Mash Seventy Manual
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Mash Seventy Manual

Mash Seventy Manual

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This manual covers the description of New seventy 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 Seventy

  • Page 1 PREFACE PREFACE This manual covers the description of New seventy 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 PetroleumInstitute : LeftHand ATDC : After Top DeadCenter MAP&IAT :Manifold absolute Pressure Sensor Sensor(MAPS) BBDC : Before Bottom Dead Center :Intake Air Temperature Sensor （IATS）...

  • 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 Purple with Black tracer...

  • 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 high lighted 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: Chapter 1 Overview 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 closingrate 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 Fig 1.1.1 The frame (or VIN code) and engine number 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 New seventy 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 New seventy Overall length 1950 mm Overall width 900 mm Overall height 1070 mm Wheelbase 1340 mm Minimum ground clearance 160 mm Turning clearance circle diameter...
  • Page 18 Chapter 1 Overview Section 8 Technical parameters ⊙ CHASSIS ITEM New seventy Front suspension Spring oil damping Rear suspension Spring oil damping Steering angle 45° (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 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: N O T E ： 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 Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

  • Page 22: Section 2 Maintenance And Adjustment

    Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment As in Fig.2.2.4. Section 2 Maintenance and adjustment Adjustment This section describes the service procedure for each section of the periodic maintenance Use a screwdriver and a socket off-set wrench to adjust the gap. VALVE CLEARANCE Loosen the lock nut ⑥.

  • Page 23: Chapter 2 Periodic Maintenance

    Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig 2.2.4 Champion Comment If the standard type spark plug tends to be black when it P-RG6C is wet, it can be replaced with this type of spark plug. Standard type. The normal spark plug is light P-RG7C gray and cotton yellow.

  • Page 24: Air Filter

    Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Note： Air filter If driving in dusty conditions, clean the filter more frequently.Not using a filter element or using a broken filter element will definitely Inspect every 4000 km, replace every 12000km. lead to accelerated engine wear.Ensure that the air filter is always in good condition.The If the air filter is blocked by the dust, the air intake...

  • Page 25: Idling Adjustment

    Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment IDLING ADJUSTMENT Fig 2.2.12 This engine features EFI (electronic fuel injection). Engine idle speed 1500±100 rpm The idle speed is not adjustable. Do not attempt to make any adjustment to the Fig 2.2.13 idle speed as it may permanently damage Throttle clearance...
  • Page 26 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig.2.2.14 As in Fig 2.2.14. Note: If there is noise in the cam transmission chain after adjustment, it indicates that the push rod may be stuck. At this time, the chain tensioner should be removed, and the push rod should be cleaned and lubricated to obtain smooth...

  • Page 27: Engine Oil And Oil Filter

    Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Engine oil and oil filter to the instructions in the engine oil replacement procedure. It should be replaced during the first 1000 As in Fig. 2.2.22 kilometers (1 month) and every 4000 kilometers (20 Engine oil viscosity and grade ：...
  • Page 28 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig 2.2.23 Transmission drive chain In the first 1000 kilometers (5 months) and every 4000 kilometers (20 months) thereafter, inspections should be carried out. Clean and lubricate every 1000 kilometers. Visually inspect the drive chain to see if it has the following damages.
  • Page 29 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Front brake disc Clean and lubricate By observing the limit line ② on the Use the kerosene to clean the chain. brake disc can check the degree of wear As in Fig. 2.2.27. of the brake disc.

  • Page 30: Front Brake Fluid Replacement

    Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Front brake fluid replacement Fig.2.2.31 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 A and insert the other end of the hose...
  • Page 31 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig.2.2.36 Release the open valve C and continue to operate the rear brake pedal until the old brake fluid is fully discharged from the rear brake sub-pump.Close vent valve C and disconnect hose.Then release the valve B and continue to operate the rear brake pedal again until the old brake fluid is fully discharged from the front brake sub-pump.Close...
  • Page 32 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Continuously pressurized rear brake pedal by hand for exhaust; Fig.2.2.41 Keep pressurizing and refueling until the brake is obviously felt, then press the pedal and release the exhaust valve C for exhaust work; Then screw the vent valve, squeeze the brake lever and open the vent valve again (note: pedal downpressure shall not be lifted before the vent screw is tightened during...

  • Page 33: Chapter 2 Periodic Maintenance Fig.2.2

    Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Fig.2.2.40 Braking light switch Regulate the rear braking light switch that the braking light illuminates before the pedal is pressed down and feels pressure. As in Fig.2.2.40 Steering mechanism It should be checked during the Fig.2.2.41 first 1000 km (5 months) and every 4000 km (20 months) thereafter...
  • Page 34 Periodic maintenance Chapter 2 Section 2 Maintenance and adjustment Tire tread condition The use of over worn tires will reduce driving stability cause dangerous situations. especially Fig.2.2.44 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 35: 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 Figure...
  • Page 36 Chapter 2 PERIODIC MAINTENANCE Section 2 Maintenance and adjustment Fig.2.2.49 Fig.2.2.50 Fig.2.2.51 Fig.2.2.52 Fig.2.2.54 Fig.2.2.53 Fig.2.2.56 Fig.2.2.55 Fig.2.2.48 2—18...

  • Page 37: Chapter 2 Periodic Maintenance Section 3 Inspection Of Compression Pressure

    Chapter 2 Periodic maintenance Section 3 Inspection of compression pressure Fig.2.3.1 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 38: Section 4 Inspection Of Oil Pressure

    Periodic maintenance Chapter 2 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. Fig.2.4.1 Oil pressure technical specification Above 0.01MPa When 2000 rpm, in cold state Under 0.03MPa If the oil pressure is lower or higher than the above requirements, the following reasons should be considered:...

  • Page 39: 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 disassemble…………………………………………………………………………………………...

  • Page 40: Chapter 3 Engine 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 Engine disassemble Remove the bracket Remove the saddle Remove the fuel tank Remove the battery cathode line. As in Fig.3.2.1. Drain out the engine oil. Fig.3.2.2 Remove the exhaust pipe bolts.

  • Page 41: Chapter 3 Engine Section 2 Engine Disassemble And Re-Assemble Fig.3.2

    Chapter 3 Engine Section 2 Engine Disassemble and Re-assemble Fig.3.2.6 Make the gasket flattened. ① Remove the engine sprocket nut and gasket. As in Fig.3.2.6 Note： When removing the engine sprocket nut, depress the braking pedal. Fig.3.2.7 ② Remove the engine sprocket .
  • Page 42 Chapter 3 Engine Section 2 Engine Disassemble and Re-assemble Fig.3.2.11 ① Remove the engine ground wire . As in Fig. 3.2.11 ② Remove the spark plug cap ③ Separate the starter motor wire . As in fig. 3.2.12 Fig.3.2.12 ④ Detach the generator connector .
  • Page 43 Chapter 3 Engine Section 2 Engine Disassemble and Re-assemble Use wheeljacks or wooden blocks to support the Fig.3.2.16 motorcycle. Remove the mounting bolts and nuts under lower bracket of the engine.As in Fig.3.2.16 Remove the nut① of rear fork axle and cushion. As in Fig.3.2.17..
  • Page 44 Chapter 3 Engine Section 2 Engine Disassemble and Re-assemble Re-assemble the engine The re-assembly of the engine can be carried out in the reverse order of removal. Assemble the engine mounting bolts and nuts as shown below. Tighten the engine mounting nut to the specified torque. As in Fig.
  • Page 45 Chapter 3 Engine Section 2 Engine Disassemble and Re-assemble Tighten the bolts of the lower connecting plate of the Fig.3.2.22 engine according to the specified torque. As in Fig. 3.2.22. Engine front bracket bolt: 23N.m (2.3Kg.m) Note： Apply a small amount of sealant to the bolt. Fig.3.2.23 Tighten the engine ground wire.
  • Page 46 Chapter 3 Engine Section 2 Engine Disassemble and Re-assemble Install the chain. Fig.3.2.27 Note： The chain buckle should be assembled with the open end in the opposite direction to the running. As in Fig.3.2.27 ① Tighten the engine sprocket nut to the specified torque.

