Malaguti DRAKON125 2022 Workshop Manual
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Malaguti DRAKON125 2022 Workshop Manual

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DRAKON125
WORKSHOP MANUAL

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Summary of Contents for Malaguti DRAKON125 2022

  • Page 1 DRAKON125 WORKSHOP MANUAL...

  • Page 3: Preface

    Preface With the increasing variety of motorcycles, more and more new designs and technologies are being introduced. To help service personnel better master the maintenance, adjustment and servicing techniques of the Drakon 125, we have compiled this maintenance manual. This manual refers to the Drakon 125. The contents of Chapter 1 to Chapter 2 refer to the adjustment of various components of the motorcycle.

  • Page 4: Table Of Contents

    Content Preface ..........................2 Chapter 1 Overview ......................5 Printing Position of Machine Number ................5 Maintenance Precautions ..................... 6 Main Performance Technical Data ................10 Torque Value of Main Standard Parts ................ 11 Wiring Diagram ......................15 Symbol Description ..................... 18 Chapter 2 Lubrication System ...................
  • Page 5 Maintenance requirements ..................88 Rear wheel, rear brake, rear suspension devices ............89 Chapter 4 General Introduction of Electrical System ............97 Battery and power supply system ................99 Starting system ......................106 Lighting signal system ....................114 Information display system ..................128 Engine management system ..................

  • 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: The frame number is engraved on the right The frame name plate is riveted on the left...

  • Page 7: Maintenance Precautions

    side of the frame riser side of the frame seat tube Printing position of engine number: The engine number is engraved under the left crankcase body Maintenance Precautions 1. Parts, accessories, lubricating oil and other auxiliary materials produced by the company or approved and recommended by the company shall be used.
  • 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.
  • Page 9 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 covers shall cover the terminal after the operation. 11. When disassembling the connector with lock, the lock must be released before operation.
  • Page 10 frame. The clamps shall clamp the wire the limit position, the wire bundle shall not bundles correctly. The wire harness shall be too tight and too loose, and it should be be clamped at the place that is not in confirmed that there is no prominent contact with...

  • Page 11: Main Performance Technical Data

    Main Performance Technical Data Items Data Length×width×height 2050 mm × 810 mm × 1110 mm Dimensions and Wheelbase 1370 mm weight Minimum ground clearance 170mm Vehicle quality Curb weight: 145 kg, full load: 320 kg Frame form Steel tube type Front suspension rear camber 25°...

  • Page 12: Torque Value Of Main Standard Parts

    Anti theft device type Type 2. Lock the steering column with the ignition switch and Fuel supply mode EFI, ECU control Ignition mode Headlamp H4 12V 55/60W Turn signals Front: 12V2W Rear: 12V2W Brake lamp/rear taillight 12V3.1W/2.7W Torque Value of Main Standard Parts Engine Items Quantity...
  • Page 13 Vehicle body Items Quantity Thread diameter (mm) Torque value (N.m) Assembly of engine front suspension 28～35 Assembly of engine rear suspension 55～65 Assembly of front damping 28～32 Cap nut of connecting plate on 60~70 steering column Steering column and front damping 45~55 Handlebar and clip 21~25...
  • Page 14 Regular maintenance table Every Mileage Initial 1000km Every 5000km Every 15000km Inspection cycle 10000km Inspection items Every 15 Every 30 Every 45 Time First 3 months months months months Air filter (filter cartridge) – Check Check Replace *Bolts and nuts of muffler Fastening –...
  • Page 15 When checking according to the items in the table, further cleaning, lubrication, adjustment or replacement shall be carried out if necessary. Note: 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 "*"...

  • Page 16: Wiring Diagram

    Wiring Diagram...
  • Page 17 1 Instrument wiring, 2 Ignition switch wiring, 3 Headlamps wiring, 1 Oxygen sensor, Radiator fan wiring, 2 Battery, 3 Headlamp, ABS, Oil pump relay, 4 Start relay, 5 Magneto wiring, 6 Voltage regulating rectifier, 7 Horn, 8 Ignition rectifier wiring...
  • Page 18 1 Fuse box, 2 ECU, 3 Fault diagnosis interface, 4 Fuel sensor wiring, 5 ABS, 6 Left and right combination switch wiring...

  • Page 19: Symbol Description

    Symbol Description Meaning of symbols in this manual: The meaning of graphic The meaning of graphic Graphic symbols Graphic symbols symbols symbols Measures to be prompted during operation, inspection Use general tools. and maintenance. Special instructions disposal measures proposed Specification of tightening to prevent certain damage to torque : 50 N.m.

  • 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 Cleaning of oil coarse filter Cleaning and replacement of oil Lubrication of each operating line filter Engine lubrication system Oil pump Maintenance Instructions This section introduces the checking and replacement methods of engine oil, as well as the cleaning methods of oil coarse filter and oil filter.
  • Page 21 used oil. Keep children away. Troubleshooting Oil contamination Excessive oil consumption 1. Failure to change the oil according 1. The engine is leaking oil; to the maintenance interval table; 2. The piston ring is worn; 2. Damage to the threads of the oil 3.

