um CHILL 125 cc. Service Manual
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um CHILL 125 cc. Service Manual

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CHILL 125 cc.
SERVICE MANUAL AND EFI SYSTEM DIAGNOSTIC
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  • Page 1 CHILL 125 cc. SERVICE MANUAL AND EFI SYSTEM DIAGNOSTIC...

  • Page 2: Table Of Contents

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC INDEX Regular Service and Maintenance .................... 3 Precautions for the run-in period of a new motorcycle ............4 Level 1 Service and Maintenance ..................... 4 Level 2 Service and Maintenance ..................... 5 Level 3 Service and Maintenance .....................

  • Page 3: Regular Service And Maintenance

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Regular Service and Maintenance The front and rear shock absorbers should work properly and reliably. The air pressure of the tire should be normal, and the electrical components at During the operation of the motorcycle, different levels of loosening and each part should be able to work properly.

  • Page 4: Precautions For The Run-In Period Of A New Motorcycle

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Precautions for the run-in period of a new Motorcycle Level 1 Service and Maintenance Within the run-in period, replace the oil after 1000 km, and clean the oil Level 1 Service and Maintenance should be performed every time after the filter screen.

  • Page 5: Level 2 Service And Maintenance

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Level 2 Service and Maintenance Level 3 Service and Maintenance Level 2 Service and Maintenance should be performed every time after the Level 3 Service and Maintenance should be performed every time after the motorcycle runs 3000km~6000km.

  • Page 6: Check And Replacement Of Lubricant

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Check and Replacement of Lubricating Oil Caution  Replace the lubricating oil when the engine is in the hot state.  When the lubricating oil is basically drained off, turn the engine for First, twist off the oil several times to completely discharge residual lubricating oil.

  • Page 7: Service And Maintenance Of The Spark Plug

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Service and Maintenance of the Spark Plug Take off the spark plug. If it is found that the color of the insulator skirt of the spark plug is brown, it indicates that the engine works properly, and there is Type of spark plug: Connecting screw, flat seating, with nut nothing wrong with the spark plug.

  • Page 8: Service And Maintenance For The Air Filter

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Service and Maintenance for the Air Filter Clean the foam filter element: Take off the foam filter element. First, soak the foam filter element of the air filter in the detergent, When the filter element of the air filter is blocked by dust, it may result in and then pinch and wash it.

  • Page 9: Adjustment Of The Accelerator Handgrip

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Adjustment of the accelerator handgrip Service and Maintenance for the Front Brake Check whether the free travel of the accelerator handgrip is within the This model uses the front disc brake, which is featured by secure and reliable specified range, and then adjust it.
  • Page 10 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC  Check the wear in the front brake. If the travel of the front braking  Check the wear of the front disc brake. If the surface of friction is handgrip is too large, it indicates that the wear of the front brake shoe abnormal or deformed, please replace it with a new disc brake.

  • Page 11: Service And Maintenance For The Rear Brake

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Service and Maintenance for the Rear Brake First check the wear of the rear brake shoes. If the travel of the rear braking pedal is too large to be adjusted, it indicates that the wear of the rear brake shoe Adjustment of the rear disc brake is already beyond the limit.

  • Page 12: Adjustment Of The Rear Braking Light

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Adjustment of the rear braking light  Due the braking light of the Motorcycle directly relates to the driving safety, the conditions of the braking light should be checked from time to time. ...

  • Page 13: Service And Maintenance For Front And Rear Tires

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Service and Maintenance for Front and Rear Tires Removal and Replacement of Front Wheel  Use the main support to prop up the motorcycle. Only when the proper air pressure is set for the tire is possible to ensure the comfort and stability of the driving and prolong the service life of the tires and ...
  • Page 14 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Removal and Replacement the Rear Wheel If the tread wear depth in the middle area of the tire of the motorcycle reaches the following limit, the tire should be replaced immediately.  Turn off the ignition lock switch. Minimum limit of tread Front wheel 2.0mm...

  • Page 15: Service And Maintenance For Battery

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Service and Maintenance for the Battery In this model, the battery is mounted below the seat cushion. DC power supply is used for the electric system of the model. For the first 1000km~3000km of the motorcycle, the battery should be checked and maintained as follows: Check whether that the battery can work properly.

