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TAYO Zontes ZT703-RR 2025 Maintenance Manual

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ZT703-RR
Maintenance manual
2025-02-20

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Summary of Contents for TAYO Zontes ZT703-RR 2025

  • Page 1 ZT703-RR Maintenance manual 2025-02-20...

  • Page 2: Preface

    ZONTES. GUANGDONG TAYO MOTORCYCLE TECHNOLOGY CO., LTD Technology Co., Ltd. reserves the right, including but not limited to, to modify the specifications, design, etc. at any time without prior notice to you, and does not assume any responsibility for this.

  • Page 3: Notice To Users

    Notice to Users This manual is written by GUANGDONG TAYO MOTORCYCLE TECHNOLOGY CO.,LTD , Ltd. to guide dealers or service personnel to use. This manual does not provide more detailed knowledge about motorcycles and is intended for service reference only. If you do not have the corresponding knowledge such as electrician, mechanic, etc., improper assembly or maintenance failure may occur during repair.

  • Page 4: Table Of Contents

    Contents Preface ......................................2 Notice to Users....................................3 Contents ......................................4 1. Motorcycle information ................................11 Pre-Service Notice ................................11 Motorcycle body identification characters ......................... 12 Technical parameters ................................13 Front wheels/steering ..............................13 Rear wheels/suspension ............................. 13 Braking system ................................13 Battery/Charging System ..............................
  • Page 5 6. Overhaul and maintenance of oil cooler ......................... 39 7. Check whether the water/oil pipe is leaking and aging ..................40 Engine oil and filter replacement ............................41 1. Put engine oil ................................41 2. Replace the fine filter .............................. 41 3.
  • Page 6 2. Change the brake fluid ............................56 2.1 Change the front brake fluid ......................... 56 2.2 Replace the rear brake fluid .......................... 57 3. Brake system exhaust ............................. 57 Rims and tires ..................................57 1. Check the tires ................................ 58 2.
  • Page 7 9. Water and oil share sensors ............................ 86 10. ECU ..................................86 11. Throttle body ................................ 87 11.1 Common fault signs ............................. 87 11.2 Disassembly ..............................87 11.3 Troubleshoot the process ........................... 87 11.4 sensor ................................87 11.4.1 Throttle position sensor........................88 11.4.2Inlet air pressure sensor ........................
  • Page 8 3. Oil level sensor ..............................110 7. Cooling system and air intake system ........................... 111 Pre-Service Notice ................................111 Troubleshooting ................................111 1. The engine temperature is too high ........................111 2. The engine temperature is too low ........................111 3.
  • Page 9 Battery disassembly and assembly ........................... 129 1. Disassembly ................................129 2. Examine ................................. 129 3. Charge ................................... 129 Charging system check ..............................129 1. Leakage test ................................129 2. Check the charging voltage ........................... 129 3. Magneto stator charging coil inspection ....................... 130 Rectifier .....................................
  • Page 10 3.Rear rims and tires ..............................144 3.1The service life of the rear rim and tires ...................... 144 3.2 How to replace the rear rim and tires ......................144 3.3 Balancing ..............................144 Replace the rear flat fork ..............................144 1.Remove the inner clay slab ............................ 144 2.Remove the rear flat fork ............................

  • Page 11: Motorcycle Information

    1. Motorcycle information Pre-Service Notice 1. It is necessary to use good quality tools, or special tools and fixtures designed by our company. Using inferior tools may result in damaged parts, detached plating, inadequate assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component sealing rings used for sealing must be replaced before assembly.

  • Page 12: Motorcycle Body Identification Characters

    Motorcycle body identification characters ①Vehicle identification code VIN, the VIN code is engraved on the side of the front steering tube of the right frame ②The nameplate is on the right side of the frame ③The muffler regulation code is at the end of the front section of the muffler ④The engine identification code is engraved on the top of the right crankcase 12 / 155...

  • Page 13: Technical Parameters

    Technical parameters Project Parameter Front tires 120/70ZR17 Rear tires 180/55ZR17 Front rim specifications MT3.5×17 Rear rim specifications MT5.5×17 Vehicle Brake fluid DOT4 0.22L Replace the fine filtration: 3.4L Oil usage Without changing the fine filtration: Idle speed (r/min) 1500±100 Motor Fuel oil 95 and above Spark plug model...

  • Page 14: Battery/Charging System

    Battery/Charging System Project Standard Type Lithium battery Capacity The battery self-discharge current ≤1mA Fully charged 13.2～13.4V Charging voltage is required for ≤12.8V Battery Voltage unloaded vehicles Charging voltage is required for ≤12V loading Charging voltage 14.6V Charging mode Maximum charging current Charging time 2 hours Power...

  • Page 15: Tightening Torque - Supplementary

    Tightening torque - Supplementary Bolt tightening torque for general fastening parts Class 4.8-6.8 (bolt head marked "4") Class 8.8 (bolt head marked "7" or "8.8") Bolt Tightening torque Breaking Tightening torque Breaking Standard value Standard value diameter range moment range moment 1～2 1.5～3...

  • Page 16: Cable/Pipe/Electrical Device Distribution Diagram

    Cable/pipe/electrical device distribution diagram 1. Distribution map of lamps and lanterns 1-Right turn signal 2-Left turn signal 3-Right daytime running light 4-Left daytime running light 5-Right front position light 6- Left front position light 7-Right front headlight 8-Left front headlight 9-Brake light 10-Left position light 11-Right position light 12-Rear license plate light 13-Left rear turn signal 14-Right rear turn signal 15-Frame left grid atmosphere light 16-Frame right grid atmosphere light 16 / 155...

  • Page 17: Throttle And Clutch Cable

    2. Throttle and clutch cable 1-Refueling line, 2-Oil return line, 3-Clutch line, 4-Throttle line, limit bracket, 5-Throttle cord clamp The following braking system introduction illustration is the J.JUAN braking system, and the Brembo braking system can be used as a reference. 3.

  • Page 18: Calipers, Brake Hoses And Wheel Speed Sensors

    The following braking system introduction illustration is the J.JUAN braking system, and the Brembo braking system can be used as a reference. 4. Calipers, brake hoses and wheel speed sensors 1-Brake hose left and right caliper interchange section 2-Disc brake caliper (front right) 3-Wheel speed sensor (front wheel) 4-ABS induction coil (front wheel) 5-Brake disc (front right) 6-FC-HU Brake hose 7-Disc Brake Caliper (Front Left) 8-Brake Disc (Front Left) 18 / 155...
  • Page 19 1-RC-HU brake hose 2-Wheel speed sensor (rear) 3-Rear disc brake caliper 4-Brake disc (rear) 5-Rear wheel sensing ring gear 19 / 155...

