Page 1 X-RIDE 125CC SERVICE MANUAL...
Page 2 PREFACE This manual covers the description of X-RIDE 125CC 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 3: Group Index
GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE FUEL SYSTEMAND THROTTLE BODY EI SYSTEM DLAGNOSISEI ELECTRICAL SYSTEMEI CHASSIS SERVICING INFORMATION...
Page 4: How To Use This Manual
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR : The text of this manual is divided into sections. As the title of these sections are listed on the previous page as GROUP INDEX, select the section where you are looking for.
Page 5 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. Use engine oil unless otherwise Apply THREAD LOCK.
Page 6: Abbreviations Used In This Manual
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 :Manifold absolute Pressure MAP&IAT Sensor(MAPS) Sensor BBDC : Before Bottom Dead Center :Intake Air Temperature Sensor （IATS）...
Page 7: Wire Color
WIRE COLOR : Black : Green : Purple : Blue : Gray : Red : Light green : Brown : Light blue :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 8 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 PuBl Purple with Blue tracer PuBr Purple with Brown tracer Purple with Green tracer...
Page 9: Table Of Contents
GENERAL INFORMATION CONTENTS INFORMATIONLABELS......................1-1 ....................1-1 WARNING / CAUTION / NOTE ......................1-2 GENERALPRECAUTIONS EXTERIOR PHOTOGRAPH......................1-3 FUNCTION OF EI SENSOREI....................1-4 SERIAL NUMBER LOCATION....................1-5 FUEL ANDOILRECOMMENDATIONS..................1-6 BREAK-INPROCEDURES......................1-8 EXTERIORILLUSTRATION......................1-9 SPECIFICATIONS........................1-10...
Page 11: Informationlabels
GENERAL INFORMATION 1-1 INFORMATIONLABELS 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. Indicates a potential hazard that could result in death or injury.
Page 12: Generalprecautions
GENERAL INFORMATION 1-2 GENERALPRECAUTIONS 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. When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
Page 13: Exterior Photograph
GENERAL INFORMATION 1-3 EXTERIOR PHOTOGRAPH N O T E Difference between photographs and actual motorcycles depends on the markets.
Page 14 GENERAL INFORMATION 1-4 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 whichisconsideredtheenginespeed,intakeairpressure,intakeairvolume,enginetemperature,oxygen volume and throttle opening angle,etc. ★ EI (Electric fuel Injector)EI EI spray the fuel to intake pipe by ECU’s injection signal.
Page 15: Serial Number Location
GENERAL INFORMATION 1-5 SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the steering head tube. The engine serial number is located on the right up side of crank case assembly. These numbers are required especially for registering the machine and ordering spare parts. FRAME SERIALNUMBER ENGINE SERIALNUMBER...
Page 16: Fuel Andoilrecommendations
GENERAL INFORMATION 1-6 FUEL ANDOILRECOMMENDATIONS FUEL If you use ethanol gasoline, ethanol gasoline above E10-E5. Do not use gasoline containing methanol,Even if it contains latent solvents and preservatives, it cannot be used. ENGINEOIL ENGINE OIL SPECIFICATION Classification Grade system Over SL 10W-40 If an SAE 10W-40 motor oil is not available, select an alternative according to the right chart.
Page 17 GENERAL INFORMATION 1-7 ANTIFREEZE Antifreeze selection: 1. Antifreeze must not be mixed using. 2.The freezing point of antifreeze is normally lower than the local minimum ambient temperature 5-10 degrees. 3. The boiling point of antifreeze is more than 107 ° C. This motorcycle engine is water cooling system.
Page 18: Break-Inprocedures
GENERAL INFORMATION 1-8 BREAK-INPROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK-IN before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life.
Page 19: Exteriorillustration
GENERAL INFORMATION 1-9 EXTERIORILLUSTRATION...
Page 20: Specifications
GENERAL INFORMATION 1-10 SPECIFICATIONS DIMENSIONS AND MASS ⊙ ITEM QM125-4Y Overall length 1990 mm Overall width 800 mm Overall height 1080mm Wheelbase 1400 mm Minimum ground clearance 230 mm Turning clearance circle diameter 5200mm Overall mass 131 kg ⊙ ENGINE ITEM分类...
Page 21 GENERAL INFORMATION 1-11 ⊙ CHASSIS ITEM QM125-4Y 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 110/70-17 Rear tire size 130/70-17 ⊙...
Page 22 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ······································································· 2-1 PERIODIC MAINTENANCE CHART··············································································· 2-1 LUBRICATION POINTS································································································ 2-3 MAINTENANCEPROCEDURES ···················································································· 2-4 VALVE CLEARANCE····································································································2-4 SPARK PLUG ············································································································2-7 EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS················································2-8 AIR CLEANER············································································································2-9 FUEL HOSE···············································································································2-10 IDLING ADJUSTMENT································································································· 2-10 THROTTLECABLE PLAY······························································································2-10 CLUTCH··················································································································· 2-11 ENGINE OIL··············································································································...
Page 23: Periodic Maintenance Schedule
PERIODIC MAINTENANCE SCHEDULE 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. More frequent servicing should be performed on motorcycles that are used under severe conditions.
Page 24 CHASSIS Interval Item Initial 1,000 km Every 4,000 km Every 8,000 km Drive chain Clean and lubricate every 1,000km Inspect Inspect ─ Brake Inspect Inspect ─ Brake hose Replace every 4 years ─ Inspect Inspect Brake fluid Replace every 2 years ─...
Page 25: Lubrication Points
LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. O- Motor oil, G– Grease Clutch lever holder Passenger footrests pivot ① ② Drive chain Side stand pivot and spring hook ③...
Page 26: Maintenanceprocedures
MAINTENANCEPROCEDURES This section describes the service procedure for each section of the periodic maintenance. VALVE CLEARANCE N O T E Inspect Initial 1,000 km and Every 4,000 km.1,0004,000 The clearance specification is for COLD state. The valve clearance specification is different for intake and exhaust valves.
Page 27 Rotate the magneto rotor to set the front cylinder’s piston at TDC (Top Dead Center) of the compression stroke. (Rotatetherotoruntil“T”lineontherotorisaligned with the center of hole on the crankcase. To inspect the front cylinder’s valve clearance, insert the thickness gauge to the clearance between the camshaft and the tappet.
Page 28 In case that valve adjustment which there is no the tappet shim selection chart, please follow instructions of example in the below. For example, the intake clearance is 0.4 and the shim is170(1.70mm),select195(1.95mm)of the shim which170(1.70mm)of the shim add up the excess clearance 0.25 mm when adjust with the standard 0.15 as the intake standard clearance 0.1-0.2 mm.
Page 29: Spark Plug
SPARK PLUG N O T E Clean Initial 1,000 km and Every 3,000 km, Replace Every 30，000 km. Disconnect the spark plug caps. Remove the spark plugs. SPARK PLUG TYPE SPECIFICATION Hot type CR7E Standard type CR8E Cold type CR9E Remove the carbon deposit with wire or pin and adjust the spark plug gap to 0.7-0.8 mm, measuring with a thickness gauge.
Page 30: Exhaust Pipe Nuts And Muffler Mounting Bolts
EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS N O T E Tighten Initial 1,000 km and Every 4,000 km. Tighten the exhaust pipe nuts ①, and muffler mounting bolts ②to the specified torque. Exhaust pipe nut 11N∙m (11kg∙m) Muffler mounting bolt :11N∙m (11kg∙m)
Page 31: Air Cleaner
AIR CLEANER N O T E Clean Every 3,000 km, Replace Every 12,000 With the hook ①、②、③removed, remove the ● right side cover. Remove the four air cleaner inlet cap mounting bolts ④, and then remove the air cleaner inlet cap ⑤.
Page 32: Fuel Hose
2-10 FUEL HOSE N O T E Inspect Initial 1,000 km and Every 4,000 km, Replace every 4 years. Remove the left frame cover. (Refer to page 5-2) Inspect the fuel hoses for damage and fuel leakage. If any defects are found, the fuel hoses must be replaced.
Page 33: Clutch
2-11 CLUTCH N O T E Inspect Initial 1,000 km and Every 4,000 km Clutch play should be 4 mm as measured at the clutch lever holder before the clutch begins to disengage. If the play in the clutch is incorrect, adjust it in the following way: Loosen the lock nut ①...
Page 34: Engine Oil
2-12 ENGINE OIL Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Don’t mix the unrecommended oil. ● ⊙ENGINE OIL SPECIFICATION It could damage the engine. When refilling the oil, don’t allow the dust ●...
Page 35: Engine Oil Level Check
2-13 ⊙ENGINE OIL LEVEL CHECK Follow the procedure below to inspect the engine oil level. Start up the engine and allow it to run for several minutes at idling speed. Turn off the engine and wait about three minutes, then check the oil level through the inspection window.
Page 36 2-14 Necessarily, confirm and clean the oil strainer when replace Engine Operating the motorcycle with an incorrect (specially, when first replacement). amount of engine oil can damage your motorcycle. Too little or too much engine oil can damage your engine. Place the motorcycle on level ground.
Page 37: Engine Oil And Filt Erchange
2-15 ⊙ENGINE OIL AND FILT ERCHANGE More frequent servicing may be performed on motorcycles that are used under severe conditions, inspect ①Quantity of Engine oil ②Pollution degree of Engine oil before riding the motorcycle and then supplement and replace at any time to prevent damage of the engine.
Page 38 2-16 Hold the motorcycle vertically using the center stand. N O T E Place the motorcycle on firm and flat ground. Place a drain pan under the engine. Remove the engine oil filler plug①. Drain the engine oil by removing the engine oil drain plug ②...
