Mash X-RIDE 50 Manual
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Mash X-RIDE 50 Manual

Mash X-RIDE 50 Manual

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This manual covers the description of X-RIDE 50 motorcycle and the inspection,
maintenance and repair procedures of its main parts and components, excluding the other general
common senses. The figures in this manual are only used for showing the basic operating
principles and working processes and do not refer to any specific motorcycle.
This maintenance manual is meant to instruct the maintenance service personnel with
competent knowledge and skills on motorcycle maintenance to inspect, adjust, repair and
maintain Qingqi motorcycles.
The final interpretation right of this manual belongs to our company. Without the company's
prior permission, no content in this manual may be quoted or reproduced.
This manual contains the latest data, explanation, figures and specifications at the time of
publication. Due to improvement or other changes, the description in this manual may be slightly
different from the practical situation. The company reserves the right to modify any content at any
time.
The product specifications and parameters may be modified at any time without prior notice!
The product configuration and accessories supply may be different at different countries and
regions. Please consult the local distributors for details!
PREFACE
PREFACE

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Summary of Contents for Mash X-RIDE 50

  • Page 1 PREFACE PREFACE This manual covers the description of X-RIDE 50 motorcycle and the inspection, maintenance and repair procedures of its main parts and components, excluding the other general common senses. The figures in this manual are only used for showing the basic operating principles and working processes and do not refer to any specific motorcycle.

  • Page 2: How To Use This Manual

    PREFACE HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR : The text of this manual is divided into sections. Holding the manual as shown at the right will allow you to find the contents of this manual easily. All chapters of this manual are listed in the table of contents.
  • Page 3 PREFACE SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Use fork oil. Data beside it indicates specified torque Apply oil.

  • Page 4: Abbreviations Used In This Manual

    PREFACE ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Liquid Crystal Display : Alternating Current : Light Emitting Diode : American Petroleum Institute : Left Hand ATDC : After Top Dead Center MAP&IAT :Manifold absolute Pressure Sensor Sensor(MAPS) BBDC...

  • Page 5: Wire Color

    PREFACE WIRE COLOR : Black : Green : Purple : Blue : Gray : Red : Light green : Shallow blue : Brown :Dark brown : Orange : White :Dark green : Pink : Yellow Black with Blue tracer Black with Brown tracer Black with Green tracer Black with Gray tracer Black with Orange tracer...
  • Page 6 PREFACE GrBr Gray with Brown tracer Gray with Green tracer Gray with Orange tracer Gray with Red tracer Light green with Red tracer Orange with Black tracer Orange with Blue tracer Orange with Green tracer Orange with Red tracer Orange with White tracer Pink with Blue tracer Pink with Green tracer PuBl...

  • Page 7: Table Of Contents

    Directory Directory Chapter 1 Overview Section 1 Information Labels………………………………………… Section 2 General Precautions………………………………………… 1-2 Section 3 Appearance Of Motorcycle………………………………… 1-3 Section 4 Function Of EI Sensor……………………………………… 1-4 Section 5 Number location…………………………………………… Section 6 Recommended fuels and oils……………………………… Section 7 Running-in steps…………………………………………… Section 8 Technical parameters………………………………………...
  • Page 8 Directory Chapter 7 Electrical system Section 1 Location of electrical components………………………… Section 2 Ignition system…………………………………………… Section 3 Charging System…………………………………………… 7-7 Section 4 Starter system and side stand ignition interlock system…… Section 5 Switches…………………………………………………… 7-13 Section 6 Lamp……………………………………………………… 7-14 Section 7 Battery……………………………………………………… 7-16 Chapter 8 Information servive Section 1 Troubleshooting……………………………………………...

  • Page 9: Chapter 1 Overview

    Chapter 1 Overview Section 1 Information Labels Chapter 1 Overview Section 1 Information Labels WARNING / CAUTION / NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.

  • Page 10: Section 2 General Precautions

    Chapter 1 Overview Section 2 General Precautions Section 2 General Precautions ❖ Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle. ❖ When 2 or more persons work together, pay attention to the safety of each other. ❖...

  • Page 11: Section 3 Appearance Of Motorcycle

    Chapter 1 Overview Section 3 Appearance Of Motorcycle Section 3 Appearance Of Motorcycle Left side view Right side view N O T E Difference between photographs and actual motorcycles depends on the markets. 1—3...

  • Page 12: Section 4 Function Of Ei Sensor

    Chapter 1 Overview Section 4 Function Of EI Sensor Section 4 Function Of EI Sensor ★ECU (Engine Control Unit, EI Control Unit)ECU ECU decide the fuel injection volume and ignition time to adjust the fuel injector opening and closing rate which is considered the engine speed, intake air pressure, intake air volume, engine temperature, oxygen volume and throttle opening angle, etc.

  • Page 13: Chapter 1 Overview Section 5 Number Location

    Chapter 1 Overview Section 5 Number location Section 5 Number location The frame (or VIN code) and engine number Fig 1.1.1 are used when registering the motorcycle. This number can help the distributor to serve you well when ordering components or entrusting special services.

  • Page 14: Chapter 1 Overview Section 6 Recommended Fuels And Oils

    Chapter 1 Overview Section 6 Recommended fuels and oils Section 6 Recommended fuels and oils 1. Fuel Warning： The gasoline is a very flammable and explosive substance. When handling the gasoline, there is the possibility of burns or serious accidents. In the storage place of gasoline or fuel, the engine must be stopped, and it is forbidden of smoking, it should keep away from flames or sparks.

  • Page 15: Front Fork Oil

    Chapter 1 Overview Section 6 Recommended fuels and oils The quality of engine oil is the main factor that affects the service life of the engine. Please replace the engine oil according to the maintenance cycle specified in the maintenance table. The engine oil should be replaced more frequently than in the maintenance table when it is run in a dusty region.

  • Page 16: Chapter 1 Overview Section 7 Running-In Steps

    Chapter 1 Overview Section 7 Running-in steps Section 7 Running-in Steps The motorcycle of X-RIDE 50 model reaches high quality standards, and all the components are made of high-quality materials. However, before the engine reaches its maximum load, all the moving components should have a running-in process.

  • Page 17: Chapter 1 Overview Section 8 Technical Parameters

    Chapter 1 Overview Section 8 Technical parameters Section 8 Technical parameters ⊙ DIMENSIONS AND MASS ITEM X-RIDE 50 Overall length 2010mm Overall width 843 mm Overall height 1153 mm Wheelbase 1420 mm Minimum ground clearance 230 mm Turning clearance circle diameter...
  • Page 18 Chapter 1 Overview Section 8 Technical parameters ⊙ CHASSIS ITEM X-RIDE 50 Front suspension Spring oil damping Rear suspension Spring oil damping Steering angle 39° (right & left) Caster 29° Front brake Disk brake Rear brake Disk brake Front tire size...

  • Page 19: Periodic Maintenance Chart

    Chapter 2 Periodic maintenance Section 1 Regular maintenance plan Chapter 2 Periodic maintenance Section 1 Regular maintenance plan The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Notice：...
  • Page 20 Chapter 2 Periodic maintenance Section 1 Regular maintenance plan Cylinder head nut、Cylinder nut Inspect Inspect Inspect Inspect Inspect Inspect LUBRICATION Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.The following maintenance cycles are expressed in miles in order to achieve the ultimate goal of maintaining the motorcycle in the most economical way Period The first time and every 5,000km...

  • Page 21: Lubrication Point

    Chapter 2 Periodic maintenance Section 1 Regular maintenance plan LUBRICATION POINT Major lubrication points are indicated below: Break lever holder Clutch lever holder Throttle cable Side stand pivot and spring hook Drive chain Note： Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the motorcycle has been operated under wet or rainy condition.

  • Page 22: Section 2 Maintenance And Adjustment

    Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Section 2 Maintenance and adjustment This section describes the service procedure for each section of the periodic maintenance VALVE CLEARANCE In the first 1000km (5 months) and every 4000km (20 months) thereafter, it should carry out the inspections.
  • Page 23 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig 2.2.5 Adjustment Use a screwdriver and a socket off-set wrench to adjust the gap. Loosen the lock nut ⑥. Insert the feeler gauge into the gap between the valve stem and adjustment screw on the rocker arm. Adjust the valve clearance by turning the adjustment screw ⑦, while fixing the lock nut ⑥.

  • Page 24: Air Filter

    Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Note： Fig.2.2.8 When replacing the spark plug, it needs to confirm the thread size and the rod length L. If the rod is too short, it will cause carbon deposits on the threaded part of the plug hole;...
  • Page 25 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Assemble the cleaned filter in the reverse order of removal. It must be confirmed that the filter element is firmly installed in the specified position and sealed reliably. Note： When the filter element is not installed, do not run the engine to avoid wearing the piston and cylinder.
  • Page 26 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Chain tensioner In the first 1000 kilometers (5 months) and every 4000 kilometers (20 months) thereafter, inspections should be carried out. The air distribution chain should be maintained at a proper tension through a manually adjustable tensioner.
  • Page 27 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig.2.2.17 Clutch In the first 1000 kilometers (5 months) and every 4000 kilometers (20 months) thereafter, inspections should be carried out. Loosen the lock nut ③ , and turn the regulator ④ clockwise or counterclockwise.
  • Page 28 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig.2.2.20 Stop the engine, wait for about 1 minute, and then check the oil level through the sight glass ③. If the oil level is lower than the "L" mark, it should be added to the proper oil level.

