Zontes ZT310T-M Maintenance Manual
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Zontes ZT310T-M Maintenance Manual

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ZT310T-M
Maintenance Manual
2022-01-22
1 / 184

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  • Page 1 ZT310T-M Maintenance Manual 2022-01-22 1 / 184...
  • Page 2 For colors or upgrades, please refer to the part codes on the official website of Zontes. This manual will not be listed in detail; if the part names in this manual are inconsistent with the official website of Zontes, please refer to the official website of Zontes.
  • Page 3 User notice This manual is compiled by Guangdong Tayo Motorcycle Technology Co., Ltd. to guide dealers or service personnel to use it. This manual cannot provide more detailed knowledge about motorcycles, and is only for reference for maintenance. If you do not have the corresponding knowledge such as electrician, machine repair, etc., improper assembly or repair failure may occur during repair.

  • Page 4: Table Of Contents

    Content Content ....................................4 1. Vehicle information ..............................13 Know Before Service ............................... 13 Body label ................................14 Technical specification ............................. 15 Front wheel/steering system ..........................16 Rear wheel/suspension system ........................16 Brake system ..............................16 Battery/charging system ........................... 17 Lamp/Speedometer/switch description ......................
  • Page 5 Engine oil ................................. 38 1. Drain the oil ..............................38 2. Replace fine filter ............................38 3. Add oil ................................39 4. Change gear box oil............................39 5. Confirm the oil level ............................39 Throttle valve body ..............................40 1. Do not dismantle the throttle body to clean up carbon deposits ..............40 2.
  • Page 6 2.1 Check the brake switch ........................63 2.2 Replace the brake switch ........................63 3. Lubricate the movable parts of the brake handle ..................63 3.1 Lubricate the front brake handle......................63 3.2 After lubricating the brake handle......................64 3.3 Replacing the brake handle ......................... 64 4.
  • Page 7 Side bracket ................................81 1. Check ................................81 2. Lubrication ..............................81 Main bracket ................................82 1. Check ................................82 2. Lubrication ..............................82 3. Install the main bracket ..........................82 4. Replace the return spring post of the main support ..................82 Sound, light, and electrical device Inspection ......................
  • Page 8 12. Crankshaft position sensor ........................101 The engine cannot start and there is no sign of fault diagnosis process ............... 102 The engine cannot be started and there is a car symptom fault diagnosis process..........103 Poor acceleration ..............................103 High idling speed of hot car ...........................
  • Page 9 1. Disassemble the fuel tank assembly ......................119 2. Disassemble the fuel pump ........................121 4. Remove the external parts of the fuel tank assembly................121 Examination ................................121 1. Fuel pressure test ............................121 2. Fuel pump inspection..........................121 3.
  • Page 10 Check the gap between the wheel speed sensor and the induction ring gear ..........137 Remove the brake hose and wheel speed sensor ..................137 Release brake fluid ..........................137 FMC-HU and RMC-HU ..........................138 FC-HU and wheel speed sensor (front wheel) ..................138 RC-HU and wheel speed sensor (rear wheel) ..................
  • Page 11 2.2 Replacement method of front wheel oil seal and bearing ..............157 3. Front wheel rims and tires .......................... 157 3.1 The service life of the front wheel rim and tire .................. 157 3.2 How to replace the front wheel rim and tire ..................157 3.3 Dynamic balance ..........................
  • Page 12 Disassembly of the storage box ..........................179 Disassembly of the rear hand rest ......................... 180 Disassembly of the left and right tail cover ......................180 Disassembly of tail light ............................180 Disassembly of rear fender ............................ 181 Disassembly of the left, right fuel tank cover ......................182 Disassembly the middle cover of the fuel tank ......................

  • Page 13: Vehicle Information

    1. Vehicle information Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component sealing rings used for sealing must be replaced before assembling.

  • Page 14: Body Label

    Body label ① The vehicle identification code VIN can be seen after opening the seat cushion, and the VIN code is engraved on the cross tube at the rear of the frame. ② The muffler code is on the inner side above the muffler. ③...

  • Page 15: Technical Specification

    Technical specification Item Specification Length 2010mm(79.1 in) Width 770mm(30.3 in) Size Height 1350mm(53.2 in) Wheel base 1390mm(54.7 in) Complete vehicle dry mass 158kg(348.3 lbs) Gross mass 168 kg(370.4 lbs) Minimum ground clearance 155 mm(6.1 in) Gasoline tank volume 12L(3.17 US gal, 2.64 lmp gal) Seat height 760mm(29.9 in) Form of frame...

  • Page 16: Front Wheel/Steering System

    Item Specification Total amount of coolant 1.64L（0.43 US gal,0.36 lmp gal） Thermostat opening temperature 80～84℃(176～183.2F) Cooling Thermostat fully open temperature 95℃(203F) system Thermostat opening stroke ≥3.5mm(0.13 in) Coolant type Ethylene glycol + distilled water Front wheel/steering system Item Standard Limit Tread depth ≥1.6mm(0.063 in) Normal temperature standard tire...

  • Page 17: Battery/Charging System

    Battery/charging system Item Standard type 6－FM－12 Capacity 12Ah Battery self-discharge current 1.1mA average full 13.1～13.3V Charging voltage required for ≤12.8V Voltage unloaded bike Charging voltage required for ≤12V loading Battery Constant voltage range 14.4～14.8V Constant voltage charging Initial charging current 0.1～0.2 times the battery mode capacity...

  • Page 18: Tightening Torque

    Tightening torque Bolt tightening torque of general tightening part Intensity level Grade 4.8-6.8 (mark "4" on the head of the bolt) Grade 8.8 (mark "7" or "8.8" on the head of the bolt) Standard Breaking Tightening torque Standard Bolt diameter Tightening torque range Breaking torque value...

  • Page 19: Cable/Cable/Pipe/Electrical Device Distribution Map

    Cable/cable/pipe/electrical device distribution map 1. Distribution map of lamps and lanterns 1-Left front turn signal 2-Left daytime running light 3-Side reflector 4-Position light 5-Right daytime running light 6- Headlight 7-Right front turn signal 8-Right-hand handle auxiliary switch 9-Right-hand handle switch 10-Rear tail light/system Moving lamp 11-Rear right turn signal 12-Rear reflector 13-License plate lamp 14-Left rear turn signal 15- Left handle switch 16-Left handle assistant switch 2.

  • Page 20: Brake Upper Pump And Brake Hose

    3. Brake upper pump and brake hose 1-Front disc brake main pump 2-FMC-HU brake hose 3-RMC-HU brake hose 4-rear disc brake main pump 4. Calipers, brake hoses and wheel speed sensors 1-Brake disc (front) 2-ABS induction ring gear (55 teeth) 3-wheel speed sensor (front wheel) 4-front disc brake caliper 5-FC-HU brake hose 6-ABS induction ring gear (54 Teeth) 7-brake disc (rear) 8-rear disc brake caliper 9-wheel speed sensor (rear wheel) 10-RC-HU brake hose Caution:The specifications of the brake disc and wheel speed sensor are the same.

  • Page 21: Distribution Map Of Brake System Accessories

    5. Distribution map of brake system accessories 1-wheel speed sensor (front wheel) 2-FC-HU brake hose 3-RC-HU brake hose 4-wheel speed sensor (rear wheel) 5- rear brake lever 6-rear brake switch 7-RMC -HU brake hose 8-rear disc brake main pump 9-FMC-HU brake hose 10- front brake switch 11-front disc brake main pump 12-front brake handle 13-hydraulic control unit 21 / 184...

