignition timing of the Inspect ignition timing engine. Repair or replace the exhaust Check whether the exhaust pipe is smooth. pipe Remove the spark plug cap, connect the spark plug, let the spark plug on the engine block, start the engine, Inspect ignition system check whether there was continuous blue and white...
  • Page 142 Fuel injector disassembly and installation 1. Disconnect the oil pump connector, start the engine until the engine goes out automatically, remove the fuel tank. 2. The two fingers press the plug button at the same time and pull out the quick connector.
  • Page 143 3. Disconnect the injector connector. 4. Remove the bolt and take off the fuel injector. 5. Assembly according to the above reverse process.
  • Page 144 Throttle valve disassembly and installation 1. Remove the fuel tank. 2. Disconnect the plug.
  • Page 145 3. Take off the throttle line (shown no.1). 4. Unscrewing the clamp between air filter and throttle body (shown no.2), unscrewing the throttle body and the hoop connected to the intake manifold (shown no.3) 5. Take off the throttle body (shown no.4). 6.

  • Page 146: Braking System

    BRAKING SYSTEM This vehicle is equipped with ABS brake system: a front disc brake, a rear disc brake, and ABS integrated unit. Operate the right brake handle and apply pressure on the front brake caliper. Operate the left brake handle and apply pressure on the rear brake caliper.
  • Page 147 Dismantle front brake calipers and brake disc 1. First lift the main stand, then unscrew and remove the bolt (shown no.1). The tightening torque M8 is 25Nm. 2. Unscrew and remove the front wheel bolt (shown no.2).Take down the front wheel. The tightening torque M12 is 60Nm.
  • Page 148 3. Use the strap (shown no.3) to pull up the bushing widget to prevent loss, unscrew and remove the 3 bolts (shown no.4), remove the brake disc (shown a) and the front ring gear (shown b). CAUTION When reassembling, the bolt thread part of Figure 4 is coated with Loctite 243 thread adhesive, and the tightening torque M8 is 25Nm.
  • Page 149 4. Unscrew and remove 2 nuts and 2 built-in bolts (shown no.5), unscrew and remove the bolts (shown no.6). 5. Take down the 2 pads (shown no.7).
  • Page 150 CAUTION Do not operate the brake lever after removing the friction hoof, otherwise the piston will come out of the caliper to cause the leakage of brake fluid. 6. Inspection and replacement of the pad and brake discs are described in part Ⅲ. CAUTION Reassembly is carried out according to the above reverse process.
  • Page 151 2. Unscrew but not remove the bolt (shown no.3). 3. Unscrew and remove the bolt (shown no.4). 4. Unscrew but not remove the 2 bolts (shown no.5) and take down the muffler (shown no.6).
  • Page 152 5. Unscrew and remove the bolts (shown no.7 and no.8) and remove right rear shock absorbers (shown no.9). 6. Unscrew and remove the 2 bolts (shown no.10) and nut (shown no.11), and remove the rear fork (shown no.12), the tightening torque of the nut (shown no.11) is 100Nm.
  • Page 153 7. Hold the left brake lever (shown no.1), unscrew and remove the 5 bolts (shown no.13) and remove the rear wheel (shown no.14). The tightening torque is M12. CAUTION When reassembling, the bolt thread part of Figure 4 is coated with Loctite 243 thread adhesive, and the tightening torque is 60Nm.
  • Page 154 10. Remove the clip (shown no.18), pull out the pin shaft (shown no.19), take off the spring leaf (shown no.20), and pay attention to the spring leaf (shown no.20) in accordance with the direction of the picture. 11. Take down the pad (shown no.21).
  • Page 155 CAUTION Do not operate the brake lever after removing the friction hoof, otherwise the piston will come out of the caliper to cause the leakage of brake fluid. 12. Inspection and replacement of pad and brake disc are described in part Ⅲ. CAUTION Reassembly is carried out according to the above reverse process.
  • Page 156 (1). Perform visual inspection on the surface and replace it if there is serious scratch or rust. (2). Use micrometer to measure the thickness on the brake disc circumference. If the minimum thickness is less than or near the minimum limit (3.6mm), replace it. (3).
  • Page 157 Clear the brake fluid loop bubble. Taking the dangers of vehicles and riders into account, it is necessary to remove bubbles in the brake fluid circuit after retrofitting or restoring the brake system. 1. Front brake fluid circuit (1). Pull out the rubber cap of the vent valve (shown no.1). (2).
  • Page 158 (3). Quickly compress and loosen the right brake lever several times, then press hard on the right brake lever. (4). Loose the valve (shown no.2) about 1/4 circle to allow the brake fluid to flow into the container. Release the pressure on the brake lever until the end of the stroke.

  • Page 159: Brake Fluid Replacement

    Brake fluid replacement 1. Front brake fluid replacement (1). Pull out the rubber cap of the vent valve (shown no.1). (2). A clear plastic pipe (shown no.3) is inserted on the vent valve (shown no.2), and the other end of the tube (shown no.3) is connected to a container for collecting the discharged brake fluid.
  • Page 160 (3). Quickly compress and loosen the right brake lever several times, then press hard on the right brake lever. (4). Loose the valve about one circle to allow the brake fluid to flow into the container. Release the pressure on the brake lever until the end of the stroke.

  • Page 161: Cooling System

    COOLING SYSTEM System composition...
  • Page 162 Coolant replacement 1. Coolant emptying (1)Remove the 6 bolts (shown no.1), remove the right cover (shown no.2) and the left cover (shown no.3). (2)Release clamps (shown no.4), Slide off the water pipe (shown no.5), Collect the coolant into the pre-prepared container.
  • Page 163 CAUTION Remove the expansion box cap to help the coolant evacuate. Rising the front wheel at least 55cm, can make the coolant in the system loop empty.
  • Page 164 2. Coolant injection (1)Plugged in outlet pipe (shown no.5) again, tighten the clamps(shown no.4), (2)Fill the expansion tank with coolant until the liquid level reaches the "MAX" reference line. (3)Fill the water tank with coolant until it is full and cover the water tank cover (shown no.2).
  • Page 165 (4)Start the engine and idle running until the fan works. (5)Turn off the engine and cool it down fully (about 12 hours). (6)Check the liquid level of expansion tank and water tank again, if necessary, add to the correct level. (7)Reinstall the right cover (shown no.2) and left cover (shown no.3).

  • Page 166: Final Inspection

    FINAL INSPECTION After Vehicle maintenance, before the normal riding, the following checks shall be carried out. Appearance check 1. The paint surface of a leaking part 2. Assembly of plastic parts with external leakage 3. Scratch Tightening torque check 1. Front and Rear suspending device 2.
  • Page 167 Electrical system First check the battery positive and negative, then check following 1. Key switch 2. Head light: High beam, low beam, position light and warning light 3. Adjust the low beam according regulations. 4. Front & rear brake switch and stop lamp 5.
  • Page 168 2. Instrument panel operation 3. The sensitivity of throttle control 4. Stability of acceleration and brake 5. Front and Rear brake effect (GP200S with ABS, GP125S with ABS or CBS) 6. Front and Rear shock absorption effect 7. Is there any abnormal noise...
  • Page 169 Inspection of vehicles after driving 1. Vehicle hot start 2. Brake rod stroke 3. Front and Rear tyre pressure 4. Angle of rear view mirror 5. Radiator fan run 6. Possible leaks 7. Abnormal sound of engine When the above check is completed, the user can ride normally.

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Gp200s

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