  • Page 22: Lubrication Position Of The Whole Vehicle

    Lubrication position of the whole vehicle Except the drive chain shown in the figure above use special chain oil, the rest positions adopts lithium grease. All oils not specified in this manual shall adopts 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 Lower crankcase oil passage 1 The oil flows from the primary filter assembly to the oil pump, 2 The oil flows from the oil filter to the oil passage orifice, 3 The oil flows from the oil pan to the primary filter assembly Upper crankcase body oil passage...
  • Page 25 1 The oil flows from the orifice of the oil passage to the main shaft, 2 The oil flows from the orifice to the cylinder head, 3 The oil flows from oil pan to thick filter set, 4 The oil flows from oil pump to oil filter Cylinder head oil passage...
  • Page 26 1 The oil flows from upper case to cylinder head Lubrication of camshaft journal 1 The oil flows from cylinder head to intake cam, 2 The oil flows 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 1 Engine oil sight window, 2 Engine oil upper limit line, 3 Engine oil lower limit line Replacement of oil Oil changes should be done before the engine has cooled down. Only in this way can the oil in the crankcase be removed quickly and completely. During replacement, open oil bolt, drain waste oil, clean oil drain bolt, replace new gasket, and then install oil drain bolt.
  • Page 29 1 Loosen the oil drain bolt, 2 Fill the oil Oil pump When the oil pump fails, it needs to be removed for maintenance or replacement. It is not necessary to remove the engine from the frame to perform this work. This part includes the following main contents:...
  • Page 30 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 2. Remove the right crankcase cover; clutch control arm; 3.
  • Page 31 Oil pump Oil pump Oil pump Inspection of oil pump Check whether the clearance of the oil pump is within the maintenance limit with a standard feeler gauge. Inspection of radial clearance inspection of end clearance Maintenance limit: 0.20 mm Maintenance limit: 0.12 mm inspection of end clearance Maintenance limit: 0.12 mm...

  • Page 33: Chapter 3 Inspection And Adjustment

    Chapter 3 Inspection and Adjustment Idle speed Maintenance Instructions Braking System Spark plug Timing phase Running System Lubricating oil Clutch operating line Coolant Drive chain Cylinder pressure Battery Timing chain tension Headlight Dimming Valve clearance Riser steering bearing Air filter and oil collector Suspension System Throttle control Bolts, Nuts and Fasteners...
  • Page 34 Cylinder pressure ≥0.6MPa/300rpm Tire pressure Front wheel Single: 220 kPa, double: 220 Rear wheel Single: 250 kPa, double: 250 Tire size Front wheel 100/80-17 M/C 52S Rear wheel 130/70-17 M/C 62S 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.
  • Page 35 cylinder head cover to see if it is in the timing position (as shown in the figure). Check whether coolant accumulator is between the upper and lower marking lines. If it is too little, replenish it in time. Lubricating oil Use a special fixture to support the motorcycle on the flat ground, so that the engine is in a horizontal position and does...
  • Page 36 coolant slowly until the coolant level is at difficult to start, other faults have been the upper limit of the middle part. Then eliminated. When it is suspected that the cover the radiator cap. cylinder pressure is abnormal, check the cylinder pressure.
  • Page 37 Warning: Before opening the radiator cap, make sure that the engine and radiator are completely cooled, otherwise it may cause the coolant to spray out and cause serious scald. Remove the spark plug and test the cylinder pressure The main reasons for low cylinder pressure are as follows: Incorrect valve clearance adjustment Valve leakage...
  • Page 38 the tail of the new chain tensioner, rotate to make the front end of the tensioner retract and lock, replace with a new seal washer, install a new chain tensioner and fasten it. Pull out the lock key of the tensioner to tighten the timing chain.
  • Page 39 Loosen air cleaner cover Throttle control Idle speed First, check whether the throttle operating Note: line is deformed, kinked or damaged. Then measure the free stroke of the throttle After other items of the engine have handle. Turn the handle to one side of the been adjusted to the specified range, free stroke, draw a straight line between check and adjust the idle speed.
  • Page 40 Fine adjustment: Pull open protective rubber sleeve, loosen the lock nut A, and turn the adjusting screw to adjust to a suitable free stroke. Then tighten the lock nut A and install the protective rubber sleeve. Lock nut A Rough adjustment: If the fine adjustment can not be in place, separate the throttle control line from the throttle body, loosen the lock nut B, and adjust the larger stroke...
  • Page 41 Braking System Inspection of brake fluid level: Check the free stroke of the front brake Check the brake fluid level in the front handle. brake cylinder. If the level is too low but not completely empty, replenish the brake fluid The free stroke of the brake handle is 5-10 directly.
  • Page 42 and refilled. Refer to the vacuum filling method of brake fluid in the next section. If the brake fluid in the front and rear brake cylinders is exhausted, use a vacuum pump to pump air at the brake caliper body bleeder nozzle, and then fill the cylinder.
  • Page 43 Warning: The brake fluid is highly corrosive and shall not be splashed on the surface of painting parts or plastic parts; In case of contact with eyes skin, rinse immediately with plenty of water and consult a doctor Front brake cylinder cover Rear brake cylinder cover Running System Clutch operating line...
  • Page 44 If the fine adjustment can not achieve Note: suitable free stroke, the clutch operating line at the handle end must be removed to Check the tire pressure when the tire is adjust the engine end. at the normal temperature. Rough adjustment: First remove the clutch operation line at the handle end, then remove the clutch control arm at the engine end, rotate the clutch control arm to...
  • Page 45 If the tire pressure does not meet the specified requirements, check the tire for cuts, embedded nails or other sharp objects. 1 Adjust nut, 2 Lock nut Remove the clutch operating line Chain adjuster adjusting nut Note: The marking on the chain adjusters on both sides must be consistent.
  • Page 46 the tension of the drive chain. The method If it is damaged, replace the chain. Then is to press the chain up and down with your install the chain and apply the special fingers to check the up and down lubricant for the chain;...
  • Page 47 bolt of the battery bracket.At this time, the steering handle can not rotate freely, and battery can be taken out. there is axial movement or stagnation, adjust the adjusting nut of the front fork Clean the positive and negative pole riser.
  • Page 48 The headlamp can be adjusted value. vertically. Rear suspension Adjustment method: Use a cross Press the rear of the seat cushion screwdriver to rotate clockwise to adjust firmly to check whether the rear fork sleeve the light height upward, otherwise, adjust is worn or damage.