  • Page 22: Oil Supply System

    6. Oil supply system 6.1 Fuel evaporation 1- Fuel level sensor 2- Fuel tank 3- Fuel pump 4- Oil-air separator (welded inside the fuel tank) 5- Fuel tank cap 6- Adsorption/vent pipe 7-High pressure fuel pipe 8-Carbon tank 9-Carbon tank solenoid valve 10- Solenoid valve intake pipe 11-solenoid valve outlet pipe 12-throttle valve body assembly 13-intake pipe Caution: The carbon canister assembly includes a carbon canister 8, an adsorption/vent pipe 6, a solenoid valve intake pipe...

  • Page 23: Fuel Supply

    6.2 Fuel supply Fuel supply system: Air→Carbon canister→Adsorption/vent pipe→Oil separator (inside the oil tank) Fuel → Fuel pump filter screen → Fuel pump → High pressure fuel pipe → Fuel injector → Cylinder 7. Distribution map of cooling system accessories 1- Main water tank 2- Water tank filling port 3- Secondary water tank 4- Aluminum water inlet pipe 5- Aluminum water outlet pipe 6- Small water tank 7- Water and oil shared sensor 8- Thermostat 9- Water pump cover assembly 23 / 184...

  • Page 24: Electrical Device Layout

    8. Electrical device layout 1-TFT Speedometer 2-Flasher 3-horn 4-faucet lock 5-PKE 6-main cable 7-ignition coil 8-side bracket flameout switch 9-engine controller (ECU) 10-buzzer 11-cushion lock 12 -Dump switch 13-Windshield motor controller 14-USB charging cable 15-Front storage box lock 16-Electronic fuel tank lock 17-Canister solenoid valve 18-Battery 19-Rectifier 24 / 184...
  • Page 25 1-TFT meter 2-Windshield motor controller 3-PKE 4-faucet lock 5-front storage box lock 6-speaker 7-USB charging cable 8-dump switch 1- Cushion Lock 2- Rectifier 3- Buzzer 4- Engine Controller (ECU) 5- Battery 6- Fuse Box 1 7- Electronic Fuel Tank Lock 8- Fuse Box 2 9- Fuse Box 3 10- Ignition Coil 11- Side Bracket flameout switch 25 / 184...

  • Page 26: Intake And Exhaust System

    9. Intake and exhaust system 1- External oil and gas separator 2- Cylinder head 3- Throttle valve body assembly 4- Intake manifold 5- Cylinder head exhaust pipe 6- Air filter intake pipe 7- Air filter outlet pipe 8- Cylinder 9- Muffler 10- Crankshaft Box exhaust pipe Intake system (indicated by the green arrow): Air →...

  • Page 27: Tool

    Tool 125-piece tool set Torque wrench On-board tools Claw hammer Pull code Rubber hammer Dynamic Balancing Machine Tire raking machine Oil pan Measuring cup Funnel Taps, dies Micrometer Depth gauge Vernier caliper Feeler gauge 27 / 184...
  • Page 28 PT300 electronic spraying and Tire pressure gauge Magnetic base + dial indicator writing diagnostic Speedometer 17#Inner hexagon （16PIN） Hoop clamp Internal Circlip Pliers External circlip pliers Clamp multimeter Multimeter Dust blow gun Some of the above pictures are from the Internet, and the copyright belongs to the author of the original picture. Do not use it for other purposes.

  • Page 29: Expansion Nail Description

    Expansion nail description ①Press down the center cylinder with 4# inner hexagon or other tools, you can hear a sound or the center cylinder moves axially by 2mm; ②Pry open the gap with a blade, nail or carving knife, etc. and remove it; if space permits, you can reach it Push out from the back;...

  • Page 30: Maintenance

    2. Maintenance Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component seals used for sealing must be replaced before assembly.

  • Page 31: Maintenance Schedule

    Maintenance schedule Inspection cycle Km/ Mile Initial 1000/621 Every 5000/3107 Every Number of months initial 3 Every 15 10000/6214 Check item Every 30 Air filter (filter element) inspection replace Engine air inlet filter inspection replace Bolts and nuts of muffler Fastening Fastening Spark plug...

  • Page 32: Air Filter (Filter Element), Air Inlet Filter Element

    unpredictable failures. ●The first maintenance is carried out for the first 1000 kilometers (621mile) or 3 months (whichever arrives first), and thereafter regular maintenance is carried out every 5000 kilometers (3107mile) or 15 months (whichever arrives first). ●Replacement of unqualified parts will cause accelerated wear of your vehicle and shorten its service life. ●Check the brake disc, muffler, spark plug, coolant and other items after cooling down.

  • Page 33: Replace The Air Inlet Filter

    shown in the figure. The bolt here cannot be removed air inlet cover in the direction shown. temporarily, just loosen it completely. 5. Remove the air filter housing a. Use a Phillips screwdriver to remove the 9 screws that fix the housing of the air filter. b.

  • Page 34: Inspection Air Filter Waste Oil Pipe

    c. replace the new filter element and sealing strip. 7. Inspection air filter waste oil pipe Wipe clean the surface of the waste oil pipe and visually check for liquid. If so, use pliers to remove the waste oil pipe clamp, clean the waste oil pipe, and then reinstall it.

  • Page 35: Bolts And Nuts Of Muffler

    ●The air filter element and the engine air inlet element engine exhaust port gasket. should be cleaned regularly in accordance with the b. If there is no sign of air leakage, use 6# inner provisions of the regular maintenance and lubrication hexagon to check whether the M8 nut at the exhaust table.

  • Page 36: Spark Plug

    Spark plug Caution: ●Before disassembling, blow off the dust near the spark plug with a dust blower. ●After removing the spark plug, prevent foreign objects from falling into the engine. 1. Disassemble the spark plug f. Use your fingers or a plastic crowbar to forcefully a.

  • Page 37: Check The Spark Plug

    replace the spark plug with a new one. b. Clean the electrode with a special spark plug cleaner. Use a hard iron wire or steel needle to remove the attached carbon deposits. c. Use a feeler gauge to inspect the gap between the center electrode and the side electrode.

  • Page 38: Engine Oil

    Engine oil ●The vehicle must be parked on a flat and stable ground or a lifting platform. ●Once the engine and muffler have cooled down, the d. After placing an oil pan under the oil drain bolt, use operation can be performed. a 14# sleeve to remove the oil drain bolt ⑴...

  • Page 39: Add Oil

    the groove of the fine filter cover ⑵, and then install it counterclockwise. back to the engine box. f. Screw back the 3 nuts (1), first pre-tighten the bottom 2 with a 10# sleeve, and tighten the upper nut (1a) with a 10# torx wrench; then tighten the bottom 2 screws.

  • Page 40: Throttle Valve Body

    draw it out or add it to the standard. up, and then pull it out toward the rear of the vehicle. Note that there are buckles on both sides of the front. The rebate position needs to be inserted in the front when re-installing.
  • Page 41 f. Pull out the two relay wires. j. Remove the decorative buckle ⑻ of the M6 hexagon socket bolt; remove the bolts on both sides There are a total of 8 relays, the model is: KH-1A4T. with 4# hex socket ⑶, remove the bushing ⑷ and the g.

  • Page 42: Remove The Throttle Valve Body Assembly To Clean Up Carbon Deposits

    it out, and then pull out the desorption tube (3). d. Loosen the bolt of the clamp ⑷ with a 4# inner hexagon and pull out the air filter outlet pipe ⑸ and clamp ⑹ in the direction of the arrow to pull out the n.

  • Page 43: Disassemble The Three-In-One Sensor

    5. Throttle valve body troubleshooting process body outlet respectively. It is forbidden to directly soak Throttle valve body the throttle valve body assembly and intake manifold troubleshooting process assembly with any liquid. h. After cleaning the heat insulation pad, replace 2 Idle adjustment bolt Throttle body sensor looseness,poition...

