Benelli TNT 600 - Benelli Keeway Motorcycles Sdn. Bhd.

Transcription

Benelli TNT 600
Service Manual
BENELLI KEEWAY MOTORCYCLES SDN. BHD.
0
Contents
Preface ..................................................................................................................................................................... - 1 Preparing Documents ............................................................................................................................................... - 2 General Safety .................................................................................................................................................. - 2 Maintenance Rules .......................................................................................................................................... - 3 Specification .................................................................................................................................................. - 13 Failure Diagnosis............................................................................................................................................ - 15 Inspection/Adjustment ................................................................................................................................... - 21 Inspection and Maintenance of the Electrical System ........................................................................................... - 41 1. Battery/Charging System ................................................................................................................................... - 42 1.1 Preparing Documents............................................................................................................................... - 42 1.2 Failure Diagnosis...................................................................................................................................... - 43 1.3 Battery ..................................................................................................................................................... - 44 1.4 Charging System ...................................................................................................................................... - 45 1.5 Voltage/Current Regulator ........................................................................................................................ - 46 1.6 Magnetor Charging Coil............................................................................................................................ - 46 1.7 Magnetor Disassembly............................................................................................................................. - 47 2. Ignition System................................................................................................................................................... - 50 2.1 Preparing Documents............................................................................................................................... - 50 2.2 Failure Diagnosis...................................................................................................................................... - 51 2.3 Ignition System Check ............................................................................................................................. - 52 2.4 ECU Unit ................................................................................................................................................... - 53 2.5 Ignition Coil .............................................................................................................................................. - 54 2.6 Sensor of the Crankshaft ......................................................................................................................... - 54 3. Starting System .................................................................................................................................................. - 56 3.1 Preparing Documents............................................................................................................................... - 56 3.2 Failure Diagnosis...................................................................................................................................... - 57 3.3 Starter Motor ............................................................................................................................................ - 57 3.4 Starter Relay ............................................................................................................................................ - 59 4. Bulbs/ Switches / Meters ................................................................................................................................... - 61 4.1 Preparing Documents............................................................................................................................... - 61 4.2 Failure Diagnosis...................................................................................................................................... - 62 4.3 Replacement of Headlamp Bulbs ............................................................................................................. - 62 4.4 Replacement of Front Position Lamp Bulbs ............................................................................................. - 63 4.5 Replacement of Tail Lamp ........................................................................................................................ - 64 4.6 Replacement of Rear Registration Plate Lamp Bulbs .............................................................................. - 65 4.7 Replacement of Front Steering Lamp Bulbs ............................................................................................ - 66 4.8 Replacement of Rear Steering Lamp Bulbs ............................................................................................. - 66 4.9 Meters ...................................................................................................................................................... - 66 4.10 Main Switch ........................................................................................................................................... - 67 4.11 Horn ....................................................................................................................................................... - 67 4.12 Handlebar Switch ................................................................................................................................... - 68 Inspection and Maintenance of the Motorcycle Body............................................................................................. - 69 1
5. Brake .................................................................................................................................................................. - 72 5.1 Maintenance Instruction .......................................................................................................................... - 72 5.2 Failure Diagnosis...................................................................................................................................... - 73 5.3 Front Disc Brake....................................................................................................................................... - 75 5.4 Rear Disc Brake ....................................................................................................................................... - 79 6. Body ................................................................................................................................................................... - 83 6.1 Disassembly ............................................................................................................................................. - 83 6.2 Assembly .................................................................................................................................................. - 83 7. Front Wheel/Handlebar/Front Suspension.......................................................................................................... - 87 7.1 Preparing Documents............................................................................................................................... - 87 7.2 Failure Diagnosis...................................................................................................................................... - 88 7.3 Front Wheel .............................................................................................................................................. - 89 7.4 Steering Handlebar .................................................................................................................................. - 94 7.5 Front Fork................................................................................................................................................. - 96 8. Rear Wheel/Rear Suspension ........................................................................................................................... - 100 8.1 Preparing Documents............................................................................................................................. - 100 8.2 Failure Diagnosis.................................................................................................................................... - 100 8.3 Rear Wheel ............................................................................................................................................. - 101 8.4 Rear Absorber ........................................................................................................................................ - 105 8.5 Drive Chain ............................................................................................................................................. - 106 8.6 Rear Swinging Arm ................................................................................................................................ - 108 9. Fuel Tank .......................................................................................................................................................... - 111 9.1 Preparing Documents............................................................................................................................. - 111 9.2 Failure Diagnosis.................................................................................................................................... - 111 9.3 Fuel Tank ................................................................................................................................................ - 112 10. Disassembly and Installation of Engine .......................................................................................................... - 114 10.1 Preparing Documents........................................................................................................................... - 114 10.2 Disassembly of Engine ......................................................................................................................... - 114 10.3 Installation of the Engine ..................................................................................................................... - 120 Inspection and Maintenance of Engine ................................................................................................................ - 121 11. Lubricating System......................................................................................................................................... - 122 11.1 Preparing Documents........................................................................................................................... - 122 11.2 Failure Diagnosis.................................................................................................................................. - 122 11.3 Oil Pump ............................................................................................................................................... - 123 12. Cylinder Head ................................................................................................................................................. - 128 12.1 Preparing Documents........................................................................................................................... - 128 12.2 Failure Diagnosis.................................................................................................................................. - 129 12.3 Cylinder Head ....................................................................................................................................... - 130 13. Crankcase....................................................................................................................................................... - 138 13.1 Preparing Documents........................................................................................................................... - 138 13.2 Failure Diagnosis.................................................................................................................................. - 140 13.3 Upper Case ........................................................................................................................................... - 141 13.4 Piston ................................................................................................................................................... - 142 13.5 Lower Case .......................................................................................................................................... - 147 13.6 Clutch ................................................................................................................................................... - 151 2
13.7 Gearshift Mechanism ........................................................................................................................... - 154 13.8 Crankshaft Connecting Rod Assembly Chamber and Variable Speed Chamber ................................... - 157 14. Cooling System............................................................................................................................................... - 163 14.1 Preparing Documents........................................................................................................................... - 163 14.2 Failure Diagnosis.................................................................................................................................. - 164 14.3 Water Pump .......................................................................................................................................... - 164 Inspection and Maintenance of Exhaust Emission System .................................................................................. - 167 15. Exhaust Emission & Control System............................................................................................................... - 168 15.1 Warranty on the Exhaust Emission & Control System .......................................................................... - 168 15.2 Instructions on Periodic Maintenance .................................................................................................. - 169 15.3 Mechanical Function of the Exhaust Control System ........................................................................... - 169 15.4 Catalytic Transfer System .................................................................................................................... - 170 15.5 Measures When the Idle Speed Emission Value Exceeds the Standard ............................................... - 172 Inspection and Maintenance of Electronic Fuel Injection (EFI) System ................................................................ - 173 16. Electronic Fuel Injection System .................................................................................................................... - 174 16.1 Introduction of Electronic Fuel Injection System.................................................................................. - 174 16.2 Components of Electronic Fuel Injection System ................................................................................. - 174 16.3 Methods for Fault Diagnosis and Maintenance .................................................................................... - 187 16.4 Common Fault Removal Techniques .................................................................................................... - 197 TNT 600 Circuit Diagram ...................................................................................................................................... - 202 -
3
Preface
This service manual is used for operating and maintaining the TNT 600.
Preparing Documents include all necessary instructions and statements. Please read carefully
this manual before operation.
Inspection & Adjustment states how to check and adjust your motorcycle. All safety rules and
maintenance regulations shall be carried out from the beginning of periodic inspection.
Except for Chapter I, the rest chapters explain the disassembly/ assembly/ inspection of
Electronic Fuel Injection System, engine, entire motorcycle and electrical equipment.
Breakdown drawing, systematic drawing, failure analysis and statements are contained at the
first part of each chapter.
Please note that photos, pictures or instructions are for your reference only. The actual object
may differ from what is mentioned here. We will not make any notification for any discrepancy.
- 1 -
Preparing Documents
1. General Safety
2. Maintenance Rules
3. Specification Table
4. Inspection/Adjustment
1. General Safety
Carbon monoxide
Engine must be started up in a well-ventilated place, not in a closed area.
Note
Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human.
Start engine in an open place. The exhaust ventilating system shall be adopted if the engine is started up in a
closed area.
Petrol
Ventilation is required for working places. Naked fire is strictly forbidden in any working place or where petroleum
is stored.
Battery
Battery emits explosive gas. Therefore, it should be distance away from fire sources, naked flame or smoking. Make
sure good ventilation during charging.
Battery contains sulfuric acid (electrolyte). It will burn your skin or eyes when contacted. Therefore, wear protective
clothing and mask.
• Clean with fresh water immediately if electrolyte splashes on the skin.
• Clean with fresh water at least for 15 minutes immediately and then go to the doctor if electrolyte splashes
on eyes.
- 2 -
Electrolyte is poisonous. Drink a large quantity of fresh water, milk, milk of magnesia (laxative antacid) or mineral
oil if electrolyte is swollen accidentally. Seek doctor advice immediately.
Lubricating and Fuel
It may trigger cancer if repeatedly expose the hands in the air after contacting with oil. Although there is little
possibility for you to contact with oil in the daily life, wash hands thoroughly with water and soap if you have
contacted.
Thermal Energy
Parts of the engine and cooling system produce heat, which can last for some time before the engine gets started.
Wear protective when handling such heated items.
2. Maintenance Rules
Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage.
Clean up the surface of components or assembly parts before removing or opening the body cover for maintenance,
which can prevent dirt from falling into the engine, the chassis or the braking system.
Wash and dry parts with air compressor after disassembly and for
measurement.
Solvent or oil can easily damage rubber parts. Check rubber component
before reassembly and replace if necessary.
When removing assembly parts, please start form outside to inside. Small
assembly parts shall be loosened first.
Complex assembly parts, such as gearbox, shall be stored in proper order for
facilitating reinstallation.
Please specially note important steps before disassembly. Replacement parts
which will not be in use before disassembly.
- 3 -
Bolts and screws with different length shall be separately used for different
assembly parts and shields, and they shall be correctly mounted. Insert a bolt
into a hole to check whether it is of proper length.
Fill the groove with grease before mounting an oil seal. Check whether the oil
seal is smooth or damaged during assembly.
When installing a rubber hose (fuel, vacuum or cooling agent), insert its end
into the bottom of the connector so that the hose clip can properly fix the
connector. Rubber or plastic dirt-proof boot shall be mounted at the original
design position.
During dismantling ball bearings, one or two (inside & outside) bearing rollers
shall be supported by tools. Ball bearings may be damaged during
disassembly and have to be replaced if only one roller (either inside or outside)
is imposed with force.
- 4 -
Loose cables may affect proper electrical flow. Check each
cable after it is clamped to another for electrical safety;
Wire clamps are not allowed to bend towards welding point;
Bind cables at the designated place;
Do not deploy cables at the end of frame or at sharp point;
Do not deploy cables at the end of bolts or screws;
Cable deployment shall be far from heat source and where
cables may be clamped during moving;
Cables along the handlebar shall be neither too tight nor too
loose, and do not interface with any neighboring parts at
steering positions;
Cables shall be properly deployed without twist or knot;
Check whether the connector jacket is damaged and whether
the connector is over-stretched before mounting connectors;
Adopt adhesive tape or hose to protect cables if they are
positioned at sharp point or corner;
Bind cables with tape after repairing;
Control cables shall not be bent or twisted. Clumsy operation
may be caused in light of damaged control cables.
- 5 -
Identification
1．The frame number, see figure
Frame Number
Frame
2．Rivets of the frame sign and the frame, see figure
Frame Number
Rivets
3．The serial number of the engine, see figure
Engine Number
Significant Notes
1. Please insist genuine parts and accessories. Any part or accessory not in accordance with the design
specification may cause damage to engine.
2. Only metric tools are valid for maintenance and repair. Metric screws, bolts and nuts must always be used.
3. New gaskets, O-rings, cotter pins and locking pieces shall be used for re-assembly.
4. Bolts with large diameter or positioned inside shall be fastened first and then diagonally screw down until
reaching required torque.
5. Clean disassembled parts with cleanser. Lubricate all sliding surface before assembly.
6. Check whether all the parts and accessories are correctly mounted and operated after assembly.
7. Clean and remove oil before measurement. Add recommended lubricant to the lubricating areas during
assembly.
8. Apply lubricant to the surface of engine and driving system if they are dismantled for long-term storage,
which can prevent rust and dirt.
- 6 -
Special Tools
Special tools refer to tools which are specially designed for assembling or disassembling some motorcycle
parts on special positions. Applicable special tools are necessary for precise adjustment and installation. With them,
parts and accessories can be mounted safely, reliably and rapidly, which improves efficiency and saves energy.
1. Tools for repairing the engine
Special tools are required for properly disassembling/assembling some engine parts.
Table and drawing (1-1, 1-2) of special tools for disassembling/assembling engine parts are as follows:
Table 1-1
Name
Remark
Special socket spanner
Used for assembling/disassembling bolts for flywheels, Fig. 1-3
Clutch clamp holder
Fig.1-4
Flywheel puller
Fig. 1-4
Feeler gauge
Fig. 1-5
Bearing disassembly tools
Fig. 1-6
Bearing assembly tools
Fig. 1-7
Oil seal remover
Fig. 1-8
Handle for dismantling tools
Fig. 1-9
Piston pin pulling device
Fig. 1-10
Piston pin pliers
Fig. 1-11
Socket spanner for spark plug
Fig. 1-12
Clutch thickness measuring device
Fig. 1-13
Cylinder diameter measuring device
Fig. 1-14
Dial indicator
Fig. 1-15
Dial indicator, V-block
Measuring the inner diameter of the piston pin, Fig. 1-16
Dial indicator
For measuring the bending of the valve rod，Fig. 1-17
Assembly/disassembly tool for valve catheter
For measuring the external diameter of the valve rod，Fig. 1-18
Assembly tool for valve catheter
Fig. 1-19
Adjustment tool for valve space
Fig. 1-20
Assembly/disassembly tool for valve spring
Fig. 1-21
Valve catheter reamer
Fig. 1-22
Disassembly tool for crankcase
Fig. 1-23
Fig. 1-24
Table 1-2 (continued)
Fig. 1-3
Fig. 1-4
- 7 -
Fig. 1-5
Fig. 1-6
Fig. 1-7
Fig. 1-8
Fig. 1-9
Fig. 1-10
①handle
Fig. 1-11
Fig. 1-12
①pliers
②piston
- 8 -
Fig.1-13
Fig.1-14
Fig. 1-15
Fig. 1-16
Fig. 1-17
Fig. 1-18
Fig. 1-19
Fig. 1-20
Fig. 1-21
Fig. 1-22
- 9 -
Fig. 1-23
Fig. 1-24
2. Tools for repairing the chassis
Table and drawing (1-25, 1-26) of ordinary tools and special tools for disassembling/assembling chassis
parts are as follows:
Fig. 1-25
Name
Remark
Torque spanner
Fig. 1-27
Inner hexagon spanner
Fig. 1-28
Socket spanner
Fig. 1-29
Micrometer
Fig. 1-30
Magnetic rack, V-block
Fig. 1-31
Dial indicator
Fig. 1-32
Vernier calipers
Fig. 1-33
Circlip pliers
Fig. 1-34
Screwdriver with striking cap
Fig. 1-35