  • Page 29: Chapter 2 Periodic Maintenance Fig

    Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig 2.2.23 Note： Standard transmission chain is: 428H or 428UO. Our company recommends using this standard transmission drive chain as a replacement part. Inspect and adjust Loosen the nut ② and the rear axle ①. Turn the chain adjuster nut ②...
  • Page 30 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig.2.2.28 Warning： Re-assemble the chain buckle that the open end is opposite to the direction of rotation. As in Fig.2.2.28. Brake In the first 1000Km (5 months) and thereafter every 4000Km (20 months), it needs to carry out inspections.

  • Page 31: Front Brake Fluid Replacement

    Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig.2.2.31 Front brake fluid replacement Keep the motorcycle parked upright with the handle bar straight. Remove front brake pump cover and diaphragm. Drain all the old brake fluid and add new brake fluid. Specification and classification：DOT4 Connect the clean hose to the front caliper vent valve ○...
  • Page 32 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig.2.2.36 Fill the reservoir with new brake fluid within the mark of the oil cup. As fig. 5.2.36 Rear caliper exhaust valve :7.5N∙m (7.5kg∙m) Exhaust of brake fluid circuit When air is drawn into the brake fluid loop, acting as a cushion, it can absorb most of the compression force generated by the main cylinder, resulting in interference with the braking performance of the brake calipers.
  • Page 33 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig.2.2.40 Continuously pressurized rear brake pedal by hand for exhaust; Keep pressurizing and refueling until the brake is obviously felt, then press the pedal and release the exhaust valve B for exhaust work; Then screw the vent valve, squeeze the brake lever and open the vent valve again (note: pedal down pressure shall not be lifted before the vent screw is tightened during...
  • Page 34 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Steering mechanism It should be checked during the first 1000 km (5 months) and every 4000 km (20 months) thereafter In order to turn the handle smoothly and drive safely, it should adjust the steering mechanism correctly. Too tight Fig.2.2.45 steering mechanism will hinder smooth operation of the handle, and too loose one will cause poor stability.
  • Page 35 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Tire tread condition Fig.2.2.48 The use of over worn tires will reduce driving stability cause dangerous situations. especially recommended to replace the tire when the remaining depth of the tread reaches the following specifications. Check the tire tread depth with using the tire depth gauge.

  • Page 36: Chapter 2 Periodic Maintenance Section 2 Maintenance And Adjustment

    Chapter 2 PERIODIC MAINTENANCE Section 2 Maintenance and adjustment Frame bolt and nut Tightening should be performed during the first 1000 kilometers (5 months) and every 4000 kilometers (20 months) there after. Check whether all bolts and nuts on the car body are tightened to the specified torque. Number Component name Kg.m...
  • Page 37 Chapter 2 PERIODIC MAINTENANCE Section 2 Maintenance and adjustment Fig.2.2.51 Fig.2.2.52 Fig.2.2.53 Fig.2.2.54 Fig.2.2.55 Fig.2.2.56 Fig.2.2.57 Fig.2.2.58 Fig.2.2.60 Fig.2.2.59 2—19...

  • Page 38: Chapter 2 Periodic Maintenance Section 3 Inspection Of Compression Pressure

    Chapter 2 Periodic maintenance Section 3 Inspection of compression pressure Section 3 Inspection of compression pressure The compression pressure reading is displayed with the built-in indicator. It usually judges if the cylinder needs heavy maintenance based on the results of the compression pressure test.

  • Page 39: Chapter 2 Periodic Maintenance Section 3 Inspection Of Oil Pressure

    Chapter 2 Periodic maintenance Section 3 Inspection of oil pressure Section 4 Inspection of oil pressure Regularly check the oil pressure to keep the moving parts of the motorcycle in good condition. Hydraulic step Fig.2.4.1 Remove the cover nut using the "copper washer" on the cylinder head cover;...

  • Page 40: Chapter 3 Engine

    Chapter 3 Engine Section 1 Detachable engine components on-site Chapter 3 Engine Section 1 Detachable engine components on-site The components listed below can be disassembled and reinstalled without removing the engine from the frame. For disassembly and assembly instructions, see below Engine center Exhaust pipe and muffler………………………………………………………...

  • Page 41: Section 2 Engine Disassemble And Re-Assemble

    Chapter 3 Engine Section 2 Engine Disassemble and Re-assemble Fig.3.2.1 Section 2 Engine Disassemble and Re-assemble Removal of engine Remove left and right frame guard panels Remove the saddle Unload fuel tank Remove the negative cable of the battery. As shown in figure 3.2.1 Fig.3.2.2 Drain the engine oil...
  • Page 42 Chapter 3 Engine Section 2 Engine Disassemble and Re-assemble Fig.3.2.6 Remove engine sprocket screw ① and washer. As shown in figure 3.2.6 Note: When removing the engine sprocket screws, depress the brake pedal. Fig.3.2.7 Remove the engine sprocket ② . As shown in figure 3.2.7 Note: If it is difficult to remove the engine sprocket, loosen the rear rocker nut and chain regulator nut to...
  • Page 43 Chapter 3 Engine Section 2 Engine Disassemble and Re-assemble Remove the engine ground wire ① . As shown in Fig.3.2.11 figure 3.2.11 Remove the spark plug cap ②. Separate the starter motor wire ③. As shown in figure 3.2.12 Fig.3.2.12 Separate the generator connector ④...
  • Page 44 Chapter 3 Engine Section 2 Engine Disassemble and Re-assemble Fig.3.2.16 Use jacks or wooden blocks to support the motorcycle. Remove the engine guard plate fixing bolt ⑦. As shown in figure 3.2.16 Fig.3.2.17 Remove the engine protection plate bracket around four fixing bolts ⑧.
  • Page 45 Chapter 3 Engine Section 2 Engine Disassemble and Re-assemble Reinstall the engine Fig.3.2.22 The reinstallation of the engine can be performed in the reverse order of disassembly. Tighten engine front connecting frame bolts with specified torque. As shown in figure 3.2.22 Engine front connection bracket bolt: 23 Newton ·...
  • Page 46 Chapter 3 Engine Section 2 Engine Disassemble and Re-assemble Loosen rear axle nut and drive chain regulator nut. Fig.3.2.27 Install engine sprocket as shown. As shown in figure 3.2.27. Put on the chain. Note: The opening end of the chain connection should be assembled in the opposite way to the running direction.

  • Page 47: Section 3 Engine Disassembly

    Chapter 3 Engine Section 3 Engine disassembly Section 3 Engine disassembly The steps to disassemble the engine are described in the Fig.3.3.1 following order: Remove the observation hole plug (1) and the magneto cap (2). As shown in Figure 3.3.1. Fig.3.3.2 Line A on the rotor of the magneto is aligned with mark B on the bonnet and the piston is in TDC position.
  • Page 48 Chapter 3 Engine Section 3 Engine disassembly Fig.3.3.5 Remove the chain tensioning device ①. As shown in Figure 3.3.5. Fig.3.3.6 Remove the left and right cover of the cylinder head ②. See Figure 3.3.6 and Figure 3.3.7. Fig.3.3.7 Remove the timing sprocket bolt and remove the sprocket ③.
  • Page 49 Chapter 3 Engine Section 3 Engine disassembly Fig.3.3.10 Remove the cylinder head liner ①. Remove the CAM chain guide plate ②. As shown in Figure 3.3.10. Note: If the cylinder cannot be removed, use a plastic hammer to gently tap the fin free part to loosen the padded connection.
  • Page 50 Chapter 3 Engine Section 3 Engine disassembly Fig.3.3.14 Remove the bushing ⑧, shaft ⑦ and starting idler ⑥. As shown in Figure 3.3.14. Fig.3.3.15 Remove the magneto cover As shown in Figure 3.3.15. Fig.3.3.16 Remove reduction gear shaft, shaft pin and gasket ⑨. As shown in Figure 3.3.16.
  • Page 51 Chapter 3 Engine Section 3 Engine disassembly Fig.3.3.18 Remove the 4 screws M5×12, and remove the clutch end cover, crankshaft through tubing, through tubing spring and through oil casing ②. As shown in Figure 3.3.18. Fig.3.3.19 Clamp magneto rotor fixing bolts. Remove the primary drive gear fastening nut and disc and thrust gasket ③...
  • Page 52 Chapter 3 Engine Section 3 Engine disassembly Fig.3.3.22 Remove the hex socket M6 bolt, and remove the gear positioning plate assembly and spring ③. Remove the cross screw, take down the shift wheel, the gear pin press plate and the 4 gear indicator pins ④ and take down the shift shaft combination ⑤...
  • Page 53 Chapter 3 Engine Section 3 Engine disassembly Remove the crankcase bolts and wire clamps, remove the Fig.3.3.27 hex socket bolts M6x20, and remove the elastic washer and gear display contact combination (1). As shown in Figure 3.3.27. Use special tools to separate the right and left crankcases. Tool used: crankcase separator ①...
  • Page 54 Chapter 3 Engine Section 3 Engine disassembly Fig.3.3.31 Remove the spring ①, remove the starting shaft assembly ②. As shown in Figure 3.3.31. Remove the oil screw and gasket ① and remove the oil Fig.3.3.32 filter ②. As shown in Figure 3.3.32. 3—15...
  • Page 55 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.1 Section 4 Inspection and maintenance of engine componenets Crankcase bearing Bearing inspection Check the bearing in the crankcase and turn the inner seat ring to check that the rotation is smooth. If it cannot run smoothly without noise, or there are abnormal signs, it Fig.3.4.2 indicates that the bearing is defective and must be replaced...
  • Page 56 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.5 Outer diameter of rocker arm shaft Measure shaft diameter of rocker arm. As shown in Figure 3.4.5. Tools used: calliper (0-25mm) standard：Φ Fig.3.4.6 The rocker inner diameter Measure the inner diameter of rocker arm and check the wear of camshaft contact surface.
  • Page 57 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Remove the taper clamp ① from the valve rod. Fig.3.4.8 As shown in Figure 3.4.8. Tool used: tweezers Remove the valve spring seat ②, remove the valve spring ③, outer spring ④. As shown in Figure 3.4.9.
  • Page 58 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Cylinder head deformation Remove carbon deposits from the combustion chamber. Remove the cylinder head gasket and clean the Fig.3.4.12 residue on the joint surface of the cylinder head. Check whether the joint surface of cylinder head is deformed by using ruler and feeler.
  • Page 59 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Valve rod deflection Fig.3.4.16 Lift the valve from the valve seat approximately 10mm. "x" and "y" directions, and perpendicular to each other, to determine the deflection of the valve rod. The micrometer is positioned as shown.
  • Page 60 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.20 Insert a ring into the valve guide sleeve. Oil the valve stem holes of each valve guide sleeve and use special tools to drive the valve guide set into the holes.
  • Page 61 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.24 Clean and assemble the inlet and exhaust valves. Fill the inlet and outlet with kerosene and check for leakage. If leakage occurs, check for burrs or other objects that may hinder valve sealing.
  • Page 62 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.28 Lubricate the valve oil seal (2), and manually press the oil seal into the correct position. See Figure 3.4.28. Note: the oil seal that has been removed cannot be ②...
  • Page 63 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.33 Air intake pipe bending As shown in Figure 3.4.33. Note: Apply a new paper pad to prevent air leakage from the joint. Valve camshaft Camshaft inspection If the engine produces abnormal noise, vibration, or low power, the camshaft may be deformed or worn to its Fig.3.4.34 limit.