  • Page 20: Distribution Map Of Braking System Accessories

    The following braking system introduction illustration is the J.JUAN braking system, and the Brembo braking system can be used as a reference. 5. Distribution map of braking system accessories Front disc brake main cylinder 2- FMC-HU brake hose 3-Brake hose left and right caliper interchange section 4- Wheel speed sensor (front wheel) 5- FC-HU Brake Hose 6-ABS Hydraulic Control Unit 7- RC-HU Brake Hose 8-Rear disc brake main cylinder 9- Rear disc brake caliper 10-Wheel speed sensor (rear) 11- RMC-HU Brake Hose 12-Rear brake pedal 13-Front disc brake caliper (right) 14-Front disc brake caliper (left)

  • Page 21: Oil Supply System

    6. Oil supply system 6.1 Fuel evaporation 1-Fuel Tank Lock2-Fuel Pump 3-High Pressure Oil Hose 4-Throttle Valve Body Assembly 5-Adsorption/Snorkel 6-Carbon Canister 7-Solenoid Valve Outlet Pipe 8-Carbon Canister Solenoid Valve 9-Solenoid Valve Intake Pipe 10-Fuel Tank 11-Oil-Oil Separator (Inside Fuel Tank Lock) Fuel evaporation: Oil and gas→-oil and gas separator (inside the tank lock) →...

  • Page 22: Fuel Supply

    6.2 Fuel supply Oil Supply System: Air → canister→ adsorption/ventilation pipe→ air-air separator (inside the tank lock) Fuel → fuel pump filter→ fuel pump→ high-pressure tubing→ injector → cylinder 7. Distribution diagram of cooling system accessories 22 / 155...

  • Page 23: Electrical Device Layout Diagram

    1-Main water tank water inlet 2-Sub water tank connecting water pipe 3-Main water tank water inlet pipe 4-Water tank water inlet connecting water pipe 5-Auxiliary water tank 6-Small circulating water pipe 7-Main water tank 8-Auxiliary water tank leaking pipe 9-Engine water inlet pipe 10-Water pump cover assembly 11-Oil cooler 12-Engine oil outlet pipe 13-Thermostat 14- Engine oil inlet pipe.
  • Page 24 1-LCM Lighting Controller 2-Faucet Lock 3-Horn 4-Cable Assembly (shown in yellow) 5-Dual-port universal USB charging cable 6-Tire pressure receiver 7-Electronic fuel tank lock substrate 8-Engine controller (ECU) 9-Electronic fuel tank lock 10- GPS antenna 11- PKE external antenna 12-Starting relay 13-Cushion lock 14-Third generation PKE host 15-Non-electric induction antenna 16-Lithium battery 17-Side kill switch 18-Carbon canister solenoid valve 19-Frame grid atmosphere light driver 20-Tilt switch 21-Rectifier 22-Relay 23-Charging port holder 24-Buzzer 24 / 155...

  • Page 25: Intake And Exhaust System

    9. Intake and exhaust system 9.1 Air intake system 1-Stamping intake pipe assembly 2-Air filter assembly 3-Throttle fill valve 4-Stepper motor rubber hose (2) 5-Stepper motor rubber hose (3) 6-Stepper motor rubber tube (1) 7-Throttle valve body 8-Cylinder head 9-Secondary make-up valve 10-Exhaust gas snorkel Air Intake System: Main air flow direction of the air intake system (red arrow)

  • Page 26: Exhaust System

    9.2 Exhaust system 1-Air filter assembly 2-Cylinder head 3-Exhaust gas snorkel 4-Front muffler 5-Rear muffler Exhaust system: The main exhaust gas emission flow direction Cylinder heads→ front mufflers→ rear mufflers Secondary cycle exhaust emission process Cylinder heads→ exhaust gas snorkels→ air filter assemblies→ cylinder heads→ front mufflers→ rear mufflers 26 / 155...

  • Page 27: Tool

    Tool 125-piece tool set Torque wrench On-board tools Claw hammer Pull code Rubber hammer Dynamic balancing machine Tire scraper Oil sump measuring cup funnel Taps, dies micrometer Depth gauge Vernier calipers Feeler gauge PT300 Electrojet brush Magnetic mount + dial Tire pressure gauge writing diagnostic 17# Inner hexagon...

  • Page 28: Expansion Nail Description

    Hoop pliers Inner circlip pliers Circlip pliers Clamp-on multimeter 14-side 65mm cap filter T45/50 Torx socket with multimeter Blow guns wrench (for M350 fine filter holes replacement) T25/45/50 Torx wrench with holes Some of the above pictures are from the Internet, and the copyright belongs to the original author. Do not use for any other purpose.

  • Page 29: Maintenance

    2. Maintenance Pre-Service Notice It is necessary to use good quality tools, or special tools and fixtures designed by our company. Using inferior tools may result in damaged parts, detached plating, inadequate assembly, etc. The O-rings, paper gaskets, copper gaskets, and component sealing rings used for sealing must be replaced before assembly. 3.

  • Page 30: Maintenance Of Periodic Tables

    Maintenance of periodic tables I: Inspection (cleaning, lubrication, adjustment or replacement if necessary) R: Replacement T: Fastening: Annotation Before initial driving ×1000km Check the items Annual inspection Replace it regularly examin ×1000mile Air Cleaner (Element) The clutch handle is free to travel spark plug Engine oil...
  • Page 31 NOTE 2: First maintenance for the first 500 kilometers (300 miles), oil and oil filter changes, second maintenance for the instrument after the actual mileage reaches 5,000 kilometers (3,000 miles) or 15 months (whichever arrives first), and then every 5,000 kilometers (3,000 miles) or 15 months (whichever comes first) for regular maintenance. NOTE3: Check, clean, and lubricate every 10000 kilometers (6000 miles).

  • Page 32: List Of Daily Motorcycle Operation Inspection Items

    List of daily motorcycle operation inspection items Seria Check the Check the contents l number items Neutral light Lights up when neutral Turn signals The switch is normal and the flashing is normal horn The switch is normal, the volume is normal, and the sound quality is good Brake lights Lights up normally when braking Headlamps...

  • Page 33: Air Filter Element Replacement

    Air filter element replacement Note: ●Please replace the air filter element of the motorcycle in strict accordance with the motorcycle maintenance cycle. Steps: 1. Remove the corresponding parts Refer to "Removal of Fuel Tank" to remove the fuel tank. 4. Reassemble the corresponding partsa. Refer to the disassembly steps to put the fuel tank and other parts back on.

  • Page 34: Muffler Overhaul And Maintenance

    Muffler overhaul and maintenance 1. Disassembly of the muffler decorative cover a. Lay down the side brackets and place the motorcycle on flat ground. Refer to “Disassembly of Covers” to remove the left and right lower surrounds. Note: If the motorcycle is started before disassembly, wait for the muffler assembly to cool down before disassembling to prevent burns.

  • Page 35: Reassembly Of Mufflers And Other Components

    ties that hold the oxygen sensor harness. g. Use the 6# hexagon socket to remove the 6 pieces of M8 nuts that hold the front end of the muffler in place. c. Use the 8# sleeve to remove 2 pieces of M6×22 bolts (9) and 1 piece of M6×30 bolt (10) that fix the oil cooler.

