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RA GP125i Maintenance Manual

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Summary of Contents for RA GP125i

  • Page 3 Dear users: Thank you for choosing your RoyalAlloyGP125I/150I/180Iscooter. 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 thestructure 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....................................17 MAINTENANCE.................................23 ELECTRICAL SYSTEM..............................50 REMOVE ENGINE FROM VEHICLE..........................58 ENGINE DISASSEMBLY..............................80 EFI SYSTEM..................................1177 BRAKING SYSTEM................................141 FINAL INSPECTION................................. 162...

  • Page 5: Characteristics

    CHARACTERISTICS Maintenance rules Vehicle identification Specifications Transmission system description Lubrication system description Fuel 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 spareparts 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 strokeSAE 10W/40-SJ. 2.
  • Page 7 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 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 GP125i 1P52QMI (125) Model Engine model GP150i...
  • Page 9 10.5:1 (125) Net weight (kg) Compression ration 10.4:1 (150) 10.2:1 (180) 7.1KW/7500rpm(125) Max loading weight Max net power, rate 8.3KW/8000rpm(150) (kg) (kW/r/min) 8.8KW/7500rpm (180) 9.2Nm/7000rpm(125) Max net torque, rate Fuel tank capacity (L) 10.5 11Nm/6000rpm(150) (Nm/r/min) 12.5Nm/5500rpm(180) Front tyre size/ Inflating 110/70-12 /32 PSI Start mode Electric...
  • Page 10 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 Gear ratio 2.363～0.765（125/150/180） Gear ratio 45/13*41/15=9.46（125/150/180） Engine wheel total ratio 7.24～22.354（125/150/180） Lubrication system description Item Standard Change Engine oil 850m l Engine oil 1000ml...
  • Page 11 Transmission oil 200ml Change transmission oil 150m l Brand name: 75W-80 Dismantle engine, inject oil 180m l Fuel system description Item description Fuel number Unleaded fuel 92 or higher Fuel tank capacity 10.5L Chassis and suspensions system Item Standard Steering rake angle 26.30°...
  • Page 12 Rear suspension travel 85mm Steering rake angle 26.30° 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) Braking system description Item Standard ABS or CBS...
  • Page 13 Rear brake Ø220mm disc brake with hydraulic transmission Brake fluid FMVSS DOT4+ Electrical system description Item Standard Battery capacity 12V- 9A h Fuses 20- 10-10A (Permanent-magnet) Alternator 12 V - 200W at 7000 rpm Spark plug NGK CR7HSA Bulbs/ High-/low-beam bulb Square lamp:12V 35/35W warning Round lamp:LED...
  • Page 14 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 15 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 Locking nut fixing direction column Nut fixing handlebar...
  • Page 16 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 25～30 Cylinder head fixing bolt 8～12 Cylinder head fixing Gear box cover fixing screw 25～30 Timing sprocket screw 8～12...
  • Page 17 Front clutch nut 60～70 Rear clutch nut 60～70 Generator rotor fixing screw 60～70 Cylinder temperature sensor 6～9 Spark plug 9～12 bolt fixing 9～12 Reference bolts for other specifications: GB1231-2006 bolt torque standard...

  • Page 18: Tooling

    TOOLING 1. Special tools (The following tools are restricted to professional technicians only,consumers must not operate without authorization) Name Tool number Picture Valve spring compressor...
  • Page 19 Tightener Tool Clutch Drive Wheel Drive Wheel Limiter Shaft bearing punch Z06.1---Z06.8...
  • Page 20 Oil seal punch Z07.1--Z07.9 Flywheel extractor Spark plug sleeve...
  • Page 21 8、 Fault diagnosis instrument 9、 Shock absorber adjusts handle 2. General tools Name Picture “T” sleeve: 8#. 10#. 12#.
  • Page 22 Tool case 1 Tool case 2 Spring pliers...
  • Page 23 Screwdriver Pliers Nylon hammer Multimeter...