  • Page 49: Fuel System

    Fuel system This section describes the knowledge of the fuel system. 1 Fuel tank, 2 Fuel injector, 3 High pressure pipe, 4 Air cleaner, 5 Valve body, 6 Fuel pump and fuel sensor Maintenance Instructions Replacement of fuel filter Disassembly and installation of Troubleshooting air filter Disassembly and installation of...
  • Page 50 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. When reassembling, be sure to use a new seal Components. Do not disassemble the throttle body (the fuel injector can be removed). Technical Specifications Throat diameter is equal to Φ31mm.
  • Page 51 2. Remove 2 M5 ×12 and 2 M6 × 16 5. Remove the fuel tank. connect bolts from fuel tank trim cover assemblies. In order to avoid the contamination of the 3. Remove 1 M6× 30 fixing bolt from oil fuel delivery pipeline, the joint shall be tank assembly.
  • Page 52 avoid fuel pipeline pollution. Disassembly / installation of fuel tank Sequence Procedure Quantity Remark The installation sequence is reverse to the Disassembly sequence disassembly sequence Seating washer Bolt M6X35 Screw M6 X 16 Screw M5 X 12 Fuel tank trim cover assembly Bolt M6x30 Straight Bushing φ6×φ15-3.5 Rear buffer ring of oil tank...
  • Page 53 Pay attention to the oil outlet of the oil pump towards the front of the fuel tank during assembly. Sequence Procedure Quantity Remark The installation sequence is reverse to the Disassembly sequence disassembly sequence Bolt M5 × 12 Fuel pump assembly Fuel tank separator Fuel tank cap bond pad Fuel tank...
  • Page 54 Replacement cycle: 15000km. Tools: flat type screw driver. Note: Do not pull the liquid level sensor and float rod assembly hard during installation and disassembly. Take out the filter element Disassembly procedures of filter: Press the inverted buckle of the filter and pull out the filter.
  • Page 55 Set screw Take out the air filter cover...
  • Page 56 Cooling system 1 Engine, 2 Short circle hose/ water pipe, 3 Radiator grille cover, 4 Water outlet Hose/ water pipe 5 Radiator, 6 Water inlet pipe, 7 Thermostat, 8 Temperature sensor Maintenance Water pump Instructions Troubleshooting Thermostat Inspection of Cooling electrical performance system Radiator...
  • Page 57 The maintenance of this part must be carried out under cold or low temperature. The maintenance of this part can be carried out on the vehicle. 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.
  • Page 58 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 well 1. Poor fan switch; 1.
  • Page 59 specified pressure range for 6 seconds, it Specified pressure: 73.5-103 kPa. can be used Confirm whether the pipe connecting parts are leaking. Note: Do not increase the pressure above the When installing the cap on the detector, specified pressure, which may cause first coat the sealing surface with water.
  • Page 60 Installation of radiator Reverse the order of disassembly. Avoid damaging the radiator during disassembly. After installation, don't forget to fill in the coolant and check whether the connection parts are leaking. Disassembly / installation of radiator Sequence Procedure Quantity Remark...
  • Page 61 The installation sequence is Disassembly sequence reverse to the disassembly sequence Drakon 125 water-cooled (with cover, fan, sub black) Drakon 125 auxiliary radiator grille (with cover) Water pipe assembly(φ7×φ11×(35+30+190+65),φ10) Drakon 125 water pipe assembly((φ14×φ22+φ19×φ27)×(50+115+80) GB/T16674.1 bolt M6×55 (trivalent chromium blue white zinc, grade 8 8) ZS150-48D Headlamp cushion Drakon 125 water pipe...
  • Page 62 The assembly sequence is reverse to the Decomposition sequence disassembly sequence Radiator body Temperature control switch Bolt M6 × 16 Spring washer ф6 Washer φ6 Water tank cover Fan components Water pump Disassembly and assembly of water pump Inspection of water pump Be sure to drain the coolant before Remove the connecting bolts, open the disassembling the water pump.
  • Page 63 shall be smeared on the water pump mounting hole to facilitate assembly. Replace the seal washer (6) at the drain hole during installation. Disassembly/ installation of water pump Sequence Procedure Quantity Remark The installation Disassembly sequence is reverse sequence to the disassembly sequence Pump assembly...
  • Page 64 1 Thermostat, 2 Water temperature Thermostat gauge Boiling point 71℃ Full boiling temperature 88℃ Degree of full boiling 3.5mm Note: Do not let the thermostat touch the container. If the thermostat has a little valve open at room temperature, it should be replaced.
  • Page 65 Circuit diagram Introduction of main components Fan switch (temperature control switch) 1. Working principle The fan switch is actually a kind of heat sensitive switch. When the temperature rises, the paraffin expands and pushes the moving contact to move. The paraffin expansion coefficient is proportional to the temperature.
  • Page 66 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. The motor uses a 12V DC motor, which drives the fan leaf to rotate to form the flow of wind and take away the heat from the radiator.

