Вы находитесь на странице: 1из 173

OUTLOOK(DIERRE) 125 EFI Service Manual

KEEWAY Motorcycle Co., Ltd.

Contents
Contents ................................................................................................................................................................. - 1 Preface ................................................................................................................................................................... - 5 Preparing documents ..................................................................................................................................... - 6 Inspection/Adjustment ................................................................................................................................. - 15 I. Battery/Charging System.................................................................................................................................. - 27 1.1 Preparing documents ............................................................................................................................. - 27 1.2 Failure diagnosis .................................................................................................................................... - 28 1.3 Battery ................................................................................................................................................... - 29 1.4 Charging system .................................................................................................................................... - 30 1.5 Voltage/current regulator ....................................................................................................................... - 31 1.6 Magnetor charging coil .......................................................................................................................... - 32 1.7 Magnetor disassembly ........................................................................................................................... - 32 II. Ignition System ............................................................................................................................................... - 35 2.1 Preparing documents ............................................................................................................................. - 35 2.2 Failure diagnosis .................................................................................................................................... - 36 2.3 Ignition system check ............................................................................................................................ - 37 2.4 CDI Group ............................................................................................................................................. - 40 2.5 Ignition coil (picture to be updated) ...................................................................................................... - 40 2.6 Trigger ................................................................................................................................................... - 41 III. Startup System ............................................................................................................................................... - 44 3.1 Preparing documents ............................................................................................................................. - 44 3.2 Failure diagnosis .................................................................................................................................... - 45 3.3 Startup motor ......................................................................................................................................... - 45 3.4 Starter relay............................................................................................................................................ - 47 IV. Bulbs/Switches/Meters .................................................................................................................................. - 49 4.1 Preparing documents ............................................................................................................................. - 49 4.2 Failure diagnosis .................................................................................................................................... - 49 4.3 Replacement of headlamp bulbs ............................................................................................................ - 49 4.4 Replacement of front steering lamp bulbs ............................................................................................. - 50 4.5 Replacement of tail lamp bulbs ............................................................................................................. - 50 4.6 Meter (picture to be updated)................................................................................................................. - 51 4.7 Main switch ........................................................................................................................................... - 51 4.8 Horn ....................................................................................................................................................... - 52 4.9 Handlebar switch ................................................................................................................................... - 52 V. Brake ............................................................................................................................................................... - 55 5.1 Maintenance instruction......................................................................................................................... - 55 5.2 Failure diagnosis .................................................................................................................................... - 55 5.3 Front disc brake ..................................................................................................................................... - 56 5.4 Rear disc brake ...................................................................................................................................... - 58 VI. Body .............................................................................................................................................................. - 61 - 1 -

VII. Front Wheel/Front Suspension ..................................................................................................................... - 63 7.1 Preparing documents ............................................................................................................................. - 63 7.2 Failure diagnosis .................................................................................................................................... - 63 7.3 Front wheel ............................................................................................................................................ - 64 7.4 Steering handle ...................................................................................................................................... - 66 7.5 Front fork ............................................................................................................................................... - 67 7.6 Radiator/expansion tank assembly......................................................................................................... - 68 VIII. Rear Wheel/Rear Suspension ...................................................................................................................... - 70 8.1 Preparing documents ............................................................................................................................. - 71 8.2 Failure diagnosis .................................................................................................................................... - 71 8.3 Rear wheel ............................................................................................................................................. - 71 8.4 Rear absorber/rear swing arm ................................................................................................................ - 72 IX. Lubricating System........................................................................................................................................ - 76 9.1 Preparing documents ............................................................................................................................. - 76 9.2 Failure diagnosis .................................................................................................................................... - 76 9.3 Fuel pump .............................................................................................................................................. - 77 X. Cylinder Head/Valve ....................................................................................................................................... - 81 10.1 Preparing documents ........................................................................................................................... - 81 10.2 Failure diagnosis .................................................................................................................................. - 82 10.3 Cylinder head ....................................................................................................................................... - 82 10.4 Cylinder head check ............................................................................................................................ - 84 10.5 Valve .................................................................................................................................................... - 85 10.6 Valve check .......................................................................................................................................... - 86 10.7 Replacement of valve guide................................................................................................................. - 87 10.8 Adjustment of the valve retainer .......................................................................................................... - 89 10.9 Installation ........................................................................................................................................... - 90 XI. Cylinder Block and Piston ............................................................................................................................. - 92 11.1 Preparing documents............................................................................................................................ - 92 11.2 Failure diagnosis .................................................................................................................................. - 93 11.3 Cylinder block...................................................................................................................................... - 93 11.4 Piston ................................................................................................................................................... - 94 11.5 Piston installation ................................................................................................................................. - 98 11.6 Cylinder installation ............................................................................................................................. - 98 XII. Drive Face/Clutch/Driven Wheel ............................................................................................................... - 101 12.1 Preparing documents ......................................................................................................................... - 101 12.2 Failure diagnosis ................................................................................................................................ - 101 12.3 Left crankcase cover .......................................................................................................................... - 102 12.4 Drive face .......................................................................................................................................... - 102 12.5 Clutch/driven wheel ........................................................................................................................... - 105 12.6 Breakdown of clutch and driven wheel ............................................................................................. - 106 12.7 Installation ......................................................................................................................................... - 110 XIII. Decelerator ................................................................................................................................................ - 112 13.1 Preparing documents ......................................................................................................................... - 112 - 2 -

13.2 Failure diagnosis ................................................................................................................................ - 112 13.3 Gearbox ............................................................................................................................................. - 112 13.4 Installation ......................................................................................................................................... - 114 XIV. Crankcase .................................................................................................................................................. - 115 14.1Preparing documents .......................................................................................................................... - 115 14.2 Failure diagnosis ................................................................................................................................ - 116 14.3 Crankcase........................................................................................................................................... - 116 14.4 Installation ......................................................................................................................................... - 118 XV. Cooling System .......................................................................................................................................... - 120 15.1 Preparing documents ......................................................................................................................... - 120 15.2 Failure diagnosis ................................................................................................................................ - 120 15.3 Thermostat ......................................................................................................................................... - 121 XVI. Exhaust Emission & Control System ....................................................................................................... - 125 16.1 Warranty on the exhaust emission & control system ......................................................................... - 125 16.2 Instructions on the periodic maintenance .......................................................................................... - 126 16.3 Mechanical function of the exhaust control system ........................................................................... - 127 16.4 Catalytic conversion system .............................................................................................................. - 127 XVII. EFI System .................................................................................................................................................. 129 17.1. Connection of the EFI system ............................................................................................................... 129 17.2. Engine controller (MC21)..................................................................................................................... 130 17.3. Power supply requirements ................................................................................................................... 135 17.4. Work temperature.................................................................................................................................. 135 17.5 Maintenance and repair.......................................................................................................................... 135 XVIII. M3 and M3.5 Fuel Injector ........................................................................................................................ 137 18.1. List of spare parts.................................................................................................................................. 137 18.2. General work principle ......................................................................................................................... 137 18.3. Appearance ........................................................................................................................................... 138 18.4. O-ring.................................................................................................................................................... 139 18.5. O-ring replacement ............................................................................................................................... 139 18.6. Suggested lubricant............................................................................................................................... 139 18.8. Temperature range ................................................................................................................................ 140 18.9. Fuel contaminants ................................................................................................................................. 141 18.10. Cable arrangement .............................................................................................................................. 141 18.11. Instructions.......................................................................................................................................... 141 18.13. Replacement ....................................................................................................................................... 143 18.14. Replaceability ..................................................................................................................................... 144 18.15. Fuel injector blocked .......................................................................................................................... 144 18.16. Cleaning .............................................................................................................................................. 145 XIX. Throttle Valve Assembly............................................................................................................................... 145 19.1. List of spare parts.................................................................................................................................. 145 19.2General work principle ........................................................................................................................... 146 19.3. Appearance ........................................................................................................................................... 146 19.4. Technical parameters ............................................................................................................................ 146
- 3 -

19.5. Work environment ................................................................................................................................ 147 19.6. Disassembly of the throttle valve.......................................................................................................... 147 19.7. Cleaning ................................................................................................................................................ 147 19.8. Installation of the throttle valve ............................................................................................................ 148 19.9. Precautions............................................................................................................................................ 148 19.10. Instruction ........................................................................................................................................... 148 XX. Water Temperature Sensor for the Engine ..................................................................................................... 150 20.1 List of spare parts................................................................................................................................... 150 20.2. General work principle ......................................................................................................................... 150 20.3. Appearance ........................................................................................................................................... 150 20.4. Installation requirements....................................................................................................................... 150 20.5. Work environment ................................................................................................................................ 151 20.6. Storage environment ............................................................................................................................. 151 20.7. Electric environment ............................................................................................................................. 151 20.8. Cleaning samples .................................................................................................................................. 151 XXI. Intake Air Temperature Sensor ..................................................................................................................... 152 21.1. List of spare parts.................................................................................................................................. 152 21.2. General work principle ......................................................................................................................... 152 21.3. Appearance ........................................................................................................................................... 152 21.4. Technical parameters ............................................................................................................................ 152 21.5. Installation requirements: ..................................................................................................................... 152 21.6. Cleaning samples .................................................................................................................................. 152 XXII. Oxygen Sensor ............................................................................................................................................ 153 22.1. List of spare parts.................................................................................................................................. 153 22.2. General work principle ......................................................................................................................... 153 22.3. Appearance ........................................................................................................................................... 153 22.4. Technical parameters ............................................................................................................................ 153 22.5. Installation requirements....................................................................................................................... 154 22.6. Fuel quality requirements ..................................................................................................................... 154 XXIII. Fuel Pump Assembly ................................................................................................................................. 154 224. List of spare parts................................................................................................................................... 154 23.2. General work principle ......................................................................................................................... 155 23.3. Appearance and structure ...................................................................................................................... 155 23.4. Dimension ............................................................................................................................................. 156 23.5. Label and mark ..................................................................................................................................... 156 23.6. Work environment ................................................................................................................................ 156 23.8. Maintenance procedures ....................................................................................................................... 157 XXIV. Failure Diagnosis ....................................................................................................................................... 163 24.1. Diagnostic tools .................................................................................................................................... 163 24.2. Pin definition for the diagnosis interface: ............................................................................................. 163 24.3. Software instruction .............................................................................................................................. 164 24.4 Cross reference table for malfunction code ........................................................................................... 168 Circuit Diagram ................................................................................................................................................. 172
- 4 -

Preface
This maintenance manual is used for operating and maintaining EFI Motorcycle OUTLOOK (DIERRE) 125. Preparing Documents include all necessary instructions and statements. Please carefully read 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 engine, entire motorcycle and electrical parts. 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 this mentioned here. We will not make notification for any discrepancy.

KEEWAY Motorcycle Co., Ltd.


- 5 -

Preparing documents
General safety Maintenance rules

Specification table General Safety


Carbon monoxide

Failure diagnosis

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 up engine in an open place. The exhaust cleaning system shall be adopted if engine is started up in a closed area.

Petrol
Ventilation is required for working places. Fire is strictly forbidden in any working place or where petroleum is stored.

- 6 -

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 shield for maintenance, which can prevent dirt from falling into the engine, chassis or braking system. Wash and dry parts with air compressor after disassembly and before measurement of attrition value.

Do not bend or twist it. Otherwise it will cause difficulty in operation or early damage.

error

Solvent or oil can easily damage aging rubber articles. Check rubber before reassembly and replace rubber if necessary.

boot

When loosening assembly parts, please start from outside to inside. Small assembly parts shall be loosened first.

Complex assembly parts, such as gearbox, shall be stored in proper order for facilitating installation in the future.

- 7 -

Please specially note important connections before disassembly. Replace parts which will not be in use before disassembly.

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 proper if you are confused.

Fill the groove with grease before mounting an oil seal. Check whether the oil seal is smooth or damaged during assembly.

When installing a 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.

groove clip connector 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. Bearings will be broken under either occasion as mentioned.

- 8 -

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.

1Tools 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 Special socket spanner Clutch clamp holder Flywheel puller Feeler gauge Bearing disassembly tools Bearing assembly tools Oil seal remover Handle for dismantling tools Piston pin pulling device Piston pin pliers Socket spanner for spark plug Clutch thickness measuring device Cylinder diameter measuring device Dial indicator Remark Used for assembling/disassembling bolts for flywheels, Fig. 1-3 Fig. 1-4 Fig. 1-5 Fig. 1-6 Fig. 1-7 Fig. 1-8 Fig. 1-9 Fig. 1-10 Fig. 1-11 Fig. 1-12 Fig. 1-13 Fig. 1-14 Fig. 1-15 Measuring the inner diameter of piston pin, Fig. 1-16

Table 1-2 (continued)

Fig. 1-3

Fig. 1-4

- 9 -

Fig. 1-5

Fig. 1-6

Fig. 1-7

Fig. 1-8

Fig. 1-9

Fig. 1-10 handle

- 10 -

Fig. 1-11

Fig. 1-12 pliers piston

Fig. 1-13

Fig. 1-14

Fig. 1-15

Fig. 1-16

2Tools for repairing the chassis


Table and drawing (1-17, 1-18) of ordinary tools and special tools for disassembling/assembling chassis parts are as follows: Table 1-17
Name Torque spanner Inner hexagon spanner Socket spanner Micrometer Magnetic rack, V-block Dial indicator Vernier calipers Circlip pliers Screwdriver with striking cap Tool for assembling oil seal of front fork Tool for hammering seal of front fork Steering nut spanner Remark Fig. 1-19 Fig. 1-20 Fig. 1-21 Fig. 1-22 Fig. 1-23 Fig. 1-24 Fig. 1-25 Fig. 1-26 Fig. 1-27 Fig. 1-28 Fig. 1-29 Fig. 1-30

(1) Ordinary tools for repairing the chassis Table 1-18 (continued)

- 11 -

Fig. 1-19

Fig. 1-20

1. socket head 2. crank handle 3. ratchet spanner 4. connecting rod Fig. 1-21 Fig. 1-22

Fig. 1-23

Fig. 1-24

Fig. 1-25

Fig. 1-26

Fig. 1-27 - 12 -

Fig. 1-28

(2) Special tools for repairing the chassis: tool for hammering seal of front fork

Fig. 1-29

(3) Steering nut spanner

Fig. 1-30

3Tools for electric parts


Table and drawings (1-31, 1-32) of special tools for testing electric parts are as follows: Table 1-31
Name Multimeter Ignition tester Remark Fig. 1-33 Fig. 1-34

Table 1-32 (continued)

Fig. 1-33

Fig. 1-34 - 13 -

Specification (EFI Motorcycle QJ125T-30)


EFI Motorcycle QJ125T-30 2070 715 1260 1360 Forward shaft Backshaft Total Tyre Size 50 80 130 Lubrication Engine

Model Length mm Width mm Height mm Wheelbase mm

Engine type Fuel type No. of cylinder ID stroke Total displacement Startup Cooling

QJ153MI-2A

Unleaded petrol 1 52.4*57.8 125ml Electric Water cooling Force-feed and splash Paper-made 7.4 0.2L

Weight kg (Curb weight)

Front wheel 100/80-16 Rear wheel 120/80-16

Air filter Capacity of gasoline tank Max. speed

Clutch Transmission gear Transmission

Automatic

90km/h 20 degree 1500 100rpm/min 12.5N.m/7500rpm 8.9kW/8250 rpm 10.41 1.25MPa/1500rpm