  • Page 24: Maintenance

    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. Braking system 7. Headlight inspection and adjustment...
  • Page 25 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 26 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 system sponges Intake manifold and fixed bolt Air lines Electric Throttle assembly injection...
  • Page 27 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 Valve gap Spark plug Control Throttle line, brake drawing line line Front and rear shock absorption Wheels / tires Head tube bearing Battery...
  • Page 28 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 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).
  • Page 29 (2)Remove the spark plug suppressor cap (shown no.3).
  • Page 30 （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 31 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). (2)Ensure that the spark plug suppressor cap is fitted securely, so that it will not get detached when exposed to engine vibrations.
  • Page 32 2. Check and replace the gear oil: WARNING In order to avoid the risk of ignition, please let the engine and silencer cool down before performing the following operations. A. Check (1)Park the vehicle on its main stand, unscrew and remove the oil injection hole screw (shown no.1), unscrew and remove the oil drain screw (shown no.2), then drain off the oil (get a collecting container before carrying out these operations).
  • Page 33 (2)Check that the quantity is within the specified limits (≥ 150ml), top-up with the necessary quantity if required. Visual oil color, if black or iron filings, please immediately change the oil. (3)Tighten the drain screw (shown no.2). Locking torques: 15--20Nm. (4)Fill the oil into Gear box from the oil injection hole screw (shown no.1), tighten the screw (shown no.1).
  • Page 34 A. Check the quantity of engine oil (1)Start the engine, let it idle during a few minutes and then switch it off. (2)Park the vehicle on its main stand, keeps the vehicle in an upright and level position. Wait at least five minutes to let the oil that is inside the engine to run back down into the crankcase.
  • Page 35 (5)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 36 (2)Unscrew and remove the oil release bolt of left crankcase (shown no.2), drain off the oil (get a collecting container before carrying out these operations).
  • Page 37 (3) Oil filter screen cleaning or replacement : according to the maintenance cycle to determine whether to implement. Unscrew and remove the screen cover(shown no.3), take off the oil filter screen(shown no.4),clean impurities of the filter screen and check for damage to the filter screen,if damaged, replace immediately. Fit a new oil filter screen and fit the springr(shown no.5),check the seal ring(shown no.6),screw and tighten the screen cover(shown no.3).
  • Page 38 (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. 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).
  • Page 39 (2)Loosen the lock nut(shown no.3). (3)Turn the set screw (shown no.2) so as to obtain the specified value. (4)After the adjustment, tighten the lock nut (shown no.2) and check the empty travel again. (5)Refit the protection cover (shown no.1). 5. Clean the air filter The air filter element used in this scooter is a polyurethane foam +paper element.
  • Page 40 (2)Unscrew and remove the 9 screws (shown no.2) , Remove the filter box cover . (3)Unscrew and remove the 2screws (shown no.3) ,take off the filter element (shown no.4),Split the filter element into paper filter element (shown no. 5) and foam filter element (shown no 6).
  • Page 41 (4)Clean and check the paper filter element (shown no. 5) ,replacement if necessary. (5)Foam filter element (shown no. 6) cleaning: Fill a container of a suitable size with non-flammable water soluble cleaning solvent. Immerse the filter element in the  solvent and wash it clean.
  • Page 42  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.
  • Page 43 CAUTION Without the filter element, running the engine will increase engine wear. (6)Take off the foam sponge（shown no. 7）,immerse the filter element in the non-flammable water soluble cleaning solvent to clean,Squeeze the solvent out of the washed filter element by pressing it between the palms of both hands. (7)After cleaning the air filter body, assemble in reverse order.
  • Page 44 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. If the pads and/or the disc do not need replacing, top-up the fluid.。...
  • Page 45 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 46 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 47 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 be0.5--1.6mm.
  • Page 48 C. Check ABS system(if the vehicle has CBS) 1.Check whether the whole system tubing is damaged, whether the connection is leaking, timely replacement or maintenance. 2.Operate the front wheel lock of the right brake handle. Operate the left brake handle and lock the front and rear wheels.
  • Page 49 7. 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 high 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 50 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 51: Electrical System

