Trk251 Service Manual

TRK 251
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Motorcycle Maintenance
Manual
1
Motorcycle Maintenance Manual
All rights are reserved！ Without the prior written consent of Zhejiang Qianjiang Motorcycle Co., Ltd., no
one may copy any of the contents of this Maintenance Manual, or store any contents of this Maintenance Manual
in the retrieval system or disseminate such contents in any form (electronic form, mechanical copying, recording,
etc.).
Our company has made every effort to ensure that the contents of this Manual are complete and accurate, but
we assume no responsibility for any inaccuracies or omissions that may exist in this Manual.
Our company reserves the right to modify this Manual without prior notice and is not obliged to modify the
products previously manufactured. For the latest product improvement information prepared after the publication
of this Manual, please consult your motorcycle dealer.
All contents of this Manual are prepared in accordance with the latest product information. The illustrations and
pictures in this Manual are for reference only and may differ from actual parts.
2
LIST OFABBREVIATIONS
A Ampere lb lb
ABDC After bottom dead center m Meter
AC Alternating current min minutes
ATDC After top dead center N Newton
BBDC Before bottom dead center Pa Pascal
BDC Bottom dead center PS Horsepower
BTDC Before top dead center psi Pound per square inch
℃ Degrees Celsius r Revolution
DC Direct current rpm Revolutions per minute
F Farad TDC Top dead center
℉ Degree Fahrenheit TIR Total indicator reading
ft Foot V Volt
g Gram W Watt
h Hour Ω Ohm
L Liter
Important notice

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emaiL 54107871@qq.com
3
Exhaust Emission Control Information
In order to protect our common environment, Zhejiang Qianjiang Motorcycle Co., Ltd. introduced a
crankcase blow-by gas filtration system (1) and an exhaust emission control system (2) that meet the applicable
regulations of the US Environmental Protection Agency and the California Air Resources Board. In addition, a
fuel vapor recovery system (3) that complies with the applicable regulations of California Air Resources Board is
installed for motorcycles sold only in California.
1. Crankcase blow-by gas filtration system
This system can prevent the crankcase gas from being discharged into the atmosphere. The crankcase gas
passes through the oil separator and is forced into the intake side of the engine. When the engine is running, the
gas is sent to the combustion chamber and then burned with the fuel and air sent by the fuel injection system.
2. Exhaust emission control system
This system can reduce the amount of pollutants emitted by the exhaust of this motorcycle into the
atmosphere. The fuel injection system, ignition system and exhaust system of this motorcycle have been carefully
designed and assembled to ensure high engine efficiency and low pollutant emissions.
The exhaust system of this motorcycle contains a catalytic converter system.
3. Fuel vapor recovery system
The fuel vapor in the fuel injection system is not discharged into the atmosphere, but is forced into the
working engine and then burned. If the engine is not started, the steam will be stored in the canister. If it is a liquid
fuel, it is sucked into the oil separator and then returned to the fuel tank.
The Atmospheric Protection Act is a federal law used to deal with the pollution of motor vehicles and
contains the provisions commonly known as the “Regulations on the Modification of the Atmospheric Protection
Act”.
"203(a) Prohibit conducting or abetting others from doing the followings:
(3) (A) Before the final purchaser purchases or receives any motorcycle or motorcycle engine, no one shall
dismantle any parts mounted on the motorcycle or motorcycle engine in accordance with the provisions of this
Manual or damage them; any manufacture or dealer shall not deliberately dismantle or damage any parts after
selling or delivering any motorcycle or motorcycle engine to the final purchaser.
(3) (B) After the sale or delivery of any motorcycle or motorcycle engine to the final purchaser, any person
engaged in the repair, maintenance, sale, leasing or trading of a motorcycle or motorcycle engine or a person
operating a motorcycle fleet shall not dismantle any parts mounted on the motorcycle or motorcycle engine in
accordance with the provisions of this Manual or damage them..."
Remarks
The meaning of “dismantling or damaging any component” is generally considered as follows:
1. Temporary removal of any part for maintenance or temporary failure to operate the part does not belong to
“modification”.
2. The following cases belong to “modification”:
a. Incorrectly adjust the components of vehicle, so that the exhaust gas exceeds the emission standards.
b. Use replacement parts or accessories, thus affecting the performance or durability of motorcycle.
c. Add parts or accessories, which makes the motorcycle out of standard.
d. Permanently dismantle, disassemble or damage any parts of exhaust emission control system.
All dealers are advised to comply with the above provisions of federal law and any violators will be subject
to civil penalties.
4
It is strictly forbidden to modify the noise
control system
Federal law prohibits any one from conducting or abetting others to do the followings: (1) Any one
dismantles any part of motorcycle and makes it unable to operate before the final purchaser purchases or receives
any motorcycle or during the use of motorcycle, unless such parts need to be maintained, repaired or replaced; (2)
any one continue to use the motorcycle after dismantling any part of motorcycle and making it unable to operate.
The following behaviors belong to “modification of motorcycle”:
 Replace the original exhaust system or silencer with parts that do not comply with federal regulations.
 Remove silencer or its internal components.
 Remove the air filter or its cover.
 Modify the muffler or air intake system by cutting, drilling or other means, to increase the noise level.
Important notice

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whatsapp: 008613758665150
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5
Contents
Exhaust Emission Control Information ................................................................................................................... 4