  • Page 44: Throttle Cable

    Throttle cable bracket to adjust. Torque: 3.0 N.m (0.3 kgf.m, 2.2 lbf.ft). 1. Inspection a. Check whether the rubber sleeve of the right hand handle and the throttle cable are damaged. b. Check whether the rubber sleeve of the right hand rotates smoothly and whether it can return automatically.

  • Page 45: Idle Speed

    Idle speed Caution: ●Before checking the idle speed, you should check other engine maintenance items and the condition is normal before proceeding. ●Check the following items before checking the idle speed: The maintenance indicator light " " should not light up. The status of the spark plug has been checked.

  • Page 46: Fuel Evaporative Pollutant Control System

    Fuel evaporative pollutant control system 1- Fuel level sensor 2- Fuel tank 3- Fuel pump 4- Oil-air separator (welded inside the fuel tank) 5- Fuel tank cap 6- Adsorption/vent pipe 7-High pressure fuel pipe 8-Carbon tank 9-Carbon tank solenoid valve 10- Solenoid valve intake pipe 11-solenoid valve outlet pipe 12-throttle valve body assembly Remarks: The carbon canister assembly includes carbon canister 8, adsorption/vent pipe 6, solenoid valve inlet pipe 10, and solenoid valve outlet pipe 11.

  • Page 47: Radiator

    b. After opening, buckle the rubber plug as shown in Radiator the figure by hand, and be careful not to use sharp tools or nails to buckle. ●The vehicle must be parked on a flat and stable ground or a lifting platform. ●Once the engine and muffler have cooled down, the operation can be performed.

  • Page 48: Add Coolant To The Radiator

    c. Grasp the upper part of the storage box with one thermostat is stably overflowed with coolant, the coolant level can be seen at the water filling port. hand, and remove the bottom bolt ⑴ with the 4# inner hexagon with the other hand. e.

  • Page 49: Check All Water Pipes For Leaks; Aging

    b. Pull the deformed fins straight with a flat engraving knife or a small flat-blade screwdriver. If the deformed fins exceed 20%, a new heat sink needs to be replaced. 6. Check all water pipes for leaks; aging. 1-Radiator 2-Coolant expansion tank 3-Aluminum water inlet pipe 4-Aluminum water outlet pipe 5-Small radiator 6- Water and oil shared sensor 7-thermostat 8-water pump assembly 49 / 184...
  • Page 50 1- Main water tank inlet pipe 2- Leakage pipe 3- Small radiator outlet pipe 4- Water inlet pipe 5- Secondary water tank connection pipe 6 Main water tank outlet pipe 7- Engine inlet pipe 8- Small radiator inlet pipe 9- Small circulation outlet pipe 10-Water pump cover inlet pipe 11-Cylinder inlet pipe 50 / 184...

  • Page 51: Fuel Pipe

    Fuel pipe Caution: ●A small amount of fuel will flow out when the high- pressure fuel pipe is removed. ●Work in an open and ventilated place. Smoking, mobile phone calls, etc. that may cause sparks are prohibited on the job site. 1.

  • Page 52: Fuel Pump

    3. Fuel pump pulling about 20mm (0.8 in) toward the rear wheel with 3.1 Use oil pressure gauge to measure fuel pressure the other hand. There is a bracket at the place shown in a. Refer to steps a to k of "Remove stepper motor and the small picture, so it cannot be pulled down directly.

  • Page 53: Treatment Of Abnormal Fuel Pressure

    vehicle shall be powered off for more than 10 seconds a. Whether the fuel pipe is leaking; and then check according to the above operation. b. Whether the fuel tank vent pipe is blocked or bent 4. Treatment of abnormal fuel pressure excessively;...

  • Page 54: Belt

    V belt 1. System Components Parts information Serial number part name quantity serial M12×1.25×35 hexagon flange bolts (grade φ23.2×φ40×3.25 washer 10.9/environmental protection color) M14×1 Hexagon Flange Nut (Grade φ12.3×φ40×4 washer 10/Environmental Protection Color Zinc) Driving wheel drive disc φ21.8×φ1.8 Acrylic O-ring Distance tube φ14.5×φ25×16 driven wheel bushing V-shaped transmission belt...

  • Page 55: Maintenance

    2. Maintenance Caution: ●Special tools are required to disassemble the driving wheel and driven wheel components. ●It is recommended to regularly check and replace it by a designated dealer or repair shop. ●Belts should be checked every 10,000 kilometers e. Use an 8# sleeve to remove the 12 M6×30 (6213 mile) or 30 months.
  • Page 56 b. Use a torque wrench (or wind screw) and a 17# sleeve to remove the M12×1.25×35 hexagon flange f. Remove the driven wheel clutch cover from the bolts counterclockwise. drive shaft. c. Loosen the M14×1 hexagonal flange nut counterclockwise with a torque wrench (or wind screw) and a 19# sleeve.

  • Page 57: Inspection

    belt. It needs to be replaced when the width is ≤25.4mm (1 in). 2.3 Inspection Caution: Every 3 years or driving 20000 kilometers (12427 mile), the continuously variable clutch sub- assembly needs to be inspected, maintained or repaired! ! ! e.

  • Page 58: Assembly

    2.4 Assembly Caution: ●Before assembling, it is necessary to conduct a comprehensive inspection of all the parts of the disassembled continuously variable clutch sub- assembly, and replace the parts that reach the limit of use. ●Use compressed air to completely clean the dust accumulated in the left crankcase belt chamber before assembling.
  • Page 59 clockwise. After lifting the moving plate of the driven wheel by about 10mm (0.4 in), quickly extend your finger near the side of the V-shaped drive belt to slide the V-shaped drive belt into the belt groove between the moving plate of the driven wheel and the fixed plate. Finally, clamp the middle of the belt with an elastic clip to prevent the belt from loosening by itself.

  • Page 60: Common Fault Phenomena/Troubleshooting

    3. Common fault phenomena/troubleshooting 3.1 The engine can be started, but the rear wheel does not rotate a. The V-shaped transmission belt is severely worn or broken. b. The clutch shoe is worn or damaged. c. The large spring of the driven wheel is damaged. d.

  • Page 61: Braking System

    Braking System Caution: ●For the layout of the brake hose on the vehicle, please refer to the brake system accessories distribution diagram in the "Vehicle Information" chapter of this manual. Braking system component diagram: 1- rear brake handle 2- rear disc brake main pump 3- RMC-HU brake hose 4- wheel speed sensor (front wheel) 5- front disc brake caliper 6 front disc brake main pump 7- front brake handle 8-FMC-HU brake hose 9-ABS hydraulic control unit 10-FC-HU brake hose 11-wheel speed sensor (rear wheel) 12-rear disc brake caliper 13-RC-HU brake hose...

  • Page 62: Check The Brake Components

    Caution: c. Measure the thickness of the front and rear brake discs. If it is less than 4.0mm (0.16 in), replace it. Hang ●This inspection should be completed by a qualified maintenance organization. the front wheel in the air and turn the front wheel by ●Regularly check whether the brake fluid level is at 3/4 hand to observe whether there are obvious damages on of the observation window.

  • Page 63: Check The Front And Rear Brake Switches

    Front brake switch Rear brake switch 2.2 Replace the brake switch Take the replacement of the rear brake switch as an g. Pull out the rear caliper assembly and check the example to explain. wear of the brake pads. If it is nearly worn or worn to the a.

  • Page 64: After Lubricating The Brake Handle

    evenly. disc and the brake pads are fully run-in. . Allow enough braking distance before running in sufficiently to ensure d. Wipe clean the bolt ①, and apply high vacuum silicone grease evenly. driving safety. e. Reinstall. 3.2 After lubricating the brake handle Refer to the above method to lubricate the rear brake ●The brake pads must be replaced in pairs, only handle.