Tool for assembling oil seal of front fork
Fig. 1-36
Tool for hammering seal of front fork
Fig. 1-37
Steering nut spanner
Fig. 1-38
(1) Ordinary tools for repairing the chassis
Table 1-26 (continued)
Fig. 1-27
Fig. 1-28
Fig. 1-29
Fig. 1-30
- 10 -
Fig. 1-31
Fig. 1-32
Fig. 1-33
Fig. 1-34
Fig. 1-35
Fig. 1-36
(2) Special tools for repairing the chassis: tool for hammering seal of front fork
Fig. 1-37
(3) Steering nut spanner
Fig. 1-38
- 11 -
3. Tools for electric parts
Table and drawings (1-39, 1-40) of special tools for testing electric parts are as follows:
Fig. 1-39
Name
Remark
Multimeter
Fig. 1-41
Ignition tester
Fig. 1-42
Fig. 1-40 (continued)
Fig. 1-41
Fig. 1-42
- 12 -
Specification
Motorcycle Model
TNT 600
Engine Type
BJ465MS-A
Length mm
2155
Fuel type
Unleaded petrol（95/97）
Width mm
765
No. of cylinder
4
Height mm
1100
ID × stroke
65.0×45.2
Wheelbase mm
1480
Total displacement
600cc
Petrol tank capacity
15L
Startup
Electric
Weight kg
(Curb weight)
Forward
115
Cooling
Liquid cooling
Back shaft
105
Lubrication
Pressure splash lubrication
Total
220
Clutch type
Wet multi-plate
Front tire
120/70 ZR
Variable speed
Six variable speed
Rear tire
180/55 ZR
Transmission
Chain
Tire Size
Electric
devices
Engine
Battery capacity
12V-9AH
Magnetor
Flywheel permanent magnet
Spark plug
CR9E(NGK)
Spark plug gap
0.6-0.7mm
Ignition
TLI
Max. Hp
60.0kW/11000rpm
Primary
transmission ratio
Transmission ratio
of gear 1
Transmission ratio
of gear 2
Transmissio
Transmission ratio
n devices
of gear 3
Transmission ratio
of gear 4
Transmission ratio
1.864
2.846
1.947
1.556
1.333
1.190
of gear 5
Max. torque
52N.m/8000rpm
Compression ratio
11.5：1
Max. speed
185km/h
Transmission ratio
of gear 6
Final Transmission
ratio
1.083
3.286
Performance
Dia. of front liquid
brake disc（mm）
320mm
Brake
Fuel consumption
limit
≤5.2L/100km
Dia. of rear liquid
brake disc（mm）
240mm
- 13 -
TNT600
- 14 -
Failure Diagnosis
Diagnosis on difficulty or failure in starting up
Failure Diagnosis
Adjustment & Inspection
Check if petrol
pump is working
properly
Oil provided to fuel
injector is sufficient
and smooth
No
petrol
provided to
fuel injector
Disassemble
spark
plug into its cap,
ground it with engine
to check if it can spark
Spark-over
Weak sparks
No
Test compression pressure
Normal
Causes of Failure
No petrol in the tank
Oil tube of fuel injector blocked
Oil tube of petrol pump blocked
Tube of combustion chamber’s
Evaporation Control System
blocked
Petrol air filter blocked
Low oil pressure of petrol pump
Abnormal spark plug
Polluted spark plug
Abnormal CPU group
Abnormal trigger
Open circuit or short circuit of
ignition coil’s wire
ignition coil
Abnormal main switch
Abnormal charging coil
Abnormal clutch for startup
Abnormal piston of cylinder and
piston ring
Too low
No
Leakage of cylinder gasket
No ignition
outbreak of
the engine
Ignition outbreak
of the engine but
no sign of startup
Abnormal
actuation
automatic
choke
Intake manifold with air
Incorrect ignition time
Disassemble once agian the
spark plug to check
Dry spark plug
Wet spark plug
Abnormal adjustment to throttle
valve and bolt
Excessive oil injected to fuel
injector
Abnormal automatic choke
actuation
Throttle opens too large
- 15 -
Unsmooth gyration (No speed or weak speed)
Failure diagnosis
Adjustment specification
Start engine with
soft refueling
accelerated
gyration speed
of engine
Air filter blocked
Abnormal petrol
blocked
Exhaust pipe blocked
Abnormal automatic choke
Abnormal throttle valve
Engine cannot
fully speed up
Adjust ignition timing and
use ignition timing light
Correct
ignition time
Causes of failure
Abnormal CPU group
Incorrect ignition
time
Abnormal trigger
Test compression pressure
Abnormal piston of cylinder and
piston ring
Normal
Too low
Leakage of cylinder gasket
Blocking check to Carburetor
No
Yes
Contaminant removal
Disassemble the spark plug to
check
No pollution nor
discoloration
Contaminant removal
Polluted and
discolored
Heat value of spark plug does
not conform
Check oil level in crankcase
if it is high or polluted
Normal
Excessive oil
Insufficient oil
No replacement of oil
High oil level
Check the lubrication
cylinder head
Normal
Abnormal
Overheated engine
Yes
No
Accelerated driving or
running
Engine knock
No engine knock
of
Abrasion in piston cylinder
Mixed gas too thin
Abnormal petrol
Too much carbon fouling in the
combustion chamber
Earlier ignition time
Too much carbon fouling in the
combustion chamber
Abnormal petrol
Clutch slipping
Thin mixed gas
Earlier ignition time
- 16 -
Unsmooth gyration（especially in low speed）
Failure Diagnosis
Causes of Failure
Adjust ignition time
Abnormal CPU group
Normal
Abnormal
Abnormal trigger
Adjustment to throttle valve and
bolt
Mixed gas too thin (loosen bolt)
Good
Bad
Mixed gas too dense (tighten
bolt)
Spacer inhaled air or not
Yes
Abnormal spacer of heat
insulation piece
Throttle valve fixed, bolt
loosened
Heat insulation piece ruptured
Negative pressure pipe ruptured
No
Disassemble spark plug
into its cap and ground it
with engine to check if it
can spark
Good
spark-over
Bad spark-over
Spark plug abnormal or polluted
Abnormal CPU
Abnormal ignition coil
spark plug’s wire
Negative pressure pipe damaged
Good
Bad
Air pass-hole blocked
- 17 -
Unsmooth gyration (high speed)
Failure Diagnosis
Causes of Failure
Adjust ignition time
Abnormal CUP group
Normal
Abnormal
Abnormal trigger
Little oil in petrol tank
Normal
Petrol filter of the pipe blocked
Abnormal
Blocked oil injector
No
Good
Blocked
Spring broken
Weak elasticity
blocked
Abnormal automatic oil ring
Remove
Abnormal spring
- 18 -
Poor battery charging (over discharge or over charge)
Failure Diagnosis
Causes of Failure
Test the voltage of
battery’s two ends, and
stat engine
Battery used up
No voltage rise
Voltage rises to normal
value, and back to
original voltage value
after flameout
Check the plug of
regulator if it is loose
Normal
Poor battery
voltage
Poor connection of the plug
Abnormal
Open circuit of the red wire of
the charging wire
Check if the red wire of voltage regulator’s
socket connects the multimeter, while
anode and cathode wire to the voltage
between parts of the body
Voltage
available
No voltage
Voltage regulator
Open circuit of the white wire of
the charging wire
Test the resistance
alternator’s coil
Normal
of
Abnormal coil
Poor connection of the joint
Open circuit of alternator’s
white wire
Poor battery
Abnormal
Poor battery charging
Overcharging
Voltage above
normal value
value
Start the engine, connect the red wire of the
voltage regulator’s socket to the multimeter,
while anode and cathode wire to the voltage
between parts of the body
Normal voltage
Check if charging wire of the voltage
regulator connects well
Normal
Loose
Bad connection
Poor connection of the joint and
Use monomer of the voltage regulator
to test impedance
charging wire to the ground
Abnormal voltage regulator
- 19 -
No spark-over of the spark plug
Failure Diagnosis
Causes of Failure
Replace on new spark
plug and check again
Weak spark-over or
no spark-over
Strong spark
Original spark plug abnormal
Check again after
checking spark plug
No sign of loose
Loose
Spark plug cap loose
Check plugs of CDI group if they
are loose
Normal
Abnormal
Bad connection of the plug
Check conduction between terminals
of CDI group’s plugs, and test
resistance value
Abnormal charging coil
Normal
Abnormal
Abnormal trigger
Check relevant parts
Normal
Abnormal
Breakage of main wire
Bad connection of the plug and
socket
Use CDI tester to check CDI group
Normal
Abnormal CPU group
Abnormal
Use CDI tester to check ignition coil
Abnormal
- 20 -
Inspection/Adjustment
1.
Preparing information
2.
Periodic Maintenance & Inspection Table
3.
Engine oil/ Oil filter
4.
Liquid coolant
5.
Assembly / Disassembly of the Clip of the Radiator’s Hose
6.
Fuel Injector and Oil-route
7.
Throttle Cable Adjustment
8.
Air filter
9.
Spark plug
10. Battery
11. Fuse replacement
12. Cylinder Compression
13. Drive Chain Free Play
14. Front Brake Free Play
15. Free play of rear brake
16. Headlamp
17. Clutch
18. Front/rear suspension system
19. Bolt/nut/fastener
20. Wheel/tire
21. Fixing steering stem bearing & handlebar
22. Throttle Body
23. Components to Lubricate
1. Preparing Information
General
Warning!
•
Make sure that it is well ventilated before starting the engine. Do not start the engine in a closed area Exhaust
gas, which contains monoxide, may cause unconsciousness or even death.
•
Petrol is liable to volatile or exploded under certain condition. Ventilation is required. Fire is strictly forbidden
in working areas or where oil is stored.
- 21 -
Specification
Engine
ID × stroke
65.0×45.2
Total displacement
600cc
Ignition
TLI
Spark plug gap
0.6-0.7mm
Spec. of spark plug
CR9E(NGK)
Type of combustion chamber
spherical
Frame
Free play of front brake lever
10-20mm
Free play of rear brake pedal
20-30mm
Specification
Tire pressure unit：kpa
Torque
value
TNT 600
Tire pressure
Front tire
120/70 ZR 17
250±10kpa
Rear tire
180/55 ZR 17
290±10kpa
Fixing front wheel
spindle
100-140 Nm
Fixing nut of rear
wheel spindle
130-150 Nm
- 22 -
2. Periodic Maintenance & Inspection Table
Service cycle
and time
Per
300 Km
New
Inspection item
Per
Per
Per
1000K
3000
6000K
m
Km
m
One
Three
Six
Twelve
Fifteen
month
months
months
months
months
C
C
R
Per
12000 Km
14500 Km
Air filter
*
Petrol filter
I
I
R
Ordinary tools
*
Fuel filter
C
C
C
Ordinary tools
Replacement of engine fuel
R
Tire pressure
I
I
I
I
I
I
Battery inspection
I
I
I
I
I
I
Densimeter, multimeter
Actuation gap inspection
I
I
I
I
I
I
Ordinary tools
I
I
I
Ordinary tools
Absorber working inspection
I
I
I
Ordinary tools
Screw fastening inspection
I
I
I
I
I
I
Torque spanner
Oil leakage inspection for gearbox
I
I
I
I
I
I
Ordinary tools
I
R
R
I
Ordinary tools
fastening
*
*
Inspection or replacement of spark
plug
Replacement of gearbox oil
C
Tools
*
Inspection of steering handle
I
Per
Replacement every 1000KM
I
I
Ordinary tools
Replacement every 5000KM
Lubrication of each part
L
L
Ordinary tools
Tire pressure gauge,
inflator
Ordinary tools
Lubricator
Muffler
I
I
I
I
I
I
Ordinary tools
*
Ignition timing
I
I
I
I
I
I
Timing lamp
*
Carburetor
A
I
A
A
A
A
A
I
A
A
A
A
analyzer
*
*
Exhaust gas inspection at idle
speed
Throttle inspection
I
I
I
I
I
Ordinary tools
Fuel pipeline inspection
I
I
I
I
I
Ordinary tools
Lighting/metering/electric devices
I
I
I
I
I
Visual multimeter
Main stand bracket
I
I
I
I
I
I
I
Ordinary tools
I
I
I
I
Torque spanner
I
I
I
I
Ordinary
I
I
I
A
Ordinary
I
I
I
I
Ordinary
I
I
I
I
Feeler
I
Absorber
*
Torque force of engine bolts
I
Front/rear brake
Drive chain
I
Clutch
*
Tachometer, CO HC
Valve
I
Ordinary tools
- 23 -
Anticipated Inspection
1
Ignition system—obviously continuous ignition abnormality, engine fire or overheating, which requires
inspection and maintenance.
2
Carbon fouling elimination—obviously insufficient horsepower, which requires carbon fouling removal from
cylinder head, piston head and exhaust system.
3
Piston & cylinder—excessive abrasion; replace cylinder if it is worn.
Please have your motorcycle inspected and adjusted periodically at Qianjiang distributors for being in best
condition.
The above table is established under the presupposition of 1000 km/month.
I—Inspection
A—Adjustment R—Replacement C—Cleaning L—Lubrication
Note: 1. “*” Regulations on exhaust emission made by the State Environmental Protection Agency shall be complied
with. Maintenance must be carried out in accordance with the instruction manual supplied by the company. We are
not responsible for any loss rising from private adjustment or maintenance.
2. Increase frequency of washing air filter if your motorcycle runs on the sandy/gravel road or under heavily
polluted environment so as to extend its service life.
3. Motorcycles which often run at high speed or with high mileage shall be maintained frequently.
3. Engine Oil/Filter
Oil level
* Note
• The motorcycle should be parked on a flat ground when
checking its oil level.
• After the engine runs for 2-3 minutes or stops running for about
2-3 minutes, check the oil level.
Check the oil level.
Add oil to the upper limit when there is warning light from the oil
level sensor.
Check oil level
*Note
1. Do not tighten dipstick when check.
2. Check the oil level, when the motorcycle is vertical.
3. Oil level must be checked regularly when oil is constantly
being consumed, and refuel to a right level.
Oil capacity: 3.0L change oil 3.2L disassemble
The working of engine and clutch will be affected if the
oil level is too high.
- 24 -
And if it is too low, it will lead to overheated engine and earlier abrasion of the components. Always use high quality
oil to prolong engine life. Disassemble the dipstick after the engine stops, and dry it with a clean cloth. Put the
dipstick into the measurement hole with the engine on the flat ground, but do not tighten it up. Take out the dipstick
and check the oil level. If it is below or near the minimum level, refuel with the recommended oil to the maximum
level.
*Note
•
•
Check the O-ring.
Assemble the dipstick.
Oil Replacement
* Note
It will be easier to change oil when the engine is warming up.
1. Preheat the engine.
2. Place a drip pan under the engine, and disassemble the
drain bolt and the dipstick.
3. Repeatedly start the engine for several times until the oil
is discharged completed.
4. When the oil is discharged completely, install back the
drain bolt and the packing washer after cleaning.
5. Refuel recommended oil to the crankcase to a required
capacity.
6. Assemble the dipstick.
7. Start the engine to run in an idle speed for 2-3 minutes.
8. Stop the engine, and check if the dipstick is at the maximum level several minutes later.
9. The engine should be upright while checking.
10. Make sure that there is no leakage.
Replacement of the Oil Filter
*Note
It will be easier to change oil when the engine is warming up.
1. Turn off the engine.
2. Make the oil filter stuck with special removal tool, spin
anticlockwise and disassemble the oil filter that needs
replacement.
3. Replace on new oil filter and coat a layer of lubricant on
the O-ring.
Note:
Do not disassemble the O-ring, otherwise it will make the O-ring
Oil filter
- 25 -
out of position while installing, which can lead to oil leakage or the damage of the engine.
Install the new oil filter to the engine with hands, spin until it cannot be screwed any further, and then tighten it
with Torque spanner (torque: 12-20Nm).
Check oil leakage when the engine operates at its idle speed for minutes.
3. Liquid Coolant
Check the level of the coolant in the expansion chamber during
maintenance.
Recommended model of the cooling liquid: FD-2
Total liquid capacity of the cooling system: about 2.0L
Remove the front shield on the right side. The filler cap of radiator
is located.
Open the filler cap and fill a right amount of coolant.
Re-install the cap after filling up.
Check the coolant of the expansion chamber after the engine has
been turned off and cooled down.
While checking, make sure the motorcycle is on the flat ground
and its body upright.
Observe the capacity of the coolant in the expansion chamber
through the frame hole from the right side of the motorcycle.
Keep the capacity between the mark of H and L. If the liquid is below H, remove the cap of the expansion chamber
and then add coolant.
Warning:
Add the coolant after the engine is turned off and cooled down. In case of heat, do not open the filler cap
before the engine has cooled down. The cooling system is under pressure
- 26 -
4. Assembly / Disassembly of the Clip of the Radiator’s Hose
The clip of the radiator’s hose is disposable component, so the old
clamp cannot be reused when disassembled. And the clip can only be
assembled by special clamp pliers, or it may not in place, which will
lead to the breakdown of the vehicle.
5. Fuel Injector and Oil-route
The fuel pump has two connectors; oil passes through the
fuel filter② from one of the two connector into the fuel
injector③, and finally injects oil into the intake manifold of
the engine. When the fuel is under too high pressure, it will
pass through another connector back to the fuel pump.
Please connect the inlet and outlet fuel hose as shown in the
figure at right.
- 27 -
7. Throttle Cable Adjustment
*Note
Adjust the idle speed of the engine first before adjusting the
free play of the throttle cable.
The throttle cable free play should be 3-5mm.
Adjust if it does not conform to the specified value.
The motorcycle is fitted with 2pcs cable, among the two
cables, A for throttle forward
1. Remove the dustproof boot of the steel rope of
the throttle.
2. Loosen the locking nut.
3. Screw in completely the adjusting nut.
4. Loosen the locking nut.
5. Rotate the adjusting nut to make the free
stroke of controlling handlebar of the throttle
to 10°～15°.
6. Tighten up the locking nut.
7. Adjust nut to make the controlling handlebar of
the throttle flexible.
8. Tighten up the locking nut.
After adjusting the free stroke, the handle should be
twisted left and right to make sure that there is no
change of the idle speed of the engine.
8. Air Filter
Filter Replacement
1. Open the rear seat cushion with the key, and remove it.
2. Pull the seat cable, open the front seat and take it off.
- 28 -
3. Disassemble the cover of the fuel tank and its front
fixing bolt, and open the fuel tank.
4.
5.
6.
7.
8.
Disassemble the cover of the air filter.
Take off its element.
Check whether the element is stained or damaged.
Replace it if necessary.
Clean thoroughly but gently the element with the
cleanser.
9. Do not use petrol, in case of fire.
10. Do not distort or wring the cartridge so as not to
damage the foam.
11. Then apply the engine oil to it, and squeeze out the
excess oil to make the element seem moist, but
make sure there is no oil dripping.
Air filter Element
Replacement Time
Replace it as early as possible if the motorcycle is always running on rainy days or on rugged road.
*Note
Do not start engine when disassemble the element of the air filter, otherwise, the engine will intake unfiltered air,
which may lead to rapid abrasion of other components, and the damage of the engine too.
In addition, rotation without element will cause sequential malfunctions of the carburetor, and it may lead to
overheat of the engine.
Install in reverse order.
- 29 -
9. Spark Plug
Remove the spark plug:
1. Lift up the fuel tank.
2. Disassemble the intake air temperature sensors① on both
side of the air filter, and then remove the air filter.
3. Remove the stators of the spark plug caps on both sides.
4. Remove the spark plug cap, and you can see the spark plug.
5. Remove the spark plug with the spark plug wrench.
Check
 Whether the insulator is cracked or damaged
 Whether the electrodes are abrasive
 The combustion condition and color
 The condition is good in light grey
 Combustion color of pale indicates that the ignition system gets
a breakdown or the mixed air is too thin.
 The condition of wet or there is black carbon deposition
indicates that the mixed air is too thick.
If there occur any cases mentioned above, please remove with spark
plug cleaner or steel brush, and replace if necessary.
Check the spark plug visually.
Replace the cracked or abrasive insulator if necessary.
Replace the spark plug after 8000 kilometers of each driving.
Check the spark plug gap.
Gap: 0.6-0.7mm
Model: CR9E(NGK)
*Note
Re-install the spark plug to the cylinder head, and screw tight with a
specified torque.
Torque value: 20-25N.m
Manually install the spark plug first, and then tighten with the spark plug sleeve.
Do not tighter the spark plug too tight, so as to avoid damage the threads of the cylinder head.
When remove the spark plug, avoid impurities from entering into the engine.
- 30 -
10. Battery
Battery Disassembly
Disassemble the front seat.
Remove the mounting plate of the battery.
Remove the negative wire and then the positive wire.
Remove the battery from the battery box.
Take out the battery.
Warning!
When the positive wire is disassembled, do not make the tool
contact with the frame. Otherwise, it may cause short-circuit
spark, which may ignite gasoline and damage the battery. It is
dangerous.
Install it in reverse order.
Warning!
To prevent short circuit, connect the positive wire first and then the negative wire. Do not remove the battery when
the engine is running. Otherwise, it may cause damage to inner parts of the vehicle.
Check the Charging Condition (closed circuit voltage)
Open the front seat.
Remove the battery from the battery box.
Remove the negative wire and then the positive wire.
Take out the battery.
Test the voltage between battery terminals.
Fully charged: 13.1V
Insufficient charging: 12.3V（1 hour off work）
*Note
Use a voltmeter to check the charging condition.
Charging
Connection: Connect the positive pole of the charger to the positive pole of the battery.
Connect the negative pole of the charger to the negative pole of the battery.
- 31 -
Warning!
• The battery should be far away from fire source.
• Turn off the charger before or after charging to avoid
explosive danger caused by spark which may exist in any
connection.
• Comply with the current and time requirements for charging
as stated on the battery.
* Note
• Except emergencies, you should not use emergency charging.
• Measure voltage in 30 minutes after the battery is charged.
Charging current: standard: 0.3A
quick: 3.0A
Charging time:
standard: 10-15 hours
quick: 30 minutes
Charging accomplished: open-circuit voltage : above 12.8V
11. Fuse Replacement
The fuse is under the driver’s seat, and near the battery.
The main fuse is set on the starter relay, and the fuse box is near
the fuse. As shown in the figure ① refers to the fuse, model: 40A,
② refers to the spare fuse of the main fuse, model: 40A, ③
refers to the fuse box, the configuration of the fuse is shown in the
figure:
Frequent fuse blowout indicates that there is short circuit or
circuit overload.
Note:
Before check or replace the fuse, set the ignition switch to “off
”, in case of short circuit or damage to other electrical
components.
Use the specified fuse only, or it will cause serious effect to the
electric system, and it can even burn the lamps of the motorcycle
or cause a fire or loss of engine traction, which is very dangerous.
- 32 -
12. Cylinder Compression
1.
2.
3.
4.
5.
Warm up the engine.
Insert the compression gauge.
Turn the choke lever to the fully open position.
Start up the engine repeatedly,
The pressure of the cylinder: 1～1.2mpa
*Note
Start the engine until the reading does not rise.
Reasons for low pressure:
 Incorrect valve adjustment
 Leakage of the valve
 Abrasive piston ring or cylinder
Reasons for high compression:
 Carbon deposition in the combustion chamber or piston
Turn off the engine, and remove the spark plug/spark plug cap
13. Drive Chain Free Play
The life of the drive chain depends on appropriate lubrication
and adjustment. Improper maintenance could lead to earlier
abrasion of the dive chain and the sprocket. It must be
maintained frequently if harshly used.
Free play: 10-20mm
Adjustment to the drive chain:
Adjust the drive chain to the sag of 10-20mm in every
1000 kilometers’ drive. Regular adjustment may need which
depends on your driving.
Warning:
It is the maximum interval for adjustment as
recommended; in fact, you should adjust the chain before
every drive. Over loosened chain may cause the accessory
chain off the drive chain or serious damages to the engine.
Adjust the chain according the following methods mentioned：
1. Put up the motorcycle with the support frame.
2. Loosen the rear axle nut①.
3. Loosen the locking nut②.
4. Turn right or left the adjustment bolt③ to adjust the looseness of the chain, and keep the centers of the
rear and back sprockets into a straight line. There are benchmarks on the swinging arm and each chain
adjuster to facilitate your adjustment, and they can be aligned with each other and the reference from one
- 33 -
side to the other. Align and adjust the looseness of the chain to 10 - 20mm, and then fix again the rear axle
nut for the final check.
Note:
The two sprockets of the newly replaced chain should be checked to make sure whether they are abrasive or
not, replace if necessary.
Inspect periodically the following condition of the chain:
1. Loose pin
2. Damaged idler wheel
3. Dry and rusty chain
4. Twisted or blocked chain link
5. Excessive damage
6. Adjust loose chain
If the chain has defects as mentioned above, then there is a high possibility that the sprocket will damage the chain.
So the following items should be check to the sprocket:
1. Excessively abraded gear tooth
2. Broken or damaged gear tooth
3. Loose fixing nut of the sprocket
Lubrication of the drive chain
Priority should be given to lubricate by the lubrication grease for the drive chain, and you may buy it or use engine
oil or other lubrication oil instead. Dip every chain joint to make the lubrication grease penetrate to the space
between the chain plates, pins, bushings and rollers.
*Note
Do not assemble new drive chain to worn out sprocket or vice versa.
The sprocket and the chain should be used as a set, or it will cause quick abrasion of the newly replaced chain or
sprocket.
14. Front Brake Free Play
Measure the free play of front brake at the tip of the brake
lever.
Free play: 10-20mm
Regulator of Lever Grip of the Front Brake
Depending on the operating needs for the comfort, the position
of the lever grip of the front brake can be adjusted by
adjusting the knob with the ring nut. There are four positions
for adjustment, and you can adjust to a desired position just by
moving gently forward the lever of the brake, and then rotating