  • Page 64: Use Limit

    Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Chain tensioning device Fig.3.4.38 Check the putting motion. If the push rod is stuck or the spring does not work, a new chain tensioner assembly is required. As shown in Figure 3.4.38. Clearance between piston and cylinder The gap between the piston and the cylinder is the difference between the cylinder diameter and the piston...
  • Page 65 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Use limit Piston ring opening clearance ： First ： Fig.3.4.43 0.08-0.2/ Second：0.05-0.2mm Use limit Free opening clearance of piston ring：First： 4.3/Second：4mm Clearance between piston ring and groove Use a feeler to measure the backlash of the first and second rings.

  • Page 66: Section 4 Inspection And Maintenance Of Engine Componenets

    Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Pin hole The inner diameter of piston pin hole is measured by inner Fig.3.4.47 micrometer, and the outer diameter of piston pin is measured by calliper. If either exceeds the specified requirements, difference between...
  • Page 67 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Inner diameter of small end of connecting rod Fig.3.4.49 Measure the inner diameter of the small end of the connecting rod with an inner micrometer. If the inner diameter of the small end of the connecting rod exceeds the limit of use, the connecting rod should be replaced.
  • Page 68 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.54 Electric starting clutch Attach THE STARTING GEAR TO THE clutch and TURN THE STARTING gear by hand (THE gear can only turn in one direction). The starting gear should run smoothly.
  • Page 69 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets A rotor gripper is used to fix the generator Fig.3.4.58 rotor and the starting clutch bolt is removed manually. As shown in Figure 3.4.58. Tool used: rotor gripper Reinstall Apply a small amount of thread sealant to the starting clutch bolts.
  • Page 70 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets The transmission system Tear open outfit Detachable transmission (variable speed) gears are shown below. Countershaft second gear Output sprocket 13T Countershaft third gear Sprocket fixing plate Countershaft fourth gear Main shaft Main shaft Countershaft...
  • Page 71 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets The clutch Fig.3.4.61 Clutch active friction plate The thickness of the clutch plate and the width of the clutch claw are measured by using vernier caliper. If the clutch plate is not within the limit of use, the clutch plate should be replaced in sets.

  • Page 72: Section 5 Engine Reassembly

    Chapter 3 Engine Section 5 Engine re-assembly Fig.3.5.1 Section 5 Engine re-assembly The reinstallation of the engine can be done in the reverse order to the removal. The following steps require special attention or should be taken. Note: Apply oil to each moving and sliding part before reinstalling.

  • Page 73: Starting Device

    Chapter 3 Engine Section 5 Engine re-assembly Fig.3.5.5 The crankshaft When loading the crankshaft into the crankcase, use a rubber hammer to gently tap the right crank head until the left crankcase. As shown in Figure 3.5.5. Note: Apply oil to crankshaft bearings and connecting rods.
  • Page 74 Chapter 3 Engine Section 5 Engine re-assembly Fig.3.5.9 The spring seat convex head is stuck on the right box by hand ② , and the return spring is hooked on the right box by clockwise rotation with special tools into the starting shaft ③.
  • Page 75 Chapter 3 Engine Section 5 Engine re-assembly Fig.3.5.13 Install tensioning plate and timing chain, as shown in Figure 3.5.13. Fig.3.5.14 Install the timing chain limit plate and tighten the two bolts M6x10. As shown in Figure 3.5.14. Fig.3.5.15 Rotor for magneto Remove and wipe the grease from the cone hole of the rotor and the cone of the crankshaft.
  • Page 76 Chapter 3 Engine Section 5 Engine re-assembly Fig.3.5.18 Oil pump Before installing the oil pump, oil should be added to the sliding surface, inner and outer rotors and shafts of the oil pump housing. Install the two 3 x 16 positioning pins, as shown in Figure 3.5.18.
  • Page 77 Chapter 3 Engine Section 5 Engine re-assembly Fig.3.5.22 Installation shift shaft combination; As shown in Figure 3.5.22. Fig.3.5.23 Install the bracket pin pressure plate; Install shift wheel; Screw M6×12, as shown in Figure 3.5.23. Fig.3.5.24 Install positioning plate spring and gear positioning plate combination.
  • Page 78 Chapter 3 Engine Section 5 Engine re-assembly Install primary driven gear and primary driven gear Fig.3.5.26 retaining ring, then install clutch washer, primary drive gear bushing and primary drive gear. Note that the main gear end of the primary drive gear is facing down. As shown in Figure 3.5.26.
  • Page 79 Chapter 3 Engine Section 5 Engine re-assembly Install clutch end cover gasket and clutch end cover, Fig.3.5.30 oil through casing, oil through tubing spring, crankshaft through tubing, and lock the clutch end cover with 4 screws M5×12. As shown in Figure 3.5.30. Note: Use a new gasket.
  • Page 80 Chapter 3 Engine Section 5 Engine re-assembly Fig.3.5.33 Install the right crankcase cover assembly with M6x45 bolts for the positioning pin holes and M6x40 bolts for the other six right crankcase cover holes. Install the right small cover using screw M5 x 12 tightening. As shown in Figure 3.5.33.

  • Page 81: Piston And Piston Ring

    Chapter 3 Engine Section 5 Engine re-assembly Piston and piston ring Fig.3.5.36 First, install the oil ring septum ① into the oil ring groove, and then install the oil scraper ② on both sides. If the oil ring and scraper are new, they do not have special upper and lower ends.
  • Page 82 Chapter 3 Engine Section 5 Engine re-assembly Fig.3.5.41 Place a piece of clean cotton cloth over the opening of the cylinder to prevent the piston pin spring from falling into the crankcase. Install the piston pin clamp spring ③ with needle-nose pliers. Note: A new piston pin clamp spring should be used to prevent damage.

  • Page 83: Cylinder Head

    Chapter 3 Engine Section 5 Engine re-assembly Cylinder head Fig.3.5.45 Before installation, adjust the piston to TDC and turn the crankshaft counterclockwise. When tightening the chain, align line B on the rotor of the magneto with mark A on the cover of the magneto.
  • Page 84 Chapter 3 Engine Section 5 Engine re-assembly Fig.3.5.49 Cylinder head cover left and right The cylinder head left cover needs to be gasketed with a new cylinder head left cover, note that the one with a high boss faces straight down. As shown in Figure 3.5.49. The right cover of the cylinder head needs a new gasket for the right cover of the cylinder head.
  • Page 85 Chapter 3 Engine Section 5 Engine re-assembly Fig.3.5.53 Replace the motor O-ring and install the starter motor. As shown in Figure 3.5.53 Note: crankcase exhaust pipe installation. Check valve clearance Intake and exhaust valve clearance specifications are not the same. Valve clearance (cooler) : Fig.3.5.54 Intake and exhaust: 0.04 -- 0.06mm...

