Motron NOMAD 125 Service Manual
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Motron NOMAD 125 Service Manual

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NOMAD 125
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Summary of Contents for Motron NOMAD 125

  • Page 1 NOMAD 125 Service manual ENGLISH...

  • Page 3: Preface

    This manual takes Nomad 125 two wheeled motorcycle as the main line. The contents of Chapter 1 to Chapter 2 are applicable to the adjustment of various parts of motorcycle. In Chapter 3, we narrate separately according to each component of motorcycle.

  • Page 4: Table Of Contents

    Content Preface ......................................2 Content ......................................3 Chapter 1 Overview ..................................5 Printing Position of Machine Number ..........................5 Maintenance Precautions ..............................6 Main Performance Technical Data ............................ 9 Torque value of main standard parts ..........................11 Regular maintenance table .............................. 13 Wiring Diagram .................................
  • Page 5 Battery and power supply system ..........................108 Main components ................................110 Starting system ................................116 Main components ................................117 Lighting signal system ..............................124 Main components ................................126 Information display system ............................135 Main components ................................137 Engine management system ............................144 Electrical Schematic Diagram ............................

  • Page 6: Chapter 1 Overview

    Chapter 1 Overview Printing Position of Machine Number Maintenance Interval Table Maintenance Precautions Wiring Diagram Main Performance Technical Data Symbol description Standard Torque Value Printing Position of Machine Number Vehicle picture: Printing position of frame number: Location of nameplate:...

  • Page 7: Maintenance Precautions

    The frame number is engraved on the right side of The frame name plate is riveted on the left side the frame seat tube of the frame seat tube Printing position of engine number: The engine number is engraved under the left crankcase body Maintenance Precautions 1.
  • Page 8 3. When fastening bolts or nuts, they shall be carried out in diagonal cross sequence and tightened step by step in 2-3 times to reach the specified standard torque value. 4. After the parts are disassembled, they shall be cleaned before inspection and measurement. When cleaning parts, non combustible or high ignition point cleaning fluid shall be used.
  • Page 9 positive terminal (+) should be connected first. 9. When the fuse is blown, the reason shall be checked and the corresponding fuse must be replaced according to the specified capacity after repair. 10. The cover shall cover the terminal after the operation.

  • Page 10: Main Performance Technical Data

    it contacts with the head and front part of bolts the instructions in the operation manual and operate and screws. The wiring harness should not be according to the maintenance manual. loosened or pulled by force. If the electric wire harness needs to contact with the edge and acute corner in any case, it should be protected with 15.
  • Page 11 Engine Type Single cylinder, four strokes, water cooled 58mmX47mm Cylinder diameter piston stroke 124cm3 Cylinder displacement 12:1 Compression ratio 9.5kw/9000rpm Maximum power 10.5N.m/7000rpm Maximum torque INLET 0.15-0.25 Valve clearance (cold state) OUTLET 0.15-0.25 Valve drive mechanism Chain drive Air filter element Paper filter type Lubricating system Pressure splash lubrication...

  • Page 12: Torque Value Of Main Standard Parts

    172W / 5000r / min, 12V18 pole_ Three-phase full-wave Generator 12V 9Ah Battery capacity Power supply system DC power supply 20A*1、10A*1、5A*2 Fuse NGK CR9E Spark plug model 0.6~0.7mm Spark plug gap Electric and Type 2. Lock the steering column with the ignition Anti theft device type switch and turn off the ignition circuit Fuel supply mode...
  • Page 13 33~35 Connecting rod cap nut 27~31 Isolator bolt 103~105 Primary driving gear bolt 23~27 Mounting bolt of oil pressure sensor 10~14 Oil pressure sensor Mounting bolt of shift display 16~20 Fine filter pipe joint 8~12 Fine filter 14~16 Water temperature sensor 11~13 Clutch lifting plate bolt 8~12...

  • Page 14: Regular Maintenance Table

    45~55 Cradle rear component and rear stabilizer connecting shaft 60~70 Cradle rear component and cradle front component shaft 60~70 Cradle rear component and flat fork connecting shaft 60~70 Cradle front component and frame connecting shaft 75~85 The frame is connected with the rear flat fork 28~32 Brake disc and hub connection...
  • Page 15 Engine oil Replace Replace Replace Replace Oil filter Replace Replace Free stroke of clutch handle Check Check Check Check *Throttle body Check Check Throttle cable clearance Check Check Check Check Idle speed Check Check Check Check Fuel evaporative pollutant control Check system Replace every 8000 km or every 24 months...
  • Page 16 When driving for a long time under bad road conditions and high power conditions, the inspection frequency shall be increased. Note: The items marked with "*" in the table should be handled by the qualified franchise Repair Shop.

  • Page 17: Wiring Diagram

    Wiring Diagram 1 Instrument wiring, 2 Headlamp wiring, 3 Wheel Speed sensor wiring, 4 Front turn signal wiring...
  • Page 18 1 Oxygen sensor, Radiator fan wiring, 2 Battery, 3 Ignition coil wiring, 4 Horn, 5 Voltage regulating rectifier, 6 Magneto wiring, 7 Start relay, 8 Headlamp and ABS oil pump relay 1 Fuse box, 2 Fault diagnosis interface, 3 Fuel sensor wiring, 4 ECU, 5 ABS, 6 Left and right combination switch wiring...

  • Page 19: Symbol Description

    Symbol description Meaning of symbols in this manual: Graphic Graphic The meaning of graphic symbols The meaning of graphic symbols symbols symbols Measures to be prompted during operation, inspection Use general tools. maintenance. 50N.m Special instructions or disposal Tightening torque specification: 50 measures proposed prevent...

  • Page 20: Chapter 2 Lubrication System

    Chapter 2 Lubrication System Maintenance Instructions Inspection of engine oil Troubleshooting Replacement of oil Lubrication position of the whole vehicle Cleaning of oil coarse filter Lubrication of each operating line Cleaning and replacement of oil filter Engine lubrication system diagram Oil pump Maintenance Instructions This section introduces the checking and replacement methods of engine oil, as well as the cleaning...
  • Page 21 your hands thoroughly with soap and water performance immediately after handling used oil. Keep at high temperature children away.