  • Page 47: Chapter 3 Engine Section 3 Engine Dissassembly

    Chapter 3 Engine Section 3 Engine dissassembly Section 3 Engine disassembly Fig.3.3.1 The steps for disassembling the engine are described in order as follows: ① Remove the Connecting sleeve and the Tachometer gear As shown in Figure 3.3.1. Fig.3.3.2 Remove the observation hole plug① and the magneto cap ②,as in Fig.3.3.2 Fig.3.3.3 Align the A line on the magneto rotor with the B...
  • Page 48 Chapter 3 Engine Section 3 Engine dissassembly Remove camshaft end plug① Fig.3.3.6 As in Fig.3.3.6 Level the clamping plate and remove the camshaft sprocket bolts Remove the C-ring②.. Fig.3.3.7 As in Fig.3.3.7 Note： Do not let the C-ring fall into the crankcase.
  • Page 49 Chapter 3 Engine Section 3 Engine dissassembly ① Remove cylinder head gasket Fig.3.3.11 ② Remove the CAM chain guide plate Remove the nut M6 and remove the cylinder.As in Fig.3.3.11 Note: If the cylinder head cannot be removed, use a plastic hammer to gently knock the part without heat sink.
  • Page 50 Chapter 3 Engine Section 3 Engine dissassembly Remove starting motor Fig.3.3.16 As in Fig.3.3.16 Remove the oil filter. As in Fig.3.3.17 Fig.3.3.17 Remove the clutch cover①.. As in Fig.3.3.18 Fig.3.3.18 Clamp the magneto rotor fixing bolts. Remove the clutch spring plate assembly bolt diagonally and then remove the clutch spring and clutch spring plate.
  • Page 51 Chapter 3 Engine Section 3 Engine dissassembly Remove the washer ③, bearing ④ ② , push rod Fig.3.3.21 ⑤ push rod As in Fig.3.3.21 Fig.3.3.22 Leveling clutch spline sleeve safety washer. As in Fig.3.3.22 Fig.3.3.23 Use a special tool to remove the clutch spline sleeve nut.①...

  • Page 52: Chapter 3 Engine Section 3 Engine Dissassembly Fig.3.3

    Chapter 3 Engine Section 3 Engine dissassembly Fig.3.3.26 Remove the shift shaft⑧.. As in Fig.3.3.26 Fig.3.3.27 Remove the elastic ring①and cushion②.. As in Fig.3.3.27 Remove countersunk head screws and CAM baffle ③ ⑤ and CAM retainer Fig.3.3.28 Dismount shift CAM driven tooth block combination ④...
  • Page 53 Chapter 3 Engine Section 3 Engine dissassembly Fig.3.3.31 Use a special tool to remove the primary driving gear/oil pump driving gear nut M6⑨.. As in Fig.3.3.31 Tools: rotor support⑩ Note: The nut M6 is left thread. Remove the cushion Remove the driving gear of oil pump①and primary ②...
  • Page 54 Chapter 3 Engine Section 3 Engine dissassembly Fig.3.3.36 Remove the magneto rotor key（11） Remove the starting slave wheels.⑩.. As in Fig.3.3.36 Fig.3.3.37 Remove the valve chain①.. As in Fig.3.3.37 Use special tools to remove sprocket nut, sprocket Fig.3.3.38 baffle and sprocket. Tools: sprocket holder②...
  • Page 55 Chapter 3 Engine Section 3 Engine dissassembly Fig.3.3.41 Remove the M14 bolt⑩，Remove the idle CAM top pin and spring. As in Fig.3.3.41 Fig.3.3.42 Remove crankcase bolts. As in Fig.3.3.42 Use special tools to separate left and right crankcases. Tools: crankcase separator① Fig.3.3.43 As in Fig.3.3.43 Note:...
  • Page 56 Chapter 3 Engine Section 3 Engine dissassembly Remove the transmission gear Fig.3.3.46 As in Fig.3.3.46 Remove the shift CAM positioning plate①.. Fig.3.3.47 As in Fig.3.3.47 Use special tools to remove the crankshaft. Tools: crankcase separator② Fig.3.3.48 As in Fig.3.3.48 Remove the M6 bolt③ Fig.3.3.49 ⑤...

  • Page 57: Chapter 3 Engine Section 4 Inspection And Maintenance Of Engine Componenets

    Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Section 4 Inspection and maintenance of Fig.3.4.1 engine componenets Crankcase bearing Bearing inspection Check the bearing in the crankcase, rotate its inner race, and check whether it rotates smoothly. If it cannot run smoothly without noise, or if there are signs of abnormality, the bearing is defective and must be replaced according to the Fig.3.4.2...
  • Page 58 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Remove the right box bearing. Fig.3.4.6 As in Fig.3.4.6 Install the left box bearing and use special tools to assemble the bearing. The driving shaft bearing is installed, and the washer Fig.3.4.7 ①...

  • Page 59: Chapter 3 Engine Section 4 Inspection And Maintenance Of Engine Componenets Fig.3.4

    Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.10 Cylinder cranium As in Fig.3.4.10 Note: Mark the position of each removed component. The components shall be placed in groups (i.e., intake or exhaust) so that they can be assembled in place.

  • Page 60: Cylinder Head

    Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Reassemble Fig.3.4.15 The cylinder head can be reassembled in the reverse order of its disassembly. The following points should be noted during assembly:Grease or oil is applied to the rocker shaft. As in Fig.3.4.15 ①...
  • Page 61 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.20 Remove tapered clip from valve stem.① As Fig. 3.4.20 Tools: tweezers Fig.3.4.21 ② Remove the valve spring seat and remove the valve ③ ④ As in Fig.3.4.21 inner spring and o uter spring .
  • Page 62 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Valve working face wear Visual inspection valve surface wear, if abnormal wear, Fig.3.4.25 need to be replaced. Measure the air surface thickness T, if beyond the specified range, should be replaced with a new one. As Fig.
  • Page 63 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.29 Valve rod wear Measure the outside diameter of the valve rod using a micrometer caliper. If it exceeds the regulations, it should be replaced with a new one. If the outer diameter of the valve stem is within the specified range and the valve stem cannot be deflected, the valve guide sleeve should be replaced.
  • Page 64 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets After installing the valve guide sleeve, use a special Fig.3.4.33 tool to repair its hole. Be sure to clean the valve guide sleeve and fill oil after dressing the hole. As Fig.
  • Page 65 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.37 Valve springs Check the strength of the valve spring by measuring the free length of the spring and the force required to pressurize it. If the length of the spring is below the Use limit, or the force required for pressurizing it is not within the specified range, the spring should be replaced.
  • Page 66 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Assemble inlet and exhaust valves Fig.3.4.41 Apply molybdenum disulfide oil to the entire valve stem. As in Fig.3.4.41 Note: When assembling each valve, care should be taken not to damage the valve oil seal sealing lip. Fig.3.4.42 Assemble valve spring with tight end A facing down.
  • Page 67 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.46 Air distribution camshaft Camshaft inspection: If the engine produces abnormal noise, vibration, or insufficient power, the camshaft may deform or wear out to service limits.Camshaft should be checked for deviation and camshaft journal should be checked for wear or damage.
  • Page 68 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Cylinder Deformation Use a ruler and a feeler to check whether the cylinder Fig.3.4.51 surface is deformed. Read the distance at the decimal point. If the reading value exceeds the use limit, the cylinder should be replaced.
  • Page 69 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Clearance between piston ring and groove Fig.3.4.55 Measure the backlash of the first and second rings using a feeler gauge. As Fig. 3.4.55 3.4.56 If any of the clearance limits are exceeded, the piston and piston ring should be replaced.
  • Page 70 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Increase the ring Increase the piston rings Use the enlarged piston ring below. As Fig. 3.4.59 It bears the following label. Piston rings 1 and 2：0．50mm：50 Fig.3.4.59 1． 0mm：100 Increase the oil ring Use the enlarging ring below.
  • Page 71 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Crank and connecting rod Crank connecting rod assy Primary drive gear NT:17 Connecting rod Nut M16 Needle roller bearing 28×36×15.8 Lock washers The right crank Left the crank Piston Right crank bearing 28×68×18 Piston ring assy Piston pin...
  • Page 72 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.62 Inner diameter of small end of connecting rod Measure the inner diameter of the small end of the connecting rod with an inner diameter micrometer. If the inner diameter of the small end of the connecting rod exceeds the service limit, replace the connecting rod.
  • Page 73 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Starting clutch and starting driven gear Electric starting clutch Fig.3.4.67 Attach the starting gear to the clutch and turn the starting gear by hand (the gear can only turn in one direction).
  • Page 74 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.69 Remove Remove the starting gear. ① ② ③ Remove roller , spring and pin sleeve from the rotor and starting clutch assembly (As shown in Fig.3.4.69). As in Fig.3.4.70 Fig.3.4.70 The rotor gripper is used to fix the generator rotor and the starting clutch bolts are removed manually.
  • Page 75 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. Note: If 2 gears are to be removed, gear remover and appropriate auxiliary devices can be used. Drive shaft needle...
  • Page 76 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Re-install Reassembly of the intermediate shaft and drive shaft may be carried out in reverse order of disassembly. The following points should be noted: Note: Before mounting gears, lightly coat intermediate and drive shafts with a paste of lubricant or engine oil.
  • Page 77 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Shift fork Fig.3.4.77 Use feeler gauge to measure the clearance of shift fork in corresponding gear slot. Each gap in the two shift forks plays an important role in the smooth and reliable shift action. Each fork has a fork and is arranged in a angular groove of its gear.
  • Page 78 Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Fig.3.4.79 Standard Thickness of shifting fork No．Ⅰ：4．8—4．9mm No．Ⅲ：5．3—5．4mm As in Fig.3.4.79 Primary driven gear If the inner sleeve wears, it creates a gap between the gear and hub wheel, which can cause abnormal noise. Fig.3.4.80 If the clearance is too large, the primary driven gear needs to be replaced with a new one.