  • Page 86: Chapter 4 Ei System Diagnosis

    Chapter 4 EI system diagnosis Section 1 Maintenance Precautions Fig.4.1.1 Chapter 4 EI system diagnosis Section 1 Maintenance Precautions CONNECTOR / COUPLER When separating the cylindrical plug connection, hold the terminal and do not pull the lead. When the access plug is connected, push it in and firmly connect.
  • Page 87 Chapter 4 EI system diagnosis Section 1 Maintenance Precautions Clamp Fig. 4.1.6 See "Wiring, Cables and Hoses Setup Routes" for proper clamping procedures. 正确 不正确 Bend clamp appropriately as shown. Do not let the main thread hang down when clamping. Do not use wire or other objects instead of belt clips.
  • Page 88 Chapter 4 EI system diagnosis Section 1 Maintenance Precautions Fig. 4.1.11 Battery The battery used on this motorcycle does not require maintenance (e.g. electrolyte position check, distilled water replenishment). No hydrogen is produced during normal charging. Overcharging, however, can produce hydrogen. Therefore, when charging the battery, there must be no fire or spark source (such as short circuit) nearby.
  • Page 89 Chapter 4 EI system diagnosis Section 1 Maintenance Precautions •Before measuring voltage at each terminal, check to Fig. 4.1.16 make sure that battery voltage is 11 V or higher. Terminal voltage check at low battery voltage will lead to erroneous diagnosis. As in Fig. 4.1.16 •Never connect an ohmmeter to the ECU with its coupler connected.
  • Page 90 Chapter 4 EI system diagnosis Section 2 Technical characteristics of EI system Section 2 Technical characteristics of EI system EI SYSTEM’S CONTROL DIAGRAM EI MAP & IAT Sensor (Temperature function) FUEL TANK AIR CLEANER ISC Solenoid TP Sensor FUEL PUMP THROTTLE BODY MAP &...

  • Page 91: Injection Time (Injection Volume)

    Chapter 4 EI system diagnosis Section 2 Technical characteristics of EI system INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.
  • Page 92 Chapter 4 EI system diagnosis Section 2 Technical characteristics of EI system COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from each sensor to compensate for fuel injection time (volume). DESCRIPTION SIGNAL WATER COOLANT TEMPERATURE When engine temperature is low, injection time (volume) is increased.
  • Page 93 Chapter 4 EI system diagnosis Section 2 Technical characteristics of EI system EI SYSTEM PARTS LOCATION ①Speedometer ②Fuel injector ③TP-TMAP SENSOR ④CKP SENSOR ⑤GP switch ⑥CLT sensor ⑦ISC solenoid ⑧Regulator 4—8...
  • Page 94 Chapter 4 EI system diagnosis Section 2 Technical characteristics of EI system ⑨Oxygen sensor ⑩Fuel pump relay 4—9...

  • Page 95: Chapter 4 Ei System Diagnosis Section 3 Self-Diagnosis Funtion

    Chapter 4 EI system diagnosis Section 3 Self-diagnosis funtion 第六 章 EI 诊断 系统 第八 节 故障 代码及 故障 信息 Section 3 SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECU. The user can only be notified by the engine warning lamp “ ”...
  • Page 96 Chapter 4 EI system diagnosis Section 3 Self-diagnosis funtion 第六 章 EI 诊断 系统 第八 节 故障 代码及 故障 信息 For cylinder O₂S heater Circuit Low Voltage P0032 O₂S heater Circuit Low Voltage For cylinder P0107 IAP&TS(Pressure function) Circuit Low Voltage or Open P0108 IAP&TS(Pressure function) Circuit High Voltage P0112...
  • Page 97 Chapter 4 EI system diagnosis Section 3 Self-diagnosis funtion 第六 章 EI 诊断 系统 第八 节 故障 代码及 故障 信息 Blinking CODE CODE MALFUNCTION PART REMARKS P0131 TPS Circuit High Voltage TPS Circuit High Voltage P0132 O2SCircuitHighVoltage O2SCircuitHighVoltage P0171 Injection Fuel Shortage Injection Fuel Shortage P0172 Injection Fuel Excess...
  • Page 98 Chapter 4 EI system diagnosis Section 3 Self-diagnosis funtion 第六 章 EI 诊断 系统 第八 节 故障 代码及 故障 信息 Blinking CODE CODE MALFUNCTION PART REMARKS P0500 Speed Sensor Malfunction P0505 ISC Error P0562 Battery Voltage Low P0563 Battery Voltage High P0601 Ecu Fault P0650...

  • Page 99: Section 4 Ei System Troubleshooting

    Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING Section 4 EI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
  • Page 100 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING MOTORCYCLE / ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition 口 Fair 口 Cloudy 口 Rain 口 Snow 口 Always 口 Other 口 Hot 口 Warm 口 Cool 口 Cold( °F/ °C) 口...

  • Page 101: Self-Diagnostic Procedures

    Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING SELF-DIAGNOSTIC PROCEDURES Don’t disconnect couplers from ECU, battery cable from battery, ECU ground wire harness from engine or main fuse before confirming malfunction code (self-diagnostic trouble code) stored in memory. To check malfunction code, read SELF-DIAGNOSIS FUNCTION carefully to have good understanding as to how to use it.

  • Page 102: Malfunctioncode And Defective Condition

    Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING MALFUNCTIONCODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running, if oxygen sensor heater signal open or is happenedthegroundshortfaultfor1secondby10timesin12 Low Voltage times test cycle,thecodeP0031isindicated. P0031 Oxygen sensor, lead wire / coupler connection.
  • Page 103 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR Vehicle soak time ＞ 240min，engine is running, during the period of the accumulated air mass is more than 2000g, if the P0111 Stuck IAT is lower than 2 ℃, P0111 is indicated.
  • Page 104 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running, the oxygen sensor signal is inputted in ECU since then 300sec. In this case ,the sensor voltage should be the following. 30mV P0131 Low Voltage ≤Sensor output voltage...
  • Page 105 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING DETECTED FAILURE CONDITION MALFUNCTION DETECTED CODE CHECK FOR ITEM After engine running, if the magneto rotor tooth’s error is happenedcontinuouslyby10timesin100times test cycle,the code P0336 is indicated. Noisy P0336 Signal CKP Sensor wiring and mechanical parts.(CKP Sensor lead wire coupler connection) After engine running, if the CKP Sensor signal does not reach ECU for more than 0.5 sec., the code P0335 is indicated.
  • Page 106 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING DETECTED FAILURE CONDITION MALFUNCTIO DETECTED N CODE CHECK FOR ITEM When ML on The ECU will check malfunction code, if there’s ECU error the code P0601 is indicated. The fuel injection will be cut off ECU Fault P0601 Accordingly...
  • Page 107 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING “P0031”, or “P0032” OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION & “0131”, or “0132” OXYGEN SENSOR CIRCUIT MALFUNCTION ● DETECTED CONDITION POSSIBLE CAUSE ● Oxygen sensor, Oxygen sensor heater circuit open or short. To read the flash code, with the EFI diagnostic ●...
  • Page 108 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING ▣ INSPECTION 1) The connectors of oxygen sensor is located under the fuel tank, Turn the ignition switch to the “OFF” position. 2) Check the Oxygen sensor coupler for loose or poor contacts.
  • Page 109 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING “ P0107” or “P0108 MAP & IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● Clogged vacuum passage between throttle body ☞ To read the flash code, with the EFI diagnostic And MAP &...
  • Page 110 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING Is the input voltage OK? Go to Step 2. ● Loose or poor contacts on the ECU coupler. ● Open or short circuit in the O/B wire or G/Bl wire. ◈...
  • Page 111 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING “P0112” or “P0113” MAP & IAT Sensor CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION ● MAP & IAT Sensor circuit open or short. ● MAP & IAT Sensor malfunction. ☞ To read the flash code, with the EFI diagnostic ●...
  • Page 112 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING TP-TMAP (Temperature function) Sensor resistance Intake Air Temp. Resistance ㏀ -20 ℃ (-40 ℉ ) Approx 115.993 ㏀ -0 ℃ (32 ℉ ) Approx 35.629 ㏀ 20 ℃ (68 ℉ ) Approx 12.688 ㏀...
  • Page 113 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING “P0117” or “P0118” CLT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● CLT sensor circuit open or short. ● CLT sensor malfunction. ☞ To read the flash code, with the EFI diagnostic ●...
  • Page 114 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING CLT sensor resistance Engine Coolant Resistance (To ECU) Temp. ㏀ -40 ℃ (-40 ℉ ) Approx. 452.252 ㏀ 0 ℃ (32 ℉ ) Approx.35.629 ㏀ 15 ℃ (59 ℉ ) Approx.
  • Page 115 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING “P0122” or “P0123” TP Sensor（TPS）CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● TP Sensor circuit open or short. ● TP Sensor malfunction. ☞ To read the flash code, with the EFI diagnostic ●...
  • Page 116 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING ◈ Step 2 Turn the ignition switch to the “OFF” position. Disconnect the TP sensor coupler. Check the continuity between ○ A (Gr/Bl) and ground. ∞ Ω TP sensor continuity (Infinity) Ground) Tester knob indication : Resistance (㏀)