    ELECTRICAL SYSTEM Components arrangement...
  • Page 53 1.Headlamp 2.Flasher 3. Horn 4. Front turning lamps 5.Side stand switch 6.Cylinder temperature sensor 7. Throttle body 8. Rear turning lamps 9. Taillight 10.Fuel pump 11..Battery 12.Electric lock 13. Left handlebar switch 14.Speedomete 15. Injector 16.STARTER MOTOR 17.Voltage regulator 18. Generator 19.
  • Page 54 Instrument Panel Indications 1. Engine RPM Indicator 2. Fuel gauge...
  • Page 55 3. LH Direction Indicator 4. ABS fault indicator warning light: If this warning light appears during running please consult your dealer； CBS without the indicator light. 5. High beam/ Low beam indicator 6. Engine fault indicator warning light: If this warning light appears during running please consult your dealer. 7.
  • Page 56 Harness diagram...
  • Page 58 Conceptual diagram...

  • Page 59: 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 60 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), 3.Remove the belt (shown no.14), remove the battery screw "-"...
  • Page 62 Remove the Fuel evaporation system 1. Loosen the clamp (shown no.1), pull out the trachea (shown no.2). 2.Take off the air valve (shown no.3), pull out the bracket (shown no.4), then take off the dump valve (shown no.5) ..
  • Page 63 3. Release the desorption pipe clamp (shown no. 6) and the negative pressure pipe clamp (shown no.8) connecting the carbon tank, and pull out the desorption pipe (shown no.7) and the negative pressure pipe (shown no.9). 4. Cut the tie band (shown no.10), remove the carbon canister (shown no.11).
  • Page 64 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.11).
  • Page 65 Remove the Fuel tank 1. Disconnect the oil pump plug (shown no.1) and the oil level sensor plug (shown no.2) 2. Remove two bolts (shown no.3), disconnect plug and remove ECU; Remove two bolts ((shown no. 4), loosen and remove two bolts (shown no. 5), two bolts (shown no.6) , remove battery bracket.
  • Page 67 3. Insert the key (shown no.22) into the tank lock ((shown no.23) and rotate counterclockwise with the lock cover to remove the tank lock. Hold and pull the high-pressure tubing quick connector ((shown no. 25) by hand, if the CBS system removes the tank directly.
  • Page 68 Remove the air filter 1. Remove cylinder head clamp (shown no.1) and gear box pipe clamp (shown no.3), separate air filter pipe (shown no.2 and shown no. 4). 2. Loosen the clamp (shown no.5) and separate the air filter outlet pipe (shown no.6). 3.
  • Page 69 4. Remove the screw (shown no.9), two bolts (shown no.8) and remove the air filter.
  • Page 70 Remove the throttle body 1. Disconnect the intake pressure/temperature sensor plug (shown no. 1) 2. Disconnect the throttle position sensor plug (shown no.2) 3. Disconnect the plug of idle stepping motor (shown no. 3)
  • Page 71 4. Release the nut (shown no.5) from the thread and remove the throttle line (shown no.6). 5. Release the two bolts of the rubber sleeve of the intake pipe (shown no.4) and remove the throttle body.
  • Page 72 Remove the exhaust system 1. Loosen and remove two bolts (shown no.1) and bolts (shown no.2). 2. Disconnect the plug of the oxygen sensor (shown no.3) and dismantle the oxygen sensor (shown no.4). If it is not necessary, it is not recommended to dismantle the oxygen sensor.
  • Page 73 3. Remove two fixed nuts of muffler on cylinder head (shown no. 5) and remove muffler (shown no. 6) Remove the connection plug 1. Disconnect the fuel injector plug (shown no.1) 2. Disconnect the plug of the cylinder temperature sensor (shown no.2) 3.
  • Page 75 Remove the rear wheel 1. Hold the left brake lever (shown no.3), unscrew and remove the 5 screws (shown no.1), and take down the rear wheel (shown no.2). CAUTION When reassembling, the bolt thread part of Figure 1 is coated with Loctite 243 thread adhesive, and the tightening torque is 60Nm.
  • Page 76 2. Hold the left brake lever (shown no.3), unscrew and remove the nut (shown no.7) 3. Remove tubing clamp bolts (shown no. 4) and clamp fixing bolts (shown no.5). Remove rear brake disc brake pump (shown no. 6) and brake disc (shown no.8). CAUTION When reassembling, the nut thread part of Figure 7 is coated with Loctite 243 thread adhesive, and the tightening torque is 100Nm.
  • Page 77 4. If ABS system: loosen and remove the bolt (shown no.28), remove the sensor (shown no.29). If CBS system does not have this content. CAUTION After the sensor 29 is removed, it is temporarily fixed in the proper position of the frame with a tie belt to avoid damage.
  • Page 78 Take down the engine 1. Release engine fixed axle nut (shown no.1), do not remove engine fixed axles (shown no.2); Release middle stand axle nuts(shown no. 3), do not remove middle axle (shown no. 4) and middlestand (shown no.5). When reassembling: Torque of engine fixed shaft nut M10: 45Nm Torque of middle stand axle nut M8:25--30Nm...
  • Page 79 3. Unscrew and remove the bolts (shown no.6) ,separate the rear shock absorber (shown no.7) from the engine.
  • Page 80 4. Re-confirm that the connecting parts of the engine have been removed, remove the fixed shaft of the engine (shown no.2), remove the engine, remove the mid-brace (shown no.4), and remove the mid-brace (shown no.5). Reassembly CAUTION Reassembly according to the above reverse procedure, and tighten to the required torque.