CVT

Gradeability Idle speed -rpm

Drive

Belt drive

Performance Max. torque Max. Hp Compression ratio Cylinder pressure

Electric devices

Battery 12V-6Ah/ capacity/type dry-charged Magnetor QJ 153-2 12V type 200W/8500 rpm Spark plug CR8EH (NGK)

- 14 -

Spark plug gap Ignition

0.6-0.7mm Electric spark lighter DC capacitance

Braking system

Unit of front fluid brake disc (mm) Unit of rear fluid brake disc (mm)

240mm

240mm

Inspection/Adjustment
Preparing information Periodic Maintenance & Inspection Table Engine oil/ Oil filter Fixing steering stem bearing & handlebar Inspection & adjustment of throttle cable Air filter Spark plug Battery Ignition timing Rim/tyre Tyre specification Cylinder pressure Gear oil Replacement of gear oil Driving belt Free stroke of front/rear brake

Inspection of brake fluid level Headlamp Clutch Front/rear suspension system Bolt/nut/fastener

Preparing Principles
General
Warning! Make sure that it is well ventilated before starting the engine. It is forbidden to start it in a closed area. Exhaust gas, which contains monoxide, may cause unconsciousness or even death of human being. Petrol is liable to volatile or explode under certain condition. Ventilation is required and no any fire exists in working places. Fire is strictly forbidden in working areas or where oil is stored.
- 15 -

Specification
Engine
Idle speed Spark plug gap Spec. of spark plug Cylinder compression pressure Ignition time 1500 100rpm/min 0.6-0.7mm C5HSA(NGK) 1.25Mpa/1500rpm BTDC12 degree degree, 1500 1 100rpm

Frame
Free stroke of front brake lever Free stroke of rear brake lever Specification Tyre pressure unit: Kpa EFI Motorcycle QJ125T-30 Front wheel Rear wheel 10-20mm 10-20mm Tyre pressure

100/80-16 120/80-16
55-62 N m

225kpa 225kpa

Torque value

Locking nut for front wheel spindle Fixing nut for rear wheel

100-113 N m

- 16 -

Periodic Maintenance & Inspection Table


Per 300 KM Per 1000 KM Per 3000 KM Per 6000 KM Per 12000 KM Twelve months R R C Per 14500 KM Fifteen months C Ordinary tools Ordinary tools Ordinary tools Ordinary tools I I I Tyre pressure gauge, inflator Densimeter, multimeter Ordinary tools Ordinary tools Ordinary tools I I I Torque spanner Ordinary tools Ordinary tools Ordinary tools Lubricator I I A I I I Ordinary tools Timing lamp Tachometer, CO HC analyzer Ordinary tools Ordinary tools Visual multimeter

Service cycle and time

Tools

Inspection item New * * * Air filter Petrol filter Fuel filter Replacement of engine fuel Tyre pressure Battery inspection Actuation gap inspection Inspection of steering handle fastening Absorber working inspection Screw fastening inspection Oil leakage inspection for gearbox * * Inspection or replacement of spark plug Replacement of gearbox oil Lubrication of each part Exhaust pipe * * * Ignition timing Exhaust gas inspection at idle speed Throttle inspection Fuel pipeline inspection Lighting/metering/electric devices I I A I I I I I I I I I A I I I
- 17 -

One Three Six month months months C C I C

I I C R I I I I I I I I I I I I I I

Replacement every 1000KM I I I I I I I I I I I I I R I I I I I I I R

Replacement every 5000KM L I I A I I I L I I A I I I

Main stand bracket Absorber * Torque force of engine bolts

I I I I

I I I

I I I I I

Ordinary tools Ordinary tools Torque spanner

Anticipated Inspection
1 2 3 Ignition systemobviously continuous ignition abnormality, engine fire or overheating, which requires inspection and maintenance. Carbon fouling eliminationobviously insufficient horsepower, which requires carbon fouling removal from cylinder head, piston head and exhaust system. Piston & cylinderexcessive abrasion; replace cylinder if it is blocked.

Please have your motorcycle inspected and adjusted periodically at KEEWAY distributors for being in best condition. The above table is established under the presupposition of 1000 km/month. IInspection AAdjustment RReplacement CCleaning LLubrication 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.

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 it is below the lower limit. dipstick upper limit lower limit filter
- 18 -

Oil replacement
*Note* It will be easier to change oil when the engine is warming up. Turn off the engine. Remove the bolt at the bottom of the crankcase and discharge oil. When oil is discharged completely, you can install the bolt and packing washer after they are cleaned. Add oil to the required level. Check oil leakage when the engine operates at its idle speed for minutes. Check the oil level again.

Throttle cable inspection/adjustment


Check whether the throttle cable works smoothly. Check the free stroke of the throttle cable. Free stroke: 5-10mm Loosen the fixing nut and then rotate the adjusting nut for adjustment. fixing nut adjusting nut

Air

filter

(picture

to

be

updated)
Filter replacement. Remove the fixing screws of air filter. Remove the top cap of air filter. Remove the cartridge from the filter. clamp assembly Check whether the cartridge is stained or damaged.
- 19 -

Replace it if necessary. Remove the clamp assembly. Remove the filter. Check whether the filter is stained or damaged. Replace it if necessary.

Replacement time
Replace it as early as possible if the motorcycle is always running on rainy days or on rugged road. *Note* Make sure the air filter cap is well installed before installing the filter. top cap of the air filter mounting screw resonance box body cartridge

Spark plug
Remove the spark plug. Check whether the spark plug is damaged or stained or has carbon fouling. If yes, please clean it with spark plug cleaner or steel brush. Check spark plug gap. Gap: 0.6-0.7mm *Note For the installation of spark plug, it shall be installed with hand first and then fastened with spark plug sleeve. spark plug gap

- 20 -

Igition timing (picture to be updated)


*Note Check the ignition system if ignition timing is incorrect. Remove the fastening bolt. Remove the magneto end cap. Check ignition timing with ignition timing lamp. fastening bolt magnetor end cap

Cylinder pressure
Operate it when the engine warms up. Remove the seat and body guard. Remove the spark plug. Install the cylinder pressure gauge. At full throttle, measure the cylinder pressure by starting the engine. Compression pressure: 1.25Mpa/1500rpm Following items shall be checked in case of extra-low pressure: measure cylinder pressure whether the spacer of cylinder head is damaged; whether piston ring is damaged; whether piston ring is worn; whether the piston, cylinder or valve is worn. When compression pressure is too high, please check whether there is too much carbon fouling inside the combustion chamber and at piston head.

- 21 -

Gear oil
Inspection
*Note Set the middle kickstand on the flat ground and keep the motorcycle upright for checking the oil level. Remove the oil-check bolt after the engine is stopped. It is good if the oil level is at the lower limit of the oil-check bolt hole. Add gear oil when the oil level is too low. Install the oil-check bolt. *Note Make sure whether the bolt is well sealed, slippery or damaged.

drain bolt right cover

Gear oil replacement


Remove the oil-check bolt. Remove the drain bolt and gear oil is drained. Install the drain bolt. *Note Make sure whether the bolt is well sealed, slippery or damaged. Add gear oil. Check whether there is oil leakage in any part. Install the oil-check bolt. drain bolt right cover

Drive belt
Remove the cover of left crankcase. Check whether the drive belt is ruptured or abraded. Periodically maintenance shall be guaranteed, and replace the drive belt if necessary. drive belt
- 22 -

Free stroke of front/rear brake


Free stroke of front brake
Measure the free stroke of front brake at the tip of the brake lever. Free stroke: 10-20mm

Free stroke of rear brake


Measure the free stroke of rear brake at the tip of the rear brake lever. Free stroke: 10-20mm

Inspection of brake fluid level


Brake to the maximum and check the oil level through the oil sight glass. In case the brake fluid level is at or below the arrow in the picture, certain brake fluid shall be added until it reaches the upper limit. Note: The fuel pump assembly shall be parallel with the ground during inspection. fuel pump body sight glass oil

- 23 -

Headlamp
Remove the front shield. Disconnect the connector of the headlamp. Remove the headlamp.

Clutch
Start the engine and increase its speed gradually to check the work condition of the clutch. If the motorcycle fails to run or the engine flames out, you should check the clutch block. Replace it if necessary.

Front/rear suspension system


Front
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.

Compress upwards or downwards

compress upwards or downwards

Rear
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. compress upwards or downwards

- 24 -

Rim/tyre
Check whether tyres or rims have any crack, nail or any other damage. Check tyre pressure.

*Note Check tyre pressure when it is cold.

Required pressure Specification EFI Motorcycle QJ125T-30 Front wheel Rear wheel

Unit: Kpa Tyre pressure

100/80-16 120/80-16

225 225

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: locking nut of the front wheel spindle fixing nut of the rear wheel measure tyre pressure 55-62 N m 100-113 N m

Fixing steering stem bearing and handlebar (picture to be updated)


Move the handlebar to confirm there is no wire interference. Rotate the front wheel and move the handlebar freely for check. If the handlebar is not moved freely or loosened, check the steering stem bearing. move from side to side

- 25 -

FBT switch lock assembly startup motor

stabilizer

battery

Charging System
- 26 -

I. Battery/Charging System
Preparing documents -------------1.1 Battery -----------------------------1.3 Voltage/current regulator --------1.5 Disassembly of magnetor--------1.7 Failure diagnosis --------------1.2 Charging system ---------------1.4 Charging coil of magnetor----1.6

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. For battery with performance degradation (reduced capacity), 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: overvoltage 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 overvoltage 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 the electric load. 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.

Preparing principles
Item Battery Capacity/Type Voltage Fully charged
- 27 -

Specifications 12V-6AH/ dry-charged 13.1V

20

Necessary charging

12.3V (not working for 1h) Standard: 0.6A, quick: 6A Standard: 10-15 hours, quick: 30 mins 200W/8500rpm Between white-black 3.3-3.5 Three-phase full-wave 14.5 0.5V/5.000rpm

Charging current Charging time Magnetor Voltage regulator Capacity Coil impedance (20) Type Charging voltage

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


Battery overdischarge Unconnected battery wiring Fuse blow Poor switch

Interrupted current
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

- 28 -

1.3 Battery 1.3.1 Battery disassembly


Remove the battery cover. Remove the fixing plate. Remove the negative lead and then positive lead. Remove the battery. Warning! During the removal of the positive terminal, the tool should not be contacted with the frame. It is dangerous that spark caused by short circuit will ignite petrol and destroy the battery. Install the battery in a reversal order. battery cover fixing plate assembly battery battery box pedal

*Note First positive terminal and then negative terminal to prevent short circuit. Check the charging situation (open circuit voltage). Open the battery cover and remove the fixing plate assembly of the battery. Remove the lead of the battery connector. Measure voltage between terminals. Fully charged: 13.1V Insufficiently charged: 12.3V (not working for 1h) *Note Use a voltmeter to check the charging situation.

1.3.2 Charging
Connection method: connect the positive terminal of the charger with the positive terminal of the battery; connect the negative terminal of the charger with the negative terminal of the battery.
- 29 -

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: 0.6A quick: 6.0A Charging time: standard: 10-15 hours quick: 30 minutes 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 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.

- 30 -

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. *Note Set the multimeter to the AC voltage position. multimeter Limiting voltage: 13.1 0.5V/5.000rpm Check the voltage/current regulator if the limiting voltage is not within its required range.

1.5 Voltage/current regulator 1.5.1 Main wiring check


Remove 4p plug of the voltage/current regulator. Check conductivity between main wiring terminals. Item (wire color) Between Battery(red) and GND of the body Between GND wire (black) and GND of the body Between charging coil (white) and the GND of the body Judgment With battery voltage

With lead

3 2 1

Resistance in the coil of the magnetor.

black red white

1.5.2 Voltage-current regulator check


- 31 -

1. Select diode in the multimeter; 2. The black probe connects the red terminal of the stabilizer, and the red probe respectively connects white terminals of the stabilizer (white1, white 2 and white3). Pointers indicate values. If not, the stabilizer is damaged and needs replacement. 3. The red probe connects the black terminal of the stabilizer and the black probe connects white terminals of the stabilizer (white1, white2, white3). Pointers indicate values. If not, the stabilizer is damaged and needs replacement. *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 Magnetor charging coil


*Note Check the magnetor charging coil on the engine.

Check
Remove the 6p connector of the magnetor. Measure impedance between the white coil of the magnetor and the body with multimeter. Standard: 0.6-120 Replace the magnetor coil when the measured value exceeds the standard value.

1.7 Magnetor disassembly 1.7.1 Disassembly


Remove the body guard. Fix the flywheel using the universal spanner. Remove fixing bolts of the flywheel. Remove the flywheel using the flywheel remover. Remove the solid key. Remove the conductor joint. Remove the stator.
- 32 -

bolt

1.7.2 Installation
Install the stator on the body of the engine. Connect the magnetor 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 bolt Install the left body guard.

- 33 -

power lock assembly relay

igniter

electric horn

battery

SPARK PLUG W/G W W W BL/W

MAIN SW B/W B B/R BL/W W/G

IGNITION COIL MAGNETO

Ignition System
- 34 -

BATTERY

II. Ignition System


Preparing documents--------------2.1 Failure diagnosis ------------------2.2 Ignition system check-------------2.3 CDI Group ----------------2.4 Ignition coil --------------2.5 Trigger --------------------2.6

2.1 Preparing documents


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 CDI group and you dont 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 CDI 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 magnetor and the stator according to instructions.

Preparing principles
Item Spark plug recommended Standard Hot type Cold type Standard value

C5HSA(NGK) C6HSA(NGK) C7HSA(NGK) 0.6-0.7mm 0.4 10 8-11K 4.5-5.5K 100-200 95-400V Above 1.7V
- 35 -

Spark plug gap


Ignition coil impedance (20) Primary coil Secondary coil With plug cap Without plug cap

Impedance of trigger20 Measure the maximum primary voltage of the ignition coil Trigger voltage

Tools
Attachments to the Maximum Voltage Table Multimeter

2.2 Failure diagnosis


Non-sparking of spark plug Abnormality Cause (confirm it sequentially as follows) The inner resistance is too small and it should be tested by required tester. Low speed of the crankshaft. Interfered tester (It is normal that voltage is always beyond the required value upon several measurements.) Poor wiring contact of the ignition system. Poor ignition coil. Poor charging coil (measured at the maximum voltage). Incorrect connection of the tester. Poor main switch. Poor contact of CDI terminal. Short circuit or poor contact of the GND of CDI. Poor contact of charging coil (measured at the maximum voltage). Poor trigger (measured at the maximum voltage). Poor terminal of high-voltage wires. Poor CDI group (when item - is checked to be abnormal or there is no spark for spark plug.) Poor spark plug or secondary leakage of the ignition coil. Poor ignition coil. The inner resistance is too small and it should be tested by required tester. Low speed of the crankshaft. Interfered tester (It is normal that voltage is always beyond the required value upon several measurements.) Poor charging coil (Item - is checked to be normal.)

Ignition coil

Too low high-voltage

No or interrupted high voltage Side voltage

Normal high voltage, but no spark

Charging coil

No high voltage

- 36 -

No or interrupted high voltage

Poor ignition coil. Poor charging coil. The inner resistance is too small and it should be tested by required tester. Low speed of the crankshaft. Interfered tester (It is normal that voltage is always beyond the required value upon several measurements.) Poor trigger (Item - is checked to be normal.) Poor ignition coil. Poor trigger.

Too low high-voltage Trigger

No or interrupted high voltage

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 an input impedance above 10M10CV to the multimeter.

multimeter

19.1 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
- 37 -

between the primary coil terminal (black/white) 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.