  • Page 117: Fuel Injector

    Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING “P0261”or “P0262” FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● Injector circuit open or short. ● Injector malfunction. ☞ To read the flash code, with the EFI diagnostic ● ECU malfunction. instrument ▣...
  • Page 118 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING ◈ Step 2 Turn the ignition switch to the “ON” position. Measure the injector voltage between B/G wire and ground. Battery voltage Injector voltage ⊕ ⊖ B/G- Ground, Tester knob indication: Voltage(—) NOTE Injector voltage can be detected only 3 seconds after ignition switch is turned “ON”...
  • Page 119 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING “P0231” or “P0232” FUEL PUMP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● Fuel pump relay circuit open or short. ● Fuel pump relay malfunction. ☞ To read the flash code, with the EFI diagnostic ●...
  • Page 120 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING “P0336” or “P0337” , “P1693”or“P1694” CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● Metal particles or foreign materiel being attached on the CKP and rotor tip. ☞ To read the flash code, with the EFI diagnostic ●...
  • Page 121 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING “P0505” ISC SOLENOID RANGE ABNORMAL DETECTED CONDITION POSSIBLE CAUSE ● ISC solenoid malfunction. ☞ To read the flash code, with the EFI diagnostic ● ISC solenoid’s step is out of the specified range. instrument ●...
  • Page 122 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING “P0562” or “P0563” BATTERY VOLTAGE MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● Battery voltage circuit open and short. ● Battery malfunction. ☞ To read the flash code, with the EFI diagnostic ●...
  • Page 123 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING “P0650” ENGINE WARNING LAMP CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION ● engine warming lamp circuit open and short. ● engine warning lamp malfunction. ☞ To read the flash code, with the EFI diagnostic ●...
  • Page 124 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING “P0850” GP or CLUTCH LEVER SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● GP switch circuit open or short. ● GP switch malfunction. ☞ To read the flash code, with the EFI diagnostic ●...
  • Page 125 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING Is OK? ● If wire and connection are OK, intermittent trouble or faulty ECU. ● Recheck each terminal and wire harness for open circuit and poor connection. Replace the GP switch or Clutch lever switch with a new one.
  • Page 126 Chapter 4 EI system diagnosis Section 4 EI SYSTEM TROUBLESHOOTING SENSORS ⊙ CKP INSPECTION The CKP is installed in the magneto cover. ⊙CKP REMOVAL AND INSTALLATION Remove the magneto cover. • Install the magneto cover in the reverse order of •...

  • Page 127: Chapter 5 Fuel And Lubrication System

    Chapter 5 Fuel System and Iubrication System Section 1 Fuel System Chapter 5 Fuel System and lubrication system Section1 Fuel System Gasoline must be handed carefully in an area well ventilated and away from fire or sparks. REMOVAL AND DISASSEMBLY Gasoline is very explosive.
  • Page 128 Chapter 5 Fuel System and Iubrication System Section 1 Fuel System Remove the fuel tank mounting bolts②. Disconnect the high-pressure tubing ③ Disconnect the fuel sensor connector ④and fuel pump wire connector ⑤ Disconnect tank vent line. Remove the fuel tank. As gasoline leakage may occur in this operation, keep away from fire and sparks.

  • Page 129: Reassembly And Installation

    Chapter 5 Fuel System and Iubrication System Section 1 Fuel System Remove the fuel pump mounting nuts. Remove the fuel pump. ❖ Gasoline is highly flammable and explosive. ❖ Keep heat, spark and flame away. REASSEMBLY AND INSTALLATION Reassembly and installation the fuel tank in the reverse order of removal and disassembly.

  • Page 130: Fuel Pump Relay Inspection

    Chapter 5 Fuel System and Iubrication System Section 1 Fuel System Fuel pressure of Approx. 3.46 ~ 3.67kgf/cm fuel pump 340 ~ 360kPa, 49.31 ~ 52.21 psi) If the fuel pressure is lower than the specification, inspect the following items : Fuel hose leakage Clogged fuel filter Pressure regulator...

  • Page 131: Fuel Mesh Filter Inspection And Cleaning

    Chapter 5 Fuel System and Iubrication System Section 1 Fuel System FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compressed air.

  • Page 132: Section2 Throttle Body

    Chapter 5 Fuel System and Iubrication System Section 2 Throotle body Section2 Throttle Body 4—6...
  • Page 133 Chapter 5 Fuel System and Iubrication System Section 2 Throotle body REMOVAL Remove the fuel tank. Disconnect the fuel hoses. Remove the all couplers connected to the throttle body. Loosen the throttle body clamp screws. Disconnect the throttle cables from their drum. Remove the bolts (2) on the left and right sides connecting throttle...

  • Page 134: Installation

    Chapter 5 Fuel System and Iubrication System Section 2 Throotle body Do not use wire to clean passageways. Wire can damage passageways. If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip-type cleaning solution and allow them to soak.

  • Page 135: Section 3 Lubrication System

    Chapter 5 Fuel System and Iubrication System Section 3 Lubrication system Section 3 Lubrication system Oil pressure Chapter ii Regular Maintenance Chapter IV Oil saving pressure Inspection Oil filter Chapter Periodic Maintenance Section Maintenance and Adjustment Procedures Oil filter When replacing the oil, check whether the oil filter is broken or damaged and be sure to clean the oil filter regularly 4—9...
  • Page 136 Chapter 5 Fuel System and Iubrication System Section 3 Lubrication system Engine lubrication system table 连 杆小 头 Connecting rod small head CAM shaft neck 凸 轮轴 颈 Cylinder wall 气 缸壁 CAM chain CAM surface 凸轮 面 凸轮链 条 Connecting rod head bearing 连...

  • Page 137: Chapter 6 Vehicle Body

    Chapter 6 Vehicle Body Section 1 Exterior Parts Chapter 6 Vehicle Body Section 1 Exterior Parts Figure6.1.1 DISASSEMBLE FRONT FENDER With the bolts removed, remove the front fender As shown in Figure6.1.1 SEAT Open the saddle switch lock and remove the saddle ①. Figure6.1.2 As shown in FigureAs in Fig.6.1.2 COVER SIDE LH...

  • Page 138: Rear Center Cover

    Chapter 6 Vehicle Body Section 1 Exterior Parts Figure6.1.5 REAR CENTER COVER Remove the mounting screws on the left and right sides. As shown in Figure6.1.5 Figure6.1.6 Remove the six mounting screws on the left and right. Remove the rear cover and center cover of the Frame As shown in Figure6.1.6 REAR FENDER Figure6.1.7...

  • Page 139: Chapter 6 Vehicle Body Section 2 Front Wheel

    Chapter 6 Vehicle Body Section 2 Front Wheel Section 2 Front Wheel Fig.6.2.1 6. The speedometer 1. Front tire (90/90-17) 7. Front axle (including nuts) 2. Front wheel inner tube (90/90-17) 8. Tire pads 3. Front rim combination 2.5-17 9. Axle rubber cap 4.

  • Page 140: Inspection And Disassembly

    Chapter 6 Vehicle Body Section 2 Front Wheel Figure6.2.3 Remove the bushing③ and oil seal ④. As in Fig. 6.2.3 Figure6.2.4 Remove the brake disc. As in Fig. 6.2.4. Tools: hexagonal wrench Figure6.2.5 Inspection and disassembly Speedometer drive box Turn the speedometer gear to check whether the gear and the speedometer pinion run smoothly.
  • Page 141 Chapter 6 Vehicle Body Section 2 Front Wheel Fig.6.2.8 Note: Removed bearings should be replaced with new ones. Front axle Use the dial meter to detect the front axle with unbiased pendulum, if the pendulum exceeds the limit, should be replaced. As Fig.
  • Page 142 Chapter 6 Vehicle Body Section 2 Front Wheel Note: First install the left wheel bearing, then install the right wheel bearing. Bearing seal cover must face outwards. As in Fig.6.2.13. Fig.6.2.14 The brake disc Make sure the brake disc is clean and free of grease. Apply thread sealant to brake disc bolts and tighten according to specified torque.

  • Page 143: Chapter 6 Vehicle Body Section 3 Front/Rear Brakes

    Chapter 6 Vehicle Body Section 3 Front/Rear brakes Section 3 Front/Rear brakes 1. Brake pedal combination 2. Brake spring 8. Rear disc brake assembly 3. Brake pedal return spring plate (rocker arm 9. Rear brake pump spring plate) 10. Rear brake tubing 4.
  • Page 144 Chapter 6 Vehicle Body Section 3 Front/Rear brakes Fig.6.3.1 Replacement of friction plate Loosen the front brake friction disc mounting bolt ①and rear brake friction disc mounting bolt ⑥ Remove the front caliper mounting bolts ② and rear caliper mounting bolts ⑤...
  • Page 145 Chapter 6 Vehicle Body Section 3 Front/Rear brakes Fig.6.3.5 Remove the brake caliper holder④. Remove the spring ⑤. As in Fig.6.3.5 和 6.3.6. Place a rag on the brake caliper piston to prevent it from popping out suddenly. The piston is then forced out Fig.6.3.6 with compressed air.
  • Page 146 Chapter 6 Vehicle Body Section 3 Front/Rear brakes Fig.6.3.9 Remove the rear brake caliper friction plate ④ and the fixing screw ⑤. Remove the spring sheet ⑥. Use the air gun to push the caliper piston out. Warning: Place a piece of cloth on the piston to prevent it from popping out and flying, and keep your hand off the piston.
  • Page 147 Chapter 6 Vehicle Body Section 3 Front/Rear brakes Fig.6.3.14 Install piston ring as shown. As in Fig.6.3.14. Apply grease to the brake fixing shaft. As in Fig.6.3.15 Fig.6.3.15 According to the specified torque, tighten the front and rear brake installation bolts ③ , ⑤ and the friction plate installation bolts ②, ⑥.
  • Page 148 Chapter 6 Vehicle Body Section 3 Front/Rear brakes Use a dial meter to measure the skewness. If the Fig.6.3.19 deflection exceeds the service limit, the brake disc should be replaced. As Fig. 6.3.19. Tool used: Micrometer (0-100 mm) Magnetic rack Limit of use: Brake disc offset: 0.30mm If the measured value exceeds the service limit,...
  • Page 149 Chapter 6 Vehicle Body Section 3 Front/Rear brakes Fig.6.3.24 Remove the oil storage box cover. As Fig. 6.3.24. Drain brake fluid. Fig.6.3.25 Remove the dust cover ⑤. As Fig. 6.3.25. Use special tools to remove the open spring ring. Tools used; Spring clamp pliers Fig.6.3.26 Remove piston/auxiliary pump ①...
  • Page 150 Chapter 6 Vehicle Body Section 3 Front/Rear brakes Fig.6.3.28 Note: Before assembly, clean master cylinder parts with new brake fluid. After cleaning cylinder parts, do not wipe the brake fluid above. When cleaning cylinder parts, special brake fluid should be used. Never use cleaning solutions or cleaners such as gasoline and kerosene.