  • Page 81: 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 82 the bearing outer ring and inner ring at the same time. otherwise the bearing may damage or produce murmurs again. 4. Principle of oil seal assembly When the oil seal is replaced, a little anaerobic adhesive is applied to the surface of the A surface. The bottom B surface of the oil seal is a force surface.
  • Page 83 Discharge oil，fill oil 1. Discharge oil from gear box Unscrew and remove gear box oil injection holes crew (shown no.1) and oil discharge screw (shown no.2), release oil (prepare suitable containers in advance to collect gear oil),screw the bolts and gaskets into place in time.
  • Page 84 Reassembly attention: (1). Rear gear box: add 180CC lubricating oil of 75W/80. (2). Check whether there is damage and deformation of one gasket in each of the oil injection hole bolts and the oil discharge bolts, and replace them in time according to the situation. (3).The tightening torque of theoil injection holes crew (shown no.1) and oil discharge screw (shown no.2) is 15-20Nm.
  • Page 85 B. Remove the filter cover (shown no.3), remove the filter screen ((shown no.4), release oil , clean and check the filter, and put it back in place in time. Reassembly attention: (1). Crankcase: Add 1000CC lubricating oil of 10W/40，it is recommended to use the grade APL SJ above。 (2).
  • Page 86 Disassembly and assembly of intake manifold (1). Force the removal of the anti-disassembly nut (shown no.2).with the screwdriver. If it is not necessary, it is not recommended to remove the intake manifold. (2). Remove nuts(shown no.1) and remove intake pipe connectors shown no.3)
  • Page 87 (3). shown no. shown no. shown no. Remove the paper pad ( 1), the bakelite pad ( 2), and the paper pad ( Reassembly attention: According to the order of paper cushion-bakelite cushion-paper cushion, and ensure that the bakelite cushion has a gap side towards the cylinder head.
  • Page 88 (4). Remove the cylinder temperature sensor. It is not recommended to demolish it if it is not necessary. CAUTION Cylinder temperature sensor (shown no.1) is a high-precision object. It is strictly forbidden to knock or smash when disassembling or assembling. Cylinder Temperature Sensor (shown no.3) Tightening Torque: 6 9Nm...
  • Page 89 Disassembly and assembly the fan cover and plastic parts (1). Loosen and remove 5 screws, remove the fan cover. (2).Loosen and remove 5 screws, remove plastic A and B covers.
  • Page 90 Disassembly and assembly the CVT cover Remove 8 bolts ,then remove the left cover, gasket and positioning pin in turn.
  • Page 91 Disassemble front and back clutch (1). Loosen and remove the nut （shown no.1），remove the retaining disc （shown no.2）. (2). Remove nuts (shown no.1), remove clutch driven wheel assembly (shown no. 2) and belt (shown no. 3) (3). Remove clutch drive wheel assembly (shown no.1) and bushing (shown no. 2)
  • Page 92 Reassembly attention: (1) Use external force to rotate the driven wheel assembly counterclockwise, push the spring open, and then load the belt, otherwise it can not be assembled. (2) Check and confirm that the sealing surface of clutch roller (Puli bead) is opposite to the direction of clutch rotation. (2) Front clutch nut (Coated with Loctite 243 thread adhesive), tightening torque 60 ~ 70Nm.
  • Page 93 Disassembly and assembly the generator (1) Remove four bolts (shown no.1) , remove the fan (shown no.2) (2) Remove the flywheel nut (shown no.1) , remove the flywheel (shown no.2) with the special tool (shown no.3).
  • Page 94 (3) Remove two bolts (shown no.1) , remove the pressure plate ((shown no.2); Remove two bolts (shown no.3) , remove the trigger (shown no. 4); Remove two bolts (shown no.5) , remove the generator stator (shown no.6). Reassembly attention: (1) Special tooling detection trigger gap: 0.7±0.1mm. (2) Gently tap the semicircle key with a copper hammer, and the upper plane is parallel to the center line of the crankshaft.
  • Page 95 Disassembly and assembly the cylinder head 1. Remove 4 bolts and remove cylinder head 2. Remove two bolts and remove chain tensioner.
  • Page 96 Reassembly attention: (1) First remove the screw and O- ring of the tensioner(shown no.1). (2) Rotate the key clockwise (shown no.2 or similar iron sheet) and return the tensioner jack rod from position A to position B before assembling, otherwise it can not be loaded. (3) Tighten 2 bolts again.
  • Page 97 3. Remove 2 bolts (shown no.1), remove timing sprocket (shown no.2); remove 2 bolts (shown no.3) and 4 nuts with gaskets (shown no.5), and remove cylinder head (shown no.6).
