Page 1 ZT368K Maintenance manuals 2025-1-14 1 / 135...
Page 2 When it comes to color or upgrading, please refer to the part code on the official website of ZONTES , and this manual will not be listed in detail; If the name of the part in this manual is inconsistent with the official website of ZONTES, the official website of ZONTES shall prevail.
Page 3: Notice To Users
Notice to Users This manual is written by Guangdong Tayo Motorcycle Technology Co., Ltd. to guide dealers or service personnel to use. This manual does not provide more detailed knowledge about motorcycles and is intended for service reference only. If you do not have the corresponding knowledge such as electrician, mechanic, etc., improper assembly or maintenance failure may occur during repair.
Page 4: Table Of Contents
Directory Directory ......................................4 1.Vehicle information ..................................10 Know Before Service ................................. 10 Body stickers ..................................... 11 368K technical parameters................................ 13 Front wheels/steering ............................... 13 Rear wheels/suspension ..............................13 Braking system .................................. 14 Battery/Charging System..............................14 Lamp/Meter/Switch Description ............................14 Tighten the torque ................................
Page 5 5.Confirm the oil level ............................... 37 Throttle body .................................... 38 1.Do not disassemble the throttle valve body to clean up the carbon deposit ..............38 2.Dismantle the stepper motor and clean up the carbon deposits .................. 38 3.Dismantle the throttle body assembly to clean up carbon deposits ................39 4.Throttle body removal sensor ............................
Page 6 2.lubrication ..................................55 3.Install the main bracket ..............................56 4.Replace the main bracket return spring post ......................... 56 3.EFI system ...................................... 57 Know Before Service ................................. 57 Fault codes ....................................59 1.Read the fault code through the meter ......................... 59 2.Read the fault code through the diagnostic instrument ....................
Page 7 Know Before Service ................................. 80 Troubleshooting ..................................80 1.Starting relays................................. 80 2.Starter motor ................................. 81 3.The starter motor runs slowly ............................81 4.The starter motor is working fine, but the engine does not start .................. 81 Starting system layout ................................82 Electrical schematic diagram of the starting system .........................
Page 8 2.2Pressure relief valve inspection ..........................97 3.Auxiliary tank ................................. 97 4.Water and oil share sensors ............................97 5.Thermostats ................................... 98 5.1 Examine ................................98 5.2 Fault phenomenon .............................. 98 5.3 Dismantle ................................98 6. Water pipes ................................... 99 7.Inspect the water pump cover assembly ........................99 8.Braking system .....................................
Page 9 2. Install the front wheel assembly ..........................118 Exploded view of the front wheel assembly: .......................... 120 Front wheel assembly inspection and maintenance: ......................121 1.Disc brake discs ................................121 1.1The service life of the disc brake disc ......................... 121 1.2 How to replace the disc brake disc ........................
Page 10: Vehicle Information
1.Vehicle information Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component sealing rings used for sealing must be replaced before assembling. 3.
Page 11: Body Stickers
Body stickers ①The VIN is visible when the seat cushion is opened, and the VIN code is engraved on the rear tube of the frame ② Muffler code on the inside above the muffler ③ The nameplate is above the radiator ④...
Page 12 12 / 135...
Page 13: Technical Parameters
368K technical parameters project parameter Front tires 120/70－15 CM－SC13 56S Rear tires 140/70－14 CM－SC13 68S Front rim specifications MT:3.5×15 Rear rim specifications MT:3.75×14 Brake fluid DOT4 0.25L（0.07 US gal,0.06 lmp gal） Whole vehicle 1.75L（0.46 US gal,0.39 lmp Replace the fine filtration: gal）...
Page 14: Braking System
Braking system project standard Limit values Brake fluid DOT4 Front disc brakes Brake pad use limit Bottom of the trough Brake disc thickness ≥5.0mm(0.197 in) ＜4.5mm(0.177 in) Brake fluid DOT4 Rear disc brakes Brake pad use limit Bottom of the trough Brake disc thickness ≥4.5mm(0.177 in) ＜4.0mm(0.157 in)
Page 15: Tighten The Torque
Tighten the torque The bolt tightening torque of the general fastening part Class 4.8-6.8 (bolt head marked "4") Class 8.8 (bolt head marked "7" or "8.8") Bolt Tightening Torque Breaking Tightening Breaking Standard Value Standard Value Diameter Range Torque Torque Range Torque 1.5-3 8-12...
Page 16: Control Cable/ Power Cable/Pipe/Electrical Device Distribution Diagram
Control cable/ Power cable/pipe/electrical device distribution diagram 1.Lamp distribution map 1-headlight（①-low beam position ②-High beam position ③-Position light/daytime running light position） 2-Right turn signal 3-Left turn signal 4-side reflector 5-Left hand handle switch 6-Left hand handle sub switch 7-Right hand handle sub switch 8-Right hand handle switch 9-Handle the heating switch 10-Rear tail light（④-Rear left turn signal ⑤-Rear right turn signal）...
Page 17: Throttle Pull
2.Throttle pull 1-throttle cable 3.Brake upper pump and brake hose 1-Front disc brake main cylinder 2-FMC-HU brake hose 3-RMC-HU brake hose 4-Rear disc brake main cylinder 17 / 135...
Page 18: Calipers, Brake Hoses And Wheel Speed Sensors
4.Calipers, brake hoses and wheel speed sensors 1-Front brake discs 2-FC-HU Brake hoses 3-Wheel speed sensor (front) 4-Front disc brake calipers 5-Rear brake disc 6-Rear disc brake calipers 7-Wheel speed sensor (rear) 8-RC-HUBrake hoses 5.Distribution diagram of brake system parts 18 / 135...
