Lambretta G350 Service Manual

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Model G350 Scooter

Service Manual

Chongqing Gaokin Industries Co., Ltd.

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Summary of Contents for Lambretta G350

Page 1 Model G350 Scooter Service Manual Chongqing Gaokin Industries Co., Ltd.
Page 2 Model G350 Scooter Service Manual Chief Editor: Edited by: Chongqing Gaokin Industries Co., Ltd.
Page 3 This manual takes the G350 two-wheel scooter as the main line, and the contents of Chapter I to Chapter III are applicable to the adjustment of each part of the scooter. Chapters IV to XX are described separately according to the components of scooters.
Page 4 CONTENTS 1. Overview 2. Lubrication system (16) 3. Inspection and adjustment (22) 4. Fuel system (33) 5. Cooling system (41) 6. Engine disassembly and installation (48) 7. Cylinder head cover, cylinder head, cylinder block, and piston (54) 8. CVT transmission device, and reducer (65) 9.
Page 5 Overview Printing position of engine Maintenance cycle table Maintenance Precautions Wiring Diagram Main Performance Technical Symbol Description Data Standard torque value Printing position of engine No. And VIN Picture of complete vehicle: VIN Printing Location: Engine No. Printing Location: Nameplate Location: Nameplate Engine No.
Page 6 Maintenance Precautions 1. Parts, fittings, lubricants, and other auxiliary materials produced by Chongqing Gaokin Industries Co., Ltd. or approved and recommended by Chongqing Gaokin Industries Co., Ltd. shall be used. Damage to the motorcycle may occur if the parts used do not meet the “Gaokin”...
Page 7 When removing the connectors, hold the connector contact with the car body edges and sharp corners. body, and do not pull the wire harness. The wire harness shall not pass through where it contacts the head and front end of the bolt and screw. The wire harness shall not be loose or pulled by force.
Page 8 Main Performance Technical Data Projects Data Total length 1956mm Total width 770mm Total height 1129mm Wheelbase 1400mm Minimum ground clearance 153mm Maximum total mass Empty vehicle: 166kg, refurbish: 173kg, full load: 343kg Frame type Monocoque frame Front suspension caster ≥25° Front suspension Connecting rod type hydraulic shock-absorption with five- speed adjustable spring...
Page 9 Projects Data Clutch Transmission mode Ratio of transmission CVT Ratio of transmission 0.81-2.20 Final transmission ratio 6.790 Generator 420w/5000rpm, permanent magnet AC magneto Battery capacity 12V8A.h Power supply system DC power supply. The generator is only responsible for charging the battery Fuse 30A*1, 20A*2, 15A*1, 10A*1, 5A*2 Spark plug...
Page 10 Thread Torque value Projects Quantity diameter N. m 50～60 Connecting shaft of front hanger 46～50 Connecting shaft of hanger 80～90 Engine connecting shaft 28～32 Front absorber connection to steering column 55～60 Front absorber connection to front left and right rocker arms 55～60 Front left and right rocker arms connection to the steering column 55～60...
Page 11 Periodic Maintenance Sheet Initial Every Every Inspection cycle Mileage/Km Every 5000 Every 20000 1000 10000 15000 Inspection items Time/month Initial 3 Every 15 Every 30 Every 45 Every 600 Secure fastening Spark plug* Drive belt* Throttle Valve Controller* Buffer rubber of side bracket and main bracket CVT transmission box and dust cover...
Page 12 Wiring Diagram      Part 1 magnification Headlight Connecting Cable Connecting cable for rear brake Connecting cable for rear brake switch switch Right switch connecting cable Left switch connecting cable...
Page 13 Ignition lock connecting Part 2 magnification cable IMMO coil connecting cable BCM Connecting Cable Horn connecting cable Speed Sensor Connecting Cable Right steering lamp connecting cable Left steering lamp connecting cable ABS Connecting Cable Right fan connecting cable USB Power Component II Connecting Cable Left fan connecting cable Main Cable Components Starting motor connecting...
Page 14 Rear Wheel Speed Sensor Water temperature sensor Connecting Cable connecting cable Part 4 magnification Connecting cable for oil pressure sensor Diagnostic port Fuse box Speed Sensor Connecting Cable Stepping motor connecting cable USB Power Component I Connecting Cable Isolated Absolute Temperature Pressure Sensor Connecting Cable Throttle Position Sensor Connecting...
Page 15 Symbol Description Meaning of symbols in this manual: Description: Measures to be prompted during operation, inspection, and maintenance. Attention: Special instructions or measures to prevent the vehicle from being damaged. Warning: Special instructions or measures proposed to avoid major injury or personal injury.
Page 16 Lubrication system Maintenance Instructions Inspection and replacement of reducer oil Troubleshooting Oil Filter Replacement Engine Lubrication System Inspection of oil pump Diagram Inspection and replacement of Model selection of oil Maintenance Instructions This section describes the inspection and replacement of engine oil, as well as the methods for cleaning the primary oil screen and oil filter.
Page 17 When inspecting the oil quantity of the reducer, place the vehicle on the horizontal ground with the main bracket, loosen the oil quantity control bolt, slowly fill the oil from the oil filling port, and stop the oil filling when the oil quantity control bolt flows out (or take out the oil level position after inserting from the oil injection port with a clean small screwdriver, and inspect whether it reaches the position of the reducer oil quantity control bolt according to the same angle ratio outside the reducer cover).
Page 18 Engine Lubrication System Diagram Crankshaft left bearing shell Left bearing of balance shaft Oil pressure alarm Crankshaft right Crankshaft Connecting rod bearing shell bearing shell Left bearing of Oil pump Fine filter balance shaft Cylinder Cylinder Camshaft block head Primary oil Piston screen Magneto...
Page 19 Oil Replacement When changing the oil, it should be done before the engine has cooled down after the engine is stopped, so that the oil in the crankcase can be drained quickly and thoroughly. During oil draining, use the side bracket to tilt the vehicle to the left, unscrew the oil drain bolt, collect the oil in the crankcase with the oil pan, and clean the oil drain bolt.