  • Page 65: Replace The Brake Pads After Replacement

    d. Grasp the outer brake pad with your left hand and insert the pin ② with your right hand, being careful not to insert it to the end. Install the inner brake pad in place, then insert the pin to the end and use the 5# inner hexagonal lock pin ②.

  • Page 66: Replace The Brake Disc

    6. Replace the brake disc ●The vehicle must be parked on a flat and stable ground or a lifting platform. ●After replacing the brake discs, brake pads, or reassembling the front and rear wheels, the brake handle must be operated repeatedly until the brakes restore the braking effect. ●Contaminated disc brake discs and disc brake pads will reduce the braking effect.

  • Page 67: Brake Hose

    Then use a 12# sleeve to remove the bolt ⑾ that fixes Refer to steps 1 and 2 of checking brake fittings in the the rear shock absorber, and then remove the rear brake system, you can use the endoscope with LED to shock absorber and tie it.

  • Page 68: Replace The Brake Fluid

    the main pump of the disc brake or the piston will become stuck, which will cause the braking effect to deteriorate or fail, which will affect driving safety. 2.1 Replace the front brake brake fluid a. Wrap around the front brake main pump with oil- resistant plastic film, as shown in the previous section.

  • Page 69: Replace The Rear Brake Fluid

    Tire Then put the rubber cap on the air nozzle. h. Reinstall the upper cover of the main pump. i. Repeatedly pinch and hold the brake handle to check whether the brake returns to normal hydraulic ●Check the tire condition and tire pressure before resistance.

  • Page 70: Check The Tires

    dust-proof, sun-proof, and ventilated place; or cover it with a car jacket to protect the body parts and the tires better. If you do not drive for a long time, you should support the vehicle firmly and let the tires hang in the air to avoid deformation caused by long-term load on the ground contact.

  • Page 71: Check The Steering Mechanism

    ●Too small steering mechanism clearance will cause inflexible steering and accelerate bearing wear. When it is too large, it will cause driving jitter and abnormal noise when braking. 1. Check the steering mechanism a. Support the front wheel with a suitable tool so that the front tire is hung in the air and then rotate the direction handle left and right to confirm whether the rotation is flexible and smooth;...

  • Page 72: Malfunction

    4. Malfunction whether the front shock absorber is leaking; whether Normally rotate the handle, if it feels more laborious, there are scratches, pits, rust, etc. on the surface of the you need to investigate the following reasons: front fork tube. Shallow scratches, small pits, and slight a.

  • Page 73: Check The Shock Absorption Performance

    slightly, straighten the pressure and small stroke several times, and measure while straightening. The radial run out after correction should be less than 0.05mm (0.002 in). If the original bending deformation part is out of round after correction, it should be replaced. If the deformation is too large, the shock absorption should be replaced.

  • Page 74: Check

    1. Check a. One person straightens the vehicle and stabilizes the vehicle, and one person presses the rear armrest behind to observe whether the rear shock absorber can recover smoothly. b. Check whether the shock-absorbing bolts are b. Use the 4# inner hexagon to insert into the hole of loose.

  • Page 75: Replace The Shock Absorption

    e. Open the air filter slightly, and adjust the left rear shock to the same gear with reference to the adjustment of the right rear shock absorption method. Grasp the left tail skirt and remove the expansion nail (3), and take off the left tail skirt. 3.

  • Page 76: Bolts And Nuts For Body And Engine Installation

    Bolts and nuts for body and engine engine as shown in the figure are loose. The nut on the installation right front part (a in the figure) needs to be pulled out or pulled out of the high-pressure oil pipe and cable Caution: connector to facilitate tightening with tools.

  • Page 77: Valve Clearance Adjustment

    Valve clearance adjustment 1. Maintenance information 1.1 General information a. This chapter introduces the operation method of valve clearance adjustment. b. The adjustment of the valve clearance can only be carried out after the engine is removed from the vehicle. c.
  • Page 78 engraved line on the timing driven sprocket should also be aligned with the raised mark line on the cylinder head. Caution: Once the T-point engraved line turns over the marked line when rotating the flywheel, it cannot be reversely rotated back to the right point. The crankshaft must be turned clockwise twice again to realign the points! ! ! e.
  • Page 79 g. The adjusting shim is small and easy to fall into the engine when it is taken out. The original adjusting shim can be sucked out with a magnet rod. Then use tweezers to put in the adjustment shim to be replaced. i.Set the two valve rocker arm limit blocks on the M5×15-5# hexagon socket head bolts, and then apply a After replacing the two adjusting shims on the same...
  • Page 80 j. Wipe off the oil and residual sealant on the joint surface of the cylinder head and the seal ring of the cylinder head with a clean rag, and reapply a proper amount of sealing silicone on the corners of the joint surface of the cylinder head.

  • Page 81: Side Bracket

    and the flame should be automatically turned off, Side bracket otherwise it is necessary to troubleshoot the flameout Caution: switch or brake switch failure. ●Park the vehicle on a flat and stable ground or a lifting d. Check whether the side bracket mounting plate is platform, and put down the main support.

  • Page 82: Main Bracket

    b. Remove the spring from the main support. c. Apply a proper amount of grease to the end face, inner hole of the engine box bushing and the surface of Main bracket the main support shaft. Caution: ●Park the vehicle on a flat and stable ground or a lifting platform, and put down the side brackets.

  • Page 83: Sound, Light, And Electrical Device Inspection

    ⑦FUEL: Press to check whether the fuel tank cover is normally opened. Sound, light, and electrical device Inspection Caution: c. The left switch button test. If you need a more ●Before driving, check whether the lights of the whole detailed understanding of each button function, you can car are normal, including turn signals, tail lights, brake check the driver's manual.

  • Page 84: Headlight Height Adjustment

    Open the protective cap ①, pull out the PKE insurance ③, first insert the DC output plug of the d. Check the battery voltage charger provided with the car into the PKE charging Open the cushion, take off the battery cover and use a port;...

  • Page 85: Fuse Box

    3.Fuse box Caution: ●If the fuse is blown, you must replace the fuse of the same specification. It is forbidden to use wires such as copper or iron wire for direct connection. ●If it is blown after replacement, you need to troubleshoot the entire vehicle cable before replacing it. ●This vehicle uses a small fuse.

  • Page 86: Troubleshooting

    start up Protection starting circuit ① Protect the ABS controller ② Protect position lights, turn signals, tail lights, brake lights, Assistant ③ license plate lights, horns, overtaking lights and other lamps Protect the deputy handle switch, Speedometer, windshield, Others ④ anti-theft device connector There are two 10A spare fuses on the outside of the fuse box.

  • Page 87: Left Hand Handle Auxiliary Switch

    troubleshooting. c. "SEAT" button failure If the battery is out of power and inconvenient to charge, or the cushion lock fails to open, you can fill in the quality feedback form and let the engineer guide the method of manually opening the cushion. For safety reasons, this manual does not provide this method.
  • Page 88 ●It is prohibited to adjust the bracket nut ③. a. If the horn switch does not respond, please refer to the troubleshooting process of the left-hand switch on the next page b. The speaker sounds abnormal If the sound is small, hoarse, etc., first confirm whether the battery is sufficient, and turn on the headlights to determine whether the battery is sufficient according to the brightness of the light.

  • Page 89: Left Hand Switch

    4.5 Left hand switch The left hand switch controls the turn signal, horn and far, low beam, hazard warning light, and overtaking light. It is difficult to check if there are more lines. 89 / 184...

  • Page 90: Light

    4.6 Light Caution: ●When using wires to detect lamps, please pay attention to distinguish the positive and negative poles. For detailed wire colors, please refer to the electrical schematic diagram in the driver's manual provided with the car. The troubleshooting methods of the lamps are basically the same. You can directly lead the wires to the battery with the battery.