Page 19 1-Wheel speed sensor (front) 2-FC-HUBrake hoses 3-RC-HUBrake hoses 4-Wheel speed sensor (rear) 5-Rear disc brake main pump 6-Rear brake handle 7-Rear brake switch 8-RMC-HU Brake hoses 9-FMC-HU Brake hoses 10-Front brake switch 11-Front disc brake main pump 12-Front brake handle 13-Hydraulic control unit 19 / 135...
Page 20: Oil Supply System
6.Oil supply system 6.1 Fuel evaporation 1-Oil level sensor 2-Fuel tanks 3-Fuel pump 4-High-pressure tubing 5-Solenoid valve outlet pipe 6-Throttle body assembly 7-Canister solenoid valve 8-Carbon canisters 9-Carbon canister adsorption tube 10-External oil and gas separator 11-Fuel tank snorkel 12-Fuel tank cap 13-Solenoid valve intake pipe Fuel evaporation：...
Page 21: Fuel Supply
6.2Fuel supply Oil Supply System: Air → canister→adsorption/ventilation pipes→ air-air separators (inside the tank) Fuel → fuel pump filter→ fuel pump→ high-pressure tubing→ injector → cylinder 21 / 135...
Page 22: Distribution Of Cooling System Components
7.Distribution of cooling system components 1-Main water tank 2-Water tank filling port 3-Auxiliary tank 4-Main tank inlet pipe 5-Main tank outlet pipe 6-Aluminum water pipes 7-Thermostat outlet pipe 8-Engine water inlet pipe 9-Water and oil share sensors 10-Thermostats 11-Water pump cover assembly 22 / 135...
Page 23: Electrical Device Layout Diagram
8.Electrical device layout diagram 1-TFT meter 2-Flasher 3-Windshield motor controller 4-accumulator 5-horn 6-Side bracket kill switch 7-Canister solenoid valve 8-No electrical inductive antenna 9-Steering lock 10-Electric handbar switch 11-Tire pressure receiver 12-Engine controller (ECU) 13-rectifier 14-Cushion lock 15-PKE 16-Tilt switch 23 / 135...
Page 24 1-TFTappearance 2-Front left storage compartment lock 3-Windshield motor controller 4-Steering lock 5-Dual-port USB charging cable 6-Single-port charging cable 7-EFI relays 8-Start the relay 9-Charging port base 10-Electronic lock of the fuel tank 1-Cushion lock 2-rectifier 3-Engine controller（ECU） 4-buzzer 5-Ignition coil body 6-Canister solenoid valve 24 / 135...
Page 25: Intake And Exhaust Systems
9.Intake and exhaust systems 1-cylinder head 2-cylinder head exhaust pipe 3-Air filter intake 4-Gearbox exhaust pipe 5-Air filter outlet pipe 6-Throttle body assembly 7-intake manifold 8-cylinder 9-muffler Air intake system (indicated by green arrows)： air→Air filter intake→Air filter cartridges→Air filter outlet pipe→Throttle valve assembly body→intake manifold→cylinder→silencer Cylinder head exhaust gas control system (indicated by small red arrows)：...
Page 26: Tool
Tool 125-piece tool set Torque wrench On-board tools Claw hammer Pull code Rubber hammer Dynamic balancing machine Tire scraper Oil pan measuring cup funnel Taps, dies micrometer Depth gauge Vernier calipers Feeler gauge 26 / 135...
Page 27 PT300 Electrojet Brush Magnetic mount + dial Tire pressure gauge Writing Diagnostic 17# hexagon gauge Instrument (16PIN) Hoop pliers Inner circlip pliers Circlip pliers Clamp-on multimeter multimeter Blow guns Some of the above pictures are from the Internet, and the copyright belongs to the original author. Do not use for any other purpose.
Page 28: Expansion Nail Description
Expansion Nail Description ①Press the center cylinder with 4# hexagon or other tools, you can hear a sound or the center cylinder moves axially by 2mm； ②Use a razor, fingernail or carving knife to pry open the gap and remove it; If space permits, reach for the back and push it out； ③Pinch the outer ring with two fingers and push the center cylinder up to the initial position；...
Page 29: Maintenance
2.Maintenance Know Before Service 1.It is necessary to use high-quality tools, or special tools and fixtures designed by our company. Using inferior tools may result in damaged parts, detached plating, inadequate assembly, etc. 2.O-rings, paper gaskets, copper gaskets, component seals, etc. used for sealing must be replaced before assembly. 3.Fasteners with torque requirements need to use a torque wrench to check the torque;...
Page 30 Only some of the basic requirements for the prevention of accidental injuries can be enumerated; It is not possible to exhaustively list all scenarios. Be vigilant during disassembly and assembly to prevent accidents. 30 / 135...
Page 31: Maintenance Cycle Table
Maintenance cycle table : Check ( clean, lubricate, adjust or replace if necessary ) : Replacement : Tightening :annotation Frequency* 1 Regular replacement (inspection) drive Inspection items inspection × 1000 km × 1000 mile 1 year or 10,000 km Cradle cushion rubber ( 6214 miles ) Check once Air filter ( filter element ) Replace every 6,000 km...
Page 32: Air Filter (Filter), Air Inlet Filter
● Initial maintenance should be performed strictly according to the above table, otherwise it may cause motorcycle damage or other unpredictable failures. ● To keep your motorcycle running normally, it is recommended that you have it serviced by a dealer or a qualified repair unit. Improper maintenance or care may cause motorcycle damage or other unforeseen failures.
Page 33: Remove The Air Filter Housing
inner wall clean with a clean non-woven fabric. comes first). c. Replace the filter element and sealing strip with a new one. b.Remove the sponge and replace with a new filter, 6.Check the waste oil pipe of the air filter keeping the black side facing the engine and the white side Observe the waste oil drain for dirt or water accumulation.