Page 20 Oil pump When the oil pump fails, remove the engine for repair or replacement. When doing this, remove the engine from the frame. This part includes the following main contents: Removal procedure and diagram of oil pump; Installation procedures of oil pump; Disassembly and assembly of oil pump.
Page 21 Installation procedures of oil pump: thread release glue, and the rotor bolts The assembly procedure is the reverse of the removal shall be tightened according to the procedure. During assembly, note the following points: specified torque. Parts are clean and intact; When the right crankcase cover is When assembling the rotor, it is assembled, gently rotate the impeller of...
Page 22 Inspection and adjustment Maintenance Instructions Brake system Spark plug Running system Timing phase CVT and belt Lubricant Battery Coolant Headlight Dimming Cylinder pressure Standpipe steering bearing Air cleaner and oil collector Suspension system Throttle operation Bolts, nuts, and fasteners Idle speed...
Page 23 Maintenance Instructions This section describes the inspection and adjustment of each part of the G350 two-wheel motorcycle. At the same time, the technical requirements for inspection and adjustment are also introduced. Description: Unless specified or indicated in the maintenance cycle table, please inspect and adjust each part of the G350 two-wheel motorcycle before each use in accordance with this section.
Page 24 Spark plug Remove spark plug cap. Remove spark plug with socket spanner. Visually inspect if there is damage on spark plug insulator, and ablation on the electrode. Replace it, if any. Inspect the electrode clearance with a feeler gauge. Spark plug electrode clearance is 0.8 0.9 mm.
Page 25 Inspect whether the coolant in the accumulator is between Throttle handle fully open the upper and lower marking lines. If it is too little, replenish it in time. Start button Accumulator cover Key-turning Ignition Position Accumulator Supplementary method: Remove the accumulator cover, and slowly introduce the coolant into the funnel until the liquid level of the coolant is between the mid-upper limit.
Page 26 Cleaning and replacement of air cleaner element 1. Use the key to open the seat cushion Description: 1. Remove the filter element and inspect whether the filter element is normal. The filter element is a paper filter element. The dust and foreign matters can be 2.
Page 27 Free play is 2~6mm. Brake system Inspect the free stroke of the front brake handle. The free stroke of brake handle is 11~19mm. 11~19mm If the free play is insufficient or too large, the adjustment shall be made. Adjustment method: Fine adjustment: open the seat cushion to remove the storage box, loosen the locknut M6, rotate the adjusting screw to adjust to a satisfactory free stroke.
Page 28 Brake fluid vacuum filling method: This method is applicable to the brake fluid filling when the brake fluid in a new vehicle or brake cylinder is empty. 1. Use the vacuum pump to pump air at the brake caliper body venting nozzle. Lowest marking line Front brake caliper body Lowest marking line...
Page 29 Open rear brake cylinder cover 3. Operate the brake handle to remove the dead angle inside the brake caliper body. 4. When the vacuum pump has completely exhausted the air inside the brake caliper body, after pumping the brake fluid, tighten the handle or step on the pedal, fast tighten the bolt of venting nozzle, with the tightening torque range of Front tire pressure...
Page 30 Tire specification and recommended tire pressure: Front tire Rear tire Remove the identification cover plate and battery clamp plate 120/70-12 51P 130/70-12 62P Single person Double person Front tire Rear tire Front tire Rear tire 200kPa 220kPa 200kPa 240kPa If the tire pressure does not meet the specified requirements, inspect the tire for cuts, nails, or other sharp objects.
Page 31 Headlight Dimming Adjusting nut Inspect the headlight direction before driving. The headlight can be adjusted vertically. Adjustment method: Suspension system Front suspension Keep the front brake in braking state, and press the front fork riser several times to inspect whether the front suspension works normally.
Page 32 Fuel system High-pressure fuel pipe Injector Fuel tank Fuel pump Intake pipe Throttle valve body...
Page 33 Fuel system Maintenance Instructions Fuel Fine Filter Replacement Troubleshooting Removal and installation of air cleaner Removal and installation of fuel Removal installation tank throttle valve body Disassembly and Assembly of Fuel Tank Maintenance Instructions This section describes the knowledge of the fuel system. Warning: Pay attention to fire prevention when handling gasoline! When disassembling each component of the fuel system, pay attention to the installation position of the seal.
Page 34 Removal and installation of fuel tank 5. Remove the decorative plate and rear handrail of the fuel filler. (It is recommended to install the fuel tank cover back on the fuel tank after removing the fuel filler Removal procedure: decorative plate) 1.
Page 35 Installation procedure: The fuel tank assembly procedure is the reverse of the disassembly procedure. During assembly, pay attention to the wiring of fuel pump control line, and strictly follow the wiring diagram. Take care to avoid contamination of the fuel lines.
Page 36 Disassembly and Assembly of Fuel Tank The fuel tank shall be disassembled and assembled according to the following figure. The assembly procedure is the reverse of the installation procedure. When assembling, take care to face the outlet port At the time of assembly, directly in front of the fuel tank.
Page 37 Removal and installation of air cleaner After removing the air cleaner, the upper and lower bodies can be removed to take out the filter element, and clean or replace the filter element. Removal procedure: 1. Use the key to open the seat cushion; 2.
Page 38 Removal/installation of air cleaner The installation procedure is the reverse of the removal procedure. 1. Open the seat cushion , take out the 3. Remove the air cleaner mounting storage box , remove the left side cover bolts  . 2.
Page 39 Removal and installation of throttle valve body Installation procedure: The installation procedure is the reverse of the removal procedure. When installing, the location notch of the air inlet manifold connecting pipe must be aligned with the locating projection of the throttle valve body. ...