19.2 Charging coil


*Note Install the spark plug on the cylinder head and carry out measurement when the compression pressure is normal.
/ / /

/ Remove 4P connector and 2P connector from CDI group. Install a high-pressure shunt between the charging coil with 2P connector (red/white terminal) and 4P connector (black terminal). Press the startup motor or step the actuating lever to measure the maximum voltage of the charging coil. Connection: positive pole to red/white; negative pole to black. black red white green blue 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 CDI Group is abnormal, dismantle the body guard and the magnetor terminal. Connect the charging coil (black/red) to the shunt. If the voltage of CDI 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 CDI and magnetor terminal appears to be abnormal, it is caused by poor charging coil. Please refer to charging coil check.
/ / / /

black red white green blue

19.3 Trigger
- 38 -

*Note Install the spark plug on the cylinder head and carry out measurement when the compression pressure is normal. Remove 6P connector of CDI group. Connect the peak-voltage shunt between the trigger with 6P connector (blue/white terminal) and 6P connector (black terminal). Press the startup motor or step the actuating lever to measure the maximum voltage of the trigger. Connection: positive pole to blue/white; negative pole to black. Minimum voltage: above 1.7V. *Note Never touch any metal part of the test rod with your finger to avoid electric shock. white blue When the maximum voltage measured at the terminal of CDI Group is abnormal, dismantle the right body guard and the magnetor connector. Connect the trigger (blue/white) to the shunt. If the voltage of CDI 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 CDI and magnetor terminal appears to be abnormal, it is caused by poor trigger. Please refer to the table of failure diagnosis.

- 39 -

2.4 CDI Group


20.1 System check
Check the system. Remove the CDI Group, and check components of the ignition system at the terminal.

/ / /

20.2 Check
Remove CDI Group and check whether the terminal is loose or corrosive. black red white green blue Item Main switch Trigger Primary coil of the ignition coil Secondary coil of the ignition coil Test terminal Red--red/white
Blue/white white/green

Standard (20) Conduction when the main switch is OFF 100-200 0.4 10 4.5-5.5K 10

Black/white--black Black--spark plug capexcluding the spark plug

2.5 Ignition coil (picture to be updated)


21.1 Disassembly
Remove the body guard. 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/white terminal.

(ignition coil)

21.2 Check the primary coil


- 40 -

Measure impedance between terminals of the primary coil. Standard: 0.4 1020 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.

21.3 Secondary coil


Attached with spark plug. Measure the impedance between the wiring side of the spark plug cap and the terminals. Standard: 8-11K20 It shows good if the impedance is within the range of standard values. The impedance indicates that the coil breaks. Remove the spark plug cap. Measure the impedance between the primary side wire of the ignition coil and the negative terminal. Standard: 4.5-5.5K 1020 (ignition coil)

2.6 Trigger
*Note Check the trigger on the engine.

Check
Remove the body guard. Remove the trigger terminal. Measure the impedance between the blue/white terminal of the side wire of the engine and the body GND. Standard: 100-20020 Replace the magnetor if the measured value exceeds the standard value.

white blue

- 41 -

/ /

DJ7061Y-2.3-21 DJ621-2.3A MFD004-2


/ white/green / blue/white white connector assembly copper pieces waterproof bolt

- 42 -

FBT switch lock assembly startup motor

stabilizer

battery

BRAKE SWITCH BRAKE SWITCH STARTER SWITCH

BATTERY

RELAY

STARTOR MOTOR

Startup Diagram
- 43 -

III. Startup System


Preparing documents---------------3.1 Failure diagnosis -------------------3.2 Startup motor------------------------3.3 Starter relay--------------------------3.4

3.1 Preparing documents


Work Instructions
Disassemble the startup motor on the engine. For the disassembly of the startup clutch, please comply with related regulations.

Preparing principles
Item Length of the brush of the startup motor Bushing of the startup idler shaft Outer diameter of the startup idler shaft Standard 12.5mm Limit for use 8.5mm 8.3mm 7.94mm

Tightening torque force


Bolts for the clutch cover of the startup motor Fixing bolts for the clutch of the startup motor 12 N m 95 N m

Tools
Spanner for fixing nuts Universal fixing spanner

- 44 -

3.2 Failure diagnosis


Startup failure Weak in rotation of the startup motor
Fuse blow Low battery Poor main switch Poor startup clutch Poor brake switch Poor starter relay Poor wiring contact Poor startup motor Low battery Poor wiring contact Gear seized

No rotation of RE rotary engine of the startup motor


Poor startup clutch Reversal rotation of the startup motor Low battery

3.3 Startup motor


3.3.1 Disassembly
*Note Before the startup motor is disassembled, turn off the main switch, remove the GND wire of the battery, and then power on to check whether the startup motor works for ensuring safety. Remove the wire clip of the startup motor. Remove the fixing bolts, separate the front and rear end caps, and dismantle the startup motor. Roll the waterproof rubber case and dismantle the terminal commutator of the startup motor.

3.3.2 Breakdown
Remove screws in the shell, front cover, motor housing and other parts.

3.3.3 Check
Check other components.
- 45 -

Replace any part with abraded, damaged or burnt surface. carbon brush Clean the commutator surface if there is metal power attached to it. Check conduction between the surface 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.

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 surface of the brush and the armature shall not be damaged. Pay attention that the armature shaft shall not damage lips of the oil seal. Install the rear cover of the motor. 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.
- 46 -

Then install the startup motor. Install the wire clip for rear brake.

3.4 Starter relay


3.4.1 Check
Remove the body guard 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.

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 starter relay 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.

starter relay green yellow black

- 47 -

3.4.4 Check
Connect the starter relay to the battery, and the terminal of the startup motor to the multimeter. Connect 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.

- 48 -

IV. Bulbs/Switches/Meters
Preparing documents --------------4.1 Failure diagnosis--------------4.2 Replacement of headlamp bulbs --------4.3 Meters ----------------4.6 Main switch --------------4.7 Horn ----------------4.8

Replacement of front steering lamp bulbs------4.4 Handlebar switch -------4.9 Replacement of tail lamp bulbs-------4.5

4.1 Preparing documents


Work Instructions
Remove the switch from the vehicle to measure its conduction.

4.2 Failure diagnosis


When the main switch ON is not light, it is due to Poor bulbs. Poor switch. Bad contact or broken wires.

4.3 Replacement of headlamp bulbs


4.3.1 Disassembly
Remove the front shield. Remove fixing screws for dismantling the headlamp. Disconnect the headlamp connector. Remove the headlamp. Remove the glass of the headlamp. Fix the headlamp and rotate the socket clockwise to remove the bulb. headlamp
- 49 -

4.3.2 Installation
Install the bulb in reverse order.

4.4 Replacement of front steering lamp bulbs


4.4.1 Disassembly
Remove the handlebar shade. Loosen fixing screws of steering lamps. Remove the bulb socket from the lamps.

4.4.2 Installation
Install the bulb in reverse order.

left/right steering lamp

4.5 Replacement of tail lamp bulbs


4.5.1 Disassembly
Remove the body guard. Remove fixing screws to dismantle the tail lamp shield. Disconnect the tail lamp connector. Remove the tail lamp. (tail lamp)

4.5.2 Installation
Install the tail lamp in reverse order.

4.5.3 Replacement of tail lamp bulbs


4.5.3.1 Disassembly
Remove screws to dismantle the tail lamp shield. Remove the bulb from the socket. tail lamp bulb
- 50 -

4.5.3.2 Installation
Install the bulb in reverse order.

4.6 Meter (picture to be updated)


Remove the rearview mirror. Remove the handlebar shade and waterproof connector. Remove screws. Remove the odometer assembly to dismantle the odometer. Install the odometer in reverse order. odometer

4.7 Main switch


4.7.1 Check
Remove the front guard. Remove the main switch lead terminal. Check conduction of the terminal.

/ /

P
red /red/white yellow /orange/blue power switch

4.7.2 Replacement of main switch


Remove the front guard. Remove fixing bolts and the fixing seat for the main switch. Remove fixing bolts and replace the main switch.

- 51 -

4.8 Horn
Check
Remove horn wires. It shows good when the horn wire is connected to the battery.

4.9 Handlebar switch

1. Dipswitch 2. Steering lamp switch 3. Horn switch 4. Lamp switch 5. Startup switch

PASSING

- 52 -

Front disc brake

1. front disc brake assembly 2. handle 3. handle screw 4. hexagon flange locking nut 5. hexagon flange bolt 6. packing washer 7. fuel pump assembly 8. bolt 9. fixing cover 10. brake switch assembly 11. screw 12. brake hose assembly 13. brake cylinder assembly 14. connecting bracket of the front disc brake 15. brake shoe assembly 16. bolt

- 53 -

Rear disc brake

1. rear disc brake assembly 2. fuel pump assembly 3. brake cylinder assembly 4. brake hose assembly 5. handle 6. packing washer 7. hexagon flange locking nut 8. hexagon flange screw 9. fixing cover 10. brake switch assembly 11. cross recessed countersunk screw 12. hexagon flange locking nut 13. handle screw 14. connecting bracket of the rear disc brake 15. brake shoe assembly 16. mounting bolts for rear disc brake 17. rear disc brake clamp

- 54 -

V. Brake
Maintenance instruction ------------------------5.1 Failure diagnosis---------------------------------5.2 Front disc brake ---------------------------------5.3 Rear disc brake ----------------------------------5.4

5.1 Maintenance instruction


Work Instructions
*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. *Check brake before riding.*

5.1.1 Specification
Item Thickness of front brake disc Thickness of front brake shoe Thickness of rear brake disc Thickness of rear brake shoe EFI Motorcycle QJ125T-30 240mm Standard (mm) 4.0 6.0 4.0 6.0 Diameter of front disc brake: 240mm Limit for use (mm) 3.0 3.0 3.0 3.0 Diameter of rear disc brake:

5.1.2 Torque force


Fixing bolts for front/rear brake disc Mounting bolts for front brake cylinder assembly Mounting bolts for rear brake cylinder assembly 22-29 N m 22-29 N m 22-29 N m

5.2 Failure diagnosis


Brake
- 55 -

Poor brake performance


1. Improper adjustment of the brake 2. Abraded brake shoe 3. Improper installation of the brake shoe 4. Stained brake shoe or brake disc

Slow reaction or tight lever


1. Improper adjustment of the brake 2. Abraded brake shoe 3. Improper installation of the brake shoe

Abnormal noise
1. Abraded brake shoe 2. Stained brake shoe or brake disc

5.3 Front disc brake


5.3.1 Disassembly
*Note Replace the brake shoe assembly. If the brake shoe will be used again, mark it before disassembly so as to reinstall it at the original place. Remove following assemblies from the front absorber. Front brake: 1. brake cylinder assembly 2. front brake hose assembly 3. brake shoe assembly 4. connecting bracket of the front brake fuel pump assembly brake cylinder assembly *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. Loosen fixing bolts for the brake cylinder assembly. Remove the brake cylinder assembly from the front absorber. Remove the front wheel spindle. Remove the front wheel. Remove the brake disc from the front wheel.

5.3.2 Check
Check whether brake shoes are abraded. Replace it if necessary. Measure the brake shoe and the brake disc. Record maximum values.
- 56 -

Specification Diameter of the front brake disc Thickness of the front brake disc *Note Measurement with micrometer.

240mm 4.0mm

Measure the thickness of the brake shoe. 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 3.0mm brake disc 3.0mm Note: replace brake shoes in pair.

brake shoe

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 the brake 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: Fixing bolts for the brake disc 22-29 N m Mounting bolts for the front brake shoe assembly 22-29 N m Do not stain brake shoes with oil spots. Use brake cleaning agent to clean brake shoes with oil spots. brake shoe brake cylinder *Note Any oil spot on brake shoes will reduce brake performance.
- 57 -

5.4 Rear disc brake


5.4.1 Disassembly
Remove the body guard. Remove the rear brake cylinder assembly. Remove the rear wheel. Remove the brake disc from the rim of the rear wheel.

fuel pump assembly brake cylinder assembly brake hose assembly *Note Replace the brake shoe assembly. If the brake shoe will be used again, mark it before disassembly so as to reinstall it at the original place. Remove following assemblies from the rear wheel. Rear brake: 1. brake shoe assembly 2. rear brake hose assembly 3. brake cylinder 4. connecting bracket of the rear disc brake 5. rear disc brake clamp pump assembly fuel brake cylinder assembly brake hose assembly Note: for details, see P60

5.4.2 Check
Check whether the brake disc and the brake shoes are abraded. Replace it if necessary. Measure the brake shoe and the brake disc. Record maximum values. *Note Scrub the rusty brake disc with sandpaper #120. Measurement with micrometer. Measure the thickness of the brake disc and the brake shoes. If the thickness of the brake disc or the brake shoe is below
- 58 -

the required value for maintenance or it is stained with grease, please replace it. Note: replace brake shoes in pair. Diameter of the rear brake disc 240mm Thickness of the rear brake disc 4.0mm Limit for use: brake shoes 3.0 mm brake disc 3.0mm

5.4.3 Installation
Install the rear brake disc. Install the rear wheel. Install the rear brake cylinder assembly. *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.

brake shoe brake cylinder Torque force: Fixing bolts for rear brake shoe assembly: 22-29 N m Do not stain brake shoes and brake disc with oil spots. Use brake cleaning agent to clean brake shoes and brake disc with oil spots. *Note Any oil spot on brake shoes will reduce the brake performance. Note: for details, see P60.

pump assembly fuel brake cylinder assembly brake hose assembly

- 59 -

front shield lattic front shield front fender windshield handlebar front shield decorating frame of the front shield front wind board of the radiator rear wind board of the radiator front inner fender rear handlebar shield battery cover frame number cover pedal lower fender left/right lattice of the foot guard tail box cover assembly battery front left guard left/right pedal guard front right
- 60 -

guard seat assembly front right guard right cover of the left pedal left cover of the right pedal rear lower fender rear inner fender rear inner fender rubber rear right guard rear left guard left decorating board for the guard right decorating board for the guard rear handrail rear fender rear reflector

VI. Body
Dismantle the body in following order.

Handlebar front shield windshield handlebar rear shield meter front shield front inner fender foot guard battery box cover left/right pedal cover left/right pedal rubber left/right pedal guard rear handrail seat helmet box left/right rear guard left/right front guard rear fender rear inner fender rear inner fender rubber rear lower fender pedal front fender
*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 no damage any part during assembly.

- 61 -

Front wheel/front suspension

Front wheel

cotter pin gear housing assembly front rim oil seal brake disc left bushing of the front wheel front wheel spindle slotted nut rolling bearing front tyre middle spindle sleeve of the front wheel rolling bearing mounting bolts for the brake disc

- 62 -

VII. Front Wheel/Front Suspension


Preparing documents-------------------------7.1 Failure diagnosis -----------------------------7.2 Front wheel -----------------------------------7.3 Steering handle -------------------------------7.4 Front fork -------------------------------------7.5

7.1 Preparing documents


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 brake shoes and brake discs shall not be stained with grease during operation.

Motorcycle Standards
Measurement points Front wheel spindle Front wheel Rim shimmy Item Bending Vertically Horizontally Within 1.0 Standard (mm) Limit for use (mm) 0.2 2.0 2.0

Torque force
Fixing bolts for the steering handle Locking nut for the front wheel spindle 40-60 55-62 N m N m

Tools Bearing puller Locking nut spanner

7.2 Failure diagnosis


7.2.1 Difficulty in steering
Failure of the steering handle bearing. Damaged steering handle bearing. Low tyre pressure.
- 63 -

Flat tyre.

7.2.2 Unsteady steering


Damaged steering handle bearing. Low tyre pressure. Bending of the front fork or the front wheel spindle. Deformed or unbalanced front tyre.