Page 34: Bolts, Nuts For Mufflers
●If the replacement cycle is not reached, if there is no damage and the surface of the filter element is relatively clean, you can use a dust gun to blow air from the clean side of the filter ●If the air filter is clogged with dust, it will increase the intake element to blow away the dust on the surface of the filter resistance and decrease the output power.
Page 35: Engine Oil
Engine oil prevent foreign objects from falling into the engine. ●The motorcycle must be parked on a level, stable ground or lifting platform. ●Operation is required to wait for the engine and muffler to cool down. ●Add oil to prevent oil from dripping onto the surface of the muffler.
Page 36: Add Oil
c.Wipe the filler port with a non-woven fabric. d.Check whether the O ring (2) is damaged or aged, if not, c.Drain the oil inside the fine filter. wipe it clean, and replace it if so. The specifications of the O- ring used in the dipstick are: 18×3×3.5.
Page 37: Confirm The Oil Level
wipe it clean, and replace it if so. h.Using non-woven fabric, clean the nut (3) and the oil filler cap thoroughly. First, slip the O-ring (4) onto the nut (3), and then manually rotate it clockwise to reinstall it back onto the oil filler port of the gearbox.
Page 38: Throttle Body
Throttle body ambient light plug on the left side of the locker, and remove note： the plug completely after unplugging. ●The throttle body sensor and stepper motor cannot be immersed with any liquid. ●It is forbidden to adjust the idle adjustment screw on the valve body.
Page 39: Dismantle The Throttle Body Assembly To Clean Up Carbon Deposits
3.Dismantle the throttle body assembly to clean up carbon deposits a.Disconnect the plugs of the stepper motor (1) and the sensor (2). e.Remove the valve body assembly from the engine after removing the 2 bolts (6) with 5# hexagon sockets. b.Place a small container underneath the high-pressure fuel line.
Page 40: Throttle Body Removal Sensor
4.Throttle body removal sensor a.If the idle speed is abnormal, it is easy to stall and the spark plug and high-voltage coil are excluded. It should not be disassembled under normal circumstances. b.Unplug the stepper motor (1) and sensor (2) according to the procedure for removing carbon deposits from the throttle valve body without dismantling.
Page 41: Throttle Pull
lock the car； b.If the above adjustments cannot achieve the desired e.Wait for 5 seconds and unlock the motorcycle again to effect, you can remove the throttle body assembly according complete the EFI system Bit. to the description in "Removing the Throttle Valve Body Throttle pull Assembly and Cleaning the Carbon Deposition".
Page 42: Check The Idle Speed
ZONTES special Check the idle speed maintenance point or qualified maintenance unit. ： Checking the idle speed of the engine should be done with a Abnormal idle speed or flameout should be checked or hot engine.
Page 43: Fuel Evaporative Pollutant Control System
Fuel evaporative pollutant control system 1-Oil level sensor 2-Fuel tanks 3-Fuel pump 4-Air-oil separator (welded inside the tank) 5-Fuel tank cap 6- Adsorption/ventilation tubes7-High-pressure tubing 8-Carbon canisters 9-Canister solenoid valve 10-Solenoid valve intake pipe 11-Solenoid valve outlet pipe 12-Throttle body assembly Fuel evaporation：...
Page 44: Fuel Lines
Fuel lines Note: ●When disassembling the high-pressure oil pipe, a small amount of fuel will flow out, and it needs to be undertaken with an oil tray. ●Work should be carried out in an open and ventilated place. Smoking, phone calling, and all other behaviors that may cause sparks are prohibited at the work site.
Page 45: Fuel Pump
3.Fuel pump 4.Abnormal fuel pressure disposal 3.1 Fuel pressure is measured using an oil pressure gauge Follow the above steps to pull out the high-pressure oil pipe If the fuel pressure is higher than the standard value, the at the fuel injector. Connect the high-pressure oil pipe of the fuel pump needs to be replaced.
Page 46: Radiator
Radiator ●The motorcycle must be parked on a level, stable ground or lifting platform. ●Operation is required to wait for the engine and muffler to cool down. ●Swallowing or inhaling coolant can be harmful to the human body. 2.Addition of coolant (antifreeze) to the auxiliary ●Regularly check the coolant level, ensuring it is always tank above the "L"...
Page 47: Drain The Coolant
and remove the M6×12 drain bolt (3) and the O ring (4) of φ5.6×φ1 with a 10# sleeve. c.Wear waterproof gloves and use the extended funnel to add coolant to the main tank inlet. The coolant level is visible at the water inlet until the coolant is spilled at the stable position of the thermostat bleed bolt.
Page 48: Check All Water Pipes For Leakage And Aging
6.Check all water pipes for leakage and aging 1-Main tank filler 2-Main water tank 3-Auxiliary tank 4-Main tank outlet pipe 5-Aluminum water pipes 6-Engine water pipes 7- The water pump covers the inlet pipe 8-Water pump cover assembly 9-Thermostat assembly10-Water and oil share sensors 11- Thermostat outlet pipe 12-Main tank inlet pipe 1-Main tank outlet pipe 2-Aluminum water pipes 3-Engine water pipes 4-Thermostats 5-The water pump covers the inlet pipe 6- Water pump cover outlet pipe joint 7-The water pump covers the outlet pipe 8-Thermostat outlet pipe 9-Main tank inlet pipe...
Page 49: Brake Hoses
Brake hoses master cylinder with oil-resistant plastic film to prevent brake Note: fluid from dripping onto parts and damaging the paint. ●This inspection should be handed over to a qualified maintenance unit to complete. ●Inspect the brake hose regularly according to the maintenance schedule.