  • Page 22: Lubrication Position Of The Whole Vehicle

    Troubleshooting Oil contamination Excessive oil consumption 1. Failure to change the oil according to the 1. The engine is leaking oil; maintenance interval table; 2. The piston ring is worn; 2. Damage to the threads of the oil injection port, poor sealing; 3.
  • Page 23 The positions shown in the figure above use lithium grease except for the special oil for the drive chain. All oils not specified in this manual shall be common oils. All sliding surfaces and cables not shown in this figure shall be coated with oil or grease. Lubrication of each operating line The clutch control line and throttle control line shall be regularly checked.

  • Page 24: Lubrication Of Engine

    Lubrication of engine Engine lubrication system diagram...
  • Page 25 Lower crankcase oil passage 1 oil goes from the primary filter assembly to the oil pump, 2 oil goes from the oil filter to the oil passage orifice, 3 oil goes from the oil pan to the primary filter assembly Upper crankcase body oil passage 1 oil flows from the oil passage orifice to the main shaft, 2 oil flows from the orifice to the cylinder head,...
  • Page 26 Cylinder head oil passage 1 oil flows from upper case to cylinder head Lubrication of camshaft journal 1 oil goes from cylinder head to intake cam, 2 oil goes from intake cam to exhaust cam Lubrication of crankshaft...
  • Page 27 Inspection of engine oil Support the motorcycle on a flat surface with a special clamp and check the oil sight window on the right crankcase cover. If the oil level is below the lower engraved line, the recommended oil should be replenished so that it is filled to the upper limit of the middle deviation.
  • Page 28 During replacement, open oil bolt, drain waste oil, clean oil drain bolt, replace new gasket, and then install oil drain bolt. Loosen the oil filling plug, slowly fill 1.0L new code-designated engine oil into the crankcase with funnel, and then install the oil filling plug. 1 loosen the oil drain bolt and 2 fill the oil Oil pump When the oil pump fails, it needs to be removed for maintenance or replacement.
  • Page 29 Disassembly steps and diagrams of oil pump; Installation steps of oil pump; Disassembly and assembly of oil pump. Disassembly steps and diagram of oil pump: 1. Separate the clutch control line from the clutch 2. Remove the right crankcase cover; control arm;...
  • Page 30 Disassembly and assembly of oil pump Sequence Procedure Quantity Remark Oil filter cover screw Nail Oil filter cover Use thread sealant during assembly Seal washer Oil pump driven gear Oil pump driven gear shaft Oil pump Inspection of oil pump Check whether the clearance of the oil pump is within the maintenance limit with a standard feeler gauge.

  • Page 32: Chapter 3 Inspection And Adjustment

    Throttle control Bolts, Nuts and Fasteners Maintenance Instructions This section introduces the checking and adjustment of various parts of Nomad 125 two wheeled motorcycle. The technical requirements for checking and adjustment are also introduced. Instruction Unless otherwise specified or indicated in the maintenance interval table, inspect and adjust all parts of the Nomad 125 two-wheeler in accordance with this section before each use.
  • Page 33 The free stroke of throttle handle is 2-6 mm Engine The free stroke of clutch handle is 10-20 mm NGK CR9E The free stroke of front brake handle is 5-10 mm The free stroke of the rear brake pedal is 10 -15mm Spark plug: NGK CR9E The tension of drive chain is 15-25 mm The spark plug gap: 0.6~ 0.7 mm...
  • Page 34 Spark plug Remove spark plug cap Remove the spark plug with socket wrench. Check whether the spark plug insulator is damaged and whether the electrode is ablated. If it is damaged , replace it. Clearance: 0.6-0.7mm Check the electrode clearance with a feeler gauge. Spark plug electrode gap Inspection: clearance 0.6~0.7mm Adjust the clearance carefully.
  • Page 35 Use a special fixture to support the motorcycle on the flat ground, so that the engine is in a horizontal position and does not tilt. Visually check whether the oil level in the oil window on the right crankcase cover is between the upper and lower marking lines.
  • Page 36 If the accumulator is empty, check the coolant level of the radiator. Turn the radiator cap counterclockwise to see if the coolant level reaches the bottom of the neck of the radiator injection port. If not, add coolant. Warning Before opening the radiator cap, make sure that the engine radiator completely...
  • Page 37 Start the engine at idle speed. 3. Remove the air filter cover and air filter element Carefully listen to the engine running sound, if the timing chain has a relatively crisp "click" sound, it means that the chain tension is insufficient, so the chain tension shall be replaced.
  • Page 38 Cleaning and replacement of air filter element 1. Open and remove the seat cushion with the key 2. Loosen the fastening screws of the air filter housing Loosen air cleaner cover...
  • Page 39 Throttle control Idle speed First, check whether the throttle operating line Caution is deformed, kinked or damaged. Then measure the free stroke of the throttle handle. Turn the handle to one side of the free stroke, draw a straight line After other items of the engine have been adjusted between the handle and the counterweight with a to the specified range, check and adjust the idle...
  • Page 40 Check whether the throttle can rotate smoothly from full open to full close in any position. If there is hysteresis, adjust or replace it Lock nut B...
  • Page 41 Braking System Inspection of brake fluid level: Check the free stroke of the front brake handle. Check the brake fluid level in the front brake The free stroke of the brake handle is 5-10 mm. cylinder. If the level is too low but not completely empty, replenish the brake fluid directly.
  • Page 42 Vacuum filling method of brake fluid: 3. Operate the brake handle or pedal to remove the residual air of the brake caliper. 4. When the vacuum pump has completely eliminated This method is applicable to the filling of brake the air in the brake caliper and the brake fluid, fluid in a new car or when the brake fluid in the squeeze the handle or step on the pedal tightly, brake cylinder is exhausted.
  • Page 43 Rear brake cylinder cover...
  • Page 44 Running System Clutch operating line Size and pressure of tire Check the free stroke of the clutch handle. Free stroke of clutch control handle: 10-20 mm. Check the tire pressure with a tire pressure gauge to see if it meets the recommended tire pressure Adjustment method: requirements.
  • Page 45 1 Adjust nut, 2 Lock nut...
  • Page 46 Remove the clutch operating line Chain adjuster adjusting nut Caution The marking on the chain adjusters on both sides must be consistent. Warning The rear axle nut must be tightened with a Adjust clutch operating line tightening torque of 75 ~ 85 Nm. Drive chain Cleaning and inspection of chain Inspection of drive chain tension...
  • Page 47 Caution The chain of the car is connected by locking plate. During installation, the open end of the spring clip of the chain joint should be opposite to the movement direction of the chain. Rear axle nut Sagging degree...
  • Page 48 Battery Riser steering bearing Disassembly of battery Support the motorcycle with a jack or other bracket to make the front wheel off the ground, and check whether the steering handle can rotate freely. If the steering handle can not rotate freely, and First, remove the seat cushion, remove the fixing there is axial movement or stagnation, adjust the bolt of the left cover, remove the negative pole...