  • Page 67: 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 Maintenance Installation of engine Instructions Disassembly of engine Maintenance Instructions Only when the crankshaft, balance shaft Specifications and transmission part of the engine are Engine net weight 35 kg...
  • Page 68 motorcycle shall be supported on the flat ground with side bracket, and the cooling water and engine lubricating oil shall be Important torque figures drained. Engine suspension bolt M10: 55 ～ 65 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.
  • Page 69 grounding wire Disassembly of spark plug cap. Remove the magneto output line and water temperature sensor line Disassembly of transmission control sub- Disassembly of engine front suspension assembly mounting bolts Disassembly of engine rear suspension Sequence Procedure Quantity Remark mounting bolts...
  • Page 70 The installation sequence is Disassembly reverse to the sequence disassembly sequence Closure panel, fuel Refer to tank, radiator, relevant muffler, air filter, etc chapters Variable speed control components Left rear cover Disassembly the engine Bolt M8 × 28 Nut M8 Bolt M8 ×...

  • Page 71: Frame, Exhaust System

    Frame, exhaust system 1 Tail light component, 2 Rear fender, 3 Closure panel, 4 Frame, 5 Muffler Disassembly / installation of Maintenance Instructions rear fender Disassembly/ installation of Troubleshooting exhaust muffler Closure panel, headlamp Rear lamp assembly and instrument Maintenance Instructions During the maintenance of this part, special attention shall be paid to the covers,...
  • Page 72 instruments and lamps not to be scratched or damaged. Disassembling or maintaining parts before the exhaust system cools may cause severe burns. This part mainly includes the disassembly and installation of cover, rear fender, exhaust muffler, radiator and lamp. Troubleshooting Excessive emission noise Work abnormalities 1.
  • Page 73 upper connecting plate. Installation procedures of cover, headlamp and 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. Note: In the process of disassembly, do not scratch the appearance surface of the...
  • Page 74 Disassembly/ installation of exhaust muffler Disassembly procedures exhaust Installation procedure of exhaust muffler in muffler the reverse order of disassembly. 1. Support the motorcycle on the ground Proceed reverse order with the main bracket, and pull out the disassembly. oxygen sensor plug. The muffler seal washer at the engine exhaust port should be replaced with a new one.
  • Page 75 of the lower shroud assembly. 3. Remove 2 connecting screws, M8× 30 inner hexagon screw, between muffler and engine exhaust port. Remove 2 connecting bolts, M8× 45 inner hexagon bolt, between the rear silencer and the frame. Remove the muffler. Disassembly / installation of rear tail lamp 4.
  • Page 76 2. Remove 2 fixing bolts, M6 × 16 bolt, of 5. Remove 3 connecting screws, self ECU controller. tapping screw ST4.2 × 13, between left and right car body cover and rear tail lamp. Remove the left and right car body covers. Note: Only when the main power is off can the ECU be pulled out.
  • Page 77 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 Direction column Control sub-assembly Front brake Maintenance Instructions When maintaining the front wheel, the motorcycle should be reliably supported by a jack...
  • Page 78 Important torque figures Front axle 75～85 N.m Fastening bolts of 20～25 N.m front shock Handlebar fixing bolt 21～25 N.m 60～70 N.m absorber plate Fixing bolts of upper and 28～32 N.m 28～32 N.m Front fork riser nut lower connecting plates Fastening screw of brake disc Troubleshooting Unstable direction...
  • Page 79 3. Deformation or looseness of wheel Poor brake performance spokes 1. There is air in the brake pipe; 4. Front axle is loose 2. The brake shoe is worn; 5. Tire is damaged 3. There is water or oil on the brake shoes. Disassembly / assembly of control sub-assembly Note The front brake master cylinder shall be hoisted with steel wire rope, and its height shall...
  • Page 80 The cable and wiring are consistent with the wiring diagram. 1. Pull out the brake switch plug 5. Pull off the clutch switch plug. 2. Remove the front brake master cylinder 6. Remove the clutch handle bolt. clip bolt. 3. Remove the right combined switch 7.
  • Page 81 Maintenance requirements Sequence Procedure Quantity Remark Disassembly sequence The installation sequence is reverse to the disassembly sequence Brake switch plug Note: 1. First tighten the upper bolt, and then tighten the Clamp bolt of front brake master lower bolt; 2. There are two raised triangular marks on cylinder the clip pointing upward Front brake cylinder block...