7.2.3 Front tyre shimmy


Deformed rim. Loose front wheel bearing. Poor tyre.

7.2.4 Difficulty in wheel rolling


Failure of wheel bearing or gear housing.

7.2.5 Abnormal noise of the front absorber


Fricative sound of the absorber guard. Loose bolts in the absorber.

7.3 Front wheel


7.3.1 Disassembly
Support the body bottom to suspend the front wheel. Remove the cotter pin and locking nuts for the front wheel spindle. Remove the front wheel spindle, gear housing assembly and front wheel. Remove screws, front fender and odometer cable. Remove the front brake hose. Remove the oil seal and the bearings respectively with oil seal remover and bearing puller.

wheel spindle

7.3.2 Check
7.3.2.1 Check the bending of the wheel spindle
- 64 -

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.

7.3.2.3 Check the front wheel bearing


Remove the left bushing and the oil seal of the front wheel. front rim rolling bearing brake disc left bushing of the front wheel middle spindle sleeve of the front wheel oil seal mounting bolts for the brake disc front wheel spindle

Check rolling of the bearings. The bearings will not roll if abraded or loosened. Replace it.

clearance

axially

radially

7.3.3 Bearing replacement


Remove the front wheel spindle, front wheel, middle spindle sleeve and left spindle sleeve; then remove the oil seal and the bearing respectively with oil seal remover and bearing puller. Note: replace dismantled bearings with new ones.
- 65 -

Lubricate the bearings with grease during installation. Then press the bearings in with bearing installation tools. *Note Bearings must be pressed in horizontally. The oil seal side of the bearings shall be pressed in from outside.

7.3.4 Installation
Lubricate the oil seal of the front wheel with grease. Lubricate gear engagement parts and moving parts with grease. Install the middle spindle sleeve, bearings and oil seal. Align the gear housing assembly and then install the front wheel. Note If the gear housing assembly of the odometer is not aimed at and locked with the front wheel spindle, the gear housing assembly will be deformed. After the rim is installed, rotate the rim to ensure that the drive shaft of the odometer works normally. Install and tighten the front wheel spindle. * Note: for the disassembly and assembly of the front suspension of EFI Motorcycle QJ125T-30, please see P65. Torque force Locking nuts for the front wheel spindle 55-62 N m

7.4 Steering handle


7.4.1 Disassembly
Remove the front and rear shield and the rearview mirror assembly. Remove the front brake handle and the rear brake handle. Remove the decorating cover of the grip, the throttle cable assembly and the right grip assembly. Remove the left steering handle sleeve. Remove fixing bolts for the steering handle. Remove the steering handle. left steering handle sleeve rearview mirror assembly
- 66 -

weld

assembly of the steering handle bolt locking nut fixing sleeve of the steering stem throttle cable assembly decorating cover of the grip right grip assembly screw right handle sleeve

7.4.2 Installation
Install it in reverse order. Fixing bolts Torque force: 40-60 N m

7.5 Front fork


7.5.1 Disassembly
Remove the front wheel. Remove the front shield, front inner fender and front fender. Remove the brake hose and the odometer cable. Loosen the gland nut and the lock washer. Remove the upper and the lower bearing cups. Remove the front fork. Tools: Fixing bolt spanner for the steering handle. Fixing nut spanner. Special disassembly tool for bearing cups. *Note: The opening of the body guard shall be cleaned with cloth.

7.5.3 Installation
Tools: Fixing nut spanner. Ensure the front fork is not loose by left and right movement. Steps: Install the steering handle. Install the absorber. Install the front wheel. weld assembly of the lower connecting bracket front left absorber assembly gland nut lock washer upper cup of the upper bearing steel ball lower cup of the upper bearing bearing washer spring washer bolt front right absorber assembly

- 67 -

7.6 Radiator/expansion tank assembly


7.6.1 Disassembly
Remove the body guard. Remove the headlamp. Loosen four fixing bolts for the radiator assembly. Loosen fixing bolts for inlet/outlet hoses of the radiator. Remove the power cord of the cooling fan. Remove the radiator assembly and the expansion tank assembly. heat sink

7.6.2 Check
Open the water tank cover and check the coolant level inside. Add coolant when it approaches the limit. Broken or twisted heat sink will reduce the cooling heat sink capability of the radiator. Repair the radiator with a small club when over 1/3 of heat sink is damaged or twisted. Check the liquid level of the radiator. Remove the radiator cover after the liquid is fully cooled; Completely discharge the coolant; Add the prepared coolant slowly through the filling hole (mounting hole of the radiator) until it reaches the edge of the hole; Install the radiator cover. Note: please use KEEWAY coolant; The minimum temperature for using KEEWAY coolant is -35.

edge

heat sink

coolant

- 68 -

Check the switch of the fan. Replace it when the switch can not work normally.

cooling fan

fan switch

Pressure test for the radiator. Remove the radiator cover after coolant is fully cooled; Apply required pressure to the cooling system with the radiator cover tester (lower than pressure for opening the valve of the cover) and ensure that it can keep for at least 6s under the required pressure; In the case of pressure leakage, check the hose, all connections, pump position and inspection hole.

7.6.3 Installation
Install it in reverse order. radiator cover tester

- 69 -

Rear wheel/rear suspension (picture to be updated)

VIII. Rear Wheel/Rear Suspension


Preparing documents -----------------8.1 Failure diagnosis ----------------------8.2 Rear wheel -----------------------------8.3 Rear absorber/rear swing arm -------8.4
- 70 -

8.1 Preparing documents


Work Instructions
The surface of brake discs and brake shoes shall not be stained with oil spots.

Preparing Principles
Item Rear wheel shimmy Vertically Horizontally Standard (mm) Limit for use (mm) 2.0 2.0

Locking torque force


Fixing nuts for the rear wheel Top nuts for the rear absorber Bottom nuts for the rear absorber 100-113 N m 37 - 44 N m 22 - 29 N m

8.2 Failure diagnosis


8.2.1 Rear wheel shimmy
Deformed rim. Tyre failure. Rear wheel not fixed. Low tyre pressure.

8.2.2 Too soft absorber


Elastic fatigue of spring

8.3 Rear wheel


8.3.1 Disassembly
Remove the body guard and the muffler. Remove the rear brake cylinder assembly. Remove the nuts of the rear wheel spindle and the fixing bolts of the rear right absorber. Remove the rear absorber bracket assembly. Remove the rear wheel. rear wheel spindle nut
- 71 -

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 shimmy exceeds the limit, the rear wheel bearing is loose, which causes shimmy. Check and replace the rear wheel bearings.

8.3.3 Installation
Install the rear wheel in reverse order and lock nuts. Fixing nuts for the rear wheel Torque force: 100-113 N m

Rear wheel of EFI Motorcycle QJ125T-30

mounting bolts for brake discs brake disc tyre right bushing of the rear wheel seal ring rear absorber bracket left bushing of the rear wheel oil seal cotter pin retainer ring bearing retainer ring slotted nut fixing sleeve assembly of the fixing bracket stationary bushing assembly of the rear absorber rear rim rear absorber bracket assembly

8.4 Rear absorber/rear swing arm


- 72 -

8.4.1 Disassembly of the rear absorber


Remove the seat and the left/right rear guard. Remove the rear handrail and the rear fender. Remove the muffler. Remove the air cleaner assembly. Remove the fixing bolts for the rear absorber. Remove the rear absorber.

8.4.2 Installation
Install the rear absorber. Torque force: Upper fixing nut: 37-44 N m Lower fixing nut: 22-29 N m Install the rear absorber. Install the air cleaner. Install the muffler. Install the rear handrail and the rear fender. Install the seat and the rear left/right guard. bolt rear absorber assembly

- 73 -

Table of Torque Force of Engine Fasteners

Name of fastening parts and fasteners

Tightening torqueN m

Cylinder cover bolts Drain bolts Spark plug Closing bolts Blots for the transmission chamber cover Fixing bolts for the motor Fixing bolts for the fuel pump Fixing bolts for the fuel pump sprocket Locking nuts for the flywheel Right cover stud Double-end stud Fixing bolts for the chain adjuster Fixing screws for the electrical cable clamp

2528 2225 1015 1012 1012 1012 1012 1012 5060 1012 1822 1012 47

- 74 -

Lubricating system diagram

camshaft

piston

crankshaft

Fuel pump

Fuel pump filter

- 75 -

IX. Lubricating System


Preparing documents -----------9.1 Failure diagnosis-----------9.2 Fuel pump-------------9.3 9.1 Preparing documents Work Instructions
After the fuel pump is disassembled, carefully clean each part and its surface with high-pressure gas. When the fuel pump is disassembled, do not make any impurity fall into the crankcase.

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.

Preparing Principles
Item Fuel capacity when replacing fuel when disassembly radial clearance between inner and outer rotors Fuel pump rotor clearance between outer rotor and pump body clearance between rotor surface Standard 0.9L 1L 0.040.15 0.150.21 0.07-0.12 Limit for use / / 0.20 0.21 0.18

9.2 Failure diagnosis Decreasing fuel


Natural consumption of fuel Fuel leakage Abrasive or incorrectly installed piston ring

Burnt engine
No fuel or low fuel pressure Blocked fuel pipes No fuel used
- 76 -

9.3 Fuel pump 9.3.1 Disassembly


Remove the right cover and one-way clutch assembly. Loosen the fixing bolts for the fuel pump chain cover and then remove the chain cover.

chain cover

screw

Remove the fixing nuts for the sprocket. Remove the sprocket and the chain.

chain

sprocket

nut

Remove screws and fuel pump assembly.

fuel pump screw


- 77 -

Remove screws and fuel pump cover.

fuel pump cover

Check the radial clearance between inner and outer rotors. Limit for use: 0.20mm

Check the clearance between the outer rotor and the fuel pump housing. Limit for use: 0.21mm gauge

Check clearance between rotor surface. Limit for use: 0.18mm

gauge
- 78 -

panel

9.3.2 Breakdown
Break down the fuel pump according to the following picture.

inner rotor fuel pump fuel pump shaft fuel pump chain cotter pin outer rotor fuel pump cover screw Note: After assembly, the inner and outer rotors shall rotate flexibly without being seized.

9.3.3 Installation
Install it in reverse order.

- 79 -

- 80 -

X. Cylinder Head/Valve
Preparing documents---------------11.1 Failure diagnosis---------------11.2 Cylinder head-----------------11.3 Cylinder head check-------------11.4 Valve-------------------11.5 10.1 Preparing documents Work Instructions
To ensure sealing between the cylinder head and the cylinder block, the cylinder head shall sustain the bolt pretension of 50Nm. All parts shall be cleaned and blown with high-pressure gas before check.

Valve check---------------11.6

Replacement of valve guide-----------11.7 Adjustment of valve retainer ---------11.8 Installation-------------------11.9

Function of cylinder head: The cylinder head is used for sealing the cylinder and constitutes the combustion
chamber with the piston to sustain high-temperature and high-pressure gas. It achieves gas intake and exhaust with the valve actuating mechanism.

Preparing Principles
Item Cylinder pressure Flatness of cylinder cover Valve clearance Inner diameter of valve guide Clearance between the valve stem and the valve guide Width of valve seat Valve spring Swing arm Free length Diameter of swing arm hole Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake/exhaust Intake/exhaust
- 81 -

Unit: mm Standard 1.25MPa 0.03 0.10 0.13 5.00-5.012 5.00-5.012 0.010-0.035 0.030-0.05 1.2 1.2 35.4 Limit for use / 0.03 0.12 0.14 5.03 5.03 0.08 0.10 1.7 1.7 34.9

Valve Valve guide

10.00-10.015

10.10

Diameter of swing arm shaft Clearance between the swing arm hole and the swing arm shaft Cam height

Intake/exhaust Intake/exhaust

9.982-9.988

9.90

0.012-0.033 Intake Exhaust 29.78 29.54

0.033 29.83 29.59

10.2 Failure diagnosis Low compression pressure


Poor adjustment of the valve clearance Burnt or bent valve Poor sealing of the valve seat Leakage of the cylinder head spacer Poor installation of spark plug

Abnormal noise in the cylinder head


Poor adjustment of the valve clearance Damaged valve spring Abrasive or damaged camshaft Abrasive camshaft or valve swing arm

High compression pressure


Too much carbon deposit in the combustion chamber

10.3 Cylinder head 11.3.1 Disassembly


Remove fixing bolts.

fixing bolt

- 82 -

Remove bolts, chain tensioner and spacer.

chain tensioner spacer Remove the washer and the cotter pin. Loosen bolts and remove the camshaft bracket assembly. Note: when the bolts of the camshaft bracket are removed, apply staggered steps. Otherwise, the bracket will be broken.

washer

cotter pin

camshaft bracket

Remove the chain from the timing driven sprocket. Remove the camshaft. Remove the cotter pin. Remove the cylinder head. Note: hang the chain with a section of metal wire to prevent it from falling into the crankcase.

camshaft
- 83 -

cotter pin

Fasten M5 screw into the swing arm shaft and pull the shaft out. Remove the swing arm and the decompressor.

M5 M5 screw

10.4 Cylinder head check


Check the outer ring of the bearing. Replace it if it can not rotate steadily and flexibly. Check the inner ring of the bearing. Replace it if it is not fastened on the camshaft. Check the raised part of the camshaft. Replace it if it has abrasive, scratched or blue spots. Measure the cam height and meanwhile check whether it is abraded or damaged. Replace it if it can not meet requirements. Limit for use: Cam height: intake: 29.83mm exhaust: 29.59mm Measure the outer diameter of the swing arm shaft. Limit for use: 9.90mm

micrometer

- 84 -

Measure the inner diameter of the swing arm hole. Limit for use: 10.10mm Clearance between the swing arm hole and the swing arm shaft. Limit for use: 0.033mm

tester

Compress the valve spring with the valve spring compression tool and remove the valve cotter. Remove the spring plate, valve spring, spring washer for the outer valve and valve in sequence.

valve cotter

10.5 Valve Valve breakdown

- 85 -

valve spacer valve cotter

spring plate

valve oil seal

spring

10.6 Valve check


Eliminate carbon deposit on the cylinder cover. Measure the flatness of the connection surface of the cylinder cover. Limit for use: 0.15mm When the flatness of the connection surface of the cylinder cover exceeds the limit, place the emery paper on the plate and contact the connection surface of the cylinder cover with the emery paper. Scrub the surface in the shape of 8.

ruler

gauge

Measure the free length of the valve spring. Limit for use: spring: 34.9 mm

vernier caliper Measure the outer diameter of the valve stem. Limit for use: 4.95mm

- 86 -

Check the valve guide and eliminate carbon deposit in the valve guide with reamer before check. Note: rotate the reamer clockwise, but not counterclockwise.

valve reamer

Measure the inner diameter of each valve guide. Limit for use: intake/exhaust: 5.03mm Limit for use for the clearance between the valve and the valve guide: Intake valve: 0.08mm Exhaust valve: 0.10mm

tester

10.7 Replacement of valve guide


Note: when the clearance between the valve and the valve guide exceeds the limit, replace the valve guide. After replacement, adjust the surface of the valve retainer. Place the valve guide in the freezer for cooling for 1 hour. Heat the cylinder head in the stove or oven to 100-150.

valve guide screwdriver

- 87 -

Fix the cylinder head. Remove the valve guide from the cylinder head with the valve guide disassembly tool. Place a new O-ring on the new valve guide. Install the valve guide over the cylinder head. Note: do not damage the cylinder head when the valve guide is installed.

valve guide screwdriver

Insert the valve guide. Adjust it with the valve guide reamer. Note: add some cutting oil when cutting with the reamer which shall rotate clockwise.

valve reamer Eliminate carbon deposit inside the combustion chamber and the valve. Thoroughly clean the intake valve and the exhaust valve. Check the width of the contact surface of the valve seat (width of the valve retainer). Limit for use: intake/exhaust: 1.7mm

contact surface of the valve seat

- 88 -

10.8 Adjustment of the valve retainer

Remove any hackly or uneven part in the surface of the valve retainer with a milling cutter of 45 . Note: add a layer of transparent or Prussian blue coating on the valve retainer so as to see it clearly.

hackly part Eliminate 1/4 of the outer edge of the valve retainer with a milling cutter of 20 .