  • Page 49: Fuel System

    Rear suspension Remove the electrode wire and band Press the rear of the seat cushion firmly to check whether the rear fork sleeve is worn or damaged. Headlight Dimming If it is damaged, replace it. Check whether the whole suspension assembly is firmly installed and whether it is damaged or deformed.
  • Page 50 Fuel sensor Maintenance Instructions Replacement of fuel filter Troubleshooting Disassembly and installation of air filter Disassembly and installation of fuel tank Removal and installation of throttle body Disassembly and assembly of fuel tank Warning Pay great attention to fire prevention when handling gasoline! When disassembling the components of the fuel system, pay attention to the installation position of the seal Components.
  • Page 51 Removal and installation of fuel tank removal 4. Remove the connector of the fuel sensor. steps: Disassemble the fuel pipe . Remove fuel pump . 1. Remove the seat cushion (open the seat cushion with the key and take it off). 2.
  • Page 52 Disassembly / installation of fuel tank Sequence Procedure Quantity Remark Disassembly sequence The installation sequence is reverse to the disassembly sequence Bolt M6X20 Front seat cushion Fuel tank trim cover assembly Screw M6X12 Screw M6X20 Screw M6X16 Bolt M8x30 Fuel tank assembly...
  • Page 53 Disassembly and assembly of fuel tank Refer to the figure below for the disassembly and assembly of the fuel tank. The assembly procedures are in reverse order to the disassembly procedures. Pay attention to the oil outlet of the oil pump towards the front of the fuel tank during assembly. Sequence Procedure Quantity...
  • Page 54 Replacement of fuel filter Replacement cycle: 15000km. Tools: flat type screw driver. Caution Take out the filter element Do not pull the liquid level sensor and float rod assembly hard during installation and disassembly. Disassembly procedures of filter: Press the inverted buckle of the filter and pull out the filter.
  • Page 55 Take out the air filter cover...

  • Page 56: Cooling System

    Cooling system 1 Engine, 2 Water tank cover, 3 Auxiliary water tank, 4 Outlet pipes, 5 Small circulating water pipes, 6 Radiator, 7 Water inlet pipe, 8 Thermostat, 9 Fan, 10 Temperature sensor Maintenance Instructions Water pump Troubleshooting Thermostat Inspection of performance Cooling electrical system Radiator Maintenance Instructions...
  • Page 57 The replenishment of coolant is carried out by the hydraulic accumulator. The radiator cap shall not be removed except for the re replenishment of coolant after the disassembly of the cooling system or the extraction of the radiator. After the inspection and maintenance, the radiator detector is used to check whether there is water leakage in each connecting part and sealing part.
  • Page 58 Use the specified coolant to replenish. Avoid mixing with other brands of coolant. This coolant is toxic and must not be drunk. For the lowest temperature in the use area, the mixture ratio with about - 5 ℃ shall be selected. Troubleshooting Water temperature rise too high The water temperature does not rise or does not rise...
  • Page 59 Inspection of performance Inspection of radiator cap Radiator detector Warning Radiator cap Make sure the coolant is completely cool before opening the cover. Inspection of radiator pressurization Install the radiator cap on the radiator detector to increase the pressure of the pump. If it can be Install the radiator detector on the radiator, maintained within the specified pressure range for increase the pressure of the pump, and confirm...
  • Page 60 Radiator Disassembly of radiator 1. Park the motorcycle on the flat ground, loosen 2. Remove the radiator cover. the hoop and pull out the water pipe 3. Pull out the radiator outlet pipe and drain the 4. Unplug the temperature control switch connector coolant power cord.
  • Page 61 Avoid damaging the radiator during disassembly. After installation, don't forget to fill in the coolant and check whether the connection parts are leaking.
  • Page 62 Disassembly / installation of radiator Sequence Procedure Quantity Remark The installation sequence Disassembly sequence reverse disassembly sequence Auxiliary water tank Water pipe assembly(φ7×φ11)×(20+90+27) Water pipe assembly(φ7×φ11)×(25+53+68) Water pipe assembly(φ7×φ11)×(30+75+41+50) Water pipe assembly(φ13×φ21)×(32+86+103+52) Water pipe assembly (φ13×φ21×190) Water pipe assembly(φ13×φ21)×(60+189+105) Right water cooler Left water cooler (fan) Lower bracket of water cooler...
  • Page 63 Disassembly / assembly of radiator Refer to the figure below for disassembly / assembly of radiator. Be careful not to damage the heat sink. Sequence Procedure Quantity Remark The assembly sequence is reverse to the Decomposition sequence disassembly sequence Left water cooler temperature control switch Bolt M6X16 Spring washerф6...
  • Page 64 Water pump Inspection of water pump Disassembly and assembly of water pump Remove the connecting bolts, open the water pump, and check whether the seal washer and the water pump turbine are damaged. Be sure to drain the coolant before disassembling the water pump.
  • Page 65 Pump assembly Water pump Special shaped seal washer Connecting water pipe Small circulating water pipe Clamp 27 Clamp 22 Bolt 6x20 Bolt M6X60 Seal washer O-shaped seal washer...
  • Page 66 Thermostat Inspection of thermostat Disassembly and assembly of thermostat Put the thermostat into the detection container, then gradually increase the water temperature and detect the valve opening temperature. Loosen the connecting bolt with T-shaped sleeve and pull out the thermostat. 1 Thermostat, 2 Water temperature gauge boiling point Thermostat...
  • Page 67 Cooling electrical system Summary When the working temperature of the engine reaches a limit, the cooling water will circulate through the radiator, and the temperature will continue to rise. Turn on the fan switch on the radiator, turn on the power supply of the fan, and the fan will rotate to take away the engine heat of the cooling water circulation, and the water temperature will drop until the fan switch is turned off and the fan stops running.
  • Page 68 dc12v5a. 3. Possible failures The switch is always on; The switch cannot be connected; The switch action temperature deviation is too large; The insert is rusted and has poor contact. Fan assembly 1. Working principle The fan assembly is composed of fan motor, fan leaf and bracket. The cooling fan of radiator is generally axial-flow fan, the air inlet is fan leaf end, the air outlet is motor end, and the wind direction of inlet and outlet is in the same direction.
  • Page 69 Failure phenomenon Possible causes Solutions: Line open circuit; Connection repair; The water temperature Open circuit failure of fan switch; Replace the fan switch; has given an alarm and the fan still doesn't Fan motor failure; Replace the fan motor; work The fan page is stuck or slipping.