Page 40 Cooling system Accumulator Cover Combination Overflow pipe Yellow Liquor Body Water pipe A Water pipe B Fluid Radiator replenishing Water pipe C Thermostat cover Fan component Water pipe G Water pipe D Water pipe E Water pipe F Aluminum Pipe Welding Combination Engine Water pump cover...
Page 41 Cooling system Maintenance Instructions Troubleshooting Performance Inspection Radiator Cooling electrical system Maintenance Instructions Maintenance of this part must be carried out at normal or low temperature to avoid injury to maintenance personnel. Maintenance of this part can be carried out on the vehicle. After inspection and maintenance, air tightness inspection shall be carried out on the radiator with airtight testing equipment.
Page 42 Table of coolant mixing ratio Minimum temperature Mixing ratio Antifreeze (ml) Purified water (ml) in service area -9℃ 2000 -16℃ 1750 -25℃ 1000 1500 -37℃ 1250 1250 -44.5℃ 1375 1125 The bold font is the mixing ratio of coolant filling when the vehicle leaves the factory. When replenishing, use the coolant specified by Gaokin.
Page 43 Performance Inspection Inspection of accumulator cover connecting parts. Warning: Accumulator cover inspection Ensure that the coolant cools completely before opening the cover. Install the accumulator on the pressure gauge, and increase the charging pressure to 0.11Mpa. If it can be kept within the specified pressure range for 6 seconds.
Page 44 4. Loosen the anchor ear, pull out the fluid replenishing pipe and remove the accumulator. 1. Loosen fixing bolts 3. Take out water pipe F 2. Loosen the anchor ear at both ends, pull out the water pipe, and remove the welding combination of aluminum pipe. 8.
Page 45 Installation of radiator Proceed in the reverse order of disassembly. Avoid bumping the radiator plate when disassembling and assembling. After installing, don`t forget to fill the coolant and inspect the connecting parts for water leakage. Loosen fixing bolts 11. Remove the fixing bolts of the lower left and right wind guide covers of the fender, loosen the connector between the main cable and radiator fan, loosen the fixing bolts of radiator, and finally remove the radiator...
Page 46 Cooling electrical system Overview When the operating temperature of the engine reaches a limit value, the cooling water will circulate through the radiator. The temperature will continue to rise. After reaching the set fan opening temperature, the fan on the radiator shall be operated through the control of the ECU to take away the engine heat generated in the cooling water circulation, so that the water temperature drops.
Page 47 4. Failure mode Open circuit failure of fan motor; Short circuit failure of fan motor; The flabellum interferes with the fan housing, so the noise is great when the fan runs; The connection between the flabellum and the motor shaft slips; The fan housing is broken.
Page 48 Engine disassembly and installation Maintenance Instructions Installation of engine Removal of engine Maintenance Instructions It is only necessary to remove the engine from the frame when maintaining the crankshaft, balancing shaft, cylinder head, etc. of the engine. When maintaining other parts of the engine, it is not necessary to remove the engine from the frame.
Page 49 Removal of engine Open the seat cushion, remove the storage box, remove the left and right auxiliary foot pedal, the left Park the motorcycle on a horizontal ground, remove and right side cover assemblies, the oil filler ① - ⑤ fasteners and ⑥ oxygen sensor and remove decorative plate, the passenger handrail, and the fuel the silencer.
Page 50 Remove the magneto cable away from the fixing points of the regulator and frame.(see figure below) Engine Out Direction 向发动机移出方 Magneto cable  Remove the rear wheel speed sensor line clamp Adjustable bracket supporting position  oil sensor wire , throttle valve position sensor wire ...
Page 51 Installation of engine The engine is installed in the reverse order of removal. During installation, pay attention to the cable. The wiring shall be arranged according to the wiring diagram. Engine removal/installation Sequence Procedure Quantity Remarks Removal sequence Installation sequence is opposite to removal sequence 1.1 Remove silencer, drain coolant and Refer to relevant sections...
Page 52 Screw M8x32 Requirements for tightening torque: 25~30N. m/add threadlocker Rear brake oil pipe and rear wheel speed 1 each sensor Convex bolt M6X12/rear brake pipe clamp 2 each Requirements for tightening torque: 8～12N.m Bolt M6×16 Requirements for tightening torque: 8～12N.m Bolt M10×1.25×52 Requirements for tightening torque: 55～60N.m Nut M10x1.25...
Page 53 Cylinder head cover, cylinder head Cylinder head cover Intake rocker combination Exhaust rocker arm combination Rocker shaft Cylinder head Cylinder head gasket Camshaft...
Page 54 Cylinder head cover, cylinder head Maintenance Instructions Cylinder head cover Troubleshooting Camshaft Cylinder head Maintenance Instructions The engine needs to be removed from the frame when performing maintenance repairs in this section. Lubrication of camshaft and rocker arm is realized by oil pump through oil passage of cylinder head. Before assembly, please inspect whether oil passage is smooth and clean.
Page 55 Specifications and Maintenance Basis (continued) Projects Standard value Maintenance limit value Free length 40.5 Valve spring When installing elastic force is 170~200 N/33mm 4.47～4.485 IN Valve Stem Outer Diameter 4.44 4.5～4.512 Inner diameter of conduits 4.53 0.015～0.042 Fit clearance 0.09 Valve 4.455～4.47 EX Valve Stem Outer...
Page 56 Troubleshooting  Low cylinder pressure 1. Valve: 6. The piston or cylinder hole is scratched or scuffing. Incorrect valve clearance adjustment; --Valve ablation or bending;  Excessive noise --The valve is not sealed tightly; 1. Incorrect valve clearance adjustment --Wrong valve timing; 2.
Page 57 Removal/installation of cylinder head cover Sequence Procedure Quantity Remarks Removal sequence Installation sequence is opposite to removal sequence Cylinder head cover bolt Tightening torque 10N.m Cylinder head cover Sealing ring Replace if damaged...