the adjuster of the ring nut at the arrow ○
A . And position 1 of
the front brake lever is most remote to the controlling handlebar of the throttle, while the position 4 nearest to it.
- 34 -
15. Rear Brake Free Play
Measure the free stroke of the brake pedal.
Free play: 20-30mm
If specified value has not been met, it should be adjusted.
Adjust the free play of the brake pedal.
First loosen the nut 1.
Screw in or out nut 2 to adjust the free play of the brake pedal.
Screw in 2 to reduce the free play;
Screw out 2 to increase the free play.
Tighten the fixture 1 until the specified value is met.
After being adjusted, dragging should not occur to the brake.
16. Headlamp
Disassemble the fixing bolt① of the headlamp support.
Disassemble the fixing bolt② of the headlamp support.
- 35 -
Unplug the lamp holder connector③ of the headlamp,
remove the lamp holder, loosen the snap ring, and take out
the bulb.
*Note
During the installation, avoid direct touch with the glass of the bulb,
and avoid oil-stained or it will affect the transparency, life and
luminous flux of the bulb.
Once stained with oil, wipe thoroughly with a damp cloth with
alcohol or rubber solution of strong volatility.
17. Clutch
Check the free play of the clutch cable.
Free play: 10-15mm
Adjust the free play of the cable of the clutch.
First loosen the clamp nut（1）.
Then screw in or back to the adjusting device（2）.
Until the specified value of the free play is met.
Finally, tighten the clamp nut.
If adjusting the handle of the inhaul cable of the clutch to its
ultimate position cannot meet the requirement of the free play, and
A of the engine and the adjusting nut○
B
then adjust the locking nut○
with the inhaul cable.
- 36 -
18. Front/Rear Suspension System
Front Absorber
Compress upwards or downwards
Pull the front brake tight; compress the front absorber
upwards or downwards for check.
Check whether there is oil leakage in the front absorber and
whether any component is damaged or loosened
Rear Absorber
Compress upwards or downwards
Compress the rear absorber upwards or downwards for
check. Check whether each part of the rear absorber is
damaged or loosened. Suspend the rear wheel and check
shimmy. Check whether the suspension bushing of the
engine is loose or not.
19. Bolt/ Nut/Fastener
Check whether each bolt, nut and fastener is loose. If yes, tighten it to required torque.
- 37 -
20. Wheel/Tire
Check whether tires or wheel have any crack, nail or any
other damage.
Check tire pressure.
*Note
Check tire pressure when it is cold.
Specification
TNT600
Tire pressure
Front tire
120/70 ZR 17
250±10kpa
Rear tire
180/55 ZR 17
290±10kpa
When the thread depth on the central thread of the tire
reaches to the figure in the table, the tire should be replaced.
Minimum thread depth
Front tire
1.6mm
Rear tire
2.0mm
Warning:
Improper tire inflation will lead to abnormal
abrasion of the tire and threat the safety. And insufficient
inflation will cause tire slip, or disengage the tire, or lead
to the deflation of tire which is out of control. It is
dangerous to drive with excessively abraded tires, and it
is adverse to the adhesion or driving.
Check whether the locking nut of the front wheel spindle is loose.
Check whether the fixing nut of the rear wheel is loose.
Tighten it to the required torque value if it is loose.
Torque value: Fixing the front wheel spindle
Fixing nut of the rear wheel spindle
55-62 Nm
85-108 Nm
- 38 -
21. Fixing Steering Stem Bearing and Handlebar
1.
2.
3.
Move the handlebar to confirm there is no wire interference.
Rotate the front wheel and move the handlebar freely for check.
If the handlebar moves difficultly, release it and then check the bearing of the fixing steering stem.
22. Throttle Body
The idle speed of the motorcycle will be reduced to some
extent due to the pollution of the throttle body. It is better
to clean it after every 5000 kilometer’s run.
When cleaning, disconnect the negative pole of the battery,
connectors of the sensor installed on the throttle; and
remove the throttle cable, hose connected to the air filter
and the intake manifold, and the throttle body.
Open the lid on the bottom of the throttle body, spray
cleanser to its in-wall and brush the dust and carbon
deposition, etc.
After cleaning, operate in reverse order, install the throttle
and make sure that all parts are in place, and try to start
the engine successfully.
- 39 -
23. Components to Lubricate
Appropriate lubrication is of great importance to the normal operation of each part of the motorcycle, to an
extended life and to the safety drive. Lubricate the motorcycle after a long time running or exposure in the rain or
after cleaning. As for detailed points for lubrication and maintenance, see the following figure:
Ｙmotorcycle
□
lubrication
Ｚ
□ grease
1. axis of the rear brake pedal Ｚ
□
2. single bracket joint and spring hookＺ
□
3. pin of the gearshift riding rod Ｚ
□
4. throttle cableＹ
□
5. pin of the front brake handle Ｚ
□
6. clutch handle（pin）Ｙ
□
- 40 -
Inspection and Maintenance of the Electrical System
- 41 -
1. Battery/Charging System
Preparing Documents-----------------------1.1
Failure Diagnosis----------------------------1.2
Battery-----------------------------------------1.3
Charging System-----------------------------1.4
Voltage/Current Regulator -------------------1.5
Charging Coil of Magnetor ------------------1.6
Disassembly of Magnetor -------------------1.7
1.1 Preparing Documents
Work Instructions
*Note
1. Battery can be charged or discharged repeatedly. If it is placed after discharge, its service life will be
shortened and performance is undermined. Normally, the battery performance will be degraded after two
or three years. As for battery of degraded performance (reduced capacity), whose voltage will recover
temporarily after charging but decrease sharply when loading.
2. Battery overcharge: normally, overcharge can be judged upon the battery. In the case of short circuit inside
the battery, its terminal is unable to detect voltage or the detected voltage is very low. Regulator failure:
over voltage inside the battery will shorten its service life.
3. The battery will be self-discharged if being stored for a long time, which reduces its capacity. It shall be
charged about every three months.
4. Check the charging system following the sequence listed on the failure diagnosis table.
5. Do not remove the connector when there is current through electrical parts, otherwise it will cause over
voltage and damage to electrical parts inside the voltage regulator. Please operate it after the main switch
turns off.
6. It is unnecessary to check the maintenance-free battery and add electrolyte and distilled water.
7. Check all electric loads.
8. Emergency charging can only be used under emergency situation.
9. Remove the battery from the motorcycle for emergency charging.
10. Do not use electrolyte-added batteries when interchanging batteries.
11. Use a voltmeter to check charging condition of the battery.
- 42 -
Preparing Principles
Item
Specifications
Capacity/Type
Battery
Magnetor
Voltage
regulator
Voltage
（20℃）
12V-9AH/ dry-charged
Fully charged
13.1V
Necessary
charging
12.3V(not working for 1h)
Charging current
Standard: 0.8A, quick:8A
Charging time
Standard: 10-15 hours, quick: 30 mins
Impedance of the coil
（20℃）
Between white-white 1.5-3.5Ω
Type
Three-phase full wave
Charging voltage of the
battery
14.5±0.5V/5.000rpm
Tightening Torque Force
Rectifier bolt
High-voltage coil fixing bolt
Flywheel fixing nut
Body guard bolt
5.0 N·m
9.0 N·m
5.0 N·m
9.0 N·m
Tools
Universal fixing spanner
Flywheel remover
Test instrument
Multimeter
1.2 Failure Diagnosis
Power Supply Dead
Interrupted Current
Battery over-discharge
Unconnected battery wiring
Fuse blow
Poor switch
Poor contact of the charging wire
Poor contact of the charging system
Poor contact or short circuit of the lighting system
Low Voltage
Poor battery charging
Poor contact
Poor charging system
Poor voltage/current regulator
Poor Charging System
Poor contact, short circuit or open circuit of wire terminals
Poor voltage/current regulator
Poor magnetor
- 43 -
1.3 Battery
1.3.1 Battery Disassembly
As for details, please see page 31.
Warning!
When the positive wire is disassembled, do not make
the tool contact with the frame. Otherwise, it may
cause short-circuit spark, which may ignite gasoline
and damage the battery. It is dangerous.
*Note
To prevent short circuit, connect the positive wire
first and then the negative wire.
Check the charging condition (closed circuit voltage).
Remove the seat.
Remove cables of the battery.
Test the voltage between battery terminals.
Fully charged: 13.1V
Insufficient charging: 12.3V (not working for 1 hour)
* Note
Use a voltmeter to check the charging condition.
1.3.2 Charging
Connection method: connect the positive pole of the charger with the positive pole of the battery; connect the
negative pole of the charger with the negative pole of the battery.
Warning!
• The battery should be far away from fire source.
• Turn off the charger before or after charging to avoid explosive danger caused by spark which may exist in
any connection.
• Comply with the current and time requirements for charging as stated on the battery.
*Note
• Except emergencies, you should not use emergency charging.
• Measure voltage in 30 minutes after the battery is charged.
- 44 -
Charging current: standard: 0.8A
quick: 8.0A
Charging time: standard: 10-15 hours
quick: 30 mins
Charging completed: open circuit voltage: above 12.8V
1.4 Charging System
1.4.1 Short-circuit Test
Remove the earth lead from the battery. Install a voltmeter between the negative terminal and the earth lead. Turn
off the switch. Check the short-circuit.
*Note
Connect the positive terminal of the multimeter with
the negative terminal of the battery.
Check whether there is short-circuit in the main switch or in the main wire in the case of any abnormality.
1.4.2 Charging Check
Use a multimeter to check the charging status of the battery when it is being fully charged.
Install the fully charged battery after the engine warms up.
Connect a voltmeter between terminals.
Remove the main fuse and connect an ammeter between terminals.
Start the engine and increase its speed gradually to measure the limiting voltage and current.
Limiting voltage/speed: 14-15V （5.000rpm）
Check the voltage regulator if the limiting voltage is not within its required range.
Check the limiting voltage of the lighting system.
Remove the seat.
*Note
Set the multimeter to the AC voltage position.
Limiting voltage: 13.1（+/-）0.5V/5.000rpm
Check the voltage/current regulator if the limiting voltage is not within its required range.
- 45 -
1.5 Voltage/Current Regulator
1.5.1 Main Wiring Check
Remove the shield of the body.
Remove 4p plug of the voltage/current regulator.
Check conductivity between main wiring terminals.
Item (wire color)
Judgment
Between Battery(red) and GND
of the body
With battery
voltage
Between GND wire (black) and
GND of the body
With lead
Between charging coil (white)
and the GND of the body
Resistance in the
coil of the
magneto.
1.5.2 Voltage-current Regulator Check
1. Choose diode file with multimeter.
2. The black probe connects to the red wire terminal of the voltage regulator, and the red probe connects
respectively with the white wire terminal (white 1, white 2, white 3). The pointer gauge shows a certain value,
otherwise it indicates the damage of the voltage regulator and replacement is needed.
3. The red probe connects to the black wire terminal of the voltage regulator, and the black probe connects
respectively with the white wire terminal (white 1, white 2, white 3). The pointer gauge shows a certain value,
otherwise it indicates the damage of the voltage regulator and replacement is needed.
*Note
• Do not touch any metal part of the test rod of the
multimeter with your finger for check.
• Check with multimeter. Different multimeters show
different impedance and different results.
Replace the voltage-current regulator when the impedance between terminals is abnormal.
1.6 Magneto Charging Coil
Ω
*Note
Check the magneto charging coil on the engine.
白
白
白
Check
Remove the 6p connector of the magneto.
Measure the impedance between the three white terminals of the magneto with the multimeter.
Standard: 1.5-3.5Ω（20℃）
Replace the magneto coil when the measured value exceeds the standard value.
- 46 -
1.7 Magneto Disassembly
Left cover and
the magnetic coil
1.7.1 Disassembly
Loosen the fixing nuts on the left cover, and
remove the left cover and the magnetic coil.
Bolt
Fix the flywheel with the universal fixing spanner.
Remove fixing bolts of the flywheel.
Remove the flywheel with the flywheel remover.
Remove the solid key.
Remove the conductor joint.
Remove the stator.
Bolt
Loosen the four fixing bolts of the magnetic coil,
and remove the magnetic coil.
Bolt
- 47 -
Loosen the locking nuts of the flywheel with
electric, pneumatic tools or torque spanner.
Remove the flywheel assembly.
Locking nut of
the flywheel
1.7.2 Installation
Install the stator on the body of the engine.
Connect the magneto joint.
Clean up the crankshaft and the taper part of the flywheel.
Install the solid key into the groove above the upper crankshaft key and confirm it.
Aim the groove in the flywheel at the solid key on the shaft.
* Note
Ensure there is no any bolt in the inner magnetic
side of the flywheel.
Fix the flywheel with the universal spanner and tighten fixing nuts.
Torque force: 9.0 N·m
- 48 -
- 49 -
2. Ignition System
Preparing Documents -----------------2.1
Failure Diagnosis ---------------------2.2
Ignition System Check ---------------2.3
ECU Group----------------------------2.4
Ignition Coil ---------------------------2.5
Trigger ---------------------------------2.6
Work Instructions
1. Check the ignition system following the sequence listed in the table of failure diagnosis.
2. This ignition system is an electronically and automatically angling device. It is solidified in the ECU unit and
you don’t have to adjust the ignition time.
3. Check the ignition system following the sequence listed in the table of failure diagnosis.
4. Do not make ECU of the ignition system fall down or hang down or hammer it with strong force (primary
causes for failure). Pay special attention during disassembly.
5. Failure of the ignition system is mostly caused by poor contact of the socket. Check whether each
connector is in good condition.
6. Check whether the heat value used for the spark plug is proper. If not, the engine may work abnormally or
the spark plug may be burnt.
7. Check in this chapter is based on the maximum voltage. It also refers to check on the impedance of the
ignition coil.
8. Check the main switch according to the conduction table.
9. Remove the magneto and the stator according to instructions.
Item
Standard value
Spark plug
recommended
Standard
Spark plug gap
Ignition coil impedance
（20℃）
Primary coil
CR9E(NGK)
0.6-0.7mm
650±50mΩ
Impedance of trigger（20℃）
100-300Ω
Measure the maximum primary voltage of the ignition coil
14V
Trigger voltage
Above 1.7V
Tools
Attachments to the Maximum Voltage Table
Multimeter
- 50 -
No spark-over of the spark plug
Abnormality
Cause (confirm it sequentially as follows)
①The inner resistance is too small and it should be
tested by required tester.
②Low speed of the crankshaft.
Ignition
coil
③Interfered tester (It is normal that voltage is always
Too low high-voltage
beyond the required value upon several measurements.)
④Poor wiring contact of the ignition system.
⑤Poor ignition coil.
⑥ Poor charging coil (measured at the maximum
voltage).
①Incorrect connection of the tester.
②Poor main switch.
③Poor contact of ECU terminal.
④Short circuit or poor contact of the GND of ECU.
No or interrupted high voltage
⑤ Poor contact of charging coil (measured at the
maximum voltage).
⑥Poor trigger (measured at the maximum voltage).
Side voltage
⑦Poor terminal of high-voltage wires.
⑧Poor ECU group (when item ①-⑦ is checked to be
abnormal or there is no spark for spark plug.)
①Poor spark plug or secondary leakage of the ignition
Normal high voltage, but no spark
coil.
②Poor ignition coil.
No high voltage
Charging coil
④Poor charging coil (Item ①-③ is checked to be
normal.)
①Poor ignition coil.
②Poor charging coil.
Too low high-voltage
Trigger
④Poor trigger (Item ①-③ is checked to be normal.)
①Poor ignition coil.
②Poor trigger.
- 51 -
2.3 Ignition System Check
*Note
• When there is no spark, check whether there is
loose wiring
or poor contact, and make sure all voltage values
are normal.
• There are kinds of multimeters with different
impedances and different test values.
Connect a high-pressure shunt or an ammeter with
input impedance above 10MΩ10CV to the multimeter.
Multimeter
High-pressure shunt
2.3.1 Primary Voltage of the Ignition Coil
If you replace the original spark plug with a better one, make ground connection with the engine.
*Note
Make sure all wiring is correct before test.
Cylinder compression pressure normally refers to the
test value when the spark plug is installed on the
cylinder head.
Connect the lead of the ignition coil and also the shunt
between the primary coil terminal (black/red) and the GND.
Press the startup motor or step the actuating lever to
measure the maximum primary voltage of the ignition coil.
Minimum voltage: above 95V
*Note
Never touch any metal part of the test rod with your
finger to avoid electric shock.
- 52 -
2.3.2 Sensor of the Crankshaft
*Note
Install the spark plug on the cylinder head and carry
out measurement when the compression pressure is
normal.
Remove 18 connectors of ECU group. Connect the
peak-voltage shunt between the charging coil
(blue/white terminal) with 18 connector and
the 18 connector (white/green terminal).
Press the startup motor or step the actuating lever to measure
the maximum voltage of the charging coil.
Connection: positive pole to blue/white; negative pole to white/green.
Minimum voltage: above 95V
*Note
Never touch any metal part of the test rod with your
finger to avoid electric shock.
When the maximum voltage measured at the terminal of ECU Group is abnormal; dismantle the shield of the body
and the magnetor terminal.
• If the voltage of ECU is measured to be abnormal while the voltage at the magnetor terminal is normal, it is
caused by poor contact or disconnected wiring.
• If the voltage at both ECU and magnetor terminal appears to be abnormal, it is caused by poor charging coil.
Please refer to charging coil check.
2.4 ECU Unit
2.4.1 System Check
Check the system.
Remove the ECU Unit, and check components
of the ignition system at the terminal.
- 53 -
2.5 Ignition Coil
2.5.1 Disassembly
Remove the body.
Remove the spark plug cap.
Remove the primary lead of the ignition coil.
Remove the fixing bolts and then the ignition coil.
Install the ignition coil in reverse order.
*Note
Install the primary coil with black/red
terminal.
2.5.2 Check the Primary Coil
Measure the impedance between terminals of the primary coil.
Standard: (4±0.2)Ω (20℃)
It shows good if the impedance is within the range of standard values.
Replace the primary coil if the impedance shows ∞ which indicates that the coil breaks.
2.6 Sensor of the Crankshaft
*Note
Check the trigger on the engine.
Check
Remove the shield of the body.
Remove the trigger terminal.
Measure the impedance between the blue/white terminal of
the side wire of the engine and the body GND.
Standard: 100-300Ω（20℃）
Replace the magnetor if the measured value exceeds the
standard value.
- 54 -
BATTERY
G/Y
M
G/Y
Startup Schematic Diagram
- 55 -
3. Starting System
Preparing Documents ----------------3.1
Failure Diagnosis ---------------------3.2
Startup Motor -------------------------3.3
Starter Relay --------------------------3.4
Starter Clutch--------------------------3.5
Work Instructions
Disassemble the startup motor on the engine.
For the disassembly of the startup clutch, please comply with related regulations
Item
Standard
Limit for use
Length of the brush of the
startup motor
12.5mm
8.5mm
Bushing of the startup idler
shaft
8.3mm
Outer diameter of the startup
idler shaft
7.94mm
Tightening torque force
Bolts for the clutch cover of the startup motor
Retaining nut for the clutch of the startup motor
12 Nm
95 Nm
Tools
Spanner for retaining nuts
Universal fixing spanner
- 56 -
Startup failure
•
•
•
•
•
•
•
•
Fuse blow
Low battery
Poor main switch
Poor startup clutch
Poor brake switch
Poor starter relay
Poor wiring contact
Poor startup motor
Weak in rotation of the
starter motor
•
•
•
Low battery
Poor wiring contact
Gear seized
No rotation of the engine of
the starter motor
•
•
Poor startup clutch
Reversal rotation of the
starter motor
•
Low battery
3.3 Starter Motor
3.3.1 Disassembly
Loosen the two fixing bolts of the startup motor, and
remove the motor.
Bolt
Starter motor
* Note
Before the starter motor is disassembled, turn off the
main switch, remove the GND wire of the battery, and
then power on to check whether the starter motor
works for ensuring safety.
- 57 -
Remove the wire clip of the startup motor.
Remove the fixing bolts of the startup motor, separate the
front cover and the back cover, and dismantle the startup
motor.
Roll the waterproof rubber case and dismantle the connector
of the startup motor.
3.3.2 Breakdown
Remove screws in the shell, front cover, motor housing and other parts.
3.3.3 Check
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Check other components.
Replace any part with abraded, damaged or burnt
surface.
Clean the commutator surface if there is metal
power attached to it.
Check conduction between the surfaces of other
components.
Ensure non-conduction between armature shafts of
the commutator.
Check the conduction of the shell of the startup
motor.
Ensure non-conduction between the conduction terminal and the startup motor shell.
Check conduction between the conduction terminal and the brush.
Replace any abnormal part.
Check conduction of the brush bracket. Replace it when there is conduction.
Measure the length of the brush.
Limit for use: replace it if lower than 8.5mm
Check smooth rotation of the needle bearing inside the front cover and whether it is loose when press-in.
Replace it if there is any abnormality.
Check whether the oil seal is abraded or damaged.
- 58 -
3.3.4 Assembly
Lubricate the oil seal inside the front cover with grease.
Install the brush on the bracket.
Lubricate moving parts at two ends of the brush shaft
with grease.
Press each brush into the bracket,
* Note
• Pay special attention that the contact surface between
the brush and the armature shall not be damaged.
• Pay attention that the armature shaft shall not damage
lips of the oil seal.
and install the back cover of the electric machine.
Aim the screw hole of the motor shell at the screw hole of the front cover for installation.
Lock screws in the shell.
* Note
When the shell and the front cover are assembled, it is
easy to pull the front cover with magnet to attract the
armature. Press it gently for assembly.
3.3.5 Installation
Install the lead of the startup motor and the dustproof boot.
And then install the startup motor.
Install the wire clip for rear brake.
3.4 Starter Relay
3.4.1 Check
When the main switch is “on”, check there is “click” sound at
the time of pressing the startup motor.
With click sound, it is normal.
Without click sound: • check voltage of the starter relay;
• check the GND loop of the starter relay;
• check the movement of the starter relay.
- 59 -
3.4.2 Check Voltage of the Starter Relay
Set up the main stand, and measure voltage between the
negative pole of the green/yellow wire of the starter relay
terminal and the body ground connection.
When the main switch is “on”, hold the brake lever. The
battery voltage shall comply with regulations.
When there is no voltage at the starter relay terminal,
check the conduction of the brake switch and leads.
3.4.3 Check GND Loop of the Starter Relay
Remove the starter relay connector.
Check conduction between the black wire of the lead terminal and the body ground connection.
When the startup button is pressed, it shall show good conduction between the black wire of the terminal and the
body ground connection.
Check conduction of the startup button and leads when it is not conducted.
3.4.4 Check
Connect the starter relay to the battery, and the terminal
of the startup motor to the multimeter.
Connect the fully charged battery between the black wire
and the green/yellow wire of the relay. The relay shall
sound “click” and the multimeter shall indicate
resistance of “zero”.
Ω
- 60 -
4. Bulbs/ Switches / Meters
Preparing Documents ------------------------------------------------------------4.1
Failure Diagnosis -----------------------------------------------------------------4.2
Replacement of Headlamp Bulbs------------------------------------------------4.3
Replacement of Front Position Lamp Bulbs------------------------------------4.4
Replacement of Tail Lamp--------------------------------------------------------4.5
Replacement of Rear Registration Plate Lamp Bulbs-------------------------4.6
Replacement of Front Steering Lamp Bulbs -----------------------------------4.7
Replacement of Rear Steering Lamp Bulbs ------------------------------------4.8
Meters-----------------------------------------------------------------------------4.9
Main Switch ---------------------------------------------------------------------4.10
Horn -----------------------------------------------------------------------------4.11
Handlebar Switch ---------------------------------------------------------------4.12
Work Instructions