  • Page 70: Disassembly And Installation Of Engine

    Disassembly and Installation of Engine 1 Throttle valve body, 2 Air filter, 3 Engine, 4 Frame, 5 Muffler, 6 Transmission pedal Disassembly and Installation of Engine Specifications Maintenance Installation of engine Instructions Engine net weight 35 kg Add 1.2L to the broken engine oil tank and 1.0L to Disassembly of the daily maintenance engine...
  • Page 71 In order to maintain the cylinder head, cylinder block, piston and other heat engine parts, it is necessary to remove the cover, oil tank, radiator, throttle body, air filter assembly, etc. If you need to remove the left front cover of the engine for maintenance, you need to remove the transmission pedal and left rear cover, etc.
  • Page 72 Disassembly of engine Disassembly of left rear cover Park the motorcycle on the flat ground and drain the cooling water and engine lubricating oil. Remove the cover, oil tank, muffler and radiator (refer to relevant chapters). Disassembly of left rear cover Remove the drive chain Remove the starting motor wire and engine grounding Disassembly of clutch cable.
  • Page 74 Sequence Procedure Quantity Remark Disassembly of engine rear suspension mounting bolts Installation sequence and Disassembly removal sequence In reverse order Panel, oil tank, radiator, Refer to muffle, relevant chapters air filter, etc Disassembly the engine Variable speed control components Left rear cover M870 Bolt M870 M890...