Eliminate 1/4 of the bottom end of the valve retainer with a milling cutter of 60 Remove the milling cutter and check . any milled part.

- 89 -

Mill the valve retainer with a refined milling cutter of 45 to make it have proper width. Any dent or hackly part must be removed. Standard width of the valve retainer: intake: 1.2m exhaust: 1.2m

If the higher part of the valve is contacted, reduce the height of the valve retainer with end mills of 20 . If the lower part of the valve is contacted, increase the height of the valve retainer with an inner milling cutter of 60 . Mill the valve retainer with a refined milling cutter of 45 again to make it meet requirements. After milling, coat the valve surface with brightener and slightly polish the valve. high contact surface low contact surface

10.9 Installation
Install it in reverse order. Note: When the valve spring is installed, point the spring end with smaller pitch to the combustion chamber. When the valve cotter is installed, apply a valve spring compression tool. When the valve is installed, apply some fuel to the surface of the valve stem and then install it into the valve guide.

- 90 -

- 91 -

XI. Cylinder Block and Piston


Preparing documents -----------------12.1 Failure diagnosis -----------------12.2 Cylinder block -------------------12.3 11.1 Preparing documents Work Instructions
All parts shall be cleaned and blown with high-pressure gas before check.

Piston-------------------12.4 Piston installation-------------12.5 Cylinder installation-------------12.6

Function of the cylinder block: The cylinder block provides space for gas compression, combustion and
expansion, and also guides the piston movement. It transfers part of heat inside the cylinder to cooling medium around.

Function of the piston:


1It is able to sustain pressure caused by combustion of mixed combustible gas in the cylinder and transfer such pressure to the connecting rod which drives the crankshaft to rotate. 2It forms a combustion chamber with the cylinder cover.

Preparing Principles
Item Inner diameter Cylinder Cylindricity Roundness Flatness Marked direction Standard 52.40-52.413 0.004 0.005 0.05

Unit: mm Limit for use 52.413 0.004 0.005 0.05 /

IN opposite the intake valve 52.3652.37 (7mm below the bottom of the piston skirt 14.00214.008 13.994-13.999 0.03-0.053 0.030.07

Outer diameter measuring point Piston Piston ring Piston pin Inner diameter of the piston pin hole Outer diameter of the piston pin Clearance between the cylinder and the piston Clearance Ring 1

52.37

14.04 13.97 0.053 0.10

- 92 -

between the piston ring and the ring slot Joint gap of the piston ring

Ring 2 Ring 1 Ring 2 Oil ring

0.030.07 0.10-0.25 0.20-0.35 0.10.6 0.003-0.014 14.01014.018 0.0110.024

0.10 0.50 0.60

Clearance between the piston and the piston pin Inner diameter of the smaller end of the connecting rod Clearance between the connecting rod and the piston pin

0.03 14.04 0.05

11.2 Failure diagnosis Low compression pressure


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

11.3 Cylinder block 119.1 Disassembly of the cylinder block


Remove the cylinder head, spacer for the cylinder cover and locating pin. Remove the main chain plate. Remove the cylinder.

cylinder

locating pin
- 93 -

spacer

main chain plate

119.2 Cylinder block check


Check the abrasion of the inner wall of the cylinder. If it is serious, replace it.

Remove the spacer and the locating pin. Remove any residual spacer attached to the cylinder. locating pin spacer

11.4 Piston 120.1 Disassembly


Remove the retainer ring of the piston. Note: during assembly, do not make the retainer ring fall into the crankcase. Remove the piston pin and the piston. piston pin retainer ring

Check the piston, piston pin and piston ring. Remove the piston ring. Note: Do not rupture or damage the piston ring. Eliminate carbon deposit in the groove of the piston ring.

- 94 -

Install the piston ring. Measure the clearance between the piston ring and the piston ring groove. Limit for use: top ring: 0.10mm. Ring 2: 0.10mm.

piston gauge push in piston ring

Remove the piston ring and install each piston ring at the cylinder bottom. Note: Press the piston ring into the cylinder with the piston head. Measure the joint gap of the piston ring. Limit for use: 0.5mm.

gauge Measure the inner diameter of the piston pin hole. Limit for use: 14.04mm.

piston ring

- 95 -

Measure the outer diameter of the piston pin. Limit for use: 13.97mm. Clearance between the piston pin hole and the piston pin. Limit for use: 0.03mm.

Measure the outer diameter of the piston. Note: The measuring point shall be at 90 degree with the piston pin, and at 7mm below the piston skirt. Limit for use52.37mm

90

7mm

Check whether the inner wall of the cylinder 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: 52.413mm Measure the clearance between the cylinder and the piston. Record the maximum value. Limit for use: 0.053mm

tester

- 96 -

Measure the roundness of the inner wall of the cylinder (inner diameter difference at X direction and Y direction). Limit for use: 0.005mm Measure the cylindricity of the inner wall of the cylinder (inner diameter difference at the top, middle and bottom points of X direction or Y direction). Limit for use: 0.004mm

Check the flatness of the cylinder surface. Limit for use: 0.05mm

ruler

gauge

Measure the inner diameter of the smaller end of the connecting rod. Limit for use: 14.04mm

smaller end of the connecting rod

- 97 -

11.5 Piston installation


Install the locating pin. Apply fuel to each piston ring and piston. Install the piston ring with marked side upward. 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.

top ring ring 2 oil ring

Open the right cover and remove the starting lever assembly. 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: Install the piston with its top mark IN towards the intake valve.

IN IN mark

11.6 Cylinder installation


Install the spacer and the locating pin on the crankcase.

locating pin spacer


- 98 -

Evenly apply fuel to the inner wall of the cylinder, piston and piston ring. Carefully install the piston ring into the cylinder. Note: Do not damage the piston ring.

- 99 -

- 100 -

XII. Drive Face/Clutch/Driven Wheel


Preparing documents -------------------13.1 Failure diagnosis -------13.2 Clutch/driven wheel ---------13.5

Breakdown of clutch and driven wheel----13.6 Installation --------------------13.7

Left crankcase cover--------------------13.3 Drive face -------------------------------13.4 12.1 Preparing documents Work Instructions

During operation, the surface of the triangle belt can not be stained with any grease which must be removed. It helps avoid slipping between the triangle belt and the belt pulley as much as possible. Function: Drive face, clutch and driven wheel constitute stepless transmission. The triangle belt transfers torque
between the drive face and the driven wheel.

Preparing Principles
Item Inner diameter of right half-driven wheel Outer diameter of the sliding sleeve Width of the triangle belt Thickness of the clutch facing Inner diameter of the clutch sleeve Free length of the clutch spring Outer diameter of the bushing on the right half driven wheel Outer diameter of the sliding sleeve on the left half driven wheel Outer diameter of the ball Standard 28-28.02 23.967-23.98 21.222.8 1.5 125125.2 69 1 42.92-42.98 33.9533.975 20-20.2

Unit: mm Limit for use 28.04 23.98 22.8 1.5 125.5 70 42.90 34.00 19.5

12.2 Failure diagnosis No run after engine startup Insufficient horsepower


Abrasive triangle belt Abrasive triangle belt
- 101 -

Vibration during run


Ruptured or damaged clutch facing

Damaged driven wheel Broken or damaged clutch facing Ruptured clutch spring

Deformed clutch spring Abrasive ball Stained surface of the driving pulley

12.3 Left crankcase cover Disassembly


Remove fixing bolts, spacer and locating pin.

left cover Note: Fixing bolts shall be removed in staggered sequence.

fixing bolt

Remove the spacer and locating pin.

spacer

locating pin

12.4 Drive face Disassembly


Remove fixing nuts for the drive face and the left half-drive face. Remove the triangle belt from the drive face.

fixer triangle belt : left half drive face spanner

- 102 -

Check whether the triangle belt is cracked and whether rubber or cotton yarn falls down or is abnormally abrasive. Measure the width of the triangle belt. Limit for use: 22.8mm Note: apply original parts from our company for replacement.

Width

Remove the right half drive wheel assembly.

right half drive wheel assembly

Breakdown of right half drive wheel assembly

- 103 -

Check abrasion of the ball. Measure the outer diameter of the ball. Limit for use: 19.5mm

Measure the inner diameter of the right half drive wheel. Limit for use: 28.04mm Measure the outer diameter of the sliding sleeve. Limit for use: 23.98mm

- 104 -

sliding sleeve

right half drive wheel

12.5 Clutch/driven wheel 13.5.1 Disassembly


Fix the clutch sleeve with the fixer and remove fixing nuts. Remove the clutch sleeve, clutch and driven wheel.

driven wheel clutch sleeve fixer

socket spanner

13.5.2 Breakdown of clutch


Remove the retainer ring and break down the clutch. Note: do not stain the clutch facing with any grease during breakdown.

retainer ring

clutch facing

- 105 -

Check abrasion of the clutch sleeve. Measure the outer diameter of the clutch sleeve. Limit for use: 125.5mm.

Check abrasion of the clutch facing. Measure the thickness of the clutch facing. Limit for use: 1.5mm

clutch facing

12.6 Breakdown of clutch and driven wheel


Clutch spring compressor must be used for disassembling the clutch spring. Note: spring compressor must be used for disassembly to avoid damage to spring. Fix the spring compressor to remove fixing nuts of the clutch. Loosen the compressor, and disassemble the clutch and the driven wheel.

spanner

clutch spring compressor

- 106 -

Remove the spring guard.

spring guard Remove the guide pin. Remove the weldment on the left half driven wheel. Remove the oil seal on the left half driven wheel.

weldment on the left half driven wheel guide pin

oil seal

Check the free length of the clutch spring. Limit for use: 70mm.

free length

- 107 -

Check abrasion of the driven wheel. Measure the outer diameter of the bushing on the right half driven wheel. Limit for use: 42.90mm. Measure the inner diameter of the sliding sleeve on the left half driven wheel. Limit for use: 34.00mm. right half driven wheel left half driven wheel

13.6.1 Replacement of the bearing on the right half driven wheel


Remove the needle bearing from the right half driven wheel. Remove the elastic retainer ring and the outer rolling bearing.

needle bearing elastic retainer ring rolling bearing Note: Removed bearings can not be used any more.

Apply grease evenly to the outer rolling bearing and then place it into the sleeve. Note: place the outer rolling bearing into the sleeve with its marked side outwards. Then fill the sleeve with 8-9g grease. Install the elastic retainer ring.

bearing screwdriver elastic retainer ring rolling bearing


- 108 -

Install the needle bearing. Press the needle bearing in as shown in the picture.

bearing screwdriver

13.6.2 Combination of clutch and driven wheel


Eliminate any grease on the surface of the driven wheel. Install the oil seal in the sliding sleeve of the left half driven wheel. Apply grease evenly on the O-ring and install it on the sliding sleeve of the left half driven wheel.

lubricating grease oil seal

O o-ring

Combine the left half and the right half driven wheel. Apply grease evenly to the guide pin and then install it into the guide groove.

guide pin

guide groove

- 109 -

Install the spring guard. Eliminate leaked grease.

spring guard

Install the clutch spring and the clutch on the driven wheel. Use the clutch spring compression combination. Install locking nuts after compression. Note: properly compress the spring to avoid damage to the spring.

spanner (locking nut)

clutch spring compressor

12.7 Installation
Install the drive face/ clutch/ driven wheel in reverse order.

- 110 -

input shaft

intermediate shaft

output shaft

- 111 -

XIII. Decelerator
Preparing documents -----------------14.1 Failure diagnosis ---------------------14.2 Gearbox --------------------------------14.3 Installation ----------------------------14.4 13.1 Preparing documents
Function: transfer torque and decide final output torque and rotational speed.

13.2 Failure diagnosis No run after engine startup


Broken driving gear Burnt driving gear

Leaked gear oil


Too much gear oil Damaged oil seal

13.3 Gearbox 14.3.1 Disassembly


Remove bolts and the gearbox cover.

gearbox cover bolt


- 112 -

Remove the spacer and the locating pin.

locating pin Remove the output shaft assembly. Remove the intermediate shaft assembly. Remove the input shaft.

spacer

output shaft assembly intermediate shaft assembly input shaft

Check abrasion of the input shaft, output shaft and each gear. It shall be replaced if being abraded seriously. Remove the oil seal from the gearbox cover and hammer out the bearing. Note: Removed bearing can not be used any more. It shall be replaced. Use special tools to dismantle the bearing and the oil seal.

bearing
- 113 -

oil seal

13.4 Installation
Install it in reverse order. Note: Use special tools to install the bearing and the oil seal to avoid any damage.

- 114 -

XIV. Crankcase
Preparing documents-----------------15.1 Failure diagnosis ---------------------15.2 Crankcase -----------------------------15.3 Installation ----------------------------15.4 14.1Preparing documents Work Instructions
The crankcase is thin-section casting thus shall not suffer impact during operation which may cause deformation or fracture. All components must be cleaned and blown with high-pressure gas before test. Lubricant in the crankcase should be drained out before operation.

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 head, 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.

Preparing Principles
Item Left-right clearance of the larger end of the connecting rod Radial clearance of the larger end of the connecting rod Standard 0.1-0.35 0.008-0.016

Unit: mm Limit for use 0.55 0.05

Crankshaft

Tools
Universal holder Screwdriver lever Guide rod Clutch spring compressor Socket spanner Bearing screwdriver

- 115 -

14.2 Failure diagnosis Noise in the crankcase


Loose or broken parts inside the crankcase Loose crankpin bearing Loose crankshaft bearing Seized clutch

14.3 Crankcase 15.3.1 Crankcase disassembly


Loosen bolts and remove the right crankcase cover.

right crankcase cover Remove the spacer. Loosen locking nuts with a special tool and remove the magneto. Remove the starter idler gear and the shaft.

bolt

electric starter idler gear locking nut Remove bolts and the end cap of the fuel pump sprocket. Remove the fuel pump.

magneto spacer

sprocket cap bolt

- 116 -

Remove the bolts of the right crankcase. Put down the left crankcase and remove the right crankcase.

right crankcase

Remove the spacer and the locating pin. Remove the connecting rod combination. Remove the timing chain.

locating pin

spacer

connecting rod combination

15.3.2 Check
Measure the left-right clearance of the larger end of the connecting rod. Limit for use: 0.55mm.

measuring point at the larger end of the connecting rod

- 117 -

Measure the clearance of the larger end of the connecting rod (X-Y direction). Limit for use: 0.05mm.

Check whether there is noise when the crankshaft bearing rotates or whether it is loose. If yes, replace the crankshaft assembly.

crankshaft bearing Remove the oil seal from the left crankcase. Note: Removed oil seal can not be used any more. Remove the oil seal with a special tool.

oil seal

14.4 Installation
Install the crankcase in reverse order. Note: Install the oil seal with special tools to avoid any damage to it.