Remove the switch from the vehicle to measure its condition.
All plastic connectors have clamping jaws,
lift the clamping jaws and clamps before disassembly,
and make sure that the clamping holes aim at the clamping jaws when installing.
When looking up for electric faults,
check the continuity of the circuit passing through the electronic devices.
The state of the battery must be confirmed before carrying out any inspection,
including the voltage, to confirm that whether it is normal or not.
- 61 -
The ignition switch “ON” is not light, which due to
• Poor bulbs.
• Poor switch.
• Bad contact or broken wires
• Weak battery power or no voltage.
4.3 Replacement of Headlamp Bulbs
Remove the two fixing bolts① of the headlamp at the
bottom left and bottom right of the meter.
Lower the headlamp forward, you can see the back of
the headlamp, and remove its dustproof cover②.
- 62 -
The figure below shows the bulb of the dipped headlight
③, and the bulb of the headlight on full beam④,
remove the power cord socket, bulb snap, fixing bolts
and the bulb snap buckle of the dipped headlight and
the headlight on full beam that need to be replaced, and
finally remove the damaged bulb.
Aim the position of the light snap, and replace on a new
one of the same specification.
*Note
Keep combustible materials and your hands a distance
away from the bulb when it is light. Because the bulb is
very hot at that moment, you should let it cool down
before touching it.
Install the bulb in reverse order.
During the installation, avoid direct touch with the glass
of the bulb, an do not make it oil-stained. Or it will affect
the transparency, life and luminous flux of the bulb.
Once stained with oil, wipe thoroughly with a damp cloth of alcohol or rubber solution of strong volatility.
Install headlamp devices.
4.4 Replacement of Front Position Lamp Bulbs
The front position lamp and the headlamp are in one
lamp body, as shown in the figure, there is a front
position lamp bulb① on the right and left sides.
(1) Operate according to the prompts of the above
chapter—Replacement of the Headlamp Bulbs.
(2) Remove the damaged bulb, and replace on a new
one of the same specification.
(3) Install the bulb in reverse order.
- 63 -
4.5 Replacement of Tail Lamp
The illuminant of the tail lamp is LED, replace the whole
lamp if necessary.
(1) Remove the passenger’s seat and the driver’s.
(2) Remove the tow fixing nuts① of the tail-hood shield,
and then move it horizontally backward to take it
down.
(3)
Remove the two fixing nuts ② of the rear lamp
combination.
(4)
Remove the three fixing bolts③ of the rear lamp
combination.
Remove the cable of the rear lamp combination, take
off the damaged lamp, and replace on a new one of
the same specification.
Install the lamp in reverse order.
(5)
(6)
- 64 -
4.6 Replacement of Rear Registration Plate Lamp Bulbs
(1) Remove the fixing nuts① of the rear registration plate
lamp to take down the tail-hood② of it.
(2) Take off the damaged bulb, and replace on a new one
of the same specification.
(3) Install the lamp in reverse order.
- 65 -
4.7 Replacement of Front Steering Lamp Bulbs
The illuminant of the front steering lamp is LED, replace
the whole lamp if necessary.
(1) Operate according to the prompts of the above
chapter—Replacement of the Headlamp Bulbs.
(2) Remove the fixing nuts① of the right or left steering
lamp.
(3) Remove the cable of the front steering lamp, take off the damaged lamp, and replace on a new one of the same
specification.
4.8 Replacement of Rear Steering Lamp Bulbs
The illuminant of the rear steering lamp is LED, replace
the whole lamp if necessary.
(1) Remove the fixing nuts① of the right or left steering
lamp from the back of bracket of the rear registration
plate.
(2) Remove the cable of the rear steering lamp, take off the damaged lamp, and replace on a new one of the same
specification.
4.9 Meters
Remove the rearview mirror;
Remove the handle cover, and unplug the connectors.
Remove the nuts the meter.
Install the meter in reverse order.
- 66 -
4.10 Main Switch
4.10.1 Check
Remove the front shield.
Remove the main switch lead terminal.
Check the conduction of the terminal.
POWER LOCK
ON
OFF
LOCK
R
R/W
4.10.2 Replacement of Main Switch
Remove the front shield.
Remove the fixing bolts, and take off the fixing socket of the main switch.
Remove the fixing bolts, and replace the main switch.
4.11 Horn
Check
Remove horn wires.
It shows good when the horn wire is connected to the battery.
- 67 -
4.12 Handlebar Switch
Switch classification:
1. Light changing switch
2. Start switch
3. Steering switch
4. Horn switch
5. Turn off switch
6. Warning switch
B : blue
Y : yellow
R: red
LB: light blue
BK: black
GY: grey
W: white
G: green
- 68 -
Inspection and Maintenance of the Motorcycle Body
Tightening Torque of the Body
Name of fastening parts and fasteners
Tightening torque（N·m）
Fixing bolt of the front absorber M6
Locking screw of the front wheel spindle M6
Front fixing bolt of the fuel tank M6
Fixing bolt of the front fuel pump assembly M6
Fixing bolt of the rear fuel pump assembly M6
Fixing bolt of the fixing seat on the handlebar M8
Fixing bolt of the upper connecting bracket M8
Rear fixing bolt of the fuel tank M6
Mounting bolt of the front brake cylinder assembly M10
Mounting bolt of the rear brake cylinder assembly M8
Fixing bolt of the sprocket M10
Fixing bolt of the rear frame M10
Fixing bolt of the pillar
Top bolt of the rear absorber M10
Bottom bolt of the rear absorber M10
Fixing bolt of the engine M10
Fixing bolt of the rear swinging arm axle M14
Front wheel spindle M16
Fixing nut of the rear wheel spindle M24
5-10
5-10
5-10
5-10
5-10
22-34
22-34
5-10
37-55
22-34
37-55
37-55
50-70
37-55
37-55
37-55
70-105
100-140
130-150
- 69 -
Front Disc Brake
A
B
C
D
E
F
G
H
I
Dia. of the front left/right brake
disc:320mm
Thickness of the front left/right brake
disc:4.0mm
Limit for use: 3.6mm
Thickness of the brake shoes:7.8mm
Limit for use:3.8mm
Torque for mounting bolt 4 in the
figure:5-10N·m
figure:30-35N·m
figure:
5-7N·m
figure:30-35N·m
figure:37-55N·m
figure:22-34N·m
1. handlebar assembly of the front brake disc 2.handlebar screw 3.fixing cover 4.bolt M6×23 5.hexagon
flange screw 6.brake switch 7.screw M4×12 8.nut M6 9.brake hose assembly 10.11. bleed nipple
12.mounting bolt of the oil tube 13.gasket 14.bolt M10×1.25×55 15.front left brake cylinder assembly
16.brake shoes 17.bolt M8×16 18.D.320front brake disc 19.front right brake cylinder assembly
- 70 -
Rear Disc Brake
A
B
C
D
E
F
G
Dia of the rear disc brake: 240mm
Thickness of the rear disc brake: 5.0mm
Thickness of the brake shoes: 7.0mm
figure:30-35N·m: 22-34 N·m
figure:30-35N·m: 5-10 N·m
figure:30-35N·m: 30-35 N·m
figure:30-35N·m: 30-35 N·m
1.pin 2.joint M6 3.cotter 4.nut M6 5.pushrod 6.rear fuel pump assembly 7.gasket 8.rear brake
indicator 9.rear brake hose assembly 10.mounting bolt of the oil tube 11.rear brake cylinder assembly
12.brake shoes 13.rear disc brake 14.screw M6×20 15.bolt M8×1.25×20
- 71 -
5. Brake
Maintenance Instruction ------------------------5.1
Failure Diagnosis --------------------------------5.2
Front Disc Brake ---------------------------------5.3
Rear Disc Drake ---------------------------------5.4
5.1 Maintenance Instruction
Work Instructions
*Note
 A stained brake disc or protective gasket will reduce brake force, so discard
stained gasket and clean the brake disc with quality brake degreaser.
 Check the brake system through the brake lever and pedals.
 Spilled brake liquid is harmful to the focusing and paint of the equipment, and
the rubber parts too. So be careful whenever you remove the cap of the oil cup,
and the first thing you should do is to make sure that the liquid in the cup is
aclinic.
 Never let the earth, water or other dirt into an open cup.
 Use the DOT4 brake liquid taken out from a sealed container when doing
maintenance, and do not mix it with other type of liquid, since they can not
coexist.
* Check the brake before riding.*
5.1.1Specification
Item
Standard
Limit for use
Special brake liquid
DOT4
-
3.6mm
Thickness of the brake disc
5.0mm
4.5mm
7.8mm
3.8mm
Thickness of the brake shoe
7.0mm
3.7mm
Φ320mm
-
Dia. of the brake disc
Φ240mm
-
0.1mm
-
0.1mm
-
Φ16+0.043
mm
0
-
Φ11+0.027
mm
0
-
O.D. of the oil-pumping piston Φ16-0.032
-0.059 mm
-
Φ11-0.032
-0.059 mm
-
Φ34+0.08
+0.03 mm
-
I.D. of the caliper cylinder
Φ32+0.08
+0.03 mm
-
-
O.D. of the caliper piston
Φ32
-
Special brake liquid
Thickness of the left/right brake
disc
Thickness of the left/right brake
shoe
Dia. of the left/right brake disc
Front The jump of the brake surface
of the left/right brake disc
I.D. of the pump oil cylinder
I.D. of the caliper cylinder
O.D. of the caliper piston
Standard
Limit for use
DOT4
-
4.0mm
32
-0.032
-0.065
mm
Item
Rear
The jump of the brake
surface of the brake disc
I.D. of the pump oil cylinder
O.D. of the oil-pumping
piston
-0.032
-0.065
mm
- 72 -
5.1.2 Torque Force
Fixing the front wheel spindle
100-140N·m
Mounting screw of the front left brake cylinder assembly
37-55N·m
Mounting screw of the front right brake cylinder assembly
37-55N·m
Fixing nut of the rear wheel spindle
Mounting screw of the rear brake cylinder assembly
130-150N·m
22-34N·m
5.2.1 Poor Brake Performance
1.
2.
3.
4.
Improper adjustment of the brake
Abraded brake shoes assembly or disc brake
Improper installation of the brake shoes assembly
Stained brake shoes assembly or disc brake
5.2.2 Slow Reaction or Tight Lever
1. Improper adjustment of the brake
2. Abraded brake shoes assembly or disc brake
3. Improper installation of the brake shoes assembly
5.2.3 Abnormal Noise
1． Abraded brake shoes assembly or disc brake
2． Stained brake shoes assembly or disc brake
5.2.4 Soft or Spongy Brake Lever/Pedal
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Air in the hydraulic system
Leakage of the hydraulic system
Stained brake pedal/disc
Abraded seal of the caliper piston
Abraded brake pedal/disc
Stained caliper
Abnormal slip of the caliper
Insufficient brake liquid
Blocked brake liquid channel
Bended/fragmentary caliper piston
Bended/fragmentary piston of the main cylinder
- 73 -
12. Stained piston of the main cylinder
13. Bending braking lever/pedal
5.2.5 Brake Jam or Pulled to One Side
1．
2．
3．
4．
5．
Stained brake pedal/disc
Wheel deviation
Blocked or limited joint of the brake hose
Bending/fragmentary brake disc
5.2.6 Brake Resistance
1．
2．
3．
4．
5．
Strained brake pedal/disc
Wheel deviation
Abraded brake pedal/disc
Bending/fragmentary brake pedal/disc
5.2.7 Stiff Brake Lever/Pedal
1．
2．
3．
4．
5．
6．
7．
Blocked/limited brake system
Sticked/abraded caliper piston
Blocked/limited brake liquid channel
Abraded sealing gasket of the caliper piston
Sticked/abraded piston of the main cylinder
Bending brake lever/pedal
- 74 -
5.3 Front Disc Brake
5.3.1 Disassembly
*Note
 Replace the brake shoes assembly.
 If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place.
Remove following assemblies from the right grip and the front absorber.
Front brake:
Nut of the rearview
1. brake handle
i
2. fuel pump assembly
3. brake hose assembly
Fixing screw of
4. left/right brake cylinder assembly
the fuel pump
5. left/right brake disc
*Note
 Do not stain the brake assembly with oil spots during
installation or disassembly.
 Clean it with required cleaning agent to maintain the brake
performance
Fixing screw of the handle
Fixing bolt of the brake hose
Brake hose
- 75 -
Bleed nipple
Right brake cylinder assembly
Fixing bolt of the brake cylinder
Loosen the fixing screws of the brake cylinder assembly.
Remove the brake cylinder assembly from the front absorber.
Bleed nipple
Left brake cylinder assembly
Fixing bolt of the brake
li d
1.
2.
3.
Remove the front wheel
spindle.
Remove the front wheel.
Remove the disc brake off the
front rim.
- 76 -
5.3.2 Check
Check whether the brake shoes assembly and the brake disc
are abraded. Replace brake shoes if necessary.
Measure the brake shoes and the brake disc. Record
maximum values.
Specification
Diameter of the front brake disc
Thickness of the front brake disc
Φ320mm
4.0mm
*Note
Measure them with micrometer.
Measure the thickness of the brake shoes.
If the thickness of the brake disc or the brake shoe is below
the required value for maintenance or it is stained with
grease, please replace it.
Limit for use
brake shoe
3.8mm
brake disc
3.6mm
Note:
Replace brake shoes in pair.
- 77 -
5.3.3 Installation
Install the brake disc and the front wheel.
Install the front brake hose assembly and the brake cylinder assembly.
Do not stain shoes and the brake disc with grease.
* Note
Any grease on brake shoes will reduce the brake performance and even lead to failure.
Tighten bolts and nuts to the required torque force.
Torque force
120N·m
The bolt of the brake disc
28N·m
The fixing bolt of the fuel pump assembly
8N·m
Mounting bolt of the front brake cylinder assembly
50N·m
Do not stain the brake shoes with oil spots.
Use brake cleaning agent to clean brake shoes with oil spots.
*Note
Any grease on brake shoes will reduce the brake performance.
*Note
• Do not stain the brake assembly with oil spots during installation or disassembly.
• Clean it with required cleaning agent to maintain the brake performance.
- 78 -
5.4 Rear Disc Brake
5.4.1 Disassembly
*Note
 Replace the brake shoes assembly.
 If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place.
Remove the following assembly off the frame and the rear swinging arm.
Rear disc brake:
(1) Fuel pump assembly
(2) Brake hose assembly
(3) Brake cylinder assembly
(4) Brake discs
Loosen the fixing screws of the right pedal cover plate
Right pedal cover
Fixing screws
Loosen the fixing screws of the oil pump assembly.
Remove the oil pump cylinder.
Fuel pump
Fixing screws
- 79 -
Remove the brake cylinder assembly off the rear
swinging arm.
Rear brake hose
Fixing bolt
Brake cylinder
Fixing screw
Remove the rear wheel spindle.
Then take off the rear wheel.
Remove the bake disc off the rear rim.
5.4.2 Check
Check whether the brake shoes assembly and the brake disc
are abraded. Replace brake shoes if necessary.
Measure the brake shoes and the brake disc. Record
maximum values.
Specification
Diameter of the rear brake disc
Φ240mm
Thickness of the rear brake disc
5.0mm
*Note
• Measure with micrometer.
- 80 -
Measure the thickness of the brake shoes.
If the thickness of the brake disc or the brake shoe is below
the required value for maintenance or it is stained with
grease, please replace it.
Limit for use
brake shoe
3.7mm
brake disc
4.5mm
Note:
Replace brake shoes in pair.
5.4.3 Installation
Install the rear brake disc.
Install the rear wheel.
Install the brake cylinder.
* Note
Any grease on brake shoes will reduce the brake performance and even lead to failure.
Tighten bolts and nuts to the required torque force.
Torque force
Fixing the rear wheel spindle
120N·m
The bolt of the brake disc
28N·m
The fixing bolt of the fuel pump assembly
8N·m
Mounting bolt of the rear brake cylinder assembly
50N·m
Do not stain the brake shoes with oil spots.
Use brake cleaning agent to clean brake shoes with oil spots.
*Note
• Do not stain the brake assembly with oil spots during installation or disassembly.
• Clean it with required cleaning agent to maintain the brake performance.
- 81 -
Body
*Note:
Do not damage any body part during disassembly.
Do not damage any hook or claw in the body during
disassembly.
Aim panels in the body at each corresponding
groove.
Ensure correct installation of each hook or claw
part during assembly.
Do not damage any part during assembly.
1. right air deflector mounting plate 2. windshield 3. left air deflector mounting plate 4. 5. right front shield 6.
right shield of the tank 7 bottom right shield 8. right shield 9. trim-cover of the right muffler 10. decorative cover of
the right muffler 11. back seat assembly 12. right rear handrail 13. left rear handrail 14. 16. left assembly of the
rear fender 17. right assembly of the rear fender 18. left shield 19. battery box 20. bottom left shield 21. front seat
assembly 22. middle shield of the tank 23. left shield of the tank 24. left front shield 25. front shield of the tank
26.connecting board of the left/right shield
- 82 -
6. Body
6.1 Disassembly
Disassemble in the following order:
back seat assembly→ front seat assembly → front shield of the tank→ left shield of
the tank→ right shield of the tank→ left front shield→ right front shield → middle
shield of the tank → tank assembly
↓
rear connecting board of the left/right shield → left rear handrail → right rear handrail
→ bottom left shield→ left shield→ bottom right shield → right shield → taillight →
rear bottom fender → decorative cover of the right muffler → trim-cover of the right
muffler → decorative cover of the left muffler → trim-cover of the left muffler →
barrel assembly of the muffler → rear fender assembly → battery box
↓
mounting frame assembly of the headlamp → windshield → left air deflector
mounting plate → right air deflector mounting plate → headlamp
*Note
Do not damage any body part during disassembly.
Do not damage any hook or claw in the body during disassembly.
6.2 Assembly
Assembly in reverse order.
*Note
Aim panels in the body at each corresponding groove.
Ensure correct installation of each hook or claw part during assembly.
Do no damage any part during assembly.
- 83 -
Front Suspension
A
B
C
D
E
F
Torque for mounting the
fixing bolt 20 of the steering
column in the figure:
50-70N·m
fixing bolt 16 of the upper
base of the steering handlebar
in the figure: 22-34N·m
fixing bolt 13 of the upper
connecting board in the
figure: 22-34N·m
fixing bolt 5 of the front
absorber in the figure:
5-10N·m
Torque for mounting the front
wheel spindle 1 in the figure:
100-140N·m
locking bolt 28 of the head of
the front wheel spindle in the
figure: 5-10N·m
1. front wheel spindle 2. bolt M5×0.8×14 3. screw M6×15.2 .4. front right absorber assembly 5. bolt M6×20
6. screw M5×0.8×12 7. bolt M6×1×14 8. suspension bush 9. mounting base under the headlamp 10.
spacer bush 11. screw M6×1×16 12. mounting base above the headlamp 13. bolt M8×1.25×25 14. upper
connecting board 15. upper base of the steering handlebar 16. bolt M8×1.25×25 17. locking screw of the
inner hexagon flat end M4×6 18. pin 19. column 20. fixing screw of the upper connecting board 21. nut 22.
locking nut of the upper connecting board 23. steering bearing 24. screw M6×8 25. fixing wire clip of the
front brake tube 26. bottom connecting board 27 front left absorber assembly 28. bolt M6×30 29. left
spacer bush of the front wheel
- 84 -
Handlebar
1. balance piece assembly 2. throttle lever 3. mounting base of the balance piece 4. front cover of the throttle
cable 5. screw 6. right switch group 7. handlebar 8. left switch group 9. cover of the left handlebar 10.
handle combination of the clutch 11. clutch cable assembly 12. throttle cable assembly I 13. throttle cable
assembly II
- 85 -
Front Wheel
A
B
C
D
E
Tyre size: front tyre: 120/70
ZR17
Pressure of the front tyre:
250±10kpa
Minimum
non-skid
depth:
1.6mm
Rim run-out limit:
Vertically: 2.0mm
Horizontally: 2.0mm
Torque for mounting the bolt 1
of the brake disc: 22-34N·m
1. bolt M8×16 2. front brake disc 3. bearing 6005-2RS/1-C3 4. middle spacer bush of the front wheel 5. front rim 6.
vacuum tyre 120/70 ZR17 7. front brake disc 8. valve
- 86 -
7. Front Wheel/Handlebar/Front Suspension
Preparing Documents--------------------------7.1
Failure Diagnosis-----------------------------7.2
Front Wheel-----------------------------------7.3
Handlebar--------------------------------------7.4
Front Suspension-----------------------------7.5
Work Instructions
Before removing the front wheel, you should use jack to support the body bottom and suspend the front wheel
which shall not be reversely rotated.
Pay attention that the brake shoes and the brake disc shall not be stained with grease during operation.
A stained brake disc or brake shoe will reduce brake force, so discard stained gasket and clean the brake disc with
quality brake degreaser.
Motorcycle Standards
Standard
(mm)
Measurement points
Item
Front wheel spindle
Bending
Front wheel
Rim shimmy
0.2
Vertically
Horizontally
Fixing bolt of the upper connecting board assembly
Limit for use (mm)
2.0
Within 1.0
2.0
Torque Force
Tools
22-34N·m
Bearing puller
100-140N·m
Locking nut spanner
Locking screw of the head of the front wheel spindle
5-10N·m
Fixing screw of the front absorber
5-10N·m
Fixing bolt of the steering column
50-70N·m
Assembling bolt of the front brake cylinder
37-55N·m
- 87 -
7.2.1 Difficulty in Steering