  • Page 76: Frame, Exhaust System

    Frame, exhaust system 1 Tail light component, 2 Rear fender, 3 Cover, 4 Frame, 5 Muffler Maintenance Instructions Disassembly / installation of rear fender Troubleshooting Disassembly / installation of exhaust muffler Cover, headlamp and instrument Rear lamp assembly Maintenance Instructions During the maintenance of this part, special attention shall be paid to the covers, instruments and lamps not to be scratched or damaged.
  • Page 77 1. The emission system is damaged; 1. The exhaust system is deformed; 2. Exhaust leakage; 2. Exhaust leakage; 3. The muffler is blocked. Cover, headlamp and instrument Disassembly procedures of cover, headlamp and instrument 2. Remove one mounting bolt from each side cover. 1.
  • Page 78 3. Remove 4PCS headlamp fixing screws and socket head cap screws M6X12. Remove the headlamp Installation procedures of cover, headlamp and assembly. instrument: The installation steps of the cover, headlamp and instrument are in the reverse order of the disassembly. Pay attention not to scratch the cover and damage the bulb during installation.
  • Page 80 Disassembly / installation of exhaust muffler Installation procedure of exhaust muffler in the reverse order of disassembly. Disassembly procedures of exhaust muffler Proceed in the reverse order of disassembly. 1. Support the motorcycle on the ground with the main bracket, and pull out the oxygen sensor plug. The muffler seal washer at the engine exhaust port should be replaced with a new one.
  • Page 82 Front wheel, front suspension, steering column, front brake 1 Control subassembly, 2 Upper connecting plate, 3 Front fork assembly, 4 Front wheel components, 5 Front axle Maintenance Instructions Front wheel Important torque figures Front suspension Troubleshooting Steering column Control sub-assembly Front brake Maintenance Instructions When maintaining the front wheel, the motorcycle should be reliably supported by a jack or other...
  • Page 83 Important torque figures Front wheel shaft 75~85Nm Fastening bolts of front damping plate 20~25Nm Handle tube fixing bolt 21~25Nm Front fork riser nut 60~70Nm Upper and lower connecting plate fixing bolts Brake disc fastening screw: 28~32Nm 28~32Nm...
  • Page 84 Troubleshooting Difficulty in turning the wheel. Unstable direction 1. The wheel bearing and axle sleeve are damaged 1. The bearing of riser is damaged; 2. The tire pressure is not enough. 2. Insufficient tire pressure; 3. The brake disc does not reset. 3.
  • Page 85 4. Front axle is loose 5. Tire is damaged Disassembly / assembly of control sub-assembly Caution The front brake master cylinder shall be hoisted with steel wire rope, and its height shall be at least the same as that of the original installation position, so as to prevent air from invading the master cylinder and affecting the braking performance.
  • Page 86 1. Pull out the brake switch plug 5. Pull off the clutch switch plug. 2. Remove the front brake master cylinder clip 6. Remove the clutch handle bolt. bolt. 7. Remove the left combined switch screw. 3. Remove the right combined switch screw. 8.
  • Page 87 Maintenance requirements Sequence Procedure Quantity Remark The installation sequence is reverse to the disassembly Disassembly sequence sequence Brake switch plug Note: 1. First tighten the upper bolt, and then tighten the lower bolt; 2. There are two raised Clamp bolt of front brake triangular marks on the clip pointing upward master cylinder Front brake cylinder block...
  • Page 88 Front wheel disassembly / assembly 1 Front axle, 2 Front wheel right bushing, 3 Front brake disc, 4 Front wheel left bushing, 5 Front brake disc bolts Caution Soiled brake discs and friction discs may reduce braking performance. Please pay attention to replacing friction discs and cleaning soiled brake discs.
  • Page 89 Front suspension disassembly / assembly 1 Upper shock absorber bolt, 2 Lower shock absorber bolt, 3 Front shock absorber, 4 Front fender Caution Lift the front brake master cylinder with steel wire rope, and the height shall be at least the same as that of the original installation position.
  • Page 90 Front brake caliper components Note: Lift the front brake master cylinder with wire rope, and do not twist brake hose. Flex brake hose Bolt M6X12 Front fender bolts Front fender Hexagon socket boss bolt M6x16 Mudguard bracket screw Mudguard bracket Lower connecting plate...
  • Page 91 Disassembly / ssembly of steering column 1 Upper damping bolt, 2 Steering column locking bolt, 3 Lower damping bolt, 4 Steering column combination Caution Soiled brake discs and friction discs may reduce braking performance. Please pay attention to replacing friction discs and cleaning soiled brake discs. When the brake caliper is removed, do not pull the brake handle to avoid difficulties when assembling the front wheel.
  • Page 92 Lower connecting plate damping Torsion force of left and right front damper : bolt M10X40 45~55 Nm; Adjusting nut The assembly torque is 10~12 Nm, and the steering column is rotated repeatedly during assembly Tapered roller bearing Steering column assembly Turn the steering column repeatedly during assembly Direction...
  • Page 93 Assembly of directional column Apply enough lithium grease on the surface of bearing roller. Place the steering column into the frame riser. Put in the bearing and adjusting nut in turn. While tightening the adjusting nut, turn the steering column repeatedly to make the bearing roller fit with the washer. Adjust the adjusting nut of the steering column to 35 ~ 45 Nm, then loosen the adjusting nut of the steering column (the adjusting nut can be freely turned by hand), and then use the torque wrench to adjust to 10 ~ 12 Nm.
  • Page 94 Tighten the bolts before connecting the connecting plate on the steering column. Torque requirement: 28~32 Nm...
  • Page 95 Front brake Maintenance Instructions Soiled brake discs and friction discs may reduce braking performance. Please pay attention to replacing friction discs and cleaning soiled brake discs. Do not clean the brake components with air duct or dry brush in case of inhaling friction plate dust and causing respiratory discomfort.
  • Page 96 6. The piston seal of brake master cylinder is worn and aged. 6. The brake handle is bent. The brake deviates to one side 7. The piston of brake auxiliary cylinder is stuck 1. Dirty brake discs / friction plates. and worn.
  • Page 97 Front brake caliper components removal / assembly 1 Front brake disc, 2 Brake caliper bolts, 3 Front brake caliper Caution Soiled brake discs and friction discs may reduce braking performance. Please pay attention to replacing friction discs and cleaning soiled brake discs. Lift the front brake master cylinder with steel wire rope, and the height shall be at least the same as that of the original installation position.
  • Page 98 Disassembly sequence The installation sequence is reverse to the disassembly sequence Brake caliper bolt M10X40 Tightening torque: 55-65 Nm Front brake caliper components Lift the front brake main cylinder with steel wire rope, and do not twist the brake hose Hose Spring clip Friction plate locating pin...
  • Page 99 Rear wheel, rear brake, rear suspension devices 1. Rear brake disc 2 Rear brake caliper body 3 Rear fork assembly 4 Rear shock absorber 5 Rear wheel combination 6 Sprocket 7 Rear axle 8 Chain guard Maintenance Instructions Rear fork assembly Troubleshooting Rear shock absorber Rear wheel...
  • Page 100 Troubleshooting Swings of the rear wheel Difficulty in turning the wheel. 1. Deformation of wheel rim; 1. Damaged wheel bearing and shaft sleeve; 2. Worn rear wheel bearing; 2. Incorrect wheel installation; 3. Low tire pressure; 3. Bent rear axle 4.
  • Page 101 Rear wheel 1. Rear axle 2 Rear wheel left bushing 3 Sprocket 4 Chain adjuster and nut 5 Rear wheel combination 6 Flat fork combination 7. Rear brake caliper body 8 Rear brake disc 9 Rear speed signal panel 10 Right rear wheel bushing 11 Rear brake disc fastening screws Disassembly steps of rear wheel 1.
  • Page 103 5. Take out the right rear wheel bushing. 6. Take out the left rear wheel bushing. 7. Take out the sprocket to get the rear wheel. 8. Take out the disc of rear disc brake.
  • Page 104 Rear fork Disassembly steps of rear fork: Caution 1. Remove the rear wheel assembly first (refer to disassembly steps of rear wheel). When removing the brake caliper body, make sure 2. Remove the brake oil pipe clamp. that the rear brake caliper body is lower than the rear brake cylinder body to prevent air from entering the cylinder body reducing the braking performance.
  • Page 105 Inspection of flat fork shaft Place the flat fork shaft on the V-shaped seat, and test the deflection of the flat fork shaft with a dial indicator. If the figure goes beyond or equal to 0.2 mm, replace the flat fork shaft with a new one.
  • Page 106 Sequence Procedure Quantity Remark Decomposition sequence The assembly sequence is reverse to the disassembly sequence Chain adjuster Chain guard Flat fork shaft bushing When assembling, make sure that the shaft sleeve rotates flexibly...

  • Page 107: Chapter 4 General Introduction Of Electrical System

    Chapter 4 General introduction of electrical system Precautions for Circuit Inspection System Principle and Structure Precautions for Circuit Inspection 1. When disconnecting and connecting the connector, turn the ignition switch to the off position to avoid damage to the electrical components. 2.
  • Page 108 System Principle and Structure The electrical system is an essential guarantee that the motorcycle can operate normally, safely, reliably and efficiently. It covers a considerable amount of disciplines, including motor, electrical, electronic technology, computer, electrochemistry, acoustics, optical materials, etc. And with the development of electronic technology in particular, the motorcycle electrical system will undergo significant changes.
  • Page 109 Battery and power supply system Summary Main components Circuit diagram Main fault diagnosis Parts layout Summary Power supply system is the premise of vehicle electrical system, which can provide sufficient power for other electrical subsystems. The functions include: charging, storing and discharging. Power supply system is characterized by large power supply capacity, up to 168W.
  • Page 110 Charging winding of magneto Parts layout 1 Ignition switch, 2 Main electrical harness, 3 Battery, 4 Voltage regulating rectifier, 5 Magneto...