It is strictly forbidden to modify the noise control system ...................................................................................... 5
Introduction .............................................................................................................................................................. 1
Chapter I Basic Information .....................................................................................................................................2
Maintenance instructions ................................................................................................................................. 3
Installation of battery ............................................................................................................................... 3
Sharp edge of part .................................................................................................................................... 3
Solvent ......................................................................................................................................................3
Cleaning the motorcycle before disassembly .......................................................................................... 4
Sorting out and cleaning the removed parts ............................................................................................ 4
Storing the removed parts ........................................................................................................................ 4
Check ........................................................................................................................................................4
Replacement part ..................................................................................................................................... 5
Assembly sequence ..................................................................................................................................5
Fastening sequence .................................................................................................................................. 5
Locking torque ......................................................................................................................................... 5
Force .........................................................................................................................................................6
Gasket, O-ring ..........................................................................................................................................6
Liquid gasket, locking agent ....................................................................................................................6
Press fitting .............................................................................................................................................. 6
Ball Bearing and Needle Bearing ............................................................................................................ 7
Oil seal, grease seal ..................................................................................................................................7
Circlip, cotter pin ..................................................................................................................................... 7
Lubrication ............................................................................................................................................... 8
Engine rotation direction ......................................................................................................................... 8
Wire .......................................................................................................................................................... 8
Cable connector check ............................................................................................................................. 8
1. Disconnect ....................................................................................................................................9
2. Check ........................................................................................................................................... 9
3. Check ........................................................................................................................................... 9
4. Check ........................................................................................................................................... 9
5. Check ......................................................................................................................................... 10
Cable arrangement ................................................................................................................................. 10
Tool .........................................................................................................................................................11
Model information ......................................................................................................................................... 12
China ...................................................................................................................................................... 12
Europe .................................................................................................................................................... 13
Non-European ........................................................................................................................................ 14
Important recognition .............................................................................................................................15
Basic specifications ........................................................................................................................................16
General Technical Parameters ........................................................................................................................17
Unit conversion table ..................................................................................................................................... 21
6
Chapter II Regular Maintenance ............................................................................................................................22
Regular maintenance table .............................................................................................................................24
Torque and locking agent ...............................................................................................................................26
Main locking torque specifications ........................................................................................................26
Locking torque and related parameters of nuts, bolts and screws .........................................................30
Technical parameters ......................................................................................................................................31
Regular maintenance procedures ................................................................................................................... 34
Fuel injection system (EFI) ....................................................................................................................34
Check throttle control system ........................................................................................................ 34
Check idle speed ............................................................................................................................ 35
Check fuel hose (fuel leak, hose rupture, hose installation) ..........................................................35
Check fuel vapor recovery system (models in China, Europe and the US) ..................................36
Cooling system .......................................................................................................................................38
Check coolant level ........................................................................................................................38
Check radiator pipes (coolant leakage, radiator pipes damage, installation status of radiator pipes)
..........................................................................................................................................................38
Engine cylinder head and cylinder head cover ......................................................................................39
Check valve clearance ................................................................................................................... 39
Adjusting the valve clearance ........................................................................................................40
Check whether the air inlet unit has been damaged ...................................................................... 44
Clutch ..................................................................................................................................................... 45
Check if the clutch control system is normal ................................................................................ 45
Check the free stroke of clutch handle .......................................................................................... 45
Wheel/tire ...............................................................................................................................................46
Check the tire pressure ...................................................................................................................46
Check wheel / tire for wear ............................................................................................................46
Check the wear of tread ................................................................................................................. 46
Check whether the wheel bearing has been damaged ................................................................... 47
Final drive mechanism ...........................................................................................................................48
Check the lubrication state of drive chain ..................................................................................... 48
Check whether the drive chain is slack ......................................................................................... 48
Adjust drive chain slackness ..........................................................................................................48
Check wheel alignment ..................................................................................................................50
Check the wear of drive chain ....................................................................................................... 50
Check the wear of chain guide .......................................................................................................51
Brake ...................................................................................................................................................... 52
Check brake hoses and brake lines for damage and ensure their installation status .....................52
Free stroke of front brake ...............................................................................................................52
Free stroke of rear brake ................................................................................................................ 52
Check brake ................................................................................................................................... 53
Check brake fluid level .................................................................................................................. 53
Inspection of wear of brake pad .....................................................................................................54
Check brake light switch ................................................................................................................55
Check the output voltage of speed sensor ..................................................................................... 55
Suspension system ................................................................................................................................. 57
Check front fork / rear shock absorber .......................................................................................... 57
7
Check the front fork shock absorber for oil leakage ..................................................................... 57
Check the rear shock absorber for oil leakage ...............................................................................58
Steering system ...................................................................................................................................... 59
Check steering clearance ............................................................................................................... 59
Adjust the steering seat properly ................................................................................................... 59
Lubricate steering stem bearings ................................................................................................... 60
Electrical system .................................................................................................................................... 61
Check lights and switches ..............................................................................................................61
Check the headlight accuracy ........................................................................................................ 65
Check the sidestand flameout switch .............................................................................................66
Check emergency stop switch ........................................................................................................67
Others ..................................................................................................................................................... 68
Lubricate frame parts ..................................................................................................................... 68
Check the tightness of bolts, nuts and fasteners ............................................................................ 69
Replacement of part ............................................................................................................................... 71
Replacement of air filter element .................................................................................................. 71
Replacement of fuel hose ...............................................................................................................74
Replacement of coolant ................................................................................................................. 75
Replacement of radiator hose ........................................................................................................ 78
Replacement of oil ......................................................................................................................... 79
Replacement of brake hose ............................................................................................................ 80
Replacement of rear brake hose .....................................................................................................82
Replacement of brake fluid ............................................................................................................83
Replacement of rubber parts of master cylinder ............................................................................86
Replacement of rubber parts of caliper............................................................................................88
Replacement of spark plug.............................................................................................................. 92
Chapter III Electronic Fuel Injection (EFI) ........................................................................................................... 93
Introduction to EFI .........................................................................................................................................96
EFI system ......................................................................................................................................................97
EFI part position .............................................................................................................................................99
Technical parameters ....................................................................................................................................106
Fuel tank .......................................................................................................................................................108
Exploded view of fuel tank ..................................................................................................................108
Fuel vapor recovery system ................................................................................................................. 110
Fuel tank ...............................................................................................................................................111
Disassemble fuel tank .................................................................................................................. 111
Check the fuel tank ...................................................................................................................... 112
Install the fuel tank .......................................................................................................................112
Precautions for EFI overhaul ....................................................................................................................... 113
Precautions for EFI overhaul ............................................................................................................... 113
ECU................................................................................................................................................................ 115
Engine controller (MT05 ECU) ........................................................................................................... 115
ECU appearance ...................................................................................................................................115
ECU disassembly ................................................................................................................................. 115
ECU installation ................................................................................................................................... 115
Precautions for ECU ............................................................................................................................ 116
8
ECU power supply requirements ......................................................................................................... 116
ECU temperature requirements ............................................................................................................116
Fuel pump .....................................................................................................................................................117
Working principle of fuel pump ...........................................................................................................117
Appearance of fuel pump .....................................................................................................................117
Fuel pump composition ........................................................................................................................118
Fuel pump label and logo .....................................................................................................................118
Working environment of fuel pump .....................................................................................................119
Maintenance process of fuel pump: ..................................................................................................... 119
Safety protection: ......................................................................................................................... 119
Fault diagnosis of fuel pump assembly: ...................................................................................... 120
Disassembly of fuel pump assembly: .......................................................................................... 120
Installation of fuel pump assembly: .............................................................................................120
Fuel pressure release process: ......................................................................................................121
Fuel leakage check process: .........................................................................................................121
Notes for use: ....................................................................................................................................... 121
Throttle body: ...............................................................................................................................................123
Working principle of throttle body: ..................................................................................................... 123
Appearance of throttle body: ............................................................................................................... 123
Technical parameters ........................................................................................................................... 124
Throttle body: ...............................................................................................................................124
Throttle position sensor: .............................................................................................................. 124
Idle air control valve: ...................................................................................................................124
Operating temperature of throttle ........................................................................................................ 124
Disassembly of throttle body ............................................................................................................... 124
Cleaning method of throttle ................................................................................................................. 124
Installation of throttle body ..................................................................................................................124
Notes for the installation of throttle body ............................................................................................125
Notes for the use of throttle body ........................................................................................................ 125
Fuel injector ................................................................................................................................................. 126
Working principle of fuel injector ....................................................................................................... 126
Appearance of fuel injector ..................................................................................................................126
Fuel injector seal .................................................................................................................................. 126
O-ring seal connected to oil rail or oil injection cap ................................................................... 127
O-ring seal connected to intake pipe end.......................................................................................127
List of recommended lubricants .................................................................................................. 127
Overvoltage impact of fuel injector .....................................................................................................127
Temperature range of fuel injector: ..................................................................................................... 127
Fuel contaminants of fuel injector ....................................................................................................... 128
Fuel injector harness arrangement ....................................................................................................... 128
Notes for use of fuel injector ............................................................................................................... 128
Installation requirements for fuel injector ........................................................................................... 129
Replacement method of fuel injector ...................................................................................................129
Replaceability of fuel injector ............................................................................................................. 130
Blocking of fuel injector ...................................................................................................................... 130
Engine water temperature sensor .................................................................................................................131
9
Working principles of engine water temperature sensor ..................................................................... 131
Appearance of engine water temperature sensor .................................................................................131
Installation requirements for engine water temperature sensor .......................................................... 131
Operating environment of engine water temperature sensor ...............................................................131
Electrical environment of engine water temperature sensor ............................................................... 131
Cleaning of engine water temperature sensor ..................................................................................... 132
Inlet temperature sensor ...............................................................................................................................133
Working principle of intake temperature sensor ..................................................................................133
Appearance of intake temperature sensor ............................................................................................133
Pin position definition and function diagram ...................................................................................... 134
Installation position of intake temperature sensor ...............................................................................134
Cleaning ............................................................................................................................................... 134
Inlet pressure sensor .....................................................................................................................................135
Working principles of inlet pressure sensor .........................................................................................135
Appearance of inlet pressure sensor .................................................................................................... 135
Operating environment ........................................................................................................................ 135
Storage environment ............................................................................................................................ 135
Electrical environment ......................................................................................................................... 136
Pin definition ........................................................................................................................................136
Position .................................................................................................................................................136
Cleaning ............................................................................................................................................... 136
Oxygen sensor ..............................................................................................................................................138
Working principle of oxygen sensor ....................................................................................................138
Appearance of oxygen sensor .............................................................................................................. 138
Installation requirements ......................................................................................................................138
Oxygen sensor pin definition: ..............................................................................................................139
Characteristic curve ............................................................................................................................. 139
Requirements for fuel quality .............................................................................................................. 140
Idle speed stepper motor .............................................................................................................................. 141
Working principle of idle speed stepper motor ................................................................................... 141
Appearance of idle speed stepper motor ..............................................................................................141
Pin definition ........................................................................................................................................142
Characteristic parameters: ....................................................................................................................142
Cleaning ............................................................................................................................................... 142
Canister solenoid valve (ECP) .....................................................................................................................143
Overview of working principle ............................................................................................................143
Appearance ...........................................................................................................................................143
Pin of ECP solenoid valve ................................................................................................................... 143
Fault Maintenance and Diagnosis Method of EFI System ..........................................................................145
Conduct diagnosis directly using the flashing fault lamp at meter ..................................................... 145
Diagnose fault using diagnostic apparatus .......................................................................................... 147
Check fault using diagnostic software PCHUD .................................................................................. 148
10
Common troubleshooting methods for electronic fuel inject system ..........................................................155
Maintenance tool ..................................................................................................................................155
Engine working data flow displayed by diagnostic apparatus ............................................................ 155
Step I ............................................................................................................................................ 155
Step II ...........................................................................................................................................155
Step III ..........................................................................................................................................156
Simple troubleshooting ........................................................................................................................ 156
Daily use and maintenance .......................................................................................................... 156
Fault phenomenon-Start fault ...................................................................................................... 156
Fault phenomenon—Start failure with tempering .......................................................................158
Fault phenomenon—Instable idle speed ..................................................................................... 158
Fault phenomenon—Too high or too low idle speed (idle speed is obviously inconsistent with
target idle speed) .......................................................................................................................... 158
Fault phenomenon—Instable idle speed with deceleration and flameout .................................. 158
Fault phenomenon—Insufficient power of deceleration .............................................................158
Fault phenomenon—Slight burning phenomenon ...................................................................... 158
Fault phenomenon—Fault lamp is on, but fault code is inconsistent with fault .........................158
Fault phenomenon—Extremely high fuel consumption ............................................................. 158
Chapter IV Cooling System ................................................................................................................................. 161
Exploded view of cooling system ................................................................................................................162
Exploded view of water pump ..................................................................................................................... 164
Coolant flow diagram .................................................................................................................................. 165
Coolant ......................................................................................................................................................... 168
Check coolant for deterioration ........................................................................................................... 168
Check coolant level ..............................................................................................................................168
Drain the coolant ..................................................................................................................................168
Add the coolant .................................................................................................................................... 168
Detect pressure .....................................................................................................................................168
Flush cooling system ........................................................................................................................... 168
Disassembly/installation of coolant reserve tank.................................................................................. 169
Water pump .................................................................................................................................................. 170
Disassembly of water pump .................................................................................................................170
Installation of water pump ................................................................................................................... 171
Check water pump impeller .................................................................................................................171
Radiator ........................................................................................................................................................ 172
Disassembly of radiator and radiator fan .............................................................................................172
Installation of radiator and radiator fan ............................................................................................... 173
Inspection of Radiator ..........................................................................................................................173
Inspection of radiator cover................................................................................................................... 175
Inspection of radiator filler.................................................................................................................. 176
Thermostat ....................................................................................................................................................177
Disassembly of thermostat ...................................................................................................................177
Installation of thermostat ..................................................................................................................... 178
Inspection of thermostat .......................................................................................................................178
Hose and pipeline .........................................................................................................................................180
11
Installation of hose ...............................................................................................................................180
Check hose ........................................................................................................................................... 180
Water temperature sensor .............................................................................................................................181
Disassembly / installation of water temperature sensor ...................................................................... 181
Check water temperature sensor ..........................................................................................................181
Chapter V Engine .................................................................................................................................................182
Lubrication system .......................................................................................................................................184
Exploded view of fuel pump ................................................................................................................184
Oil flow diagram .................................................................................................................................. 186
Preparatory information .......................................................................................................................186
Fuel pump.............................................................................................................................................. 188
Disassembly of fuel pump ........................................................................................................... 188
Inspection of fuel pump ............................................................................................................... 189
Installation of fuel pump ..............................................................................................................190
Sub-assembly of cylinder head .................................................................................................................... 191
Exploded view of cylinder head .......................................................................................................... 191
Exploded view of camshaft and valve ................................................................................................. 193
Exploded view of timing drive mechanism .........................................................................................194
Special tools and sealants .................................................................................................................... 197
Cylinder head ....................................................................................................................................... 199
Disassembly of cylinder head ......................................................................................................199
Valve decomposition ....................................................................................................................201
Inspection of combustion chamber ..............................................................................................201
Inspection of the cylinder head joint surface............................................................................... 201
Inspection of intake and exhaust springs .....................................................................................202
Inspection of valve stem .............................................................................................................. 202
Inspection of valve guide .............................................................................................................203
Replacement of valve guide .........................................................................................................203
Adjustment of valve seat ring ...................................................................................................... 204
Installation of cylinder head ........................................................................................................ 206
Tensioner ..............................................................................................................................................207
Function of tensioner ................................................................................................................... 207
Disassembly of tensioner ............................................................................................................. 207
Assembly of tensioner ................................................................................................................. 207
Inspection of tensioner .................................................................................................................207
Cylinder block and piston ............................................................................................................................ 208
Exploded view of cylinder body ..........................................................................................................208
Exploded view of piston / crankshaft .................................................................................................. 209
Technical parameters ............................................................................................................................211
Inspection and replacement of cylinder block .....................................................................................212
Disassembly of cylinder block .....................................................................................................212
Installation of cylinder ................................................................................................................. 212
12
Inspection of cylinder block ........................................................................................................ 213
Piston ....................................................................................................................................................213
Disassembly of piston ..................................................................................................................213
Installation of piston .................................................................................................................... 214
Check the piston, piston pin and piston ring ............................................................................... 215
Crankshaft connecting rod ........................................................................................................................... 218
Exploded view of crankshaft connecting rod ...................................................................................... 218
Crankshaft combination .......................................................................................................................222
Disassembly of crankshaft connecting rod combination .............................................................222
Assembly ......................................................................................................................................222
Inspection ..................................................................................................................................... 222
Balance shaft ........................................................................................................................................ 223
Function of balancer shaft ........................................................................................................... 223
Disassembly of balancer shaft ..................................................................................................... 223
Assembly of balancer shaft ..........................................................................................................224
Inspection of balancer shaft ......................................................................................................... 224
Clutch ........................................................................................................................................................... 225
Exploded view of clutch ...................................................................................................................... 225
Special tool ...........................................................................................................................................227
Disassembly of clutch ..........................................................................................................................228
Installation of clutch ............................................................................................................................ 231
Inspection of clutch ..............................................................................................................................231
Gearshift mechanism ................................................................................................................................... 232
Exploded view of gearshift mechanism ...............................................................................................232
Disassembly of gearshift mechanism .................................................................................................. 235
Installation of gearshift mechanism .....................................................................................................236
Inspection of gearshift mechanism ...................................................................................................... 236
Disassembly of primary / auxiliary shaft component ..........................................................................236
Inspection of primary / auxiliary shaft component ..............................................................................240
Chapter VI Finished Motorcycle ......................................................................................................................... 240
Wheel/tire .....................................................................................................................................................246
Exploded view of front wheel/tire ....................................................................................................... 246
Exploded view of rear wheel/tire .........................................................................................................247
Special tool ...........................................................................................................................................250
Wheel (rim) .......................................................................................................................................... 251
Disassembly of front wheel ......................................................................................................... 251
Installation of front wheel ............................................................................................................252
Disassembly of rear wheel ...........................................................................................................253
Installation of rear wheel ............................................................................................................. 254
Inspection of wheel ......................................................................................................................255
Inspection of wheel axle .............................................................................................................. 256
13
Adjustment of static balance of rim .............................................................................................256
Adjustment / inspection of tire pressure ......................................................................................258
Inspection of tire .......................................................................................................................... 258
Disassembly of tire ...................................................................................................................... 258
Installation of tire .........................................................................................................................259
Hub bearing ..........................................................................................................................................262
Disassembly of hub bearing .........................................................................................................262
Installation of hub bearing ........................................................................................................... 262
Inspection of hub bearing ............................................................................................................ 263
Hub bearing lubrication ............................................................................................................... 263
Drive mechanism ......................................................................................................................................... 264
Exploded view of drive mechanism .................................................................................................... 264
Special tool ...........................................................................................................................................267
Drive chain ...........................................................................................................................................268
Inspection of slackness of drive chain .........................................................................................268
Inspection / adjustment of wheel alignment ................................................................................268
Insppection of wear of drive chain .............................................................................................. 268
Drive chain lubrication ................................................................................................................ 268
Disassembly of drive chain ..........................................................................................................268
Installation of drive chain ............................................................................................................ 269
Sprocket, collar, collar bearing.............................................................................................................. 271
Disassembly of rear sprocket .......................................................................................................271
Installation of rear sprocket ......................................................................................................... 271
Disassembly of collar bearing....................................................................................................... 272
Installation of collar bearing ........................................................................................................272
Inspection of collar bearing ......................................................................................................... 272
Lubrication of collar bearing ....................................................................................................... 273
Inspection of damper of collar .....................................................................................................273
Inspection of wear of drive chain ................................................................................................ 273
Check the deformation of rear sprocket ...................................................................................... 274
Brake ............................................................................................................................................................ 275
Exploded View of brake .......................................................................................................................275
Special tool ...........................................................................................................................................278
Brake lever, brake pedal .......................................................................................................................279
Adjustment of position of brake lever ......................................................................................... 279
Adjustment of position of brake pedal ........................................................................................ 279
Disassembly of brake pedal ......................................................................................................... 280
Installation of brake pedal ........................................................................................................... 280
Caliper ..................................................................................................................................................282
Disassembly of front caliper ........................................................................................................282
Disassembly of rear caliper ......................................................................................................... 282
Installation of caliper ................................................................................................................... 282
14
Assembly of front caliper ............................................................................................................ 283
Diassembly of rear caliper ........................................................................................................... 283
Assembly of rear caliper .............................................................................................................. 283
Inspection of fluid sea of caliper for damage .............................................................................. 283
Inspection of dust seal of caliper for damage ..............................................................................283
Inspection of the caliper piston and brake cylinder for damage ................................................. 284
Brake pad ............................................................................................................................................. 284
Disassembly of front brake pad ................................................................................................... 284
Installation of front brake pad ......................................................................................................285