  • Page 98 Reassembly attention: (1) Four nuts on the cylinder head (shown no.5) tightening torque: 25-30Nm (diagonal tightening). (2) When installing the cylinder head, ensure that two positioning pins and cylinder gaskets are put in. (3) When assembling the exhaust rocker arm and the intake rocker arm, please ensure that they are in accordance with the disassembly.
  • Page 99 4. Cylinder head assembly disassembly and assembly: If necessary, disassembly and assembly are not recommended. (1) Remove the positioning plate bolt (shown no.1), remove the positioning plate (shown no.4); remove the exhaust rocker shaft (shown no. 2) and the intake rocker shaft (shown no.3), remove the intake rocker arm (shown no.6) and rocker arm spring (shown no.8), exhaust rocker arm (shown no.7) and rocker arm spring (shown no.9);...
  • Page 100 Reassembly attention: (1) Camshaft (shown no. 5) Mark A upward. (2) Remove the lock clamp of the intake valve with special tools (shown no. 11), remove the upper seat of the intake valve spring (shown no.12) and the intake valve spring (shown no.10); remove the lock clamp of the exhaust valve with special tools (shown no.14), remove the upper seat of the exhaust valve spring (shown no.15) and the exhaust valve spring (shown no.13).
  • Page 101 (3) Remove the intake valve (shown no.16) and exhaust valve (shown no.17), remove the valve oil seal (shown no.18) and valve spring seat (shown no.19).
  • Page 102 Reassembly attention: A. If there is no burning oil in the valve oil seal, try not to remove it, otherwise it must be replaced after removal. B. Valve umbrella seal face and cylinder head seal face clean up carbon deposit, visual inspection before assembly.
  • Page 103 C. After assembling according to the above reverse process, the sealing of the valve seat must be tested. Gasoline is introduced into the intake and exhaust ports separately. Leakage can be observed from the intake and exhaust valve seats, but only through excessive leakage.
  • Page 104 Disassembly of cylinder and piston 1.Remove the cylinder (shown no.7) and the seal pad (shown no.6). 2.Remove the retaining ring (shown no.3), remove the piston pin (shown no. 2) and remove the piston (shown no.1).
  • Page 105 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 the seal pad (shown no.6) is damaged or soaked in oil, it needs to be replaced.
  • Page 106 (4). 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 Yellow 52.39～52.395 52.37～52.375 0.015～0.025 125CC Blue 52.395～52.4 52.375～52.38 0.015～0.025 Green...
  • Page 107 (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 108 Disassembly of right cover 1.Remove two bolts (shown no.1 and shown no. 2) and remove the starting motor (shown no.3). When reloading the motor, you must first put the motor on the bottom and then lock the bolt, otherwise the O-ring on the motor will be damaged.
  • Page 109 2. Remove 10 bolts, remove right cover and seal gasket. Reassembly attention: (1) Check the sealing gasket and replace it in case of oil immersion, damage and folding. (2) Check whether the positioning pin is on the right cover or the right box, and then place the sealing gasket.
  • Page 110 3. Remove the four-groove nut clockwise (shown no.3), take down the gasket (shown no.4), the overrunning clutch body (shown no.5), the idler axle (shown no.1) and the idler wheel (shown no.2).
  • Page 111 4. Remove two bolts (shown no.6), remove cover plate (shown no. 7), remove bolts (shown no. 1 and 2), and remove oil pump (shown no. 3)
  • Page 112 Disassembly of gearbox 1. Remove 7 gearbox bolts; Remove gear box cover、sealing pad and positioning pin. (Be careful that the gear chamber cover and internal gear fall off, a bolt can be left when disassembled) The bolt tightening torque is 25~30Nm when the gear housing cover is reinstalled.
  • Page 113 2. Remove gears (shown no.1), shafts (shown no.2), and gears (shown no.3) When reassembling, make sure that the positioning pin is loaded and the gasket is under gear 3. 3.The rear axle is fitted with interference. If it is not necessary, it is not recommended to dismantle it. Otherwise, the bearing will be damaged and special tooling will be needed for reassembly.
  • Page 114 Disassembly of crankshaft 1. Remove two bolts (shown no.1 and 2), tap the right box several times with nylon hammer, and remove the right box.
  • Page 115 2. Tap left crankshaft with nylon hammer , remove crankshaft.
  • Page 116 3. Remove the chain (shown no.1) When reinstalling the crankshaft, insert the chain into the left box as much as possible to prevent the crankshaft from pressing into the chain.
  • Page 117 Assembly: 1. Assemble according to the above reverse process. 2. Pay attention to lip protection when installing various oil seals: butter on inner ring. 3. Inspection of sealing gaskets, if oil immersion, damage, folding and other conditions must be replaced. 4.