  • Page 151: Chapter 6 Vehicle Body Section 4 Front Shock Absorbers

    Chapter 6 Vehicle Body Section 4 Front shock absorbers Section 4 Front shock absorbers Chart 6.4.1 1. Invert the right front shock absorber 2. Invert the left front shock absorber 3. Side reflector Disassembly and decomposition Safely and firmly supports the motorcycle. Take off the front wheel ①.
  • Page 152 Chapter 6 Vehicle Body Section 4 Front shock absorbers Fig.6.4.3 After loosening the upper and lower clamping bolts (1) and (2) of the front shock absorber, remove the front shock absorber. Note:Gently loosen the front fork fastening screw plug ③ for later disassembly and assembly. As in Fig.6.4.3.
  • Page 153 Chapter 6 Vehicle Body Section 4 Front shock absorbers Separate the inner tube from the outer tube..As in Fig.6.4.8 Fig.6.4.8 Remove the following parts: oil seal ③, sliding metal ring ④, oil lock piece ⑤ As in Fig.6.4.9 Fig.6.4.9 Front fork spring Measurement of the free length of the front fork spring, if shorter than the limit of use, should be replaced with a new.
  • Page 154 Chapter 6 Vehicle Body Section 4 Front shock absorbers Fig.6.4.12 On the inner tube, assemble the following parts: As in Fig.6.4.12 ① Dust-proof seal ② Oil seal plug ring ③ Oil seal ① ② ④ Oil seal retainer ③ ⑤ Sliding metal ④...
  • Page 155 Chapter 6 Vehicle Body Section 4 Front shock absorbers Fig.6.4.17 Warning: Replace with a new gasket. The front fork oil When the inner tube is in a fully compressed position, pour the indicated amount of front fork oil into the inner tube, then perform several strokes to drain the air out of the inner tube.
  • Page 156 Chapter 6 Vehicle Body Section 4 Front shock absorbers Tighten the clamping bolt ① under the front fork and Fig.6.4.22 the front fork cover bolt ③ according to the specified torque. Tighten the upper front fork clamping bolt ② according to the specified torque. As Fig.

  • Page 157: Chapter 6 Vehicle Body Section 5 Steering Lever

    Chapter 6 Vehicle Body Section 5 Steering lever Section 5 Steering lever Structure (Figure 6.5.1) 1. Direction (cross-country) 2. Top press the block 3. Hex flange bolt M8*45 4. Instrument transfer bracket 5. Left handle glue 6. Right hand glue assy 7.
  • Page 158 Chapter 6 Vehicle Body Section 5 Steering lever ①. Fig.6.5.3 Remove left handle counterweight. (This is only for vehicles equipped with counterweights) Remove the two screws fastening the left hand handle switch and remove the left hand handle switch combination (2).
  • Page 159 Chapter 6 Vehicle Body Section 5 Steering lever Fig.6.5.5 Disassemble the ignition switch latch. As Fig. 6.5.13. Remove ignition switch lock retaining bolt. As Fig. 6.5.5 Remove ignition switch lock. Remove large cover nut ③ and large washer. As Fig. Fig.6.5.6 6.5.6 Gently tap the upper tray (4) and remove it.
  • Page 160 Chapter 6 Vehicle Body Section 5 Steering lever Fig.6.5.10 Remove steering rod nut ④ with special tool. As Fig. 6.5.10 Tools used: steering rod nut wrench Pull out the steering rod lower bracket assembly. Note:Hold the lower bracket of the steering bar to prevent it from falling suddenly.
  • Page 161 Chapter 6 Vehicle Body Section 5 Steering lever Reassemble and install Fig.6.5.15 Reassemble and install steering rods in the reverse order of disassembly and disassembly. In doing so, the following points should be noted: Use special tools to advance the upper and lower bearing seat rings.
  • Page 162 Chapter 6 Vehicle Body Section 5 Steering lever Install the speedometer. Connect the flexible axis of Fig.6.5.20 the speedometer. Make sure the speedometer connector is properly and securely connected to the connector on the main bundle. Then use the cable tie to tighten the waterproof sleeve on the main bundle.

  • Page 163: Chapter 6 Vehicle Body Section 6 Rear Wheel

    Chapter 6 Vehicle Body Section 6 Rear wheel Section 6 Rear wheel The rear wheel structure Figure 6.6.1 8. Right axle sleeve of rear wheel 1. Rear tire 9. After the axles 2. Rear tire inner tube Chain 10. 3. Rear wheel left bushing 11.

  • Page 164: Chapter 6 Vehicle Body Section 6 Rear Wheel Fig.6.6

    Chapter 6 Vehicle Body Section 6 Rear wheel Fig.6.6.1 Disassembly Raise the rear wheel off the ground with a jack or block.Lift the rear wheel off the ground with a jack or tackle Remove chain cover fixing bolts and chain cover As in Fig.6.6.1 Fig.6.6.2...
  • Page 165 Chapter 6 Vehicle Body Section 6 Rear wheel Fig.6.6.6 Remove the rear brake caliper Remove rear disc brake①. As in Fig.6.6.6. Fig.6.6.7 Remove large sprocket mounting nut.As in Fig.6.6.7. Fig.6.6.8 Remove the rear wheel left compartment ②, remove the large sprocket ③. As in Fig.6.6.8.
  • Page 166 Chapter 6 Vehicle Body Section 6 Rear wheel Remove the bearings ①② and the middle bushing ③ on the left and right sides of the hub with special tools. Fig.6.6.10 As Fig. 6.6.10. Tool used: hub bearing remover Note: the removed bearing should be replaced. After the sprocket Check whether sprocket teeth are worn.
  • Page 167 Chapter 6 Vehicle Body Section 6 Rear wheel Note:First assemble the right bearing of the wheel, then the left bearing of the wheel.The seal cap on the bearing must be outward. Fig 6.6.14 left left right right After the sprocket Fig.6.6.15 Tighten rear sprocket nut to specified torque.

  • Page 168: Chapter 6 Vehicle Body Section 7 Rear Suspension System

    Chapter 6 Vehicle Body Section 7 Rear suspension system Section 7 Rear suspension system Structure Fig.6.7.1 1. After the fork 14. Chain box 27. Rocker shaft bolt 2. Rear flat fork shaft 15. Bolt M6 * 12 28. The washer 3.
  • Page 169 Chapter 6 Vehicle Body Section 7 Rear suspension system Fig.6.71 Remove the Raise the rear wheel off the ground with a jack or block. Lift the rear wheel off the ground with a jack or tackle Remove chain cover fixing bolts and chain cover. As Fig. 6.7.1.
  • Page 170 Chapter 6 Vehicle Body Section 7 Rear suspension system Remove the rear shock absorber retaining skin②. As in Fig.6.7.7 Fig.6.7.7. Remove the bolts under the rear shock absorber ⑥ , Fig.6.7.8 remove the rocker arm bolts after shock absorption ⑦ . Separate the rear shock absorber and the rear rocker arm.
  • Page 171 Chapter 6 Vehicle Body Section 7 Rear suspension system Fig.6.7.12 Inspection and disassembly Check the dust cover, needle roller bearings, lining sleeve oil seal, back flat fork shaft lining sleeve is damaged. If defective, replace with a new one. As in Fig.6.7.12. Rocker arm needle roller bearing Insert the ring into the needle roller bearing and move it Fig.6.7.13...
  • Page 172 Chapter 6 Vehicle Body Section 7 Rear suspension system Fig.6.7.17 After the shock absorber Remove the fixing bolt (1) from the rear shock absorber, and remove the rear shock absorber (2). As Fig. 6.7.17 Check air nozzle, needle roller bearings, bolts and replace if necessary.
  • Page 173 Chapter 6 Vehicle Body Section 7 Rear suspension system Fig.6.7.21 Install the rear rocker arm, tighten the rocker shaft nut according to the specified torque. Rocker shaft nut: 72 Newton · m (7.2 kg · m) As Fig. 6.7.21. After assembling the shock absorber, tighten the upper and lower mounting bolts and nuts ①, ⑥...

  • Page 174: Chapter 7 Electrical System

    Chapter 7 Electrical System Section 1 Location of electrical components Chapter 7 Electrical System Section 1 Location of electrical components 1. The headlamps 2. Front turn signal (L & R) 3. Clutch switch 4. Electric spray relay 5. Oil pump relay 6.
  • Page 175 Chapter 7 Electrical System Section 1 Location of electrical components 15. The flasher 16. Front brake switch assembly 17 18. Rear brake switch assembly 19. Starting motor 20. Oxygen sensor Be sure not to misassemble the position of battery plus & minus terminal. 7 —...