Disassembly of rear brake pad .....................................................................................................285
Installation of rear brake pad....................................................................................................... 286
Inspection of wear of brake pad ...................................................................................................286
Master cylinder .................................................................................................................................... 286
Disassembly of front master cylinder ..........................................................................................286
Disassembly of rear master cylinder ........................................................................................... 288
Installation of rear master cylinder ..............................................................................................289
Assembly of master cylinder ....................................................................................................... 289
Check the master cylinder (visual inspection) .............................................................................289
Brake disc .............................................................................................................................................289
Disassembly of front brake disc .................................................................................................. 290
Disassembly of rear brake disc .................................................................................................... 290
Installation of brake disc ..............................................................................................................291
Inspection of wear of brake disc ..................................................................................................291
Inspection of deformation of brake disc ......................................................................................292
Brake fluid ............................................................................................................................................292
Inspection of level of brake fluid .................................................................................................292
Replacement of brake fluid ..........................................................................................................292
Exhaust the air inside the brake line ............................................................................................292
Brake hose ............................................................................................................................................293
Disassembly / installation of brake hose and brake line ............................................................. 293
Inspection of brake hoses and brake lines ................................................................................... 293
Anti-lock brake system (ABS) .............................................................................................................294
Part position ................................................................................................................................. 294
ABS system circuit diagram ........................................................................................................ 295
Pin name .......................................................................................................................................296
ABS overhaul ...............................................................................................................................297
ABS diagnostic flow chart ...........................................................................................................301
Questions need to be asked for the rider ..................................................................................... 302
ABS hydraulic mechanism .......................................................................................................... 310
Speed sensor .................................................................................................................................314
Suspension system ....................................................................................................................................... 318
Exploded view of front suspension system ......................................................................................... 318
15
Exploded view of rear suspension system ...........................................................................................320
Special tool ...........................................................................................................................................323
Front shock absorber ............................................................................................................................324
Disassembly of front shock absorber ...........................................................................................324
Installation of front shock absorber ............................................................................................. 324
Replacement of front shock absorber fluid ................................................................................. 325
Inspection of inner tube and outer tube ....................................................................................... 330
Inspection of dust seal ..................................................................................................................330
Inspection of spring tension .........................................................................................................331
Rear shock absorber .............................................................................................................................332
Adjustment of pretightening force of spring ............................................................................... 332
Disassembly of rear shock absorber ............................................................................................ 333
Assembly of rear shock absorber .................................................................................................334
Inspection of rear shock absorber ................................................................................................ 334
Rear swing arm .................................................................................................................................... 335
Disassembly of swing arm ...........................................................................................................335
Installation of swing arm ............................................................................................................. 336
Disassembly of swing arm bearing ..............................................................................................337
Installation of swing arm bearing ................................................................................................ 337
Inspection of swing arm bearing ................................................................................................. 337
Inspection of chain guide .............................................................................................................338
Control system ............................................................................................................................................. 339
Exploded view of control system ........................................................................................................ 339
Special tool ...........................................................................................................................................341
Control system ..................................................................................................................................... 342
Inspection of control system ........................................................................................................342
Adjustment of control system ......................................................................................................342
Handlebar ............................................................................................................................................. 343
Disassembly of handlebar ............................................................................................................343
Installation of handlebar .............................................................................................................. 344
Steering stem ........................................................................................................................................346
Disassembly of steering stem and steering stem bearing ............................................................ 346
Installation of steering stem and steering stem bearing .............................................................. 347
Lubrication of steering stem bearing ........................................................................................... 349
Inspection of deformation of steering stem ................................................................................. 349
Frame ............................................................................................................................................................350
Exploded view of frame .......................................................................................................................350
Exploded view of left footpeg ............................................................................................................. 352
Exploded view of right footpeg ........................................................................................................... 354
Exploded view of muffler...................................................................................................................... 356
Exploded view of rack and luggage carrier ......................................................................................... 358
Exploded view of fender ......................................................................................................................360
Exploded view of headlight cover ....................................................................................................... 362
Exploded view of cowling ................................................................................................................... 364
16
Exploded view of fuel tank cover ........................................................................................................366
Exploded view of seat cushions and covers ........................................................................................ 368
Exploded view of engine accessories .................................................................................................. 370
Seat cushion ......................................................................................................................................... 371
Disassembly of seat cushion ........................................................................................................371
Installation of seat cushion .......................................................................................................... 371
Cover .................................................................................................................................................... 372
Disassembly of left cover ............................................................................................................ 372
Installation of left cover ...............................................................................................................372
Disassembly of right cover .......................................................................................................... 372
Installation of right cover .............................................................................................................372
Rear rack and side case bracket ........................................................................................................... 374
Disassembly of side case bracket ................................................................................................ 374
Installation of side case bracket ...................................................................................................374
Disassembly of rear rack ............................................................................................................. 375
Installation of rear rack ................................................................................................................ 376
Side cover .............................................................................................................................................377
Disassembly of side cover ........................................................................................................... 377
Installation of side cover ..............................................................................................................377
Rear fender ...........................................................................................................................................378
Disassembly of rear fender .......................................................................................................... 378
Installation of rear fender .............................................................................................................378
Front fender ..........................................................................................................................................379
Disassembly of front fender .........................................................................................................379
Installation of front fender ........................................................................................................... 379
Windshield and cowling .......................................................................................................................380
Disassembly of windshield .......................................................................................................... 380
Disassembly of cowling ...............................................................................................................381
Installation of windshield and cowling 3.........................................................................................81
Headlight cover and left and right front panel .....................................................................................382
Disassembly of headlight cover ...................................................................................................382
Installation of headlight cover and left and right panel ...............................................................385
Fuel tank cover.......................................................................................................................................386
Disassembly of fuel tank cover ....................................................................................................386
Installation of fuel tank cover ...................................................................................................... 386
Frame ....................................................................................................................................................387
Disassembly of frame .................................................................................................................. 387
Installation of frame .....................................................................................................................387
Inspection of frame...................................................................................................................... 388
Sidestand .............................................................................................................................................. 389
Disassembly of sidestand .............................................................................................................389
Installation of sidestand ............................................................................................................... 389
17
Left front footpeg .................................................................................................................................390
Disassembly of left front footpeg.................................................................................................. 390
Installation of left front footpeg ...................................................................................................390
Left rear footpeg .................................................................................................................................. 392
Disassembly of left rear footpeg ..................................................................................................392
Installation of left rear footpeg .................................................................................................... 392
Front right footpeg ............................................................................................................................... 393
Disassembly of front right footpeg ..............................................................................................393
Installation of front right footpeg ................................................................................................ 393
Rear right footpeg ................................................................................................................................ 394
Disassembly of rear right footpeg ............................................................................................... 394
Installation of rear right footpeg ..................................................................................................394
Muffler ................................................................................................................................................. 395
Disassembly of muffler ................................................................................................................395
Installation of muffler .................................................................................................................. 397
Disassembly/installation of engine ...................................................................................................... 398
Exploded view of disassembly/installation of engine ................................................................. 398
Disassembly of engine ................................................................................................................. 400
Installation of engine ................................................................................................................... 404
Chapter VII Electrical System ............................................................................................................................. 407
Precautions ................................................................................................................................................... 410
Special tool ...................................................................................................................................................412
Electrical wiring ...........................................................................................................................................413
Wiring check ........................................................................................................................................ 413
Charging system ...........................................................................................................................................414
Charging system circuit diagram ......................................................................................................... 414
Battery ..................................................................................................................................................415
Disassembly of battery .................................................................................................................415
Installation of battery ................................................................................................................... 415
Activation of battery .................................................................................................................... 416
First charge ...................................................................................................................................417
Inspection of charging state ......................................................................................................... 419
Alternator ............................................................................................................................................. 421
Disassembly of alternator............................................................................................................ 421
Inspection of alternator ................................................................................................................ 422
Installation of alternator ...............................................................................................................422
Voltage regulator/rectifier .................................................................................................................... 423
Disassembly of rectifier ............................................................................................................... 423
Inspection of circuit at main wiring terminal .............................................................................. 423
Inspection of rectifier ...................................................................................................................423
Installation of rectifier ................................................................................................................. 423
Ignition system .............................................................................................................................................424
Ignition system circuit diagram ........................................................................................................... 424
Precautions for operation ..................................................................................................................... 424
Crankshaft sensor .................................................................................................................................425
18
Disassembly of crankshaft position sensor ..................................................................................425
Inspection of crankshaft position sensor ..................................................................................... 425
Ignition coil .......................................................................................................................................... 426
Disassembly of ignition coil: ....................................................................................................... 426
Inspection of ignition coil ............................................................................................................ 426
Installation of ignition coil ...........................................................................................................426
Spark plug ............................................................................................................................................ 427
Inspection of spark plug ...............................................................................................................427
Inspection ..................................................................................................................................... 427
Inspection of IC igniter ................................................................................................................ 428
ECU unit .............................................................................................................................................. 428
Ignition system troubleshooting .......................................................................................................... 429
Starter system ...............................................................................................................................................430
Starter system circuit diagram ............................................................................................................. 430
Starter motor ........................................................................................................................................ 431
Disassembly of starter motor ....................................................................................................... 431
Inspection of starter motor ...........................................................................................................431
Inspection of brush .......................................................................................................................431
Cleaning and Inspection of commutator ......................................................................................432
Inspection of brush lead ...............................................................................................................432
Inspection of right end cover assembly ....................................................................................... 433
Installation of starter motor ......................................................................................................... 433
Starter relay .......................................................................................................................................... 434
Disassembly of starter relay .................................................................................................................434
Inspection of action of starter relay ..................................................................................................... 434
Installation of starter relay ................................................................................................................... 434
Lighting system ............................................................................................................................................435
Headlight ..............................................................................................................................................435
Disassembly of headlight relay controller ...................................................................................435
Inspection of headlight relay controller .......................................................................................435
Installation of headlight relay controller ..................................................................................... 435
Disassembly of headlight .............................................................................................................436
Replacement of headlight bulb .................................................................................................... 436
Replacement of night light bulb .................................................................................................. 436
Installation of headlight ............................................................................................................... 436
Turn signal light ................................................................................................................................... 436
Disassembly of front turn signal light ......................................................................................... 436
Disassembly of rear turn signal light ...........................................................................................437
Replacement of turn signal light bulb ..........................................................................................437
Installation of turn signal light .....................................................................................................437
Disassembly of flasher .................................................................................................................437
Inspection of flasher .....................................................................................................................438
Installation of flasher ................................................................................................................... 438
Taillight ................................................................................................................................................ 438
Disassembly of taillight ............................................................................................................... 438
Replacement of taillight bulb .......................................................................................................439
19
Installation of taillight ..................................................................................................................439
License plate light ................................................................................................................................ 439
Disassembly of license plate light ............................................................................................... 439
Replacement of license plate light bulb .......................................................................................439
Installation of license plate light ..................................................................................................439
Meters ...........................................................................................................................................................440
Disassembly of meter ...........................................................................................................................440
Installation of meter ............................................................................................................................. 441
Switch and sensor and other parts ................................................................................................................442
Power lock switch ................................................................................................................................ 442
Disassembly of power lock ..........................................................................................................442
Inspection of power lock ............................................................................................................. 442
Installation of power lock ............................................................................................................ 442
Handlebar switch ................................................................................................................................. 443
Switch state (non-headlights are always on) ............................................................................... 443
Switch state (headlights are always on) .......................................................................................444
Inspection of time for turning on brake light .......................................................................................445
Adjustment of time for turning on the brake light ...............................................................................445
Inspection of switch ............................................................................................................................. 445
Connection of rear brake light switch ..........................................................................................445
Connection of sidestand switch ................................................................................................... 445
Speed sensor .........................................................................................................................................446
Disassembly of speed sensor ....................................................................................................... 446
Inspection of speed sensor ........................................................................................................... 446
Installation of speed sensor ..........................................................................................................447
Oxygen sensor ......................................................................................................................................448
Disassembly of oxygen sensor .....................................................................................................448
Inspection of oxygen sensor ........................................................................................................ 448
Installation of oxygen sensor ....................................................................................................... 448
Fuel level sensor .................................................................................................................................. 449
Disassembly of fuel level sensor ................................................................................................. 449
Inspection of fuel level sensor ..................................................................................................... 449
Installation of fuel level sensor ....................................................................................................449
Horn ......................................................................................................................................................450
Disassembly of horn .................................................................................................................... 450
Inspection of horn ........................................................................................................................ 450
Installation of horn .......................................................................................................................450
Fan ........................................................................................................................................................451
Disassembly of fan .......................................................................................................................451
Inspection of fan .......................................................................................................................... 451
Installation of fan ......................................................................................................................... 452
Water temperature switch .................................................................................................................... 453
Disassembly of water temperature switch ...................................................................................453
Inspection of water temperature switch .......................................................................................453
Installation of water temperature switch ..................................................................................... 453
Relay and fuse box ...............................................................................................................................454
20
Disassembly of relay and fuse box .............................................................................................. 454
Inspection of relay circuit ............................................................................................................ 455
Inspection of relay circuit (disconnect battery) ........................................................................... 455
Inspection of relay circuit (with battery) ..................................................................................... 455
Internal circuit of relay box ......................................................................................................... 456
Fuse ...................................................................................................................................................... 458
Disassembly of fuse ..................................................................................................................... 458
Installation of fuse ....................................................................................................................... 459
Inspection of fuse .........................................................................................................................460
Chapter VIII Appendixes ..................................................................................................................................... 461
Winding method of cables, wires and hoses ................................................................................................463
Alignment of main cable: .................................................................................................................... 464
Alignment of clutch: ............................................................................................................................ 471
Alignment of brake pipe: ..................................................................................................................... 473
Other matters: .......................................................................................................................................476
Troubleshooting guide ................................................................................................................................. 479
Diagnostic procedure for the fault that engine cannot be started or it is difficult to start the engine: 479
Starter motor does not work: ....................................................................................................... 479
The starter motor is rotating, but the engine does not work: .......................................................479
The engine does not run: ..............................................................................................................479
Fuel does not flow: ...................................................................................................................... 479
No sparks; sparks are weak: ........................................................................................................ 479
There is a problem with the fuel/air mixture: ..............................................................................480
Too low cylinder pressure: ...........................................................................................................480
It cannot run properly at a low speed: ................................................................................................. 480
Sparks are weak: .......................................................................................................................... 480
The cylinder pressure is low: .......................................................................................................480
Others: ..........................................................................................................................................481
It cannot run properly at a high speed or the power is insufficient: ....................................................481
Ignition is abnormal: ....................................................................................................................481
There is a click sound: ................................................................................................................. 481
Others: ..........................................................................................................................................482
The temperature is too high: ................................................................................................................ 482
The muffler is overheated: ...........................................................................................................482
The cylinder pressure is high: ......................................................................................................482
The output force of engine is insufficient: ...................................................................................482
Not properly lubricated:.................................................................................................................482
The fuel cooler is abnormal: ........................................................................................................ 482
Meter is abnormal: ....................................................................................................................... 482
The coolant is abnormal: ............................................................................................................. 482
The components of cooling system are not working properly: ...................................................483
21
Overcooling: .........................................................................................................................................483
The clutch is not working properly: .....................................................................................................483
The clutch is slipping: ..................................................................................................................483
The clutch cannot be separated properly: .................................................................................... 483
There is a problem with shifting: .........................................................................................................483
It is unable to operate the gear smoothly; control pedal cannot be reset: ................................... 483
Jump ............................................................................................................................................. 483
Excessive speed change: ..............................................................................................................484
The engine makes an unusual noise: ................................................................................................... 484
The piston makes a sound: ...........................................................................................................484
The valve makes noise: ................................................................................................................484
The drive system makes an unusual noise: ..........................................................................................484
Clutch makes a noise: .................................................................................................................. 484
The drive device makes a noise: ..................................................................................................484
The drive system makes a noise: ................................................................................................. 485
The frame makes an unusual noise: .....................................................................................................485
The front fork makes a noise: ...................................................................................................... 485
The rear shock absorber makes a noise: ...................................................................................... 485
The brake disc makes a noise: ..................................................................................................... 485
Other noises: ................................................................................................................................ 485
Excessive exhaust gas: .........................................................................................................................485
White exhaust: ............................................................................................................................. 485
Black exhaust: ..............................................................................................................................485
Brown exhaust:.............................................................................................................................. 485
Poor performance and / or stability: .................................................................................................... 485
It is difficult to rotate the handlebar: ........................................................................................... 485
The handlebars vibrate or shake severely: ...................................................................................485
The handlebar is placed on one side: ...........................................................................................486
The damping effect is not ideal: .................................................................................................. 486
Brake is unable to work properly ................................................................................................ 486
Battery has failed: ................................................................................................................................ 486
Battery has run out: ......................................................................................................................486
Battery is overcharged: ................................................................................................................ 486
Circuit Diagram ............................................................................................................................................487
22
Preface
This Manual is designed for well-trained and quickly find the corresponding chapters. Each
mechanics in well-equipped stores. However, the chapter has a comprehensive catalog.
contents of this Manual are detailed and the basic For example, if you want to know the ignition
information is perfect， so motorcycle owners can use coil, use “Quick Guide” to find the chapter “Electrical
this Manual to carry out basic maintenance and repair System”, and then find the section where “Ignition
work. In order to carry out maintenance or repair of Coil” is located from the catalog on the first page of
motorcycle smoothly, the operator must have the basic this chapter.
knowledge of mechanic and understand how to use the If you see the following warning and reminder signs,
repair tools properly and know about workshop please be sure to pay attention to the above contents!
processes. If motorcycle owners are inexperienced or Remember to operate safely!
unable to ensure that they can properly adjust,
maintain and repair the motorcycle, please ask a WARNING
qualified mechanic to conduct the above operations. This warning sign is used to alert the operator to
In order to perform the above operations obey certain instructions or procedures,
efficiently and to avoid serious errors, please read this otherwise, personal injury or death may be
Manual before operation, familiarize yourself with the caused.
relevant procedures, and then operate in a clean place.
Do not use other temporary substitutes if you have Notes
special tools or equipment specified in this Manual. This reminder sign is used to alert the operator
Only with the right tools can you ensure accurate to obey certain instructions or procedures,
measurement results. In addition, the safety of otherwise, devices may be damaged or destroyed.
operation may be affected when alternative tools are In addition to “Warning” and “Notes”, this Manual
used. also contains four other signs to help you distinguish
During the warranty period, it is recommended to between different information.
perform repair and maintenance in strict accordance
with this Maintenance Manual. If any motorcycle Remarks
owner fails to perform maintenance or repair in ○ This sign indicates some operational tips to make the
accordance with this Manual, the motorcycle will not operation more convenient and improve efficiency.
be warranted. ● This sign indicates a step or a work to be completed.
In order to maximize the service life of your ○ This sign indicates a substep or how to complete the
motorcycle, please comply with the following work of this step. This sign may also be placed before
requirements: a certain “remarks”.
 Observe the Regular Maintenance Form in the ★ This sign indicates the measures taken according to
Maintenance Manual; the test or inspection results in the previous steps.
 Careful observe and pay attention to regular An exploded view of system components is available
maintenance and repair; behind the catalogs of most of chapters. These
 Use the proper tools and original Benelli illustrations describe the parts that require specific
motorcycle parts. This Maintenance Manual locking torque, oil, grease or threading fasteners
describes the specific tools, meters, and test during installation.
equipment required to repair a Benelli
motorcycle. For the original parts used as spare
parts, see the Parts Catalog.
 Operate in strict accordance with the procedures
in this Manual, and do not take shortcuts.
 Remember to make detailed maintenance and
repair records, including dates and new parts
installed.
Instructions on how to use this manual
This Manual describes the systems of motorcycle in
chapters. “Quick Guide” helps you know clearly about
various systems of this motorcycle
1
Chapter I Basic Information
Contents
Maintenance instructions ................................................................................................................................. 3
Installation of battery ............................................................................................................................... 3
Sharp edge of part .................................................................................................................................... 3
Solvent ......................................................................................................................................................3
Cleaning the motorcycle before disassembly .......................................................................................... 4
Sorting out and cleaning the removed parts ............................................................................................ 4
Storing the removed parts ........................................................................................................................ 4
Check ........................................................................................................................................................4
Replacement part ..................................................................................................................................... 5
Assembly sequence ..................................................................................................................................5
Fastening sequence .................................................................................................................................. 5
Locking torque ......................................................................................................................................... 5
Force .........................................................................................................................................................6
Gasket, O-ring ..........................................................................................................................................6
Liquid gasket, locking agent ....................................................................................................................6
Press fitting .............................................................................................................................................. 6
Ball Bearing and Needle Bearing ............................................................................................................ 7
Oil seal, grease seal ..................................................................................................................................7
Circlip, cotter pin ..................................................................................................................................... 7
Lubrication ............................................................................................................................................... 8
Engine rotation direction ......................................................................................................................... 8
Wire .......................................................................................................................................................... 8
Cable connector check ............................................................................................................................. 8
1. Disconnect ....................................................................................................................................9
2. Check ........................................................................................................................................... 9
3. Check ........................................................................................................................................... 9
4. Check ........................................................................................................................................... 9
5. Check ......................................................................................................................................... 10
Cable arrangement ................................................................................................................................. 10
Tool .........................................................................................................................................................11
Model information ......................................................................................................................................... 12
China ...................................................................................................................................................... 12
Europe .................................................................................................................................................... 13
Non-European ........................................................................................................................................ 14
Important recognition .............................................................................................................................15
Basic specifications ........................................................................................................................................16
General Technical Parameters ........................................................................................................................17
Unit conversion table ..................................................................................................................................... 21
2
Maintenance instructions
Please read the following precautions before
checking, disassembling or assembling the motorcycle.
In order to facilitate the actual operations, each chapter
is provided with remarks, illustrations, pictures, notes
and detailed instructions as needed. This section
describes the special considerations in the process of
removing and reassembling or disassembling and
reassembling common parts.
Pay special attention to the followings:
Installation of Battery
Disconnect the battery cable and battery before
any operation on the motorcycle to prevent the engine
from accidentally starting. Disconnect the negative
wire (-) first, then disconnect the positive wire (+).
After completing the operation, connect the positive
wire (+) to the positive terminal (+) of the battery, then
connect the negative wire (-) to the negative terminal
(-).
Sharp edge of part