Failure or damage of the steering handlebar.
Damaged bearing of the handlebar.
Too tight of the adjusting bolt of the faucet bearing.
Insufficient tire pressure.
7.2.2 Unsteady Steering




Damaged steering handlebar.
Insufficient tire pressure.
Bending of the front fork or the front wheel spindle.
Deformed or unbalanced front tire.
7.2.3 Front Tire Shimmy




Deformed rim.
Abraded front wheel bearing.
Flawed front tire.
Unbalanced tire or wheel.
7.2.4 Difficulty in Wheel Rolling




Failure in the front wheel spindle bearing.
Braking fault of the brake.
Failure in the front wheel spindle.
Bending of the front wheel.
7.2.5 Abnormal Noise of the Front Absorber



Insufficient liquid in the absorber.
Fricative sound of the absorber guard.
Loose bolts in the absorber.
7.2.6 Operation Only Available in One Side or Move in Curve







Unbalanced adjustment of the left and right forks
Bending absorber
Bending wheel
Incorrect installation of the wheel
Bending frame
Broken wheel bearing
Broken central axis of the swinging arm
7.2.7 Soft Front Absorber



Insufficient liquid in the absorber
The spring of the absorber is not firm.
Too low of the tyre pressure
- 88 -
7.2.8 Too Stiff of the Front Absorber


Improper weight of the liquid
Blocked pathway of the liquid in the absorber
7.3 Front Wheel
7.3.1 Disassembly
Note:
Support the motorcycle firmly.
Support the motorcycle with a safety frame or firm crane.
Disassemble the front fender, and loosen the fixing screws①②.
Bleed nipple
Fixing bolt of the bake hose
Fixing
li d
bolt
of
the
brake
Disassemble the braking caliper of the front disc brake.
Remove the brake cylinder assembly off the front absorber.
- 89 -
Bleed nipple
Fixing bolt of the bake hose
Fixing bolt of the brake cylinder
Remove the clamping screw① of the front wheel spindle
(right front absorber)
Disassemble the front wheel spindle①
- 90 -
Disassemble the front wheel assembly①
Remove the left spindle sleeve of the front wheel②
Disassemble the bearing with the bearing remover.
Note:
Do not operate the brake controlling lever after the removal of the brake caliper.
- 91 -
7.3.2 Check
7.3.2.1 Check the Bending of the Wheel Spindle
Place the wheel spindle on the V-base and measure the
eccentricity ratio with a dial indicator.
Limit for use: replacement when beyond 0.2mm
7.3.2.2 Check the Rim Shimmy
Place the rim on a precision bracket and check the rim shimmy.
Rotate the wheel by manual and read indication.
Limit for use:
Vertically: replacement when beyond 2.0mm
Horizontally: replacement when beyond 2.0mm
Balance of the wheel：
Warning：
The balance of the wheel directly affects the stability, operation
and safety of the motorcycle. Check the stability of the wheel
when it is removed.
Note:
In order to keep balance, mark on the tire near the bleed nipple
by drawing a dot at the rim. Assemble the tire when necessary.
7.3.2.3 Balance of the Front Wheel
Note:
Paste marks of the rotating direction on wheels and tires.
Remove the dust-proof sealing ring off wheels;
Install the wheels, tires and brake disc assembly at the Checkpoints;
Stop the rotating wheels, and mark the lowest (highest) point with the chalk.
Verify the most important sector in this way for 2 or 3 times.
If the wheel is in balance, it will not stop at one point.
In order to keep the wheel in balance, put on weight to it at the higher side of the rim, and mark with the chalk at
the other side. Add enough weight to the wheel when it is on rotation until it does not stop at one point.
Do not add weight above 60g to the wheel.
- 92 -
7.3.2.4 Check the front wheel bearing
Remove the bearing①, and the middle sleeve of the
front wheel②.
Check the rolling of the bearings.
Replace it if the bearing does not roll, or the rolling is
unsmooth or unstable, or the it is abraded or loose.
7.3.3 Bearing Replacement
Remove the front wheel spindle, front wheel, left
spindle sleeve and the middle spindle sleeve. Then
remove the oil seal and the bearing respectively with
the oil seal remover and the bearing puller.
Note:
Replace dismantled bearings with new ones.
Lubricate the bearings with grease during
installation.
Then press the bearings in with bearing installation
tools.
*Note
• Bearings must be pressed in horizontally.
7.3.4 Installation
Note:
Lubricate the front wheel spindle, left spindle sleeve of the front wheel, bearing 6005-2RS/1-C3, and the middle
spindle sleeve.
Albany grease is suggested.
When tighten the front wheel and the caliper assembly of the disc brake, make sure that the brake disc is between
the brake pads.
The free stroke of the front brake lever cannot be adjusted.
*Note
Torque of fixing the front wheel spindle: 100-140N·m
- 93 -
7.4 Steering Handlebar
7.4.1 Disassembly
Remove the left/right rearview mirror assembly.
Right rearview mirror
Left rearview mirror
Remove the oil pump assembly of the front brake.
Remove the right switch group.
Remove the mounting base assembly of the throttle
cable.
Oil pump assembly
Mounting base assembly of the throttle
Fixing screw
Right switch group
Fixing screw
- 94 -
Remove the left handle assembly.
Remove the left switch group.
Left handle
Fixing screw
Left switch group
Remove the balance block assembly①.
Remove the right handle assembly②.
Remove the balance block③.
Remove the fixing bolts② of the upper base of the
steering handlebar.
Turn the upper base① of the steering handlebar.
Remove the tube of the handlebar.
7.4.2 Installation
Install in reverse order.
Note:
Fixing screw of the upper base of the steering handlebar
Torque: 22-34N·m
- 95 -
7.5 Front Fork
7.5.1 Disassembly
Support well the middle bracket of the motorcycle.
Disassemble the front wheel.
Disassemble the brake caliper and the brake pipe
clamp.
Remove the steering handlebar.
Remove the pillar bolt①.
Remove the meter and the meter bracket.
Loosen the fixing bolts① of the upper connecting
board.
Remove the upper connecting board②.
Remove the headlamp and its bracket.
Loosen the clamping bolts① of the upper connecting
board.
Remove the front absorber.
- 96 -
Tools:
Fixing nut spanner.
Special disassembly tool for bearing cup.
*Note:
The opening of the body guard shall be cleaned with cloth.
The upper/lower bearing cup shall be dismantled with a special disassembly tool for bearing cup.
7.5.3 Installation
Note:
Make sure that the hole of the front wheel spindle is concentric when installing the left and right absorber.
Steps are contrary to the process of disassembly.
Note:
Fixing screws for the bottom connecting board:
Fixing screws for the upper connecting board:
10N.m
28N.m
- 97 -
Rear Wheel/Rear Suspension
A
B
C
D
E
F
G
Tyre size: rear tyre: 180/55 ZR
17
Pressure of the rear tyre:
290±10kpa
Minimum
non-skid
depth:
2.0mm
Rim run-out limit:
Vertically: 2.0mm
Horizontally: 2.0mm
Torque for mounting the bolt 2 in
the figure: 5-10N·m
Torque for mounting nut 19 in the
figure: 37-55N·m
Torque for mounting nut 20 in the
figure: 130-150N·m
1. rear wheel spindle 2. screw M6×20 3. right spacer bush of the rear wheel 4. DIA.240 disc brake 5. bearing
6006-2RS1-3C 6. spacer bush of the rear wheel 7. valve 8. rear rim 9. vacuum tyre 180/55 ZR17 1. bearing
6006-2RS1-3C 11. buffer bushing 12. left spindle sleeve of the rear wheel 13. bearing 30×62×23.8 14. spindle
sleeve of the sprocket wheel 15. fixing bolt of the sprocket wheel 16. sprocket wheel rim 17. sprocket wheel 18.
retaining ring Φ62 19. self-locking bolt M10×1.25 20. self-locking bolt M24×1.5
- 98 -
Rear Suspension/Rear Absorber
A
T
C
Torque for mounting bolt 1
in the figure: 70-105 N·m
Torque for mounting nut
10 in the figure: 37-55
N·m
Torque for mounting nut
10 in the figure: 37-55
N·m
1. screw 2. mounting sleeve of the rear swinging arm 3. rolling bearing 61905-2RS 4. straight pin 4×8 5. middle
spacer bush 6. mounting sleeve of the rear swinging arm 7. sleeve 8. rear absorber assembly 9. mounting gasket of
the rear absorber 10. fixing spindle of the rear absorber 11. nut M10×1.25 12. supporting board of the brake clamp
13. rear chain cover 14 bolt M6×8 15. bolt M6×1×14 16. chain protecting block 17 bolt M6×1×14 18 front chain
cover 19 bolt M6×1×14 20 fixing spindle of the rear absorber
- 99 -
8. Rear Wheel/Rear Suspension
Preparing Documents --------------------8.1
Failure Diagnosis -------------------------8.2
Rear Wheel --------------------------------8.3
Rear Absorber -----------------------------8.4
Chain Drive--------------------------------8.5
Rear Swinging Arm----------------------8.6
Work Instructions
The surface of the disc brake and the brake shoes shall not be stained with oil spots.
Item
Rear wheel
shimmy
Standard (mm)
Limit for use (mm)
Vertically
2.0
Horizontally
2.0
Locking torque force
Fixing nuts for the rear wheel spindle
Top bolts for the rear absorber
Bottom bolts for the rear absorber
Fixing bolts for the rear swinging arm
Fixing nuts for the sprocket wheel
Fixing bolts for the rear brake disc
130-150N·m
37-55N·m
37-55N·m
70-105N·m
37-55N·m
5-10N·m
8.2.1 Rear Wheel Shimmy



Deformed rim
Abraded rear wheel spindle
Tire failure
- 100 -





Abraded or damaged bearings of the swinging arm spindle
Incorrect adjustment of the drive chain
Unbalanced tires and wheels
Too low of the tire pressure
Bending frame or the rear swinging arm
8.2.2 Inflexible Rolling of the Wheel



Bending rear disc brake
Abraded bearings of the rear wheel spindle
Too tight of the drive chain
8.2.3 Too Soft of the Suspension




Insecure or shaking damping spring
Incorrect front suspension regulator
Oil leakage of the absorber
Too low of the tire pressure
8.2.4 Too Stiff of the Suspension






Damaged assembly bearing of the absorber
Bending tube of the absorber
Damaged bearing of the rear swinging arm axis
Bending of the rear swinging axis
Fault in the suspension regulator
Too high of the tire pressure
8.2.5 Operation Only Available in One Side or Move in Curve


Bending rear wheel spindle
Incompetent of the axle arrangement/chain regulator on both sides
8.3 Rear Wheel
8.3.1 Disassembly
Support the motorcycle firmly with the rear wheel
above the group.
- 101 -
Caliper of the rear disc brake
Fixing screws of the caliper of
the rear disc brake
Adjusting screw of the rear wheel
Remove the caliper of the rear disc brake.
Loosen the adjusting screws of the rear wheel.
Remove the nuts of the rear wheel spindle and left adjusting block of the chain.
Nut of the rear wheel spindle
Left chain adjusting block
Adjusting screw of the rear wheel
Remove the rear wheel spindle and the right adjusting
block of the chain.
Take the chain off the big sprocket wheel.
Chain
Big sprocket
- 102 -
Remove the rear wheel assembly.
Remove the supporting board of the brake clamp.
Supporting board of the brake
l
Remove the sprocket wheel assembly.
Remove the fixing bolts of the sprocket wheel.
Fixing bolts of the sprocket
- 103 -
8.3.2 Check
8.3.2.1 Check the Rim Shimmy
Rotate the wheel by manual and measure the eccentricity
ratio with a dial indicator.
Limit for use:
Vertically: replacement when beyond 2.0mm
Horizontally: replacement when beyond 2.0mm
When the rear wheel indication goes beyond the limit for use,
the rear wheel bearing is loosened leading to the rear wheel
shimmy. Replace the rear wheel bearing after check.
8.3.3 Installation
Install the rear wheel in reverse order, and lock the nuts.
Fixing nuts for the rear wheel spindle
Torque force: 130-150 N·m
- 104 -
8.4 Rear Absorber
8.4.1 Disassemble the Rear Absorber
Remove the upper/lower fixing nut of the rear absorber.
Remove the rear absorber.
8.4.2 Check the Rear Absorber
Visually inspect of the absorber for damage.
Check the following items:
——whether the absorber tube is bent or damaged
——whether the absorber has signs of deformation or oil leakage
——whether the rubber block is abraded or damaged.
——whether the spring is damaged
Check all other parts for damage or abrasion
If necessary, replace the absorber
8.4.3 Install the Rear Absorber
Install the upper fixing nut and lower fixing bolt of the rear absorber.
Lock to the specified torque force.
Fixing bolts
- 105 -
8.5 Drive Chain
8.5.1. Disassembly
Put the motorcycle on level ground, and firmly support it.
Remove the left rear cover.
Fixing bolt of the left rear cover
Engine left rear cover
Disassemble the rear wheel, rear absorber, the drive
chain shade and drive chain.
8.5.2 Check
Measure the length of ten chain links
,
if the length doesn’t meet the specified value, replace the
drive chain.
The limit value of the length of ten chain links is
1587.5mm.
- 106 -
* Note:
• Measure after stretching the chain by hand.
• Range from chain link roller (1) to the inside of roller (11).
• Measure the length of ten chain links.
• Measure the length of ten chain links of different parts 2-3 times.
Clean the drive chain, put it into the kerosene,
and wash off the dust as much as possible,
then take the chain out of kerosene and dry it.
Check the rotor ① and side panels ②,
if damaged or frayed, replace the drive chain.
The lubricant for drive chain can be purchased from the
shop to lubricate the drive chain.
Check the hardness of drive chain,
clean, lubricate or replace it if hard.
- 107 -
Check the drive sprocket and driven sprocket.
If one-fourth of the teeth of a cogwheel
is frayed,
replace the sprocket,
the bending of the teeth of a cogwheel also requires
the replacement of sprocket.
8.5.4. Installation
Fixing nuts
Note:
Adjust the laxation degree of the drive chain and the free stroke of the brake pedal.
If the laxation degree of the chain is too small, engine and other vital parts will be overloaded.
The laxation degree of the chain should be kept within the prescribed limit value.
8.6 Rear Swinging Arm
8.6.1 Disassemble the Rear Swinging Arm
Put the motorcycle on level ground, and firmly support it.
Disassemble the rear wheel.
Disassemble the lower fixing nut of the absorber.
Disassemble the bolt and drive chain shade.
Disassemble the fastening bolt of the swinging arm spindle
from the frame.
Disassemble the rear swinging arm spindle and rear swinging
arm assembly.
- 108 -
Disassemble the rear swinging arm spindle bearing and the
rear swinging arm spindle
8.6.2 Check the Rear Swinging Arm
Check the rear swinging arm mounting spindle, rotate the
spindle on a flat surface or measure with a dial indicator, if
bent, replace it.
*Note
Don’t attempt to straighten the spindle already bent.
Clean the parts of the rear swinging arm mounting spindle in
the solvent.
Check the sleeve of the rear swinging arm and the middle
sleeve, if damaged, replace them.
Rear swinging arm
Check the bearing for the damage
Use your finger to rotate in the inner bush of the right-pivot
bearing
The bearing shall rotate smoothly and steadily, and the
installment of the bearing's outer ring on the wheel hub
should be checked for security
If the ring cannot rotate smoothly and steadily, or it is flexible
in installation on the pivot, please disassemble and discard it
Bearing
8.6.3 Install the Rear Swinging Arm
Spindle bush of the pivot should be greased,
Note:
Bolts for the rear swinging arm spindle
Torque force: 70-105N·m
- 109 -
Fuel Tank
Gasoline capacity of the
A
gasoline tank:
15±0.2L
B
D
E
F
Torque force of bolt 3:
5-10N·m
5-10N·m
5-10N·m
5-10N·m
1.fuel tank body assembly 2.gasket 6.4×12.5×1.6 3.bolt M6×70 4.fuel pump seal gasket 5.fuel pump
assembly 6.petrol pump screw 7.fuel pipe assembly 8.filter assembly 9.bolt M6 10.gasket 5,3×10×1
11.oil level sensor assembly 12.bolt M6×25 bolt M6×25 13. rubber gasket tube 14.fuel tank front mounting
pad 15.fuel tank front mounting board 16.bolt M8×1.25×20 17.fuel tank cover support assembly 18.fuel
tank lock 19.socket head cap screw M5×30 20.socket head cap screw M5×14 21.fuel tank cover seal gasket
- 110 -
9. Fuel Tank
Preparing Documents -----------9.1
Failure Diagnosis -----------9.2
Fuel Tank -----------------9.3
Work Instructions:
It shall be dismantled far from fire sources.
Tighten all the bolts and screws to the required torque value for assembly.
After assembly, check whether all the parts are correctly installed and operated.
Item
Standard
Limit for use
Gasoline tank capacity
15±0.2L
/
Tightening torque force
Front fixing bolts for the gasoline tank
Rear fixing bolts for the gasoline tank
Fixing bolts for the fuel tank front mounting pad
Fixing bolts for the fuel pump
Fixing bolts for the oil level sensor
22-37N·m
5-10 N·m
5-10 N·m
5-10N·m
5-10N·m
9.2.1 Decreasing Gasoline


Natural consumption of gasoline
Leakage of gasoline
- 111 -
9.3 Fuel Tank
9.3.1 Disassembly
Remove the rear seat and the front seat
Remove the upper body of the fuel tank.
Remove the front fixing bolt of the fuel tank.
Remove the high-pressure oil pipe assembly.
Remove the fuel pump connector jacket.
Remove oil level sensor connector jacket
Front fixing bolt of the fuel tank.
Oil level sensor
Fuel pump
High-pressure oil pipe assembly
Fuel pump connector jacket
Oil level sensor connector jacket
- 112 -
Remove the rear fixing bolt of the fuel tank.
Rear fixing bolt of the
fuel tank
Remove the fuel tank.
9.3.2 Installation
Torque force for mounting:
Front fixing bolts for the gasoline tank
Rear fixing bolts for the gasoline tank
Fixing bolts for the fuel tank front mounting pad
Fixing bolts for the fuel pump
Fixing bolts for the oil level sensor
22-37N·m
5-10 N·m
5-10 N·m
5-10N·m
5-10N·m
- 113 -
10. Disassembly and Installation of Engine
Preparing Documents -------------10.1
Disassembly and Installation of Engine ----------10.2
Work Instructions
It shall be dismantled far from fire sources.
Tighten all the bolts and screws to the required torque value for assembly.
After assembly, check whether all the parts are correctly installed and operated.
Locking torque force
Gearshift rod bolt:
Engine fixing bolt:
10N.m
50N.m
10.2 Disassembly of Engine
Support the motorcycle firmly to make its rear
wheel above the ground.
- 114 -
Unscrew the clamp of the engine water pump
inlet/outlet, remove the cooling water-pipe and
exhaust the coolant
Disassemble the front and rear seats
Disassembly of the rear seat
Insert the key into the guard lock, and open it
clockwise;
Slightly push the back of the rear seat with your
right hand, pull the rear seat upwards and
backwards
Remove the rear seat;
Disassembly of the front seat
Remove the rear seat;
Hold the front seat cable with hands;
Slightly push the back of the front seat with your
left hand, pull the front seat upwards and
backwards
Remove the front seat;
Note:
Confirm the left and right limits are set at
positions when installing the front seat.
- 115 -
Disassemble the fuel tank assembly
See 9.3.1 Disassembly of the fuel tank
Disassemble the air filter assembly
Disassemble the air filter fixing bolt
Disassemble the air filter hoop
Disassemble the connector jacket of the intake air
temperature sensor;
Disconnect the breather rubber pipe from the vent of
cylinder cover;
Remove the air filter
Note:
The stepper motor of the throttle body should be
set well to position when installing the air filter.
Disassemble the throttle body assembly
Remove the throttle cable assembly and throttle cable
assembly II;
Disassemble four throttle body hoops in 1-2-4-3
order;
Remove the connector jacket of the intake air
pressure sensor.
Remove the ejector connector jacket;
Remove the connector jacket of the idle stepper
motor;
Remove the canister desorption rubber pipe;
Remove the intake oil pipe;
Remove the throttle body assembly
Note:
Confirm the throttle cable assembly and throttle cable
assembly are set at positions;
Confirm the oil pipe is connected well to place
without oil leakage after the correct installation of the
throttle body assembly.
Confirm the electric components are connected at
positions;
- 116 -
Disassemble the canister assembly
Canister assembly
Disassemble the clutch steel rope assembly
Clutch steel rope assembly
Disconnect the battery wire, disassemble the starter motor wire
and the ground wire
Disassemble the FBT connector jacket, rectifier and
outlet water temperature switch connector jacket
Battery wire
- 117 -
Disassemble the anterior segment of muffler exhaust
pipe
Disassemble the radiator filler, water tank, and
disconnect the fan switch connector jacket
Disconnect the crankshaft position sensor, neutral
switch connector jacket
Disconnect the single-kickstand flameout switch
connector
jacket
and
disassemble
the
single-kickstand flameout switch
Single kickstand flameout switch
- 118 -
Disassemble gearshift lever swing arm and the left cover of the
engine
Disassemble the small sprocket and detach the chain from the
sprocket
Release the engine fixing bolt and lift the engine
- 119 -
10.3 Installation of the Engine
Note:

Place an appropriate holder under the frame in case of rollover when disassembling the engine.