- 118 -

Cooling System Diagram (picture to be updated) Filler

Water outlet pipe Water pipe inlet

Thermostat

Pump

- 119 -

XV. Cooling System


Preparing documents -----------------16.1 Failure diagnosis----------------------16.2 Thermostat-----------------------------16.3

15.1 Preparing documents


Function of the cooling system: Use water as heat absorption medium to take heat outside through the
cylinder block and the cylinder cover in the engine. Then dissipate heat into air with the radiator to ensure the engine works under the best temperature condition.

Work Instructions:
1. Check and maintain the cooling system after the engine is cooled. 2. Do not remove the radiator cover except that the radiator liquid is filled up again or drained out after the cooling system is dismantled. 3. It is feasible to maintain the cooling system on the motorcycle.

15.2 Failure diagnosis


Insufficient cooling water
Evaporation or leakage Cracked or aged hose Loose joint Poor sealing of the cylinder gasket Deformed iron pipe at the outlet of the hose

Overheated engine
Poor cooling cycle Leakage of cooling water which causes little working medium Too much impurity inside the radiator pipe Wrinkled water pipe Pump in bad condition Dirty radiator lattice

- 120 -

15.3 Thermostat
Disassembly
Drain out the coolant and remove the thermostat. Put the thermostat into the water vessel. Raise water temperature and check the temperature when the valve of the thermostat opens. Initial temperature for opening Full-open temperature Lift at the time of fully opening 7284 C 9396 C Above 4.27mm Hydrostatic test at 392KPa shall be carried out on the thermostat for 3 minutes. There shall be no leakage.

sensor assembly thermostat assembly bolt thermostat chamber upper lid of the thermostat chamber ring of the thermostat seal o o-ring

Radiator
Repair the radiator with a small club when over 1/3 of heat sink is damaged or twisted.

heat sink

- 121 -

Water assembly

outlet

temperature

switch

Conductivity temperature: 93 2 C C Reset temperature: 88 2 C C

water outlet temperature switch assembly

Coolant replacement
Confirm the coolant is cooled. Remove drain bolts, tilt the body to the right, completely drain out coolant and then install drain bolts.

drain bolt

Fill the prepared coolant into the filling hole.

filler cap assembly

water inlet pipe

water outlet pipe

- 122 -

Pump check
Check whether the mechanical seal is damaged through the leakage inspection hole. If the coolant is leaked through the hole, it shows there is damage to the mechanical seal. Replace the whole pump. For any pump which can be disassembled, replace the mechanical seal.

pump

leakage inspection hole

- 123 -

Muffler (picture to be updated)

- 124 -

XVI. Exhaust Emission & Control System


Warranty on the exhaust emission & control system ---------------------------17.1 Instructions on the periodic maintenance/ compliance with standards-------17.2 Mechanical function of the exhaust control system ----------------------------17.3 Catalytic conversion system -------------------------------------------------------17.4 Measures when the idle speed emission value exceeds the standard---------17.5 16.1 Warranty on the exhaust emission & control system
1. The exhaust emission & control system of this motorcycle is in conformity with the revision of EC/97/24/5/I and 2002/81/EC B issued by the EU. 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. 2. Warranty range 1Function 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 (15000 kilometers). 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. 1Users 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. 3Overload or improper operation. 4Refit the motorcycle, remove original parts or replace with other devices in private. 5Ride the motorcycle on race tracks or on any non-motorized vehicle lane frequently. 6Damage to the motorcycle due to extreme weather such as typhoon or flood, or damage or failure due to negligence, crash or impact. 7Users fail in periodic maintenance since it is out of service for a long time. 8The odometer is not repaired immediately after being damaged, or it is refit, stopped, or replaced in private. 9Users fail in periodic exhaust inspection at the station every three months. new motorcycles delivered by our company have satisfied the noise test and comply with EC 97/24/9 All implemented by the EU.

- 125 -

16.2 Instructions on periodic maintenance


is the national requirement that all motorcycles produced domestically shall comply with exhaust emission It 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. any problem, please contact KEEWAY distributors or KEEWAY service center. For Relevant emission provisions are shown as follows: Emission regulation Emission standard CO 2.0g/km HC 0.3g/km NOX 0.5 g/km

The latest national regulation shall prevail if there is any change. are not responsible for any problem due to failure in periodic maintenance at our distributor or service center. We Please carry out necessary inspection to ensure its best condition. Note: Clean the air filter frequently if the motorcycle runs in sandy road or under seriously polluted condition to extend the service life of the engine. Increase maintenance if the motorcycle often runs at high speed or frequently.

Pay attention to following items to ensure compliance with emission standards:


1Please use lead-free gasoline. 2Please use fuel with stipulated specification. 3Please 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, etc.) 5Notes: Since any problem in the ignition system, the charging system or the fuel system has significant effect on the catalytic 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. 6The 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.

- 126 -

16.3 Mechanical function of the exhaust control system


General This system adopts four-stroke single-cylinder engine and air conduction device to maintain qualified exhaust gas. Meanwhile, active carbon canister is used for exhaust gas evaporated from fuel.

Engine improvement
As the spark plug, 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.

Air induction device


Induce air into the exhaust pipe, which enables incompletely combusted CO and HC to be reacted again and become harmless gas. Division Exhaust system Device Catalytic device Constitution Catalytic converter Function Canned oxidized catalyst installed in the center of the exhaust pipe is able to oxidize CO, HC and NOX.

Adjustable parameters and suggested value setting Adjustment of idle speed rotating speed of engine 1500 100rpm/min CO concentration 0.5-1.2

16.4 Catalytic conversion system 17.4.1 Structure:

- 127 -

where catalyst is placed

17.4.2 Instruction
1. The function of convertible catalyst is to converse exhaust gas HC, CO and NOX after complete combustion to harmless gas such as H2O, CO2andN2 before emission. 2. Convertible catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used. Note that lead gasoline may invalidate catalyst. General instructions for maintaining motorcycles (exhaust pipe) with catalytic converter: 1For motorcycles with catalytic converter, when the engine is running or just closes down, it shall not be touched for a while because of high temperature. 2Motorcycles with catalytic converter shall not be near flammable material. 3There is CO inside the exhaust pipe, which is harmful to health. So do not run the engine in closed space. 4Lead gasoline can not be used for motorcycles with catalytic converter (to prevent catalytic poison). 5Do not push the motorcycle to run the engine. If it is necessary, you must wait until the temperature of the engine and the catalytic converter lowers down. 6Do not make gear up or flame out when descending. 7Do not drive the motorcycle with bad ignition. 8Do not remove spark plug and run the engine to see whether there is spark when maintaining the ignition system of the engine. If necessary, it shall be finished in a short time.

- 128 -

XVII. EFI System


17.1. Connection of the EFI system
The following figure 1 shows the connection diagram of a typical double-cylinder engine EFI system. Full lines in this figure represent input signals of the engine controller, while dotted lines represent input signals obtained from sensors and switches by the engine.

Figure 1
Crankshaft position target wheel Crankshaft position sensor Heated oxygen sensor Magneto temperature sensor / Air intake temperature/pressure combined sensor Neutral gear switch Dump switch Ignition switch Battery Burglar alarm Selective Engine control module Serial communication interface for the failure diagnosis switch Failure indicator Engine rotating speed signal Throttle position sensor Idle speed control valve Throttle valve body Ignition coil Nozzle Fuel pressure regulator Fuel pump Metal carrier catalytic converter
- 129 -

17.2. Engine controller (MC21) 17.1.1 Work principle


MC21 controller is the last generation of 16-bit digital control device used for some small engines. This controller is able to monitor data related to engine temperature, air intake pressure, crankshaft angle and exhaust oxygen sensing signal for accurate fuel injection and ignition control. Thus, the engine fuel can be used economically and dynamically. The shell of MC21 controller is made of plastic and glass fiber. It is encapsulated and sealed. It is shockproof and waterproof.

17.1.2. Label and mark


The following figure 7 is the label on MC21 controller. Information includes ECU type, component code, customer code, hardware code, production code, software revision and bar code. Any erasion from or stain in this label will affect product warranty.

Figure 7

17.1.3. Pin definition for the controller interface


The following figure 8 shows the pin definition diagram for the controller interface. It shall be ensured that input/output load is within the range of the table 9.
- 130 -

Figure 8

Figure 9

- 131 -

Figure 10

- 132 -

17.20. Instructions
MC21 controller instructions Instruction the exhaust pipe during transfer. Cause temperature which also easily damages the plastic shell of ECU. Forbidden: Place ECU in water, oil or ECU is sensitive to liquid. liquid environment. Forbidden: ECU is covered with mud or Unfavorable for heat dissipation of ECU water drops. randomly. on the connector. corrosive liquid. Should: Clean ECU with wet cloth and Prevent ECU from damage. keep it dry. Should: When ECU is reinstalled, check Keep vehicle performance. whether the air intake pipe is blocked. If yes, clean it. Should: When ECU is reinstalled, fix the Keep vehicle performance. air intake pressure pipe and ensure no leakage. Clamps and air intake pressure hoses shall match with the vehicle type. Should: Keep the air intake hose always Prevent dust from entering into the engine connect ECU and intake manifold. to ensure safety. Should: When the air intake hose is pulled Prevent joints inside ECU from being loose out from ECU, loosen the clamp at the joint and coating from being damaged. and then pull the hose carefully from ECU. surface. damages ECU. ECU. Forbidden: Power connection to ECU It seriously affects ECU work and definitely Forbidden: Water drops or too much vapor Short-circuit of ECU connector or damaged Forbidden: Clean ECU with agent or Damage ECU shell. Table: 4

Forbidden: Place ECU beside the engine or The service life of ECU is affected by high

- 133 -

17.21. Installation requirements


The installation requirements for MC21 controller are shown in figure 11 (the tightening torque force for fixing bolts (M6) is 5Nm).

11

- 134 -

17.3. Power supply requirements


Power on Under normal condition, the input voltage from battery keeps stable. When the ignition switch closes and the battery voltage exceeds 6.5V, ECU starts normal work. Operation: When the EFI system works, the battery voltage shall keep between 9-16V to ensure normal operation of the system. Power down: When the ignition switch turns off, the ignition voltage is below 6.2V, ECU enters into power down condition. ECU records values in EEPROM, such as fault code, frozen fault code, closed-loop value, revised air flow value and throttle value. Based on these values, it enables precision calculation on each parameter for next startup. Reset mode: When ECU receives reset command or faces serious problem, the system enters into the reset mode. All I/O interface is reset to the predefined state and enters into normal work condition after reset is finished. Overvoltage/counter-voltage ECU, which works under overvoltage of 24V for no more than 1 minute, will not be damaged. ECU, which works under counter-voltage of 14V for no more than 1 minute, will not be damaged.

17.4. Work temperature


Normal

work temperature range: -30 to 70 Maximum work temperature: 80 (continuous work for no more than 30 minutes) Storage temperature range: -40 to 85

17.5 Maintenance and repair


The controller can not be maintained after sale. When there is any problem, make sure whether it is cause by calibration or software first. If
- 135 -

yes, update the calibration software. If any controller hardware fails or is damaged during the warranty period, the controller must be sent back to the factory, attached with detailed controller component number, serial number, vehicle type, date of production, accumulated kilometers, where be used, and date of return. The following table shall be filled up by the distributor and sent to the factory with the controller for finding reasons. Some actions are only valid for products within the warranty period. Otherwise, users shall be responsible for expenses resulting from the replacement of damaged controllers. DELPHI Request on the Repair of Workshop

Damaged Controller
Distributor: Address: Engine displacement: Date of vehicle production: Accumulated kilometers: Details on controller: Telephone: Mobile telephone: Contact: Detailed description of failure: Part number: Serial number: Date of controller production: Vehicle type: Date of failure:

Failure under what condition:

- 136 -

Any measures taken by users and the distributor after failure:

Other information and inferred causes:

XVIII. M3 and M3.5 Fuel Injector


18.1. List of spare parts
List of spare parts of the fuel injector Name of spare parts M3 fuel injector M3.5 fuel injector Table: 5 Remark

18.2. General work principle


M3 fuel injector boasts high performance and excellent durability. It is designed by DELPHI and used for engines. Electromagnetic coil is around the iron core inside. Two electrode from the electromagnetic coil are input control interface of the oil injector. When the coil is connected to power, the electromagnetic attraction suppresses spring force and fuel pressure of the ball valve, and raises the valve. Thus, high-pressure fuel in the fuel pipe (250400kPa) runs through the valve seat hole and the orifice plate, forms cone-shaped fog and injects to the air intake valve. After the injector is disconnected, the magnetic force of the electromagnetic coil vanishes automatically, and the ball valve of the fuel injector closes automatically under the action of return spring, which stops fuel injection. The work principle of M3.5 fuel injector is similar to that of M3 fuel injector. The difference is that its electromagnetic coil is more
- 137 -

efficient and it has better durability and speed of response.

18.3. Appearance
The following figure 12 shows the appearance of M3 fuel injector. O-ring for connecting the fuel rail or the fuel injector cap.

O-ring for connecting the end of the air intake pipe.

Figure 12 There are two types of M3.5 fuel injector: long-type and mini-type. M3.5 fuel injector is able to provide better integrated function.

Long-type fuel injector

Mini-type fuel injector

Figure 13
- 138 -

18.4. O-ring
O-ring shown in figure 12 is able to ensure that there will no leakage in the fuel injector when working at between -40 and 150 (-40 and 302). It also resists corrosion from kinds of fuel additives (such as ethanol). The current o-ring design is shown below. If any DELPHI fuel injector is not consistent with following data, please contact DELPHI. O-ring for connecting the fuel rail or the fuel injector cap Dimension: Inner diameter: 6.35mm Outer diameter: 14.85mm Section thickness: 4.25mm Material: Viton GLT(blue): application under low temperature Viton A(black): application except for low temperature O-ring for connecting the end of the air intake pipe Dimension: Inner diameter: 9.61mm Outer diameter:14.49 mm Section thickness: 2.44 mm Material: Viton A (blue or brown)

18.5. O-ring replacement


Use

the suggested lubricating oil to lubricate O-ring. Do not contact the orifice plate with lubricating oil, otherwise it affects fuel injection. We suggest that o-ring can be used only once. If replacement is impossible, please check whether it is damaged before repeated use. Any minor damage will cause fuel leakage. To avoid any danger, please strictly comply with requirements to install the oil injector. When o-ring is installed into the fuel injector, please be careful and do not damage the o-ring.

18.6. Suggested lubricant


- 139 -

For the convenience of fuel injector installation, lubricant shall be applied to o-ring. Table 4 lists applicable and proved lubricant. According to test, following lubricant will not affect the performance of fuel injector.
Suggested lubricant Name of lubricant Spindura 10 Spindura 22 DTE-24 DTE-25 DTE-26 Norpar15 Drawsol 60 NocoLube AW 46 NocoLube AW 32 Advantage Spindle Oil Manufacturer Equilon Equilon Mobil Mobil Mobil Exxon/Mobil DA Stewart NOCO Energy NOCO Energy Advantage Lubrication Specialties Table: 6 Viscosity (cSt) @40 10 21 32 46 68 <1 1-2 46 32 10

18.7. Over-voltage effect


M3 fuel injector and M3.5 fuel injector can work under the voltage of 26V and pulse width of 100ms (200ms for a cycle) for 1 minute (with fuel). It will not affect flow or cause permanent damage to the electromagnetic coil or reduce the electromagnetic performance.