To avoid scratching the hand with sharp edges,
wear gloves when moving parts with large size or
weight.
Vehicle
Use a solvent with a high flash point when
cleaning parts. Use a solvent with a high flash point
according to the instructions provided by the solvent
manufacturer.
3
Cleaning the motorcycle before disassembly
Thoroughly clean the motorcycle before
disassembly. If dust or other foreign matter enters the
sealed part during the disassembly process, excessive
wear may be caused and thus the performance of
motorcycle may be reduced.
Sort out and clean the removed parts

The removed parts may be confused. Therefore,
the removed parts should be arranged in the order of
disassembly, and the parts should be cleaned and
reinstalled.
Store the removed parts

After cleaning all parts (including
subassemblies), store the parts in a clean area. Cover
the parts with a clean cloth or plastic film to prevent
any foreign objects from falling into them before
reassembly.
Check
Major accidents may be caused in case of using
worn or damaged parts. Visually inspect the removed
parts for corrosion, discoloration or other damage. The
limits for the use of individual parts are detailed in the
corresponding sections of this Manual. If any damage
is found, or the part has exceeded the operating limit,
the part must be replaced.
4
Replacement part
Replacement parts must be original Benelli parts
or parts recommended by Benelli. Parts such as
washers, O-rings, oil seals, grease seals, circlips or
cotter pins must be replaced with new ones once
removed.
Assembly sequence
In most cases, the assembly sequence is the
reverse of disassembly sequence, but if the
Maintenance Manual describes the assembly sequence,
it must be assembled in the order given.
Fastening sequence
In general, when fixing parts with a few of bolts,
nuts or screws, place the parts in the corresponding
holes, then screw them in without applying torque, and
then tighten them in the specified order to prevent
warping or deformation which may result in part
failure. Conversely, if you want to unscrew the bolt,
nut or screw, first twist a quarter turn, loosen it, and
then continue to unscrew it. If the tightening sequence
is not specified, tighten the fasteners alternately in a
diagonal way.
Locking torque
If you apply the wrong torque to a bolt, nut or
screw, serious damages may be caused. Therefore, the
fastener must be tightened to the specified torque with
a high-quality torque wrench.
5
Force
Common sense and basic judgment are required
during the process of removing and installing parts to
prevent excessive force which may result in difficult
maintenance or excessive maintenance costs. If
necessary, use a pneumatic wrench to remove the
screw with locking agent. If you need to hit the
fastener, please use a mallet.
Gasket, O-ring
If the gasket or O-ring is hardened, shrunk or
damaged after being removed, its sealing performance
will be reduced. Remove the old gasket and
thoroughly clean the sealing surface to prevent any
gasket material or other materials from remaining on
the sealing surface. A new gasket must be used for
reinstallation and the used O-ring seal should be
replaced.
Liquid gasket, locking agent

If you need to use liquid gasket or locking agent,
you must first clean the contact surface to avoid any
oil residue on the contact surface before using the
liquid gasket or locking agent. Do not use too much
liquid gasket or locking agent, as excessive liquid
gasket or locking agent may block the oil passage and
cause serious damage.
Press fitting
Parts such as bearings and oil seals must be
pressed for proper fitting, so it is required to apply a
small amount of oil to the contact area. It must be
aligned with the contact area and slowly pressed into
the part during installation.
6
Ball bearing and needle bearing
Do not remove the balls or needles in the bearing
unless necessary. Once removed, it must be replaced
with a new one. When pressing the bearing, pay
attention to making the manufacturer and the size
mark face outward. Apply force to the correct bearing
race (as shown) and press the bearing into place.
If the force is applied to incorrect bearing race,
the bearing may be damaged because of stress in the
inner and outer races.
Oil seal, grease seal