  • Page 176: Chapter 7 Electrical System Section 2 Ignition System

    Chapter 7 Electrical System Section 2 Ignition system Section 2 Ignition system INSPECTION CKP Sensor MAGNETO Using the pocket tester, measure the resistance between the lead wires in the following table. If the resistance is not within the specified value, replace the stator coil, with a new one.

  • Page 177: Ignition Coil Primary Peak Voltage Inspection

    Chapter 7 Electrical System Section 2 Ignition system IGNITION COIL PRIMARY PEAK VOLTAGE INSPECTION Remove the frame cover and fuel tank. Cylinder Disconnect the spark plug caps. With the spark plug cap connected, place a new spark plug on the engine to ground it. N O T E ❖Check that all the couplers are connected.
  • Page 178 Chapter 7 Electrical System Section 2 Ignition system While testing, do not touch the tester probes and spark plugs to prevent receiving an electric shock. If the peak voltage is lower than the specified values, inspect the ignition coil. IGNITION COIL RESISTANCE INSPECTION Remove the fuel tank.

  • Page 179: Spark Plug Gap

    Chapter 7 Electrical System Section 2 Ignition system SPARK PLUG CARBON DEPOSITS Check to see if there are carbon deposits on the spark plug. If carbon is deposited, remove it with a spark plug cleaner machine or carefully use a tool with a pointed end.
  • Page 180 Chapter 7 Electrical System Section 2 Ignition system PARK PLUG INSTALLATION Before tightening the spark plug to the specified torque, carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage the aluminum threads. First, finger tighten the spark plug, and then tighten them to the specified torque.

  • Page 181: Section 3 Charging System

    Chapter 7 Electrical System Section 3 Charging System Section 3 Charging System INSPECTION CHARGING OUTPUT CHECK Start the engine and keep it running at 5,000 rpm. Using the pocket tester, measure the DC voltage between the battery terminal If the voltage is not within the specified value, check the magneto no-load performance and regulator / rectifier.
  • Page 182 Chapter 7 Electrical System Section 3 Charging System MAGNETO NO-LOAD PERFORMANCE Disconnect the three lead wires from the magneto terminal. Start the engine and keep it running at 5,000 rpm. Using the pocket tester, measure the AC voltage between the three lead wires. If the voltage is under the specified value, replace the magneto with a new one.

  • Page 183: Section4 Starter System And Side Stand Ignition Interlock System

    Chapter 7 Electrical System Section4 Starter System and Side stand Ignition Interlock system Section4 Starter System and Side stand Ignition Interlock system STARTER SYSTEM DE SCRIPTION The starter system consists of the following components : the starter motor, starter relay, clutch lever switch, side stand switch, GP switch, starter switch, engine stop switch, ignition switch and battery.
  • Page 184 Chapter 7 Electrical System Section4 Starter System and Side stand Ignition Interlock system TRANSMISSION : Neutral –“ON” Side stand - Down Clutch lever - Squeeze TRANSMISSION : Neutral -“OFF” Side stand - Up Clutch lever - Squeeze X-RIDE 50CC are equipped with the side stand ignition interlock system. Fuel injector is controlled by ECU depends on the condition of side stand switch.

  • Page 185: Starter Motor Removal And Disassembly

    Chapter 7 Electrical System Section4 Starter System and Side stand Ignition Interlock system STARTER MOTOR REMOVAL AND DISASSEMBLY Disconnect the starter motor lead wire ② With loosen the bolt ①, remove the starter motor. Disassemble the starter motor. STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, crack or smoothness in the brush holder.

  • Page 186: Starter Motor Reassembly

    Chapter 7 Electrical System Section4 Starter System and Side stand Ignition Interlock system STARTER MOTOR REASSEMBLY Reassembly the starter motor. Pay attention to the following points : Reassembly the starter motor as shown in the illustration. 7 — 13...
  • Page 187 Chapter 7 Electrical System Section4 Starter System and Side stand Ignition Interlock system Align the mark ① on the housing with the line ② on the housing end. Apply GREASE to the O-ring ③ and remount the starter motor. 7 — 14...

  • Page 188: Chapter 7 Electrical System Section 5 Switches

    Chapter 7 Electrical System Section 5 Switches Section 5 Switches Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch assemblies with new ones. Pocket tester :09900 - 25002 ENGINE STOP IGNITION SWITCH Br/W DIMMER STARTER...

  • Page 189: Chapter 7 Electrical System Section 6 Lamp And Meter

    Chapter 7 Electrical System Section 6 Lamp and meter Section 6 Lamp and Meter Headlamp/Turn signal lamp/Break lamp Fig. 7.6.1 Fig. 7.6.2 Remove the fixing hook of the front headlight cover and remove the front headlight cover. As in Fig. 7.6.2 Disconnect the connecting wire of the front headlight assembly.
  • Page 190 Chapter 7 Electrical System Section 6 Lamp and meter Fig. 7.6.4 Remove the two mounting screws of the headlamp. As in Fig. 7.6.4 Fig. 7.6.5 Remove the headlamp. As in Fig. 7.6.5 Disconnect the connecting wire of the front left and Fig.
  • Page 191 Chapter 7 Electrical System Section 6 Lamp and meter Fig. 7.6.7 Disconnect the connecting wire of break lamp. As in Fig. 7.6.7 Fig. 7.6.8 Remove the two fixing nuts of the tail lamp and remove the break lamp, As in Fig. 7.6.8 Fig.

  • Page 192: Combination Meter

    Chapter 7 Electrical System Section 6 Lamp and meter COMBINATION METER Remove the combination meter. Disassemble the combination meter as shown in the illustration. As in Fig. INSPECTION Using the pocket tester, check the continuity between lead wires in the following illustration. If the continuity measured incorrect, replace the respective part.

  • Page 193: Recharging Operation

    第七章 电气系统 第七节 电池 Setion7 Battery X-RIDE 50CC . Use only the genuine battery on CAUTION OF BATTERY TREATMENT The battery needs attention generally as it occur flammability gas. If you don’t follow the instruction in the below, there may be an explosion and severe accident. Therefore, please pay attention to the following points.

  • Page 194: Battery Installation

    第七章 电气系统 第七节 电池 After recharging, wait for more than 30 minutes and check the battery voltage with a pocket tester. If the battery voltage is less than the 12.5 V, recharge the battery again. If battery voltage is still less than 12.5 V, after recharging, replace the battery with a new one.

  • Page 195: Chapter 8 Information Service

    Section1 Troubleshooting Chapter 8 Information service Section1 Troubleshooting MALFUNCTION CODE AND DEFECTIVECONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT noEr After engine running,if oxygen sensor heater signal open or is happened the ground short fault for 1 second by 10 times in P0031 12 times test cycle,the code 0031is indicated.
  • Page 196 Section1 Troubleshooting MALFUNCTION DETECTED ITEM DETECTED FAILURE CONDITION CODE CHECK FOR The sensor should produce following voltage. 0.2 V≤Sensor output voltage Low Voltage Without the above range for7.8sec.and more,0122is indicated. or Open P0122 TP-TMAP(TPS) Throttle position sensor, lead wire / coupler connection. Circuit The sensor should produce following voltage.Sensor output voltage ≤4.9 V...
  • Page 197 Section1 Troubleshooting DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CHECK FOR CODE After engine running, if the magneto rotor tooth’s error is happened continuously by10times in 100 times testcycle,the code P0336 is indicated. P0336 Noisy CKP wiring and mechanical parts.(CKP lead wire coupler Signal connection) After engine running, if the CKP signal does not reach ECU for...
  • Page 198 Section1 Troubleshooting DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CHECK FOR CODE After engine running, if “FI” check lamp signal open or is P0650 happened the high / ground short fault for 1 second by 40 Engine warning lamp times in 80 times test cycle, the code P0650 is indicated. Circuit Malfunction “FI”...
  • Page 199 Section1 Troubleshooting ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. Adjust. Tappet clearance out of adjustment Repair or replace. Worn valve guides or poor seating of valves. Mistimed valves. Adjust.
  • Page 200 Section1 Troubleshooting Complaint Symptom and possible causes Remedy 1. Tappet clearance out of adjustment. Adjust. Engine idles Poor seating of valves. Replace or repair. poorly. Defective valve guides. Replace. Worn down camshafts. Replace. Too wide spark plug gaps. Adjust or replace. Defective ignition coils.
  • Page 201 Section1 Troubleshooting Complaint Symptom and possible causes Remedy Noisy engine. Excessive valve chatter Too large tappet clearance. Adjust. Weakened or broken valve springs. Replace. Worn tappet or cam surface. Replace. Worn and burnt camshaft journal. Replace. Noise seems to come from piston Worn down pistons or cylinders.
  • Page 202 Section1 Troubleshooting Remedy Complaint Symptom and possible causes Defective engine internal / electrical parts Engine runs Replace. Weakened valve springs. poorly high Replace. Worn camshafts. speed range. Adjust. Valve timing out of adjustment. Adjust. To on arrow spark plug gaps. Replace ECU.
  • Page 203 Section1 Troubleshooting Complaint Symptom and possible causes Remedy Defective engine internal / electrical parts Engine Adjust. Loss of tappet clearance. lacks Replace. Weakened valve springs. power. Adjust. Valve timing out of adjustment. Replace. Worn piston rings or cylinders. Repair. Poor seating of valves. Clean or replace.
  • Page 204 Section1 Troubleshooting Complaint Symptom and possible causes Remedy Check with inspection Too much engine oil in the engine. Dirty or window, drain out excess oil. Worn piston rings or cylinders. heavy Heavy boring Worn valve guides. exhaust Replace. Cylinder walls cored or scuffed. smoke.
  • Page 205 Section1 Troubleshooting ELECTRICAL Complaint Symptom and possible causes Remedy Defective ignition coils or spark plug caps. Replace. No sparking or poor Defective spark plugs. sparking. Defective CKP. Replace. Defective ECU. Replace. side stand switch Defective Replace. Open-circuited wiring connections. Replace. Check and repair.