  • Page 111: Main Components

    Main components Magneto 1. Outline drawing 2. Working principle The crankshaft drives the rotor to rotate, and the stator winding coil cuts the magnetic line of force to generate the induced electromotive force to output alternating current, E=Blv. Motorcycle magneto is a permanent magnet alternator.
  • Page 112 Voltage regulating rectifier 1. Outline drawing 2. Working principle The three-phase sinusoidal alternating current which fluctuates with the speed of the magneto is converted into a stable direct current through a full wave rectification and controllable voltage stabilizing charging circuit. The voltage regulating rectifier provides power to the load and charge the battery.
  • Page 113 Battery 1. Outline drawing 2. Working principle Immersed in electrolyte, the two kinds of lead (negative electrode) and lead dioxide (positive electrode) can produce 2V voltage. There are six cells connected in series, and the voltage can reach 12 ~ 13V. It is the auxiliary power supply of the electrical system and can absorb the overvoltage in the circuit.
  • Page 114 Combined ignition switch 1. Outline drawing 2. Working principle The ignition lock cylinder with double slot and 8-tooth is the main switch of the whole vehicle power supply. It also the head direction lock. 3. Basic parameter switch menu Switch key inter-opening rate should be no more than 0.1%; Gear Color Black...
  • Page 115 Wire harness 1. Outline drawing 2. Working principle The wire bundle consists of wires of various specifications, connector sheaths, terminals, conduit pipes, tapes, fuse and other parts of various specifications through bifurcation, riveting, wrapping and assembly. Through the connection of wire harness, the electrical and electronic equipment of the whole vehicle can work normally.
  • Page 116 Main fault diagnosis Failure phenomenon Possible causes Solutions: Burnt out main fuse; Replace the main fuse Poor contact of main fuse circuit; Plug in again No power for the whole Poor contact of the positive and negative vehicle: Reconnect lines of the battery; No electricity in the whole car, i.e.
  • Page 117 Starting system Summary Main components Circuit diagram Main fault diagnosis Parts layout 1. Overview When the engine starts to work, it needs the help of external force to make it work first, then it can perform the ignition and fuel supply program, and the internal-combustion engine can cycle combustion and work stably.

  • Page 118: Main Components

    Parts layout 1 Flameout switch, 2 Start switch, 3 Clutch switch, 4 ECU, 5 Cable harness, 6 Start relay, 7 Battery, 8 Side bracket switch, 9 Gear switch, 10 Start motor Main components Starting motor 1. Outline drawing 2. Working principle The current carrying conductor is subject to electromagnetic force in magnetic field, F=Bli.
  • Page 119 State Voltage(V) Current(A) Speed(r/min) Torque(Nm) No load 11.5 ≤30 ≥10000 Motor features Loaded ≤120 ≥6000 Braking ≤300 ≥2.5 Specification: 12V650W; Rotation direction of output shaft: viewed from the tooth end, clockwise; Output characteristics 4. Failure mode motor open circuit failure; Excessive wear of carbon brush; Broken stator magnetic steel;...
  • Page 120 Contact voltage drop: below 0.2V (at 150A); Coil current: below 3.5A. 4. Possible failures Open circuit of the coil or lug causing failure in the contact point pulling in; Short circuit of the coil, causing failure in the contact point pulling in; Corroded or ablated contact point, causing failure in connection even if it is closed;...
  • Page 121 Orange Green Light blue Emerge lamp White Blue yellow Left Light Black Blue turn green yellow signal Dipped Horn beam High Right Overta beam turn king signal lamp Right combined switch functions Red and Black black white Turned Black Yellow and red white Turn on...
  • Page 122 Stow Can start the engine Lower Can not start engine; engine is off Gear switch functions Gear 1 (Pink) Gear 0 (Green and red) Gear 2 (Blue and red) Gear 3 (Green and black) Gear 4 (Yellow and red) Gear 5 ( Yellow and white) Gear 6 (Purple) Gear switch 3.
  • Page 123 Loose side bracket switch and poor contact; Abrasion, open circuit or open circuit of side bracket switch lead-out wire; Switch worn, vibrated, and corroded by water. Main fault diagnosis Failure phenomenon Possible causes Solutions: The battery voltage is too low; Charge the battery;...
  • Page 124 not enough; Excessive engine resistance. Check the engine.
  • Page 125 Lighting signal system Summary Main components Circuit diagram Main fault diagnosis Parts layout 1. Overview Lighting signal system is an important guarantee for the safe driving of vehicles, which includes the headlamp lighting system, signal lamp control system, and horn system. Headlamp lighting system: When the vehicle is driving at night, it needs the headlamp to illuminate the road and remind the surrounding vehicles and people of the existence of the vehicle.
  • Page 126 Turn signals Horn Headlamp relay Flasher Front brake lamp switch Rear brake lamp switch Left and right combined switch Circuit diagram Parts layout...