Do not remove the compressed oil seal or grease
seal if it is not necessary. Once removed, it must be
replaced with a new one. When pressing the new oil
seal, pay attention to making the manufacturer and the
size mark face outward. Make sure the oil seal is in the
proper position during installation.
Apply a specified amount of grease to the edges

of oil seal before installation.
Grease
Circlip, cotter pin

Replace the removed circlip or cotter pin with a
new one. In order to prevent deformation, the opening
of circlip or cotter pin should not be too large during
installation.
Important notice

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7
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Lubrication
In order to minimize the wear during running-in
period, it is necessary to lubricate the rotating or
sliding parts. Inject the proper amount of lubricating
oil or grease as specified, and each lubrication point
will be given in this Manual.
Engine rotation direction

When the crankshaft is rotated by hands, an
incorrect direction of rotation may cause a
misjudgment of relevant gap adjustment. So please
rotate the crankshaft in the positive direction
(clockwise from the output).
Wire
Two-color line: first the base color, then the color
of stripe. Only the wires of the same color are allowed
to be connected, except as noted.
Cable connector check

Make sure that there are no rust, moisture or other
defects on the connector.
8
1. Disconnect
Wire
Connector
Joint
2. Check
Wire
Connector
Joint
If there is moisture, use compressed air to dry.
If there is rust, connect the connected parts for several
times or use a rust remover. Replace the seriously
rusted parts timely.
3. Check
All connectors
If any of the joints are loose, reconnect them properly.
Notes
If the “A” pin on the terminal is flat, please bend it.
4. Check
Wire
Connector
Joint
Notes
Make sure all joints are securely assembled.
9
5. Check
Continuity (using a multimeter)
Notes
If there are no items that need to be checked,
please clean the terminals.
When checking the wire sheath, follow Steps I to III
For quick correction, please use the [Contact
Reagent] available from most of parts stores.
Cable arrangement
Loose cable is a potential safety hazard of
electrical safety. Check the next cable after clamping
the cable, to ensure electrical safety;
Wire clamps are not allowed to bend in the
direction of the solder joint;
Bundle the cable at the designated location;
Cables are not allowed to be placed at the end of
frame or at the corners;
Cables are not allowed to be placed at the ends of
bolts or screws;
Keep cables away from heat source or the
position where the cable may be caught during
movement;
Cables should not be kept too tight or loose when
being placed along the faucet handle, and must not
interfere with adjacent parts in any steering position;
Cables should be smoothly placed and must not
be twisted or knotted;
Before connectors are mated, check whether the
connector sheath is damaged and the connector is
opened excessively;
If the cable is at a sharp or corner, please protect
it with tape or a hose;
After the cable is repaired, use tapes to securely
bind the exposed area;
The control wire must not bend or twist. If the
control line is damaged, inflexible operation may be
caused;
10
Tools
In order to make the measurement accurate, it is
necessary to use an accurate meter. Read the
instructions provided by the manufacturer carefully
before using the meter. Inaccurate measurements may
affect the adjustment results.
Important notice

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11
Model information
China
BJ250-18 left view
BJ250-18 right view
12
Europe
BJ250-18 (European regulation) left view
BJ250-18 (European regulation) right view
13
Non-European
BJ250-18 (non-European) left view
BJ250-18 (non-European) right view
14
Important recognition
Frame number: Engine number:
China: ☆LBBPGNJ0？？？？？？？？？ ☆ China: BJ178MM-D*□□□□□□□□*
European regulation: European regulation: BJ172MM-A*□□□□□□□□*
Important notice

331898951255744
whatsapp: 008613758665150
wechat: W54107871
15
Basic specifications
Dimensions Normal
Full length 2090mm
Full width 830mm
Full height 1310mm
Wheel Base 1375mm
16
General Technical Parameters
Item BJ250-18 (China), BJ250-18 (European

regulation), BJ250-18 (non-European
regulation)
Dimensions
Length overall 2090mm
Total width 830mm
Total height 1310mm
Wheel Base 1375mm
Terrain clearance 170mm
Seat height 800mm
Curb weight:
BJ250-18 (China) 173kg
BJ250-18 (European regulation) 173kg
BJ250-18 (non-European regulation) 173kg
Distribution of complete vehicle kerb mass in front axle
Distribution of complete vehicle kerb mass in rear axle
Maximum total mass
Distribution of maximum total mass in front axle
Distribution of maximum total mass in rear axle
Maximum technical carrying capacity of each axis
Maximum technical carrying capacity of front axis 1098N
Maximum technical carrying capacity of rear axis 2166N
Maximum ramp starting capacity at maximum total mass 41 %
Fuel tank capacity 18.0±0.5L
Rated maximum load mass 150kg
performance
Minimum Turning Radius 5m
17
Item BJ250-18 (China) BJ250-18 (European regulation) /
BJ250-18 (non-European regulation)
Engine
identity Four-stroke, double overhead camshaft, single cylinder
Cooling System Liquid-cooled
Bore and stroke 78.0×52.2mm 72×61.2 mm
Displacement 249.4ml 249ml
Compression ratio 12.1：1 11.2：1
Maximum horsepower 20.0kW/10500rpm 18.5kW/9000rpm
Maximum torque 20.5N·m/8500rpm 21.0N.m/7000rpm
Idle speed-rpm 1500±100r/min 1400±100rpm/min
Cylinder pressure 1.25MPa/1500rpm
Fuel vaporization system EFI (fuel injection)
Starter System Electric starter
Ignition System Battery and coil (full crystal ignition system)
Ignition advance angle control Electronic advance angle control (electronic igniter in the ECU)
Ignition timing 10° BTDC @1 from 100 r/min (rpm)
Spark plug NGK CR8E
Valve timing:
Intake:
Open valve 41°
Close valve 71°
Total time interval 292°
Exhaust:
Open valve 64°
Close valve 34°
Total time interval 278°
Lubrication System Pressure splash
Motor oil:
identity API SE, SF or SG
API SH, SJ or SL (with JASO MA, MA1 or MA2)
Viscosity SJ 10W-50 or SN 15W-50
Capacity 1.2±0.05L (when replaced);
1.5±0.05L (when engine is disassembled completely)
Air filter
Type Oil filter type
Element Sponge
Intake resistance 1.5±0.15KPa
Muffler
Type Impedance composite (with fiber-absorbing materials)
Catalytic converter (with/without) Have
identity Redox type
18
Item BJ250-18 (China), BJ250-18 (European regulation),
BJ250-18 (non-European regulation)
Drive mechanism
Primary deceleration system:
identity Gear
Reduction ratio 3.043
Clutch type Wet multi-piece
Transmission:
identity 6-speed, constant-time meshing, reciprocating gear
Type (automatic / manual) Manual
Transmission control mode (manual / foot-operated) Foot-operated
Gear ratio:
First 2.643
Second 1.833
Third 1.318
Fourth 1.040
Fifth 0.889
Sixth 0.786
Final drive system:
Type: Chain drive
Reduction ratio 3.462
Maximum design speed 129km/h
Climbing ability ≥20°
Frame
identity Cantilever back bone frame
Caster angle (dip angle) 23°
Tail 94 mm
Front tire:
Type: Vacuum tire
Size: 110/70-17 CORDIAL
110/70R17 METZELER (elephant brand)
Tire pressure 220±10kPa
Wheel type 12-spoke aluminum alloy
Rim size 17×MT3.50
Rim material Aluminum alloy
Rear tire:
identity Vacuum tire
Dimensions 140/60-17 CORDIAL
150/60R17150/ METZELER (elephant brand)
Tire pressure 250±10kPa
Wheel type 12-spoke aluminum alloy
Rim size 17×MT4.00
Rim material Aluminum alloy
Front suspension system:
identity Inverter, telescopic sleeve, oil damping shock absorber
19
Item BJ250-18 (China), BJ250-18 (European regulation), BJ250-18
(non-European regulation)
Total stroke 135mm
Rear suspension system:
identity Single cylinder, hydraulic spring, damping shock absorber
Total stroke 51mm
Steering mechanism
Transmission type Mechanical
Steering mechanism operation type Handlebar type
Brake type:
Front brake: Single disc φ280mm
Operation method Manual
Rear brake Single disc φ240mm
Operation method Foot-operated
Electrical equipment
Battery:
identity Maintenance-free battery
Model YTX7L-BS
Headlight:
identity Semi-hermetic reflected beam type
Light bulb:
High-beam light 12V/LED
Low-beam light 12V/LED
Tail light / brake light 12V/LED
Turn signal light 12V/LED
Rear license plate light 12V/W3W (halogen)
Alternator:
Type: Three-phase alternator
Rated output power 12.8V//225W/5000rpm
Ignition coil:
Type Open magnetic circuit ignition coil
Primary/secondary resistor 4Ω/13.5KΩ
Primary/secondary voltage 12V/29KV
Spark plug:
Model CR8E
Type Resistor type
Contact gap 0.7±0.1mm
ECU: Delphi
Model MT05
Operating voltage 12V
Adjustability The procedure can be rewritten by an external communication interface
It is subject to change without notice and may not be applicable in every country.
20
Unit conversion table
Unit prefix: Length unit:
Prefix Sign: Power Km × 0.6214 = miles
mega M × 1 000 000 m × 3.281 = miles
kilo k × 1 000 mm × 0.03937 =feet
centi c ×0.01
milli m ×0.001 Unit of torque:
micro μ × 0.000001 N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
Unit of mass: N·m × 8.851 = in·lb
kg ×2.205=lb kgf·m × 9.807 = N·m
g × 0.03527 = oz kgf·m × 7.233 = ft·lb
kgf·m × 86.80 = in·lb
Unit of volume
L × 0.2642 = gallon (US) Unit of pressure:
L × 0.2200 = gallon (imp) kPa × 0.01020 = kgf/cm²
L × 1.057 = quart (US) kPa × 0.1450 = psi
L × 0.8799 = quart (imp) kPa × 0.7501 = cmHg
L × 2.113 = pint (US) kgf/cm² × 98.07 = kPa
L × 1.816 = pint (imp) kgf/cm² × 14.22 = psi
mL × 0.03381 = ounce (US) cmHg×1.333=kPa
mL × 0.02816 = ounce (imp)
mL × 0.06102 = cubic inch Unit of speed:
km/h × 0.6214 = mph
Mechanical unit: Unit of power:
N × 0.1020 = kg kW ×1.360=PS
N × 0.2248 = lb kW ×1.341=HP
kg ×9.807=N PS × 0.7355 = kW
kg ×2.205=lb PS × 0.9863 = HP
Unit of temperature:
21
Chapter II Regular Maintenance
Contents
Regular maintenance table .............................................................................................................................24
Torque and locking agent ...............................................................................................................................26
Main locking torque specifications ........................................................................................................26
Locking torque and related parameters of nuts, bolts and screws .........................................................30
Technical parameters ......................................................................................................................................31
Regular maintenance procedures ................................................................................................................... 34
Fuel injection system (EFI) ....................................................................................................................34
Check throttle control system ........................................................................................................ 34
Check idle speed ............................................................................................................................ 35
Check fuel hose (fuel leak, hose rupture, hose installation) ..........................................................35
Check fuel vapor recovery system (models in China, Europe and the US) ..................................36
Cooling system .......................................................................................................................................38
Check coolant level ........................................................................................................................38
Check radiator pipes (coolant leakage, radiator pipes damage, installation status of radiator pipes)
..........................................................................................................................................................38
Engine cylinder head and cylinder head cover ......................................................................................39
Check valve clearance ................................................................................................................... 39
Adjusting the valve clearance ........................................................................................................40
Check whether the air inlet unit has been damaged ...................................................................... 44
Clutch ..................................................................................................................................................... 45
Check if the clutch control system is normal ................................................................................ 45
Check the free stroke of clutch handle .......................................................................................... 45
Wheel/tire ...............................................................................................................................................46
Check the tire pressure ...................................................................................................................46
Check wheel / tire for wear ............................................................................................................46
Check the wear of tread ................................................................................................................. 46
Check whether the wheel bearing has been damaged ................................................................... 47
Final drive mechanism ...........................................................................................................................48
Check the lubrication state of drive chain ..................................................................................... 48
Check whether the drive chain is slack ......................................................................................... 48
Adjust drive chain slackness ..........................................................................................................48
Check wheel alignment ..................................................................................................................50
Check the wear of drive chain ....................................................................................................... 50
Check the wear of chain guide .......................................................................................................51
Brake ...................................................................................................................................................... 52
Check brake hoses and brake lines for damage and ensure their installation status .....................52
Free stroke of front brake ...............................................................................................................52
Free stroke of rear brake ................................................................................................................ 52
Check brake ................................................................................................................................... 53
22
Check brake fluid level .................................................................................................................. 53
Inspection of wear of brake pad .....................................................................................................54
Check brake light switch ................................................................................................................55
Check the output voltage of speed sensor ..................................................................................... 55
Suspension system ................................................................................................................................. 57
Check front fork / rear shock absorber .......................................................................................... 57
Check the front fork shock absorber for oil leakage ..................................................................... 57
Check the rear shock absorber for oil leakage ...............................................................................58
Steering system ...................................................................................................................................... 59
Check steering clearance ............................................................................................................... 59
Adjust the steering seat properly ................................................................................................... 59
Lubricate steering stem bearings ................................................................................................... 60
Electrical system .................................................................................................................................... 61
Check lights and switches ..............................................................................................................61
Check the headlight accuracy ........................................................................................................ 65
Check the sidestand flameout switch .............................................................................................66
Check emergency stop switch ........................................................................................................67
Others ..................................................................................................................................................... 68
Lubricate frame parts ..................................................................................................................... 68
Check the tightness of bolts, nuts and fasteners ............................................................................ 69
Replacement of part ............................................................................................................................... 71
Replacement of air filter element .................................................................................................. 71
Replacement of fuel hose ...............................................................................................................74
Replacement of coolant ................................................................................................................. 75
Replacement of radiator hose ........................................................................................................ 78
Replacement of oil ......................................................................................................................... 79
Replacement of brake hose ............................................................................................................ 80
Replacement of rear brake hose .....................................................................................................82
Replacement of brake fluid ............................................................................................................83
Replacement of rubber parts of master cylinder ............................................................................86
Replacement of rubber parts of caliper............................................................................................88
Replacement of spark plug.............................................................................................................. 92
23
Regular maintenance table
In order to keep the motorcycle in good running conditions, it must be regularly maintained according to
the following table. The first maintenance is very important, so it must not be ignored.
Regular checklist
Whichever is the earlier Odometer reading
Frequency × 1 000 km
Page
Item Interv
1 6 12 18 24 30 36
al
Fuel injection system Page 103
Throttle control system (operation, smooth
1 year ● ● ● ●
return, no resistance) - check
Idle speed-check ● ● ● ●
Fuel leak (fuel hoses and fuel hoses) - check 1 year ● ● ● ●
Damage of fuel hoses and fuel hoses-check 1 year ● ● ● ●
Installation state of fuel hoses and fuel
1 year ● ● ● ●
hoses-check
Function of evaporative emission control system
● ● ● ● ● ● ●
-- check (CAL and SEA models)
Cooling System
Coolant level-check ● ● ● ●
Coolant leakage (radiator hoses and radiating
1 year ● ● ● ●
pipes) - check
Damage of radiator hoses-check 1 year ● ● ● ●
Installation state of radiator hoses-check 1 year ● ● ● ●
Engine cylinder head and cylinder head cover
Valve US, CA, AU models ●
clearance Other models except US, CA, and AU
-check Every 42000 km
models
Damage of air induction system - check ● ● ●
Clutch
Clutch operating mechanism (running,
● ● ● ●
disengaging, closing) - check
Free stroke of clutch handle 1 year ● ● ● ● ● ● ●
Wheel and tire
Tire pressure - check 1 year ● ● ●
Wheel/tire damage - check ● ● ●
Wear and abnormal wear of tire tread - check ● ● ●
Damage of wheel bearing - check 1 year ● ● ●
Final drive mechanism
Lubrication state of drive chain - check# Every 600 km
Looseness of drive chain - check # Every 1000 km
Wear of drive chain - check # ● ● ●
Wear of chain guide - check ● ● ●
Brake
Brake fluid leak (brake hose) - check 1 year ● ● ● ● ● ● ●
Brake hose damage - check 1 year ● ● ● ● ● ● ●
Installation state of brake hose-check 1 year ● ● ● ● ● ● ●
Brake operation (effectiveness, operation, no
1 year ● ● ● ● ● ● ●
resistance) - check
Brake fluid level - check 6
month ● ● ● ● ● ● ●
s
Brake pad wear - check# ● ● ● ● ● ●
Brake light switch operation - check ● ● ● ● ● ● ●
24
Continued
Whichever is the earlier Odometer reading
Frequency × 1 000 km
Page
Item Interva
1 6 12 18 24 30 36
l
Suspension system
Operation of front fork / rear shock absorber
● ● ●
(smooth damping and stroke) - check
Oil leak of front fork / rear shock absorber - 1 year ● ● ●
check
Operation of swing arm - check ● ● ●
Tie rod - check ● ● ●
Steering system
Steering clearance - check 1 year ● ● ● ●
Steering rod bearing - lubrication 2 years ●
Electrical System
Operation of light and switch - check 1 year ● ● ●
Headlight accuracy - check 1 year ● ● ●
Operation of sidestand switch - check 1 year ● ● ●
Operation of emergency stop switch - check 1 year ● ● ●
Others
Frame parts - lubrication 1 year ● ● ●
Tightness of bolts and nuts - check ● ● ● ●
-clean# Every 6000 KM
Air filter element
-Replace# Every 12000 KM
Fuel hose-replace 4 years ●
Coolant-replace 3 years ●
Radiator hose and O-ring - replace 3 years ●
Clutch hose -- replace 4 years ●
Clutch oil -- change 2 years ● ●
Rubber parts for the master/slave cylinder of 4 years ●
clutch - replace
Oil - replace 1 year ● ● ● ● ●
Oil filter - replace 1 year ● ● ● ● ●
Brake hose - check 4 years ●
Brake fluid - check 2 years ● ●
Rubber parts for the master cylinder of clutch / 4 years ●
brake caliper - replace
Spark plug - replace ● ● ● ● ●
#: If you use a motorcycle in a harsh environment such as dusty, humid and muddy environment, or frequently
drive at high speed or start or stop, you should increase the maintenance frequency.
If the odometer reading exceeds this table, repeat the maintenance at the frequency interval specified in this
Manual.
25
Torque and locking agent
Main locking torque specifications