Page 50: Change The Front Brake Fluid
stagnate, resulting in poor braking effect or failure, and then affecting driving safety. 2.1 Change the front brake fluid ●The discharged brake fluid should be properly disposed of a.Wrap the area around the front brake main pump with oil- and no further use should be prohibited. It is forbidden to resistant plastic film, as shown in the previous section.
Page 51 cracks, cuts, or other damage. ●When using new tires, exercise extra caution while driving. Unbroken-in new tires may slip, leading to loss of control of the ●Regularly check tire pressure. Under normal temperature vehicle. conditions, the standard pressure is 240 kPa (2.5 kgf/cm², 35 ●During the first 150 kilometers (93 miles) after replacing tires, PSI) for the front tire and 260 kPa (2.7 kgf/cm², 37.7 PSI) for avoid rapid acceleration, sharp turns, and emergency braking.
Page 52: Check The Tires
1.Check the tires pressure sensor. Before press-fitting the tire, it should be a.Park the motorcycle on a flat, stable ground or lift installed according to the direction of rotation indicated on the platform and lower the main bracket. sidewall, and the yellow marked tap should be aligned with the valve position.
Page 53: Check The Appearance
●If the motorcycle is not driven for a long time, it should be during assembly is normal. parked in a ventilated and dry environment, as the dark and d.Check whether there is leakage at the bottom of the humid environment can easily lead to rust of the fork pipe and bottom cylinder with the help of a mirror or mobile phone lens, rust other parts of the vehicle.
Page 54: Troubleshooting
Side brackets Note ●Park the motorcycle on a flat, stable ground or lift platform and lower the main bracket. ●When disassembling and installing the spring, it is necessary to prevent the spring from suddenly flying off and causing personal injury. 1.Examine The slight deformation of the deformation <...
Page 55: Lubrication
1.Examine or brake switch for malfunction. d.Check the side bracket mounting plate for deformation or cracking. 2.lubrication a.Retract the side brackets so that the springs are in the shortest position for easy removal. b.The thick steel wire can be rolled into a circle and sleeved into the spring (1) hook, and attention should be paid to ensure that the steel wire cannot be loosened or spread out during the pulling process.
Page 56: Install The Main Bracket
4.Replace the main bracket return spring post After removing the main bracket according to the previous steps, remove the main bracket counterclockwise with an 8# sleeve to reset the spring column. It is recommended to apply an appropriate amount of thread fastening glue before assembly.
Page 57: Efi System
3.EFI system Know Before Service 1.The structure and working principle of the EFI system are complex, and it is necessary to have a certain understanding of the working principle and structural characteristics of each EFI system before checking and troubleshooting. The content of this chapter requires certain maintenance experience, and it is recommended to go to a maintenance unit with maintenance qualifications for inspection or maintenance.
Page 58 ●For new motorcycles or vehicles that are about to run out of fuel, never turn on the kill switch. Be sure to fill up with enough fuel before turning it on, otherwise the fuel pump will dry without oil and cause damage. ●Do not plug and unplug the plugs of each part at will, and do not directly clean the plug with water.
Page 59: Fault Codes
Fault codes Note: ●The motorcycle is unlocked and the ignition switch is turned on, and the EFI fault light is always on when it is not started, and the motorcycle cannot be started if it is not lit. ●After starting the motorcycle, if the fault light lights up to report the EFI fault, it means that the EFI system is abnormal. ●When the EFI system reports a malfunction, continuing to drive the motorcycle may cause damage.
Page 60 code illustrate code illustrate The upstream 1-cylinder oxygen sensor heating The voltage of the rear oxygen sensor signal circuit is P0030 P0137 control circuit is open too low and faulty The voltage of the heating control circuit of the The voltage of the rear oxygen sensor signal circuit is P0031 P0138 upstream 1-cylinder oxygen sensor is too low...
Page 61: Clear The Fault Code
1. The voltage of the signal circuit of the oxygen P0131 P1098 The tip sensor signal voltage is too low and faulty sensor is too low 1. The voltage of the signal circuit of the oxygen P0132 P1099 The tip sensor signal voltage is too high and faulty sensor is too high and faulty The 1-way oxygen sensor has a delayed failure to Rear oxygen sensor signal line to heating line coupling...
Page 62: Efi Parts Layout
EFI parts layout OBD Diagnostic Canister solenoid Tilt switch Interface (Main Fuel pump Ignition coil EFI relays valve Cable) Water and oil share Crankshaft position Injector Oxygen sensor Throttle body sensors sensor *The throttle body assembly consists of (sensor, idle control valve, stepper motor). The crankshaft position sensor is integrated with the magneto stator 62 / 135...
Page 63: Fault Diagnosis And Troubleshooting Of Efi Parts
Fault diagnosis and troubleshooting of EFI parts Note: ●Once the EFI parts are disassembled, the EFI system needs to be reset. For details, see the service information in this section. ●Fuel pumps, three-in-one sensors, stepper motors, ECUs and other precision parts, such as dismantling without permission, may cause damage, and are not within the scope of the three guarantees for human reasons.
Page 64: Obd Interface
2.OBD interface tubing. Use an oil pressure gauge to measure the fuel pressure, The main line cable comes with an OBD interface, and the or a simple test method to test whether the fuel pump is location is shown in the previous one, and the fault code is healthy.
Page 65: Efi Relays
Use a multimeter to measure the resistance between the Front Light Green Black White two tabs of the solenoid valve plug of the canister should be Motor Green 35±2Ω, otherwise the solenoid valve fault can be judged. Rear Light Green Black White Motor...