  • Page 36: Inspection And Replacement Of Spark Plugs

    ●It is forbidden to touch all metal surfaces of the muffler during engine operation or after riding to prevent burns. ●The motorcycle must be parked on a level, stable ground or lifting platform. ●If a new exhaust gasket is required, the muffler must be completely cooled before operation.

  • Page 37: Check The Spark Plug

    ●Never pull or tap the center electrode. ●If the engine is damaged by replacing the spark plug with improper calorific value or inferior quality, it is not within the scope of the three guarantees. ●The torque of the spark plug should not be too large, and the threads should be manually screwed in before tightening.

  • Page 38: Check The Coolant

    1. Check the coolant liquid level no longer drops. Note: Do not touch the coolant in the motorcycle with your hands after starting the a. Place the motorcycle on level ground and inspect it motorcycle to prevent burns. with the engine cold. d.

  • Page 39: Overhaul And Maintenance Of Oil Cooler

    the air duct. b. Use a flat carving knife or a small flathead screwdriver to straighten the deformed fins. If the fins are deformed by more than 20%, a new radiator will need to be replaced. 6. Overhaul and maintenance of oil cooler It is recommended to check the oil cooler every time you change the oil.

  • Page 40: Check Whether The Water/Oil Pipe Is Leaking And Aging

    7. Check whether the water/oil pipe is leaking and aging 1- ZT703-F main water tank inlet pipe 2- ZT310-R auxiliary water tank leakage pipe 3- ZT703-RR water tank water inlet connection water pipe 4-ZT703-F small circulation water pipe 5-ZT703-RR engine water inlet pipe 6- ZT703-RR engine oil inlet pipe 7-ZT703-RR engine oil outlet pipe 40 / 155...

  • Page 41: Engine Oil And Filter Replacement

    Engine oil and filter replacement ●The motorcycle must be parked on a level, stable ground or lifting platform. ●Operation is required to wait for the engine and muffler to cool down. ●Add oil to prevent oil from dripping onto the surface of the muffler.

  • Page 42: Confirm The Oil Levela

    b. After removing the refueling cap, use the funnel measuring cup to add oil to the filling port of the right crankcase cover of the engine. c. Use non-woven fabric to clean the oil filler. Big Adjustments: d. Check whether the O ring is damaged or aged, if not, If the fine-tuning cannot meet the requirements, loosen wipe it clean, and replace it if there is.

  • Page 43: Adjust The Clutch Handle

    4. Adjust the clutch handle c. Hold the steering handle with both hands, turn to both sides, and turn the right hand handle rubber sleeve at the In order to accommodate more drivers driving this same time, and confirm whether the throttle can be reset model, it is equipped with an adjustable clutch handle.

  • Page 44: Lubricate The Throttle Cable

    Idle speed Big Adjustments: If the above adjustments cannot achieve the desired Note: effect, you can remove the throttle body assembly according ●Before checking the idle speed, other engine maintenance to the description in "Removing the Throttle Valve Body items should be checked and the condition is normal before Assembly and Cleaning the Carbon Deposition".

  • Page 45: Fuel Evaporative Pollutant Control System

    Fuel evaporative pollutant control system The picture above is a schematic of the equipment with LED endoscope, the picture comes from the Internet, and the 1-Fuel Tank Lock 2-Fuel Pump 3-High Pressure Oil Hose 4- copyright belongs to the author of the original picture. Do Throttle Valve Body Assembly 5-Adsorption/Snorkel 6- not use for any other purpose.

  • Page 46: Fuel Pump

    b. Use a T25 torx wrench to remove 2 M6 × 14 shaft f. Refer to the steps in "Replacing the Spark Plug" to shoulder bolts (6). remove the entire air filter. Press and hold the tubing buckle to pull out the high-pressure tubing (12). g.
  • Page 47 ●When pulling out the executive tubing, pay attention to pulling it out in the direction of the axis, and do not press or push or pull the protruding part of the fuel pump and high-pressure oil rail. ●All actions that may cause a fire, such as smoking, dialing and dialing mobile phones, are prohibited at the demolition site. ●The fuel pump is a precision component，It needs to be assembled in a clean room and requires strict testing, so it is forbidden to disassemble it by yourself.

  • Page 48: Chain, Rear Flat Fork Wear Block

    Chain, rear flat fork wear block Note: ●Before lubricating the chain, it is necessary to ensure that the chain is completely dry. The chain is then lubricated with a special lubricant ●Never use a new chain on a worn sprocket, or the new chain will wear out quickly.

  • Page 49: Replace The Rear Flat Fork Wear Block

    Replace the rear flat fork wear block Replace the rear fork and remove the rear fork wear block according to the "Fork Assembly" in this book. ●In order to ensure safety, the inspection and adjustment of the transmission chain should be done in advance before driving.

  • Page 50: Braking System

    Braking system Note： ●The arrangement of the brake hose on the motorcycle is detailed in the distribution diagram of the brake system accessories in the "Vehicle Information" chapter of this manual. Remark： In order to facilitate after-sales tracking, all those who need to purchase brake hoses, disc brake calipers and disc brake main cylinders, and hydraulic control units need to be reviewed by our company before purchasing.

  • Page 51: Check The Brake Components

    in the air and rotate the front wheels by hand to observe Note： whether there is obvious damage on the surface, such as ●This inspection should be handed over to a qualified pits, deep scratches, grooves, etc., if any, it is recommended maintenance unit to complete.

  • Page 52: Check The Front And Rear Brake Switches

    braking distance after replacing the brake disc or brake pads, Rear brake switch： and it will take about 300 kilometers (200 miles) of use to Refer to the disassembly of the right pedal bracket before achieve the best braking effect after the brake discs and dismantling, remove the seat cushion and rear brake pedal brake pads are fully running-in.

  • Page 53: Replace The Brake Handle And Brake Pedal

    c. Wipe the bearings on the rear section of the brake Big adjustment: Loosen the bolt on the brake pedal, pedal with a clean non-woven fabric, lubricate and maintain adjust the brake pedal to the angle that the driver is the bearings, and replace the bearings if necessary.

  • Page 54: Replace The Rear Brake Pads

    b. Use a T25 socket torx wrench to remove the upper pin the brake pad (1). Tighten the pin (2) with a T25 hexagon torx (2) and then the lower pin in turn. wrench. c. Remove the shrapnel (3), remove the brake pad (1). d.

  • Page 55: Abnormal Sound Of Brake Pads

    6.1 Replace the front brake disc Note that the side with grooves is facing the brake disc; The black metal back panel faces the calipers. The front brake disc can be removed by referring to the steps described in this manual "Fork Assembly" to remove the front wheel assembly.

  • Page 56: Brake Fluid Is Added To The Front And Rear Disc Brake Main Cylinders

    1. Brake fluid is added to the front and rear disc brake main cylinders 1.1 Add front brake master cylinder brake fluid a. Place the vehicle. b. Wrap the main cylinder around the main cylinder with an oil-resistant plastic film to prevent brake fluid from dripping onto the surface of the parts and damaging the paint layer.