  • Page 91: Efi System

    3. EFI system Know Before Service Caution: 1. The structure and working principle of the EFI system are relatively complicated, and it is necessary to have a certain understanding of the working principle and structural characteristics of each EFI system before checking and troubleshooting.
  • Page 92 Maintenance personnel themselves also need to have certain professional knowledge and experience accumulation process. ●Do not turn on the flameout switch for a new car or a vehicle that is about to run out of fuel. Be sure to replenish enough fuel before turning it on, otherwise the fuel pump will be damaged if it runs dry without fuel.

  • Page 93: Error Code

    Error code Caution: ●Unlock the vehicle and turn on the flameout switch. When it is not started, the EFI fault light is always on as normal. If it is not on, the vehicle cannot be started. ●After starting the vehicle, if the fault light is on and the EFI failure is reported, it means that the EFI system is abnormal.

  • Page 94: Clear Fault Code

    Code Instruction Code Instruction The heating control circuit of the Engine coolant temperature sensor signal is P0030 upstream 1 cylinder oxygen sensor is PD116 unreasonable open The upstream 1 cylinder oxygen sensor Engine coolant temperature sensor circuit voltage P0031 P0117 heating control circuit voltage is too low is too low The upstream 1 cylinder oxygen sensor...

  • Page 95: Efi Parts Layout

    ●When the engine is running, the fault light does not turn on, and the fault light flashes after the engine is turned off, it is a historical fault, which will not affect the performance and life of the whole vehicle, and will automatically disappear later.

  • Page 96: Fault Diagnosis And Elimination Of Efi Parts

    Fault diagnosis and elimination of EFI parts Caution: ●Once the EFI components are disassembled, the EFI system needs to be reset. For details, see the service information in this chapter. ●Fuel pumps, three-in-one sensors, stepping motors, ECUs, etc. are precision parts, such as unauthorized disassembly may cause damage, and it is not within the scope of the three guarantees for human reasons.

  • Page 97: Carbon Canister Solenoid Valve

    5. EFI relay vehicle, the fuel pump can be used to drain the fuel in There are two PVC sheaths at the battery, each the fuel tank. After lifting the vehicle, press the plug sheath covers 4 relays. buckle as shown in the figure to pull out the cable. Remove 5 bolts from the bottom with a 10# sleeve, and then remove the fuel pump after removing the high-pressure fuel pipe bracket.

  • Page 98: Fuel Injector

    high-pressure oil pipe at the end of the fuel pump to After the Light Black/ discharge the remaining fuel. Use a 10# sleeve to green White green white remove the bolt ⑴, remove the injector holder ⑵, and starts 6. Fuel injector then take off the injector ⑶.
  • Page 99 grasp the middle of the cover, press down the back of the cover and pull out the left cover at the same time. b. Pull out in sequence in the direction of the arrow (from the rear wheel to the front wheel). Note that d.

  • Page 100: Throttle Valve Body

    8. Throttle valve body 8.1 Common failure phenomena 1. The engine is easy to stall when the vehicle is running, and it is difficult to start, especially cold starting. 2. Idle speed is unstable or no idle speed, and there is intermittent jitter when accelerating. 3.

  • Page 101: Oxygen Sensor

    10. Oxygen Sensor ●The oxygen sensor must be removed after the engine and muffler have cooled down completely. When there is poor engine performance, unstable idle speed, high fuel consumption, and incorrect air-fuel ratio, check the oxygen sensor. The fault code can be read through the diagnostic Speedometer to confirm whether the oxygen sensor is faulty.

  • Page 102: The Engine Cannot Start And There Is No Sign Of Fault Diagnosis Process

    measure the resistance of the crankshaft position sensor ① at 25°C (77F), it should be 150±20Ω, otherwise it should be replaced. In addition, the three-hole plug of the stator ② of the magneto uses a multimeter to measure the phase-to-phase resistance of any two terminals at 25°C (77F), which should be 0.7±0.15Ω.

  • Page 103: The Engine Cannot Be Started And There Is A Car Symptom Fault Diagnosis Process

    The engine cannot be started and there is a car symptom fault diagnosis process When the start button is pressed, the starter motor can drive the engine to run normally. When there are signs of a car but cannot start, you can refer to the following diagnosis process to troubleshoot the cause of the fault. Check the ignition coil Check the air filter outlet pipe and the air filter element;...

  • Page 104: High Idling Speed Of Hot Car

    High idling speed of hot car When a cold car occurs, it can run at a normal fast idling speed. After a hot car, the idling speed does not fall back to 1500-1700 rpm. You can refer to the following diagnosis process to troubleshoot the cause of the fault. Warm up idling Check the wires speed is too high...

  • Page 105: Unsteady Idling, Easy To Cutoff

    Unsteady idling, easy to cutoff The engine is running at an unstable idling speed, easy to stall, and can return to normal after a warm car. You can refer to the following diagnosis process to troubleshoot the cause of the fault. Unsteady idling / flameout Check the oil circuit Whether it returns to...

  • Page 106: Analysis Flow Chart Of Efi Failure Indicator Light Always On

    Analysis flow chart of EFI failure indicator light always on If the EFI failure indicator light " " is always on, you should first check whether the wires of the EFI sensors are loose. The fault light is always on during driving Read fault code Idle speed fault...

  • Page 107: Electrical Schematic Diagram Of Efi System

    Electrical schematic diagram of EFI system 107 / 184...

  • Page 108: Ignition System

    4. Ignition system Know Before Service 1. The content of this chapter requires certain maintenance experience. It is recommended to check or repair with a qualified maintenance organization. 2. Do not disassemble the parts connected to the 12V power supply at will after power-on, to avoid the self-inductance of the coil in the electrical appliance, which may damage the ECU or sensor due to the instantaneous voltage.

  • Page 109: Troubleshooting

    Troubleshooting Check the following items before diagnosing the ignition system a. Check whether the spark plug is abnormal; b. Check whether the ignition coil high-voltage cap or plug is loose; c. Check whether water enters the high pressure cap; d. If there is no spark, find the ignition coil of the same model to confirm that there is no fault and install it on the faulty vehicle to test whether there is spark;...

  • Page 110: Ignition System Layout

    Ignition system layout 1- Dump switch 2- Side bracket flameout switch 3- Faucet 4- PKE 5- Ignition coil 6-Spark plug 7- Right-hand handle auxiliary switch 8- Right-hand handle switch 9 Fuse box 10- Relay 11-Starting relay 12-Battery 13-Magnetic Motor stator 14-Crankshaft position sensor 15-ECU Caution: ●The fuse box comes with the main wiring harness and there are 3 in total.

  • Page 111: Ignition System Inspection

    Ignition system inspection Caution: ●If there is no spark in the spark plug, check all the cable connections for looseness or poor contact before checking the ignition system. ●Use a high-precision digital multimeter. For details of the ignition coil test method, please refer to the section "Ignition Coil" in the "Electronic Injection System"...

  • Page 112: Installation

    Flywheel Checking Fixture： Box triangle timing mark Flywheel timing marking Remove the rotor from the engine, install the flywheel gauge as shown in Figure 1, and check whether the marking line on the side of the rotor is in the slot (Figure 2). Flywheel limit b.

  • Page 113: Starting System

    5. Starting system Know Before Service 1. If current flows through the starter motor when the engine is not started, it can be judged that the starter motor is damaged and needs to be replaced. 2. Before servicing the starter motor, turn on the engine stop switch to " "...

  • Page 114: Starter Motor

    2. Starter motor Does the Brake switch or After the vehicle is Short circuit starter motor flameout switch energized, the flameout relay work? failure switch is hit“ ” The flameout switch of the Whether the EFI Press the start Does the starting Relay failure right handle is fault light is on...