Page 66: Throttle Body
oil pipe, and release the residual fuel. Remove the bolt (1) with a 10# sleeve and remove the injector holder (2) to remove the injector (3). If you need to replace the injectors, wait until the engine and muffler have cooled down. After placing the oil connection container at the bottom, pull out the high-pressure oil pipe at the end of the fuel pump according to the steps of removing the high-pressure...
Page 67: Water And Oil Share Sensors
8.Water and oil share sensors When the engine is difficult to start, the idle speed is unstable, the engine performance is poor, and it is easy to stall, it is necessary to check whether this sensor is abnormal. The fault code can be read by the diagnostic instrument to confirm whether the water and oil sharing sensor is faulty.
Page 68 68 / 135...
Page 69: Engine Fails To Start And No Starting Symptoms Fault Diagnosis Process
Engine Fails to Start and No Starting Symptoms Fault Diagnosis Process When pressing the start button to start the motor can drive the engine to run normally, but the engine cannot work normally, and there are no signs of landing, you can refer to the following diagnostic process to investigate the cause of the fault. No spark or weak Check the ignition strength...
Page 70: Poor Acceleration
Poor acceleration Turning the right hand handle rubber sleeve engine speed can not be increased immediately, there is a lag phenomenon, and the acceleration is slow; You can refer to the following diagnostic process to troubleshoot the cause of the fault. Check Check if the air Poor...
Page 71 Unsteady idling / flameout Check the oil circuit Whether it returns to normal Is gasoline enough normal after filling gasoline Check whether the gasoline bottom layer is obviously stratified (water Change the gasoline deposits) Check whether the oil pressure of the high-pressure oil pipe reaches Check whether the battery Can the fuel cutoff speed be...
Page 72: Efi (Electronic Fuel Injection) Fault Indicator Light On: Analysis Flowchart
EFI (Electronic Fuel Injection) Fault Indicator Light On: Analysis Flowchart If the EFI fault indicator light " " stays on, the first step is to check if the connections of the EFI sensors are loose. The fault light is always on during driving Read fault code Idle speed fault...
Page 73: Efi System Electrical Schematic Diagram
EFI System Electrical Schematic Diagram 73 / 135...
Page 74: Ignition System
4.ignition system Know Before Service 1.The content of this chapter requires certain maintenance experience, and it is recommended to go to a maintenance unit with maintenance qualifications for inspection or maintenance. 2.After powering on, the parts connected to the 12V power supply should not be dismantled at will, so as to avoid the coil in the appliance from self-induction and instantaneous voltage damage to the ECU or sensor.
Page 75: Troubleshooting
Troubleshooting Check the following items before diagnosing the ignition system a.Check if the spark plug is abnormal. b.Check if the ignition coil’s high-voltage cap or connector is loose. c.Check if the high-voltage cap has water ingress. d.If there is no spark, find a working ignition coil from the same model and install it on the faulty vehicle to test if there is spark. e.Check the "initial voltage"...
Page 76: Ignition System Layout
Ignition system layout 1-Tilt switch 2-PKE 3-Relays 4-Steering lock 5-The right hand handles the secondary switch 6-Right-hand handle switch 7-accumulator 8-Fuse box 9-Start the relay 10-Ignition coil 11-Side bracket kill switch 12-spark plug 13-Crankshaft position sensor 14-Magneto stator 15-ECU Note: ●The fuse box is included with the main wiring harness and there are 3 of them.
Page 77: Ignition System Electrical Schematic Diagram
Ignition System Electrical Schematic Diagram 77 / 135...
Page 78: Ignition System Check
Ignition system check Note: ●If there is no spark from the spark plug, all cable joints should be checked for loose or poor contact before the ignition system is checked. ●Use a high-precision digital multimeter. For details of the ignition coil test method, please refer to the ignition coil section in the "EFI Parts Fault Diagnosis and Troubleshooting"...
Page 79: Installation
Remove the rotor from the engine. Install the flywheel inspection tool as shown in Figure 1 and check whether the marking line on the rotor side is within the groove (as shown in Figure 2). Installation a.Align the flywheel keyway with the half-round key and install the flywheel. Place a φ10.3×φ28×4 washer and M10×1.25×45 hex flange bolt.
Page 80: Starting System
5.Starting system Know Before Service 1.If there is a current flowing through the starter motor when the engine is not started, it can be judged that the starter motor is damaged and needs to be replaced. 2.Before repairing the starter motor, the engine shutdown switch must be turned to " "...
Page 81: Starter Motor
2.Starter motor Does the Brake switch or After the vehicle is Short circuit starter motor flameout switch energized, the flameout relay work? failure switch is hit“ ” The flameout switch of the Whether the EFI Press the start Does the starting Relay failure right handle is fault light is on...
Page 82: Starting System Layout
Starting system layout 1- Right-hand handle switch (kill switch, start button) 2- Right hand handle sub switch (unlock vehicle) 3- Front disc brake main cylinder (front brake switch) 4- Rear disc brake main cylinder (rear brake switch) 5- Fuse 6- Accumulator 7- Starting relay 8- Starter motor 9- side bracket power off switch 82 / 135...
Page 83: Electrical Schematic Diagram Of The Starting System
Electrical schematic diagram of the starting system 83 / 135...
Page 84: Starter Motor
Starter motor D.Pull the outlet pipe to the right side of the motorcycle to Note: expose the two M6×30 bolts that fix the starting motor, and ●If the starter motor is removed for maintenance, replace the remove them with an 8# sleeve. After removing the bolts, O-ring with a new one and apply an appropriate amount of oil.
Page 85 1-M6×90 bolt×2 2-O ring×2 3-O ring 4-starter motor front cover 5-gasket 6-rectangular sealing ring 7-starter motor outer shell 8- rectangular sealing ring 9-electric pestle 10-screw ×2 11-negative brush ×2 12-worm spring ×4 13-positive brush ×2 14-brush rack 15-brush holder insulating gasket 16-starting motor back cover 17-insulating pad 18-nut×2 19-gasket 85 / 135...