  • Page 57: Replace The Rear Brake Fluid

    handle with your left hand slowly and at a constant speed to the end and keep it still. Lock the deflation valve clockwise and slowly release the handle. Pay close attention to the ●The discharged brake fluid should be properly disposed of fluid level of the front brake main cylinder, and add it in time and no further use should be prohibited.

  • Page 58: Check The Tires

    ●Check the tire pressure regularly, the standard is 250kPa (2.55 kgf/cm2, 36 PSI) at room temperature for the front and rear wheels; Maximum tire pressure must not be greater than 290 kPa (2.96 kgf/cm2, 42 PSI) in cold. ●When you find that the tire pressure drops, you should check whether the tire has nails and small holes;...

  • Page 59: Adjust The Steering Mechanism

    f. Assemble the orientation assembly back. g. The front wheel is suspended in the air to correct the steering handle, and the steering mechanism is smooth and free of stagnation by gently pushing and pulling the steering handle with your hand. The fork assembly should be able to 2.

  • Page 60: Check The Appearance

    against the dust seal at close range. lens, if there is a slight leakage, check whether the bolt is ●If the motorcycle is not driven for a long time, it should be loose, where the bolt torque is 20~26N.m (2~2.7 kgf.m, parked in a ventilated and dry environment, as the dark and 15~19 lbf.ft).

  • Page 61: Troubleshooting

    copper sheet, etc. on the contact surface to prevent the fork back to observe whether the rear shock absorption can be tube from scratching, use the press slowly, small pressure smoothly recovered. and small stroke to straighten it many times, and measure b.

  • Page 62: Bolts/Nuts/Fasteners

    Bolts/nuts/fasteners Note: ●Regularly check the body fasteners according to the maintenance schedule. Check the fasteners in the critical areas Check whether the front disc brake caliper bolts, front shock absorber bottom barrel bolts, upper and lower plate bolts, disc brake disc and sprocket bolts, rear axle nuts and cotter pins, and side bracket stop switch bolts are loose. Check whether the rear axle cotter pin is abnormal.

  • Page 63: Lubrication

    d. Put down the side bracket (parking position) should not be able to start the vehicle; put down the side bracket (driving position) without pinching the front or rear brake handle should not start the vehicle; after starting the vehicle, put down the side bracket should automatically turn off, otherwise it is necessary to check the fault of the stop switch or brake switch..d.

  • Page 64: Shift Lever Rocker Arm Height Adjustment

    Shift lever rocker arm height adjustment 1- M6×22 bolt 2- GB6170 M6-LH 3- GB6170 M6 4- adjusting screw If you need to fine-tune the height of the rocker arm of the shift lever, you can fix the adjustment screw (4) with a 10# open- end wrench, and then loosen the nuts (2) and (3) in the direction of the arrow, rotate the adjustment screw to make the shift rocker arm to a suitable height, and then lock the nut.

  • Page 65: Audio, Optical And Electrical Device Inspection

    Audio, optical and electrical device inspection Note: ●Before driving, you should check whether the lights of the whole motorcycle are normal, including turn signals, tail lights, brake lights, headlights, etc. Whether the horn is normal. Whether the windshield is raised and lowered normally. 1.
  • Page 66 c.The function of the left-hand handle switch is shown in the figure below 66 / 155...
  • Page 67 67 / 155...

  • Page 68: Adjust The Light Height Of The Headlights

    d.Check the battery voltage Open the cushion, lift the protective rubber case of the positive and negative electrodes of the battery, and use a multimeter to measure the battery voltage. The charging voltage of the charger should not be higher than 15V. When the motorcycle is not used for a long time, it should be charged regularly in accordance with the requirements of the driver's manual.

  • Page 69: Fuse Box

    3. Fuse box Note： ●If the fuse is blown, the fuse of the same specification must be replaced, and it is forbidden to use wires such as copper and iron wire for direct connection. ●If it is fused again after replacement, it is necessary to check the fault of the motorcycle cable before replacement. ●This motorcycle uses a small fuse.

  • Page 70: Lamps

    If you need to remove the horn, use the T25 Torx wrench to remove the 2 bolts. Pull the horn out and remove it after pulling the plug. 4.2 Lamps Note: ●When using wires to detect lamps, it is necessary to pay attention to distinguishing between positive and negative poles, and the detailed line color can refer to the electrical schematic diagram in the driver's manual provided with the vehicle.
  • Page 71 The general process of troubleshooting lamps： After power on, turn on Unplug the plug, Check whether the the left/right hand switch Check if the connect the lamp Troubleshoot switch lighting terminal is and the lamp does not insurance is blown and the battery with or cable failure plugged in...

  • Page 72: Efi System

    3. EFI system Pre-Service Notice 1. The structure and working principle of the EFI system are complex, and it is necessary to have a certain understanding of the working principle and structural characteristics of each EFI system before checking and troubleshooting. The content of this chapter requires certain maintenance experience, and it is recommended to go to a maintenance unit with maintenance qualifications for inspection or maintenance.

  • Page 73: Fault Codes

    Fault codes Note： ●The motorcycle is unlocked and the ignition switch is turned on, and the EFI fault light is always on when it is not started, and the motorcycle cannot be started if it is not lit. ●After starting the vehicle, if the fault light lights up to report the EFI fault, it means that the EFI system is abnormal. ●When the EFI system reports a malfunction, continuing to drive the motorcycle may cause damage.

  • Page 74: Information On Common Fault Codes

    3. Information on common fault codes Code Illustrate code Illustrate Cylinder temperature sensor line high 3 cylinder injector short circuit to low voltage/open P0118 P0267 voltage/open circuit fault circuit fault Cylinder temperature sensor line low P0117 P0108 Air intake sensor line high voltage/open circuit fault voltage fault Crankshaft position sensor line signal P0336...

  • Page 75: Clear With A Diagnostic Device

    4.2 Clear with a diagnostic device The steps may vary depending on the brand or model, so follow the description in the diagnostic instrument manual to clear the fault code. ●During the operation of the engine, the fault light is not lit, and the fault light flashes after the ignition is a historical fault, which has no impact on the whole motorcycle and will disappear by itself in the future.

  • Page 76: Efi Parts Layout Drawing

    EFI parts layout drawing 1-Clutch rocker arm assembly; 2-Right hand handle switch; 3-Faucet lock; 4- Ignition coil; 5-Throttle assembly; 6-Oil pump pump; 7-Battery; 8-Relay; 9-Starting relay; 10-PKE main engine; 11-Dump switch; 12-Side bracket; Kill switch; 13-Magneto 14-spark plug 15-oxygen sensor 16-fuel injector 76 / 155...