Page 58 Camshaft Removal procedure for camshaft: 3. Release camshaft retainer, pull out rocker shaft, and take out intake/exhaust rocker arm 1. Remove the cylinder head cover (refer to the removal combination. of cylinder head cover), rotate the locking bolt on the camshaft end face, so that the sprocket location pin Camshaft retainer Intake...
Page 59 5. After aligning timing, install camshaft fastening bolts, tighten according to torque requirements, insert tensioner hole with flat screwdriver, screw in tensioner Measuring 塞尺测量 plunger to make chain under proper tension state (upper position of feeler 位置 and lower oscillator 0.5) gauge Inspect position of chain tightness...
Page 60 Inspection of camshafts Inspect camshafts for abnormal wear. Camshaft Inspection Inside micrometer Measure the diameter of left, middle and right shaft journals of camshafts. Measurement of inner diameter of camshaft hole External micrometer Cylinder head Removal procedure of cylinder head: 1.
Page 61 method camshaft disassembly Installation procedure of cylinder head: assembly. Proceed in the reverse order of disassembly. Note during installation: 1. Confirm location pin; clean parts and inspect whether oil passage of cylinder head is smooth and clean, without leakage. 2. Replace the cylinder head gasket with a new one. 3.
Page 62 Disassembly/assembly of cylinder head combination After removing the cylinder head combination, the cylinder head combination can be disassembled/assembled again, refer to the following figure. Sequence Procedure Remarks Removal sequence Installation sequence is opposite to removal sequence Cylinder head cover Tensioner cover Camshaft bolt Timing driven sprocket Camshaft retainer...
Page 63 Disassembly/assembly of cylinder block and piston The cylinder block and piston can be removed by removing the cylinder head as described above Sequence Procedure Remarks Removal sequence Installation sequence is opposite to removal sequence Cylinder head cover Tensioner cover Camshaft bolt Timing driven sprocket Camshaft retainer Cylinder bolt...
Page 64 CVT transmission reducer CVT wind guide cover Driving wheel combination Driven wheel Left crankcase cover combination...
Page 65 CVT transmission reducer Maintenance Instructions Left crankcase cover Troubleshooting CVT transmission reducer Maintenance Instructions The engine may not have to be removed from the frame when performing maintenance and repairs in this section. First, unscrew the left crankcase cover bolts and remove the left crankcase cover bolts, and remove the CVT transmission device from the engine.
Page 66 Left crankcase cover and CVT Removal procedure of left crankcase cover and CVT: 4. Remove two exposed CVT wind guide cover screws and left crankcase cover bolts. 1. Open the seat cushion. 5. Remove the left crankcase cover from the left crankcase, rotate the left cover centered on the 2.
Page 67 7. Loosen and remove the CVT locknut. 9. Take out the driven wheel from the input shaft together with the belt. Fixed plate of driving wheel Clutch housing CVT Locknut 10. Take out bushing, driving wheel driven disc, ball, 8. Remove the fixed plate of driving wheel and clutch etc.
Page 68 Maintenance Instructions During maintenance and repair of this part, it is not necessary to remove the engine from the frame. Firstly remove the exhaust silencer, then loosen the bolt at the lower end of the right rear absorber and rear rocker arm, loosen the fender and take out the rear wheel to remove the reducer.
Page 69 Removal procedure for reducer cover: Rear rocker arm mounting screw 1. Place the vehicle smoothly on the horizontal ground with the main bracket. Unclip the seat cushion, and loosen the two screws at the auxiliary foot pedal (One of them Absorber mounting screw can only be seen after opening the pedal), and the right cover with the screws inside the rear end of...
Page 70 2. Install the reducer cover, tighten the bolts according to the torque requirements, loosen the oil filler bolts and oil level control bolts, and slowly inject gear oil 0.2L~0.25L. Gear oil type ： 85W-140,of lubricating oil from the oil filler, or until the lubricating oil flows out of the oil level Output shaft oil seal control hole.
Page 71 Magneto and starting system Starting motor Dual gear Right crankcase cover Rotor combination Water pump cover Disk-shaped gear...
Page 72 Magneto and starting system Maintenance Instructions Rotor combination Right crankcase cover Starting motor and starting drive system Maintenance Instructions The engine must be removed from the frame when performing maintenance and repairs in this section. Remove engine lubricants and coolant. Before assembly, clean all parts with cleaning agent and blow dry with compressed air.
Page 73 3. Remove the right crankcase cover bolts, and remove 4. Remove the combination of dual gear and rotor. the right crankcase cover. Dual gear Disk-shaped gear Rotor combination Removal/installation of right crankcase cover and magneto Sequence Procedure Remarks Removal sequence Installation sequence is opposite to removal sequence Drain crankcase oil...
Page 74 Attention: 1 Do not hurt the varnished wire, and do not crush the stator coil. Tension disc bolts, stator combination mounting bolts, and sensor mounting bolts shall be assembled with thread release glue, and tightened in place according to torque requirements.
Page 75 Crankcase, crankshaft Crankshaft combination Balance shaft component Right crankcase body Right crankcase body...
Page 76 Crankcase, crankshaft Maintenance Instructions Crankshaft and balance shaft Troubleshooting Crankcase Maintenance Instructions The engine must be removed from the frame when performing maintenance and repairs in this section. In order to repair crankshaft and balance shaft, the left/right crankcase body must be separated, commonly known as box separation.
Page 77 Crankcase Removal procedure for crankcase: Remove the engine from the frame (cooling water and oil have been drained), and place on the assembly table. Remove the right crankcase cover, magneto rotor, oil pump, left cover, CVT parts, cylinder head parts, cylinder block, starting motor, etc.
Page 78 Installation procedure of crankcase: Place the left crankcase on the assembly table, crankshaft connecting rod combination, balance shaft combination into the crankcase with the teeth marks aligned. Left crankcase body Right box mould assembling bolt Turnover assembly left box side box bolt Assemble other engine parts in sequence.