The table below lists the locking torques for the primary fasteners that require locking agent or silicone
sealants.
The letters in the "Remarks" column have the following meanings:
AL: Tighten the fastening bolts alternatively in accordance with the higher locking torque.
G: Apply grease.
L: Apply locking agent.
M: Apply the grease containing molybdenum disulfide.
MO: Apply the oil solvent containing molybdenum disulfide. (A mixture of engine oil and molybdenum
disulfide-containing grease prepared in a weight ratio of 10:1)
R: Replace the part.
S: Observe the specified tightening sequence.
Si: Apply silicon grease.
SS: Apply silicone sealant.
Torque
Fastener Remarks
N·m kgf·m
Fuel Injection System (EFI)
Air filter element cover bolt 6 0.70
Air filter element bracket screw 6 0.70
Camshaft position sensor bolt 10 1.0
Crankshaft sensor bolt 5.9 0.60
Pipe clamp bolt 2.0 0.20
Fuel tank mounting bolt 10 1.0
Fuel pump bolt 4 0.4 S
Inlet air pressure sensor bracket screw 10 1.0
Oxygen sensor 25 2.5
ECU bolt 3.9 0.40 L
Speed sensor bolt 3.9 0.40 L
Water temperature sensor 25 2.5
Cooling System
Radiator mounting bolt (lower) 10 1.0
Radiator mounting bolt (upper) 10 1.0
Radiator (water pipe) hose fastening screw 2.0 0.20
Coolant reserve tank mounting bolt 10 1.0
Coolant drain bolt 10 1.0
Thermostat cover mounting bolt 10 1.0
Water pump cover bolt 10 1.0
Water temperature sensor 25 2.5
Cylinder head cover bolt 10 1.0 L
Camshaft sprocket mounting bolt 15 1.5 L
Camshaft cover bolt 10 1.0 S
Camshaft chain guide bolt 12 1.2 S
Camshaft chain tensioner mounting bolt 10 1.0
Cylinder head bolt (M11) 50 5.0 L（3）
Exhaust pipe mounting bolt 22 2.2
Spark plug 25 2.5
26
Continued
Torque
Fastener Remarks
N·m kgf·m
Clutch
Clutch cover bolt 10 1.0 L(1)
Clutch wheel hub nut 120 12.0 R
Clutch spring bolt 10 1.0
Engine lubrication system
Engine oil drain bolt M12 30 3.0
Stopper of oil filler - - Tighten
fuel pump bolt using hands 10 1.0
Fuel pump cover bolt 10 1.0
Crankshaft/ drive mechanism
Balancer shaft clamp nut M14 40 4.0
Assembling bolt M6 12 1.2 S
Crankcase bolt 12 1.2 S
Flywheel locknut M25 100 10.0
Driving gear locknut M20 80 8.0
Shift positioner bolt M6 12 1.2
Disassembly/Installation of Engine
Front bracket bolt of engine (M10) 45 4.5 S
Upper bracket bolt of engine (M8) 25 2.5 S
Upper mounting bolt of engine (M10) 50 5.0 AL、S
Front mounting bolt of engine (M10) 50 5.0 AL、S
Rear mounting bolt of engine (M10) 50 5.0 AL、S
Wheel/tire
Front axle clamp nut 20 2.0 AL
Front wheel axle 107 10.7
Rear wheel axle 150 15.0
Rear wheel axle nut 150 15.0
Upper stop block bolt of chain 10 1.0 L
Chain protective block bolt 10 1.0 L
Engine sprocket cover bolt 10 1.0
Engine sprocket nut 125 12.5 MO
Rear sprocket nut 50 5.0
Brake
Purge valve 7.8 0.80
Hollow bolt of brake hose 25 2.5
Pivot bolt of brake lever 6 0.6 Si
Pivot bolt locknut of brake lever 6 0.6
Brake pedal bolt 22 2.2
Mounting bolt of front brake disc 27 2.7 L
Front brake light switch screw 1.2 0.12
Mounting bolt of primary cylinder reservoir cap of 1.2 0.12
front brake
Front caliper assembly bolt 27 2.8 L
Front caliper mounting bolt 34 3.5
Purge valve of front master cylinder 7.8 0.80
Clamp bolt of front master cylinder 11 1.1 S
Mounting bolt of rear brake disc 27 2.8 L
Rear caliper assembly bolt 37 3.8 L
27
Continued
Torque
Fastener Remarks
N·m kgf·m
Rear caliper mounting bolt 25 2.5
Rear primary cylinder mounting bolt 10 1.0
Rear master cylinder push rod locknut 10 1.0
Suspension system:
Front axle clamp nut 20 2.0 AL
Front shock absorber clamp bolt (upper) 22 2.0
Front shock absorber clamp bolt (lower) 22 3.1 AL
Top plug of front shock absorber 22 2.2
Piston rod nut of front shock absorber 28 2.8
Rear shock absorber bolt (upper) 45 4.5
Rear shock absorber bolt (lower) 45 4.5
Rear shock absorber nut (lower) 45 4.5
Mounting nut of rear rocker arm axis 108 10.8
Rear rocker arm shaft 108 10.8
Steering system
Steering stem clamp nut 35 3.5 AL
Steering stem locknut 24 2.4 AL
Clamp screw of upper bracket 25 2.5
Handlebar positioning double-end stud mounting 45 4.5 AL
nut
Handlebar bolt 25 2.5 L
Left switch clamp screw 3.5 0.35
Right switch clamp screw 3.5 0.35
Rear clamp bolt of left lever 10 1.0
Pivot bolt of left lever 6 0.6
Pivot bolt locknut of left lever 6 0.6
Grip end bolt 10 1.0
Frame
Front seat cushion bolt 10 1.0
Rear seat lock bolt 10 1.0
Bolt of rear grab rail 22 2.2
Mounting bolt of holder of rear fender bracket 10 1.0
Mounting bolt of rear fender bracket 10 1.0
Front left pedal bracket mounting bolt 45 4.5
Shift rod mounting base bolt 10 1.0
Shift rod assembly bolt 10 1.0
Front right pedal bracket bolt 45 4.5
Rear left pedal bracket bolt 25 2.5
Rear right pedal bracket bolt 25 2.5
Muffler cylinder mounting bolt 22 2.2
Rear bolt of muffler cylinder 22 2.2
Rear locknut of muffler cylinder 22 2.2
Sidestand bolt 50 5.0
Locknut of side stand bolt 45 4.5
Sidestand flameout switch bolt 6 0.6
Battery holder bolt 10 1.0
28
Continued
Torque
Fastener Remarks
N·m kgf·m
Electrical System
Alternator cover bolt 10 1.0
Alternator wire holding plate 10 1.0 L
Alternator rotor bolt 100 10.0 S
Camshaft position sensor bolt 9.8 1.0
Camshaft sensor bolt 5.9 0.60 L
Camshaft sensor cover bolt 9.8 1.0 L(1)
Grounding terminal bolt of engine 10 1.0
Front brake light switch screw 1.2 0.12
Front turn signal light mounting nut 6 0.6
Fuel level sensor bolt 10 1.0 L
Lower bracket bolt of headlight 10 10
Lower mounting bolt of headlight 10 1.0
Left switch clamp screw 3.5 0.35
License plate light cover mounting screw 0.90 0.09
Oil pressure switch 15 1.5 SS
Oxygen sensor 25 2.5
Rear turn signal light mounting nut 6 0.6
Rectifier bolt 10 1.0
Right switch clamp screw 3.5 0.36
Sidestand flameout switch bolt 6 0.6 L
Starter relay bolt 10 0.6 L
Starter motor joint nut 6 0.6
Bond strap bolt 10 0.6
Starter motor mounting bolt 10 1.0
Starter motor binding post locknut 6 0.6
Important notice