Engine fuel: 3.2L when assembling.

Start the engine and check it for abnormal vibration, noise and engine lubrication.

After the engine works properly at idle speed for a period of time, turn the throttle handle to maximum
level, then completely relax the throttle handle, at this time if the idle speed changes, it shows that the throttle
cable hasn’t been regulated well. Therefore, attention should be given to the regulation in this regard prior to
the testing the engine.

a.
b.
c.
d.
Checking method of engine fuel
Pull out the fuel rod, wipe it off with a clean cloth.
Insert the rod into the oil and remove it to check the oil level, if the oil level is lower than the
lowest limit, increase the fuel.
Heating up for 5 minutes and cooling for 3 minutes, then check the oil level again, if the oil level is
lower than the lowest position, increase the fuel.
The oil level should always be kept between the lowest limit and the toppest limit.
- 120 -
Inspection and Maintenance of Engine
Table of Torque Force of Fasteners
Name of fastening parts and fasteners
Tightening torque (N·m)
Magnetic bolt M14
Oil pan bolt M6
cylinder double-end bolt
Flywheel locking bolt
Gearshift positioner bolt M6
Crankcase bolt M6
Crankcase bolt M8
Crankcase bolt M10
Connecting rod bolt
Left/right crankcase cover bolt M6
Flywheel bolt M8
Fuel filter
Fuel filter connecting bolt
Fuel filter bolt M14
Round nut M20
Clutch release plate bolt M6
Cylinder cover shade bolt M6
Camshaft sprocket bolt M7
Fuel pump bolt M6
Gearshift positioning plate bolt M6
Spark plug
20~25
10~12
60~62
100~110
10~12
10~12
22~24
35~39
23~27
10~12
20~24
18~22
40~45
40~45
95~105
10~12
10~12
20~25
10~12
10~12
22~25
- 121 -
11. Lubricating System
Preparing Documents ------------11.1
Failure Diagnosis ------------11.2
Fuel Pump ---------------11.3
Function of the lubricating system:
The lubricating system of the engine is to provide lubricating oil to the frictional surface of each part, which
transforms dry friction into liquid friction between lubricating oil particles and also reduces abrasion of parts. It also
cools components with high thermal load, absorbs shock from bearings and other parts, reduces noise, increases
sealing between piston ring and cylinder wall, and cleans and removes particles in the surface.
Work Instructions:
Clean all parts carefully and blow the parts surface clean with high-pressure gas after disassembly of the fuel
pump.
Foreign matter shall not fall into the crankcase when the carburetor is disassembled
Standard of benchmark items and table of limit for use
Item
Standard
Limit for use
When oil change
3.0L
＿
When disassembling
3.2L
＿
The radial clearance between
inner and outer rotors
0.04-0.11mm
0.15mm
The clearance between
outer rotor and pump body
0.04-0.11mm
0.15mm
Fuel capacity
Fuel pump rotor
Decreasing Oil
Natural consumption of oil
Oil leakage
Burnt engine
No oil pressure or low fuel pressure
Blocked oil pipes
- 122 -
11.3 Oil Pump
11.3.1 Disassembly
Remove the clutch cover, loosen the oil pump fixing bolt, and take down the oil pump drive sprocket and the oil
pump drive chain.
Oil pump chain
Screw
Oil pump drive sprocket
Remove the screw.
Remove the oil pump body.
Screw
Oil pump body
Remove the screw, take down the oil pump cover, and decompose the
oil pump.
Screw
Oil pump cover
- 123 -
Check the radial clearance between inner and outer rotors
Limit for use: 0.15mm.
Gauge
Check the clearance between outer rotor and oil pump cover
Gauge
- 124 -
11.3.2
Assembly of Oil Pump
Oil pump
drive sprocket
As shown below
Oil pump cover
Outer rotor
Inner rotor
Pump body
Pump shaft
Note: After the combination, the inner and outer rotors should rotate flexiblely without stagnation.
Installation
- 125 -
11.3.3 Lubricating Systematic Drawing
Piston cooler
- 126 -
- 127 -
12. Cylinder Head
Preparing Documents --------------------12.1
Failure Diagnosis -------------------------12.2
Cylinder Head / Valve--------------------12.3
Function of the cylinder head:
The cylinder head is used to seal the cylinder and form the combustion chamber with the piston. It bears HPHT gas,
and achieves air intake and exhaust through distribution mechanism.
Work Instructions:
The cylinder cover bears large bolt pretension to ensure sealing between the cylinder head and the upper cylinder
block. Pretension: 12 N·m, torque force: 60 N·m. All components must be cleaned and dried with high-pressure air
before check.
Unit: mm
Item
Standard
Limit for use
Flatness of cylinder cover
0.03
0.05
Intake
013-0.19
__
Exhaust
0.19-0.25
__
Intake
3.97-3.98
3.96
Exhaust
3.97-3.98
3.96
Intake
4.03-4.04
4.07
Exhaust
4.03-4.04
4.07
Intake
0.05-0.07
0.11
Exhaust
0.05-0.07
0.11
Intake
1.0-1.1
1.5
Exhaust
1.0-1.1
1.5
Intake
38.8
37.3
Exhaust
41.6
40.1
0.041-0.054
0.08
Valve gap
Outer diameter of valve stem
Valve
Valve catheter
Inner diameter of valve catheter
Clearance between valve stem
and valve catheter
Width of valve seat
Valve spring
Camshaft
Free length
Fitting clearance between camshaft and
cylinder head
- 128 -
Low compression pressure
Noise in Cylinder head
Valve clearance maladjustment
Valve clearance maladjustment
Burnt or bent valve
Damaged valve spring
Poor air-tightness of valve seat
Over high compression pressure
Cylinder head gasket leaks gas
Too much carbon fouling in the combustion
chamber.
Poor installation of spark plug
- 129 -
12.3 Cylinder Head
12.3.1 Disassembly
Remove the ignition coil.
Loosen six locating bolts, remove the gasket and cylinder cover shade.
Cylinder
Locating bolt
Loosen the fastening bolt, and remove the air-distributing chain
regulator.
Fastening bolt
Air-distributing chain regulator
Loosen the four sprocket bolts of the camshaft.
Sprocket bolt of the camshaft
Measure the fitting clearance between camshaft and cylinder
head.
Gauge
- 130 -
Loosen the camshaft holder.
Camshaft holder
Remove the camshaft, camshaft sprocket and chain.
Camshaft
Camshaft chain
Camshaft sprocket
Guide chain
plate
Cylinder
cover
Loosen the cylinder cover locking bolt.
Remove the cylinder cover.
Remove the top stem, compress the valve spring with valve spring
compression tools, and remove the valve block.
Remove the valve adjusting gasket, valve spring, valve spring
upper/lower seat and valve.
- 131 -
12.3.2 Cam Assembly Breakdown
Seal cover D13
Camshaft
Camshaft sprocket
Bolt
12.3.3 Valve Breakdown
Valve
Valve spring
Valve spring
lower seat
Valve block
Valve spring
upper seat
Top
stem
Valve adjusting
gasket
Ruler
Gauge
Check
Eliminate carbon deposit in the cylinder cover.
Measure the flatness of the joint surface of the cylinder cover.
When the flatness of the joint surface of cylinder cover exceeds
the limit for use, place the fine-sand paper on the flat plate, with
the joint surface of cylinder cover fitting the sand paper, and mill
it according to 8-shape.
- 132 -
Vernier calipers
Measure the free length of valve intake/ exhaust spring.
Limit for use: intake spring: 37.3mm.
exhaust spring: 40.1mm.
Measure the outer diameter of the valve stem.
Limit for use: intake valve 3.96mm
Micrometer
exhaust valve 3.96mm
Check the valve catheter after eliminating the carbon deposit in
it with a reamer.
Note: The reamer should be rotated clockwise, and mustn’t be
rotated anti-clockwise.
Tester
Measure the inner diameter of each valve catheter.
Limit for use: intake/ exhaust: 4.07mm.
Limit for use of the clearance between valve and valve catheter:
Intake valve: 0.11mm.
Exhaust valve: 0.11mm.
- 133 -
Screwdriver
12.3.4 Replace the Valve Catheter
Note: When the clearance between valve and valve catheter
exceeds the limit, replace the valve catheter. After the
replacement, trim the surface of the valve seating.
Put the valve catheter in the freezer of the refrigerator to cool
for one hour.
Heat the cylinder head to 100-150℃ with an electric furnace or
a hot oven.
Fix the cylinder head, disassemble the valve catheter from the
upper side of cylinder head with valve catheter disassembly
tools.
Put a new O-ring on the new valve catheter.
Install the valve catheter from the top of the cylinder head.
Note: The cylinder head shall not be damaged when installing
the valve catheter.
Valve
reamer
After inserting the valve catheter, trim with a valve catheter
reamer.
Note: Add proper amount of cutting oil when cutting with an
reamer. And the reamer should be rotated clockwise.
Eliminate the carbon deposit in the combustion chamber and
valve, clean thoroughly the intake/exhaust valve. Check the
width of the contact surface of the valve seat (width of the
valve seating).
Limit for use: intake/ exhaust: 1.5mm.
Contact surface of the valve seat
- 134 -
12.3.5 Trim of Valve Seating
Rugged part
Remove the rugged or ragged parts of the valve seating surface
with a milling cutter at 45°angle.
Note: Coat a transparent or prussian-blue cladding on the valve
seating to get a better view.
Remove 1/4 of the outer end of valve seating with a milling
cutter at 25°angle.
25°
Remove 1/4 of the bottom of valve seating with a milling cutter
at 60°angle. Take down the milling cutter and check the parts
treated.
60°
Grind the valve seating with a refining milling cutter at 45°angle
to achieve the proper width.
All dents and ragged parts must be removed.
1.0mm
Standard width of the valve seating: intake: 1.0mm
exhaust: 1.0mm
45°
- 135 -
If the contact is the part where the valve is too high, please
lower the valve seating with a flat milling cutter at 25°angle.
If the contact is the part where the valve is too low, raise the
valve seating with a inner milling cutter at 60°angle.
Refine the valve seating again with a refining milling cutter at
45°angle to meet the specifications required.
After grinding the valve seating, please coat the polish on the
surface of valve to gently polish the valve.
High contact surface
25°
Low contact surface
60°
12.3.6 Installation
Note:
When installing the valve spring, the end with smaller pitch of the spring shall be installed towards the
combustion chamber.
When installing the valve collet, install it by compressing the valve spring with valve spring compression tools
When installing the valve, the surface of the valve stem shall be coated with proper amount of fuel prior to
installing to the valve catheter.
- 136 -
- 137 -
13. Crankcase
Preparing Documents------------------------------------------------------13.1
Failure Diagnosis-----------------------------------------------------------13.2
Upper Box-------------------------------------------------------------------13.3
Piston------------------------------------------------------------------------13.4
Lower Box------------------------------------------------------------------13.5
Clutch-----------------------------------------------------------------------13.6
Variable Speed Gear Transmission---------------------------------------13.7
Camshaft Connecting Rod Assembly-------------------------------------13.8
Function of the upper box:
The cylinder block in the upper box provides space for gas compression, combustion and expansion, and also
guides piston movement.
It also transfers part of heat energy in the cylinder to cooling medium around.
Function of the piston:
1. It bears pressure arising from mixed gas combustion inside the cylinder and transfers such pressure to the
connecting rod for driving the crankshaft.
2. It forms combustion chamber along with the cylinder cover.
Function of the crankcase:
The crankcase is the load-bearing part of the engine. Its main function is to support the crankshaft, clutch, gearbox,
cylinder block and cylinder cover, sustain combustion shock and inertia force from the movement of the connecting
rod, and form part of closed space (oil sealing, gas sealing).
Suspension holes in the crankcase are linked with suspension holes in the body, which connects the engine to the
frame and other parts.
Work Instructions:
All components must be cleaned and blown with high-pressure gas before test.
The crankcase is thin-section casting thus shall not suffer impact during operation which may cause deformation or
fracture.
Lubricant in the crankcase should be drained out before operation.
- 138 -
Item
Standard
Diameter of the cylinder
use
Cylinder I 65 (0.025, 0.03)
65.100
Cylinder II 65 (0.03, 0.035)
65.110
Cylindricity of the cylinder
0.008
0.050
Roundness of the cylinder
0.006
0.050
Flatness of the cylinder
0.03
0.05
Outer diameter of piston (measured in piston skirt)
Upper box
Limit for
Piston I 65 (-0.03, -0.025)
64.90
Piston II 65 (-0.025, -0.02)
64.91
Inner diameter of piston pin hole
16 (0.002, 0.008)
16.04
Outer diameter of piston pin
16（-0.008, 0）
15.96
0.002-0.016
0.04
Ring 1
0.05-0.09
0.11
Ring 2
0.04-0.08
0.11
Ring 1
0.15-0.30
0.5
Ring 2
0.25-0.45
0.65
Fuel ring
0.20-0.70
1.0
16 (0.016, 0.034)
16.04
0.016-0.042
—
1.5 (0-0.09)
1.48
0.025-0.05
0.065
0.1-0.25
0.5
0.008-0.016
0.05
1.5 (0-0.012)
1.44
0.03-0.05
0.07
2.8 (-0.05, +0.05)
2.45
3（-0.1, 0）
2.6
24.3（-0.15, +0.15）
22.8
23.5（-0.2, +0.2）
22.4
Outer diameter of fork shaft
11.973-11.984
11.96
Diameter of fork inner hole
12-12.018
12.03
Thickness of fork
5.80-5.90
5.75
Outer diameter of gearshift drum
41.9-42.1
41.5
5.45-5.55
5.65
Clearance between piston pin hole and piston pin
Clearance between piston ring and
ring groove
Joint gap of the piston ring
Inner diameter of the smaller head of connecting rod.
Clearance between connecting rod and piston pin
Thickness
Connecting-rod
Clearance
bearing
connecting-rod
between
bearing
the
and
crankshaft
Left-right clearance of the larger
Connecting rod
end of the connecting rod
Radial clearance of the larger end
of the connecting rod
Thickness
Main-shaft
Clearance between main shaft
bearing
Lower box
and crankshaft
Thickness of friction disc
Clutch
Length of pressure spring
Variable
speed
transmission
gear
Width of gearshift drum lock
groove
- 139 -
Abrasive, burnt or ruptured piston
Abrasive or damaged cylinder or piston
Damaged spacer or crankcase leakage
White smoke from the exhaust pipe
Abrasive or damaged piston ring
Abrasive or damaged cylinder or piston
Over-high compression pressure
Too much carbon deposit in the combustion chamber
Abnormal noise of the piston
Damaged cylinder, piston or piston ring
Abrasive piston pin hole and piston pin
Crankcase leakage
Engine overheating
Clutch slipping
Poor lubricating
Not in gear
Broken or deformed variable speed fork
Broken fork guide pin
Abrasive gear convex claw
Abnormal noise in the crankcase
Loose or broken parts inside the crankcase
Engine automatic stopping
Seized clutch
Gear skip shift
The clutch isn’t completely released
Abnormal transmission return spring
Abrasive gearshift drum lock groove
Out of gear automatically
Abrasive joint claw, round edge
Decreasing elasticity of variable speed gear return spring
Abrasive spline gear of spline shaft and spline groove of sliding gear, leading to higher axial force when the gear
works
Abrasive gearshift drum and fork
- 140 -
13.3 Upper Case
BJ465MS/QJ465MS Engine cylinder block
Namely it is part of the upper case.
Upper case
Check
Check the abrasion of the inner wall of the cylinder.
If it is serious, replace it.
Spacer
Remove the spacer and locating pin.
Locating pin
- 141 -
13.4 Piston
13.4.1 Disassembly
Remove the retainer ring of the piston pin.
Note: during assembly, do not make the retainer ring fall into
the crankcase.
Remove the piston pin and the piston.
Retainer ring of the piston
Piston pin
Remove the piston ring.
Check the piston, piston pin and piston ring.
Note:
Do not rupture or damage the piston ring.
Eliminate carbon deposit in the groove of the piston ring.
Install the piston ring.
Measure the clearance between piston ring and piston ring
groove.
Limit for use: ring 1: 0.11mm.
Piston
ring 2: 0.11mm.
Push into
Piston ring
Gauge
- 142 -
Remove the piston ring, and install each piston ring on the
cylinder bottom.
Note:
Press the piston ring into the cylinder with piston head.
Measure the joint gap of the piston ring.
Limit for use: ring 1: 0.5mm.
Piston ring
ring 2: 0.65mm.
Gauge
Measure the inner diameter of the piston pin hole.
Tester
Measure the outer diameter of the piston pin.
Clearance between piston pin hole and piston pin.
1
2
3
- 143 -
Measure the outer diameter of the piston I and piston II.
Note:
The measuring point shall be at 90°with the piston pin, and at
the piston skirt.
Limit for use of the piston I: 64.90mm.
Limit for use of the piston II: 64.91mm.
90°
11mm
Check whether cylinder I/II inner wall is scratched or abraded.
Note:
It is at 90 degree with the piston pin. Measure the inner
diameter of the cylinder at the top, middle and bottom points.
Limit for use of the cylinder I: 65.100mm.
Limit for use of the cylinder II: 64.110mm.
Tester
Measure the roundness of the inner wall of the cylinder (inner
diameter difference at X direction and Y direction).
Measure the cylindricity of the inner wall of the cylinder (inner
diameter difference at the top, middle and bottom points of X
direction and Y direction).
In
Ex
Top
Middle
Bottom
- 144 -
Check the flatness of the cylinder surface..
Ruler
Gauge
Upper box
Measure the inner diameter of the smaller end of the
connecting rod.
Inner diameter of
smaller
end
of
connecting rod
the
the
Tester
Measure the clearance between connecting-rod bearing and crankshaft.
Connecting-rod bearing
- 145 -
Measure the clearance between main shaft bearing and crankshaft.
Main shaft bearing
Plastic gauge
13.4.2 Piston Installation
Top ring
Install the locating pin.
Apply fuel to each piston ring and piston. Install the piston ring
in place.
Ring 2
Fuel ring
Note:
Do not scratch the piston or break the piston ring.
After the piston ring is installed, it shall be able to rotate freely
in the piston ring groove.
- 146 -
Remove any residual spacer attached to the crankcase.
Note:
Do not make any object fall into the crankcase.
Install the piston, piston pin and retainer ring.
Note:
The dot mark on the top of the piston shall be installed towards
the intake valve.
Dot mark
- 147 -
13.5 Lower Case
13.5.1 Disassembly of the Crankcase Left Cover
Loosen the fixing bolt of starter motor, remove the starter motor.
Loosen the bolt of the crankcase left cover.
Remove the left cover.
Remove the electric starting bear, needle bearing and spacer.
Motor idle gear
Starter motor
Locating pin hole
Remove the starter motor idle gear.
Remove the spacer and locating pin hole.
Loosen the flywheel locking nut with the electric or pneumatic tool.
Pull the flywheel assembly (including the star wheel )
Flywheel assembly
- 148 -
13.5.2 Disassembly of the Clutch Cover
Loosen the fixing bolt, and remove the clutch cover.
Bolt
Clutch cover
Remove the clutch release stem from the right cover.
Right cover
Release stem assembly
Remove the fixing bolt, clutch, gearshift arm assembly and fuel pump sprocket.
Clutch assembly
Gearshift arm assembly
Fuel pump sprocket
Driven gear
- 149 -
Loosen the locking nut with the electric or pneumatic tool,
and remove the clutch.
Loosen the fuel pump screw, and remove the fuel pump
gear.
Gearshift drum assembly
Fuel pump chain
Fuel pump sprocket
- 150 -
13.6 Clutch
13.6.1 Disassembly
Unscrew the four bolts of the release plate in diagonally staggered sequence.
Loosen the clutch nut.
Remove the sleeve, bearing, release plate
and the clutch spring.
See the breakdown drawing for the disassembly of parts.
.
Release plate bolt
Clutch nut
Unscrew the clutch locking nut with the special tool, and remove the locking nut and gasket.
Remove the center holder of clutch.
Remove the clutch disc and friction disc.
Remove the clutch pressure plate.
See the breakdown drawing for the disassembly of
parts.
Remove the spline gasket.
Remove the shell assembly.
Four-claw socket spanner
Universal holder
Shell assembly
- 151 -
13.6.2 Clutch Breakdown
- 152 -
13.6.3 Check
Check the shell groove for burrs and brakeage, if trimmed
excessively by the file, replace it.
Check the pressure plate and the tooth profile of the center
holder for damage, if damaged, replace it.
Drive hub assembly
Driven hub
Measure the free length of the pressure spring.
Limit for use I: replace it if lower than 22.8mm.
Limit for use II: replace it if lower than 22.4mm.
Free length
Measure the thickness of the friction disc with vernier
calipers.
Limit for use I: replace it if lower than 2.45mm.
Limit for use II: replace it if lower than 2.6mm.
Thickness
- 153 -
13.7 Gearshift Mechanism
13.7.1 Disassembly
Remove the gearshift shaft assembly.
Remove the bolt and gearshift locating plate.
Remove the bolt, stop arm and spring.
Remove the locating pin.
See the breakdown drawing for the disassembly of
parts.
Gearshift shaft assembly
13.7.2 Gearshift Shaft Mechanism Breakage
Fork shaft spring
Fork
Fork shaft
Pressure plate
Gearshift drum
Gearshift drum bearing
Ratchet
Gearshift arm assembly
13.7.2.1 Check
Before the breakage, the gearshift plate should flexibly return without being seized.
Check the gearshift plate and gearshift shaft assembly for abrasion. If heavily abrasive, replace the assembly.
Check the gearshift locating plate for abrasion, If heavily abrasive, replace the assembly.
Check whether the gearshift shaft is bent, if excessively bent, replace it.
Check the return spring for decreasing elasticity, if necessary, replace it.
- 154 -
Loosen the crankcase bolt.
Upper case
Separate the crankcase.
Note: Do not damage the spacer and crankcase surface. Remove
the upper case.
Crankcase bolt
Lower case
Main shaft assembly
Countershaft assembly
Remove the main-/ countershaft.
Loosen the pressure plate bolt, and remove the pressure plate.
Pull the fork shaft.
Remove the gearshift drum.
Remove the gearshift fork.
Gearshift drum
Fork
Fork shaft
- 155 -
13.7.2.2 Check
Measure the outer diameter of the fork shaft.
Fork shaft
Micrometer
Measure the inner diameter of the fork hole.
Tester
Vernier calipers
Measure the thickness of the fork.
Width of the lock groove
Measure the outer diameter of the gearshift drum.
Measure the width of the gearshift drum locking groove.
- 156 -
13.8 Crankshaft Connecting Rod Assembly Chamber and Variable Speed
Chamber
Depository for
the main shaft
Depository
for
the
crankshaft connecting rod
Depository for
the countershaft
Gearshift chamber
- 157 -
Main shaft
assembly
Gearshift drum
assembly
Gearshift arm
assembly
Fork shaft
- 158 -
13.8.1 Crankshaft Connecting Rod Assembly
13.8.1.1 Disassembly
Remove the upper box.
Remove the crankshaft connecting rod assembly from the lower box.
Countershaft
assembly
Main shaft
assembly
Drive gear
Note: Do not damage the spacer and crankcase surface.
- 159 -
13.8.1.2 Check
Measure the left-right clearance of the larger end of the connecting rod.
Measuring point at the
clearance between the larger
Measuring point at the larger
Measure the clearance of the larger end of the connecting rod (X-Y
direction).
- 160 -
13.8.1.3 Assembly
Assemble in reverse order of breakdown and disassembly.
Remove the main shaft assembly
Remove the countershaft assembly.
13.8.2 Main-/Counter Shaft Breakdown
13.8.2.1 Main-/Counter Shaft Breakdown
Main shaft assembly
- 161 -
13.8.2.2 Check
Check the abrasion of gear surface and driving-claw point of the gear respectively.
If it is seriously abraded or damaged, replace it.
Gear surface
Check whether the bearing and oil seal are damaged, If yes,
replace it.
Driving claw
Note:
Removed bearing cannot be used any more. It shall be replaced.
Use special tools to dismantle the bearing and the oil seal.
13.8.2.3 Main-/Counter Shaft Assembly
Note:
Lubricate all gears and shafts with grease when assembling.
Ensure all gears without being seized after assembling.
Note:
Install the crankcase in reverse order.
- 162 -
14. Cooling System
Preparing Documents -------------------------14.1
Failure Diagnosis ------------------------------14.2
Water Pump ------------------------------------14.3
Function of the cooling system:
The cooling method of the engine is water cooling. Water cooling, in which the water is used as the heat
conductor, is a method of cooling high-temperature components and then transferring heat to the outside air, thus
keeping the engine working under the optimum temperature.
Specific cooling circuit:
The cooling water entering from the crankcase goes to the cylinder water jacket through the water channel of
crankcase, then goes upward through the cylinder cover, finally enters into the radiator through the pipe to dissipate
heat, and transfers heat to the outside air with the help of radiator’s fin.
- 163 -
Water leakage
Damaged seal ring
Broken pump assembly
Broken water pipe
Over high temperature in cylinder block
Damaged blade of the water pump
Blocked water pipe
Damaged cooling fan
Damaged water temperature switch
14.3 Water Pump
Disassembly
Loosen the bolt, and remove the water pump sub assembly.
Bolt
- 164 -
Water pump sub assembly
Bolt
Loosen the bolt, and remove the water pump cover.
Water pump cover
Remove the blade.
Blade
Check
Check the abrasion of the blade assembly.
If it is serious, replace it.
Note: Don’t damage the spacer and the joint surface of box during
operation.
Installation
- 165 -
Cooling Systematic Drawing
- 166 -
Inspection and Maintenance of Exhaust Emission System
1 exhaust pipe gasket assembly 2 screw M8×30 3 gasket 8 4 spring gasket 8 5 muffler assembly
buffer rubber 7 muffler decorating panel
8 heat-insulating spacer
9 combined screw M6×10
6 muffler
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15. Exhaust Emission & Control System
Warranty on the Exhaust Emission & Control System
15.1
Instructions on the Periodic Maintenance / Compliance with Standards
15.2
Mechanical Function of the Exhaust Control System
15.3
Catalytic Conversion System
15.4
Measures When the Idle Speed Emission Value Exceeds the Standard
15.5
15.1 Warranties on the Exhaust Emission & Control System
15.1.1 The exhaust emission & control system of this motorcycle is in conformity with the GB 14621-2011, GB
14622-2007, GB 19758-2005 and GB 20998-2007 standards prescribed by the state. We warrant that the exhaust
emission & control system works normally during its effective period provided that users completely comply with
all operation and maintenance requirements.
15.1.2 Warranty Range
Function warranty of the exhaust emission & control system
We warrant that it satisfies all periodic or non-periodic inspection by the related government authorities within
riding of (30000 kilometers).
15.1.3 This provision is not applicable under any following condition. However, our distributor or service store would
like to provide maintenance or repair services at reasonable prices.
1. Users fail in periodic maintenance within the required period or kilometers.
2. Periodic maintenance, adjustment or repair is not carried out at our distributor or service center, or there is
no evidence of maintenance record.
3. Overload or improper operation.
4. Refit the motorcycle, remove original parts or replace with other devices in private.
5. Ride the motorcycle on race tracks or on any non-motorized vehicle lane frequently.
6. Damage to the motorcycle due to extreme weather such as typhoon or flood, or damage or failure due to
negligence, crash or impact.
7. Users fail in periodic maintenance since it is out of service for a long time.
8. The odometer is not repaired immediately after being damaged, or it is refit, stopped, or replaced in
private.
·All new motorcycles delivered by our company have passed the noise test and comply with the GB 4569-2005 and
GB 16169-2005 standards prescribed by the state.
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15.2 Instructions on Periodic Maintenance