  • Page 77: Fault Diagnosis And Troubleshooting Of Efi Parts

    Fault diagnosis and troubleshooting of EFI parts Note: ●Once the EFI parts are disassembled, the EFI system needs to be reset. For details, see the service information in this section. ●Fuel pumps, three-in-one sensors, stepper motors, ECUs and other precision parts, such as dismantling without permission, may cause damage, and are not within the scope of the three guarantees for human reasons.

  • Page 78: Examine

    Examine Remove the pour switch without turning the plug on. The OBD diagnostic instrument can be used to detect if the dump switch is faulty. If there is no diagnostic instrument, use a multimeter to detect the output voltage and determine whether there is a fault. Standard: Horizontal position: 0.4-1.4V About 60°:3.7-4.4V...

  • Page 79: Canister Solenoid Valve

    When disassembling and assembling the fuel tank, after removing the fixing screws of the fuel tank, you must first gently lift it from the tail of the fuel tank, raise it until your hand can just reach into it, and then pull out the high-pressure oil pipe connected to the oil pump.

  • Page 80: Relay (Kh-1A4T-R)

    5. Relay (KH-1A4T-R) Remove the front and rear cushions, remove the upper cover of the electrical device box with a T25 Torx wrench, and find the fuse box in the position shown. 3 pieces of relays are visible after removing the protective cover in the fuse box; The other 2 are in the sheath next to the fuse box, and the sheath needs to be removed before they can be removed.

  • Page 81: Injector

    6. Injector When the engine idle speed is unstable, easy to stall, or can not start, it is necessary to check whether the injector is normal when reporting the injector failure. It is necessary to remove the seat cushion, fuel tank, air filter, etc. first. It can be judged by the following methods: a.
  • Page 82 b. Press the anti-release latch and slide it outwards before pulling out the plug. The static coil resistance measured with a multimeter should be 12±0.6Ω, otherwise the injector will fail and need to be replaced. 82 / 155...
  • Page 83 If you need to replace the injectors, wait until the engine and muffler have cooled down. Use a Phillips screwdriver to remove the two screws that hold the slide rail in place and remove the rail and injector together. Use a flathead screwdriver to pry open the clip of the injector to remove the injector.

  • Page 84: Oxygen Sensor

    7. Oxygen sensor ●Always wait until the engine and muffler have cooled completely before removing the oxygen sensor. When the instrument shows that the oxygen sensor is faulty, the engine performance is poor, the idle speed is unstable, and the fuel consumption is high, the oxygen sensor needs to be checked.

  • Page 85: Replacement

    After removing the cover, you can see that the oxygen sensor is fixed as shown in the figure above, the mushroom head is extruded from the fixing hole, the oxygen sensor connection plug can be unplugged, and the pin resistance corresponding to the purple line and the white wire of the oxygen sensor can be measured with a multimeter, and the standard value is 12.5±1.7Ω;...

  • Page 86: Water And Oil Share Sensors

    9. Water and oil share sensors If the instrument fails to light up, the fault information is 0118 fault code. If the diagnosticator shows that the fault exists and cannot be cleared, the engine data stream is viewed, the engine water temperature parameter is found, and the water temperature parameter is judged to be reasonable according to the current engine surface temperature.

  • Page 87: Throttle Body

    Note: To replace the ECU, you need to shut down the whole motorcycle and wait for 10 seconds before operating to avoid the abnormality of the EFI system. 11. Throttle body 11.1 Common fault signs 1. During riding, the fault light is on, and there are fault codes related to the intake pressure, temperature, and throttle position sensors.

  • Page 88: Throttle Position Sensor

    11.4.1 Throttle position sensor. If the fault light of the instrument is on, if the fault information is displayed as the fault code of the position sensor such as 0123 or 0122, and the diagnostic instrument shows that the fault exists and cannot be cleared, then the engine data flow is viewed, and the throttle position voltage parameter is found, and the position sensor voltage is 0.45~0.75V when the throttle is not moved, and the voltage is 3.6~4.2V when the throttle is screwed to the end.

  • Page 89: Stepper Motors

    Inlet air pressure sensor 11.4.3 Stepper motors If the fault light of the instrument is on, if the fault information is displayed as the 0505 fault code, and the diagnostic instrument shows that the fault exists and cannot be cleared, then check the engine data flow and find the number of steps of the stepper motor, the standard steps of the stepper motor are about 100 steps when the ignition is not ignited, and the number of steps is 50±20 steps when the ignition is idling, and it is normal for the number of steps to be different due to the influence of the engine water temperature.
  • Page 90 If you want to replace the ignition coil, you can follow these steps: It is necessary to remove the fuel tank, surrounding, air filter housing, etc. Use a dust blow gun to blow off foreign objects and dust at the cylinder head. Unplug 3 plugs. Remove the nut with the 10# sleeve sleeve and remove the ignition coil pressure plate.

  • Page 91: Relay(G8Hn-1C4T-Rj)

    13. Relay(G8HN-1C4T-RJ) The PVC sheath of the rear left tail lamp plug has a side bracket relay (model G8HN-1C4T-RJ) and a charging relay (model KH- 1A4T-R). The detection and detection of the charging relay is consistent with that of the EFI relay. Cable end relays After pulling out the relay, use the buzzer of the multimeter to measure that pins 1 and 4 should be normally closed, and the buzzer of the multimeter bee should sound at this time;...

  • Page 92: Crankshaft Position Sensor

    15. Crankshaft position sensor If the engine fails to start and the instrument panel does not display the engine speed, and the diagnostic tool indicates a crankshaft position sensor fault, the crankshaft position sensor should be inspected. The crankshaft position sensor is integrated with the stator of the magneto and is located on the left crankcase cover. Locate the sensor connector on the left side of the vehicle, press the anti-disconnection lock on the head of the connector, and unplug it.

  • Page 93: Troubleshooting Process When The Engine Does Not Start And There Are No Signs Of Landing

    Troubleshooting process when the engine does not start and there are no signs of landing When the start button is pressed, the starter motor can drive the engine to run normally, but the engine cannot work normally, and there are no signs of landing, you can refer to the following diagnostic process to investigate the cause of the fault.

  • Page 94: Poor Acceleration

    Poor acceleration Rotate the right hand handle rubber sleeve, the engine speed can not be increased immediately, there is a lag phenomenon, and the acceleration is slow; You can refer to the following diagnostic process to troubleshoot the cause of the fault. Check Check if the air Poor...

  • Page 95: The Idle Speed Is Unstable And Easy To Stall

    The idle speed is unstable and easy to stall The engine is unstable in idling and easy to stall, and it can return to normal after hot it up. You can refer to the following diagnostic process to troubleshoot the cause of the fault. 95 / 155...

  • Page 96: Efi Fault Indicator Is Always On Analysis Flow Chart

    EFI fault indicator is always on analysis flow chart If the EFI fault“ ” indicator is always on, you should first check whether the wire plug of each EFI sensor is loose. The fault light is always on during driving Read fault code Idle speed fault Canister solenoid...