  • Page 115: Starting System Electrical Schematic Diagram

    Starting system electrical schematic diagram Starter motor Caution: ●If the starter motor is removed for maintenance, replace the O-ring with a new one and apply a proper amount of engine oil. ●Our company only sells starter motor assemblies, not O-rings and motor parts separately. The O-ring has an inner diameter of φ25mm (0.98in) and a wire diameter c.

  • Page 116: Disassemble The Starter Motor

    e. When reassembling, make sure not to omit the O ring that comes with the starter motor, and align the teeth of the electric starter reduction gear. Note that the O-ring needs to be correctly assembled into the box, as it will cause leakage if cut edges occur. Torque of the two bolts for fixing the starter motor: 12±1.5 N.m (1.2±0.2 kgf.m, 9±1 lbf.ft).

  • Page 117: Examination

    1-M6×90 bolt×2 2-O ring×2 3-O ring 4-starter motor front cover 5-gasket 6-rectangular sealing ring 7-starter motor outer shell 8-rectangular sealing ring 9-electric pole 10-screw ×2 11-Negative brush×2 12-Volute spring×4 13-Positive brush×2 14-Brush frame 15-Brush holder insulation gasket 16-Starter motor back cover 17-Insulation gasket 18-Nut×2 19- Gasket Examination cable;...

  • Page 118: Check The Starting Relay

    2.2 Ground wire The vehicle is powered off and locked. Set the Commutator multimeter to the buzzer position, connect one test lead Crankshaft to the green/red wire, and one to any bolt connected to the frame. It should be conductive when the start button is pressed.

  • Page 119: Fuel Supply System

    6. Fuel supply system Know Before Service 1. Bending or twisting the control cable will affect the smooth operation, and may cause a short circuit or open circuit, causing the vehicle to lose control. 2. The operation should be carried out in an open and ventilated place. All activities that may cause sparks, such as smoking, calling on mobile phones, etc., are prohibited on the job site.
  • Page 120 c. Press the anti-trip buckle of the plug of the oil level sensor and pull out the plug. g. After confirming that the high-pressure oil pipe, vent pipe and oil level sensor plug have been unplugged, stand on the right side of the vehicle to facilitate the removal of the fuel tank assembly.

  • Page 121: Disassemble The Fuel Pump

    Remove the oil level sensor Place the removed fuel tank assembly. It is recommended to protect the fuel pump at the bottom of the fuel tank. Use a 10# sleeve to remove the 4 bolts ⑴, and pull the sensor ⑵ out. Be careful not to pull it forcibly to avoid the deformation of the float connecting rod, which will cause the deviation of the oil volume display to increase.

  • Page 122: Oil Level Sensor

    Use a multimeter to measure the voltage of the fuel pump plug cable end, unlock the vehicle, and when the engine stop switch is turned to "", the fuel pump will accumulate pressure for about 5 seconds, during which time the battery voltage should be able to be measured.

  • Page 123: Cooling System

    7. Cooling system Know Before Service 1. Please refer to the radiator section of the "Maintenance" chapter of this manual for the corresponding precautions for the coolant (antifreeze). 2. Check the cooling water pipe; check the height of the cooling liquid, adding and discharging the cooling liquid have been described in detail in the radiator section of the "Maintenance"...

  • Page 124: Coolant System Distribution Map

    Coolant system distribution map 1- Main water tank 2- Water tank filling port 3- Secondary water tank 4- Aluminum water inlet pipe 5- Aluminum water outlet pipe 6- Small water tank 7- Water and oil shared sensor 8- Thermostat 9- Water pump cover assembly 124 / 184...

  • Page 125: Coolant Flow Diagram

    Coolant flow diagram 1- Main water tank inlet pipe 2- Leakage pipe 3- Small water tank outlet pipe 4- Water inlet pipe 5- Secondary water tank connection pipe 6 Main water tank outlet pipe 7- Engine inlet pipe 8- Small water tank inlet pipe 9- Small circulation outlet pipe 10-Water pump cover inlet pipe 11-Cylinder inlet pipe Cooling system: Small loop (indicated by the blue arrow):...

  • Page 126: Cooling System Disassembly

    the plug of the cooling fan of the small water tank. Cooling system disassembly Caution: ●Before disassembling, please refer to the steps of discharging the cooling liquid in the cooling system section of the "Maintenance" chapter to drain all the cooling liquid first.
  • Page 127 water tank water inlet pipe, and pull out the water tank assembly to the left. Grasp both sides of the main water tank and pull it up in the direction of the arrow to remove the radiator assembly from the vehicle. g.

  • Page 128: Coolant System Hoop/Clamp Distribution Map

    Coolant system hoop/clamp distribution map 1-Water pipe clamp (φ26) 2-Water pipe clamp (φ22)*10 3-Water pipe clamp (φ26) 4-Water pipe clamp (φ9) 5-Water pipe clamp (φ10.5)*2 Thermostat assembly and small loop 1- Thermostat assembly 2-M6×22 bolt*2 3-Small circulating water pipe 4-Tee pipe 5-M6×12 bolt*2 6-Water pipe hoop (φ22)*3 7-Water pump cover inlet pipe 8-Water pipe hoop (φ24)*3 9-Cylinder inlet pipe 10-Water pump cover assembly Caution: The bolt (5) at the thermostat is an exhaust bolt, and the bolt at the water pump cover is a bolt for cooling...

  • Page 129: Cooling System Accessories

    b. Use an 8# sleeve to remove 2 bolts ⑵, take off the thermostat assembly, and remove the O ring ⑾ from the thermostat assembly. Once disassembled, O ring ⑾ needs to be replaced. Before reassembly, the joint surface should be cleaned. Note that the O-ring cannot be missing and must be correctly assembled in place.

  • Page 130: Attention To The Water Tank Filling Port

    foreign objects on the surface. 2. Attention to the water tank filling port: ●Special ventilation tooling (gas pressure reducing valve, air gun, sealing tube) is required for testing. ●After the soaking inspection is completed, the water stains should be wiped clean in time.

  • Page 131: Water And Oil Shared Sensor

    1-Water tank front guard bolt*4 2-Water tank front guard 3-Water tank 4-Fan nut 5-Fan 6-Fan motor 7-Fan Guard 8-Fan Guard Bolt*3 9-Fan Motor Bolt*3 6. Water and oil shared sensor For details on sensor detection and disassembly methods, please refer to the section "Electronic Injection System" chapter EFI Parts Fault Diagnosis and Elimination.

  • Page 132: Disassembly

    7.3 Disassembly Checking method of thermostat assembly: Seal the two ports, pass in compressed air of 181 kPa (1.85 Kgf/cm2, 26.3 psi) from the other port, put it in the water and let it stand to see if there are bubbles, if there is leakage. 1-M6×10 bolt*2 2-M6×12 bolt 3-φ5.6×φ1O ring 4-thermostat upper shell 5-thermostat core 6-thermostat lower shell 7.4 Thermostat core inspection Check the opening temperature, full opening temperature and lift of the main valve in the...

  • Page 133: Braking System

    8. Braking system Know Before Service 1. The content of this chapter requires certain maintenance experience. It is recommended to check or repair with a qualified maintenance organization. 2. Frequent inhalation of the dust generated by the brake pads, regardless of the composition, may have a certain impact on health.

  • Page 134: Trouble Shooting

    removal direction in the "Front Fork Assembly" of this Trouble shooting manual. Soft feeling from brake lever b. Use a 12# sleeve to loosen the disc brake oil pipe a. The brake system oil circuit enters the air bolt ⑴, pay attention to loosen it and then tighten it b.