  • Page 79: Oil Filter

    Chapter 3 Engine Section 4 Inspection and maintenance of engine componenets Clutch spring free length Use vernier calipers to measure the free length of the clutch spring. If any spring is not within the limits of use, all springs should be replaced. Tools: vernier calipers Usage limit: 29.5 mm As in Fig.3.4.84...

  • Page 80: Chapter 3 Engine Section 5 Engine Reassembly Fig.3.5

    Chapter 3 Engine Section 5 Engine reassembly Fig.3.5.1 Section 5 Engine reassembly Engine reinstallation may take place in the reverse order of disassembly. The following steps require special attention or precautions to be taken. Note: Apply oil to each moving and sliding part before reinstallation.

  • Page 81: Chapter 3 Engine Section 5 Engine Reassembly

    Chapter 3 Engine Section 5 Engine reassembly Install the transmission. Fig.3.5.6 As in Fig.3.5.6 ① Install shift CAM and shift fork B. Fig.3.5.7 As in Fig.3.5.7 Note: Use two shift forks A and B. They have to be fitted very close to each other in Fig.3.5.8 appearance and configuration.
  • Page 82 Chapter 3 Engine Section 5 Engine reassembly Fig.3.5.11 crankcase Use clean kerosene to clean the crankcase mating surface. As in Fig.3.5.11 Fig.3.5.12 Apply flat sealant evenly to the mating surface of the right crankcase.As in Fig.3.5.12 Fig.3.5.13 Install the locating pin in the left half of the crankcase. Apply oil to the big end of the connecting rod and the change gear.

  • Page 83: Magneto Rotor

    Chapter 3 Engine Section 5 Engine reassembly As in Fig.3.5.16 Grease is applied to the engine sprocket liner, oil seal ① lip and O-ring ② Then install the engine sprocket bushing on the drive shaft. Note: We're going to use a new O-ring① Fig.3.5.17 Install the oil seal baffle.
  • Page 84 Chapter 3 Engine Section 5 Engine reassembly The drive shaft seat Install the washer①and shaft baffle ring ②on the drive shaft. Fig.3.5.21 As in Fig.3.5.21 Note: New shaft retainers should be used. Primary drive gear and oil pump drive gear Fig.3.5.22 ③...
  • Page 85 Chapter 3 Engine Section 5 Engine reassembly Fig.3.5.26 Install shift CAM driven tooth block assembly. ① Install CAM baffle , shifting CAM follower tooth block ② ③ and CAM retainer As in Fig.3.5.26 Note: The large shoulder must face outwards. Apply a small amount of thread sealant to the screw threads Fig.3.5.27...
  • Page 86 Chapter 3 Engine Section 5 Engine reassembly Clutch 1.Clutch big hub 1A.Clutch big hub 2.Flat washer 3.Clutch spline combination (double combination (electric sleeve starting) starting) 4.Nut M16 5.Insurance washer 6.Clutch push rod assembly 7.Active friction plate 8.Driven piece 9.Clutch spring disc 10.Clutch spring 11.Bolt M5×16 12.Bolt M6×10...
  • Page 87 Chapter 3 Engine Section 5 Engine reassembly Fig.3.5.31 Assemble gasket①and large hub inner sleeve②on intermediate shaft. As in Fig.3.5.31 Note:Apply oil to the inner and outer surfaces of the large hub inner sleeve. Install the primary driven gear assembly③and washer ④...

  • Page 88: Clutch Cover

    Chapter 3 Engine Section 5 Engine reassembly Fig.3.5.36 The clutch friction plate in turn according to the active friction plate, driven plate... The driven plate and active friction plate are loaded into the clutch spline sleeve one by one. As in Fig.3.5.36 Assemble clutch spring disc, clutch spring, install M5 x 16 bolt.

  • Page 89: Piston And Piston Ring

    Chapter 3 Engine Section 5 Engine reassembly Fig.3.5.41 Install the starting motor and replace the motor O-ring. As in Fig.3.5.41 Magneto cover Install the electric starting idler①, pin③ and bushing Fig.3.5.42 ②. As in Fig.3.5.42 Fig.3.5.43 Install locating pin and new gasket. As in Fig.3.5.43 Fig.3.5.44 Install magneto cover and secure with bolts.
  • Page 90 Chapter 3 Engine Section 5 Engine reassembly Fig.3.5.46 Note: When assembling the oil ring spacer, care must be taken not to lap the two ends in the piston groove. As in Fig.3.5.46 In the same way, to distinguish the first and second Fig.3.5.47 piston rings: 1.
  • Page 91 Chapter 3 Engine Section 5 Engine reassembly cylinder Fig.3.5.51 Before installing the cylinder, add oil to the big and small heads of the cylinder inner diameter connecting rods, as well as to the sliding surface of the piston. Install the double-headed studs into the crankcase, and ①...
  • Page 92 Chapter 3 Engine Section 5 Engine reassembly Fig.3.5.56 Cross tighten cylinder head nut according to specified torque. Cylinder head nut (M8) : 27 n · m (2.7 kg · m) As in Fig.3.5.56 ② Tighten cylinder seat nut and cylinder head Fig.3.5.57 ②...

  • Page 93: Cam Chain Tension Adjuster

    Chapter 3 Engine Section 5 Engine reassembly Fig.3.5.61 Adjust the line mark on the camshaft to make it ① parallel to the matching surface of the cylinder head and cylinder head cover. The sprocket, chain and camshaft are assembled so ②...
  • Page 94 Chapter 3 Engine Section 5 Engine reassembly Fig.3.5.66 Turn the crankshaft in the normal direction and stop in the exhaust valve position. Loosen the positioning screw (2) for 1 turn. Tighten the setting screw (2), lock the thruster rod, and then tighten the nut (1) according to the specified torque.
  • Page 95 Chapter 3 Engine Section 5 Engine reassembly Fig.3.5.71 Install the connecting sleeve. As in Fig.3.5.71 Note: Be sure to check valve clearance. Check valve clearance Inlet valve and exhaust valve clearance specifications are not the same. Fig.3.5.72 Valve clearance (cooling machine) : Admission: 0.06 0.08 mm Exhaust: 0.10 0.12 mm Note:...