  • Page 82: Front Wheel Disassembly / Assembly

    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 Note Soiled brake discs and friction discs may reduce braking performance. Please pay attention to replacing friction discs and cleaning soiled brake discs.

  • Page 83: Front Suspension Disassembly / Assembly

    Disassembly sequence The installation sequence is reverse to the disassembly sequence Bolt Tightening torque: 55-65 N.m Front axle Tightening torque: 75-85 N.m. Apply lithium grease Front wheel left bushing Apply lithium grease during assembly Front wheel right bushing Apply lithium grease during assembly Front brake disc bolts Tightening torque: 28-32 N.m Front brake disc assembly...

  • Page 84: Maintenance Requirements

    When the brake caliper is removed, do not pull the brake handle to avoid difficulties when assembling the front wheel. Before removing the shock absorber, loosen the lock nut of the steering column, but do not remove it. Maintenance requirements Quantit Sequence Procedure...

  • Page 85: Disassembly/ Assembly Of Steering Column

    Disassembly/ assembly of steering column 1 Upper damping bolt, 2 Steering column locking bolt, 3 Lower damping bolt, 4 Steering column combination Note 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 86: Assembly Of Directional Column

    The assembly torque is 10 ~ 12 N.m, and the steering Adjusting nut column is rotated repeatedly during assembly Tapered roller bearing Steering column assembly Turn the steering column repeatedly during assembly Direction column bearing washer Assembly of directional column Apply enough lithium grease on the surface of bearing roller.

  • Page 87: Front Brake

    Tighten the bolts before connecting the connecting plate on the steering column. Torque requirement: 28~32 N.m 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 88 2. Pipeline leakage; 1. The brake system is blocked 3. The brake fluid level is low. 2. The piston of brake caliper is stuck and worn. 4. The brake friction plate is dirty; 3. Poor sliding of brake shoe. 5. The piston seal of brake auxiliary cylinder is worn and aged.

  • Page 89: Front Brake Caliper Components Removal/ Assembly

    Front brake caliper components removal/ assembly 1 Front brake disc, 2 Brake caliper bolts, 3 Front brake caliper Note 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 90: Rear Wheel, Rear Brake, Rear Suspension Devices

    Sequence Procedure Quantity Remark Disassembly sequence The installation sequence is reverse to the disassembly sequence Brake caliper bolt M10×40 Tightening torque: 55-65 N.m Lift the front brake main cylinder with steel wire rope, Front brake caliper components and do not twist the brake hose. Spring clip Friction plate locating pin Friction plate...
  • Page 91 Maintenance Instructions This section describes the removal, installation and maintenance of the rear wheel, rear brake, rear fork, rear shock absorber and rocker link. When performing repair and maintenance for the rear wheel, rear shock absorber and rocker arm connecting rod, the motorcycle should be reliably supported by an air jack or other bracket under the engine.
  • Page 92 1. Rear axle 2. Rear wheel left bushing 3. Sprocket 4. Chain adjuster and nut 5. Rear wheel assembly 6. Rear wheel left bushing 7.Flat fork assembly 8. Rear brake disc 9. Rear speed signal tray 10. Rear brake disc fastening screw 11.Rear wheel right bushing 12.
  • Page 93 2. Screw out rear axle fastening nut 4. Take out the rear wheel assembly. M14×1.5. 5. Take out the right rear wheel bushing. 6. Take out the left rear wheel bushing. 7. Remove the sprocket fasten, take out the sprocket and get the rear wheel.
  • Page 94 8. Take out the disc of rear disc brake. Rear fork Disassembly steps of rear fork: Note: When removing the brake caliper body, 1. Remove the rear wheel assembly first make sure that the rear brake caliper (refer to disassembly steps of rear wheel). body is lower than the rear brake cylinder body to prevent air from 2.
  • Page 95 entering the cylinder body reducing the braking performance. after removing the rear brake caliper body, if it does not need to be replaced, do not step on the rear brake pedal. Warning: Tighten the flat fork shaft fastening nut 3. Pull the rear brake caliper body backward to the specified torque of 75 ~ 85N.m.
  • Page 96 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 97 Sequence Procedure Quantity Remark The assembly sequence is reverse to the Decomposition sequence disassembly sequence Chain adjuster Chain guard When assembling, make sure that the shaft Flat fork shaft bushing sleeve rotates flexibly Flat fork oil seal (24×16×5) Apply lithium grease on the needle roller during Needle roller bearing HK2520 installation Rear flat fork liner...