  • Page 97: Ignition System

    4. Ignition system Pre-Service Notice 1.The content of this chapter requires certain maintenance experience, and it is recommended to go to a maintenance unit with maintenance qualifications for inspection or maintenance. 2.After powering on, the parts connected to the 12V power supply should not be removed at will, so as to avoid the coil in the appliance from self-induction and instantaneous voltage damage to the ECU or sensor.

  • Page 98: There Are No Sparks From The Spark Plugs

    There are no sparks from the spark plugs 1. Improper spark plug clearance If the gap is too small, the electrode has a "flame suppression" effect to inhibit the generation of flames, and the spark strength is weak; If it is too large, the ignition voltage will cause no sparks. Adjust to the standard 0.7-0.9mm. 2.

  • Page 99: Ignition System Layout

    Ignition system layout 1-Clutch rocker arm assembly; 2-Right hand handle switch; 3-Faucet lock; 4- Ignition coil; 5-Throttle assembly; 6-Oil pump pump; 7-Battery; 8-Relay; 9-Starting relay; 10-PKE main engine; 11-Dump switch; 12-Side bracket; Kill switch; 13-Magneto 14-spark plug 15-oxygen sensor 16-fuel injector Note: ●The fuse box comes with the main harness, and the detailed diagram can be found in the EFI relay section of "EFI Parts Fault Diagnosis and Troubleshooting"...

  • Page 100: Ignition System Check

    Ignition system check Note: ●If there is no spark from the spark plug, all cable joints should be checked for loose or poor contact before the ignition system is checked. ●Use a high-precision digital multimeter. For details of the ignition coil test method, please refer to the ignition coil section in the "EFI Parts Fault Diagnosis and Troubleshooting"...

  • Page 101: Starting System

    5. Starting system Pre-Service Notice 1. If there is a current flowing through the starter motor when the engine is not started, it can be judged that the starter motor is damaged and needs to be replaced. 2. Before repairing the starter motor, the engine shutdown switch must be turned to " "...

  • Page 102: Starter Motor

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

  • Page 103: Electrical Schematic Diagram Of The Starting System

    Electrical schematic diagram of the starting system ECM-J1 ECM-J2 4 12 ECM 15A Clutch switch Start fuse 10A PKE 15A PKE switch Flame out switch W Bk1 Bk W Side stand switch Start switch Ignition coils 40A main fuse Motor ECM main relay Start aux relay Start relay...

  • Page 104: Examine

    Disassemble and assemble the starter motor as shown below. 1-M5×98 bolt× 2 2-O ring×2 3-O ring 4-starter motor front cover 5-oil seal 6-bearing 7-rectangular sealing ring 8-starter motor outer shell 7-rectangular sealing ring 9-electric pestle 10-screw ×2 11-head screw with limit 12-washer 13-negative brush×2 14- positive brush×2 15-worm spring ×4 16-insulating brush frame 17-starter motor back cover 18-sealing rubber ring 19-insulating gasket 20 anti-loosening gasket 21 nut Examine...
  • Page 105 Starter motor back cover Check whether the bushing of the back cover is worn or damaged; Check the brushes for damage, measure the length of the brushes, and use the limit of 11.5mm (0.45in). The connection of the back cover is checked as follows： The positive brush is connected to the end of the cable;...

  • Page 106: Check The Starting Relay

    Check the starting relay 1. Operational checks a. Remove the seat cushion and the upper cover of the subframe electrical device box. b. Unlock the vehicle, the engine shutdown switch hits " ", retract the side bracket, pinch the brake handle and press the start button should be able to hear the sound of the starting relay sucking, otherwise the starting line should be checked.

  • Page 107: Disassemble And Assemble The Starting Relay

    4. Disassemble and assemble the starting relay After lifting the white protective cover of the starter relay, remove the M6 bolt with the 8# sleeve, and screw the bolt back after taking out the wire to prevent loss; Remove the other end in the same way. Unplug the relay connector. When reinstalling the relay, the red wire is installed on the threaded hole of the relay marked "B", and the black wire is installed on the threaded hole of the relay marked "M".

  • Page 108: Oil Supply System

    6. Oil supply system Pre-Service Notice 1. Bending or twisting the control cable can affect smooth operation and can cause a short circuit or open circuit, causing the motorcycle to lose control. 2. Work should be carried out in an open and ventilated place. Smoking, phone calling, and all other behaviors that may cause sparks are prohibited at the work site.

  • Page 109: Tank Disassembly

    Tank disassembly d. Break the buckle (1) first, then break open 2 mushroom tower buckles (2), and then pull gently in the Note: direction of the arrow to remove the right decorative cover ●The dismantling site must be ventilated and pay attention (4).

  • Page 110: Examine

    testing, so it is forbidden to disassemble it by yourself. The rubber sleeve (5) and the glass rubber strip (10) of Therefore, the fuel pump decomposition process is not the fuel tank decorative cover bracket can be removed explained here. directly.

  • Page 111: Cooling System And Air Intake System

    7. Cooling system and air intake system Pre-Service Notice 1. Corresponding precautions for coolant (antifreeze) are detailed in the radiator section of the "Maintenance" chapter of this manual. 2. Check the cooling water pipes; Checking the coolant level height, adding and draining the coolant is detailed in the radiator section of the Maintenance chapter and will not be repeated here.

  • Page 112: Cooling System Distribution Map

    Cooling system distribution map 1- ZT703-RR Water Tank Refill 2- ZT310-R Auxiliary Water Tank Leaking Pipe 3-ZT703-F Main Water Tank Inlet Pipe 4- ZT703-RR Auxiliary Water Tank 5- ZT703-F Small Circulation Water Pipe 6- ZT703 Thermostat 7- ZT703-RR Engine Water Inlet Pipe 8- Water Pump Cover Assembly 9- ZT703-RR Engine Outlet Pipe (TFL) 10- ZT703-RR Engine Inlet Pipe (TFL) 11- ZT703-RR Oil Cooler (13 Tubes) 12- ZT703-RR Main Water Tank (38 Tubes) 13- ZT703-RR Water Tank Water Filling Port Connected Water Pipe 112 / 155...

  • Page 113: Schematic Diagram Of Coolant Flow

    Schematic diagram of coolant flow 1-Thermostat assembly 2-Main water tank inlet pipe 3-Main water tank 4-Engine water inlet pipe 5-Water pump cover assembly 6-Small circulation water pipe 703RR Water Cooling System: Small loops (indicated by red arrows): Thermostat assemblies→ small circulating water pipes→ main water tanks (not cooled), → engine inlet pipes→ pump assemblies Large loop (indicated by green arrows): Thermostat assemblies →...

  • Page 114: Disassembly Of The Cooling System

    Disassembly of the cooling system 2. Removing the Main Radiator Assembly a. Refer to the procedure in "Draining Coolant" to fully Note: drain the coolant from the main radiator, and place a suitable ●Before disassembly, refer to the coolant discharge step in drip tray underneath the main radiator to prevent any the cooling system section of the "Maintenance"...