Page 86: Examination
Examination Starter motor front cover： Check whether the oil seal of the front cover is worn and damaged; Also check whether the outer ring fits tightly with the front cover. b.Unlock the motorcycle, turn the engine shutoff switch to " ", retract the side bracket, pinch the brake handle and press the start button.
Page 87: Check The Starting Relay
4. Disassembly and assembly of the starting relay Open the black protective cap of the starting relay and use a 10# sleeve to remove the self-contained M6 nut, take out the wire and screw it back to the nut to prevent loss; use the same method to remove the other end.
Page 88: Oil Supply System
6.Oil supply system Know Before Service 1.Bending or twisting the control cables can affect smooth operation and may cause short circuits or open circuits, leading to vehicle loss of control. 2.Work should be conducted in a spacious, well-ventilated area. Smoking, making mobile phone calls, or any actions that may cause sparks are prohibited in the work area.
Page 89: Tank Disassembly
Tank disassembly the right, place the stool at the appropriate height under the ●The motorcycle must be parked on a level, stable ground or arrow, and tiptoe the rear wheels of the motorcycle off the lifting platform. ground. ●It is necessary to wait for the engine to cool down completely before operation.
Page 90: Dismantle The Fuel Pump
it.Loosen 5 M6×20 bolts (1) diagonally with a 10# sleeve, grab the high-pressure tubing bracket (2) and remove the bolt (1) completely and remove the oil pump (3). g.Use pliers to remove the clamp on the canister that connects to the oil and gas sensor and remove the hose. When reassembling, it is necessary to pre-tighten diagonally and then tighten 5 bolts (1), otherwise the sealing ring of the fuel pump (3) is compressed unevenly, which is...
Page 91: Examine
shell and is difficult to remove. If you need to remove it, you Examine can remove it with a heat gun after heating it slightly, or use 1.Fuel pressure test a self-adhesive cleaner to remove it. Press the fuel tank cap (2) and rotate counterclockwise to remove.
Page 92: Cooling System
7.Cooling system Know Before Service 1.Please refer to the radiator section of the "Maintenance" chapter of this manual for the corresponding precautions for the coolant (antifreeze). 2.Check the cooling water pipe; check the height of the cooling liquid, adding and discharging the cooling liquid have been described in detail in the radiator section of the "Maintenance"...
Page 93: Coolant System Distribution Map
Coolant system distribution map 1-Main tank filler 2-Main water tank 3-Auxiliary tank 4-Main tank outlet pipe 5-Aluminum water pipes 6-Engine water pipes 7-The water pump covers the inlet pipe 8-Water pump cover assembly 9-Thermostat assembly 10-Water and oil share sensors 11-Thermostat outlet pipe 12-Main tank inlet pipe Schematic diagram of coolant flow 1-Main tank outlet pipe 2-Aluminum water pipes 3-Engine water pipes 4-Thermostats 5-The water pump covers the inlet pipe 6-...
Page 94: Cooling System Disassembly
Cooling system: Small loops (indicated by purple arrows): Water pump → water pump cover outlet pipe joint→ water pump cover outlet pipe → cylinder → thermostat → pump cover inlet pipe Large loop (indicated by green arrows): Water pump → water pump cover outlet pipe joint→ water pump cover outlet pipe → cylinder→ thermostat→ thermostat outlet pipe→...
Page 95: Thermostat Components And Small Cycles
Thermostat components and small cycles 1-Thermostat assembly-M6×12 bolt*2 3- M6×22bolt*2 4-Water pipe hoop(φ26)*3 5-Water pump cover inlet pipe 6-Water pipe clamp(φ24) 7-Water pump cover assembly 8-Water pump cover outlet pipe joint 9-Water pump cover outlet pipe Note：The bolt (2) at the thermostat is the exhaust bolt, and the (2) at the water pump cover is the coolant bolt. Both places have φ5.6×φ1 O-rings, which need to be replaced once disassembled.
Page 96: Cooling System Accessories
should be properly assembled in place. The clamp should be snapped into the inside of the boss to prevent it from loosening. Bolt (3) torque: 12±1.5 N.m (1.2±0.2 kgf.m, 9±1 lbf.ft). Cooling system accessories Note: ●A dedicated venting tool (gas pressure regulator, air gun, sealing tube) is required to perform the test. ●After the water submersion test, promptly wipe off any water stains or use a blow gun to dry the parts.
Page 97: Main Water Tank
1.Main water tank Check whether the buffer adhesive is aged and cracked. Plug the A and C ports with a homemade head, and vent from the C port to check the tightness. A gas with a pressure of 160kPa (1.63 Kgf/cm2, 23.2 psi) is introduced to ensure that there is no air leakage at the nozzle position, and the water tank is immersed in water and allowed to stand for 10s to observe whether there are bubbles.
Page 98: Thermostats
5.Thermostats 5.1 Examine Inspect the appearance for damage and leakage. Simple test method (test on the whole vehicle): After the cold motorcycle starts, open the water inlet cover immediately, if the liquid level does not fluctuate, the thermostat is normal, otherwise it is abnormal. When the water temperature is lower than 70 °C (158 F), the thermostat should be in the valve closed state, and when the temperature is higher than the initial opening temperature, the expansion valve of the expansion cylinder will gradually open and the circulating coolant in the radiator will begin to flow.
Page 99: Water Pipes
adjustable temperature, and replace one of the non-specified values. Or use a thermometer, water, heater, and container to test. The initial opening temperature of the thermostat is 80~84°C (176~183 F), and the core movement is 0.1mm (0.004 in). The full open temperature is 95 °C (203 F) and the core movement is greater than 3.5 mm (0.14 in).