  • Page 127: Main Components

    1 Combined tail lamp, 2 Flasher, 3 Main electric harness, 4 Right combined switch, 5 Front brake switch, 6 Left combined switch 7 Front left turn signal lamp, 8 Headlamp, 9 Front right turn signal lamp, 10 Rear right turn signal lamp Main components Headlamp...
  • Page 128 Headlamp bulb specification: 55 / 60W; Position lamp specification: LED1 4W 4. Possible failures Lamp bead failure; Water or dust in the lamp; Loose PCB welding; Smeared glass slide of lamp shell; Lamp line open circuit or short circuit; The mirror deformed at high temperature; Broken or loose baffle;...
  • Page 129 in the daytime, you forget to turn off the switch. This function can not light up the headlamp when the engine is not started. 2) another purpose is to extend the service life of the battery. 3. Possible failures The high beam lamp cannot be turned on; The low beam lamp cannot be turned on;...
  • Page 130 License plate signal lamp 1. Outline drawing 2. Working principle The light of the license plate lamp is white, and the light of the license plate lamp is formed by the reflection of the reflecting block through the transparent plexiglass below. 3.
  • Page 131 Lamp line open circuit or short circuit; Water or dust in the lamp; Scratched or damaged lamp glass; Loose or broken handle. Rear turn signal lamp 1. Outline drawing 2. Working principle The rear turn signal lamp is composed of lamp glass, lamp shell, reflector, lamp holder, handle and lamp bead.
  • Page 132 2. Working principle The electronic flasher controls the on-off of the high-power FET through an IC chip, and outputs a certain frequency voltage to make the turn signal light up. If a turn signal is disconnected, the flash frequency will be significantly increased. The flasher also has the function of short-circuit self-protection, and beeps when it is protected.
  • Page 133 2. Working principle When braking, hold the brake handle tightly, and the contact contacts with the conductive elastic sheet under the action of spring force, so as to connect the circuit, and the brake light is on. Release the brake handle, press the brake handle against the switch guide rod, compress the spring, make the contact leave the conductive spring, the circuit is disconnected, and the brake light goes out.
  • Page 134 The switch is stuck, and the pull rod cannot move; 84 Open circuit or short circuit of outgoing line. Horn 1. Outline drawing 2. Working principle Working current circuit of horn: positive lug horn coil contact negative lug. After the current passes through the horn coil, the magnetic field generates suction on the armature, which makes the bass diaphragm and the treble diaphragm move at the same time.
  • Page 135 Headlamp relay failure; Replace the headlamp relay; Lamp bead failure; Replace lamp beads; Poor connection on the line; Re plug; The relevant lines of the main cable are Repair or replace the main cable. open circuit. Poor contact of fuse, lamp bead or Re connect the poor contact area;...
  • Page 136 Information display system Summary Main components Circuit diagram Main fault diagnosis Parts layout Summary The information display system displays the static and dynamic information of the whole vehicle through the instrument panel, and provides it to the driver to guide the driver to operate safely. The displayed vehicle information includes the following contents: vehicle speed, engine speed, oil level, gear, voltage alarm, water temperature alarm, steering indication, high beam indication, accumulated / subtotal mileage / time, clock, EMS fault code.
  • Page 137 GREEN OIL LEVEL DISPLAY YELLOW/WHITE WATER TEMPERATURE DISPLSY W/GA WHITE/GREEN A GEAR SIX WHITE/BLUE GEAR FIVE WHITE/YELLOW GEAR FOUR YELLOW/RED GEAR THREE G/BL GREEN/BLACK GEAR TWO BLUE/RED GEAR ONE PINK REVOLUTION SIGNAL Y/BL YELLOW/BLACK SPEED SIGNAL BR/W BROWN/WHITE SPEED SENSOR POWER 5V+ BL/R BLACK/RED HIGHBEAM INDICATOR...

  • Page 138: Main Components

    Parts layout 1 Rear right turn signal lamp, 2 Rear license plate lamp, 3 Combined tail lamp, 4 ECU, 5 Right combined switch, 6 Instrument, 7 Left combination switch, 8 Front left turn signal lamp, 9 Headlamp, 10 Hront right turn signal lamp Main components Instrument assembly...
  • Page 139 signals (including digital signals and analog signals), through circuit processing, all converted into digital signals, through the CPU control output, drive stepper motor pointer, LCD and led, display the information. 3. Pin menu Pin number Function Pin number Function Speed sensor power 5V+ EFI fault signal CAN_H (reserved) Speed (vehicle speed signal)
  • Page 140 Gear switch 1. Outline drawing 2. Working principle The rotation of the speed change drum drives the moving contact to rotate, and the moving contact is pressed and contacted with the end contact of the gear switch under the action of the spring force. Seven contacts are arranged on the end face of the gear switch according to the corresponding position of the gear drum: 1-neutral-2-3-4-5-6, and seven color lines are led out.
  • Page 141 The gear switch vibrates or the press fit is broken; The gear switch is loose; Poor contact of connector; Open circuit or short circuit of outgoing line. Oil level sensor 1. Outline drawing High oil level：高油位 Low oil level：低油位 2. Working principle The oil level sensor consists of float, floating rod, magnetic core, lead wire, etc.
  • Page 142 1 grid flicker 85R95 1 grid 70R85 2 grids 36R70 3 grids 24R36 4 grids 5 grids Note: when one grid is displayed, one grid flashes; When the resistance value is more than 95 the 6 cells and the icon flash together. 4.
  • Page 143 signal, processes it and sends it to the instrument, which displays the water temperature scale to remind the driver. 3. Corresponding relationship between instrument display scale and resistance value of water temperature sensor Temperature (℃) Standard resistance 265.0~323.0 216.0~264.0 185.0~229.0 148.5~180.5 74.6~90.6 53.5~66.5...
  • Page 144 Poor wiring, open circuit or short Re plug or repair. circuit. The moving contact spring fails; Replace the spring; The moving contact or gear switch Change the moving contact or gear contact is worn; switch; Gear indication fault: no gear indication;...