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whatsapp: 008613758665150
wechat: W54107871
29
Locking torque and related parameters of nuts, bolts and screws
The table below lists the basic torques for bolts and nuts (different thread diameters correspond to different
locking torques). This table is only for the bolts and nuts that do not require specific torque values. All values in
the table below apply to the threads cleaned with an anhydrous solvent.
Locking torques and related parameters of nuts
Basic locking torques
Nut
N·m kgf·m
4 2.3 0.2
5 4.5 0.4
6 10 1.0
8 25 2.5
10 45 4.5
12 80 8.0
14 130 13.0
16 200 20.0
18 240 24.0
20 325 32.5
Locking torque and related parameters of bolts and screws
Basic locking torques
Bolt/screw Grade 8.8 Grade 10.9 Grade 12.9
N.m Kg.f·m N.m Kg.f·m N.m Kg.f·m
M4×0.7 3 0.3 4.2 0.4 5.2 0.5
M5×0.8 6 0.6 7.5 0.8 9 0.9
M6×1 10 1.0 13 1.3 16 1.6
M8×1.25 22 2.2 30 3.0 40 4.0
M8×1(*) 25 2.5 36 3.6 45 4.5
M10×1.5 45 4.5 65 6.5 80 8.0
M10×1.25(*) 50 5.0 70 7.0 85 8.5
M12×1.75 80 8.0 110 11.0 135 13.5
M12×1.5(*) 85 8.5 120 12.0 145 14.5
M12×1.25(*) 90 9.0 130 13.0 150 15.0
M14×2 130 13.0 185 18.5 220 22.0
M14×1.5(*) 150 15.0 205 20.5 245 24.5
M16×2 200 20.0 280 28.0 335 33.5
M16×1.5(*) 225 22.5 310 31.0 360 36.0
M18×2.5 265 26.5 370 37.0 450 45.0
M18×1.5(*) 320 32.0 450 45.0 550 55.0
M20×2.5 390 39.0 550 55.0 650 65.0
M20×1.5(*) 440 44.0 630 63.0 750 75.0
M22×2.5 540 54.0 750 75.0 900 90.0
M22×1.5(*) 600 60.0 850 85.0 1000 100.0
M24×3 670 67.0 950 95.0 1130 113.0
M24×2(*) 750 75.0 1050 105.0 1250 125.0
*: fine thread
30
Technical parameters
Item Normal usage restrictions
Free clearance of throttle grip 3∼5mm –––
Idle speed 1400 ±100 r/min –––
Negative pressure value of 50 ±3 kPa (at idle speed) –––
throttle valve
Air filter element Sponge filter element –––
Cooling System
Liquid coolant:
(Recommended type Permanent antifreezing agent (FD-2) –––
Color Green –––
Mixture ratio 50% soft water, 50% coolant –––
Freezing point –35°C –––
Boiling point 107°C –––
Total amount 1.2L
Engine cylinder head and
cylinder head cover
Valve clearance:
Vent valve 0.15 ∼ 0.17 mm –––
Inlet valve 0.13 ∼ 0.15 mm –––
Clutch
Free clearance of clutch 10∼20mm –––
operating lever
Engine lubrication system
Motor oil:
identity API SE, SF or SG –––
API SH, SJ or SL, JASO MA
Viscosity SAE 10W-50 –––
Capacity 1.2±0.05L (when replaced); –––
1.5±0.05L (when engine is disassembled –––
completely)
Liquid level Between the upper level line and the lower –––
level line (idle or stand for 2-3 minutes after
running)
Wheel/tire
Tread depth
Front tire 3.8 mm 1.6mm
Rear tire 4.8 mm 2.0mm
Tire pressure (after cooling of
tire) :
Front tire 220±10kPa –––
Rear tire 250±10kPa –––
Drive chain slackness 10∼15 mm –––
Drive chain wear (length of 20 317.5 ∼ 318.2 mm 323 mm
chain links)
Standard drive chain:
Model 520HO –––
Chain link 118 –––
31
Continued
Item Normal usage restrictions
Brake
Brake fluid
Class DOT4 –––
Thickness of friction plate of brake
pad
Front brake pad 4.0 mm 3 mm
Rear brake pad 4.0 mm 3 mm
Brake light time setting:
Front brake light It will be on after pulling –––
Rear brake light The light will be on after being –––
pressed by about 10 mm of pedal
stroke
Electrical System
Spark plug:
Model NGK CR8E –––
Clearance 0.7±0.1 mm –––
Important notice

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Special tools
The following special tools are required to perform complete and correct adjustments and assembly, and
proper special tools shall be used to avoid damage caused by improper tools or non-professional techniques. The
special tools you need to use may vary from country to country. When ordering tools, please refer to the
following information to prevent errors.
Inner circlip pliers: Negative pressure gauge:
Steering lever nut wrench: four-jaw 300-QCLM4-001 Steering lever nut wrench: seven-jaw
300-QCLM7-001
Jack: Accessories of jack:
Oil filter wrench
Important notice

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Regular maintenance procedures

Check throttle control system
●Check the free clearance of throttle grip ①.
Free clearance of throttle grip
Standard: 3-5mm
★ If the free clearance is not accurate, please adjust
the throttle cable.
●Check that the throttle grip moves smoothly from
fully open to closed, and the return spring allows the
throttle to close completely and quickly, regardless of
the steering position.
★ If the throttle grip cannot be reset normally, check
the winding method of throttle cable, the free
clearance of handle and the cable for damage. Then
lubricate the throttle cable.
Make the engine run at idle speed, rotate the
handlebar to the right and left to ensure that there is no
change in the idle speed.
If the idle speed is increased, check the free clearance
and winding method of the throttle cable.
★ If necessary, adjust the throttle cable as follows:
(1) Remove the dust cover of throttle cable ⑥.
(2) Loosen the locknut ④.
(3) Rotate the adjusting nut ⑤ until the free
clearance of the throttle grip ① is 3 - 5 mm.
(4) Tighten the locknut ④.
After adjusting the free stroke, rotate the handlebar
to the left and right to confirm whether the idle
speed of engine has changed.
If the free clearance of throttle grip cannot be met after

adjusting the upper end of throttle cable, adjust the
lower end of throttle cable [A]. Adjust the throttle
cable in the following steps:
(1) Loosen the locknut ⑧.
(2) Rotate the adjusting nut ⑦ to make the free
clearance of throttle grip large enough, until the free
clearance of the throttle grip is 3 - 5 mm.
(3) Tighten the locknut ⑧.
After adjusting the free stroke, rotate the handlebar
to the left and right to confirm whether the idle
speed of engine has changed.
★If the free clearance cannot be adjusted with the
adjuster, please replace the stay wire.
34
Check idle speed
● Start the engine and let it heat up completely.
● When the engine is idling, turn the handlebars to the
sides [A].
★ If you can change the idle speed after turning the
handlebar, it is indicated that the throttle cable is not
adjusted or the winding method is incorrect or
damaged. Be sure to correct the above problems before
riding (see sections of Chapter "Appendix" for details:
"Checking Throttle Control System" and "Winding
Method of Cables, Wires and Hoses").
WARNING
Riding when the cable is not properly
adjusted, damaged or the winding method is
incorrect, a safety accident may be caused.
● Check idle speed
Idle speed
Standard: 1400 ±100 r/min
Check fuel hose (fuel leak, hose rupture, hose installation)
○ If the motorcycle is not handled properly, the high
pressure inside the fuel hose may cause fuel leakage
[A] or fuel hose rupture. Remove the fuel tank (see
“Removal of Fuel Tank” in the chapter “Fuel Injection
System (EFI)”) and check the fuel hose.
★If any wear, crack [B] or expansion [C] is found, the
fuel hose must be replaced.
Check whether the winding method of hose complies

with the relevant provisions of section "Winding
Method of Cables, Wires and Hoses" of chapter
"Appendix".
★ If the hose is severely bent or cracked, it must be
replaced.
Hose joint[A]
Fuel hose [B]
●Check whether the hose joint is connected firmly. .

Push and pull the hose joint [A] back and forth twice
to ensure that the hose joint has been firmly fixed.
★ If it is not secure, reinstall the hose joint.
WARNING
Slide the joint to ensure that the hose joint
has been properly installed on the fuel supply
line, otherwise, the fuel may leak.
35
Check fuel vapor recovery system (models in China, Europe and the US)
●Check the canister solenoid valve as follows.
○ Remove the seat cushion (see “Frame” – “Removing
Seat Cushion”).
○ Remove the right guard (see “Frame” – “Removing
Guard” for details).
Remove the battery (see “Battery” – “Removing
Battery” for details).
○Remove the canister solenoid valve bracket
mounting screw [A].
○Remove the canister solenoid valve bracket [B].
○Remove the hose [A] connected to the separator and

remove the canister solenoid valve [B] from the right
side of motorcycle.
○ Check the canister solenoid valve for cracks and
other damages.
★ If any, it must be replaced.
★Check the canister solenoid valve (see “Canister
Solenoid Valve” in the chapter “Fuel Injection System
(EFI)”)
●Check the canister as follows.

○ Remove the battery holder A.
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○Remove the canister [C] and remove the hose [1]
connected to the canister.
○ Check the canister for cracks or other damages.
★ If any, it must be replaced.
Remarks
○ If the canister is used under normal conditions,
the canister can be used normally during the service
life of motorcycle without maintenance.
● Check the hose of fuel vapor recovery system as

follows.
○ Check whether the hoses are connected firmly and
clips are mounted properly.
○ Replace the hoses that have been cracked, corroded
or damaged.
Install the negative pressure hose in accordance with
section "Winding Method of Cables, Wires and Hoses"
of chapter "Appendix".
○ When installing the hose, avoid bending, twisting or
warping the hose, and do not bend the hose as much as
possible to avoid blocking evaporative emissions.
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Cooling System
Inspection of cooling fluid level
Remarks
○Check the fluid level when the engine is cooled (to
the indoor temperature or environment
temperature).
●Put the motorcycle vertically (do not use the side
stand) and check the coolant level of the expansion
water tank [A].
★If the coolant level is below the “LOWER” fluid
level line [C], unscrew the cover of expansion water
tank and add the coolant until the fluid level reaches
the “UPPER” fluid level line [B].
“UPPER”: High
“LOWER”: Low
Notes
When adding the coolant, the specified
mixture of coolant and soft water needs to be
added. If water is added separately, the coolant
will be diluted to reduce the anti-corrosion
performance. The diluted coolant will corrode
the aluminum engine parts. In case of
emergency, soft water can be added separately.
But the correct mixing ratio must be restored
within a few days.
If the coolant must be added frequently or
the expansion water tank is completely dry, the
leakage problems may occur in the cooling
system. Check whether the leakage occurs in the
cooling system, because the coolant will corrode
the painted surface. If the coolant is splashed on
the frame, engine, wheel or other painted parts,
rinse them with water immediately.
Check radiator pipes (coolant leakage, radiator pipes damage, installation status of radiator
pipes)
○If the radiator pipe is not properly maintained, the
high pressure inside the water pipe will cause the
coolant leakage [A] or rupture of water pipe.
●Check whether the hose is corroded. After the hose is
extruded, if the hose becomes hard, brittle or
expanded, it indicated that the hose has been corroded.
★If any wear, crack [B] or expansion [C] is found, the
hose must be replaced.
●Check whether the hose is connected firmly and
whether the clamp has been fastened correctly.
Locking torque of radiator (water) pipe fastening
38
screw: 2.0 N•m

Checking valve clearance;
Remarks
○Check and adjust the valve clearance only when
the engine is cooled (to the indoor temperature).
●Disassemble:
○ Remove the seat cushion (see “Frame” – “Removing
Seat Cushion”).
Remove the fuel tank (see “Fuel Tank” – “Removing
Fuel Tank”).
Remove the mounting screw [A] and remove the
cylinder head cover [B].
Notes
Please check the damaged or deformed rubber
washer [A]. Especially around the spark plug. If
damaged, replace it with a new rubber washer.
●Place the crankshaft on the piston TDC