Page 79 Sequence Procedure Quantity Remarks Installation sequence is opposite Removal sequence removal sequence Mould assembling bolt M6 (right box side) Tightening torque, 10N.m Tighten the torque after pre-tightening Mould assembling bolt M6 (left box side) according to the diagonal, tightening torque is10N.m Mould assembling bolt M8 Tightening torque, 25N.m...
Page 80 Vehicle body and exhaust system...
Page 81 Vehicle body and exhaust system Maintenance Instructions Removal/installation rear fender Troubleshooting Removal/installation of exhaust silencer Covers, headlights, instruments, Tail lamp combination and left and right switches Maintenance Instructions During maintenance of this part, special attention shall be paid to cover, instruments, and lamps without scratching or damage.
Page 82 Covers, headlights, instruments, and left and right switches Removal Procedure for Cover 6. The storage baffle adopts clamping structure, and 1. Support the motorcycle with side bracket or main remove the storage baffle forcefully. Storage baffle bracket on the horizontal ground, and remove the cover (L) and cover (R);...
Page 83 10. Remove two combination mounting bolts of left and right foot pedals, and remove left and right foot pedals combinations; Right pedal combination 11. Remove the left and right cover mounting bolts, and remove the side cover combination (L) and side cover combination (R).
Page 84 Removal/installation of cover Sequence Procedure Quantity Remarks Installation sequence is opposite to removal Removal sequence sequence Large plate self-tapping nail st4.2×13 Cover (L) Cover (R) Front plate Convex bolt M6×12 Front cover Combined ignition switch components File box combination Large plate self-tapping nail st4.2×13 USB Power Supply Unit I USB Mounting Board Storage baffle...
Page 85 Right pedal glue I Hexagon socket button head screw M8×20 Left pedal combination Right pedal combination Bolt M6×20 Side cover combination (L) Side cover combination (R) Inner hexagon reel bolt M6×12 Middle Shield...
Page 86 Removal procedures headlights, Remove 4 mounting screws of instrument instruments, and left and right switches: components, and remove the instrument. Support the motorcycle with side bracket on the horizontal ground, and remove the combination of Remove mounting screw left and right rearview mirror, headlight trim cover, and head cover upper body combination in sequence.
Page 87 Removal/installation of headlights and instruments Sequence Procedure Quantity Remarks Installation sequence is opposite to removal Removal sequence sequence Left rearview mirror component Right rearview mirror component Expansion screw Headlight trim cover Large plate self-tapping nail st4.2×13 Pan-head screw with cross recess M5×10 Head cover upper body combination Bolt M5×16 Large grommet A class 6...
Page 88 Removal/installation of exhaust silencer Removal procedure of exhaust silencer: Installation procedure of exhaust silencer: The silencer gasket at the engine exhaust port should be Support the motorcycle on the horizontal ground replaced with a new one. with the main bracket, and remove the cap nut During installation, install and tighten oxygen sensor connecting the exhaust silencer to the engine.
Page 89 Sequence Procedure Quantity Remarks Removal sequence Installation sequence Cap nut M8 Bolt M8×23 Welding combination of silencer Oxygen sensor combination 2 Replace according to the situation after Gasket for exhaust port removal...
Page 90 Tail lamp combination Removal procedure for tail light: Reference to removal of cover, remove the left and Disconnect the connector, remove the mounting right side covers, then remove the rear inner cover bolts, and remove the tail light combination. mounting bolts, and remove the rear inner cover. Disconnect connector Remove the mounting bolts Remove the mounting...
Page 91 Front wheel, front suspension, steering column, front brake Operate subassembly Front Fork Combination Front axle Front wheel components...
Page 92 Front wheel, front suspension, steering column, front brake Maintenance Instructions Front wheel Important torque value Front suspension Troubleshooting Steering column Operate subassembly Front brake Maintenance Instructions  When repairing the front wheel, park the vehicle on a horizontal ground and support with the main bracket. Support the vehicle with adjustable brackets on the bottom, and adjust the height of the bracket so that the front wheel is off the ground.
Page 93 Removal/Assembly of Operating Subassembly Maintenance Requirements Sequence Procedure Quantity Remarks Removal sequence Installation sequence is opposite to removal sequence Remove left rearview mirror component (4) Remove the right rearview mirror component (11) Remove the large plate self-tapping nail st4.2×13 (8) Remove the pan-head screw with cross recess M5X10 (6) Remove the inner hexagon reel bolt...
Page 94 Removal/Assembly of Front Wheel Attention Contaminated brake discs and braking lining reduce braking performance, replace braking lining and clean dirty brake discs. Do not pull the brake handle when the brake caliper is removed, otherwise it will be difficult to assemble the front wheel.
Page 95 Removal/Assembly of Front Suspension Attention Lift the front brake main oil cylinder with wire rope at least the same height as the original installation position. Do not twist the brake hose. Do not pull the brake lever when the brake caliper is removed, otherwise it will be difficult to assemble the front wheel.
Page 96 Removal/Assembly of Steering Column Maintenance Requirements Sequence Procedure Quantity Remarks Removal sequence Installation sequence is opposite to removal sequence Dust cap Steering column adjusting nut Assembly torque 60-90N.m Gasket Assemble the bearing adjusting nut firstly with the Upper bearing combination torque of 33-43N.m, and then tighten it with the torque value of 8-10N.m after 1/4 turn.
Page 97 Assembly of steering column Apply sufficient lithium-based grease to the bearing roller surface and place the steering column into the frame standpipe. Put the bearing in sequence, tighten the upper bearing adjusting nut until the torque is 33-43N.m, then turn back to 1/4 circle and tighten the adjusting nut with the torque value of 8-10N. (Figures 1 and 2) Install locknut after inserting gasket, torque value is 60-90N.
Page 98 Front brake Maintenance Instructions  Dirty brake discs and braking lining will reduce braking performance, replace braking lining and clean dirty brake discs.  Inhalation of braking lining dust may cause discomfort of respiratory system. Do not clean brake components with air duct or dry brush. Please go to professional maintenance network for repair and maintenance.