Page 39 2-17 ● The engine oil temperature may be high enough to burn you when the drain plug is loosened. Wait until the drain plug is cool enough to touch with bare hands before draining oil. ● Do not touch the hot muffler, or the hot muffler can burn you.
Page 40 2-18 Tighten the drain plug ② to the specified torque. At this time, insert the gasket necessarily. Approximately 850 mlof the engine oil Oil drain plug : 28N∙m (2.8kg∙m) must be required when changing the engine oil only without replacing the ：28N∙m（2.8kg∙m）...
Page 41: Antifreeze
2-19 ANTIFREEZE This motorcycle engine is water cooling system. During motorcycle running, the antifreeze is high temperature and high pressure in the cooling system. So, it is strictly forbidden opening the radiator cap in this state, avoiding burn. The antifreeze must be added in a timely manner and sufficient amount to prevent damaging the engine.
Page 42 2-20 Antifreeze replacement Carry out this work on about 10000 km running or when using the motorcycle for a year. 10000 The operation is following: Please stand the motorcycle on a level ground with stand, take a container and put under the draining bolt③, then remove the bolt③, so antifreeze is outflow.
Page 43 2-21 Common fault of cooling system: Tighten the radiator cover, start the engine, Check the makeup water tank, radiator, fan, repeated acceleration and deceleration of the water pump, rubber water pipe and antifreeze. If engine in place until the fan of cooling system antifreeze boiling occurs during vehicle traveling, please find the reason: turned on (or the needle of water temperature...
Page 44: Drive Chain
2-22 DRIVE CHAIN N O T E Clean and Lubricate Every 1,000 km. Visually check the drive chain for the possible defects listed below. (Support the motorcycle by the jack or block, turn the rear wheel slowly by hand with the trans- mission shifted to Neutral. ●...
Page 45 2-23 ● Count out 21 pins (20 pitches) on the chain and mea- sure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced. Service limit Drive chain 20-pitch length20 259.0 mm ●...
Page 46 2-24 ● Wash the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened. ● After washing and drying the chain, oil it with a engine oil. The standard drive chain is a 428UO recommends that this standard drive chain should be used for the replacement.
Page 47: Brake Fluid
2-25 ⊙BRAKE FLUID Operating the motorcycle in harsh condition can be hazardous if you do not Be sure to check the brake fluid level in the master inspect brake wear often. cylinder. If the level was found to be lower than the Operating in mud, water, sand, or other lower mark holding the motorcycle upright, inspect extreme conditions can cause accelerated...
Page 48: Brake Pads
2-26 ⊙BRAKE PADS Inspect the front and rear brake pads to Brakefluid,ifitleaks,willinterferewithsaferunning determine whether or not the friction pads are and immediately discolor painted surfaces. worn down to the grooved limit line. If a pad is Check the brake hoses and hose joints for worn to the grooved limit line it must be replaced cracks andoilleakagebeforeriding.
Page 49 2-27 The front and rear brake system requires the brake hose or the brake fluid to be replaced according to periodic inspection chart by your authorizeddealer for safety as they operate at high pressure. Riding with worn brake pads will reduce braking performance and will increase your chance of having accident.
Page 50: Brake Disk Inspection
2-28 BRAKE DISK INSPECTION Check the brake disk for damage or cracks. FRONTBRAKE BRAKE FLUID LEVELCHECK Keep the motorcycle upright and place the handle bars straight. Check the brake fluid level by observing the lower limit line (LOWER) on the front brake fluid reservoir. When the level is below the lower limit line (LOWER), replenish with brake fluid that meets the following specification.
Page 51: Front Brake Fluidreplacement
2-29 FRONT BRAKE FLUIDREPLACEMENT Place the motorcycle on a level surface and keep the handlebars straight. Remove the master cylinder reservoir cap and diaphragm. Suck up the old brake fluid as much as possible. Fill the reservoir with new brake fluid. Specification and Classification : DOT 4 Connect a clear hose①to the air bleeder valve of...
Page 52: Rear Brake Fluidreplacement
2-30 REAR BRAKE FLUIDREPLACEMENT Place the motorcycle on a level surface and keep the handlebars straight. Remove the master cylinder reservoir cap and diaphragm. Suck up the old brake fluid as much as possible. Fill the reservoir with new brake fluid. Specification and Classification : DOT 4 Connect a clear hose①to the air bleeder valve of...
Page 53 2-31 AIRBLEEDINGOFTHEBRAKEFLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by“sponginess”of the brake lever and also by lack of braking force.
Page 54: Rear Brake
2-32 N O T E While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir. Close the air bleeder valve, and disconnect the hose. Fill the reservoir with brake fluid to the upper line.
Page 55: Brake Lamp Switch
2-33 BRAKE LAMP SWITCH Adjust the front and rear brake light switches so that when the front brake handle is clenched or the brake pedal is pressed, the brake light will light up before the pressure is felt. Front brake lamp switch Rear brake lamp switch...
Page 56: Steering
2-34 STEERING N O T E Inspect Initial 1,000 km and Every 4,000 km. Steering should be adjusted properly for smooth turning of handlebars and safe running. Over tight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the steering stem while grasping the lower fork tubes by supporting the machine so that the front wheel is off the...
Page 57: Tire
2-35 TIRE N O T E Inspect Initial 1,000 km and Every 4,000 km. Inspect the tire pressure and the tire thread depth periodically. Inspect frequently the tire pressure for the safety and the tire life. Failure to follow these warnings may result in an accident due to tire failure.
Page 58: Tire Pressure
2-36 TIREPRESSURE Insufficient air pressure in the tires not only hasten tire wear but also seriously affects the stability of the motorcycle. Under-inflated tires make smooth cornering difficult and over-inflated tires decrease the amount o f tire in contact with the ground which can lead to skids and loss of control.
Page 59: Chassis Bolts And Nuts
2-37 CHASSIS BOLTS AND NUTS SCREW, FOREIGN MATERIAL N O T E Tighten Initial 1,000 km and Every 4,000 km.1,0004,000 Check that all chassis bolts and nuts are tightened to their specified torque. WORN, CRACK， COMPRESSION PRESSURE The compression of a cylinder is a good indicator of its internal condition.
Page 60: Compression Testprocedure
2-38 ◉ COMPRESSION TESTPROCEDURE N O T E Before testing the engine for compression pres- sure, make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted. Have the engine warmed up by idling before testing.
Page 61: Low Oil Pressure
2-39 OIL PRESSURE Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. Standard Oil pressure 1.4± 0.2 kg/cm (at 60 ℃∙4,000 rpm) If the oil pressure is lower or higher than the specification, the following causes may be considered.
Page 62 ENGINE Contents INTRODUCTIO...............................3-1 ENGINE DISASSEMBLY............................. 3-2 INSPECTION AND MAINTENANCE OF ENGINE COMPONENTS............3-20...
Page 64 ENGINE3-1 INTRODUCTIO The engine is separated from the vehicle: Remove the saddle, fuel tank (oil pipe, air pipe, power connector), and remove the guard; Remove the oil and engine coolant, remove the radiator; Disassemble the drive chain, disassemble the battery cable, magneto cable and other connectors, and the gear display switch connector;...
Page 65: Engine Disassembly
3-2 ENGINE ENGINE DISASSEMBLY Remove saddle and fuel tank Loosen the rear fixing groove of the saddle and remove the saddle①. Remove the fuel tank②. (Refer to page 5-2) Remove the frame cover correctly After removing the hooks ①、②、③ remove the right cover. After removing the hooks ④、⑤、⑥...
Page 66 ENGINE3-3 Drain the oil and the coolant; Remove the oil drain plug and drain the engine oil. Engine oil: SAE10W-40 ENGINE OIL CAPACITY Oil change 850ml Oil and filter change 950ml Engine overhaul 1,400ml Remove the exhaust pipe,remove the thermostat water pipe, remove the lower water pipe;...
Page 67 3-4 ENGINE Remove the small sprocket; Remove the two fastening bolts ① and remove the sprocket cover. Remove the two tighteningscrew and one axle bolt.②③ Remove the chain wheel. Remove the idle speed control conducting wire④. Remove the ground conducting wire ⑤...
Page 68 ENGINE3-5 Remove theclutch cable ① Remove the throttle body②. Remove the cylinder temperature sensor③ Remove the fixing bolts of the engine guard. ④ Remove the four left and right fixing boltsof the engine guard bracket.⑤...
Page 69 3-6 ENGINE Remove the nut of rear fork axle ⑥ Remove the tighten bolt of engine Pull out part of the rear fork axle so that the engine can be removed. Note: Please note do not to pull out the whole rear fork axle Take off the engine slowly.
Page 70 ENGINE3-7 Engine decomposition Take off the bolts of cylinder head cover①. NOTE Beat the cylinder head cover with a rubber hammer. Remove the plug②. Remove the plug③. Rotate the magneto rotor ④ to set the front cylinder’s piston at TDC (Top Dead Center) of the compression stroke.
Page 71 3-8 ENGINE Remove the chain guide Ⅱ①. Remove the head ass’y,cylinder②. Loosen the chain tensioner③. Remove the camshaft comp,intake④ and camshaft comp,exhaust⑤. NOTE Be careful that the chain falls into the crankcase. Remove the cylinder head. NOTE Beat the cylinder with the rubber hammer.
Page 72 ENGINE3-9 Remove the cylinder block. Remove thecirclip,piston pin②. Remove the pin,piston①. Take off the piston③. Remove the cap④ and filter comp,engine oil. Remove the water pump tee⑤. Remove the cover comp,clutch. Remove the cover,starter idle gear⑥.