18.8. Temperature range


The standard temperature range of fuel injector is as follows. Under normal temperature rang and normal flow tolerance, M3 and M3.5 fuel injector will not be invalidated. Meanwhile, under normal work environment, fuel injectors will not cause any leakage, aging or shortened service life. Work temperature range: -30125 Work limits (leading to some performance degradation): 40 150 Storage temperature: -6060
- 140 -

18.9. Fuel contaminants


Filter is designed inside the fuel injector, but it can not be maintained. It is only used for filtering accumulated impurities in the fuel pipe between the fuel filter and the fuel injector. Impurities will cause failure such as bonding, flow deviation and leakage.

18.10. Cable arrangement


of the fuel injector shall be deployed far away from heat source and protected from any outside abrasion or damage. Do not insert/pull the fuel injector connector it is not necessary.
Cables

18.11. Instructions
Fuel injector instructions Instruction Forbidden: use o-ring repeatedly. If it Void leakage. has to be used repeatedly, please check whether it is damaged before use. Forbidden: immerse the injector Block the injection hole. mouth in lubricant. Forbidden: dry run under no fuel Damage inner mechanical parts. pressure. Forbidden: operate the fuel injector Eliminate standards (leakage rate >50sccm air). Forbidden: water enters into the fuel Cause damage to the fuel injector. pipe during leakage rate inspection. Forbidden: Impose force on the fuel During installation on the nylon intake injector head during installation. pipe, it is allowed to impose force at the angle of 45 degree. Forbidden: strike the fuel injector Damage the fuel injector and o-ring. when it is installed on the intake pipe. Forbidden: impose tensile force on the Cause interrupted power supply. connector. Forbidden: use the fuel injector which Possible damage.
- 141 -

Table: 7 Cause

contaminants

and

analyze

whose leakage rate maybe exceed causes for injector interference.

has been thrown. Forbidden: store fuel injector, fuel rail Possible under non-protective environment. when lifting the assembly. Forbidden: components contact each Damage the fuel injector. other during storage. Forbidden: components contact each Possible impact, which may cause damage other during transportation. troubleshooting in the case of an error. Forbidden: use non-suggested fuel Significantly affects the performance of injector injectors. Should: note that the o-ring shall not Protect the o-ring. be cut by the installation seat during the installation of the fuel injector. Should: install it into the hole after Protect the o-ring and reduce pollution. being applied with correct lubricant. Should: test the fuel injector adhered Confirm the invalidation of the fuel to the needle valve or whose needle injector. valve fails in seating. (pulse to the fuel injector with the voltage between 9-15V for less than 5 seconds) Should: before the fuel injector is The needle valve of the fuel injector may assembled, carry out no fuel leakage fail in seating during transportation or test to confirm seating of the needle transfer, which causes fuel leakage. valve. Should: avoid liquid pollution to the Cause short-circuit of the electromagnetic fuel injector. coil. Should: carefully dismantle the cables. Cause damage to terminals. Should: use suggested lubricant during Cause corrosion to terminals. the installation of the connector.
- 142 -

damage

to

electronic of the

and fuel

or engine with fuel injector installed mechanical

components

injector by the external environment.

Forbidden: pick up the fuel injector Damage the fuel injector.

to the fuel injector.

Forbidden: hammer the oil injector for Damage the fuel injector.

instead

of

original

fuel the fuel injector.

Should: do not use fallen, damaged or Find causes to problems as soon as unqualified components, and label possible. them to indicate problems.

18.12. Installation requirements


Please strictly comply with following instructions for installation and disassembly to avoid damage to fuel injectors and electronic components.

Lubrication: apply a little lubricant to the lower part of the o-ring. Do not use ISO 10 light mineral oil or equivalent product. If it is possible, it is better to apply lubricant to the fuel injector seat other than o-ring. Thus, it can minimize pollution by the fuel injector. Do not make the orifice plate contact with lubricant, which affects the volume of fuel injection. Do not pick up lubricant with the top of the fuel injector. All M3 and M3.5 oil injector o-rings are assembled before delivery. In principle, o-rings are not allowed to be used repeatedly. Please check whether there is any damage to o-rings. Any minor damage will cause leakage. Install the o-ring into the holder carefully. Do not damage the connector when it is installed. The fuel injector connector is properly installed when there is a click sound. Do not install or disassemble unnecessary connectors. Do not tighten cables too much, otherwise it may lead to short circuit. Do not rotate the fuel injector during the installation of the connector, which will lead to deviation from fuel injection targets.

18.13. Replacement
The disassembly and replacement of M3 and M3.5 fuel injectors are as follows.
- 143 -

Note: high temperature in the fuel injector and its surrounding parts. The motorcycle flames out. Disconnect the negative pole of the battery to avoid any accidental startup of the engine. Remove the fuel injector connector. Discharge fuel pressure. Remove the fuel pipe from the fuel injector. Remove the fuel injector from the air intake pipe. Remove the fuel injector retention clamp and the fuel injector from the seating carefully. Carefully clean impurities on the contact surface of the fuel injector. Do not damage the contact surface. Apply lubricant to o-rings on two ends of the new fuel injector. Install the new fuel injector into the air intake pipe carefully and make sure it is towards the same direction as the original one is. Install the fuel injector seating and the retention clip. Tighten mounting bolts with required torque according to installation manual. Install the fuel pipe. Insert the fuel injector connector. Insert the key for power on. Check fuel leakage from the fuel injector without engine startup. Start up the engine to check its work.

18.14. Replaceability
Replace the fuel injector with the one of the same part number. Part number may change. Please check the vehicle maintenance manual and the list of spare parts to select correct fuel injector.

18.15. Fuel injector blocked


Accumulated impurities in fuel will cause flow deviation and reduction of service life. When the engine stops working, deposits may be generated in fuel as heat from the engine runs through the fuel injector head. Deposits accumulated around the fuel injection hole will
- 144 -

lead to flow deviation.

If the fuel injector is blocked, reduced flow, increased friction and accumulated impurities will take place, which finally affects emission and durability. Fuel and environment factors will cause fuel crystallization or corrosion to the fuel injector, which also leads to flow deviation. Unsteady fuel oxidation will generate deposits. Please use high-quality gasoline. Add a certain amount of fuel injection cleaner to avoid deposits. When the fuel injector is blocked, please clean the fuel injector with following methods.

18.16. Cleaning
Disconnect

the fuel pump first. Discharge fuel pressure and then remove the fuel pipe. After the fuel pipe is removed, stuff it up with some material to avoid fuel drainage. Add fuel injection cleaner and gasoline at certain proportion to the fuel injector cleaner tank. Connect the fuel injector cleaner tank to the fuel injector. Adjust the cleaner fuel pressure to the vehicle system pressure of 2.5bar. Start up the engine, and keep it at the idle speed for 15-20 minutes. Remove the cleaner tank, and re-install the fuel pipe to the fuel injector. Start up the engine and keep it at the idle speed for 2 minutes. Ensure cleaner is completely discharged.

XIX. Throttle Valve Assembly


19.1. List of spare parts
List of spare part of the fuel injector Name of spare part Remark
- 145 -

Table: 8

Throttle valve Throttle position sensor Idle adjustment screw

19.2 General work principle


The throttle valve assembly mainly consists of following parts: main cast valve body, bearing, shaft and valve block, return spring, throttle cable and throttle position sensor system. All above subsystems work together to achieve following functions: control air intake flow control air flow at the idle speed check the throttle positionprovide throttle feedback signals to the engine control system provide the throttle with return force

19.3. Appearance

Figure 16

19.4. Technical parameters


Throttle valve (inner diameter: 26mm):
- 146 -

Maximum flow: 19.29 1.0g/s@0.75kPa vacuum degree Torque for opening the throttle valve: At idle speed: 0.19 0.05Nm When fully open: 0.37 0.10Nm Throttle position sensor Reference voltage: 5 0.1VDC Resistance between T1 and T2: 3k12k

Figure 17

19.5. Work environment


Normal work environment: -40125

19.6. Disassembly of the throttle valve


Disconnect

the negative pole of the battery Disconnect the throttle position sensor Remove the throttle cable Remove the hose between the air cleaner and the intake manifold

19.7. Cleaning
Remove the cover at the bottom of the throttle valve and clean the body with carburetor cleaner (3M product suggested). Spray cleaner on the inner wall of the throttle valve and remove dust and carbon deposit slightly with brush. Do not block the bypass with impurities. If idle screws are removed and cleaned, assemble idle screws in
- 147 -

following order: Install o-ring 1 on the idle bypass screws Install spring, washer, o-ring 2 on the idle bypass screws Install above idle bypass screws on the throttle valve. After idle screws are cleaned and assembled, use diagnosis tools and adjust idle speed. Note: new o-rings shall be used every time of installation.

19.8. Installation of the throttle valve


Install the throttle valve in reverse order and pay attention to followings: Adjust the throttle cable. Ensure all removed components are installed in place. Re-install all necessary parts.

19.9. Precautions
not spray any cleaner into TPS throttle position sensor. Use the throttle cable to open the throttle valve block. Do not insert any tool or stick into the throttle valve hole to keep the valve block open. It will cause deformation of the valve block and damage to the inner wall of the throttle valve. Keep carbon deposit around the valve block to maintain air flow required by idle speed setting. Do not adjust the position of idle screws. Replace o-rings once disassembled.
Do

19.10. Instruction
Instructions of the throttle valve assembly Instruction valve connector is used. Should: avoid any liquid pollution to Ensure normal work. the throttle valve. Should: take and install only one piece Possible damage to components. of throttle valve from the component
- 148 -

Table: 10 Cause

Should: be careful when the throttle Avoid damage to the connector.

tray. Should: use a label to describe any Accurately analyze causes as soon as problem related to any fallen, possible. damaged or unqualified throttle valve (within warranty range). Should: remove and discard protective Protect the system from pollution and cap before installing components. is removed. Should: if idle screws are removed, Ensure no air leakage from o-ring. replace o-rings. Forbidden: use any fallen or defective Possible inner damage. component. Forbidden: no protective cap for Possible impact on normal work due to storage parts. Forbidden: spray. Forbidden: completely exposed to the Possible impact on normal work due to environment (humid) before assembly. system voltage. Forbidden: use excessively tightening Possible damage. torque. Forbidden: hammer the fuel injector Damage to the fuel injector. for troubleshooting when there is an error. Forbidden: components bump into Possible impact on the minimum air each other when being unpacked. throttle at any position. Forbidden: block the bypass hole with Possible impact on the stability of idle dirt or sand. Forbidden: take, store or speed. hold Possible damage.
- 149 -

keep it work normally.

Should: clean bypass when the seating Ensure stable idle speed.

pollution. no protection during Possible impact on normal work due to

transportation or transfer around salt corrosion.

corrosion.

Forbidden: tested voltage exceeds the Possible damage.

leakage or other damage.

Forbidden: completely release the Possible damage.

components in a way of possibly touching other parts.

XX. Water Temperature Sensor for the Engine


20.1 List of spare parts
List of spare parts of the water temperature sensor Name of spare part Remark Table: 11

Water temperature sensor for the Used for all water-cooled engines. engine

20.2. General work principle


This water temperature sensor is used for water-cooled engines. Within the temperature range of this sensor, its resistance will vary upon the engine temperature. Its character refers to negative temperature coefficient resistance property. It is not maintainable.

20.3. Appearance

Figure 18

20.4. Installation requirements


torque requirement: install it by manual and guide into threads correctly. Then tighten it to the required torque with electric
- 150 Dynamic

spanner at the speed of beyond 400 rounds/minute or with the manual spanner. Suggested assembly torque is as follows: Maximum: 20N m Minimum: 25N m Static torque requirement: torque used for dismantling the sensor from the engine shall be no more than 200% of the assembly torque.

20.5. Work environment


sensor is mainly used for water-cooled engine. Temperature range under normal work: -40135 (continuous work) Relative humidity under work environment: 0100% Typical work pressure: under the minimum assembly torque, the sensor can achieve coolant sealing for the engine under the actual pressure of 206.8kPa (30psi) and the temperature of 135. Extreme work environment: only for 1 hour under the maximum temperature of 150
This

20.6. Storage environment


Storage

temperature: -40 to 120 Transportation without time limit below the altitude of 13700m.

20.7. Electric environment


work pressure: reference voltage is 5 0.1VDC Maximum exciting current: When the properties of the sensor are tested under any temperature, its performance shall not be affected by current of less than 1mA.
Typical

20.8. Cleaning samples


necessary, clean the sensor with isopropanol and then dry it. Sink it in isopropanl for no more than 1 minute. Install sealed connections during cleaning to prevent cleaning agent from entering into the sensor.
If

- 151 -

XXI. Intake Air Temperature Sensor


21.1. List of spare parts
List of spare parts of the intake air temperature sensor Name of spare parts Intake air temperature sensor Remark Used for all engines Table: 12

21.2. General work principle


Within the temperature range of this sensor, its resistance will vary upon the engine temperature. Its character refers to negative temperature coefficient resistance property. It is not maintainable. 21.3. Appearance

The appearance of the intake air temperature sensor is shown as in figure 20 above.

21.4. Technical parameters


Work

voltage: 5DVC Response time: 15S Work temperature: -40150 Relative humidity: 0 to 100% RH

21.5. Installation requirements:


Suggested

diameter of mounting hole: 12mm Suggested depth of mounting hole: 12mm to 16mm Mounting angle with the horizontal plane: 50

21.6. Cleaning samples


- 152 -

If necessary, clean the sensor with isopropanol and then dry it. Sink it in isopropanl for no more than 1 minute. Install sealed connections during cleaning to prevent cleaning agent from entering into the sensor.

XXII. Oxygen Sensor


22.1. List of spare parts
List of spare parts of the oxygen sensor List of spare part Oxygen sensor Remark Table: 15

22.2. General work principle Oxygen sensor is used for monitoring the content of waste oxygen inside the exhaust pipe of the combustion engine, including wideband oxygen sensor and switch-type oxygen sensor. Normally, we use switch-type oxygen sensors for small engines. It is mainly used for controlling the fuel closed loop of the engine.

22.3. Appearance
The appearance of the oxygen sensor is shown as in figure 22 below.

Figure 22

22.4. Technical parameters


- 153 -

value for air-fuel ratio (dense): 750VDC Threshold value for air-fuel ratio (dilute): 120Mvdc Heater power for the oxygen sensor: 7.0W (above parameters are measured at the engine test bench under the exhaust temperature of 450, duty cycle of 70%, 10Hz and voltage of 13.5V. ) Heater resistance: 9.61.5 (measured below 21) Work temperature range: 260-850
Threshold

22.5. Installation requirements

Installation angle (angled with the horizontal plane) 10 degree

Figure 22

Tightening torque force: 40-60Nm

22.6. Fuel quality requirements


Pb0.005g/L P0.0002g/L S0.04%( Si4ppm

XXIII. Fuel Pump Assembly


224. List of spare parts
- 154 -

List of spare parts of the fuel pump Name Fuel pump assembly Fuel pump device Fuel pressure regulator Sealing device for the fuel pump assembly Remark

Table: 19

23.2. General work principle


Fuel pump assembly: provide the engine with fuel which satisfies the requirements of the pressure system. It is installed at the bottom of the fuel pump and supplies fuel to the engine through connected fuel pipes. Fuel pump: this electric pump obtains pressure fuel from the fuel tank by the motor impeller. Pressure regulator: mechanical diaphragm type; it regulates pressure for fuel provided by the fuel pump to make it meet constant fuel pressure requirements.

23.3. Appearance and structure

- 155 -

fuel pipe regulator pump

pressure regulator clamp

pressure fuel

fuel pump cable filter washer

pump body frame fuel pump assembly

pipe clamp

fuel pipe

fuel pump bracket

23.4. Dimension
Dimension of the bottom panel: 115mm 70mm. Mounting height: 135mm (reference dimension)

23.5. Label and mark


Fuel pump assembly, fuel pump device and pressure regulator are marked with production batch and date. Fuel pump assembly: labeled on the mounting plate of the fuel pump assembly. Fuel pump: engraved on the pump body. Fuel pressure regulator: engraved on the shell.