It is the national requirement that all motorcycles produced domestically shall comply with exhaust emission
standards to lessen environmental pollution. We strictly accord with these exhaust emission standards and
also make great effort in purifying air and reducing pollution.
This motorcycle has been strictly examined before delivery and is in conformity with all exhaust emission
standards. We provide the following periodic inspection table for exhaust emission in consideration of different
use by customers. Users shall carry out periodic inspection, adjustment or maintenance according to the
schedule to ensure normal emission.
For any problem, please contact BENELLI KEEWAY MOTORCYCLES distributors or BENELLI KEEWAY
MOTORCYCLES service center.
Relevant emission provisions are shown as follows:
Emission regulation
CO
HC
NOX
Emission standard
≤2.0g/km
≤0.3g/km
0.15g/km
※ The latest national regulation shall prevail if there is any change.
We are not responsible for any problem due to failure in periodic maintenance at our distributor or service
center. Please carry out necessary inspection to ensure its best condition.
Note: ①Clean the air filter frequently if the motorcycle runs in sandy road or under seriously polluted condition to
extend the service life of the engine.
②Increase maintenance if the motorcycle often runs at high speed or frequently.

Pay attention to following items to ensure meeting emission standards:
1. Please use lead-free gasoline #95 or #97.
2. Please use fuel with stipulated specification.
3. Please comply with periodic maintenance requirements.
4. For the exhaust control system, it is forbidden to make any adjustment or replacement at random
(including use of spark plug, adjustment of idle speed, ignition timing, throttle adjustment, etc.)
5. Notes:
•
Since any problem in the ignition system, the charging system or the fuel system has significant
effect on the muffler device, please go to our designated distributor or service center for
inspection, adjustment or repair immediately when there is any problem found in the engine.
•
Please use lead-free gasoline #95 or #97. Otherwise, the muffler device (four-stroke system) will
be affected.
6. The exhaust control system of this motorcycle is in accordance with the national regulation. For
replacement of any component, please use our original parts and have our designated distributor or
service center carry out such replacement.
15.3 Mechanical Function of the Exhaust Control System
General
This system adopts four-stroke single-cylinder engine, EFI and air conduction device to maintain qualified
exhaust gas. Meanwhile, active carbon canister is used for exhaust gas evaporated from fuel.
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※ Engine improvement
As the spark plug, spherical combustion chamber, compression ratio, ignition time, exhaust system and other
engine components are improved, as well as the intake/exhaust efficiency is enhanced, the combustion efficiency
is raised.
15.4 Catalytic Transfer System
15.4.1 Structure:
15.4.2 Instruction:
1. Function of transfer catalyst is to transfer completely burnt HC, CO and NOX to harmless gas such as H2O,
CO2、and、N2 for discharge.
2. Transfer catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used.
※ Note that lead gasoline may invalidate catalyst.
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Notes in maintaining motorcycles (gas discharge tube) with catalytic transfer:
a) For motorcycles with transfer catalyst, when the motor is running or just shut, it shall not be touched because
of high temperature.
b) Motorcycle with transfer catalyst shall not be near flammable material.
c) There is CO inside gas discharge tire, which is harmful to health. So do not run the motor in closed space.
d) Motorcycle with transfer catalyst shall not use lead gasoline. (Prevention for catalytic poison）.
e) Do not push motorcycle to run motor. If it is necessary, you must stop for temperature of motor and catalyst to
lower down.
f) Do not shut the motor with gear up when running downward.
g) Do not drive motorcycle with bad ignition.
h) Do not remove spark plug and run motor to see whether there is spark in maintain motor ignition system. If
necessary, the time shall be short.
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15.5 Measures When the Idle Speed Emission Value Exceeds the Standard
Periodic inspection (maintenance plan)
Measure idle emission (note 1)
Adjust Carburetor (note2)
Remove and clean the
carburetor
Replace the carburetor
Dismantle and repair
engine
•Valve（leakage）
•Piston（abrasive）
•Combustor（cleaning）
Qualified
Qualified
Qualified
Qualified
Qualified for
delivery
Qualified
Qualified
Notes:
1. Measure it with the idle speed measurement program.
2. Adjust the engine speed with stop screws to live up to requirements and measure CO/HC at the idle speed.
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Inspection and Maintenance of Electronic Fuel
Injection (EFI) System
- 173 -
16. Electronic Fuel Injection System
Electronic Fuel Injection System
16.1
Components of Electronic Fuel Injection System
16.2
Failure Diagnosis
16.3
Common Troubleshooting Methods
16.4
16.1 Introduction of Electronic Fuel Injection System
TNT600 adopts the small-scale engine electronic fuel injection system manufactured by Delphi Company, which is
controlled with four oxygen sensors within a closed loop. Besides, it is equipped with four-cylinder independent fuel
injection and ignition control functions. The three-way catalytic converter would go through treatment with the gas
after combustion in the engine, turn it into harmless gas and discharge it into the air. This system adopts the
closed-loop independent function that can efficiently eliminate the manufacturing differences within the system
and the other corresponding components, highly improving the integrity of the motorcycle, which can also reduce
the deviations of the motorcycle after sometime of actual using.
16.2 Components of Electronic Fuel Injection System
16.2.1 Engine Controller (MT05.2 ECU)
The engine controller can test the operation conditions of the engine with various sensors at any time and
guarantee the emission and economy of fuel by proper computing and self-study control output mechanism with
the driving performance optimized. Once failures are found within the engine, the control would go through
automatic diagnosis. The normal working of the system requires two ECU.
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16.2.1.1 ECU Appearance
ECU 12 is located on the left of battery and ECU 34 is behind the battery.
16.2.1.2 Definition of ECU Connector Pin
1) ECU 12：
J1-1
J2-1
Pin for activating 1-cylinder ignition coil
J1-2
Headlight control pin
J2-2
Pin for system grounding
J1-3
Pin for trouble light
J2-3
Pin for K line communication
J1-4
Pin for heating 2-cylinder oxygen sensor
J2-4
Pin for crank signal high potential
J1-5
Pin for signal 2-cylinder oxygen sensor
J2-5
Pin for activating 1-cylinder fuel injector
J1-6
Connector pin for tachometer
J2-6
J1-7
CAN line low signal 1 pin
J2-7
J1-8
CAN line high signal 1 pin
J2-8
Pin for intake temperature sensor signal
J1-9
J2-9
J1-10
J2-10
Pin for 5V system reference voltage grounding
J1-11
J2-11
Pin for intake pressure sensor signal
J1-12
J2-12
Pin for throttle position sensor signal
J1-13
J2-13
Pin for crank signal low potential
J2-14
Signal pin for water temperature sensor
J1-15
J2-15
Ignition power (12V positive voltage after key)
J1-16
J2-16
J1-17
J2-17
J2-18
Battery power supply (battery 12V positive voltage)
J1-14
J1-18
Dump switch (efficient at low)
Pin for neutral gear switch
Remarks:
J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey connector.
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2) ECU34：
J1-1
Idle speed stepper motor high A pin
J2-1
J1-2
Canister solenoid valve pin
J2-2
J1-3
Pin for trouble light
J2-3
Pin for K line communication
J1-4
J2-4
Pin for crank signal high potential
J1-5
J2-5
J2-6
J1-6
J1-7
CAN line low signal 2 pin
J2-7
Pin for heating 4- cylinder oxygen sensor
J1-8
CAN line high signal 2 pin
J2-8
Pin for intake temperature sensor signal
J1-9
J2-9
Pin for oil pump control signal
J1-10
J2-10
Pin for 5V system reference voltage grounding
J1-11
Idle speed stepper motor low A pin
J2-11
Pin for intake pressure sensor signal
J1-12
Idle speed stepper motor high B pin
J2-12
Pin for throttle position sensor signal
J1-13
Idle speed stepper motor low B pin
J2-13
Pin for crank signal low potential
J1-14
Dump switch (efficient at low)
J2-14
Signal pin for water temperature sensor
J1-15
Pin for vehicle speed sensor
J2-15
Ignition power (12V positive voltage after key)
J1-16
J2-16
5V reference voltage
J1-17
J2-17
J2-18
Battery power supply (battery 12V positive voltage)
J1-18
Pin for neutral gear switch
Remarks:
J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey connector.
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16.2.1.3 Circuit Diagram of Electronic Injection System
Notes:
a) Keep ECU away from places of high temperature, like muffler or engine;
a) Keep ECU away from water, engine oil or any places of liquid;
b) Keep ECU away from mud or other dirt that would affect the heat dissipation function of ECU;
c) Connect with M8 bolts and make sure the tightening torque is around 3.9Nm, keep the surface neat to prevent
outside force to ECU in case of circuit board bending;
d) The DC power supply voltage of ECU of normal working is between 9V and 16V. When it's working under a
voltage not over 26V for one minute, permanent damage would not happen to ECU, neither when the backward
voltage is not over 13V.
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16.2.2 Fuel Injector
16.2.2.1 Working Principle of Fuel Injector:
The fuel injector is designed with magnet coil surrounding iron core inside. Two electrodes from magnet coil
are input control connectors of the fuel injector. When magnet coil is energizing, electromagnetic attraction
generated by magnet coil will conquer spring force and fuel oil pressure of ball valve to uplift the ball valve. Then
high pressured fuel oil (250Kpa) in fuel pipes can inject cone-shaped fuel oil to the air inlet through value seat hole
and orifice plate. After power of the fuel injector, magnetic force of the magnet coil will automatically disappear. The
ball valve closes by the action of return spring and fuel injection stops.
16.2.2.2 Appearance:


Fuel injector is designed with a filter which is not a repairable component because it is designed for only
filtering impurities between fuel filter to fuel injector. The impurities may cause failures such as injector
bonding, flow deviation and leakage. Thus, fuel filter system is very important.
Replace the fuel injector with parts of the same models.
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16.2.3 Throttle Body
16.2.3.1 Working Principle:
The throttle body assembly is comprised of the main casting valve body, return spring, throttle position sensor
system and idle adjusting screws.
Throttle position sensor system offers accelerograph opening for ECU; idle adjusting screws controls and idle
speed and the stability by clockwise reducing the ventilation to lower the idle speed and anticlockwise increasing
the ventilation to higher the idle speed, which is normally required around 2 circles.
16.2.3.2 Appearance:
- 179 -
16.2.3.3 Cleaning
Clean the throttle body assembly with carburetor cleanser by spraying it on the inner wall of the throttle body
and brush the dusts and carbons away gently.
Notice:
Make sure the side channel is not blocked by the dirty.
16.2.4 Engine Cylinder Head Temperature Sensor
16.2.4.1 Working Principle:
This sensor is used on the air cooled engine for measuring the engine cylinder head temperature. Within the
temperature scope of the sensor, the electric resistance would vary with different temperature of the engine, which
is a negative temperature coefficient resister. It is a not a repairable part.
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16.2.4.2 Appearance
16.2.5 Intake Air Temperature Sensor
16.2.5.1 Working Principle
It is used for measuring the temperature of the intake air. Within the temperature scope of the sensor, the
electric resistance would vary with different temperatures of the engine, which is a negative temperature
coefficient resister. The intake air temperature sensor is not a repairable part.
16.2.5.2 Appearance
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16.2.6 Intake Pressure Sensor
This sensor is mainly used for measuring the absolute pressure of the intake bend tube, which, in compliance
with the change between the resistance value and the intake pressure, can measure the air input of the engine's
combustion chamber indirectly.
16.2.6.1 Appearance
16.2.7 Oxygen Sensor
Oxygen sensor is mainly used for measuring the oxygen content within the exhaust pipe of combustion engine
and for the fuel closed loop controlling in the engines, which can make sure the combustion of the engine is
maintained at a reasonable air-gasoline ratio (14.7).
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16.2.7.2 Appearance
16.2.8 Ignition Coil
The ignition coil can provide energy to the spark plug. The high voltage wire is used to connect the ignition coil
and the spark plug.
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16.2.8.1 Appearance
16.2.9 Idle Speed Stepper Engine
The idle speed control valve is used to control the ventilation circulation area aside the throttle body so as to
adjust the intake air to the engine, realizing controlling of the idle speed of the engine.
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16.2.9.1 Appearance
16.2.10 Fuel Pump Assembly
The electric pump would work together with the pressure regulator to provide 250Kpa fuel pressure for the
engine. It is installed under the gasoline tank.
16.2.10.2 Appearance
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Back side:
Front side:
16.2.10.3 Failure Diagnosis of Fuel Pump Assembly
a)
b)
c)
d)
Turn on the key and run the fuel pump for about 3 seconds. If the fuel pump starts to run, refer to step d).
Cut off the connector of the fuel pump and check whether the power supply voltage is 12V or so.
If there is nothing wrong with the second step, supply 12V DC to the fuel pump with an external storage
battery. Check whether the fuel pump runs or not.
If the fuel pump runs normally, check the oil pressure gauge to see whether the front supply pressure of
- 186 -
e)
the nozzle is about 250Kpa when the engine is idling.
If the pipe pressure is lower than 220Kpa, check if there is a leakage in the oil pipe, if the fuel pump runs
backwards, or if the filter is blocked.
16.2.10.4 Common Problems
a)
b)
The reverse connection of the connector of the fuel pump assembly causes the fuel pump run
backwards, thus leading to inadequate fuel pressure for the engine. As a result, the engine cannot
work normally.
The fuel pump is damaged and cannot run.
Note:
1. Since a new motorcycle has no gasoline in its fuel tank at the very beginning, much air remains in the fuel
line after the tank is fueled up. Therefore, it is necessary to turn the motor over for several times to discharge all
the air in the fuel line so that the engine can operate normally. This is a normal process, which will avoid the
engine from taking a long time to start but still in failure in the later startup.
2. The gasoline can cool down the fuel pump, so do no run the pump with little or no fuel, or the fuel pump will
be overheated and damaged.
16.3 Methods for Fault Diagnosis and Maintenance
The trouble light is on the instrument panel, with a sign of FI down blew. In a normal circumstance, when
turning on the key, the trouble light will turn on to indicate the electronic control injection system is power-on and is
ready to work. If the trouble light is off, it indicates that there is no power supply in the electronic control injection
circuit and thus it cannot work. In this case, check the fuse and the connection of both positive and negative
electrodes of the storage battery. After the engine has been started, if the trouble light turns off, it indicates that
there is no fault; otherwise, if the trouble light is still on, it indicates that the electronic control injection system is
abnormal and it is necessary to remove the faults.
There are three methods for fault detection:
16.3.1 Direct Diagnosis through the Flickering Trouble Light (FI) on the
Instrument Panel
When any fault is confirmed, by switching the key for three times, i.e., turning the key on-off-on-off-on, the
trouble light will flash in corresponding fault code. Then check the fault code list for the breakdown in
correspondence.
In case of reading faults with the trouble light, the rules of flash codes are illustrated as below. Take the open
circuit of intake pressure sensor or short circuit of signal end pin to the negative electrode of the battery as an
example, after the key has been switched for three times, the trouble light will flash 10 times standing for 0, flash
once after 1.2 seconds standing for 1, flash 10 times after another 1.2 seconds standing for 0 and flash 7 times
- 187 -
after another 1.2 seconds standing for 7, that is P0107. It shows that, except the number 0 is represented by
flashing for 10 times, other numbers from 1 to 9 will flash as the number itself shows. If there are other fault codes,
such as fault P0201, a fault in the fuel injector of front cylinder, the light of fault code P0201 will flash in 3.2
seconds after the flashing of P0107. The trouble lights of P0107 and P0201 will flash circularly in case of no other
fault. Then faults can be checked according to the fault code list.
Decimal number will be adopted to show the fault code in PCHUD software. The decimal number in the fault code
list is corresponded to the previous hexadecimal, thus faults can be found out in correspondence. If MULFCURR
(current fault) =263, the corresponding fault code in the fault code list is P0107, i.e., a fault of intake pressure
sensor.
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MT05 Fault Code List
Corresponding decimal
Fault code
Description
number
open circuit of intake pressure sensor or short circuit of signal end pin to the
P0107
negative electrode of the battery
263
short circuit of signal end pin of the intake pressure sensor to the positive
P0108
electrode of the battery
264
short circuit of signal end pin of the intake temperature sensor to the negative
P0112
274
open circuit of intake temperature sensor or short circuit of signal end pin to the
P0113
positive electrode of the battery
275
short circuit of signal end pin of the cylinder end temperature sensor to the
P0117
279
open circuit of cylinder end temperature sensor or short circuit of signal end pin
P0118
to the positive electrode of the battery
280
open circuit of throttle position sensor or short circuit of signal end pin to the
P0122
290
short circuit of signal end pin of the throttle position sensor to the positive
P0123
291
short circuit of signal end pin of the front cylinder oxygen sensor to the negative
P0131
305
short circuit of signal end pin of the front cylinder oxygen sensor to the positive
P0132
306
short circuit of heating end pin of the front cylinder oxygen sensor to the
P0031
50
short circuit of heating end pin of the front cylinder oxygen sensor to the positive
P0032
49
P0201
fault of for fuel injector front cylinder
513
fault of for fuel injector rear cylinder (plug-in device of the fuel injector is not
P0202
plugged)
514
P0230
open circuit of oil pump or short circuit to the negative electrode of the battery
560
P0232
short circuit of oil pump to the positive electrode of the battery
562
P0336
signal interference of crank shaft position sensor
822
P0337
no signal of crank shaft position sensor
823
P0351
fault of ignition coil for front cylinder
849
P0352
fault of ignition coil for rear cylinder
850
P0562
voltage below level of electronic control injection system
1378
P0563
over tension of electronic control injection system
1379
P0560
fault of trouble light (damage of filament or plug-in device)
1616
P1693
short circuit of tachometer line to the negative electrode of the battery
5779
P1694
short circuit of tachometer line to the positive electrode of the battery
5780
P0137
short circuit of signal end pin of the rear cylinder oxygen sensor to the negative
311
- 189 -
short circuit of signal end pin of the rear cylinder oxygen sensor to the positive
P0138
312
short circuit of heating end pin of the rear cylinder oxygen sensor to the positive
P0038
56
short circuit of heating end pin of the rear cylinder oxygen sensor to the negative
P0037
55
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16.3.2 Fault Diagnosis by Diagnostic Apparatus
Operation steps：
a) Find the 6-hole diagnostic port on the motorcycle.
b) Connect the connecting line to the port on the diagnostic apparatus.
c) Turn on the key to diagnose the faults.
16.3.3 Fault Diagnosis with the Diagnostic Software PCHUD
PCHUD software is used to inspect and record the operating data of the engine. Before using the software,
connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line. The notebook
computer needs to install the K line driver software before using.
- 191 -
Instructions of PCHUD Software:
（1）Connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line and turn on the
key.
（2）Click the icon "HUD.EXE" to start PCHUD software
（3）Select "File" on the software interface, click "Open", choose "PCHUD.HAD" and select OK.
（4）Select "Parameter File" within "Setup", click the file MT05COMMON.par, choose "Comm protocol" within
"Setup", then select "Keywork2000" and click OK, meanwhile, choose 17 in Device Code.
- 192 -
（5）If the real-time communication data fail to display on the soft ware interface when the power is on, check
whether the connection setting of COM port in "Setup". Under the normal circumstance, set COM Port: 4 and Baud
Rate: 10400, instead of DTR High at startup.
Normal communication is ready to make then. Current fault code is displayed in the position of MALFCURR and
historical fault code displayed on MALFHIST.
- 193 -
Then check the corresponding fault according to the fault code list
- 194 -
Interpretation of PCHUD Software Parameter
VRPM
engine speed
VTHROT
throttle position
VBARO
BARO
VMAP
manifold air pressure
VMAPEXP
VIGN
VCLTS
VIAT
STATUSBYTE5
VAFCMET
VBAROCMET
VCSINSYNSPRK
SATITRIG
CATLOENB
IF ENGSTATE=3
expect manifold air pressure
ignition key voltage
cylinder temperature or coolant temperature
intake air temperature
STATUSBYTE5
airflow correction met
Baro update met
sequential spark enable
tip-in Spark Advance retard trigger
catalyst light-off logic enable
engine work in run state
NISTBLIDLE
stable warm idle
FO2REDY2
O2 ready
FCNO
block learn memory cell
FBLMCOR1
cylinder 1 block learn memory
FCLCINT1
integral of close loop correction
FCLCMUL1
close loop correction
IARDRPM
desired idle rpm
IARPMERR
idle rpm error
FPWVC1
VO2
STATUSBYTE3
base pulse width of cylinder 1
Oxygen sensor signal
STATUSBYTE3
FO2STAT1
cylinder 1 oxygen sensor signal rich lean state
FCLREST1
cylinder 1 close loop correction reset
FOSHTREN
Oxygen sensor heater enable
FO2REDY1
cylinder 1 Oxygen sensor ready
IF IACV MODE=0
IAMTRLOST
IACMVIHB
idle airflow control valve close loop correction enable
IACV lost
IACV move disable
VIGNS
ignition state
FVE1
cylinder 1 Volumetric efficiency
VMAPRANG
MAP read angle
AFFNLAFR
target air fuel ratio
SAESTA
cylinder 1 Spark Advance
SAIDLDYN
idle dynamic Spark Advance
SPDWELL
dwell time
IAINTEGOFST
airflow integral of idle air control valve
IACVDSMP
desired position of idle air control valve
- 195 -
STATUSBYTE2
STATUSBYTE2
FCLCEN1
cylinder 1 close loop correction enable
PPDSEBL
prime pulse disable
FPENABL
fuel pump enable
FTRNSAES
acceleration enrich enter
FTRNSDES
deceleration enlean enter
FTRNSAEDCLOAD
acceleration enrich exit
FTRNSDEINLOAD
deceleration enlean exit
FCLCEN2
cylinder 2 close loop correction enable
- 196 -
16.4 Common Fault Removal Techniques
16.4.1 Repair Tools
a)
Disassembling the parts of the electronic control system- common disassembly tools for auto machinery parts
b)
c)
Circuit of the electronic control system and its electrical signal- digital multimeter (with beep)
Diagnosing the faults in the electronic control system and checking the engine's operation

Fault diagnostic apparatus for electronic control system(recommended)

Fault diagnosis software(PCHUD) and port wire( if available)
d)
Fault code list of the electronic control system( for emergency)
e)
Fuel pressure gauge, range: 0 ~ 300kPa
16.4.2 The Operation Data Flow of the Engine Shown on the Diagnostic
Apparatus
Analyze and check the faults in engine through the operation data flow of the engine shown on the diagnostic
apparatus.
16.4.2.1 Step One
a)
Engine wire harness and vacuum line- may influence the system in controlling air flow and oil supply.
b)
Assembly of Oxygen sensor- may influence the system in judging the air-fuel ratio.
- 197 -
c)
Engine trouble light- influences the system in fault warning.
d)
Storage battery voltage- judges whether the battery power is adequate.
e)
According to the experience, judge whether the readings of coolant temperature sensor, air intake temperature
sensor, manifold absolute pressure sensor and oxygen sensor are normal.
f)
Working range of throttle position sensor- Failure in completely turning on or off the sensor may influence the
power performance of the engine and part of system function.
16.4.2.2 Step Two
Check whether the power supply of ECU is cut off- the communication between the diagnostic apparatus and
the system halts after turning off the key switch.
16.4.2.3 Step Three
a)
Coolant temperature and its cycling- indicate whether the thermostat operates normally.
b)
Storage battery voltage- shows whether the generator works normally.
Too high: maybe a fault in the generator regulator.
Too low：maybe the inappropriate connection of generator wires or a fault in the generator
c)
Manifold air pressure- may indicate whether there is an intake air leak or an air valve clearance
The air valve clearance is too small: the over high figure may influence the power performance of the engine.
Meanwhile, because the exhaust valve opens too early, the increased temperature of the exhausted air will
significantly reduce the service lives of oxygen sensor and ternary catalytic converter.
The air valve clearance is too large: may cause the manifold air pressure become low, thus influencing the
system in judging the engine's operation and leading to abnormal idling in the engine's warming-up.
Besides, the clogged exhaust system, e.g., foreign materials in the exhaust passage, or the blocked ternary
catalytic converter caused by the over-consumption of the engine oil, or damaged pieces inside of the ternary
catalytic converter, will lead to an over high figure.
d)
Cycle number of the oxygen sensor reading- a small cycle number indicates the failure of the oxygen sensor.
16.4.3 Concise Fault Removal Techniques
Please take the following steps to repair the electronic control injection system. If the fault is removed in a
certain step, the following steps can be suspended. Then check and remove the fault code by diagnostic apparatus
in compliance with the term 14.4.2.
When using the diagnostic apparatus, the storage battery voltage cannot be lower than 8.5V.
16.4.3.1 Daily Use and Maintenance

Unleaded gasoline #92 or #95 is strongly recommended.

Though ECU is damp-proof, do not wash the cover with a high-pressure water gun.
- 198 -

The fuel filter should be replaced every 7,000-10,000km

In common circumstances, the throttle valve should be washed every 10,000km or every 1 year.
16.4.3.2 Fault Description- Startup Failure
a)
Turn the ignition lock to "ON" to check whether the trouble light turns on.
If no：
If yes：
b)


Check the fuse and the ground wire.
Check whether ECU's plug is tightly connected.
Check whether the light and circuit are normal through the inspection function of the diagnostic
apparatus's actuator.
Check and repair the light and its circuit.
Make the judgment with another ECU.

Connect the diagnostic apparatus to the system's diagnostic port.



Whether the diagnostic apparatus can be connected to the system for communication
If no:




Check the fuse and the ground wire
Check whether ECU's plug is tightly connected
Check whether the diagnostic apparatus works normally on another normal motorcycle.
If yes:

Remove the fault shown by the diagnostic apparatus.
c)
Check the faults in the ignition system- whether the spark plug can ignite normally
If no:



Check whether the high-tension cable and spark plug are connected tightly or are damaged.
Make the judgment with another ignition coil assembly
If yes:

Check whether the high-tension cable is connected with the ignition coil and spark plug in a
correct way
d)
Check the faults in the oil supply system
Whether the fuel pump is working- the working noise of the fuel pump can be heard in its nearby when
starting the engine.
If no:




Check whether the fuel pump relay works normally.
Check whether the connection of crankshaft position sensor and its operation are normal.
Check the fuel pump circuit
If yes:
1) Whether the supplied oil pressure is above 220Kpa
2) Inadequate
pressure：
3) Normal
pressure：
e)


Check whether the nozzle control line is abnormal
Whether it is necessary to clean the oil nozzle
Check whether the cylinder is flooded with oil
If yes：
f)

Check whether there is enough gasoline in the fuel tank
Check whether it is necessary to replace the fuel filter (note: the special
fuel filter for the electronic control injector should be replaced every
7,000-10,000km)
Whether the oil supply line and oil return line are damaged



Press the accelerator pedal to the limit and turn on the starter. After several seconds, there will
be a sign showing the engine running.
Whether the clearance of crankshaft position sensor is too large
- 199 -
16.4.3.3 Fault Description- Startup Failure Accompanied with Backfire
a)
Check whether the high-tension cable of ignition coil is loose
b)
Whether the timing gear is loose.
16.4.3.4 Fault Description- Unstable Idle Speed
Idle speed control
system:
Check whether the idle speed by-pass bolt is too loose or tight. Usually it is necessary to
screw 2 turns.
Oil supply system
Whether there is an oil pipeline leak
16.4.3.5 Fault Description- Too High/Low Idle Speed (Apparent Non-conformity to
Target Idle Speed)
Idle speed is
too high:
Idle speed is
too low:

When the water temperature is lower than 68℃, the system will increase the idle speed to
accelerate the warming up. Besides this normal process, check according to the following
steps.

Check whether the idle air bypass hole is too large.

Check whether the air valve clearance, especially the exhaust valve clearance, is too large.

Check the oil amount in the fuel tank, the fuel filter, the oil line pressure and the oil nozzle.

Check whether the idle air bypass hole is too tiny.

Check whether the air valve clearance is too small.
16.4.3.6 Fault Description- Unstable Idle Speed Slowing Down with Flameout
a)
Check the valve clearance
b)
Check whether the idle air bypass hole and throttle body are too dirty
16.4.3.7 Fault Description-Poor Acceleration
a)
Whether the parameters at idle speed and high idle speed are normal
b)
Check the oil amount in the fuel tank, and fuel filter.
c)
Check whether the exhaust system is blocked, e.g., whether the ternary catalytic converter is clogged because
of burning engine oil or damages.
d)
Check the oil line pressure and the oil nozzle.
e)
Check whether the trouble light turns on and whether it is because only one cylinder can work normally to
ignite.
- 200 -
16.4.3.8 Fault Description- Little Misfire
Check whether the spark plug gap meets the standard between 0.7-1mm.
16.4.3.9 Fault Description- Non-conformity between Fault Code and Fault When
Trouble Light is On
The ground wire of the system may be not connected well. Reconnect the ground wire, turn off the storage
battery power line for 3 minutes and turn it on, then start the engine.
16.4.3.10 Fault Description- Abnormally High Oil Consumption
a)
Check the assembly of the oxygen sensor of two cylinders. If it is in a loose state, the oxygen sensor will make
a wrong judgment of the slight lean burn in the cylinders, and thus add more fuel, leading to abnormally high
oil consumption.
b)
When the engine's mechanical parts and the oxygen sensor are confirmed to be normal, start the engine to
check the reading of the oxygen sensor. If the reading is always above 500 mV in a normal water temperature,
check whether there is a leakage in the oil nozzle.
Note

Most parts of electronic control injection system are non-repairable. Once a part is damaged, usually it needs
to be replaced.

When starting the engine, do not run any other organs of the engine (including the throttle, do not push the
throttle in the startup).

If the engine trouble light turns on when the engine is operating, it is necessary to check the reason and
remove the fault as early as possible.

Do not use leaded gasoline for lead will do harm to the oxygen sensor and ternary catalytic converter.

When there is an abnormal consumption of the engine oil, the fault should be removed as soon as possible, or
some substances in the engine oil will also do harm to the oxygen sensor and ternary catalytic converter.

The air valve clearance should not be too small. If the air valve does not tightly shut off in the exhaust process,
the exhaust temperature will be too high so that the service life of ternary catalytic converter will be reduced.

When the temperature is lower than 10℃, if the motorcycle and the engine run at a low speed for a long time,
the exhaust pipe may have carbon deposits and appear to be black. This is a normal phenomenon. It will
disappear after the engine operates at a high speed for some time or by adopting appropriate methods to keep
the engine coolant temperature in a specified range
- 201 -
TNT600 Circuit Diagram
怠速控制阀
黄/紫灰/白
白/黄白/黑
前刹车开关
保险盒
灯光
10A
燃油泵风扇
10A
15A
ECU1 电源锁
15A
10A
红/白
紫
红红
蓝
红粉绿红红
红1 / 红1 / / 粉 / 红 /
/ 红
红
红
橙棕
黄
黄
蓝
电瓶正极
马
达
后刹车开关
警示灯二极管
右把手
左把手
电门锁
边撑熄火
闪光器
2# Gr ECU J1
IN5408
保险丝
30A
15A
仪表
电瓶正极
启动继电器
ECU2
2#BLACK ECU J2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
左
左
绿橙
粉
红 / /
红
黄红
红
绿
/ 红
/
白/ 黄
红
白
右
右
右
右
左
左
黄淡蓝黄绿红
绿棕红
/ 蓝
/ / /
/
/
红
红黑白
白
白
橙绿
黑绿
红
/
/ /
/ 绿棕1
蓝黄
白
绿绿红橙
橙
紫
红/白/ / / / 黑
黑1白1 白白
绿橙绿
/ / /
白蓝黑
黑橙
/
黄
灰/白黄/紫灰/红1
棕/黑黄/蓝棕/蓝黑
黑/橙1 棕/红黑/白白/黄蓝/橙
黑/黄
粉红/蓝
橙/红
白/黑
白/
棕
灰
红
/
浅蓝
机油开关
棕/白
空档
节气门传感器
黑/蓝
橙/黄
灰
红/绿
黑/橙
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
黑/红2
黑/黄2
黄/蓝2
黑/蓝
白/紫白/橙黑/蓝黑/橙黄/蓝红/绿红/黄
橙/绿黑蓝/白黄/绿
红/灰白/绿绿白/灰
红/紫白/红
3缸氧传感器
绿/蓝
粉红
白/蓝
绿/黑1 墨绿灰/红黑红/白
绿/白1
蓝
棕/黑橙/黑
红/紫1
灰
黑/红2
粉红/蓝
碳罐电磁阀
绿/白
橙/白
右转向灯
橙/红
启动二极管
灰
右转向
前大灯
左转向
绿/黑
橙
绿/白
橙/白
黑
淡蓝
黑
黄
紫
黄
蓝
左转向灯
后尾灯
黄
绿/黑
牌照灯灯
橙
黑
红/紫
棕/红
棕/蓝
红/黄
黑
黑
离合器开关
橙/红
诊断仪
黑/红2
黄/绿2
白/灰2
黑/蓝
黑
喇叭
4缸氧传感器
棕
黑/蓝
红/灰2
红/白
风扇继电器
棕/浅绿
红/棕
棕/绿
黑/红2
白/紫2
红/白
大灯继电器
进气压力传感器
红/绿
蓝/绿
蓝/黄
黄/红
绿/蓝
喷油器
黑 /红2
白/红2
油泵继电器
黑/红2
红/橙
红/黑
黑
电喷控制继电器2
黑/红2
黑
绿
红/黄
黑/红2
黑/白2
黑
黑/红2
点火线圈
电喷控制继电器1
黑
绿
红/蓝
黑/红1
主继电器1
橙/绿2
红/白
橙/黄
白/橙2
红/白
黑/蓝
进气温度
黑/棕1
诊断仪
红/紫1
红/紫
棕/红1
棕/蓝1
墨绿
红/蓝
棕/黑黄/蓝1 棕/蓝黑
蓝/绿黑/黄橙/黑棕/红橙/绿
蓝/橙
黑/橙1
橙/红
白/棕红/绿红/蓝
白/红白/橙黑/蓝
黑/白黑蓝/白
红/灰白/绿绿白/灰
红/紫白/紫黄/绿
电瓶正极
白3 白2 白1
棕
/ 黑
浅
绿
棕黑
/
绿
墨绿白
/
蓝
103
℃
水温开关
风扇
油位传感器
白1白2 白3 黑
黑黑黄白
/ / / /
蓝蓝蓝棕
黑黑橙
/
/
绿1
红1
黑黑黑
/
/
红1
白1
黑白
/ /
红1 红1
黑白
/ /
红1 紫1
黑黑黑黄
/ / / /
红1黄蓝蓝1
墨灰红
绿/ /
红浅蓝
红/黑
黑
红黑蓝
/ / /
白蓝橙
红红黑
/ / /
绿1 灰1蓝
黑白黄黑
/ / / /
蓝灰1绿1 红1
白蓝
/ /
绿白
白黑
/ /
橙1 蓝
电瓶负极
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1#Gr ECU J1
防侧翻传感器
2缸氧传感器
水温传感器
速度传感器
燃油泵
进气压力传感器
1缸氧传感器
触发头
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1#BLACK ECU J2
进气温度
点火线圈
喷油器
0

Benelli TNT 600 - Benelli Keeway Motorcycles Sdn. Bhd.

Transcription

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