  • Page 98: 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 99 motorcycle electrical system will undergo significant changes. The electrical system is more advanced than traditional motorcycles in that it applies more advanced automotive electronics and is much more complex. It consists of the following subsystems. Power supply system Starting system Engine management system Cooling system (electrical part) Lighting signal system...

  • Page 100: Battery And Power Supply System

    Battery and power supply system Overview Introduction of main components Circuit diagram Main fault diagnosis Parts layout Overview 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.
  • Page 101 1 Ignition switch, 2 Main electrical harness, 3 Battery, 4 Voltage regulating rectifier, 5 Magneto Introduction of 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.
  • Page 102 steel is the rotor and the coil winding is the stator. Magneto is the main power supply of electrical system. 3. Basic parameters The rotor consists of six magnets with 12 poles; Stator winding has a total of 18 poles, which connect according to three-phase △ and the winding resistance value of each phase is 0.3-0.5 Ω;...
  • Page 103 Working current: 15A. 4. Possible failures Out-of-control voltage regulator circuit, causing overcharge to the battery; The rectifier circuit is open circuit or short circuit, and battery cannot be charged or is not charged enough; The outgoing line is short circuit or open circuit. Battery 1.
  • Page 104 Too much internal resistance, serious self-discharge phenomenon, voltage below 5V. Combined ignition switch 1. Outline drawing 2. Working principle The ignition lock cylinder with double slot and 8-tooth key is the main switch of the whole vehicle power supply. It is also the head direction lock. 3.
  • Page 105 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 106 The main fuse is blown out; Replace the main fuse Poor contact of main fuse circuit; Plug in again No power for the whole vehicle: Poor contact of the positive and negative lines Reconnect of the battery; No electricity in the whole car, i.e.

  • Page 107: Starting System

    Starting system Overview Introduction of 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 108 1 Flameout switch, 2 Start switch, 3 Clutch switch, 4 ECU, 5 Cable harness, 6 Battery 7 Starter motor, 8 Gear switch, 9 Starter relay, 10 Side holder switch Introduction of 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 109 through the reduction gear, the isolator, and the crank 3. Basic parameters Stator has four magnetic steels with four poles in total, and four carbon brushes; Specification: 12V650W; Rotation direction of output shaft: viewed from the tooth end, clockwise; Output features 4.
  • Page 110 terminal). 3. Basic parameters Nominal voltage: 12V; Rated current: DC150A; Closing voltage: ≥ DC7V; Released voltage: ≤ DC4.5V; Contact voltage drop: below 0.2V (at 150A); Coil current: below 3.5A. 4. Possible failures The coil or lug is open and the contact cannot be absorbed. Short circuit of the coil, causing failure in the contact point pulling in;...
  • Page 111 Side bracket switch Gear switch...
  • Page 112 2. Switch function Left combined switch functions Oran Emerge lamp Blue Ligh Left turn yello Horn Right Overtak turn ing light Right combined switch functions Red and Black and black white Switch off Black and Yellow and the motor white Work Start Pack up...
  • Page 113 3. Possible failures Broken switch position pin, rotating on the handle tube during use; No sense of being in place or weak the sense of being in place; The button cannot be reset; Switch failure and lead wire breakage make the switch unable to be connected; Lead wire breakage, switch dysfunction;...
  • Page 114 enough; Excessive engine resistance. Check the engine.

  • Page 115: Lighting Signal System

    Lighting signal system Overview Introduction of 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 116 Front brake lamp switch Rear brake lamp switch Left and right combined switch Circuit diagram Parts layout...
  • Page 117 1 Combination tail lamp, 2 Right combination switch, 3 Front brake switch, 4 Left combination switch, 5 Front left direction indicator lamp, 6 Headlamps 7 Front direction indicator lamp, 8 Flasher, 9 Main electric harness, 10 Rear right direction indicator lamp Introduction of main components Headlamp 1.
  • Page 118 2. Working principle The high beam filament is located at the focal point of the parabolic surface of the reflector of the headlamp. The light is reflected by the reflector and becomes a parallel beam, which is then scattered by the lamp glass to illuminate the road surface within 100m in front of it;...
  • Page 119 the adjusting screw clockwise to adjust the light to move down and vice versa. Left and right adjustment: the car can not be adjusted left and right. Headlamp relay 1. Outline drawing 2. Working principle There are two purposes to set the headlamp relay in the control of the headlamp: when the engine is not started, the headlamp will not light up, and after the engine is started, the headlamp will light up through the headlamp switch.
  • Page 120 Combined rear position lamp 1. Outline drawing 2. Working principle The combined rear position lamp integrates the functions of tail lamp and brake lamp. The light of the tail lamp and brake lamp is red, the tail lamp/brake lamp bead is a double filament bead, the low power bead is used for the tail lamp, and the high power bead is used for the brake lamp.
  • Page 121 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. Basic parameters Specification of license lamp bead: 5W; 4.
  • Page 122 2. Working principle The front turn signal lamp is composed of lamp glass, lamp shell, reflector, lamp holder, handle and lamp bead. The light emitted by the lamp beads is reflected into concentrated light by the reflector, and then scattered into uniform and soft orange light by the lamp glass.
  • Page 123 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. The light emitted by the lamp beads is reflected into concentrated light by the reflector, and then scattered into uniform and soft orange light by the lamp glass.
  • Page 124 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 125 rusted and cannot be connected. Front brake light switch 1. Outline drawing 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.
  • Page 126 2. Working principle The pull rod of the rear brake light switch is connected with the brake pedal through the spring. When the brake pedal is pressed, the brake pull rod moves downward, and the contact also moves down. It contacts with the two contact shrapnel at the same time. When the circuit is connected, the brake light is on;...
  • Page 127 3. Basic parameters Voltage: DC12V, Current: 1.5A; Sound pressure level: 105dB 4. Possible failures Contact ablation; The contact clearance is too large or too small (can be adjusted and repaired); Coil short circuit or short circuit; The leading out insert is broken or rusted 5.
  • Page 128 turn on: The corresponding fuse is not connected or Connect the fuse or replace it; burnt out: The front steering lamp cannot be turned on; The left turn signal switch fails; Repair or replace the left switch; The rear turn signal lamp Failure of right turn signal switch;...