Page 73 3-10 ENGINE Remove themotor assy, starting①. Remove the gear②. Remove the switch assy,gear shift③. Remove the cover,magneto④.
Page 74 ENGINE3-11 Remove thecontact,gearshif switch①and spring,gear shift switch contact②. Remove thecover comp,clutch③. Remove the five clutch pressure plate bolts. Remove the disk,clutch pressure④.
Page 75 3-12 ENGINE Remove the plate,clutch drive and plate, clutch driven①. Remove the clutch compression nut ②, and remove the clutch spline sleeve ③. Remove thegear assy,primary driven④. Remove the primary driving gear and drive gear of oil pump⑤. Remove the gear of oil pump⑥.
Page 76 ENGINE3-13 Remove the shift shaft assembly ①. Remove the oil pump assembly ②. NOTE Be careful that the oil pump couldn’t be separated. Remove the two bolts of the cam baffle, and remove the cam baffle ③. Remove the two bolts of the cam holder, and remove the cam holder ④.
Page 77 3-14 ENGINE Remove themagnetomotor rotor②. Remove the start the driven gear③. Fix the unpacking machine④ as the picture. Remove the left box.
Page 78 ENGINE3-15 Remove the cam comp,gear shift①. Remove the fork,gear shift NO.1 and shaft,gear shift fork NO.1②. Remove the fork,gear shift NO.3 and shaft,gear shift fork NO.2③. Remove the shaft comp,drive④. Remove the shaft comp,counter⑤. Remove theshaft comp,crank balancer⑥. Remove thecrankshaft assy⑦.
Page 79 3-16 ENGINE Cylinder head combination decomposition See if the valve room is carbon-accumulating. Twointake valve, slightly larger in diameter. Twoexhaust valve, slightly smaller in diameter. Remove the four valve lifters③ and adjusting shims④, and pay attention to their installation positions, do not mix them during assembly.
Page 80 ENGINE3-17 Pressurized gas door lock disassembly device, remove the lock plate, remove the valve base, valve oil seal. The same removal method for the intake and exhaust valves. Valve lock plate①. Valve retainer②. Valve spring ③. Valve oil seal④. Valve spring seat⑤. Valve ⑥.
Page 81 3-18 ENGINE When the piston ring is installed, 3 ring openings are staggered 120° respectively. NOTE When installing the piston, the top notch portion corresponds to the valve and the arrow markings on the piston face the exhaust valve. NOTE Note When replacing: A gas ring chrome plating①.
Page 82 ENGINE3-19 Engine assemblConsiderations 1. Reverse operation in the above order. 2. The disassembled engine must be cleaned clean. 3. When the left and right box is merged, apply the sealant evenly and the fixing bolt diagonally according to the torque requirement to lock. 4.
Page 83 3-20 ENGINE INSPECTION AND MAINTENANCE OF ENGINE COMPONENTS Be sure to identify each removed part as to its location, and lay the parts out in groups designatedas“cylinder”, “Exhaust”, “Intake”so that each will be restored to the original location during assembly. VALVEDISTORTION Decarbonate in combustion chamber.
Page 84: Camshaft Wear
ENGINE3-21 VALVE STEM RUNOUT Check the valve stem for abnormal wear or bend. Place the valve on V-blocks and measure runout. If the service limit is exceeded or abnormal condition exists, replace the valve. Valve stem runout Service limit 0.05 mm Dial gauge : Magnetic stand : V-block :...
Page 85: Valve Stemdiameter
3-22 ENGINE VALVE GUIDE-VALVE STEM CLEAR- ANCE Measure the clearance in the valve guide-valve stem, by rigging up the dial gauge. If the clearance is measured exceeds the limit specified below, then deter- mine whether the valve or the guide should be replaced to reduce the clearance to within the standard range: Valve guide-valve stem Standard...
Page 86: Valve Spring
ENGINE3-23 VALVE SPRING The force of the coil spring keeps the valve seat tight. A weakened spring results in reduced engine power out- put and often accounts for the chattering noise coming from the valve mechanism. Check the valve springs for proper strength by measuring their free length and also by the force required to compress them.
Page 87: Cylinder Distortion
3-24 ENGINE CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder.
Page 88: Cam Chain Tensioner
ENGINE3-25 CAM CHAIN TENSIONER Check the contacting surface of the cam chain tensioner. If it is worn or damaged, replace it with a new one. CAM CHAIN AND CAM CHAIN GUIDE Check the cam chain for wear, damage and kinked or binding links. If any defects are found, replace it with a new one.
Page 89: Piston-To-Cylinderclearance
3-26 ENGINE PISTON DIAMETER INSPECTION Measure the outside diameter of piston in the direction perpendicular to the piston pin axis at the height from the skirt as shown in the illustration using a micrometer. If the measurement is found less than the service limit, replace the piston.
Page 90: Piston Ring End Gapinspection
ENGINE3-27 PISTON PIN DIAMETER INSPECTION Using a micrometer, measure the piston pin outside diameter at three position, both the ends and the center. If any of the measurements is founds less than the ser- vice limit, replace the pin. Service limit Piston pin diameter 14.980 mm Micrometer(0~25 mm) :09900-20201...
Page 91: Piston Ring-To-Groove Clear Ance Inspection
3-28 ENGINE PISTON RING-TO-GROOVE CLEAR ANCE INSPECTION Remove carbon deposit both from the piston ring and its groove. Fit the piston ring into the groove. With the ring com- pressed and lifted up, measure the clearance on the bottom side of the ring using a thickness gauge.
Page 92: Crankshaft Runout Inspection
ENGINE3-29 CONROD SMALL END INSIDE DIAMETER INSPECTION Using a dial calipers, measure the conrod small end inside diameter both in vertical and horizontal directions. If any of the measurements exceeds the service limit, replace the conrod. Standard Service limit Conrod small end 13.006~13.014 13.040 mm inside diameter...
Page 93: Starter Clutch
3-30 ENGINE CRANKSHAFT REASSEBLY Measure the width between the webs referring to the figure below when rebuilding the crankshaft. Standard Width between webs 72±0.1 mm MAGNETO ASSY DISASSEMBLY Remove the stator. STARTER CLUTCH Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand(the gear turns in only one direction).
Page 94: Starter Driven Gear
ENGINE3-31 REASSEMBLY Apply a small quantity of THREAD LOCK“1324”to the starter clutch bolts and tighten them to the specified torque while holding the rotor holder. Thread Lock “1324” Rotor holder:09930-44510 Starter clutchbolt 23~28N∙m(2.3~2.8kg∙m) STARTER DRIVEN GEAR STARTER DRIVEN GEAR BUSHING Install the starter driven gear bushing ①and gear ②onto the crankshaft and turn the starter driven gear by...
Page 95 3-32 ENGINE CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the service limit, replace the clutch plates as a set. Standard Service limit Clutch drive plate 2.9~3.1 mm 2.6 mm...
Page 96: Clutch Spring Free Length
ENGINE3-33 CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using vernier calipers. If any spring is not within the service limit, replace all of the spring. Service limit Clutch spring 34.3mm free length Vernier calipers :09900-20101 :09900-20101 CLUTCH RELEASE BEARING Inspect the clutch release bearing for any...
Page 97: Oil Pump
3-34 ENGINE OIL PUMP Turn the oil pump shaft and check that rotation is smooth. If any abnormal condition is found, replace the oil pump with new one. GEARSHIFT SHAFT Disassemble and reassemble the gearshift shaft as shown in right picture. TRANSMISSION INSPECTION Using a thickness gauge, check the clearance...
Page 98: Bearing Inspection
ENGINE3-35 Thickness gauge : 09900-20806 Verniercalipers:09900-20101 Shift fork groove width Standard NO.1 & NO.2 5.0~5.1 mm NO.3 5.0~5.1mm Shift fork thickness Standard NO.1 & NO.2 4.8~4.9 mm NO.3 4.8~4.9 mm CRANKCASE BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase.
Page 99 3-36 ENGINE DISASSEMBLY RIGHT CRANKCASE BEARING Remove the bearing retainer. Remove the bearings ①②③and ④. Bearing remover(17 mm) : 09923-73210 Bearing remover(20~35 mm) :09923-74510 Bearing installer:09913-76010 Theremovedbearingshouldbereplacewithan ew one. LEFT CRANKCASE BEARING Remove the oil seals⑤and⑥. Oil seal remover :09913-50121 :09913-50121...
Page 100 ENGINE3-37 Remove the bearing retainer. Remove the bearings ①②③and④. Bearing remover(17 mm) : 09923-73210 (17 mm) : 09923-73210 Bearing remover(20~35 mm) :09923-74510 (20~35 mm) :09923-74510...
Page 101 EI SYSTEM DIAGNOSIS Content PRECAUTIONS IN SERVICING ........................1 EI SYSTEM TECHNICAL FEATURES ......................4 SELF-DIAGNOSIS FUNCTION ........................8 EI SYSTEM TROUBLE SHOOTING ......................9 CUSTOMER COMPLAINT ANALYSIS......................9 SELF-DIAGNOSTIC PROCEDURES......................11 SELF-DIAGNOSIS RESET PROCEDU...................... 11 MALFUNCTION CODE AND DEFECTIVE CONDITION................ 12 “P0031”,“P0032”...
Page 103: Precautions In Servicing
4-1 EI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the EI system, observe the following points for the safety of the system. ⊙ELECTRICAL PARTS ▣ CONNECTOR / COUPLER • When connecting a connector, be sure to push it in until a click is felt.
Page 104 4-2 EI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female terminal.