Page 99 Removal/Assembly of Front Brake Caliper Component Attention Dirty brake discs and braking lining will reduce braking performance, replace braking lining and clean dirty brake discs. Lift the front brake main oil cylinder with wire rope at least the same height as the original installation position. Do not twist the brake hose.
Page 100 Rear absorber Rear absorber Rear brake Rear rocker arm combination Lower connecting plate of rear absorber Rear tire Rear tire fender...
Page 101 Rear tire, rear brake, rear suspension device Maintenance Rear rocker Instructions Troubleshooting Rear absorber Rear rocker arm Rear tire combination Maintenance Instructions This section describes the removal, installation and maintenance of Rear tire, rear brake, rear rocker arm, and rear absorber.
Page 102 Rear rocker arm Removal procedure of rear rocker arm and Rear tire: 4. Remove the rear brake caliper 1. Remove the Rear tire speed sensor Rear brake caliper Rear tire speed sensor 5. Remove the Rear tire nut 2. Remove the oil pipe line clamp Rear tire nut Oil Pipe Line Clamp 3.
Page 103 7. Remove the lower connecting plate of rear 9. Remove the rear rocker arm to the right absorber Lower connecting plate of rear absorber 10. Remove the Rear tire combination to the right 8. Remove the rear rocker arm bolt Rear rocker arm bolt...
Page 104 Installation procedures of rear rocker arm and Rear tire: Proceed in the reverse order of disassembly. The tightening torque of rear rocker arm bolt is 55~60N.m. Attention: When removing the brake caliper body, ensure that the rear brake caliper body is lower than the rear brake cylinder block, to prevent air from entering the cylinder block and reducing the braking performance.
Page 105 Sequence Procedure Quantity Remarks Installation sequence is opposite to removal Removal sequence sequence Reel bolt M6×16 Wheel speed sensor Convex screw M6×12 Oil pipe clamp Bolt M8×32 Fastening torque: 25~30N.m Rear brake caliper Fastening torque: 90～100N.m Nut M16×1.5 Rear tire outer bushing II Apply lithium-based grease during assembly Bolt M8×52 Fastening torque: 25~30N.m...
Page 106 Disassembly/assembly of rear rocker arm combination The rear rocker arm combination shall be disassembled / assembled according to the following figure. Replace the sealing ring and deep groove ball bearing after removal. After installation, inspect whether the needle bearing rotates flexibly. Sequence Procedure Quantity...
Page 107 Rear tire Sequence Procedure Quantity Remarks Installation sequence is opposite to removal Removal sequence sequence Rear rocker arm combination Tightening torque: 28~32N.m Brake disc bolts Apply threadlocker Speed signal panel Brake disc Oil seal 25×40×7 Rear tire outer bushing I Apply lithium-based grease during assembly Rear tire combination...
Page 108 Removal/Assembly of Rear Suspension Sequence Procedure Quantity Remarks Removal sequence Installation sequence is opposite to removal sequence Screw M8×52 Fastening torque: 25~30N.m Nut M8 Fastening torque: 25~30N.m Screw M10×1.25×52 Fastening torque: 50~60N.m Nut M10×1.25 Fastening torque: 50~60N.m Lower connecting plate of rear absorber Bolt M10 1.25...
Page 109 Motorcycle electrical system will also have significant changes. The G350 electrical system uses more advanced automotive electronics technology, which is much more complicated than the traditional motorcycle. It consists of the following subsystems.
Page 110 The power supply system is the premise of the whole vehicle electrical system, which can provide sufficient power for other electrical subsystems. Including: charging, storing, and discharging. G350 power supply system is characterized by large power supply capacity, up to 420W. It consists of the following components: ...
Page 111 Parts Layout Voltage regulating Wire Harness rectification Ignition switch Battery...
Page 112 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 to produce induced electromotive force output alternating current, E=Blv. Motorcycle magneto is permanent magnet type alternator, permanent magnet steel is rotor, coil winding acts as stator.
Page 113 ○ Voltage regulating rectification 1. Outline drawing 2. Working principle The three-phase sinusoidal alternating current outputted by the magneto fluctuates with the rotating speed is converted into stable direct current by full-wave rectification and controlled voltage-stabilizing charging circuit. Provide electrical energy to the load and charge the battery.
Page 114 ○ Battery 1. Outline drawing 2. Working principle Two kinds of materials, lead (negative electrode) and lead dioxide (positive electrode) immersion in electrolyte (sulfuric acid solution) can produce 2V voltage. Six cells connected in series, the voltage can reach 12~13V. It is the auxiliary power supply of the electrical system and can also absorb the overvoltage in the circuit.
Page 115 2. Working principle The combined ignition switch is the main switch of the whole vehicle power supply, and combines the head steer locking function and file box opening function. 3. Basic parameters Switch Function Menu: Switch Function Menu Line Black color Whether the key can State of locking...
Page 116 ○ Wire Harness 1. Outline drawing 2. Working principle Wire harness is composed of various specifications of wires, connector sheaths, terminals, conduits, adhesive tapes, fuses, and other parts through bifurcation, riveting, winding and assembly. The electrical and electronic equipment of the whole vehicle can work normally only through the connection of wire harness.
Page 117 Main Fault Diagnosis Symptoms of failure Possible causes Solution The whole vehicle has no electricity: The fuse is burnt; Replacement of fuse; When the key is turned on, the Poor contact of fuse circuit; Reconnect; instrument does not have any Poor connection of positive and Reconnect;...
Page 118 Corresponding Table of Faults Description Diagnostic Fault symbol Pcode Decription (UAES) Solution （UAES） Items Open circuit in oxygen sensor heating O2 Sensor 2 Heater B_sihsve P0030 control circuit of Contr. Circ. Open ① Inspect the oxygen upstream cylinder 1 Oxygen sensor connector;...