23.6. Work environment


fuel pump shall be installed at the bottom of the fuel tank according to installation requirements. The general design of the fuel tank is only for gasoline. If it contains ethanol, please contact the fuel pump factory to ensure whether it can be used. During the first operation of the fuel pump, please ensure there is enough fuel in the tank. Do not operate it under no fuel condition. For the connection of fuel pipes, please see the reference diagram 28. Overall Fuel Pipe Arrangement
The

- 156 -

Figure 28

23.8. Maintenance procedures Safety precautions:


Please be careful and keep your safety when maintaining the fuel system. Disconnect the negative pole of the battery. Smoking is forbidden. Place a sign of No Smoking near the operation area. Ensure there is fire extinguishing devices. Ensure good ventilation and keep away from fire sources. Wear protective goggles. To release fuel vapour inside the fuel tank, open the fuel tank and then re-install it. When the engine stops working, there is still high pressure inside the fuel pipe and fuel shoots up if the fuel pipe is disassembled or loosened. Please make reference to fuel pressure release procedures in this chapter. A small amount of fuel flows out after the fuel pipe is disassembled. To avoid any danger, please apply proper and clean material to block the pipe. After maintenance, please make sure the fuel pipe and the clamp are installed according to the installation manual. After maintenance, please check fuel leakage according to the fuel leakage inspection procedures. After maintenance, make sure there is enough fuel in the fuel
- 157 -

tank when the fuel pump works.

Failure diagnosis of the fuel pump assembly:


Step 1 Operation After startup by the ignition key, the fuel pump works for 3 seconds. Disconnect the fuel pump connector, and check whether the voltage of the fuel pump is within 10-14V. Supply DC of 12V to the fuel pump; ensure there is enough fuel in the fuel tank to avoid dry run; whether the fuel pump works? When the engine works at idle speed, check whether the fuel supply pressure at the front end of the injector mouth is within 220-270kPa. Whether pressure is lower than 220kPa. Yes If you can hear fuel pump working, please go to step 4. Go to step 3. No If you cannot hear fuel pump working, please go to step 2. Check the power supply circuit of the fuel pump.

1. Check the loop 1. Check the from the fuel throttle cable; pump to ECU; 2. Check the fuel 2. Check ECU. pump. The fuel assembly normally. pump Go to step 5. works

1. Check whether 1. The fuel filter is there is leakage blocked; in the fuel pipe; 2. The fuel pipe is 2. Check fuel bent and pump device; twisted; 3. Check pressure 3. Check pressure regulator. regulator.

Disassembly of the fuel pump assembly:

Please make reference to fuel pressure in the fuel drain pipe in fuel pressure release procedures. Disconnect the negative pole of the battery. Disconnect the connector of the fuel pump assembly cable. Pump the residual fuel in the fuel tank out and store it in a proper vessel to ensure safety and reduce pollution. Disassemble the fuel pipe connecting to the fuel pump assembly with standard tools. Remove the fuel tank from the vehicle. Place the fuel tank upside down. Protect it from any scratch or
- 158 -

crash. Do not damage the filter during removal.

Installation of the fuel pump assembly:

Replace the sealing washer of the fuel pump assembly (an used washer may lead to fuel leakage). Fold the filter carefully and asymmetrically arrange mounting bolts for the fuel pump assembly which only can be installed towards required direction. The pressure regulator shall face the back of the fuel tank to ensure the surface of the fuel tank is clean and neat. Install screws in the cover plate of the fuel pump assembly and evenly tighten screws in sequence as shown in figure 33. Torque for mounting screws: 34Nm. The fuel pump assembly shall be fixed with special screws. Apply required tightening sequence and torque to fix. Over-torque or incorrect tightening sequence will lead to deformation of the washer, which causes leakage. Install the fuel tank in the vehicle. Connect the fuel pipe and clamp it properly. Connect the connector of the fuel pump cables. Check leakage according to fuel leakage inspection procedures before the engine works.

Tightening sequence for mounting screws Figure 33

Replacement of the pressure regulator


Remove the seating of the pressure regulator. Remove the snap spring from the pressure regulator with the snap
- 159 -

spring tool. Avoid any damage caused by popup of the spring. Remove the pressure regulator. Carefully avoid damage to the outer edge of the pressure regulator. Apply lubricant around o-ring of the new pressure regulator to facilitate installation. Make sure two o-rings are installed on the pressure regulator (one with larger diameter, one with smaller diameter). Install the pressure regulator in the bracket of the fuel pump frame. Do not hammer the pressure regulator (damage to the pressure device). Install the snap spring of the fuel pressure regulator. Replace o-rings of the fuel pump.

Fuel pressure release procedures:


Note: do not operate when the engine is hot. Make sure the engine is cooled and then carry out following fuel pressure release procedures: The transmission is at the status of neutral. Disconnect the connector connecting fuel pump assembly cables and vehicle cables. Start up the engine until it automatically flames out. Open and close the ignition key two or three times at an interval of 3 seconds. After above operation, connect the connector of the fuel pump assembly cables.

Fuel leakage inspection procedures:


After maintenance on any fuel system, please confirm following fuel leakage inspection test is carried out. Add enough fuel into the fuel tank. Start the ignition key for 3 seconds and then closes it for 15 seconds; repeat it three or four times to set up fuel pressure in the fuel pipe.
- 160 -

Check whether there is leakage in any component of the fuel system (fuel tank, fuel pipe, joint, etc.).
Table: 18 Cause Damage to the inside of the fuel pump.

Instructions for the fuel pump assembly Instruction Forbidden: crash the fuel pump. (no fuel from the filter at the entry of the fuel pump); make sure enough fuel in the fuel tank.

Forbidden: dry run by the fuel pump Damage to the inside of the fuel pump.

Forbidden: damage the filter during Impurities enter into the damaged filter maintenance. and then the fuel pump, which destroy the fuel pump. Forbidden: disassemble inner parts of No warranty. the pump body and the pressure regulator. Forbidden: regulate the fuel pump and the pressure regulator. Forbidden: pick up the fuel pump Damage the cables and disconnect the fuel assembly cables to lift the fuel pump pump. assembly. Forbidden: lift the fuel pump assembly cables vertically along the fuel pump cover plate. Forbidden: use damaged fuel pipe Pressure leakage/ fuel leakage. clamp. Forbidden: use seriously damaged or Impurities enter into the fuel pump broken filter in the fuel pump through the damaged filter, and damage the pump body. purpose. assembly. tank with the fuel pump.

Forbidden: draw fuel from the fuel Fuel pump is not designed for such Forbidden: use mounting screws of the Affect the installation of the fuel pump fuel pump assembly to fix other assembly. components.
- 161 -

Forbidden: damage the fuel pump Damaged is maintained.

terminals

will

cause

bad

cables when the fuel pump assembly contact/ disconnected power supply. Forbidden: the manual pump contacts Avoid damage to the fuel pump assembly. the fuel pump assembly when drawing fuel from the fuel tank. Should: ensure no damage to the fuel Avoid fuel leakage. pipe during maintenance. Should: only use original sealing Faked ones may lead to fuel leakage. washers for the fuel pump assembly. Should: use designated hose clamps. Ensure no fuel leakage on joints of the fuel pipe. Should: the fuel pump cables are fixed Reduce vibration. on the vehicle. Should: use standard fuel. Unqualified fuel will lead to early damage to the fuel pump. Should: replace the fuel filter within Blocked filter will reduce fuel supply. the stipulated period. Should: use stipulated and qualified Unqualified filter will damage the injector fuel filter. mouth, fuel pressure regulator and fuel pump. Should: ensure the correct direction of Incorrect direction or interference will the fuel pipe deployment and no damage the fuel pipe. interference with other parts. Should: ensure enough fuel in the fuel Avoid dry run of the fuel pump. tank (over the fuel pump filter). Should: replace two o-rings when the Ensure the correct pressure regulation pressure regulator is maintained. Should: cables. Should: return any fallen, damaged or Find causes as soon as possible. unqualified parts and describe related problem.
- 162 -

curve. the Avoid damage to the connector terminals.

carefully

connect

connector of the fuel pump assembly

XXIV. Failure Diagnosis


Failure diagnosis for the EFI system is carried out as follows: I. Connect a special diagnostic apparatus to the failure diagnosis interface in the motorcycle cables to effectively and accurately read failure. II. Connect a computer installed with diagnostic software to the failure diagnosis interface with a special communication cable, and then read failure in the computer. In addition, the fault light in the meter (as shown in 4-1) also provides failure warning. Under normal condition, Keyon, the fault light turns on and it turns off after startup. In the case of failure, it is always light.

24.1. Diagnostic tools


Diag Tool software of PC version (for MC21 system) is used for monitoring and recording operation data of the motorcycle. Connect the computer serial port to the diagnosis interface of the motorcycle with K line before use.

24.2. Pin definition for the diagnosis interface:


Pin 6 of the diagnosis interface is defined as follows: the pin combination can achieve different diagnostic service functions. The diagnostic tool uses three pins which are 12V, ground and K line.

- 163 -

Pin2ground Pin4: K line Pin6: 12V

24.3. Software instruction


Initial setting:

Connect the computer serial port to the motorcycle diagnosis interface with the diagnostic cable.

Start Diag Tool software.

- 164 -

Click connect for connection.

Click Engine Data for displaying and monitoring engine status.

- 165 -

Click Engine Data for displaying and monitoring engine status. Set the sampling frequency as 0.1 second and establish document name and path for data saving.

- 166 -

ECU version

- 167 -

Click Malf Code to show current malfunction code. 24.4 Cross reference table for malfunction code Malfunction Description Description of code malfunction code P0106 Map Rationality Rationality of air intake pressure P0107 Map Open/GND Open circuit or short circuit grounding of the built-in air intake pressure sensor P0108 Map Short V Short circuit power supply of the built-in air intake pressure sensor P0112 IAT Short GND Short circuit grounding of the air intake temperature sensor P0113 IAT Short V/Open Short circuit power supply or open circuit of the air intake temperature sensor P0117 Toil Short GND Short circuit grounding of the engine temperature sensor P0118 Toil Short V/Open Short circuit power supply or open circuit of the engine temperature sensor P0563 Battery voltage high Overhigh voltage of the battery P0122 TPS Open/GND Short circuit power
- 168 -

Flash code 35 34

33

69

71

15

14

49 22

P0123

P0131

P0132

P0231

P0232

P0601 P0261

P0262

P1351

P0351

supply or open circuit of the throttle position sensor TPS Short V Short circuit grounding of the throttle position sensor O2 Short GND Short circuit grounding of the oxygen sensor O2 Short V Short circuit power supply of the oxygen sensor Pump Open/GND Short circuit grounding or power supply of the fuel pump Pump Short V Short circuit power supply of the fuel pump EEPROM Error EEPROM error Cylinder 1 Inj Short circuit Open/GND grounding or open circuit of the injector of cylinder 1 Cylinder 1 Inj Short V Short circuit power supply of the injector of cylinder 1 Cylinder 1 Ign Short circuit Open/GND grounding of the ignition coil of cylinder 1 Cylinder 1 Ign Short V Short circuit power supply of the ignition
- 169 -

21

45

44

29

31

51 16

17

64

42

P1650

P0650

P1654

P0654

P0335 P1352

P0352

P0321

P1321

P0264

coil of cylinder 1 MIL Open /GND Short circuit grounding or open circuit of the fault light MIL Short V Short circuit power supply of the fault light TACO Open/GND Short circuit grounding or open circuit of the engine speed output TACO Short V Short circuit power supply of the engine speed output Crank Sensor Crankshaft position Malfunction sensor malfunction Cyl2 Ign Short GND Short circuit grounding of the ignition coil of cylinder 2 Cyl2 Ign Short V Short circuit power supply of the ignition coil of cylinder 2 Cyl1 IGBT over Overcurrent of the current ignition module of cylinder 1 Cyl2 IGBT over Overcurrent of the current ignition module of cylinder 2 Inj_2 Open/GND Short circuit grounding or open circuit of the injector of cylinder 2
- 170 -

12

11

19 95

96

79

23

P0265

Inj_2 Short V

Short circuit power 5 supply of the injector of cylinder 2

- 171 -

Circuit Diagram
QJ125T-30 ELECTROJETELECTRICITY PRINCIPLE DIAGRAM
CLOCK FAN LIGHT WATER TEMPERATURE LIGHT
B N/G

FUELMETER SPEEDOMETER LIGHT CONTROL SWITCH START SWITCH POWER LOCK BRAKE SWITCH
ON OFF
LOCK

R Y B

BL/W1 R/W B

W/Y W/BL B

B B/G Y B G/W G/B

BATTERY

RELAY

RECTIFIER

DIAGNOSE

SKID SENSOR

PUMP RELAY

BLACK
R R/W Y O/BL

B BL LBL N R/W O G/W G/B

DARK GREEN BLACK/RED ORANGE/YELLOW RED/GREEN PURPLE

Dg B/R N/Y R/G P G/BL Gr Y R O/W

INSTRUMENT LIGHT TURN SIGNAL INDICATOR LIGHT

Y/R O/BL R/W


G/Y R/W

BLUE LIGHT BLUE BROWN RED/WHITE

W/BL

B W/Y

BEAM INDICATOR LIGHT FAILURE LIGHT

BL B P R/W N/B R/W

15A FUSE 30A


G/Y B R W W W B

B R/W BL/B

B Dg

R B/R

YELLOW/RED ORANGE GREEN/WHITE GREEN/BLACK YELLOW/GREEN

Y/R GREEN/BLUE GRAY YELLOW RED

Y/G ORANGE/WHITE

N/B

R/W

BL

G/W R/W W/BL G/B B/G R

N/G N/W W/Y

Y/R G/Y P R/W O/BL

R/W

O/BL

LR B Gr

G/Y B

R W W W B

B R/N W/B R/P N/BL R/W B G/W B G/W

RIGHT TURN LIGHT

B G/W

RIGHT TURN LIGHT RIGHT TURN LIGHT

HEAD LIGHT

BL B Y

Y B P

TAIL/BRAKE LIGHT
HEAD LIGHT
Y B LBL B G/B

LEFT TURN LIGHT LEFT TURN LIGHT

LEFT TURN LIGHT

B G/B

B G/B

HORN

B N

N R/W BL Y/R LBL O R/W

G/B B G/W

G/R R/P

R/N W/B B/BL LR BL/B N/BL R/G Dg Y/G

N/W N/B

B/O W/Gr W/O W/N

Gr

B/W W/P

BL/W W/G

R/W Dg R/W B G/W G/B R G/Y W W W W/G BL/W

B/BL B/R B/O B/BL Y/G B/BL B/BL B/G W/N G/R R/G W/Gr B/R W/O

B/R B/W W/P

B/R

N/G B
W/G BL/W

R/W N/G
N R/W
BL Y/R LBL
G/B O G/W

B N/G
FAN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

ALARM SYSTEM OXYGEN SENSOR INTAKE AIR FUEL LIFT PUMP IGNITION COIL OIL RTOMIZER SOLAR TERM POSITION TEMPERTURE SENSOR ENGINE COOLANT SPARK PLUG SENSOR TEMPERATURE SENSOR

>98

TURN SWITCH LIGHT SWITCH BRAKE SWITCH HORN SWITCH

- 172 MAGNETO NEUTRAL SWITCH