Page 105: Using The Tester
4-3 EI SYSTEM DIAGNOSIS • Battery connection in reverse polarity is INCORRECT strictly prohibited. Such a wrong connection will damage the components of the EI system instantly when reverse power is applied. • Removing any battery terminal of a running engine is strictly prohibited. The moment such removal is made, damaging counter electromotive force will be applied to the ECU which may result in...
Page 106: Ei System Technical Features
4-4 EI SYSTEM DIAGNOSIS 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 CLT Sensor CYLINDER CKP Sensor Sensor EXHAUST PIPE : Electrical signal flow...
Page 107: Compensation Of Injection Time (Volume)
4-5 EI SYSTEM DIAGNOSIS ⊙ 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 108 4-6 EI SYSTEM DIAGNOSIS ⊙EI SYSTEM PARTS LOCATION ① Speedometer ② Fuel injector ③ TP sensor ④ CKP SENSOR ⑤ WTS switch ⑥ GP sensor ⑦ CLT sensor ⑧ ISC solenoid ⑨ MAP & IAT Sensor ⑩ Regulator...
Page 109 4-7 EI SYSTEM DIAGNOSIS ⑪ ⑫ Oxygen sensor Fuel pump relay...
Page 110: Self-Diagnosis Function
4-8 EI SYSTEM DIAGNOSIS SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECU. The user can only be notified by the engine warning lamp “ ” The engine warning lamp “ ” comes on when the ignition switch is set to“ON”position with the engine is stopped.
Page 111: Ei System Trouble Shooting
4-9 EI SYSTEM DIAGNOSIS EI SYSTEM TROUBLE SHOOTING 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 112 4-10 EI SYSTEM DIAGNOSIS MOTORCYCLE / ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition 口 Fair 口 Cloudy 口 Rain 口 Snow 口 Always 口 Other Weather Temperature 口 Hot 口 Warm 口 Cool 口 Cold ( °C) 口 Always °F / Frequency 口...
Page 113: Self-Diagnostic Procedures
4-11 EI SYSTEM DIAGNOSIS 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 114: Malfunction Code And Defective Condition
4-12 EI SYSTEM DIAGNOSIS MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running,if oxygen sensor heater signal open or is happened the ground short fault for 1second by10 times in12 Low Voltage times test cycle,the code P0031 is indicated.
Page 115 4-13 EI SYSTEM DIAGNOSIS 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. MAP &...
Page 116 4-14 EI SYSTEM DIAGNOSIS DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM 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 output voltage Without the above range for 28.1sec.andmore,P0131 is indicated.
Page 117 4-15 EI SYSTEM DIAGNOSIS 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. P0336 Signal CKP Sensor wiring and mechanical parts.(CKP Sensor leadwire coupler connection) After engine running, if the CKP Sensor signal does not reach ECU...
Page 118 4-16 EI SYSTEM DIAGNOSIS 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 0300 count of total misfire incident, P0300 is indicated.
Page 119: P0031","P0032" Oxygen Sensor Heater Circuit Malfunction
4-17 EI SYSTEM DIAGNOSIS “P0031”,“P0032” OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION & “P0131”,“P0132” 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 Oxygen sensor, Oxygen sensor heater ...
Page 120 4-18 EI SYSTEM DIAGNOSIS ▣ 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. Is OK? ● B/Bl , G/Bl (O Sensor)wire open or shorted...
Page 121: P0107"Or"P0108"Map&Iat (Pressure Function)Sensor Circuit Malfunction
4-19 EI SYSTEM DIAGNOSIS “P0107”or“P0108”MAP&IAT (Pressure function)SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ☞ To read the flash code,with the EFI diagnostic ● Clogged vacuum passage between throttle body And MAP & IAT Sensor. instrument ● Air being drawn from vacuum passage between NOTE : throttle body and MAP &...
Page 122 4-20 EI SYSTEM DIAGNOSIS 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. ◈ Step 2 1) Connect the MAP & IAT sensor coupler①. 2) Insert the needle pointed probes to the lead wire coupler.
Page 123: P0112"Or"P0113"Map&Iat (Temperature Function) Sensor Circuit Malfunction
4-21 EI SYSTEM DIAGNOSIS “P0112”or“P0113”MAP&IAT (Temperature function) SENSOR CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION ● MAP & IAT sensor circuit open or short. ☞ To read the flash code,with the EFI diagnostic ● MAP & IAT sensor malfunction. instrument ● ECU malfunction. ▣...
Page 124 4-22 EI SYSTEM DIAGNOSIS IAP(Temperature function) Sensor resistance Intake Air Temp. Intake Air Temp. -20 ℃ (-40 ℉ ) -20 ℃ (-40 ℉ ) -0 ℃ (32 ℉ ) -0 ℃ (32 ℉ ) 20 ℃ (68 ℉ ) 20 ℃ (68 ℉ ) 40 ℃...
Page 125: P0117"Or"P0118" Clt Sensor Circuit Malfunction
4-23 EI SYSTEM DIAGNOSIS “P0117”or“P0118” CLT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● CLT sensor circuit open or short. ☞ To read the flash code,with the EFI diagnostic ● CLT sensor malfunction. instrument ● ECU malfunction. ▣ INSPECTION 1) Turn the ignition switch to the “OFF” position. 2) Check the CLT sensor coupler for loose or poor contacts.
Page 126 4-24 EI SYSTEM DIAGNOSIS CLT sensor resistance Engine Coolant Resistance (To ECU) Temp. ㏀ -40 ℃ (-40 ℉ ) Approx. 48.140 ㏀ 0 ℃ (32 ℉ ) Approx.5.790 ㏀ 20 ℃ (68 ℉ ) Approx. 2.450 ㏀ 40 ℃ (104 ℉ ) Approx.
Page 127: P0122"Or"P0123" Tps Circuit Malfunction
4-25 EI SYSTEM DIAGNOSIS “P0122”or“P0123” 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 ● ECU malfunction. instrument ▣ INSPECTION ◈ Step 1 1) Turn the ignition switch to the “OFF”...
Page 128 4-26 EI SYSTEM DIAGNOSIS ◈ Step 2 1) Turn the ignition switch to the “OFF” position. 2) Disconnect the TP sensor coupler. 3) Check the continuity between ○ (Gr/Bl) and ground. ∞ Ω (Infinity) TP sensor continuity (A- Ground) Tester knob indication : Resistance (㏀) Is the continuity OK? Go to Step3 Replace the TP sensor with a...
Page 129: P0201" "P0262"Fuelinjector Circuit Malfunction
4-27 EI SYSTEM DIAGNOSIS “P0201” “P0262”FUELINJECTOR 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 ▣ INSPECTION ◈ Step 1 1) Remove the fuel tank. 2) Turn the ignition switch to the “OFF”position.
Page 130 4-28 EI SYSTEM DIAGNOSIS ◈ 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 131: P0231"Or"P0232"Fuel Pump Relay Circuit Malfunction
4-29 EI SYSTEM DIAGNOSIS “P0231”or“P0232”FUEL PUMP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● Fuel pump relay circuit open or short. ☞ To read the flash code,with the EFI diagnostic ● Fuel pump relay malfunction. instrument ● ECU malfunction. ▣ INSPECTION 1) Remove the seat set 2) Turn the ignition switch to the “OFF”...
Page 132: P0336"Or"P0337" , "P1693"Or"P1694"Ckp Sensor Circuit Malfunction
4-30 EI SYSTEM DIAGNOSIS “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 or short. instrument ●...
Page 133: P0505" Isc Solenoid Range Abnormal
4-31 EI SYSTEM DIAGNOSIS “P0505” ISC SOLENOID RANGE ABNORMAL DETECTED CONDITION POSSIBLE CAUSE ● ISC solenoid malfunction. ● ISC solenoid’s step is out of the specified range. ☞ To read the flash code,with the EFI diagnostic ● ECU malfunction. instrument ▣...
Page 134: P0562" Or "P0563" Battery Voltag Emalfunction
4-32 EI SYSTEM DIAGNOSIS “P0562” or “P0563” BATTERY VOLTAG EMALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● Battery voltage circuit open and short. ☞ To read the flash code,with the EFI diagnostic ● Battery malfunction. ● ECU malfunction. instrument ▣ INSPECTION 1) Remove the seat. 2) Turn the ignition switch to the “OFF”...
Page 135: P0601" Ecu Fault Malfunction
4-33 EI SYSTEM DIAGNOSIS “P0601” ECU FAULT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ● ECU error ☞ To read the flash code,with the EFI diagnostic instrument “P0650”ENGINE WARNING LAMP CIRCUIT MALFUNCTION POSSIBLE CAUSE DETECTED CONDITION ● engine warming lamp circuit open and short. ●...
Page 136: P0850"Gp Or Clutch Lever Switch Circuit Malfunction
4-34 EI SYSTEM DIAGNOSIS “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 ● Clutch lever switch circuit open or short. instrument ●...
Page 137: P2300"Or"P2301" Ignition Coil Malfunction
4-35 EI SYSTEM DIAGNOSIS 7） Measure the voltage between G18 of the ECU and the G/R wire of the wiring harness’ clutch lever switch coupler. If the measurement is out of 0.4 ~ 0.7 V, replace the DIODE with a newone Tester knob indication: Diode test( Is OK? ...
Page 138: Sensors
4-36 EI SYSTEM DIAGNOSIS 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 removal. ⊙ MAP&IAT（MAP）SENSOR INSPECTION •...
Page 139: Fuel System And Throttle Body
FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM ..............................5-1 REMOVAL AND DISASSEMBLY....................... 5-2 REASSEMBLY AND INSTALLATION....................... 5-3 FUEL PRESSURE INSPECTION....................... 5-4 FUEL PUMP RELAY INSPECTION......................5-5 FUEL MESH FILTER INSPECTION AND CLEANING................5-6 FUEL GAUGE INSPECTION........................5-6 THROTTLE BODY ............................5-7 REMOVAL...............................5-8 CLEANING..............................5-9 INSPECTION…............................5-10 INSTALLATION............................