  • Page 96: Ei System Diagnosis Section 1 Maintenance Precautions

    Chapter 4 EI system diagnosis Section 1 Maintenance Precautions Fig.6.1.1 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 97 Chapter 4 EI system diagnosis Section 1 Maintenance Precautions Clamp Fig.6.1.6 See "Wiring, Cables and Hoses Setup Routes" for proper clamping procedures. 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.As in Fig.6.1.6..
  • Page 98 Chapter 4 EI system diagnosis Section 1 Maintenance Precautions Fig.6.1.11 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 99 Chapter 4 EI system diagnosis Section 1 Maintenance Precautions •Before measuring voltage at each terminal, check to Fig.6.1.16 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.6.1.16 •Never connect an ohmmeter to the ECU with its coupler connected.

  • Page 100: Chapter 4 Ei System Diagnosis Section 2 Ei System Technical Features

    Chapter 4 EI system diagnosis Section 2 EI system technical features Section 2 EI System technical features EI SYSTEM’S CONTROL DIAGRAM MAP & IAT Sensor (Temperature function) FUEL TANK AIR CLEANER ISC Solenoid TP Sensor FUEL PUMP THROTTLE BODY MAP & IAT Sensor (Pressure function) INTAKE PIPE FUEL INJECTOR...

  • Page 101: Injection Time (Injection Volume)

    Chapter 4 EI system diagnosis Section 2 EI system technical features 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 102 Chapter 4 EI system diagnosis Section 2 EI system technical features COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). DESCRIPTION SIGNAL WATER COOLANT TEMPERATURE When engine temperature is low, injection time (volume) is increased.
  • Page 103 Chapter 4 EI system diagnosis Section 2 EI system technical features EI SYSTEM PARTS LOCATION ① Speedometer ② Fuel injector ③ MAP & IAT Sensor ④ CKP Sensor ⑤ Sensor ⑥ GP switch ⑦ ISC solenoid ⑧ TP sensor ⑨ Oxygen sensor 4—8...
  • Page 104 Chapter 4 EI system diagnosis Section 2 EI system technical features ⑩ Regulator Fuel pump relay 4—9...

  • Page 105: Chapter 4 Ei System Diagnosis Section 3 Self-Diagnosis Function

    Chapter 4 EI system diagnosis Section 3 Self-diagnosis function 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 106: 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. Forthispurpose,useofsuchaninspectionformwillfacilitatecollectinginformationtothepointrequiredforprop er analysis anddiagnosis. EXAMPLE : CUSTOMER PROBLEM INSPECTION FORM User name : Model : VIN :...

  • Page 107: Self-Diagnostic Procedures

    Chapter 4 EI system diagnosis Section 4 EI system troubleshooting MOTORCYCLE / ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather 口 Fair 口 Cloudy 口 Rain 口 Snow 口 Always 口 Other Temperature 口 Hot 口 Warm 口 Cool 口 Cold( °F/ °C) 口...
  • Page 108 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting • Repeat the above procedure 3times. In this case, engine warning lamp” ” goes off. 4—13...

  • Page 109: Malfunctioncode And Defective Condition

    Chapter 4 EI system diagnosis Section 4 EI system troubleshooting MALFUNCTIONCODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTIO DETECTED ITEM N CODE CHECK FOR After engine running,if oxygen sensor heater signal open or is happened the ground short fault for 1 second by 10 times in 12 Low Voltage times test cycle,the code P0031 is indicated.
  • Page 110 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting DETECTED FAILURE CONDITION MALFUNCTIO DETECTED ITEM N CODE CHECK FOR Vehicle soak time ＞ 240min，engine is running, during the period of the accumulated air mass is more than 2000g, if the IAT is lower P0111 Stuck ℃...
  • Page 111 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting DETECTED FAILURE CONDITION MALFUNCTIO DETECTED ITEM N CODE CHECK FOR After engine running,the oxygen sensor signal is in putted in ECU since then 300sec. In this case,the sensor voltage should be the following. P0131 Low Voltage 30mV≤Sensor out put voltage...
  • Page 112 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 happened continuously by 10 times in 100 times test cycle,the code P0336 is Noisy indicated.
  • Page 113 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting DETECTED FAILURE CONDITION MALFUNCTIO DETECTED N CODE CHECK FOR ITEM After engine running, if the misfire incident is larger than emission damage set threshold detected at the current test cycle of 400 engine cycles, the misfire incident count will be increase 1, after 20 count of 0300 total misfire incident, P0300 is indicated.

  • Page 114: Oxygen Sensor Heater Circuit Malfunction

    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 instrument ●...
  • Page 115 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 poorcontacts. Is OK? ●...
  • Page 116 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting “ P0107” or “P0108 MAP & IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ☞ To read the flash code,with the EFI diagnostic ● Clogged vacuum passage between throttle body instrument And MAP &...
  • Page 117 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting Is the input voltage OK? Go to Step 2. ● LooseorpoorcontactsontheECU coupler. ● OpenorshortcircuitintheO/Bwire or G/Bl wire. Step 2 ① 1) Connect the MAP & IAT Sensor coupler . 2) Inserttheneedlepointedprobestotheleadwire coupler.
  • Page 118 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 orshort. ☞ To read the flash code,with the EFI diagnostic ●...

  • Page 119: Sensor Resistance

    Chapter 4 EI system diagnosis Section 4 EI system troubleshooting IAP(Temperature function) Sensor resistance Intake Air Temp. Resistance ㏀ -20 ℃ (-40 ℉ ) Approx 14.541 ㏀ -0 ℃ (32 ℉ ) Approx 5.627 ㏀ 20 ℃ (68 ℉ ) Approx 2.429 ㏀...
  • Page 120 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting “P0117” or “P0118” CLT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● CLT sensor circuitopen orshort. ☞ To read the flash code,with the EFI diagnostic ● CLT sensormalfunction. instrument ● ECUmalfunction. INSPECTION 1) Turn the ignition switch to the “OFF”position.
  • Page 121 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 122 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 orshort. ☞ To read the flash code,with the EFI diagnostic ● TP Sensormalfunction. instrument ● ECUmalfunction. INSPECTION Step 1 1) Turn the ignition switch to the “OFF”position.
  • Page 123 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting Step 2 1) Turn the ignition switch to the “OFF”position. 2) Disconnect the TP sensorcoupler. 3) Check the continuity between ○ (Gr/Bl) andground. ∞ Ω (Infinity) TP sensor continuity (A- Ground) Tester knob indication : Resistance (㏀) Is the continuity OK? Go to Step3...