  • Page 206: Section 7 Battery

    Section1 Troubleshooting BATTERY Complaint Symptom and possible causes Remedy 1. Battery case is cracked. Replace the battery. “Sulfation”acidic 2.Battery has been left in a run-down Replace battery white powdery condition for a longtime. recharge. substance or spots on surfaces of cell plates.

  • Page 207: Section1 Troubleshooting

    Section1 Troubleshooting CHASSIS Complaint Symptom and possible causes Remedy Steering feels Adjust. Steering stem nut over tightened. too heavy or Worn bearing or race in steering stem. stiff. Distorted steering stem Replace. Not enough pressure in tires. Replace. Adjust. Steering Replace.
  • Page 208 Section1 Troubleshooting BRAKES Complaint Symptom and possible causes Remedy Poor braking Refill to level mark. Not enough brake fluid in the reservoir. (FRONT and Air trapped in brake fluid circuit. Bleed air out. REAR) Pads worn down. Replace. Too much play on brake lever or pedal. Adjust.

  • Page 209: Section 2 Special Tools

    Section 2 Special tools Section 2 Special tools Special tools PartNumber∙PartName∙Description PartNumber∙PartName∙Description Special tools 09900-20101 VernierCaliper 09900-21109 Torque wrench Used to conveniently measure Measure torque of tightening. various dimensions. 09900-20201 09900-21304 V-block Micrometer(0~25mm) Used for precise measurement With using magnetic stand. (00~25mm measure ranges).
  • Page 210 Section 2 Special tools PartNumber∙PartName∙Description PartNumber∙PartName∙Description Special tools Special tools 09910-32812 Crankshaft installer 09913-80112 Bearing installer Used to install the crankshaft in Used to drive bearing in. the crankcase. Used to install the crankshaft in the crankcase. 09910-34510 09915-63310 Piston pin puller Compression gauge adapter Use to remove the piston pin.
  • Page 211 Section 2 Special tools PartNumber∙PartName∙Description PartNumber∙PartName∙Description Special tools Special tools 09921-20200 Bearing 09930-44510 Rotor holder remover(10mm) Used tore move oil seal or Widely used to lock rotary parts bearing. such as a flywheel magneto. 09921-20210 Bearing 09940-10122 Clamp wrench remover(12mm) Used to remove oil seal or A hook wrench to adjust the bearing.

  • Page 212: Section3 Tightening Torque

    Section 3 Tightening torque Section3 Tightening Torque ENGINE N∙m Kg∙m ITEM Cylinder head bolts 1．0 M：8mm 2．7 Cylinder head nut M：6mm 1．0 Camshaft sprocket bolt 1．1 Valve clearance adjustment locking nut 1．4 Rocker shaft bolt 0．9 Chain tensioner adjusting bolts 0．7 Cylinder seat nut 1．0...
  • Page 213 Section 3 Tightening torque CHASSIS N∙m Kg∙m ITEM 2．9 Rear shock absorber fitting bolt or nut 5．0 Rear sprocket nut 7．8 Rear axle nut 7．2 Swing arm pivot nut 1．3 Swingarmpivot shaft nut 4．5 Steering stem nut 6．5 Steering stem head nut 2．3 Front brake disc bolt 1．0...

  • Page 214: Section 4 Service Data

    Section 4 Section 4 Service Data VALVE + GUIDE ITEM STANDARD LIMIT Valve diam. ——— 16.5 ——— Valve clearance (When cold) 0．04—0．06 ——— 0．04—0．06 ——— Valve guide to valve stem clearance 0．010—0．037 ——— 0．030—0．057 ——— Valve stem deflection IN. & EX. ———...

  • Page 215: Conrod + Crankshaft

    Section 4 Camshaft yaw Inside & outside —— CYLINDER + PISTON + PISTON RING Unit:mm ITEM STANDARD LIMIT Compression pressure 1000—1500kpa 800 kpa （10．0—15．0kg/cm2） （8kg/c m2） Piston to cylinder clearance 0．020—0．030 0．120 Cylinder bore 39．000—39．015 39．110 38．975—38．990 Piston diam. 38．880 (Measure at 12mm from the skirt end) Cylinder or cylinder head distortion ———...

  • Page 216: Oil Pump

    Section 4 OIL PUMP Unit:mm ITEM STANDARD NOTE ——— Reduction ratio of oil pump 2．000（30/15） 3000 r/time，more than 10Kpa（0．1kg/cm ——— ） Oil pressure （60℃ ） 30 Kpa less than（0．3kg/cm ） CLUTCH Unit:mm ITEM STANDARD LIMIT Clutch cable play 10—15 ——— Drive plate thickness 2．6 2．9—3．1...
  • Page 217 Section 4 N·m kgf·m ITEM Engine Coolant 5 ~ 8 0．5 0．8 temperature sensor (CLT sensor) Fuel injector mounting bolt 5 ~ 8 0．5 0．8 MAP&IAT sensor 5 ~ 8 0．5 0．8 EI SENSORS ITEM SPECIFICATION MAP sensor input voltage 4.9 ~ 5.1V MAP (Pressure function) sensor output voltage Approx.
  • Page 218 Section 4 THROTTLE BODY ITEM SPECIFICATION NOTE I.D. No. 1114400010000 Bore size Φ20 Idle rpm 1,400 ~ 1,600 rpm Throttle cable play 0.5 ~ 1.0 mm (0.02 ~ 0.04 in) FUEL INJECTOR + FUEL PUMP ITEM SPECIFICATION NOTE 11.4 ~ 12.6 Ω...
  • Page 219 Section 4 ECU / M.RELAY 15 A 15 A 15 A SPARE 15 A 15 A WATTAGE Unit:W ITEM SPECIFICATION Head lamp LED 12V 34.2W/24.3W LED 12V 2.9W Position lamp LED 12V 0.1W License lamp LED 12V 0.4W/0.1W Brake/Tail lamp Turn signal lamp LED 12V 2.2WX4 Speedometer lamp...

  • Page 220: Brake+Wheel

    Section 4 SUSPENSION Unit:mm ITEM STANDARD LIMIT Front fork stroke ——— Front fork spring free length ——— Front fork oil type ISO VIG46, JSK2001 ——— Front fork oil level ——— ——— Front fork oil capacity (each leg) ——— Rear wheel travel ———...
  • Page 221 Section 4 ITEM STANDARD LIMIT Front 200Kpa(29psi) 225Kpa(33psi) Cold inflation tire pressure (Solo riding) ） Rear 225Kpa(33psi) 225Kpa(33psi) Front 225Kpa(33psi) 200Kpa(29psi) Cold inflation tire pressure (Dual riding) 250Kpa(36psi) Rear 225Kpa(33psi) ——— Front Tire tread depth ——— Rear FUEL + OIL ITEM SPECIFICATION NOTE...

  • Page 222: Ignition Coil

    Section 4 Section 5 WIRING AND CABLE ROUTING 1180300018100 - Ignition coil 1260300903200 belt- Injector leads - Cylinder wall temperature sensor leads 1180300018100 - 3-in-1 sensor lead Wire clip - Horn leads 1223904012000 Fuel injector 1181000060000 Horn 1114111001000 Oxygen sensor 1181400061000 flasher 1181300040000...
  • Page 223 Section 4 Rectifier regulating 1114111001300 connector Oxygen sensor 1114111023000 connector High-pressure tubing 1181400042000 Rectifier voltage regulator 1260300903200 - the main beam - Rectifier leads - Oxygen sensor leads 1114111002100 1223904061000 1183200030000 1114200011000 Cylinder wall Idle speed Start up relay temperature sensor controller 1182200021000 1223904031000...
  • Page 224 Section 4 1114111002100 1260300903200 Cylinder wall Belt temperature sensor - Fuel sensor leads - Fuel pump lead sheath Display switch connector Trigger coil connector 1260300903200 belt - the main beam 1182200021000 The main line is tied to 1182200021000 the positive terminal of main line connected to the positive...
  • Page 225 Section 4 Instrument connector Ignition switch connector Speed sensor connector Left handle switch Front left turn si connector gnal connector Right handle switch Front right turn si connector gnal connector 1142200023000 Front disc brake main pump 1182200011000 tubing Ignition switch 1281400044000 1282200050000 The clutch cable...
  • Page 226 Section 4 1042200360000/104220 0370000 Front brake tubing left clamp and right clamp 1260300294200 Mileage line limit clip holder 1182200021000 sheath - Rear left turn si gnal lead - Rear right turn s ignal lead...
  • Page 227 第八章信息服务第六节接线图...
  • Page 228 1nd Ed. Apr. 2022.

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