Page 141: Fuel System
FUEL SYSTEM AND THROTTLE BODY 5-1 FUEL SYSTEM Gasoline must be handed carefully in an area well ventilated and away from fire or sparks.
Page 142: Removal And Disassembly
5-2 FUEL SYSTEM AND THROTTLE BODY REMOVAL AND DISASSEMBLY Gasoline is very explosive. Extreme care must be taken. Drain the fuel. ● Open the saddle switch lock and remove ● the saddle ①. Remove the fuel tank mounting bolts②. ● Disconnect the fuel sensor connector③，...
Page 143: Reassembly And Installation
FUEL SYSTEM AND THROTTLE BODY 5-3 Remove the fuel tank. As gasoline leakage may occur in this operation, keep away from fire and sparks. Remove the fuel pump mounting nuts. Remove the fuel pump. ❖ Gasoline is highly flammable and explosive.
Page 144: Fuel Pressure Inspection
5-4 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE INSPECTION Place a rag under the fuel injector hose. Disconnect the fuel injector hose from the ● fuelhose joint. Install the special tool between the fuel tank and ● fuel hose joint. Fuel pump pressuregauge : 09915-54510 Turn the ignition switch to the “ON”...
Page 145: Fuel Pump Relay Inspection
FUEL SYSTEM AND THROTTLE BODY 5-5 FUEL PUMP RELAY INSPECTION X-RIDE’s fuel pump relay is located in the rear ● right cover of the frame. Remove the rear right cover of the frame. ● Remove the fuel pump relay①. ● First, check the insulation between ①...
Page 146: Fuel Mesh Filter Inspection And Cleaning
5-6 FUEL SYSTEM AND THROTTLE BODY 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 147: Throttle Body
FUEL SYSTEM AND THROTTLE BODY 5-7 THROTTLE BODY...
Page 148: Removal
5-8 FUEL SYSTEM AND THROTTLE BODY REMOVAL Remove the fuel tank. Disconnect the fuel hoses. Remove the all couplers connected to the throttle body. Loosen the throttle body clamp and intake pipe screws. Disconnect the throttle cables from their drum. Dismount the throttle body assembly.
Page 149: Cleaning
FUEL SYSTEM AND THROTTLE BODY 5-9 CLEANING Clean all passageways with a spray-type throttle body cleaner and blow dry with compressed air. Some throttle body cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage.
Page 150: Inspection
5-10 FUEL SYSTEM AND THROTTLE BODY INSPECTION Check following items for any damage or clogging. O-ring Throttle shaft bushing and seal Injector cushion seal Fuel injector Throttle body Intake pipe Throttle valve Vacuum hose Check fuel injector filter for evidence of dirt and contamination.
Page 151 ELECTRICAL SYSTEM CONTENTS LOCATION OFELECTRICAL COMPONENTS ................. 6-1 IGNITION SYSTEM ..........................6-3 CHARGING SYSTEM ...........................6-7 STARTER SYSTEM AND SIDE STAND ..................6-9 SWITCHES..............................6-15 LAMP .................................6-16 BATTERY ..............................6-19 ................................6-21...
Page 153: Location Ofelectrical Components
ELECTRICAL SYSTEM 6-1 LOCATION OFELECTRICAL COMPOENTS Flasher Ignition coil Front brake lamp switch Rear brake lamp switch Startermotor Oxygen sensor...
Page 154 ELECTRICAL SYSTEM 6-2 Cylinder temperature Rectifier Throttle body position sensor sensor Air intake pressure EFI relay Oil pump relay temperature sensor Headlight relay ECU Fuse ABS Fuse Starting relay Water Temperature switch Horn Gear position switch Side stand switch ABS module...
Page 155: Ignitionsystem
ELECTRICAL SYSTEM 6-3 Be sure not to misassemble the position of battery plus & minus terminal. IGNITIONSYSTEM...
Page 156 ELECTRICAL SYSTEM 6-4 INSPECTION MAGNETO Pick-up coil 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 Charging coil resistance...
Page 157: Ignitioncoilprimarypeak Voltageinspection
ELECTRICAL SYSTEM 6-5 IGNITIONCOILPRIMARYPEAK VOLTAGEINSPECTION 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 158 ELECTRICAL SYSTEM 6-6 While testing, do not touch the tester probes spark plugs prevent receiving an electric shock. Ifthepeakvoltageislowerthanthespecifiedvalues, inspecttheignitioncoil. IGNITION COIL RESISTANCE INSPECTION Remove the fuel tank. Disconnect the ignition coil read wire. Measure the ignition coil resistance in bolt the primary secondary windings.
Page 159 ELECTRICAL SYSTEM 6-7...
Page 160: Spark Plug Gap
ELECTRICAL SYSTEM 6-8 ■ 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 161: Charging System
ELECTRICAL SYSTEM 6-9 CHARGING SYSTEM ■INSPECTION ▷C HARGING OUTPUT CHECK Start the engine and keep it running at 5,000 rpm. Using pocket tester, measure voltagebetween the battery terminal If the voltage is not within the specified value, check the magneto no-load performance and regulator / rectifier.
Page 162 ELECTRICAL SYSTEM 6-10 ▷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 163: Starter System And Side Stand
ELECTRICAL SYSTEM 6-11 STARTER SYSTEM AND SIDE STAND 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. Pressing the starter switch (on the right handlebar switch) energizes the starter relay, causing the contact points to close, thus completing the circuit from the starter motor to the battery.
Page 164 ELECTRICAL SYSTEM 6-12 TRANSMISSION : Neutral –“ON” Side stand - Down Clutch lever - Squeeze TRANSMISSION : Neutral -“OFF” Side stand - Up Clutch lever - Squeeze X-RIDE 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 Side stand...
Page 165: Starter Motor Removal And Disassembly
ELECTRICAL SYSTEM 6-13 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 166: Starter Motor Reassembly
ELECTRICAL SYSTEM 6-14 STARTER MOTOR REASSEMBLY Reassembly the starter motor. Pay attention to the following points : ● Reassembly the starter motor as shown in the illustration.
Page 167 ELECTRICAL SYSTEM 6-15 ● Align the mark ① on the housing with the line ② on the housing end. ● Apply GREASEto the O-ring ③ and remount the starter motor.
Page 168: Switches
ELECTRICAL SYSTEM 6-16 SWITCHES Measure each switch for continuity using a tester. If any abnormality is found, replace the respectiveswitch assemblies with new ones. Pocket tester :09900 - 25002：09900-25002 ENGINE STOP IGNITION SWITCH Br/W STARTER DIMMER PASSING WARNING SWITCH TURN SIGNAL INFO SWITCH INFO HORN...
Page 169: Lamp
ELECTRICAL SYSTEM 6-17 LAMP HEADLAMP TURN SIGNALLAMP...
Page 170 ELECTRICAL SYSTEM 6-18 TAIL / BRAKELAMP...
Page 171: Combination Meter
ELECTRICAL SYSTEM 6-19 COMBINATION METER Remove the combination meter. Disassemble the combination meter as shown in the illustration. INSPECTION检查 Using the pocket tester, check the continuity betweenlead wires in the following illustration. If the continuity measured incorrect, replace the respective part. Pocket tester :09900 - 25002 ：09900-25002 When making this test, it is not necessary...
Page 172: Battery
ELECTRICAL SYSTEM 6-20 BATTERY X-RIDE . Use only the genuinebattery 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. Therefore, please pay attention to the following points.
Page 173: Battery Installation
ELECTRICAL SYSTEM 6-21 Be careful not to permit the charging current to exceed 5 A at any time. ● 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.
Page 174: Abs
ELECTRICAL SYSTEM 6-22 BRAKES The X-RIDE utilizes front andrear disk brakes. Properly operating the brake systems isvital to safe riding. Be sure to perform thebrake inspection requirements as schedules. The brakes should be inspected at periodicinspection by your authorized dealer. Failure to properly inspect and maintainyour motorcycle brake systems can behazardous.
Page 175 ELECTRICAL SYSTEM 6-23 pressure. The regulatingprocess causes a slight pulsing of thefront brake lever and rear brake pedal. ABS warning lamp will light up after theignition switch is set to “ ” position andthe vehicle has traveled until a speed of 5km/h (3 mph) for a self-diagnosis test,and will go out after the vehicle has traveledover a speed of 5 km/h (3 mph).If itdoes not go out after the vehicle has traveledover a speed of 5 km/h (3 mph) or ifit lights up while riding, this indicates afault in ABS system.In this case, ABS isno longer enabled and the wheels maylock during braking.
Page 176 ELECTRICAL SYSTEM 6-24 N O T E Keep any type of magnets (includingmagnetic pick-up tools, magnetic screwdrivers,etc.) away from the front andrear wheel’s tone wheels, otherwise thefront and rear wheel’s tone wheel maybecome magnetized, resulting inimproper performance of ABS system.
Page 177 ELECTRICAL SYSTEM 6-25 Fault types Fault description Maintenance rule out Fault code ABSW/L light ABS ECU Internal Replace the ABS Module C5055 （●） fault VR relay ABS ECU Relay Replace the ABS Module C5019 failure Inlet valve EV ABS Application of Replace the ABS Module F: C5017 electromagnetic circuit...
Page 178 ELECTRICAL SYSTEM 6-26 between front and rear should rotate ABS wheels is too synchronously, and the high, the number of clearance between ABS teeth is incorrect, and sensor and gear ring every the signal is poor tooth should be guaranteed to be normal within 3mm model instructions...