Page 119 Short circuit to ② Inspect and replace ground in the control Cylinder 1- Injector the injector; B_mnev1 P0261 circuit of cylinder 1 Circuit Low ③ Replace the cable; injector Short circuit to power supply in control Cylinder 1- Injector B_mxev1 P0262 circuit of cylinder 1 Circuit High...
Page 120 In the initial operation of the engine, it is necessary to rotate it by means of external force before it can enter the ignition and oil supply procedure, and the internal combustion engine can circulate and operate steadily. The G350 motorcycle is only equipped with electronic starting.
Page 121 Parts Layout Flameout switch Start switch Front brake switch Rear brake switch Rollover sensing Wire Harness Side bracket switch Starting motor Battery Starting relay...
Page 122 Introduction of Main Components ○ Starting motor 1. Outline drawing 2. Working principle The current-carrying conductor shall be subjected to electromagnetic force in the magnetic field, F=Bli. Energize the positive and negative electrodes of the starting motor (negative electrode bond strap), rotate the motor shaft, and drive the engine to run initially through reduction gear, one-way device, and crank.
Page 123 The large current through the starting motor and relay contacts is controlled by small current through the operating switch and relay coil. The G350 starting relay also contains the power supply circuit (power pole B, coil binding post).
Page 124 ○ Left and right combination switch 1. Outline drawing Left combination switch Right combination switch Side bracket switch Rollover sensor 2. Switch function Left Switch Function Menu Right Switch Function Menu Light Red and Light Blue and Blue White Grey Orange green white...
Page 125 3. Failure mode The switch positioning buckle is broken, and is loose when used; There is no sense of positioning or sense of positioning is weak; The switch is stuck and cannot be reset; Switch failure, and disconnection of outgoing wire make the switch unable to connect; Short circuit of outgoing wire and disorder of switch function;...
Page 126 Main Fault Diagnosis Symptoms of failure Possible causes Diagnostic methods Solution Starting relay does Battery voltage is too low; Detect battery voltage; Charging the battery; not engage: press the Corresponding fuse is not Inspect whether the fuse is blown; Switch on the fuse or start button without connected or burnt;...
Page 127 Lighting signal system Overview Introduction Main Components Schematic diagram of circuit Main Fault Diagnosis Parts Layout Overview The lighting signal system is an important guarantee for the safe running of the vehicle. It includes the headlight system, the signal lamp control system, and the horn system. Headlight Lighting System: When driving at night, the vehicle needs a headlight to light the road surface, and remind the surrounding vehicles and people of the existence of the vehicle.
Page 128 Schematic diagram of circuit Front brake switch Rear brake switch Brake lamp Key switch Overtaking lamp switch Instrument High Beam Indicator Rectification High beam lamp voltage regulator High and low beam lamp switch Low beam lamp Front position lamp Rear position lamp License plate lamp Left front steering lamp Battery...
Page 129 Parts Layout Front brake switch Rear right steering signal lamp Headlights Tail light Left combination switch Rear left steering signal lamp Front right steering signal lamp Rear brake switch Horn Front left steering signal lamp Electric wire harness Introduction of Main Components ○...
Page 130 2. Working principle The headlight beads generally have high beam lamps and low beam lamps. The high beam filament is located on the focal point of the parabolic surface of the headlight mirror. The light is reflected by the reflector to become parallel beam and then scattered through the lamp glass, which can evenly light the road within 100m ahead;...
Page 131 4. Failure mode Bead failure; The lamp socket is loose; Open circuit or short circuit of light wire; Ingress of water or dust in the lamp; The lamp glass is scratched or damaged; The reflection block fell off. ○ Front steering signal lamp 1.
Page 132 ○ Rear steering signal lamp 1. Outline drawing Rear left steering lamp Rear right steering lamp 2. Working principle The rear steering signal lamp consists of a lamp cover, a lamp housing, a mirror, a circuit board, and a bead. The light emitted by the bead is reflected by the mirror into concentrated light, and then scattered by the lamp glass into uniform and soft orange light.
Page 133 4. Failure mode Switch corrosion, leakage, and failure. ○ Horn 1. Outline drawing 2. Working principle Horn working current circuit: positive lug plate → horn coil → contact → negative lug plate. After the current passes through the horn coil, the magnetic field generates suction to the armature, which makes the bass diaphragm and the high-tone diaphragm move at the same time.
Page 134 Main Fault Diagnosis Symptoms of failure Possible causes Solution Headlight fail to be lit: The engine is not started; Start the engine; High beam lamp fail to be lit; Speed sensor failure; Speed sensor failure; Low beam lamp fail to be lit; Failure of voltage regulator;...
Page 135 BCM fault light, Bluetooth, incoming-call display, ABS fault indicator, engine fault indicator, anti-theft indicator. The transmission of G350 display system signal is all electronic signal, and the instrument is also full electronic instrument. The components that make up the system include: ...
Page 136 Schematic diagram of circuit Grey Gray and Grey and Red and Blue Blue Orange and red yellow Blue Green black yellow and white black brown Setting High Anti-theft level button pressure Beam lamp sensor sensor (High) (low)
Page 137 Parts Layout Headlights Rear left steering signal lamp Front left steering signal lamp Left combination switch Instrument Right combination switch Front right steering signal lamp Tail light Rear right steering signal lamp Front Wheel Speed Sensor Oil level sensor Rear tire speed sensor Oil pressure alarm switch Water temperature sensor...
Page 138 Introduction of Main Components ○ Instrument 1. Outline drawing 2. Working principle All-electronic instrument (also called digital instrument). Firstly input all electronic signals (including digital signal and analog signal), through circuit processing, all converted into digital signals, and output through CPU control, driving stepping motor pointer, LCD and LED to display various information.
Page 139 4. Basic functions The instrument display contents include: vehicle speed, engine speed, oil level, voltage, water temperature, steering indication, high beam indication, total mileage accumulative/subtotal driving mileage, clock, oil alarm, BCM fault light, Bluetooth, incoming-call display, ABS fault indicator, engine fault indicator, anti-theft indicator, and photosensitive port. 5.