  • Page 16: Service And Maintenance For Fuse

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Service and Maintenance for the Fuse Horn Service and Maintenance The fuse is connected in series to the charging and discharging of the After the motorcycle has run for a certain period of time, the horn fixing could battery.

  • Page 17: Storage Of The Motorcycle

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Storage of the Motorcycle Long-time storage:  Increase the tire pressure to the specified standard value. Place tie If the motorcycle needs to be parked for a long-time (more than one month), it plugs below the tires of the motorcycle to lift the wheels from the should be done in the following steps: ground.

  • Page 18: Service And Maintenance Interval Table

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Service and Maintenance Interval Table Regular Service and Maintenance is generally based on the reading of the odometer. When the motorcycle is working under bad conditions or under load operation for a long time, the service and maintenance interval should be appropriately shortened. Item Odometer Times to service...

  • Page 19: Service And Maintenance Interval Table For Lubricated Parts

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Service and Maintenance Interval Table for Lubricated Parts Odometer reading Name Model Kilometers 1000 3000 6000 9000 12000 15000 18000 lubricating oil of engine SAE 10W 40 OKS-400(Multipurpose Braking pull-rod lithium-based lubricating grease) Disc brake braking liquid DOT3 or DOT4...

  • Page 20: Common Failures And Troubleshooting

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Common Failures and Troubleshooting Fault system Fault Causes Troubleshooting The Air filter element is blocked; Clean the air filter element The air filter leaks; Replace the air filter The air filter has too much dust; Clean the air filter element.
  • Page 21 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Continued Fault system Fault Causes Troubleshooting The cylinder pressure is too There is too much carbon buildup in the combustion Clean the carbon buildup in the combustion chamber and high. chamber and on the top of the piston. on the top of the piston.
  • Page 22 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Continued Fault system Fault Causes Troubleshooting The rear aluminum wheel deforms. Replace the rear aluminum wheel. Wheel system The rear wheel swings. The tire pressure is too low. Increase the tire pressure. The rear wheel shaft is loose.

  • Page 23: Schematic Wiring Diagram

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC...