Page 179 CONTENTS EXTERIORPARTS…………………………………………………………………………………………… 7 - 1 FRAMECOVER……………………………………………………………………………………………… 7 - 2 REARFRAMECOVER……………………………………………………………………………………… 7 -4 FRONTWHEEL……………………………………………………………………………………………… 7 -7 FRONT BRAKE AND REAR BRAKE……………….……………………………………………………… 7 -11 HANDLEBARS……………………………………………………………………………………………… 7 -20 7 -24 HEADLAMP COMP&SPEEDOMETER COMP…………………………………………………………… FRONTFORK………………………………………………………………………………………………… 7 -26 7 -33 PLATE STEERING&BRACKET COMP UNDER …………………….…………….……….………….… REARWHEEL…………………………………………………………………………………………………...
Page 180: Exteriorparts
7-1 CHASSIS EXTERIOR PARTS FRONT FENDER With the bolts removed, remove the front fender SEAT Open the saddle switch lock and remove the ● saddle ①.
Page 181: Framecover
CHASSIS 7-2 FRAME COVER 1.Side cover，R 2.Side cover，L 3.Rear cover 4.Carrier RIGHT SIDE COVER With the hook ①、②、③removed, remove the right side cover. LEFT SIDE COVER With the hook ④、⑤、⑥removed, remove the left side cover.
Page 182 7-3 CHASSIS FRAME REARAND REAR CENTER COVER Remove the mounting screws on the left and right sides. Remove the six mounting screws on the left and right. Remove the rear cover and center cover of the frame. FRONT FORK COVER Remove the four mounting screws.
Page 183: Rearframecover
CHASSIS 7-4 REAR FRAME COVER 1.Rear fender，front part 10. Gasket 2. Relay mounting plate 11. Rear left turn signal 3. Clamp nut M6*16*20*5 12. Rear right turn signal 4. The tail lights (TL354) 13. Rubber cover for turn signal 5.Hex flange nut (M5) 14.
Page 184 7-5 CHASSIS MUD GUARD, REAR UNIT Remove the four mounting screws. Remove the water retaining skin. REAR FENDER FRONT Remove one nut and four mounting bolts. Remove the rear fender.
Page 185 CHASSIS 7-6 SUB ASSY Remove the two mounting screws. Disconnect the circuit cable. Remove the rear tail lamp assembly. TURN SIGNALLAMP ASSY Remove the two mounting screws.① Disconnect the turn signal line connection. Remove the turn signal combination. TAIL LAMP Remove the two mounting screws.
Page 186: Frontwheel
7-7 CHASSIS FRONT WHEEL REMOVAL Loosen the axle pinch bolt ①. Loosen the front axle ②. Raise the front wheel off the ground with a blockor jack. When using a jack, take care not to cause scratches on the chassis. Remove the front wheel by removing the front axle②.
Page 187: Inspection And Disassembly
CHASSIS7-8 INSPECTION AND DISASSEMBLY For inspection of the tire : Refer to page 2-36. FRONT AXLE Measure the front axle runout using the dial gauge. If the runout exceeds the limit, replace the front axle. Service limit Axle shaft runout 0.25 mm Dial gauge : 09900 - 20606 Magnetic stand : 09900 - 20701...
Page 188: Brake Disc
7-9 CHASSIS WHEEL BEARINGREMOVAL Remove the wheel bearing by using the special tool. Wheel bearing remover :09941 - 50111 The removed bearing should be replaced with new ones. REASSEMBLY Reassemble the front wheel in the reverse order of removal and disassembly. Pay attention to the following points : WHEEL BEARING Install the wheel bearings as follows by using the special...
Page 189 CHASSIS7-10 Tighten the front axle ① and axle pinch bolt ② to the specified torque. Front axle:65N∙m (6.5kg∙m) Front axle pinch bolt : 23N∙m（2.3kg∙m）...
Page 190: Front Brake And Rear Brake
7-11 CHASSIS FRONT BRAKE AND REAR BRAKE 11. Front disc brake switch assembly 1. The ABS module 21. Socket hexagon large flat head screw 12. Front disc brake calipers 2. Brake pedal M6*20 13. Front disc brake caliper connecting combination 22.
Page 191 Do not allow brake fluid to contact the paint surface, plastic or rubber parts, or its chemical reaction can cause discoloration or crack.
Page 192: Brake Fluid Replacement
CHASSIS 7-12 BRAKE FLUID REPLACEMENT For replacing procedure of brake fluid : Refer to page 2-31 BRAKE PAD REPLACEMENT For replacing procedure of brake pad : Refer to page 2-30 CALIPER DISASSEMBLY Drain brake fluid. To prevent brake fluid from splashing on the parts nearby, cover the parts with cloth.
Page 193: Brake Inspection
7-13CHASSIS Remove the front brakecaliper pad comp. Remove the friction plate. Remove the brake caliper holder ①. Remove the spring ②. Put a rag on the brake caliper piston to prevent it from jumping out suddenly. Then compressed air is used to force the piston out. ❖...
Page 194 CHASSIS 7-14 CALIPER REAR BRAKE DISASSEMBLY Remove the rear brake caliper mounting bolts① and brakehouse bolts②. Remove the fixing screw ⑤ and the friction plate ③ Remove the spring slice ④. Using an air gun, push out the caliper piston. ❖...
Page 195: Caliper Inspection
7-15 CHASSIS Remove the dust seal ⑦ and piston seal ⑧. ❖ Care not to cause scratch on the cylinder bore. ❖ Do not reuse the piston seal and dust seal thathave been removed. CALIPER INSPECTION Inspect the front and rear caliper cylinder wall and piston surface for scratch, corrosion or other damages.
Page 196: Brake Disc Inspection
CHASSIS 7-16 Tighten the front caliper mounting bolts①and rear caliper mounting bolts③. With the hose end seated to the stopper, tighten the union bolt ② and ④. Front brake caliper mounting bolts :39N∙m (3.9kg∙m) Front brake hose union bolts :23N∙m (2.3kg∙m) Rear brake caliper mounting bolts :39N∙m (3.9kg∙m) Rear brake hose union bolts...
Page 197: Master Cylinder Disassembly
7-17 CHASSIS MASTER CYLINDER DISASSEMBLY Drain brake fluid the master cylinder. Disconnect the brake lamp switch lead wire coupler. Remove the switch assembly① Remove the union bolt②. Place a rag under the union bolt so that brake fluid can not contact the parts. Remove the master cylinder.
Page 198: Master Cylinder Inspection
CHASSIS 7-18 Remove the dust seal cover ① and remove the piston thread circlip ②. Pull out the main pump piston③and spring④. MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage. Inspect the piston surface for any scratches or other damage.
Page 199 7-19 CHASSIS Apply SUPER GREASE“A”to the brake lever pivot①. SUPER GREASE“A” When remounting the master cylinder onto the han- dlebars, align the master cylinder holder’s mating surface with punch mark on the handlebar andtighten the upper clamp bolt first. Front brake master cylinder mounting bolt : 10N∙m (1.0kg∙m) Install the brake hose union, tighten the union bolt to the specified torque.
Page 200: Handlebars
CHASSIS 7-20 HANDLEBARS HANDLEBARS RIGHT SIDE PARTS REMOVAL Remove the right rearview mirror ①. Remove fixing bolts from the front brake pump assembly. Disconnect the brake light switch wire and remove the switch assembly and oil pipe. Remove brake lever. Remove the right handlebar switches.
Page 201 7-21CHASSIS Remove the throttle cable. Remove the handlebar grip . HANDLEBARS LEFT SIDE PARTS REMOVAL Remove therearview mirror ①. Remove the clutch lever rear holder.
Page 202 CHASSIS7-22 Disconnect the clutch switch lead wires. Remove the clutch cable. Remove the clutch lever. Remove the left handlebar switches. Remove the handlebar grip.
Page 203 7-23 CHASSIS Remove the clamp bolts and detach the handlebar holders. Remove the handlebar. REMOUNTING Perform the remounting work in the reverse order of theremoval procedures while observing the following instructions. Tighten the handlebar clamp bolts to the specified torque. Handlebar clamp bolt : 18~28 N∙m (1.8 ~2.8 kg∙m) N O T E...
Page 204: Headlamp Comp&Speedometer Comp
CHASSIS7-24 HEADLAMP COMP&SPEEDOMETER COMP REMOVE THE HEADLAMP ASSEMBLY Remove the fixing hook of the front headlight cover and remove the front headlight cover. Disconnect the connecting wire of the front headlight assembly. Remove the two mounting screws of the headlamp. Remove the headlamp.
Page 205 7-25CHASSIS REMOVE THE SPEED ODOMETER COMBINATION Remove the speed odometer combination mounting bolts. Disconnect the connecting wire of the speed odometer combination. Remove the speed odometer combination. ● Remove the two mounting screws on the left and right of the electric lock. ●...
Page 206: Frontfork
CHASSIS 7-26 FRONT FORK 1. Left front reverse shaker 2. Right front reverse shaker 3. Front shock absorber cover 4. Hexagon socket cylindrical head screw M8*20 5. Lower assembly of suet pipe clamp 6. Left front reflector bracket 7. Right front reflector bracket 8.
Page 207 7-27CHASSIS Remove the front fork after loosening the front fork upper ① and lower clamp bolts② . N O T E Slightly loosen the front fork upper bolt ③ to facili- tate later disassembly. Remove the front fork upper bolt ③, O-ring ④, ③...