  • Page 118: Efi System

    EFI SYSTEM The vehicle uses the DELPHI MT05 EFI system. The schematic diagram as follows:...
  • Page 119 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 120 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 121  Start the engine until the engine is automatically extinguished, then switch the ignition key 2-3 times continuously, 3 seconds interval, then turn off the key switch  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...
  • Page 122 OBD system introduction Vehicle diagnostics system, referred to as OBD(On-Board Diagnostic). When the system fails, the fault light (MIL) or the engine (Check Engine) warning light is lit, The OBD system will save the fault information into the memory and read the related information in the form of a fault code through the standard diagnostic instrument and the diagnostic interface.
  • Page 123 fault code; the transient fault caused by bad contact, and the current lost record is the history fault code; the fault has been excluded, but the code operation of the barrier code is also used in the history fault code. The form is stored in the fault memory.
  • Page 124 P0031 O2S Heater Circuit Low Voltage P0032 O2S Heater Circuit High Voltage P0201 Injector 1 Circuit Malfunction P0202 Injector 2 Circuit Malfunction P0230 FPR Coil Circuit Low Voltage or Open P0232 FPR Coil Circuit High Voltage P0336 CKP Sensor Noisy Signal P0337 CKP Sensor No Signal P0351...
  • Page 125 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 126 4. OBD diagnostic connect and use: OBD diagnostic function: Read fault code, clear fault code, data flow display, status identification display, etc.
  • Page 127 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 128 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 129 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 battery Replace battery...
  • Page 130 (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 131 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 132 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 133 (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 134 Exclude engine mechanical Check engine cylinder pressure to see if there is failure (pay attention to insufficient cylinder pressure. 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.
  • Page 135 General diagnosis process: Inspection steps Follow steps Check whether the throttle cable is stuck or too tight, resulting in the adjustment throttle 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 136 General diagnosis process:： Inspection steps Follow steps Remark Inspect intake Check whether the air filter is blocked. system Connect the fuel pressure gauge and start the engine to check Inspect fuel whether the fuel pressure of the engine is around 250kPa at all system working conditions.
  • Page 137 Inspect ignition Check the ignition sequence and ignition timing of the engine. timing Repair or replace Check whether the exhaust pipe is smooth. the exhaust pipe Remove the spark plug cap, connect the spark plug, let the Inspect ignition spark plug on the engine block, start the engine, check whether system there was continuous blue and white high pressure fire.
  • Page 138 4. Remove the bolt (shown no.4).and take off the fuel injector(shown no.1). 5. Assembly according to the above reverse process.
  • Page 139 Throttle valve disassembly and installation 1. Remove left and right cover. 2. Disconnect intake pressure/temperature sensor (shown no.1), throttle position sensor (shown no.2), idle stepping motor (shown no.3);...
  • Page 140 3. Release the nut (shown no.5) from the thread and remove the throttle line (shown no.6) 4.Release the clamp (shown no.5), separating air filter outlet pipe (shown no. 6).
  • Page 141 5. Remove the throttle body by loosening two bolts (shown no.4). 6. Assembly according to the above reverse process.