  • Page 124: Fuel Injector

    Chapter 4 EI system diagnosis Section 4 EI system troubleshooting Is the voltage OK? ● O/B, Gr/Bl or G/Bl wire open or shorted to ground, or poor B16(J2-16) ,B12(J2-12) or B10(J2-10) connection of ECU coupler. ● If wire and connection are OK, intermittent trouble or faulty ECU.
  • Page 125 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting Step 2 1) Turn the ignition switch to the “ON”position. 2) 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 126 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting “P0231” or “P0232” FUEL PUMP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Fuelpumprelaycircuitopenorshort. ● ☞ To read the flash code,with the EFI diagnostic Fuel pump relaymalfunction. ● instrument ECUmalfunction. ● INSPECTION Remove the seat set Turntheignitionswitchtothe“OFF”position.
  • Page 127 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 rotortip. ☞ To read the flash code,with the EFI diagnostic CKP circuit open orshort.
  • Page 128 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting Are the resistance and continuity OK? Bl/Wor G/Wwire open or ● shortedtoground, or poorB4(J2-4) or B13(J2-13) connection of ECU coupler. ● If wire and connectionare OK, intermittenttroubleorfaultyECU. ● Recheck each terminal andwire harness for open circuit and poor connection.
  • Page 129 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 130 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting “P0562” or “P0563” BATTERY VOLTAGE MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● Batteryvoltagecircuitopenandshort. ☞ To read the flash code,with the EFI diagnostic ● Batterymalfunction. instrument ● ECUmalfunction. INSPECTION 1) Remove the seat. 2) Turn the ignition switch to the “OFF”position.
  • Page 131 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting “P0650” ENGINE WARNING LAMP CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● engine warminglampcircuitopenandshort. ☞ To read the flash code,with the EFI diagnostic engine warninglampmalfunction. ● instrument ● ECU malfunction. INSPECTION Turn the ignition switch to the “OFF”position.
  • Page 132 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 orshort. ● GP switchmalfunction. ● ☞ To read the flash code,with the EFI Clutch lever switch circuit open or short. ●...
  • Page 133 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting 6） Disconnect the clutch lever switch coupler and then check the continuity wire when the between G/R wire and G squeezing the clutch lever. Clutch lever Ω switch continuity (G/R Ω...

  • Page 134: Tpsensor Inspection

    Chapter 4 EI system diagnosis Section 4 EI system troubleshooting SENSORS ⊙ CKP INSPECTION The CKPis installed in the magneto cover. ⊙CKP REMOVAL AND INSTALLATION • Remove the magnetocover. • Install the magne to cover in the reverse order of removal.
  • Page 135 Chapter 4 EI system diagnosis Section 4 EI system troubleshooting ⊙ CLT SENSOR INSPECTION The engine temperature (CLT) sensor is installed at the cylinder. ⊙CLT SENSORREMOVALAN D INSTALLATION Remove the CLT sensor. • Install the CLTsensor in the reverse orderof •...

  • Page 136: Chapter 5 Fuel And Lubrication System

    Chapter 5 Fuel and lubrication system Section 1 Fuel tank and fuel tank switch Chapter 5 Fuel and lubrication system Fig.4.1.1 Section 1 Fuel tank and fuel tank switch Disassemble Note： The gasoline is easy to explode; it needs to pay special attention.

  • Page 137: Chapter 5 Fuel And Lubrication System Section 3 Lubrication System

    Chapter 5 Fuel and lubrication system Section 3 Lubrication system Section 2 Throttle body structure As in Fig.4.2.2. 5—2...
  • Page 138 Chapter 5 Fuel and lubrication system Section 3 Lubrication system ● Check following items for any damage or Disassemble clogging. Remove fuel tank. O-ring Disconnect the fuel hose. Throttle shaft bushing andseal Injector cushionseal Remove all connectors connected to throttle body. Fuelinjector Loosen the throttle body retaining clamp.

  • Page 139: Installation

    Chapter 5 Fuel and lubrication system Section 3 Lubrication system Fig.4.2.6 Fig.4.2.7 INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points : Note: Never operate the idle nuts ①to avoid variations of the ECU setting. As in Fig.4.2.6 ●...

  • Page 140: Section 3 Lubrication System

    Chapter 5 Fuel and lubrication system Section 3 Lubrication system Section 3 Lubrication system Oil pressure Refer to chapter 2 periodic maintenance and inspection of oil saving pressure. Oil filter Refer to Section 2 Maintenance and Adjustment procedures in Chapter 2 periodic Maintenance. Oil filter When changing the oil, check the oil filter for breakage or damage.
  • Page 141 Chapter 5 Fuel and lubrication system Section 3 Lubrication system Engine lubrication system table 5—6...

  • Page 142: Chapter 6 Chassis

    Chapter 6 Chassis section 1 Exterior parts Chapter 6 Chassis Fig.5.1.1 Section 1 EXTERIOR PARTS Remove With the hook removed, remove the right ● ① side cover. As in Fig.5.1.1 Fig.5.1.2 With the hook removed, remove the left ● side cover② As in Fig.5.1.2 Fig.5.1.3 Seat...

  • Page 143: Chapter 6 Chassis Section 2 Front Wheels

    Chapter 6 Chassis section 2 Front wheels Section 2 Front wheels Structure Fig.5.2.2 REMOVAL Front wheel Loosen the front axle screw nut ， Lift the front wheel off the ground with the main support.Remove the front wheel by removing the front axle①.As in Fig.5.2.2.

  • Page 144: Inspection And Disassembly

    Chapter 6 Chassis section 2 Front wheels Remove the brake disc. Fig.5.2.4 As Fig. 5.2.4. Tools: hexagonal wrench INSPECTION AND DISASSEMBLY Speedometer drive box Turn the speedometer gear to check whether the gear Fig.5.2.5 and the speedometer pinion run smoothly. As Fig.
  • Page 145 Chapter 6 Chassis section 2 Front wheels Fig.5.2.9 The front wheel The yaw (axial and radial) of the wheel should be checked to see if it exceeds the service limit. Excessive yaw is usually caused by wear or relaxation of the wheel bearing. If replacing the bearing does not reduce the yaw, adjust the spokes;...
  • Page 146 Chapter 6 Chassis section 2 Front wheels As in Fig.5.2.13. Fig.5.2.14 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. As Fig. 5.2.14. Brake disc bolts: 23 N ·...

  • Page 147: Chapter 6 Chassis Section 3 Front And Rear Brakes

    Chapter 6 Chassis section 3 Front and rear brakes Section 3 Front and rear brakes Structure Fig 5.3.1 Warning: The brake system uses glycol based DOT4 hydraulic oil. Do not use and mix different grades of brake fluid, such as silicon based or petroleum based brake hydraulic oil.

  • Page 148: Chapter 6 Chassis Section 3 Front And Rear Brakes Fig.5.3

    Chapter 6 Chassis section 3 Front and rear brakes Fig.5.3.1 Replacement of friction plate Loosen the front brake friction disc mounting bolt ②and rear brake friction disc mounting bolt ④. Remove the front caliper mounting bolts ① and rear caliper mounting bolts⑥ As in Fig.5.3.1 and Fig.5.3.2.
  • Page 149 Chapter 6 Chassis section 3 Front and rear brakes ④ Fig.5.3.5 Remove the brake caliper holder ⑤ As in Fig.5.3.6. Remove the spring Place a rag on the brake caliper piston to prevent it Fig.5.3.6 from popping out. Compressed air is then used to force the piston out. Note: Do not use high pressure air to prevent damage to calipers.
  • Page 150 Chapter 6 Chassis section 3 Front and rear brakes Fig.5.3.9 Remove the rear brake caliper friction plate④ and fixing screw⑤. Remove the spring piece.Use air gun to push caliper piston out. Warning: Place a rag on the piston to prevent it from popping and flying out, and keep your hand away from the piston.
  • Page 151 Chapter 6 Chassis section 3 Front and rear brakes Fig.5.3.14 Install piston sealing ring as shown.As in Fig.5.3.14. Grease is applied to the brake fixed shaft. As in Fig.5.3.15. Fig.5.3.15 Tighten the front and rear brake mounting bolts (1, 6) and friction plate mounting bolts (2, 4) according to the specified torque.
  • Page 152 Chapter 6 Chassis section 3 Front and rear brakes Use a micrometer to measure the yaw. If the yaw exceeds the service limit, the brake disc Fig.5.3.19 should be replaced. As Fig. 5.3.19. Tools: Micrometer (0-100 mm) Magnetic rack Limit of use: Brake disc deflection: 0.30mm If the measured value exceeds the service limit, replace the brake disc.
  • Page 153 Chapter 6 Chassis section 3 Front and rear brakes Remove the lid of the oil storage box② and the Fig.5.3.24 liner of the oil cup③. As Fig. 5.3.24. Discharge brake fluid. ⑤ Remove the dust cover Fig.5.3.25 As Fig. 5.3.25. Use a special tool to remove the open spring ring⑥.
  • Page 154 Chapter 6 Chassis section 3 Front and rear brakes Fig.5.3.28 Note: Before assembly, clean the main cylinder with new brake fluid.After cleaning the cylinder, do not erase the brake fluid on it.When cleaning cylinder parts, special brake fluid should be used.Never use cleaning fluids or cleaners such as gasoline or kerosene.Before reassembly, apply brake fluid to the main cylinder diameter and all parts to be loaded into...