  • Page 115: Disassemble The Water Pipe And Auxiliary Water Tank Components

    Cooling system accessories 3. Disassemble the water pipe and auxiliary water tank components Note: a. Use hoop pliers to remove the φ35 hoop (15) of the ●Specialized ventilation fixtures (gas pressure reducing engine water inlet pipe (16), and the engine water inlet pipe valves, air guns, sealing tubes) are required for testing.

  • Page 116: Pressure Relief Valve Inspection

    nozzle position, and the water filling port is put into the temperature is lower than 80 °C, the thermostat should be in water and let stand for 10s to observe whether there are the closed state of the valve, and when the temperature is bubbles higher than the initial opening temperature, the expansion valve of the expansion cylinder will gradually open, and the...

  • Page 117: Air Intake Systemdisassembly Of The Air Intake System

    Air intake systemDisassembly of the air Air filter system accessories intake system 1. Carbon canisters Check whether the adsorption tube, desorption tube and 1. Disassembly of air filter negative pressure tube on the carbon canister are aging. a. Refer to the steps of "Replacing the Fuel Tank" to Check whether the adsorption tube and desorption tube remove the fuel tank assembly.

  • Page 118: Air Filter Housing Check

    4. Air filter housing Check whether there are defects such as damage or pits on the surface of the shell, check whether there are signs of falling off of various inserts on the shell, and whether the threads have slippage. 118 / 155...

  • Page 119: Braking System

    8. Braking system Pre-Service Notice 1. For Brembo calipers, please refer to this section. The following illustrations use the J.JUAN caliper as a demonstration. 2. The content of this section requires certain maintenance experience. It is recommended to have inspections or repairs conducted at a qualified maintenance facility.

  • Page 120: Troubleshooting

    Troubleshooting remove the FMC-HU oil pipe, and pour out the brake fluid in the main cylinder. Bolt standard torque: 32N.m (3.3 kgf.m, The brake handle is soft 24 lbf.ft). a. Air enters the oil circuit of the braking system b. Brake fluid leakage c.

  • Page 121: Disassemble The Front Disc Brake Caliper

    waterproof gloves and remove the disc brake oil pipe bolt The piston can be blown out by blowing compressed air with the 12# sleeve, remove the RMC-HU oil pipe after from the oil port with a dust blowing gun. Pay attention to removing the copper pad, and pour out the brake fluid in the placing towels or other soft materials at the piston to main cylinder.

  • Page 122: Brake Hose And Wheel Speed Sensor

    deformed. The points that should be paid attention to in the assembly are described in detail and will not be repeated here. Front wheel 1-Caliper mounting plate pin cap 2-elastic card 3-lower sliding shaft 4-piston 5-caliper mounting plate 6-card 7- caliper pin cap 8-dust seal 9-upper sliding shaft 10-oil seal 11- air nozzle 12-air nozzle rubber cap 13-caliper housing Note:...

  • Page 123: Fmc-Hu And Fc-Hu, Wheel Speed Sensor (Front Wheel)

    step of removing the hose, wrap the plug of the hydraulic control unit with an oil-resistant plastic film bag. c. Use a T25 torx wrench and an 8# open-end wrench, remove the following two bolts, remove the front brake hose directional upper bracket, and pull out the front wheel speed sensor socket in the frame.

  • Page 124: Rc-Hu And Rmc-Hu, Wheel Speed Sensor (Rear)

    ABS system arrangement f. Check whether the surface of the removed hose has aging cracks, damage, wear and other undesirable phenomena. After wiping off the remaining brake fluid with a non-woven fabric, wrap both ends of the hose with plastic wrap or plastic bag to prevent foreign objects from entering.
  • Page 125 b. Refer to the previous steps to drain the brake fluid, remove the 4 hose connectors and unplug the cable connectors. c. Use the T45 torx wrench with holes to remove the 2 bolts of the hydraulic control unit bracket, and remove the hydraulic control unit and the bracket assembly from the car.

  • Page 126: Battery/Charging System

    9. Battery/charging system Pre-Service Notice 1. Waste batteries should be disposed of properly so as not to pollute the environment. It is recommended to hand over the waste battery to a professional recycling agency for recycling. 2. It is forbidden to use a charger that has not been tested to charge the battery. 3.

  • Page 127: Troubleshooting

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

  • Page 128: Charging System Layout Diagram

    Charging system layout diagram 1-Starter relay (40A) 2-Charging port holder 3-Rectifier 4-Battery5-Fuse box 6-Magneto Electrical schematic letter Englis Green Yellow 128 / 155...

  • Page 129: Battery Disassembly And Assembly

    Battery disassembly and assembly 3. Charge If the battery cannot be started due to insufficient 1. Disassembly power, it can be charged with the charger provided with Note: the car. According to the "ZT703-RR Disassembly and ●The whole motorcycle must be powered off before Assembly Rear Fender Bottom Cover Tutorial"...

  • Page 130: Magneto Stator Charging Coil Inspection

    Rectifier start the engine. Measure the charging voltage at 5000 rpm of the engine. Dismantle the rectifier standard： Use an 8# socket or torx wrench with ratchet to remove Battery voltage < charging voltage< 15V the two bolts that hold the rectifier and unplug the two plugs of the rectifier.

  • Page 131: Front Fork Assembly

    10. Front fork assembly Pre-Service Notice 1. Use high-quality tools or special tools and fixtures designed by our company. Using inferior tools may cause damage to parts, coating shedding, inadequate assembly, etc. 2. O-rings, paper gaskets, copper gaskets, component sealing rings, etc. used for sealing must be replaced before assembly. 3.

  • Page 132: Exploded View Of Fork Components

    Exploded view of fork components Exploded View of the steering handlebar Fork exploded 132 / 155...

  • Page 133: Exploded View Of The Lower Panel

    Exploded view of the lower panel 133 / 155...

  • Page 134: Replace The Steering Handlebar

    Replace the steering handlebar the left counterweight (1) and left heated handlebar (3). Note: ●The disc brake cup must be removed vertically upwards to prevent air from entering the brake line. ●When disassembling and assembling the handlebar switch, pay attention to adjusting the internal wiring harness and turn signal wiring harness of the switch to avoid the shell or bolt column clamping the wire skin.

  • Page 135: Replace The Front Wheel

    Replace the front wheel handlebar connector back onto the clip inside the handlebar switch and tighten the three bolts securing the left handlebar Note: switch using a Phillips screwdriver. ●Be careful not to damage the ABS ring gear when Connect the right heated handlebar connector. Install the disassembling.

  • Page 136: Exploded View Of The Front Wheel Assembly

    ●After the front wheel is installed, press the brake handle repeatedly until the brake restores the braking effect. ●Soiled disc and pads can reduce braking effectiveness, so replace them with new ones and clean the soiled discs. ●After each replacement of the front wheel, it is necessary to go to a professional institution for dynamic balance testing.