Page 100: Braking System
8.Braking system Know Before Service 1.The content of this chapter requires certain maintenance experience. It is recommended to have inspections or repairs conducted at maintenance units with proper qualifications. 2.Frequently inhaling dust produced by brake pads, regardless of its composition, may have certain health effects. Inhalation of dust particles should be avoided.
Page 101: Troubleshooting
Troubleshooting The brake handle is soft a. Air enters the oil circuit of the braking system b. Brake fluid leakage c. Brake pads or discs are oily d. Worn brake calipers or disc main cylinder piston seals e. Worn brake pads or discs f.
Page 102: Disassemble The Rear Disc Brake Main Pump
Disassemble the front disc brake caliper a.First, use 14# to loosen the tubing bolts without leakage. Then use 8# hexagon to remove 2 M10×1.5×60 bolts (red circle), the standard torque of the bolt: 45~50N.m (4.6~5.1 kgf.m, 33~37 lbf.ft). Never operate the brake lever after removing the caliper.
Page 103: Disassemble The Rear Disc Brake Caliper
placing a towel or other soft material at the piston to prevent damage caused by collision between the piston and the caliper mounting plate; In addition, the dust blowing gun needs to be far away from the caliper body, which is easy to cause damage caused by the piston suddenly flying out when the distance is too close.
Page 104 Front wheel Rear wheels 104 / 135...
Page 105: Abs Troubleshooting
ABS Troubleshooting 105 / 135...
Page 106: Fault Diagnosis Process Using A Handheld Abs Diagnostic Tool
Fault diagnosis process using a handheld ABS diagnostic tool No front wheel speed No rear wheel speed 106 / 135...
Page 107: Battery/Charging System
9 .Battery/charging system Know Before Service 1.Waste batteries should be disposed of properly so as not to pollute the environment. It is recommended to hand over the waste battery to a professional recycling agency for recycling. 2.It is forbidden to use a charger that has not been tested to charge the battery. 3.When the battery is reinstalled, the power is suddenly cut off during driving, the idle speed is abnormal, and the insurance is replugged and unplugged.
Page 108: Troubleshooting
Troubleshooting Troubleshooting process for battery damage or attenuation Battery failure Use a Measure the multimeter to battery voltage Battery Remove the battery and check whether first, then use a battery tester to there is leakage, Check the voltage<charging measure the check the battery the leakage charging voltage...
Page 109: Charging System Layout Diagram
Charging System Layout Diagram 1-Charging port (PKE) 2-Battery, 3-Main fuse (25A), 4-Magneto 5-Rectifier 109 / 135...
Page 110: Electrical Schematic Diagram
Electrical Schematic Diagram Letter 中文绿红黄 English Green Yellow Battery Removal and Installation 1.Removal Full Charge Voltage 13.1～13.3V Note： Pre-installation ≤12.8V ●The entire motorcycle must be powered off before removing Voltage Charging Voltage the battery. In-vehicle Charging ≤12V ●Disconnect the negative terminal first, followed by the Voltage positive terminal.
Page 111: Checking Charging Voltage
it exceeds the standard value, inspect the circuit for potential short circuits. 2.Checking Charging Voltage Note： ●Ensure the battery is in good condition before testing. ●Do not disconnect the battery or any electrical components without first powering off the motorcycle. b.Check the connector for looseness or corrosion.
Page 112: Fork Assembly
10.Fork assembly Know Before Service 1.It is necessary to use high-quality tools, or special tools and fixtures designed by our company. Using inferior tools may result in damaged parts, detached plating, inadequate assembly, etc. 2.O-rings, paper gaskets, copper gaskets, component seals, etc. used for sealing must be replaced before assembly. 3.Fasteners with torque requirements need to use a torque wrench to check the torque;...
Page 113: Fork Component Exploded View
Fork Component Exploded View: Direction put exploded view 113 / 135...
Page 114: Front Fork Decomposition Diagram
Front fork decomposition diagram 114 / 135...
Page 115: Exploded View Of The Lower Panel
Exploded view of the lower panel 115 / 135...
Page 116: Replace The Steering Handlebar
Replace the steering handlebar Note: ●The disc brake cup must be removed vertically upwards to prevent air from entering the brake line. ●When disassembling and assembling the handlebar switch, pay attention to adjusting the internal wiring harness of the switch to avoid the shell or bolt column clamping the wire skin. 1.Remove the steering handle a.Use a T25 Allen Torx wrench to remove the 2 shoulder bolts (1).
Page 117: Install The Direction Handle Assembly
remove the left deputy handle switch (3), rear disc brake left handlebar; Replace the throttle cord with the right main pump assembly b, right deputy handle switch (4), front heated handlebar. Note that there is a positioning hole on the disc brake main pump assembly c.
Page 118: Install The Direction Handles
4.Install the direction handles ●Be careful not to damage the ABS coil when disassembling. a.Replace the steering handle lower cover mounting plate ●After the front wheel is removed, do not press the brake with the new steering handle. handle. b.Secure all the wiring harnesses on the left and right sides ●The motorcycle must be parked on a level, stable ground or back to the direction handlebar assembly.
Page 119 ●After the front wheel is installed, press the brake handle ●After each replacement of the front wheel, it is necessary to repeatedly until the brake restores the braking effect. go to a professional institution for dynamic balance testing. ●Soiled disc and pads can reduce braking effectiveness, so ●It should not be used because tire self-replenishment may replace them with new ones and clean the soiled discs.