  • Page 155: Chapter 6 Chassis Section 4 Front Shock Absorber

    Chapter 6 Chassis section 4 Front shock absorber Section 4 Front shock absorber Structure Fig 5.4.1 Fig.5.4.2 Disassembly and decomposition Brace the motorcycle securely.Remove the front ② wheel.Remove the calipers Note:Secure the brake to the frame with a rope, being careful not to bend the brake tube.Do not grasp the brake handle.
  • Page 156 Chapter 6 Chassis section 4 Front shock absorber After loosening the upper and lower clamping bolts Fig.5.4.3 (① and ②) of the front shock absorber, remove the front shock absorber. Note: Gently loosen the fastening screw plug (3) of the front fork to facilitate subsequent disassembly. As in Fig.5.4.3.
  • Page 157 Chapter 6 Chassis section 4 Front shock absorber Fig.5.4.7 Separate the inner tube from the outer tube.As in Fig.5.4.7 Fig.5.4.8 ③ Remove the following parts: oil seal , sliding ④ ⑤.As in Fig.5.4.8 metal ring , oil lock piece Front fork spring Measure the free length of the front fork spring, and replace it with a new one if it is shorter than the service Fig.5.4.9...
  • Page 158 Chapter 6 Chassis section 4 Front shock absorber Fig.5.4.11 On the inner tube, assemble the following parts: As in Fig.5.4.11 ① Dustproof seal ② Oil seal plug ring ③ oil seal ① ④ ② oil seal holder ③ ⑤ Sliding metal ④...
  • Page 159 Chapter 6 Chassis section 4 Front shock absorber Fig.5.4.16 Warning: Replace with a new washer. The front fork oil When the inner tube is in the fully compressed position, a specified amount of front fork oil is poured into the inner tube and several strokes are performed to expel air.
  • Page 160 Chapter 6 Chassis section 4 Front shock absorber Tighten the lower clamping bolt①and the cover bolt Fig.5.4.21 ② of the front fork according to the specified torque. Tighten the clamping bolt③ on the upper part of the front fork according to the specified torque. As Fig.

  • Page 161: Chapter 6 Chassis Section 5 Steering

    Chapter 6 Chassis section 5 Steering Section 5 Steering structure （Fig 5.5.1） Fig.5.5.2 Disassembly and decomposition Remove the right rearview mirror. Disconnect the front brake light switch lead. 卸下紧固右手把开关的两个螺钉， Remove the two fastening bolts from the front brake 卸下右手把开关组合①. main pump assembly retaining seat. 分开油门线，卸下右旋把组合②.
  • Page 162 Chapter 6 Chassis section 5 Steering Fig.5.5.4 Remove the left rearview mirror.① Remove the left handle counterweight. (This is only for vehicles with counterweights) Remove the two screws fastening the left hand handle switch and remove the left hand handle switch assembly ②...
  • Page 163 Chapter 6 Chassis section 5 Steering Fig.5.5.9 Remove front left and right turn signal mounting nuts. As Fig. 5.5.9. Remove the front and left turn signals. Fig.5.5.10 Decompose the speed odometer connector. As in Fig.5.5.10. Fig.5.5.11 ① Remove the speedometer mounting bolt ②...
  • Page 164 Chapter 6 Chassis section 5 Steering Remove ignition switch lock retaining bolts. Fig.5.5.14 As Fig. 5.5.14. Remove the ignition switch lock. Remove the large cover nut③and the large washer. Fig.5.5.15 As in Fig.5.5.15. Tap the upper tray ④and remove it. As in Fig.5.5.16 Fig.5.5.16 ·...
  • Page 165 Chapter 6 Chassis section 5 Steering Fig.5.5.19 Remove the steering rod nut with a special tool④. As Fig. 5.5.19. Tools: steering lever nut wrench Pull out steering lever lower bracket assembly. Note: Hold the steering lever lower bracket to prevent it from falling suddenly. Fig.5.5.20 Remove the dust cover ⑤, upper bearing ⑥...
  • Page 166 Chapter 6 Chassis section 5 Steering Reassemble and install Fig.5.5.24 Reassemble and install steering lever in reverse order of disassembly and disassembly. In doing so, the following points should be noted: Use special tools to push the upper and lower bearing seat rings.Tools: steering rod seat ring installer Apply super grease to the upper and lower bearings.
  • Page 167 Chapter 6 Chassis section 5 Steering Fig.5.5.291 Install speed odometer.Connect the soft axis of the speedometer.Make sure the speedometer connector is properly and securely connected to the connector on the main harness.Then tighten the waterproof sleeve on the main line harness with tie strap.Install headlight assembly.First, connect the headlight connector correctly and firmly to the connector on the main line harness.Install the handlebar welding assembly so that...

  • Page 168: Chapter 6 Chassis Section 6 Rear Wheels

    Chapter 6 Chassis section 6 Rear wheels Section 6 Rear wheels The rear wheel structure Fig 5.6.1 Remove Remove the left and right rear shock absorbers fixing bolt assembly and remove the left and right rear shock 6—27...
  • Page 169 Chapter 6 Chassis section 6 Rear wheels ①. absorbers As in Fig.5.6.1. Fig.5.6.1 Remove the chain cover retaining bolts and remove Fig.5.6.2 ②. the chain cover As in Fig.5.6.2. Fig.5.6.3 ① Loosen the right drive chain adjustment nut the left drive chain adjustment nut②.As in Fig.5.6.3 As in Fig.5.6.4.
  • Page 170 Chapter 6 Chassis section 6 Rear wheels Lift the rear wheel off the ground with a jack or Fig.5.6.6 block. ⑤ Remove the rear axle self-locking nut , pull out the rear axle, remove the rear wheel.As in Fig.5.6.6. Fig.5.6.7 Remove the rear disc brake①.
  • Page 171 Chapter 6 Chassis section 6 Rear wheels Use special tools to remove the left and right side bearings ①②of the hub and the middle bushing③. As in Fig.5.6.11. Fig.5.6.11 Tools: hub bearing remover Note: The removed bearing should be replaced. Rear sprocket Check if sprocket teeth are worn, if worn, replace sprocket and chain as a whole.
  • Page 172 Chapter 6 Chassis section 6 Rear wheels Note: First assemble the right wheel bearing, then assemble the left wheel bearing. The seal cover on the bearing must be outward facing. Fig 5.6.15 Rear sprocket Fig.5.6.16 Tighten rear sprocket nut to specified torque. Rear sprocket nut: 50 N ·...

  • Page 173: Section 7 Rear Suspension System

    Chapter 6 Chassis section 7 Rear suspension system Section 7 Rear suspension system Structure Fig 5.7.1 6—32...

  • Page 174: Chapter 6 Chassis Section 7 Rear Suspension System

    Chapter 6 Chassis section 7 Rear suspension system Removl Fig.5.7.1 Remove the left and right rear shock absorbers fixing bolt assembly and remove the left and right ①. rear shock absorbers As in Fig.5.7.1. Fig.5.7.2 Remove the chain cover retaining bolts and ②.
  • Page 175 Chapter 6 Chassis section 7 Rear suspension system Fig.5.7.6 Lift the rear wheel off the ground with a jack or block. Remove rear axle self-locking nut⑤，Pull out rear axle and remove rear wheel.As in Fig.5.7.6. Remove rear flat fork self-locking nut⑥，Pull out the rear flat fork shaft, remove the chain slider Fig.5.7.7 and rear flat fork.As in Fig.5.7.7.
  • Page 176 Chapter 6 Chassis section 7 Rear suspension system Rear Fork Needle roller bearing Fig.5.7.11 Place the ring into the needle roller bearing and move it up and down to check for clearance. If the clearance is too large, it needs to be replaced with a new bearing.
  • Page 177 Chapter 6 Chassis section 7 Rear suspension system Fig.5.7.16 Reassemble and install Reassemble the swingarm and rear shock absorber inthe reverse order of disassembly. Pay attention to the following points : Install the rear flat fork shaft and tighten the rear flat fork shaft nut⑥...