  • Page 145: Engine Management System

    Engine management system 1. Overview The engine management system adopts the closed-loop EFI system. By controlling the injection quantity, it can effectively control the air-fuel ratio of the mixture, and make the air-fuel ratio of the engine reach the optimal value under various working conditions, so as to improve the power, reduce the fuel consumption, reduce the exhaust pollution, improve the driving performance, low temperature starting performance and idle performance.
  • Page 146 2. Turn on the key switch for fault diagnosis. 3. If the throttle position is adjusted, it is necessary to turn off the key switch and restart the engine for idle position self-learning. 4. In case of sensor failure, ECU will limp and continue to drive by default, and the user is requested to drive the vehicle to the special repair shop in time for maintenance;...
  • Page 147 System schematic diagram...
  • Page 148 Parts layout 1 Instrument, 2 Left combination switch, 3 Combined tail lamp, 4 Rear license plate lamp, 5 ECU, 6 Right combination switch, 7 Gear switch, 8 Battery, 9 Water temperature sensor, 10 Three in one sensor Main components Three in one sensor 1.
  • Page 149 The absolute pressure sensor of intake manifold is composed of pressure conversion element (elastic diaphragm + strain resistance) and signal conditioning circuit which amplifies the output signal of conversion element. One side of the pressure conversion element is the vacuum chamber, and the other side leads in the intake manifold pressure, so the higher the absolute pressure in the intake manifold, the greater the deformation of the diaphragm, and the deformation is proportional to the pressure.
  • Page 151 Throttle position opening Measurement range: 7% ～ 93% (from idle to full open) Throttle position sensor reference voltage: 5V±0.1V When the throttle is fully closed, the normal output of the reference voltage is 12%±5% When the throttle is fully open, the normal output is between 83% and 93% of the reference voltage The working characteristic curve of throttle position sensor is as follows: 3.
  • Page 152 The sensor fails to feed water; Mechanical failure of sensor.
  • Page 153 Engine temperature sensor 1. Outline drawing 2. Working principle The engine temperature sensor is a negative temperature coefficient (NTC) thermistor. By using the temperature sensitive characteristics of the thermistor, the change of the ambient temperature is converted into the change of the resistance value of the thermistor, which is then converted into a voltage signal through a voltage divider circuit and output to the ECU.
  • Page 154 Engine temperature sensor temperature curve R-T table...
  • Page 155 Oxygen Sensor 1. Outline drawing and pin definition Oxygen sensor pin description Cable color Function Heat positive White Heat negative Grey Signal ground Black Oxygen sensor signal 2. Working principle OSMa oxygen sensor is based on multilayer ceramic elements with flat plate structure, in which zirconia layer is the core element.
  • Page 156 13.5 V, 450 ℃ exhaust heater current: 0.52А±0.10А Nominal voltage of oxygen sensor: 13.5V Maximum operating voltage of oxygen sensor: 18V Minimum operating voltage of oxygen sensor: 10V Limit voltage of oxygen sensor (at 21 ℃, 60s): 21V 4. Possible failures Heating element failure;...
  • Page 157 2. Working principle The fuel pump is integrated with fuel pump core, fuel pump bracket, filter, oil pressure regulator, etc., which is installed in the fuel tank; The fuel pump core works, and the fuel is filtered through the pump core to the filter, and then adjusted to a certain pressure by the oil pressure regulator and output to the external oil pipe, and finally to the injector;...
  • Page 158 Injector signal：喷油器信号 2. Working principle The fuel injector is actually an electromagnetic switch control element device. Its fuel supply mode adopts top fuel supply structure. The inner part of the injector is designed with an electromagnetic coil around the iron core. The two electrodes from the electromagnetic coil are the input control interface of the injector.
  • Page 159 Poor sealing of sealing ring. Ignition coil 1. Outline drawing and pin definition Ignition coil signal：点火线圈信号 Power supply + relay：电源+继电器 2. Working principle The ignition coil consists of primary winding, secondary winding, iron core and shell. When the battery voltage is applied to the primary winding, the primary winding charges. Once the ECU cuts off the primary winding circuit, the charging will be stopped.
  • Page 160 2. Working principle High voltage connecting wire is a device connecting ignition coil and spark plug. It consists of spark plug cap, high voltage wire and ignition coil connector cap. 3. Possible failures The connection of high voltage wire with spark plug cap and ignition coil connector cap is loose; The insulation rubber sleeve of spark plug cap and ignition coil joint cap is aging and leakage;...
  • Page 161 Idle stepper motor 1. Outline drawing and pin definition 2. Working principle The basic working principle of idle bypass air volume control valve comes from the principle of stepping motor. It is composed of rotor made of two special-shaped permanent magnet modules, stator component composed of two groups of two-phase electromagnetic coils, screw rotor transmission mechanism which converts rotary motion into straight line, conical regulating control valve, input circuit signal connector, spring, metal forming assembly fixed shell, rubber sealing ring and other main components.
  • Page 162 2. Working principle ECU obtains various information about the actual working state of the engine or the whole vehicle through several sensors configured by the engine management system. ECU drives the actuator configured by the system to perform the optimization and control of engine operating conditions according to the data calibrated and stored in advance by the system.
  • Page 163 4. Basic function check battery voltage Check whether the engine can start, idle and accelerate Check the fuel pump for operation Check the ignition spark and spark plug Check the engine speed sensor for iron filings Check whether the pressure sensor hose is damaged Check whether the fuel injector is blocked.
  • Page 164 Oil pump relay failure; relay; Replacement of fine filter or oil pump: The fine filter is blocked or the oil pump fails; Replace the oil pipe; The fuel pipe is blocked or leaking; Replace the fuel injector. Injector failure. Replace intake pressure sensor or hose: readjust ignition timing: Intake pressure sensor failure or hose rupture:...
  • Page 165 Failure phenomenon Possible causes Solutions: Unstable engine speed Intake pressure sensor and hose failure; Replace intake pressure or no idle speed, fuel sensor or connecting pipe; return and flameout Water temperature sensor failure; Replace the water temperature sensor; Idle stepper motor fault; Replace the idle stepper motor and its pipeline;...
  • Page 166 acceleration Maintenance or replacement; Fuel injector blockage or failure; Engine vomiting, Clean or replace; unstable speed The signal of each sensor is abnormal; Replace the failed sensor; Poor line connection or poor grounding; Check and connect the circuit; ECU failure. Re plug or replace ECU.
  • Page 169 Distribution by: KSR Group GmbH Im Wirtschaftspark 15 3494 Gedersdorf Austria The copyright lies with the company/manufacturer: KSR Group GmbH Im Wirtschaftspark 15 3494 Gedersdorf Austria Copyright ©2021 All rights reserved. This manual is protected by copyright. Reproduction in mechanical, electronic or any other form without the written permission of the manufacturer is prohibited.

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