Page 120: Exploded View Of The Front Wheel Assembly
Exploded view of the front wheel assembly: serial name quantity remark number Oil seal TC φ28× φ42×7 GB276 deep groove ball bearing 6004- φ20×φ42×12 2RS-C3 Spacer Pay attention to the orientation when installing; The elbow Tire pressure sensor is facing left 276×5.0 brake discs 25 N.m(2.5 kgf.m，18 lbf.ft)。T45 Plum blossom hexagonal Non-standard Torx bolt M8×25...
Page 121: Front Wheel Assembly Inspection And Maintenance
Front wheel assembly inspection and time, the water and grease will become emulsion after mixing maintenance: and rubbing, and lose the original lubrication effect. This also Note： shortens the service life between the oil seal and the bearing. ●This inspection should be handed over to a qualified The front wheel seals and bearings should be checked in maintenance unit to complete.
Page 122: How To Replace The Front Rim And Tires
3.2How to replace the front rim and tires occurred, it is necessary to make the wheel correct the balance of each edge part by increasing the counterweight in a.Refer to "Replacing the Front Wheel" to remove the front the dynamic situation, and this correction process is what we wheel assembly.
Page 123: Replace Components Such As Shock Absorbers, Front Fenders, And Front Wheels
one of the shock absorbers is not properly installed, the front wheel axle may not tighten securely or may not be able to pass through the right shock absorber. In this case, you need to remove and reinstall the improperly installed shock absorber.
Page 124: Disassemble The Lower Panel Assembly
c.Ensure that the lower plate does not rotate and does not jam or loosen, and then put in the adjusting nut washer (3), the direction post adjusting nut (2), and the adjusting nut anti- loose washer (4) in turn. The nut only needs to be tightened and aligned with the first nut.
Page 125: Disassembly And Assembly Of Motorcycle Covers
11.Disassembly and assembly of motorcycle covers 1.Windshield 2.Front panel 3.Headlamp 4.Headlamp cover 5.Right pedal decorative cover 6.Front compartment panel rear 7.Right front compartment lid 8.Cushion assembly 9.Right rear armrest 10.Right tail light 11.Rear fender 12.Right tail skirt 13.Right side cover 14.Right pedal upper 15.Right pedal lower 16.Fuel tank outer cover rear decorative cover 125 / 135...
Page 126 1.Windshield 2.Front panel 3.Headlight 4.Headlight cover 5.Left pedal decorative cover 6.Front compartment panel rear 7.Left front compartment lid 8.Cushion assembly 9.Left rear armrest 10.Left tail light 11.Rear fender 12.Left tail skirt 13.Left cover 14.Left pedal upper 15.Left pedal lower 16.Fuel tank cover rear decorative cover 126 / 135...
Page 127 1.Front compartment panel front 2.Front left pedal pad 3.Left pedal decorative cover lining 4.Left pedal upper 5.Rear left pedal pad 6.Front compartment panel rear 7.Fuel tank cover 8. Front right pedal rubber pad 9. Right pedal decorative cover lining10. Right pedal upper part 11. Fuel tank outer cover rear decorative cover 12.
Page 128: Removal Of The Windshield
Note: ●When disassembling, please pay attention to the amount of control force to prevent breaking the buckle. ●When disassembling the cover, please remove it in strict order, and do not forcibly disassemble the cover, so as to prevent irreparable damage to the corresponding cover. ●When pulling and unplugging the plug, please control the size of the force and the method of disassembly, and do not forcibly pull the plug to prevent damage to the plug, which may...
Page 129: The Front Of The Front Compartment Panel Is Removed
The front of the front compartment panel is removed b.Use the 8# sleeve to remove the 4 M6×16 bolts (6), and a.Press and hold the instrument cable snap to unplug the remove the left bracket (8) and the right bracket (7). meter cable.
Page 130: Disassembly Of Headlight Assembly
Disassembly of headlight assembly a.First, open the headline plug cover (1), find the headlamp assembly wiring harness plug and unplug it. c.Use the 8# sleeve to remove 3 M6×16 bolts (8) and remove the bracket assembly (9). Remove the battery underpad (10).
Page 131: Left And Right Pedal Trim Cover Disassembled
d.Take out the decorative cover (4) after breaking out the buckle of the decorative cover of the left pedal. The disassembly method of the left and right pedal decorative covers is the same, and the right decorative cover is disassembled with reference to the above steps. Left and right pedal trim cover disassembled a.Find the turn signal plug and unplug it.
Page 132: Dismantling Of The Middle And Bottom Of The Enclosure
(4) on the rear armrest and remove the rear armrest assembly (5). Dismantling of the middle and bottom of the enclosure a.Use a T25 torx wrench to remove the shoulder bolts (1) of the 4 M6×14 that surround the middle and remove the middle Disassembly of the rear storage compartment (2).
Page 133: Removal Of The Rear Apron
the left cover (2). Remove the right cover by referring to the removal method of the left cover (2). Disassembly of the rectifier Removal of the rear apron a.Use a T25 torx wrench to remove 4 expansion nails (1) a.Use a T25 Torx wrench to remove the shoulder bolts (1) and 2 shoulder bolts (1) of M6×14.
Page 134: Disassembly Of The Left And Right Pedal Assemblies
wrench to remove the 4 M6×14 shaft shoulder bolts (2) and 2 M6×16 bolts (4) fixed on the left and right rear tail skirt linings. c.Use the 8# sleeve to remove the 2 M6×22 bolts (2) that fix the auxiliary water tank, and remove the auxiliary water tank (3).
Page 135 e.Use a T25 torx wrench to remove the 4 M6×14 shoulder bolts (1) of the box panel assembly, and then take out the box panel assembly. d.Turn on the battery, unlock the fuel tank cover lock and remove the fuel tank cover. Then use a T25 Torx wrench to remove the two M6×14 shoulder bolts (1) and M6×14 shoulder bolts (2) that hold the tank lock.

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