  • Page 178: Chapter 7 Electrical System Section 1 Location Of Electrical Components

    Chapter 7 Electrical system, Section 1 location of electrical components Chapter 7 Electrical System Section 1 Location of electrical components 1. Clutch switch 2. The diode 3. Start relay 4. ECU 5. Headlight relay 6. Efi relay 7. Oil pump relay 8.
  • Page 179 Chapter 7 Electrical system, Section 1 location of electrical components 16. Rectifier regulator 17.right switch 18.Front brake switch 19. The speaker 20.Oxygen sensor 21. Starting motor 22. Rear brake switch Be sure not to misassemble the position of battery plus & minus terminal.

  • Page 180: Section 2 Ignition System

    Chapter 7 Electrical system, Section 2 Ignition system Section 2 Ignition system INSPECTION 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. Stator coil Standard resistance...

  • Page 181: Ignition Coil Primary Peak Voltage Inspection

    Chapter 7 Electrical system, Section 2 Ignition system IGNITION COIL PRIMARY PEAK VOLTAGE INSPECTION cylinder Remove the frame coverand fuel tank. 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 ❖...
  • Page 182 Chapter 7 Electrical system, Section 2 Ignition system IGNITION COIL RESISTANCE点 0.52～0.64 Ω primary terminal— terminal 6.4～7.8 KΩ Secondary terminal— terminal Pocket Tester :09900 - 25002 10K Ω SPARK PLUG CAP RESISTANVE 16.4～17.8K Ω lgnition coil secondary/spark plug cap resistance （spark plug cap～ terminal）...

  • Page 183: 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. SPARK PLUG GAP Measure the spark plug gap with a thickness gauge.

  • Page 184: Chapter 7 Electrical System, 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 185 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.

  • Page 186: Section 4 Starter System And Side Stand Ignition Interlock System

    Chapter 7 Electrical system, Section 4 Starter System and side Stand Ignition Interlock system Section 4 Starter System And side Stand Ignition Interlock system STARTER SYSTEM DESCRIPTION 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 187 TRANSMISSION : Neutral -“OFF” Side stand - Up Clutch lever - Squeeze Seventy are equipped with the side stand ignition interlock system. Fuel injector is controlled by ecu depends on the condition of side stand switch. Neutral switch Clutch lever...

  • Page 188: Starter Motor Removal And Disassembly

    Chapter 7 Electrical system, Section 4 Starter System and side Stand Ignition Interlock system STARTER MOTOR REMOVAL AND DISASSEMBLY Disconnect the starter motor lead wire ② ① With loosen the bolt , remove the starter motor. Disassemble the starter motor. STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, crack or...

  • Page 189: Starter Motor Reassembly

    Chapter 7 Electrical system, Section 4 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. ① ② on Align the mark on the housing with the line the housing end.

  • Page 190: Chapter 7 Electrical System, Section 6 Lamp

    Chapter 7 Electrical system, Section 6 Lamp Section 5 Switches Measure each switch for continuity using a tester. If any abnormality is found, replace the respectiveswitch assemblies with new ones. Pocket tester :09900 - 25002 ENGINE STOP IGNITION SWITCH DIMMER STARTER PASSING FRONT BRAKE SWITCH...

  • Page 191: Section 6 Lamp

    Chapter 7 Electrical system, Section 6 Lamp Section 6 Lamp HEADLAMP/ TURN SIGNALLAMP REAR TURN SIGNAL LAMP / REAR TAIL LAMP 7-14...

  • Page 192: Combination Meter

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

  • Page 193: Chapter 7 Electrical System, Section 7 Battery

    Chapter 7 Electrical system, Section 7 Battery Setion 7 Battery seventy 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 a explosion and severe accident.

  • Page 194: Battery Installation

    When the vehicle is not used for a long period, check the battery every 1 month to prevent the battery discharge. BATTERY INSTALLATION seventy battery installation order pay attention to following points : ① Remove the seat, OBD bracket comp. ② Orient the battery's positive terminal toward the right side of the battery case.

  • Page 195: Section 1 Troubleshooting

    Chapter 8 Information service Section 1Troubleshooting Section 1 Troubleshooting MALFUNCTION CODE AND DEFECTIVECONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CHECK FOR CODE NO FAULT noEr Afterenginerunning,ifoxygensensorheatersignalopenoris happenedthegroundshortfaultfor1secondby10timesin12 timestestcycle,thecode0031isindicated. Voltage P0031 Sheater Oxygen sensor, lead wire / coupler connection. Circuit After engine running, if oxygen sensor heater signal is happened the high short fault for 1 second by 10 times in 12 times test cycle, High the code 0032 is indicated.
  • Page 196 Chapter 8 Information service Section 1Troubleshooting DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR The sensor should produce following voltage. 0.2 V≤Sensor output voltage Without the above range for7.8sec.and more,0122is indicated. Voltage P0122 Throttle position sensor, lead wire / coupler connection. or Open Sensor Circuit...
  • Page 197 Chapter 8 Information service Section 1Troubleshooting DETECTED FAILURE CONDITION MALFUNCTION DETECTED CODE CHECK FOR ITEM After engine running, if the magneto rotor tooth’s error is happenedcontinuouslyby10timesin100timestestcycle,the code P0336 is indicated. P0336 Noisy CKP wiring and mechanical parts.(CKP lead wire coupler connection) Signal After engine running, if the CKP signal does not reach ECU for more than 0.5 sec., the code P0337 is indicated.
  • Page 198 Chapter 8 Information service Section 1Troubleshooting ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low Adjust. startorishard Tappetclearanceoutofadjustment. Repair or replace. tostart. Wornvalveguidesorpoorseatingofvalves. Adjust. Mistimedvalves. Replace Excessively worn pistonrings. Replace. Worn-down cylinderbore. See electrical section. Startermotorcrankstooslowly. Retighten.
  • Page 199 Chapter 8 Information service Section 1Troubleshooting Complaint Symptom and possible causes Remedy 1. Tappetclearanceoutofadjustment. Adjust. Engine idles Poor seating ofvalves. Replace or repair. poorly. Defective valveguides. Replace. Worn downcamshafts. Replace. Toowidesparkpluggaps. Adjust or replace. Defective ignitioncoils. Replace. Defective CKP. Replace. DefectiveECU.
  • Page 200 Chapter 8 Information service Section 1Troubleshooting Complaint Symptom and possible causes Remedy Noisy engine. Excessive valve chatter Too large tappetclearance. Adjust. Weakenedorbrokenvalvesprings. Replace. Worntappetorcamsurface. Replace. Wornandburntcamshaftjournal. Replace. Noise seems to come from piston Worndownpistonsorcylinders. Replace. Combustionchambersfouledwithcarbon. Clean. Wornpistonpinsorpistonpinbore. Replace. Wornpistonringsorringgrooves. Replace.
  • Page 201 Chapter 8 Information service Section 1Troubleshooting Remedy Complaint Symptom and possible causes Defective engine internal / electrical parts Enginerunspoorly Replace. Weakened valvesprings. in high speed Replace. Worncamshafts. range. Adjust. Valvetimingoutofadjustment. Adjust. Toonarrowsparkpluggaps. Replace ECU Ignitionnotadvancedsufficientlyduetopoorlyworkingtiming advancecircuit. Replace. Defective ignitioncoils. Replace. Defective CKP.
  • Page 202 Chapter 8 Information service Section 1Troubleshooting Complaint Symptom and possible causes Remedy Defective engine internal / electrical parts Engine Adjust. Loss of tappetclearance. lacks Replace. Weakened valvesprings. power. Adjust. Valvetimingoutofadjustment. Replace. Wornpistonringsorcylinders. Repair. Poor seating ofvalves. Clean or replace. Fouled sparkplugs. Adjust or replace.
  • Page 203 Chapter 8 Information service Section 1Troubleshooting Complaint Symptom and possible causes Remedy Check with inspection Toomuchengineoilintheengine. Dirty or window, drain out excess oil. heavy exhaust Wornpistonringsorcylinders. Replace. smoke. Worn valveguides. Replace. Cylinderwallscoredorscuffed. Replace. Worn valvesstems. Replace. Stem oil seal is damaged Replace.
  • Page 204 Chapter 8 Information service Section 1Troubleshooting ELECTRICAL Complaint Symptom and possible causes Remedy Defectiveignitioncoilsorsparkplugcaps. Replace. No sparking or poor Defective spark plugs. Replace. sparking. Defective CKP. Replace. DefectiveECU.ECU Replace. Defective side stand switch . Replace. Open-circuited wiringconnections. Check and repair. Inspect EI system.
  • Page 205 Chapter 8 Information service Section 1Troubleshooting BATTERY Complaint Symptom and possible causes Remedy Battery case iscracked. Replace the battery. “Sulfation”acidi Battery has been left in a run-down Replace the battery or recharge. cwhite condition for a longtime. powderysubsta nce or spots on surfaces of cell plates.
  • Page 206 Chapter 8 Information service Section 1Troubleshooting CHASSIS Complaint Symptom and possible causes Remedy Steering feels Adjust. Steering stem nutovertightened. too heavy or Worn bearing or race in steeringstem. Replace. stiff. Distorted steeringstem. Replace. Not enough pressure intires. Adjust. Steering Replace. Lossofbalancebetweenrightandleftfrontsuspensions.
  • Page 207 Chapter 8 Information service Section 1Troubleshooting BRAKES Complaint Symptom and possible causes Remedy Poor braking Refill to level mark. Not enough brake fluid in thereservoir. (FRONT and Air trapped in brake fluidcircuit. Bleed air out. REAR) Pads worn down. Replace. Too much play on brake lever or pedal.