  • Page 137: Inspection And Maintenance Of Front Wheel Components

    Inspection and maintenance of front wheel occurs, the front wheel oil seal and bearing should be checked in advancea. There is an abnormal sound of the components front wheel when riding/ b. When the steering knob shakes from side to side while Notice: riding.

  • Page 138: Balancing

    3.3 Balancing plate; Then use the 8# sleeve to remove the 2 M6×22 bolts (2) on both sides. The wheel is a whole composed of tires and rims, due to manufacturing reasons, the mass distribution of each part of the wheel may not be very uniform, when the wheel rotates at high speed, it will form a dynamic unbalanced state, resulting in the phenomenon of wheel shaking and direction shaking in the motorcycle while driving, in order to avoid this...

  • Page 139: Replace The Shock Absorber, Front Mud Plate, Front Wheel And Other Components

    b. Use a T45 torx wrench with holes to loosen the bolt (7) c. Attach the two M8×35 bolts to the lower plate and for 5-8 turns. The other side is also loosened in the same insert the other shock absorber in the same way. way.

  • Page 140: Disassemble The Lower Panel Assembly

    direction column adjustment nut, use a four-jaw sleeve to tighten the direction column adjustment nut, torque: 35N.m, ensure that the upper link plate does not go up and down in series, and then loosen the direction column adjustment nut counterclockwise 1/4 turn, and finally use a torque wrench to tighten, torque: 15N.m.

  • Page 141: Rear Fork Assembly

    11. Rear fork assembly Pre-Service Notice 1. High quality tools or specialized tools, fixtures, etc. designed by our company are required. Using inferior tools may cause damage to parts, peeling of coatings, improper assembly, etc. 2. O-rings, paper pads, copper pads, component sealing rings, etc. used for sealing must be replaced before assembly. 3.

  • Page 142: Replace The Rear Wheels

    Replace the rear wheels 3.Remove the sprocket seat Note: Use a 12# torx wrench to remove the 6 self-locking nuts ●The motorcycle must be parked on a level, stable ground or that fix the sprocket, torque: 30~35N.m (3.1~3.6 kgf.m, lifting platform. 22~26 lbf.ft).

  • Page 143: Exploded View Of The Rear Wheel Assembly

    requirements of the brake line, it is necessary to ensure that causing difficulty inflation or tire pressure monitoring failure. there is enough capacity for repair and disassembly ●After each replacement of the rear wheel, it is necessary to go to a professional institution for dynamic balance testing. ●It should not be used because tire self-replenishment may clog the air holes of the tire pressure monitoring sensor, Exploded view of the rear wheel assembly:...

  • Page 144: Rear Wheel Oil Seals And Bearings

    d.Replace the rear wheel assembly. c.There are many aging and cracking phenomena in tires。 2.Rear wheel oil seals and bearings 2.1 Service life of rear wheel seals and bearings 3.2 How to replace the rear rim and tires Under normal circumstances, the bearing and oil seal in a.Refer to "Replacing the Rear Wheel"...

  • Page 145: Remove The Rear Flat Fork

    ●Use appropriate tools to support the motorcycle to prevent accidents caused by motorcycle tipping during disassembly; It is strictly forbidden to operate alone. ●All standard parts must meet the standard torque value when reassembling. ●When disassembling the rear wheel assembly, the rear disc brake caliper should not be higher than the disc brake oil cup, otherwise the brake will become soft or fail due to air entering the line.

  • Page 146: Put Back The Shock Absorber

    there is enough capacity for repair and disassembly. ●The oil seals and needle roller bearings of the rear shock- absorbing triangle connecting rod and the rear shock- absorbing straight connecting rod are interference press- fitting, please ensure that you have the ability to disassemble and assemble by yourself before disassembling by hand.

  • Page 147: Disassembly And Assembly Of Motorcycle Covers

    12. Disassembly and assembly of motorcycle covers Note： ●The motorcycle must be parked on a level, stable ground or lifting platform. ●Operation is required until the engine and muffler have cooled down completely. ●Attention and sequence when disassembling the plastic buckle to avoid buckle breakage 147 / 155...

  • Page 148: Disassembly And Assembly Of Motorcycle Covers

    1.windshield 2.The middle of the front panel 3.Front panel right 4.Right headlights 5.Right enclose the panel 6.Right shroud 7.Rear fender 8.Lower part of the tail skirt 9.Rear seat cushion 10.Right tail skirt 11.Main cushion 12.Fuel tanks 13.Fuel tank right trim cover 14.Tank cover 15.The upper part is surrounded on the right16.Instrument right trim cover 17.Upper head brace 18.The right encloses the front wind-fixing wing 19.The right surrounds the upper trim 20.Right daytime running lights 21.Right front position light 22.Head undercover 23.Surround the middle Disassembly and assembly of motorcycle...
  • Page 149 b. Use a crochet hook to remove one expansion nail from e. After removing the interior surrounding, remove the each of the left and right envelopes the interior (1). joints of the left and right mirrors from the interior panels. f.

  • Page 150: Disassembly Of Headlights

    i. Use an 8# torx wrench to remove the two M6×12 hex bolts (1) that fix the windshield assembly on the left and right c. Use a crochet hook to remove the 2 expansion pegs on sides, and use a T25 torx wrench to remove the two M6×12 the right side of the front panel.

  • Page 151: Disassembly Of The Enclosing Panel Assembly

    f. Use a crochet hook to remove the 2 expansion nails on j. Unplug the connector of the left headlight. the left side of the front panel. k. Use the 8# T-type sleeve to remove 1 M6×16 bolt (1), 2 g.
  • Page 152 b. Remove the middle of the bracket (4). f. Unplug the tire pressure sensor and remove the right bracket assembly. c.Use a T25 Allen Torx wrench to remove one of the shoulder bolts (2) of M6×14, and use a crochet hook to pry open the hook locks surrounding the left and right sides.

  • Page 153: Disassembly Of The Enveloping Assembly

    h. On the left side of the vehicle, carefully pull the buckle or c. Use a T25 Allen Torx wrench to remove 2 M6×14 mushroom peg indicated by the arrow from top to bottom, shoulder bolts. and remove the left bracket panel assembly. d.

  • Page 154: Removal Of The Seat Cushion

    Dismantling of the left and right tail skirts b. Use a Phillips screwdriver to remove the 4 non-standard Phillips self-tapping screws (1) fixed on the inner lining of the a. Use a T25 torx wrench to remove the 2 fixing bolts (1) fuel tank interior cover, and remove the left and right fixed on the left tail skirt (you need to loosen 1 fixed cushion decorative cover liners (2), and then remove the fuel tank...
  • Page 155 b. Use a T25 torx wrench to remove the 3 inner torx M6 bolts (1) that fix the subframe, and then remove the rear fender assembly from the subframe. c. Use a T25 Torx wrench to remove 2 M6 bolts (1), then remove 2 M6 nuts (2), and then separate the rear license plate (3) from the rear fender assembly (4).

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