  • Page 24: Efi Maintenance And Troubleshooting

    CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC EFI SYSTEM 1. Introduction` Because of the EFI, there are many possibilities for the engine issues. In other word, one issue may be caused by the mechanical problem or the EFI components. And the diagnostic tools cannot 100% indicate the root cause.
  • Page 25 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC  The Positive and Negative of the battery cannot be reversed. It may damage the EFI components.  Is forbidden to remove the battery when the engine is running. 3. Tools  Multimeter: Measure the voltage, the resistance and the harness connection. ...
  • Page 26 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Diagnostic help： If the malfunction code shows again after clearance, check whether the connector is connected well. Do not ignore the effect of the engine maintenance situation, the cylinder pressure, and the mechanical ignition timing. Change another ECU to do the test.
  • Page 27 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Malfunction code：P0108 Information：MAP Circuit High Voltage ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. next Check the data of ‘BARO’. Make sure whether it is about 100kPa (depending on Step 5 where you are) next...
  • Page 28 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Malfunction code：P0112 Information：IAT Circuit Low Voltage ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. NEXT STEP Check whether the data of ‘intake air temperature’ equals to the real intake air Step 5 temperature.
  • Page 29 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Malfunction code：P0113 Information：IAT Circuit High Voltage ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. next Check whether the data of ‘intake air temperature’ equals to the real intake air Step 5 temperature.
  • Page 30 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Malfunction code：P0117 Information：Coolant/Oil Temperature Sensor Circuit Low Voltage ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. next Check whether the data of ‘engine temperature’ equals to the real temperature. Step 5 Next Remove the connector and use the multimeter to check whether the resistance...
  • Page 31 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Malfunction code：P0118 Information：Coolant/Oil Temperature Sensor Circuit High Voltage or Open ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. next Check whether the data of ‘engine temperature’ equals to the real temperature. Step 5 Next Remove the connector and use the multimeter to check whether the resistance...
  • Page 32 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Malfunction code：P0122 Information：TPS Circuit Low Voltage or Open ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool and ignition on. next Check whether the data of ‘Throttle opening’ is between 0% - 1%. Step 5 Next Open the throttle to 100% slowly;...
  • Page 33 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Malfunction code：P0123 Information：TPS Circuit High Voltage ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. next Check whether the data of ‘Throttle opening’ is between 0 % - 1 %. Step 5 Next Open the throttle to 100% slowly, check whether the data of ‘throttle opening’...
  • Page 34 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Malfunction code：P0131/P0132 Information：O2S 1 Circuit Low/High Voltage ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. next Use multimeter to check whether the connection between pin B of the oxygen Harness issue sensor and pin J2-17 of the ECU is open, and whether the pin B of sensor is short to Next...
  • Page 35 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Malfunction code：P0201 Information：Injector 1 Circuit Malfunction ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. next Remove the connector of injector 1, use multimeter to check whether the voltage of Step 4 Pin A is about 12V.
  • Page 36 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Malfunction code：P0230/P0232 Information：FPR Coil Circuit Low/High Voltage or Open ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition off next Wait about 30s. Remove the fuel pump relay, ignition on. Check whether voltage of Change the pump the relay feeder ear is about 12V Next...
  • Page 37 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Use multimeter to check whether the resistance of the two coil pins is 0.5-0.65Ω Change coil @20℃ Next Use multimeter to check whether the voltage of pin B is about 12V. Help Next Check whether the connection of pin 2 of the coil and J2-01 of ECU is open or short to Harness issue...
  • Page 38 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC 5. Maintenance depending on the performance. Before issue analysis, please check:  The MIL works well.  Clear the history malfunction code.  When the malfunction code comes again, note the conditions Check the following ...
  • Page 39 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Diagnostic Help：  Make sure there is no any issue record of the engine.  Make sure the issue could repeat.  Have checked follow the instructions above and no cause found. ...
  • Page 40 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC If the issue only occurs in winter, check the oil and gear box oil. Change the oil Next Check whether the engine rotation resistance is too big or not. Check the engine Help ITEM OPERATION...
  • Page 41 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC  Difficult Starting. ITEM OPERATION RESULT NEXT STEP Check whether the fuel pump pressure is about 250kPa at idle. Next Check the pump. Pull out the spark plug, check whether the spark over is normal. Next Check the ignition system Remove the connector of the engine temperature sensor, and check whether the...
  • Page 42 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC  Unstable idle ITEM OPERATION RESULT NEXT STEP Check whether the air filter is blocked and whether the intake pipe leaks. Intake system maintenance Next Whether there is carbon deposit at the throttle body and bypass channel. Clean the TB Next Check whether the IACV works well...
  • Page 43 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC Remove the engine temperature sensor, and check whether the engine works well Change the senor Next Remove the TPS, check whether the engine works well Change the sensor Help  High idle ITEM OPERATION RESULT...
  • Page 44 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC  Acceleration gets worse ITEM OPERATION RESULT NEXT STEP Check whether the air filter is blocked and whether the intake pipe leaks. Intake system maintenance Next Check whether the fuel pressure is about 250kPa. Next Check the pump Pull out the spark plug, check whether it is wet or not...
  • Page 45 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC maintenance  Backfire ITEM OPERATION RESULT NEXT STEP Pull out the spark plug, check whether the spark over is normal. Next Check the ignition system Check whether the timing is right Next Adjust the timing Check whether there is leakage of the valve Adjust the valve...
  • Page 46 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC  Missing Spark ITEM OPERATION RESULT NEXT STEP Next Pull out the spark plug, check whether the spark over is normal. Check the ignition system Check whether the timing is right Next Adjust the timing Help Check the type and the clearance of the spark plug.
  • Page 47 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC System or Component DTC Number DTC Description Related Calibration P0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow Manifold Absolute Pressure Sensor (MAP) P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh P0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow Intake Air Temperature Sensor (IAT) P0113...
  • Page 48 CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC System Voltage P0562 System Voltage Low KsDGDM_SysVoltLow P0563 System Voltage High KsDGDM_SysVoltHigh P0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit Tachometer P1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low P1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High Oxygen Sensor 2 P0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow...

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