Page 208 CHASSIS 7-28 Remove the dust seal ① and oil seal stopper ring ②. ② Separate the inner tube from the outer tube. Remove the following parts. ③ Oil seal ④ Slide metal ⑤ Oil lock piece The removed oil seal and slide metal ③...
Page 209 7-29CHASSIS INSPECTION FRONT FORK SPRING Measure the free length of the front fork spring. If the length is found shorter than the service limit, replace the spring. Service limit Front fork spring free lengthL 301 mm INNER TUBE AND OUTER TUBE Check the sliding of the inner tube, outer tube and damper rod ring for scratch, wear, bending, or other abnormal condition.
Page 210 CHASSIS 7-30 With the oil lock piece fitted to the inner tube, assemble the inner tube to the outer tube. Apply SUPER GREASE“A”to the lip of the oil seal and install it into the outer tube using the front fork oil seal installer.
Page 211: Front Fork Oil
7-31CHASSIS Apply THREAD LOCK“1324”to the damper rod bolt②. With the damper rod held immovable, with the ② gasket ①fitted, tighten the damper rod bolt②. Front fork damper rod bolt ① : 20N∙m (2.0kg∙m) THREAD LOCK“1324” Replace the gasket with a new one. FRONT FORK OIL With the inner tube in fully compressed position, pour the specified amount of fork oil and stroke the tube...
Page 212 CHASSIS 7-32 Fit the O-ring to the front fork upper bolt and apply SUPER GREASE“A”. SUPER GREASE“A” Use a new O-ring to prevent oil leakage. Install the front fork to the motorcycle. Align the upper surface of the inner tube with the upper surface of the steering stem upper bracket.
Page 213: Plate Steering&Bracket Comp Under
7-33CHASSIS LATE STEERING&BRACKET COMP UNDER 1. Hex flange bolt M8* 45GB5789-86 6. Gasket 2. Dust cover (including upper&lower dust cover) 7. Cover nut M22*1.25 3. Lock the nut 8. Lower header assembly 4. Needle roller bearing assembly 30205 with 9. Hex flange bolt M10*50* 1.25GB5789-86 baffle bowl 10.
Page 214 CHASSIS7-34 Remove the steering stem head nut ①. Tap the steering rod bracket lightly to remove the upper steering rod bracket. Remove the steering stem nut ② using the special tool. Clamp wrench : 09940-10122 Loosen the four left and right clamping bolts ③.
Page 215 7-35 CHASSIS Remove the lower bearing ①. ❖Unless corrosion, damage or other abnormal condition is found, the bearing race need notbe replaced. ❖Once the lower inner race has been removed, replace it with a new one. Drive out the steering stem bearing outer races using the special tools ②...
Page 216 CHASSIS 7-36 Press in the lower inner race ①. Bearing installer : 09913-80112 Apply SUPER GREASE“A”to the upper bearing, lower bearing and outer races prior to installing the steering stem. SUPER GREASE A Install the upper bearing ② and dust cover ③. Install the lock nut and tighten it to the specified torque.
Page 217 7-37 CHASSIS Install the left and right shock absorber combination before installation. Tighten the clamping bolts under the front shock absorber. Install the front fender. Install the front wheel. Install the upper tray. Install the steering stem upper bracket ① and washer ②.
Page 218 CHASSIS 7-38 Install headlight combination. First, connect the headlight connector correctly and firmly with the connector on the main wiring harness. Install the handlebar welding assembly. N O T E The gap between the handle block and the holder shall be uniform Tighten the clamp bolts to the specified torque.
Page 219: Rearwheel
7-39 CHASSIS REAR WHEEL REMOVAL Raise the rear wheel off the ground with a jack or block. Remove the drive chain cover.
Page 220 CHASSIS 7-40 Remove the mounting bolts of the rear caliper, and remove the rear caliper. Loosen the right drive chain adjuster nut ①and leftdrive chain adjuster nut ②. Disengage the drive chain from the rear sprocket. Remove the rear axle nut ③. Draw out the rear axle④with the rear wheel push to the bottom.
Page 221 7-41 CHASSIS Remove the rear brake panel①. Remove the large sprocket mounting nut. Remove the left spacer ② of the rear wheel. Remove the large sprocket ③ . Remove the dust seal. Oil seal remover : 09913-50121...
Page 222: Rear Sprocket
CHASSIS 7-42 Use special tools to remove the left and right side bearings ①② and the intermediate bush ③ of the hub. Wheel bearing remover :09941 - 50111 The removed bearing should be replaced with new one. SPROCKET Inspect the sprocket s teeth for wear. If they are worn, replace the sprocket and drive chain as a set.
Page 223 7-43 CHASSIS REAR WHEEL After the rear wheel install, tighten the rear axle nut ①to the specified torque. Rear axle nut : 78 N∙m (7.8 kg∙m) After installing the drive chain to the rear sprocket, adjust the drive chain. Tighten the left and right drive chain adjusting nuts②and drive chain adjusting bolts③.
Page 224: Rearshockabsorber&Swingarm
CHASSIS7-44 REARSHOCKABSORBER&SWINGARM REMOVAL Remove the drive chain cover.
Page 225 7-45 CHASSIS Remove the mounting bolts of the rear caliper, and remove the rear caliper. Loosen the right drive chain adjuster nut ① and leftdrive chain adjuster nut ②. Disengage the drive chain from the rear sprocket. Open the link clamp and remove the chain. Raise the rear wheel off the ground with a jack or block.
Page 226 CHASSIS 7-46 Remove the water baffle. Remove the lower bolt ① of the rear shock absorber, and remove the bolt ② of the rear shock absorber rocker arm. Separate rear shock absorber and rear rocker arm combination. Remove the flat fork self-locking nut ③, pull out the rear flat fork shaft, and remove the rear flat fork and chain slider.
Page 227 Remove the pivot oil seal ②, rear rocker arm pivot inner bush ③, needle roller bearing ④, rear shock absorber pivot oil seal ⑤, rear shock absorber rocker arm pivot bush ⑥, needle roller bearing ⑦. Bearing remover :09923-73210 INSPECTION AND DISASSEMBLY Check the pivot oil seal, rear rocker arm pivot inner bushing, needle bearing, rear shock absorber pivot oil seal, rear shock absorber...
Page 228 7-47 CHASSIS SWINGARM NEEDLE BEARINGS Insert the washer into the needle bearing, rotate the washer, and check if there is any abnormal sound and rotate smoothly. If there is any abnormality, please replace the bearing with a new one. SWINGARM Inspect the swing arm for damage.
Page 229: Rear Shock Absorber
CHASSIS7-48 Service limit Swingarm pivot 0.3 mm shaftrunout Dial gauge : 09900-20606 Magnetic stand : 09900-20701 V-block : 09900-21304 REAR SHOCK ABSORBER COMBINATION REMOVAL Remove the fixing bolt ① on the rear shock absorber, and remove the rear shock absorber ②.
Page 230 The removed needle bearing needs to be replaced with a new one. REMOUNTING Reassemble the swingarm and rear shock absorber inthe reverse order of disassembly. Pay attention to the following points : Press the needle bearings into the swingarm.Pivotusing the special tool. Steering race installer : 09941-34513 When assembling the needle bearing, let the embossed mark outward.
Page 231: Servicing Information
SERVICING INFORMATION CONTENTS TROUBLESHOOTING 8 - 1 …………………………………………………………………………… SPECIAL TOOLS 8 - 15 …………………………………………………………………………………… TIGHTENING TORQUE 8 - 18 ………………………………………………………………………… SERVICE DATA 8 -20 ……………………………………………………………………………………… WIRING AND CABLE ROUTING ……………………………………………………………… 8 -29...
Page 232: Troubleshooting
SERVICING INFORMATION 8-1 TROUBLESHOOTING MALFUNCTION CODE AND DEFECTIVECONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CHECK FOR CODE NO FAULT noEr After engine running,if oxygen sensor heater signal open or is happened the ground short fault for 1second by 10 times in12 times test cycle,the code 0031 is indicated.
Page 233 8-2 SERVICING INFORMATION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CHECK FOR CODE The sensor should produce following voltage. 0.2 V≤Sensor output voltage0.2V≤ Without the above range for7.8sec.and more,0122is indicated. Voltage P0122 Throttle position sensor, lead wire / coupler connection. or Open Sensor Circuit The sensor should produce following voltage.
Page 234 SERVICING INFORMATION 8-3 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CHECK FOR CODE 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 indicated.10010，P0336 P0336 Noisy Signal CKP wiring and mechanical parts.(CKP lead wire coupler connection) After engine running, if the CKP signal does not reach ECU for more than 0.5 sec., the code P0337 is indicated.0.5ECU，P0335...
Page 235 8-4 SERVICING INFORMATION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CHECK FOR CODE After engine running, if “FI” check lamp signal open or is happened the high / ground short fault for 1 second by 40 Engine warning lamp P0650 times in 80 times test cycle, the code P0650 is indicated. Circuit Malfunction “FI”...
Page 236 SERVICING INFORMATION 8-5 ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low startorishard Adjust. Tappet clearance out of adjustment. tostart. Repair or replace. Worn valve guides or poor seating of valves. Adjust. Mistimed valves. Replace Excessively worn piston rings. Replace.
Page 237 8-6 SERVICING INFORMATION Complaint Symptom and possible causes Remedy 1. Tappet clearance out of adjustment. Adjust. Engine idles Poor seating ofvalves. Replace or repair. poorly. Defective valveguides. Replace. Worn downcamshafts. Replace. Too wide sparkplug gaps. Adjust or replace. Defective ignitioncoils. Replace.