  • Page 142: Braking System

    BRAKING SYSTEM Assemble ABS brake system or CBS brake system according to sales area or customer requirement. ABS brake system If vehicle is equipped with ABS brake system: a front disc brake, a rear disc brake, and ABS integrated unit, front and rear all equiped with counting gear disc and Hall sensor, clearance between 0.5-1.6 mm.
  • Page 144 BS brake system If vehicle is equipped with CBS brake system: a front disc brake, a rear disc brake, and CBS 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 146 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 147 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 148 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 149 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 150 Dismantle rear brake calipers and brake disc 1. Lift the vehicle main stand, unscrew and remove the 3 screws on the right side cover (shown no.1), remove the right side cover (shown no.2).
  • Page 151 2. Unscrew and remove the bolt (shown no.1、shown no.2) 3.Disconnect the oxygen sensor plug (shown no.3).
  • Page 152 4. Remove two fixed nuts of muffler on cylinder head (shown no5) and remove muffler (shown no. 6).
  • Page 153 5. Hold the left brake lever (shown no.3), unscrew and remove the 5 bolts (shown no.1) , remove the rear wheel (shown no.2). CAUTION When reassembling, the bolt thread part of Figure 1 is coated with Loctite 243 thread adhesive, and the tightening torque is 60Nm.
  • Page 154 6. Hold the left brake lever (shown no.3), unscrew and remove the nut (shown no.7) , unscrew and remove the tubing clamp bolt (shown no.4) 、two caliper fixing bolts (shown no.5),take off the brake pump (shown no.6) and the brake disc (shown no.8) Reassembly attention: The nut thread part of Figure 7 is coated with Loctite 243 thread adhesive, and the tightening torque is 100Nm.
  • Page 155 7. 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. 8.Take off the brake pad (shown no.21). 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.
  • Page 156 9. Inspection and replacement of pad and brake disc are described in part Ⅲ. CAUTION Reassembly is carried out according to the above reverse process. 10. Remove the ABS system sensor (shown no.3); CBS system does not have the counter (shown no.4) and sensor (shown no.3), the others are the same.
  • Page 157 Inspection of front and rear pad and brake disc 1. Brake disc inspection and replacement (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.
  • Page 158 2. Brake pad inspection and replacement (1)Figure 2 is front brake pad; Figure 3 is rear brake pad. (2)The thickness of the pad material is measured with a vernier depth caliper (shown no.2 and no.3). As long as the material thickness of one pad is reduced to 1.5mm, need to replace two pads at the same time.
  • Page 159 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 160 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 161 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 162 (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. (5). Always check the liquid level of the pump storage chamber. If it is lower than the "LOWER" mark, turn off the bleed valve (shown no.2).

  • Page 163: 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 164 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 165 Liquid level check 1. Hydraulic brake system level 2. Engine coolant liquid level 3. Engine oil level 4. Engine gear oil level Vehicle road check 1. Vehicle cold start 2. Instrument panel operation 3. The sensitivity of throttle control 4. Stability of acceleration and brake 5.
  • Page 166 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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