  • Page 135: Disassemble The Rear Disc Brake Main Pump

    Disassemble the front disc brake caliper a. Use 5# inner hexagon to remove bolt ⑴, and remove the wire clamp. First use a 12# sleeve to loosen the disc brake oil pipe bolt ⑷, pay attention to loosen it and then tighten it slightly to avoid leakage, otherwise it will be more difficult to loosen this bolt later.

  • Page 136: Disassemble The Rear Disc Brake Caliper

    b. Use a 14# sleeve to remove the bolt (3). Standard torque of bolt (3): 24N.m (2.4kgf.m, 18 lbf.ft). 1- Caliper mounting plate 2- Brake pad holder 3- Caliper pin rubber cap 4- Piston 5-dust seal 6-oil seal 7-caliper pin 8-bleed nozzle 9-bleed nozzle rubber cap 10-caliper housing 11-caliper mounting plate pin rubber cap 12- brake spring c.

  • Page 137: Brake Hose And Wheel Speed Sensor

    ●Apply thread fastening glue to the thread of the caliper the front and rear disc brake main pump, loosen the disc brake oil pipe bolts from the front and rear disc brake pin, torque: 27N.m (2.8kgf.m, 20 lbf.ft). ●The torque of the air release nozzle: 7～9N.m (0.7～ calipers to drain the brake fluid.

  • Page 138: Fmc-Hu And Rmc-Hu

    with tape to prevent the residual brake fluid from and cause vehicle failure. The front wheel speed sensor is also responsible for providing a speed signal to the dripping on the parts when the oil pipe nut joint is loosened. Use a 12# open-end wrench to loosen the oil meter to display the speed per hour.
  • Page 139 c. First remove the 3 pieces of wire clamp ⑷, and then pull out the wheel speed sensor ⑵ and the RC- HU hose from the 4 pieces of oil pipe clamp ⑶. If you need to remove the tubing clamp (3), you can use 4# inner hexagon to remove the bolts and then you can take it off.

  • Page 140: Abs System Layout

    ABS system layout 1-Front and rear wheel speed sensor 2-ABS hydraulic control unit 3-OBD diagnostic interface ABS hydraulic control unit Caution: ●Before disassembling the hydraulic control unit, the positive and negative electrodes of the battery must be disassembled to prevent damage to electrical components caused by misoperation.
  • Page 141 d. Remove the 2 bolts that were put back in the front (1) Remove the hydraulic control unit and bracket assembly from the car. e. After holding the hydraulic control unit firmly, use 4# inner hexagon to remove the bolt ⑵, then the hydraulic control unit ⑹...

  • Page 142: Abs Troubleshooting

    ABS troubleshooting 142 / 184...

  • Page 143: Troubleshooting Process With Portable Abs Diagnostic Scanner

    Troubleshooting process with portable ABS diagnostic scanner No front wheel speed No rear wheel speed 143 / 184...

  • Page 144: Battery/Charging System

    9. Battery/charging system Know Before Service 1. It is necessary to properly dispose of discarded batteries to avoid pollution to the environment. It is recommended that waste batteries be returned to a professional recycling agency for recycling. 2. It is forbidden to use chargers that have not passed the inspection to charge the battery. 3.

  • Page 145: Troubleshooting

    Troubleshooting Battery damage or attenuation troubleshooting process Battery failure Use a Measure the multimeter to battery voltage Remove the battery and check whether Battery first, then use a battery tester to there is leakage, Check the voltage<charging measure the check the battery the leakage charging voltage voltage<14.5～14.9...

  • Page 146: Charging System Layout Diagram

    Charging system layout diagram 1-Charging port (PKE) 2-Main fuse (25A) 3-Battery 4-Magnetic motor 5-Rectifier Electrical schematic diagram Letter Chinese green yellow English Green Yellow 146 / 184...

  • Page 147: Battery Disassembly

    Battery disassembly 3. Charging If the battery cannot be started due to insufficient 1. Disassembly power, it can be charged with the charger provided with Refer to the steps “a” to “d” in the section "Removing the car. Open the right storage box cover and remove the stepper motor and cleaning the carbon deposit"...

  • Page 148: Remove The Rectifier

    b. Refer to the steps of removing the armrests and rear skirts to remove them first. Remove the bolts ⑵ fixing the rear fender on both sides with 5# inner hexagon respectively, and remove the bush ⑷ and the rubber pad ⑷. b.

  • Page 149: Front Fork Assembly

    10. Front fork assembly Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component seals used for sealing must be replaced before assembly.

  • Page 150: Exploded View Of Front Fork Components

    Exploded view of front fork components: Directional exploded view 150 / 184...

  • Page 151: Front Fork Exploded View

    Front fork exploded view 151 / 184...

  • Page 152: Exploded View Of Lower Link Board

    Exploded view of lower link board 152 / 184...

  • Page 153: Change The Direction Of The Handle

    and remove the left auxiliary handle switch, the rear disc Change the direction of the handle brake main pump, the right auxiliary handle switch, and Caution: the front disc brake main pump. ●When removing the disc brake oil cup, it must be vertically upward to prevent air from entering the brake pipeline.

  • Page 154: Installation Of The Direction Component

    c. When installing the auxiliary handle switch, align the joint surface of the auxiliary handle switch and the e. Use 6# inner hexagon to remove the M6×80 bolt main pump of the disc brake with the triangle mark on ⑽, pull out the right balance weight and the rubber the handle switch, and then tighten the 4 M6×30 bolts sleeve of the right hand in the direction of the arrow, use with a 5# inner hexagon.

  • Page 155: Replace The Front Wheel

    2. Install the front wheel assembly a. Separate the two brake pads in the brake caliper with a single-size batch. If the resistance is too large and the two brake pads cannot be separated, please refer to the method of "Adding Brake Fluid" to remove the upper cover of the disc brake oil cup and then separate it.

  • Page 156: Front Wheel Assembly Exploded View

    ： Front wheel assembly exploded view Inspection and maintenance of front wheel assembly： The replacement mileage is not absolute. It needs to be Caution: determined according to the owner's travel habits ●This inspection should be completed by a qualified (whether you like sudden braking), road conditions, maintenance organization.

  • Page 157: Front Wheel Oil Seals And Bearings

    2. Front wheel oil seals and bearings that the road conditions are not bad and there is no tyre 2.1 Service life of front wheel oil seals and bearings puncture. Because the tires are made of rubber, there Under normal circumstances, the bearings and oil will be aging.

  • Page 158: Replacement Of The Front Shock Absorber

    d.First press the two sides of the front mud board according to the small arrow, press the protrusion on the front mud board arrow inward, and then move the front mud board up to a suitable position and then pull it out in the direction of the big arrow.

  • Page 159: Replace The Lower Link Board

    1. Disassemble parts ahead of time (5.1 kgf.m, 37 lbf.ft). If one of the shock absorbers is not Refer to "Replace the front wheel", "Replace the front installed in place, the front axle will not be tightened or shock absorber", "Replace the steering handle", and can not be inserted into the right shock absorber.

  • Page 160: Removing The Direction Pad

    3. Removing the direction pad 4. Remove the lower link board assembly a. Take out the handle switch harness and brake hose a. Use a four-jaw sleeve to remove the direction in the direction wire clip from the direction of the wire clip column adjustment nut ⑿...

  • Page 161: Install Other Disassembly Components

    c. Put the rubber pad ⒀ on the direction column adjustment nut; then screw in the second direction column adjustment nut ⑿, screw the second direction column adjustment nut ⑿ to align with the notch of the first direction column adjustment nut ⑿, put Insert the snap-in gasket ⒁;...

  • Page 162: Disassemble The Engine Of The Vehicle

    11. Disassemble the engine of the vehicle Caution: wires of the battery, screw the bolts on the battery back ●The vehicle must be parked on a level and stable with a cross-shaped screwdriver. ground or on a lifting platform. ●The operation can only be performed after the engine has cooled down completely.