Page 238 SERVICING INFORMATION 8-7 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 239 8-8 SERVICING INFORMATION Remedy Complaint Symptom and possible causes Defective engine internal / electrical parts/ Enginerunspoorly Replace. Weakened valvesprings. in high speed Replace. Worn camshafts. range. Adjust. Valve timing out of adjustment. Adjust. Toonarrow sparkplug gaps. Replace ECU. Ignition not advanced sufficiently due to poorly working timing advance circuit.
Page 240 SERVICING INFORMATION 8-9 Complaint Symptom and possible causes Remedy Defective engine internal / electrical parts/ Engine Adjust. Loss of tappetclearance. lacks Replace. Weakened valvesprings. power. Adjust. Valve timing out of adjustment. Replace. Worn piston rings or cylinders. Repair. Poor seating ofvalves. Clean or replace.
Page 241: Radiator (Cooling System)
8-10 SERVICING INFORMATION 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 Replace. Worn valveguides. exhaust Replace. Cylinder walls cored or scuffed. smoke.
Page 242 Replace. Defective cooling fan thermo-switch. Engine ut on the radiator overcools. Extremely cold weather. cover. Defective thermostat. Replace.
Page 243 SERVICING INFORMATION 8-11 ELECTRICAL Complaint Symptom and possible causes Remedy Defective ignition coils or sparkplug caps. Replace. No sparking or poor Defective spark plugs. Replace. sparking. Defective CKP. Replace. Defective ECU. Replace. Defective ROswitch. Replace. Open-circuited wiring connections. Check and repair. Inspect EI system.
Page 244 8-12 SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy Battery case iscracked. Replace the battery. “Sulfation”acidicwhit Battery has been left in a run-down condition for Replace the battery a longtime. or recharge. powderysubstance or spots on surfaces of cell plates. Check the Battery runs down The charging method is not correct.
Page 245 SERVICING INFORMATION 8-13 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. oscillation. Repair or replace. Distorted frontfork.
Page 246 8-14 SERVICING INFORMATION 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. Adjust.
Page 247: Special Tools
SERVICING INFORMATION 8-15 SPECIAL TOOLS Special tools PartNumber∙PartName∙Description∙∙ PartNumber∙PartName∙Description∙∙ Special tools 09900-20101 09900-21109 VernierCaliper Torque wrench Used to conveniently measure Measure torque of tightening. various dimensions. 09900-20201 09900-21304 Micrometer(0~25mm) V-blockV Used for precise measurement With using magnetic stand. (00~25mm measure ranges). 09900-20202 09900-22301 Micrometer(25~50mm)
Page 248 09900-20806 09910-20115 Thickness gauge Conrodholder Measure clearance of piston ring. Used to lock the crankshaft.
Page 249 8-16 SERVICING INFORMATION PartNumber∙PartName∙Description∙∙ PartNumber∙PartName∙Description∙∙ Special tools Special tools 09910-32812 09913-80112 Crankshaft installer 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 250 09913-76010 09920-53710 Bearing installer Clutch sleeve hub holder Used to drive crankshaft bearing Used to install or remove clutch sleeve hub nut.
Page 251 SERVICING INFORMATION 8-17 PartNumber∙PartName∙Description∙∙ PartNumber∙PartName∙Description∙∙ Special tools Special tools 09921-20200 09930-44510 Bearing remover(10mm) Rotor holder Usedtoremoveoilsealorbearing. Widely used to lock rotary parts such as a flywheel magneto. 09921-20210 09940-10122 Bearing remover(12mm) Clamp wrench Usedtoremoveoilsealorbearing. A hook wrench to adjust the steering head of motorcycle.
Page 252 09900-27000 09930-40113 Mode select switch Rotor holder Inspect EI system sensor.EI Widely used to lock rotary parts such as a flywheel magneto.
Page 253: Tightening Torque
8-18 SERVICING INFORMATION TIGHTENING TORQUE ENGINE N∙m Kg∙m ITEM Spark plug 2．3 Crankcase bolt 2．3 Camshaft housing bolt 1．0 Camshaft comp bolt 1．1 Gear shift pawllifterbolt 1．9 Cylinder head bolt 2．3 Cylinder head cover bolt 12 ~ 16 1．2~ 1．6 Cylinder nut 1．0 Starter clutch bolt...
Page 254 SERVICING INFORMATION 8-19 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 255: Service Data
8-20 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit : mm 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. & EX. ———...
Page 256: Conrod + Crankshaft
SERVICING INFORMATION 8-21 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 57．000—57．015 57．110 56．975—56．990 Piston diam. 56．880 (Measure at 12mm from the skirt end) Cylinder or cylinder head distortion ———...
Page 257 8-22 SERVICING INFORMATION CLUTCH Unit:mm ITEM STANDARD LIMIT Clutch cable play 10—15 ——— Drive plate thickness 2．6 2．9—3．1 11．0 Drive plate claw width 11．8—12．0 ——— 0．10 Driven plate distortion Clutch spring free length 29．5 ——— TRANSMISSION + DRIVE CHAIN Unit:mm ITEM STANDARD LIMIT...
Page 258 SERVICING INFORMATION 8-23 SERVICE DATA EI SENSORS ITEM SPECIFICATION MAP & IAT sensor input voltage 4.9 ~ 5.1V MAP & IAT sensor output voltage Approx. 1.5V at. idle speed 1.5V TP sensor input voltage 4.8 ~ 5.2V TPsensor output voltage Closed Approx.
Page 259 8-24 SERVICING INFORMATION THROTTLE BODY ITEM SPECIFICATION NOTE I.D. No. 1114400031000 Bore size Idle rpm 1,500 ~ 1,700 rpm Throttle cable play 0.5 ~ 1.0 mm (0.02 ~ 0.04 in) FUEL INJECTOR + FUEL PUMP ITEM SPECIFICATION NOTE Ω ℃ (68 ℉...
Page 260 SERVICING INFORMATION 8-25 ELECTRICAL Unit : mm (in) ITEM SPECIFICATION NOTE BTDC 10°/ 2,000 rpm and 28°/ 6,000 rpm Ignition timing Type CR8E 0.7 ~ 0.8 (0.028 ~ 0.032) Hot type CR7E Spark plug Standard type CR8E Cold type CR9E More than 8 (0.32)8（0.32）...
Page 261 8-26 SERVICING INFORMATION WATTAGE Unit:W SPECIFICATION LED 12V 34.2W/24.3W Head lamp Position lamp LED 12V 2.9W License lamp LED 12V 0.1W LED 12V 0.4W/0.1W Brake/Tail lamp LED 12V 2.2WX4 Turn signal lamp LED 12V 2W Speedometer lamp LED 12V 0.1W Engine warning lamp LED 12V 0.1W Turn signal indicator lamp...
Page 262: Brake+Wheel
SERVICING INFORMATION 8-27 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 263 8-28 SERVICING INFORMATION TIRE ITEM STANDARD LIMIT 250Kpa(36psi) Front 225Kpa(33psi) Cold inflation tire pressure (Solo riding) Rear 225Kpa(33psi) 280Kpa(41psi) Front 225Kpa(33psi) 225Kpa(36psi) Cold inflation tire pressure (Dual riding) Rear 225Kpa(33psi) 280Kpa(41psi) Front ——— Tire tread depth ——— Rear FUEL + OIL ITEM SPECIFICATION NOTE...
Page 264: Wiring And Cable Routing
SERVICING INFORMATION 8-29 WIRING AND CABLE ROUTING 1180300018100 -Ignition coil 1260300903100 - Secure the cable ties - Main bundle leads - Oxygen sensor lead - Heat dissipation fan leads - Speaker leads 1260300903200 - Secure the cable ties - Water temperature sensor lead 1180300018600 - Start the motor lead...
Page 265 SERVICING INFORMATION 8-30 Cooling 1181400042000 connector -Rectifier adjustment connector 1181400042000 -Rectifier voltage regulator 6416005000000- Radiator fan 1610400300000- Fan temperature sensor switch 1181000060000 -Horn 1114111007801 -High pressure tubing 1223904011000 -Fuel injector 1223904030000 1223904050000 -Intake temperature & pressure -Idle speed controller sensor 1223904040000 -Throttle position sensor...
Page 266 SERVICING INFORMATION 8-31 1114200031000 -ECU 1183200030000 -Starting relay 1142200160000 -ABS module 1260300903200 Fixed cable tie Side support switch lead...
Page 267 SERVICING INFORMATION 8-32 36618-30610QS sheath - File display switch connector - Trigger coil connector 1181400220000 -Front wheel speed 1182200020000 sensor connector -Main cable 1182200030000 -Main cable connect the negative 1181400230000 terminal of the battery Rear wheel speed sensor connector - belt -ABS fuse box lead - Cables to the positive pole...
Page 268 SERVICING INFORMATION 8-33 1282200010000 1182200010000 Throttle line -Ignition switch 1281400029100 1142200050000 Clutch cable Front disc brake main pump tubing 1260300901000 1161400017000 1260300901000 Fixed cable tie Speedometer Fixed cable tie Left handle switch lead Right handle switch lead Speedometer connector Ignition switch connector Speedometer sensor connector Left handle switch connector Front left turn signal connector...
Page 269 SERVICING INFORMATION 8-34 1181400210000 Rear wheel speed sensor 09408-00002 Soft axis clamp - Front brake caliper oil line - Front wheel speed sensor leads 09408-00002 Soft axis clamp - Front brake main pump oil line 1181400110000 - Front wheel speed sensor -Front wheel speed sensor leads...
Page 270 8-36 SERVICING INFORMATION WIRING DIAGRAM...
Page 271 1nd Ed. Sep. 2022.

Yamaha X-RIDE 125CC 2022 Service Manual

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