  • Page 208: Section 2 Special Tools

    Chapter 8 Information service Section 2 Special tools Section 2 Special tools Special tools PartNumber∙PartName∙Description PartNumber∙PartName∙Description Special tools 09900-20101VernierCaliper 09900-21109Torque wrench Used conveniently measure Measure torque of tightening. various dimensions. 09900-20201 09900-21304 Micrometer(0~25mm)（0 〜 25mm） V-blockV Used precise measurement With using magnetic stand. (00~25mm measure ranges).（00 〜...
  • Page 209 Chapter 8 Information service Section 2 Special tools PartNumber∙PartName∙Description PartNumber∙PartName∙Description Special tools Special tools 09910-32812 09913-80112 Crankshaft installer Bearing installer Used to install the crankshaft in the Used to drive bearing in. crankcase. Used to install the crankshaft in the crankcase. 09910-34510 09915-63310 Piston pin puller...
  • Page 210 Chapter 8 Information service Section 2 Special tools Chapter 8 Information service Section 2 Special tools PartNumber∙Par PartName∙Description PartNumbe Number∙PartName∙Description Special tools Special tools 09921-20200 09930-44510 44510 Bearing remover(10mm) Bearing remover(10mm) Rotor holder Rotor holder Usedtoremoveoilsealorbearing. Usedtoremoveoilsealorbearing. Widely used to lock rotary parts Widely used to lock rotary parts such as a flywheel magneto.

  • Page 211: Chapter 8 Information Service Section 3 Tighten Torque

    Chapter 8 Information service Section 3 Tighten torque Section3 Tightening Torque ENGINE N∙m Kg∙m ITEM Cylinder head bolts 1．0 Cylinder head nut M：8mm 2．7 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...
  • Page 212 Chapter 8 Information service Section 3 Tighten 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...

  • Page 213: Chapter 8 Information Service Section 4 Service Data

    Chapter 8 Information service Section 4 Service data Section 4 Service Data VALVE + GUIDE ITEM STANDARD LIMIT Valve diam. ——— ——— Valve clearance (When cold) 0．08—0．13 ——— 0．13—0．18 ——— Valve guide to valve stem clearance 0．010—0．037 ——— 0．030—0．057 ——— Valve stem deflection IN.

  • Page 214: Camshaft + Cylinder Head

    Chapter 8 Information service Section 4 Service data CAMSHAFT + CYLINDER HEAD Unit :mm ITEM STANDARD LIMIT inside 33．120—33．160 32．820 Height of the CAM 32．8 outside 33．120—33．160 Inside Camshaft journal clearance 0．032—0．066 0．150 &outside Inner diameter of camshaft journal 22．012—22． Inside &outside press seat 21．959—21．...

  • Page 215: Cylinder + Piston + Piston Ring

    Chapter 8 Information service Section 4 Service data CYLINDER + PISTON + PISTON RING Unit:mm STANDARD LIMIT Compression pressure 1000—1500kpa 800 kpa （10．0—15．0kg/cm2） （8kg/cm2） Piston to cylinder clearance 0．020—0．030 0．120 Cylinder bore 57．000—57．015 57．110 56．975—56．990 Piston diam. 56．880 (Measure at 12mm from the skirt end) （12mm）...

  • Page 216: Transmission + Drive Chain

    Chapter 8 Information service Section 4 Service data  TRANSMISSION + DRIVE CHAIN Unit:mm ITEM STANDARD LIMIT Primary reduction ratio ——— 3．470（59/17） Final stage reduction ratio ——— 3．000（45/15） Gear ratio 3．000（33/11） ——— 1．857（26/14） ——— 1．368（26/19） ——— 1．095（23/21） ——— 0．913（21/23） ——— Shift fork to groove clearance 0．50 0．10—0．30...
  • Page 217 Chapter 8 Information service Section 4 Service data EI SENSORS ITEM SPECIFICATION MAP sensor input voltage 4.9 ~ 5.1V MAP (Pressure function) sensor output voltage Approx. 1.5V at. idle speed 1.5V TP sensor input voltage 4.8 ~ 5.2V TP sensor output voltage Closed Approx.
  • Page 218 Chapter 8 Information service Section 4 Service data Chapter 8 Information service Section 4 Service data THROTTLE BODY ITEM SPECIFICATION NOTE I.D. No. 1114111006300 Bore size Idle rpm 1,400 ~ 1,600 rpm Throttle cable play 0.5 ~ 1.0 mm (0.02 ~ 0.04 in) 0.5 ~ 1.0 mm (0.02 ~ 0.04 in) ...
  • Page 219 Chapter 8 Information service Section 4 Service data REC. / REG. / IGN 15 A ECU / M.RELAY 15 A 15 A ABS PUMP 25 A ABS ECU ABS IGN 25 A 15 A ECU Fuse sizeECU SPARE 15 A 15 A WATTAGE Unit:W...

  • Page 220: Brake+Wheel

    Chapter 8 Information service Section 4 Service data 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) ———...
  • Page 221 Chapter 8 Information service Section 4 Service data TIRE ITEM STANDARD LIMIT Front 200Kpa(29psi) 225Kpa(33psi) Cold inflation tire pressure (Solo riding) Rear 225Kpa(33psi) 225Kpa(33psi) Front 200Kpa(29psi) 225Kpa(33psi) Cold inflation tire pressure (Dual riding) Rear 225Kpa(33psi) 250Kpa(36psi) Front ——— Tire tread depth Rear ———...

  • Page 222: Section 5 The Circuit Diagram

    Chapter 8 Information service Section 5 The circuit diagram Section 5 The circuit diagram 8-28...
  • Page 223 8-29...

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