  • Page 163: Remove The Cover

    2. Remove the cover (marked by the green circle). a. Remove the decorative glue on the rear armrest, use 4# inner hexagon to remove the 2 small arrow bolts of 2 M6×12, remove the 2 expansion nails (green mark) on the rear armrest, use 12# sleeve Remove the 5 M8×25 bolts pointed by the big arrow.

  • Page 164: Put The Coolant And Pull Out The Connection Plug

    3. Put the coolant and pull out the connection plug e. Locate and unplug the crankshaft position sensor ⑤ and the oxygen sensor ⑥ in the frame position on a. Place suitable utensils under the big arrow, use the right. water clamp pliers to remove the green hoop pointed by Caution: One end of the crankshaft position sensor is the big arrow, pull out the engine water inlet pipe, and let...

  • Page 165: Disassemble The Engine

    l. Use a 4# inner hexagon to remove one M6×12 bolt h. Use an 8# sleeve to remove a bolt on the starter ⑸ that fixes the wheel speed sensor on the rear rocker motor, and take out the negative wire ⑧ on the bolt. arm, take out the wheel speed sensor and take it out of Caution: The negative wire of the early production the fixed clamp.

  • Page 166: Install The Engine

    c. One person uses 14# torx wrench to extend from b. One person holds the whole car and slightly lifts the rear part of the frame, and one person rotates the two under the tail skirt and fix the 1 M10×1.5×55 bolt on the top of the left rear shock absorber, and one person uses rear shock absorbers to the frame installation groove, 14# socket + ratchet wrench to remove and fix the left...

  • Page 167: The Installation Of The Corresponding Cover

    part of the surrounding bottom plate is locked into the shock-absorbing sleeve of the small water tank. e. Install the rear pedal on the right side of the vehicle 6.2 Install pedal and pedal decorative cover to a suitable position, install two M8×25 bolts ⑺, and a.

  • Page 168: Install The Rear Skirt

    6.3 Install the rear skirt pay attention to each non-standard bolt The bolts a. Grasp the tail of the right tail skirt (green mark) with marked M6×16 are equipped with bushings (2) and one hand, and buckle the tail buckle (green mark) into cushioning glue (3);...

  • Page 169: Installing The Side Cover

    6.4 Installing the side cover position of the middle cover of the fuel tank to prevent a. Put down the right rear pedal, buckle the 5 the storage box from crushing the middle cover of the mushroom buckles (green markings) on the side cover fuel tank.
  • Page 170 relay at the front of the storage box, reinstall the battery cover. When installing the battery cover, you need to align the buckle position (red mark) of the battery cover with the corresponding buckle position of the storage box. Then install two expansion nails (green mark), and arrange the skirt of the battery cover.

  • Page 171: Disassembly And Assembly Of Vehicle Covering Parts

    12. Disassembly and assembly of vehicle covering parts 1. Windshield 2.Right front turn light 3. Right cover front storage box 4. Front right panel 5. Front storage box panel right decorative cover 6. Right pedal decorative cover 7.Right fuel tank cover plate 8. Right pedal 9. Right side cover 10.
  • Page 172 1. Instrument panel 2. Front right pedal pad pressure plate 3. Front right pedal pad 4. Rear right pedal pad 5. Rear right pedal pad presser 6. Fuel Tank Outer Cover 7. Fuel tank cover middle part 8. Front left pedal pad pressure plate 9.

  • Page 173: Disassembly And Assembly Of Vehicle Panel

    Disassembly and assembly of vehicle panel Caution: ●During disassembly, please pay attention to the force to prevent breaking the buckle. ●When removing the panels, please remove them in strict order. Do not forcibly remove the panels to prevent irreparable damage to the corresponding panels. ●When unplugging the plug, please control the force and disassembly method.

  • Page 174: Removal Of The Front Panel

    of the small arrow; pull out the two mushroom buttons (blue circles) on the front cover After exiting; continue to grasp the mark on the front cover (green rectangle) and pull it diagonally upward according to the big arrow until the 6 buckles on both sides of the front cover (yellow area, 3 on the left and right) are all pulled out.

  • Page 175: Removal Of Front Turn Signal

    Disassembly of the of the Speedometer panel Removal of front turn signal a. Remove the two M6x12 bolts⑷ from the front a. Use 4# inner hexagon to remove the two M6×16 turning light with a 4# socket. bolts⑴ on the front left turn signal. b.

  • Page 176: Removal Of The Front Left And Right Panels

    Removal of the front part of vent Removal of the front left and right panels Use 4# inner hexagon to remove the 2 expansion nails on the inside of the front part of vent. Then unplug a. Use 4# inner hexagon to remove two M6×12 bolts the 3 connectors () on the upper left side of the front ⑵...

  • Page 177: Disassembly Of The Left &Right Side Cover

    decoration cover of front storage box panel, take out the box panel in the order of the small arrows. The connection of the middle and left pedal decoration cover bushing ⑵and cushion rubber⑶; use 4# inner hexagon to remove 1 expansion nail on the left decoration cover (yellow area: 7 buckles on the front storage box panel, 3 of the front storage box panel.

  • Page 178: Disassembly Of The Foot Pedals And Trim Cover

    Disassembly of the foot pedals and d. Remove an M6x16 bolt⑴ from the bottom plate trim cover and the decorative cover of the left pedal with a 4# inner hexagon, and remove the bushing⑵and buffer glue⑶; a. Protrude the rear pedal rubber pad and rear pedal then remove the 1 nail of the left pedal decorative cover rubber pad pressure plate from the position indicated by and 2 nails of the bottom plate...

  • Page 179: Disassembly Of The Surrounding Bottom

    storage box panel and then remove the middle surround. Disassembly of the storage box Disassembly of the surrounding a. Use the 4# inner hexagon to remove the 2 bottom expansion nails on the battery cover, buckle the mark (green rectangle) of the battery cover by hands, break it a.

  • Page 180: Disassembly Of The Rear Hand Rest

    Disassembly of the rear hand rest pull it up until the two buckles at the junction of the tail skirt and the middle part of the fuel tank cover (yellow a. Remove the buckle from the bolt, and use the 4# area) are separated;Hold the mark on the tail skirt inner hexagon to remove two pcs M6x12 bolts⑷;...

  • Page 181: Disassembly Of Rear Fender

    C. Use 4# inner hexagon to remove the 2 expansion nails which connected to the rear clay board with the c. One person uses 14# sleeve to fix the non- taillight standard M10×1.5×55 bolt⑾ from upper of the rear shock absorption, one person uses 14# sleeve + ratchet wrench or box wrench to remove the non-standard M10×1.5 nut⑿, from the upper part of the rear shock absorption of the frame inside;...

  • Page 182: Disassembly Of The Left, Right Fuel Tank Cover

    f. One person lifts the rear or both sides of the frame b. Grasp the mark (green rectangle) of the right cover and lifts it up in the direction of the big arrow until the part of the fuel tank and pull it out in the direction of the gap between the frame and the rear shock absorber is arrow until the two buttons (blue circles) on the fuel tank sufficient and the inner mud plate is taken out, One...

  • Page 183: Disassembly The Left And Right Storage Boxes

    main wiring harness of the battery to open the tank lock bushing + buffer glue, while the lower bolts do not have or open the tank lock before removing the battery; bushing + buffer glue;Remove 1 nail of the front right Remove the M6x12 bolt⑷...

  • Page 184: Disassembly The Front Storage Box Panel

    box. Disassembly the front storage box panel a. Remove the two non-standard M6x16 bolts⑸ from the front storage box panel with the 5# inner hexagon, and remove the bushing⑵ and buffer glue⑶. b. Find out the the 3 connectors on the left side of storage box panel and unplug them on the next to the tap lock c.

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