Page 140 3. Corresponding relationship between instrument display scale and resistance value of oil level sensor Warning light flashing (frequency 2Hz) 160Ω～300Ω Warning light flashing (frequency 1Hz) 120Ω～160Ω Display 1 box (warning light is on) 100Ω～120Ω Display 2 boxes 85Ω～100Ω Display 3 boxes 65Ω～85Ω...
Page 141 3. Corresponding relationship between instrument display scale and water temperature Temperature ℃ Standard Resistance (Ω) T≤60℃ 0 box, water temperature icon is displayed normally 60℃＜T≤71℃ 1 box, water temperature icon is displayed normally 71℃＜T≤82℃ 2 box, water temperature icon is displayed normally 82℃＜T≤103℃...
Page 142 Main Fault Diagnosis Symptoms of failure Possible causes Solution Speed indication fault: The distance between speed sensor and Reduce spacing to within 2mm; The vehicle speed figure is not signal panel is too large; Replace the vehicle speed sensor; displayed; Failure of vehicle speed sensor;...
Page 143 Engine Management System Overview G350 engine management system adopts closed-loop electric injection system. By controlling fuel injection quantity, the air-fuel ratio of mixture can be effectively controlled, so that the air-fuel ratio of engine under various working conditions can reach the optimum value, to improve power, reduce fuel consumption, reduce exhaust pollution, improve driving performance, improve low temperature starting performance, and idle speed performance.
Page 144 Maintenance Precautions 1. Fault diagnosis of EFI system can be carried out through fault indicator on vehicle instrument, or communication between special diagnostic instrument and vehicle ECU can be used for fault diagnosis of EFI system and fault code reading. 2.
Page 145 Parts Layout Injector Spark plug Water temperature sensor Stepping motor Fuel pump Two-in-One Throttle Ignition coil Sensor Oxygen sensor valve...
Page 146 Introduction of Main Components Two-in-one sensor, throttle position sensor 1. Working principle Two-in-one sensor is the function of intake manifold absolute pressure sensor, and the function of intake manifold absolute temperature sensor is integrated into one whole. The intake manifold absolute pressure sensor consists of a pressure conversion element (elastic diaphragm + strain resistance) and a signal conditioning circuit that amplifies the output signal of the conversion element.
Page 147 See the following table for the characteristic parameters of the thermistor when the intake temperature sensor is unloaded:...
Page 148 Throttle Position Opening Measuring range: 3%~93% (from idle to fully open) Throttle Position Sensor Reference Voltage: 5V±0.1V When the throttle is fully closed, the normal output voltage is 0.3V±0.1V When the throttle is fully open, the normal output voltage is 4.3V±0.1V The operating characteristic curve of the throttle position sensor is shown in the following table: Rotational Angle Mechanical Stroke 3.
Page 149  Engine temperature sensor 1. Working principle The engine temperature sensor is a negative temperature coefficient (NTC) thermistor. By using the temperature sensitive characteristic of the thermistor, the change of environment temperature is converted into the change of resistance value of the thermistor.
Page 150  Oxygen sensor 1. Outline drawing and pin definition Definition of connector flat tabs PIN1: Heating (White) Tin plating PIN2: Sensor ground (Grey) Tin plating PIN3: Heating (White) Tin plating PIN4: Sensor signal (Black) Tin plating 2. Working principle The heated planar oxygen sensor uses the planar multilayer ceramic element as the basic element, and the zirconia layer is the core element.
Page 151 4. Failure mode Failure of heating element; Failure of sensor element; Cracking of ceramic tube; Short circuit or open circuit of heating circuit; Short circuit or open circuit of sensor circuit.  Fuel pump 1. Outline drawing 2. Working principle The fuel pump integrates fuel pump core, oil pump bracket, strainer, oil pressure regulator, etc.
Page 152 4. Failure mode The oil pump cannot rotate; Failure of oil pressure regulator; Failure of bracket vibration; Short circuit or open circuit of fuel pump; Poor oil sealing of sealing ring. The resistance of the oil level sensor is open or short circuited. ...
Page 153 4. Failure mode The injector is blocked; Open circuit or short circuit of solenoid coil; Failure of injector vibration; Poor oil sealing of sealing ring.  Ignition coil 1. Outline drawing and pin definition 2. Working principle The ignition coil consists of primary winding, secondary winding and iron core, shell, etc. When the battery voltage is applied to the primary winding, the primary winding is charged.
Page 154  HV connection line 1. Outline drawing 2. Working principle The high voltage connecting line is a device that connects the ignition coil to the spark plug. It consists of spark plug cap, high voltage line, and ignition coil connector cap. 3.
Page 155  Idle stepping motor 1. Outline drawing and pin definition Connector socket Circuit diagram of coil initial state 2. Working principle The basic operating principle of the idle bypass air volume regulation control valve is derived from the principle of the stepping motor.
Page 156  1. Outline drawing 2. Working principle The ECU acquires all kinds of information about the actual working status of the engine or the vehicle through several sensors configured by the engine management system. The ECU drives the actuator configured by the system according to the data calibrated and stored in advance.
Page 157 EMS Fault Diagnosis Procedure 1. Analyze the situation reflected by the user Make a detailed record of the problem (fault, other information reflected by the user) and the occurrence process stated by the user. 2. Inspect, record, and sort out DTCs The fault content can be read out through the instrument fault indicator scan tool and inspecting the fault code table DTC Validation Procedure: Turn on the power supply...
Page 158 EMS Fault Diagnosis Table Name of components Fault Code Fault determination Open circuit of upstream 1 in oxygen sensor P0030 heating control circuit Too Low Voltage of upstream 1 in oxygen Oxygen sensor heating P0031 sensor heating control circuit Too High Voltage of upstream 1 in oxygen P0032 sensor heating control circuit Signal of upstream cylinder 1 in oxygen sensor...
Page 159 Electrical system drawing...

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