  • Page 129: Information Display System

    Information display system Overview Introduction of main components Circuit diagram Main fault diagnosis Parts layout Overview 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.
  • Page 131 Parts layout 1 Combination tail lamp, 2 Rear registration plate lamp, 3 Rear right steering pilot lamp, 4 ECU, 5 Right combination switch, 6 Instrument, 7 Left combination switch, 8 Front left direction indicator lamp, 9 Front right direction indicator lamp, 10 Headlamps Introduction of main components Instrument assembly 1.
  • Page 132 2. Working principle Chinese Version All electronic instruments (also known as digital instruments), the first input is all electronic 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.
  • Page 133 mileage display, subtotal mileage display, accumulated driving time display, subtotal driving time display, EMS fault code display, green backlight. 5. Possible failures Some functions cannot be displayed correctly; The operation button can't adjust the clock and switch the mode; Water in the instrument; Shell mechanical vibration rupture;...
  • Page 134 1st Gear (pink), 0 Gear (green and red), 2nd Gear (blue and red), 3rd Gear (green and black), 4th Gear (yellow and red), 5th Gear (yellow and white), 6th Gear (purple) 4. Possible failures Contact wear to poor contact; The gear switch vibrates or the press fit is broken; The gear switch is loose;...
  • Page 135 A：High oil level B：Low oil level 2. Working principle The oil level sensor consists of float, floating rod, magnetic core, lead wire, etc. The float, floating rod and magnetic core form a variable resistor. The height of oil level changes, which drives the float up and down.
  • Page 136 4. Possible failures Float falling off; Poor contact between contact piece and thick film circuit board; The stent was broken; The circuit board is damaged; The outgoing line falls off. Water temperature sensor 1. Outline drawing 2. Working principle Water temperature sensor: after the engine starts, the temperature in the water tank rises, and the resistance value of the water temperature sensor reaches the set value.
  • Page 137 32.0~36.0 30.0~34.0 115* 25.7~31.7 23.0~27.0 2.05~24.5 Main fault diagnosis Failure phenomenon Possible causes Solutions: The distance between speed sensor Reduce the distance to 2mm; and signal panel is too large; Speed indication fault: Vehicle speed sensor failure; Replace the speed sensor; The speed number is Signal panel failure;...
  • Page 138 The instrument cannot display the information that ECU should Poor wiring or open circuit; Re-plug or repair; display information Instrument failure; Replace the instrument; ECU failure. Replace ECU. The direction indicator Poor wiring or open circuit; Re-plug or repair; cannot be turned on and the high beam indicator Instrument failure.

  • Page 139: 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 140 Throttle, idle stepper motor (intake) 3. Electronic control unit: Maintenance Precautions 1. The fault diagnosis of EFI system can be carried out through the malfunction indicator lamp of the vehicle instrument, and a special diagnostic instrument can also be used to communicate with the ECU of the whole vehicle to carry out EFI system fault diagnosis and read fault codes.
  • Page 141 System schematic diagram...
  • Page 143 Parts layout 1 Instrument, 2 Right combination switch, 3 Left combination switch, 4 Battery, 5 ECU, 6 Combination tail lamp, 7 Rear registration plate lamp, 8 Rear left direction indicator lamp, 9 Three in one sensor, 10 Gear switch, 11 Water temperature sensor Introduction of main components Three in one sensor 1.
  • Page 144 1 Inlet pressure signal, 2 5V reference voltage, 3 5V reference voltage grounding, 4 Throttle plate position signal, 5 Inlet temperature signal 2. Working principle The three in one sensor is the function of the intake manifold absolute pressure sensor, the function of the intake manifold absolute temperature sensor and the throttle opening function are integrated into one whole.
  • Page 145 Storage temperature range: - 40 ℃ ~ 150 ℃ Working voltage: 5V ± 0.25VDC； Maximum working current: < 10mA DC Relationship between intake pressure and output voltage: The characteristic parameters of thermistor when the intake air temperature sensor is unloaded are shown in the table below:...
  • Page 146 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 is 12% ± 5% of the reference voltage When the throttle is fully open, the normal output of the reference voltage is between 83% and 93% The working characteristic curve of throttle position sensor is as follows:...
  • Page 147 3. Corresponding relationship between instrument display scale and oil level sensor resistance The warning light flashes ≥97 Ω Display 1 grid 82Ω～97Ω Display 2 grids 67 Ω～ 82 Ω Display 3 grids 52 Ω～ 67 Ω Display 4 grids 37 Ω～ 52 Ω Display 5 grids 22 Ω～...
  • Page 148 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 149 Engine temperature sensor temperature curve R-T table...
  • Page 150 Oxygen Sensor 1. Outline drawing and pin definition Oxygen sensor pin definition Corresponding cable color Heating positive White Heating negative Gray Signal ground Black Oxygen sensor signal 2. Working principle SMa oxygen sensor is based on multilayer ceramic elements with flat plate structure, in which zirconia layer is the core element.
  • Page 151 120mV; The concentration and dilution response time is less than 80 mS; The response time of dilute concentration is less than 65mS. 13.5V, heater power at 450 ℃ exhaust: 7.0 13.5 V, heater current at 450 ℃ exhaust : 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...
  • Page 152 Fuel pump 1. Outline drawing 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 153 The oil pump cannot rotate; Failure of oil pressure regulator; Support vibration failure; Fuel pump short circuit or open circuit; Poor sealing of sealing ring. Fuel injector 1. Outline drawing and pin definition 2. Working principle The fuel injector is actually an electromagnetic switch control element device. Its fuel supply mode adopts top fuel supply structure.
  • Page 154 ball valve rises. The high pressure fuel (250 ~ 400kPa) in the fuel line can pass through the valve seat hole of the fuel injector through the orifice plate and form a conical spray to spray into the valve body of the intake valve. When the power of the injector is cut off, the magnetic force of the solenoid coil disappears automatically, and the ball valve of the injector closes automatically under the action of the return spring, which stops the injection action of the injector.
  • Page 155 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. At the same time, high voltage electricity will be induced in the secondary winding, and the spark will be generated through the high voltage connecting line and spark plug discharge, which will ignite the fuel air mixture in the cylinder.
  • Page 156 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;...
  • Page 157 3. Basic parameters Spark plug model: CR9E(NGK); There is a resistance of 3-6kΩ inside the spark plug 4. Possible failures Serious carbon deposition on spark plug; The spark plug electrode is ablated; The spark plug insulator is broken; The spark plug is overheated; The spark plug leaks...
  • Page 158 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...
  • Page 159 input signal); 4. Possible failures Pipeline blockage or air leakage; Idle speed actuator blocked; Open circuit or short circuit of electromagnetic coil; Idle actuator vibration failure.
  • Page 160 1. Outline drawing 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 161 Component damage; Water inlet short circuit; The components are loose and fail after vibration. EMS fault diagnosis process 1. Analyze the situation reflected by users Make detailed records of problems (faults, other situations reflected by the user) and the occurrence process stated by the user. 2.
  • Page 162 Check whether the pressure sensor hose is damaged Check whether the fuel injector is blocked Other examinations. 5. According to the confirmed fault code, appearance inspection and basic function inspection results, carry out fault treatment. 6. Use the fault diagnosis instrument to check whether the idle speed data of the hot engine in the system is within the specified range.
  • Page 163 The fuel pipe is blocked or leaking; Replace the oil pipe; Injector failure. Replace the fuel injector. Replace intake pressure sensor or Intake pressure sensor failure or hose rupture; hose: Incorrect ignition timing: Readjust ignition timing; The fuel is deteriorated or contains water. Replace the qualified fuel.
  • Page 164 Failure phenomenon Possible causes Solutions: 进气压力传感器及软管故障； Replace the intake pressure sensor or connecting pipe; Intake pressure sensor and hose failure; Replace the water temperature Water temperature sensor failure; sensor; Unstable engine speed Replace the idle stepper motor and Idle stepper motor fault; or no idle speed, fuel its pipeline;...

  • Page 165: Electrical Schematic Diagram

    Electrical Schematic Diagram （find with PDF version）...
  • Page 167 Vertrieben durch: KSR Group GmbH Im Wirtschaftspark 15 3494 Gedersdorf Austria Hersteller: KSR Group GmbH Im Wirtschaftspark 15 3494 Gedersdorf Austria Copyright © 2022 Alle Rechte vorbehalten. Diese Bedienungsanleitung ist urheberrechtlich ge- schützt. Vervielfältigung in mechanischer, elektronischer und jeglicher anderen Form ohne die schriftliche Genehmigung des Herstellers ist verboten.

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