○The TDC mark of flywheel is [A]
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○ Timing mark: [A] (crankcase half part meshing
surface)
● When at the TDC position, measure the valve

clearance between the cam and the valve tappet with a Measure the
feeler gauge [A]. clearance
Notes
Please keep the feeler gauge horizontal to avoid
being stuck due to misjudgment.
Valve clearance
Standard:
Intake valve: 0.13 - 0.15 mm
Exhaust valve: 0.15 - 0.17 mm
Notes
○ The thickness gauge shall be inserted horizontally
on the valve tappet.
Appropriate: [A]
Inappropriate: [B]
Feeler gauge: [C]
Horizontally insert it: [D]
Cam: [E]
Valve tappet: [F]
The front end of feeler gauge is stuck on the valve
tappet, which is the incorrect way: [G]
★ If the valve clearance is not within the specified

range, first keep a record of the valve clearance and
make adjustments.
Adjusting the valve clearance
● To change the valve clearance, remove the camshaft
chain tensioner, camshaft and valve tappet. Replace
the currently used valve shims with valve shims of
different thicknesses.
Remarks
○ In order to install the valve tappet and the valve
shim into the original positions, mark their positions
before removing them.
40
○ In addition to the standard valve shims in the valve
clearance adjustment table, the following valve shims
can also be used.
Adjust the valve shims:
Charset Thickness
120246030000 Valve shim 1.600mm
120216030000 Valve shim 1.625mm
120226030000 Valve shim 1.650mm
120236030000 Valve shim 1.675mm
120256030000 Valve shim 1.700mm
120266030000 Valve shim 1.725mm
120276030000 Valve shim 1.750mm
120286030000 Valve shim 1.775mm
120296030000 Valve shim 1.800mm
120306030000 Valve shim 1.825mm
120316030000 Valve shim 1.850mm
120326030000 Valve shim 1.875mm
120336030000 Valve shim 1.900mm
120346030000 Valve shim 1.925mm
120356030000 Valve shim 1.950mm
120366030000 Valve shim 1.975mm
120376030000 Valve shim 2.000mm
120386030000 Valve shim 2.025mm
120396030000 Valve shim 2.050mm
120406030000 Valve shim 2.075mm
120416030000 Valve shim 2.100mm
120426030000 Valve shim 2.125mm
120436030000 Valve shim 2.150mm
120446030000 Valve shim 2.175mm
120456030000 Valve shim 2.200mm
120466030000 Valve shim 2.225mm
120476030000 Valve shim 2.250mm
120486030000 Valve shim 2.275mm
●Clean the dust or oil on the valve shim.
● Measure the thickness of the removed valve shim
[A].
41
Exhaust valve clearance adjustment table
Example of current valve shim
Thickness (mm) 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.00～0.02 — — — — — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05
0.03～0.06 — — — — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1
0.07～0.10 — — — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15
0.11～0.14 — — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2
0.15～0.18 — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25
Example of measurement value of valve clearance (mm)
0.19～0.25 Valve clearance / without the need to adjust

0.26～0.30 1.35 1.4 1.45 1.5 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.31～0.35 1.4 1.45 1.5 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.36～0.40 1.45 1.5 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.41～0.45 1.5 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.46～0.50 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.51～0.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.56～0.60 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.61～0.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.66～0.70 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.71～0.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.76～0.80 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.81～0.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.86～0.90 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.91～0.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.96～1.00 2.05 2.1 2.15 2.2 2.25 2.3
1.01～1.05 2.1 2.15 2.2 2.25 2.3 Thickness (mm) of valve shim to be installed
1.06～1.10 2.15 2.2 2.25 2.3
1.11～1.15 2.2 2.25 2.3
1.16～1.20 2.25 2.3
1.21～1.25 2.3
1. Measure the valve clearance (the engine has cooled).

2. Check the size of the current valve shim.
3. The vertical valve clearance corresponds to the current valve shim size of the rail.
4. The value in the space between the vertical column and the horizontal bar is the specified valve shim size.
When the size of valve shims is equal to the value in the space, the size of valve clearance is just right.
Example: The current valve shim thickness is 1.60 mm.
The measured valve clearance is 0.33 mm.
Replace the 1.60 mm washer with a 1.70 mm valve shim.
5. Re-measure the valve clearance and make adjustments if necessary.
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Inlet valve clearance adjustment table
Example of current valve shim
Thickness (mm) 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.00～0.04 — — — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215
0.05～0.08 — — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2
0.09～0.12 — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25
0.13～0.19 Valve clearance / without the need to adjust
Example of measurement value of valve clearance (mm)
0.20～0.24 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.25～0.29 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.301～0.34 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.35～0.39 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.40～0.44 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.45～0.49 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.50～0.54 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.55～0.59 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.60～0.64 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.65～0.69 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.70～0.74 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.75～0.79 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.80～0.84 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.85～0.89 2.0 2.05 2.1 215 2.2 2.25 2.3
0.90～0.94 2.05 2.1 215 2.2 2.25 2.3
0.95～0.99 2.1 215 2.2 2.25 2.3 Thickness (mm) of valve shim to be installed
1.00～1.04 215 2.2 2.25 2.3
1.05～1.09 2.2 2.25 2.3
1.10～1.14 2.25 2.3
1.15～1.19 2.3
1. Measure the valve clearance (the engine has cooled).

2. Check the size of the current valve shim.
3. The vertical valve clearance corresponds to the current valve shim size of the rail.
4. The value in the space between the vertical column and the horizontal bar is the specified valve shim size.
When the size of valve shims is equal to the value in the space, the size of valve clearance is just right.
Example: The current valve shim thickness is 1.85 mm.
The measured valve clearance is 0.36 mm.
Replace the 1.85 mm washer with a 2.05 mm valve shim.
5. Re-measure the valve clearance and make adjustments if necessary.
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Notes
Be sure to re-measure the valve clearance
after selecting other valve shim in accordance
with the above table. If the valve clearance is
outside the specified range, use a supplementary
washer.
○ If there is no valve clearance, use a valve shim that
is several times smaller than that of the original one
and then measure the valve clearance again.
●When installing the valve shim, make the marked
side face the valve tappet. At this point, apply a little
oil to the valve shims or valve tappets so that the valve
shims are in place when the camshaft is installed.
Notes
Do not use multiple valve shim! In order to
prevent the engine from being seriously damaged
when the valve shims are popping up at a high
speed.
Do not attempt to reduce the thickness of
the valve shim when processing! In order to
prevent the engine from being seriously damaged
when the valve shim is broken.
● Apply oil to the surface of valve tappet and then
install the tappet.
● Install the camshaft (see "Installing the Camshaft" in
the chapter "Engine Cylinder Head and Cylinder Head
Cover").
Re-check the valve clearance and make adjustments if
necessary.
●Install the parts disassembled previously (see the
corresponding chapters).
Check whether the air inlet unit has been damaged
● Pull the intake pressure sensor and the engine intake
port connecting pipe [A] out of the intake pressure
sensor [B].
● Start the engine and make it run at idle speed.

● Press the end of the canister solenoid valve and the
engine intake port using your fingers to feel the
negative pressure pulse in the hose.
★ If you do not feel any negative pressure pulse,
check the air intake device for air leakage.
44
Clutch
Check if the clutch control system is normal
● Start the engine to ensure that the clutch does not
slip and can be separated normally.
★ If the clutch is not normal, check the clutch system.
WARNING
If you need to run a motorcycle during the
inspection, be sure to drive in a safe place.
Check the free stroke of clutch handle
Standard: 10-20mm.
★ If the free stroke is not accurate, please adjust the
clutch cable.
• Check whether the clutch handle is able to move
smoothly from full release to being griped, and the
return spring can quickly close the clutch completely,
regardless of the steering position.
★ If the clutch handle cannot be reset normally, check
the winding method of clutch cable, the free clearance
of handle and the cable for damage. Then lubricate the
clutch cable.
Rotate the handle to the right and left to ensure that
there is no change in the operation of clutch and the
gear is working smoothly.
If the gear cannot work smoothly, check the free
clearance and winding method of the clutch cable.
★ If necessary, adjust the throttle cable [A] as
follows:
⑴ Loosen the fastening nut [1] first.
⑵ The adjustment device is screwed in or out [2]
until the free stroke of the clutch handle meets the
specified value of 10-20mm.
⑶ Finally tighten the fastening nut [1].
★If the handle end of clutch cable is adjusted to the

limit position and cannot meet the requirements of free
stroke, it is adjusted by the clutch cable and the
locknut [A] and the adjusting nut [B] of the engine
end.
⑴ Loosen the fastening nut [A] first.
⑵ The adjustment device is screwed in or out [B]
until the free stroke of the clutch handle meets the
specified value of 10-20mm.
⑶ Finally tighten the fastening nut [A].
45
Wheel/tire
Check the tire pressure
●Remove the valve cap.
●When the tire is cooled (ie, the mileage traveled by
the motorcycle for 3 hours before the measurement
does not exceed 2Km), measure the tire pressure is
with a barometer [A].
● Put the valve cap back.
★ If necessary, adjust the tire pressure according to
the relevant specifications.
Tire pressure (when cooling the tire) :
Front wheel: 220±10kPa
Rear wheel: 250±10kPa
Check wheel / tire for wear
● Clean stones [A] or other foreign matter embedded
in the tread.
• Visually inspect the tire for cracks [B], cuts [C] and
nails [D] and replace the tire if necessary. If the tire
expands or bulges, it is damaged internally and needs
to be replaced.
• Visually inspect the wheel for cracks, cuts and dents.
★ If any damage is found, replace the wheel as
appropriate.
Check the wear of tread
● As the wear of tread becomes more and more
serious, the tire is more likely to burst. It is estimated
that 90% of tires are damaged during the last 10% of
the tire's service life (90% wear). So the tires have
been used until it is smoothed, which does not save
money, but it may cause safety problems.
• Use a depth gauge [A] to measure the tread depth in
the middle of the tread. Since the tires are unevenly
worn, it is necessary to measure at different locations.
★ If any of the measured values is below the
usage limit, the tires must be replaced (see
“Removing/Installing the Tire” in the chapter
“Wheels/Tires”).
Tread depth
Standard:
Front wheel: 3.8 mm
Rear wheel: 4.8 mm
Usage restrictions:
Front wheel: 1.6 mm
Rear wheel: 2.0 mm
WARNING
In order to ensure the safety and stability of
the tires, the existing tires must be replaced with
the recommended standard tires and the tires
shall be inflated according to the standard air
pressure.
46
Remarks
○ Most countries have specified the minimum depth
for the tread: Please be sure to follow the
provisions!
○ Check the wheels after the tires are replaced and
thus balance them.
Check whether the wheel bearing has been damaged
★ Lift the front wheel from the ground with a jack
(see “Removing/Installing the Tire” in the chapter
● Turn the handle all the way to the right or left.
● Shake the wheel frame to both sides with both hands
[A] and check the front wheel bearing for axial
clearance.
● Gently rotate the [B] front wheel to see whether the
wheel can rotate smoothly, whether it is difficult to
rotate, or whether there is abnormal resistance and
noise.
★ If the wheel is found to be difficult to rotate with
resistance or noise, remove the front wheel and inspect
the wheel bearing (see “Removing Front Tire and
Checking Hub Bearing” in the chapter
★ Lift the rear wheel from the ground with a jack (see
“Removing Rear Tire” in the chapter “Wheels/Tires”).
● Shake the wheel frame to both sides with both hands
[A] and check the rear wheel bearing for axial
clearance.
● Gently rotate the [B] rear wheel to see whether the
wheel can rotate smoothly, whether it is difficult to
rotate, or whether there is abnormal resistance and
noise.
★ If the wheel is found to be difficult to rotate with
resistance or noise, remove the rear wheel and inspect
the wheel bearing (see “Removing Rear Tire and
Checking Hub Bearing” in the chapter
“Wheels/Tires”) and shaft sleeve (see "Checking Shaft
Sleeve and Bearing" in the chapter "Final Drive
Mechanism").
47
Final Drive Mechanism
Check the lubrication state of drive chain
● If there is no special lubricant, it is preferred to use
heavy oil (eg SAE 90) instead of light oil, because
heavy oil can be attached to the drive chain for a
longer period of time and the lubrication effect is
better.
● If the drive chain looks dirty, it must be cleaned
before adding lubricant.
Notes
The lubricant of oil seal is sealed between
the side plates and the rollers. Therefore, in order
to avoid damage to the O-ring and reduce the
amount of lubricant, please observe the following
rules:
The O-ring of drive chain must be cleaned with
kerosene or diesel. Other cleaning solvents (eg,
gasoline or trichloroethylene) may corrode the
O-ring and cause it to expand. Dry the drive chain
with compressed air immediately after cleaning.
Make sure to clean and dry the drive chain within
10 minutes.
● Apply lubricant to both sides of the chain roller to
allow it to seep into the chain rollers and bushings.
Lubricate the O-ring to cover the surface of the O-ring.
● Wipe off excess oil.
Part to be lubricated: [A]
O-ring seal: [B]
Check whether the drive chain is slack

Remarks
○ Use a sidestand to support the motorcycle and
check whether the drive chain is slack; or use a
bracket to support the motorcycle and check
whether the drive chain is slack.
○ If the drive chain is smudged, clean it first, and
then dry and lubricate it.
● Check the wheel alignment (see "Checking wheel
Alignment" for details).
● Rotate the rear wheel to find the tightest position of
drive chain.
● Measure the up and down swing of the chain
between the front and rear sprockets (drive chain is
slack) [A].
★ If the drive chain slackness is beyond the standard,
please adjust it!
Drive chain slackness
Standard: 20-35 mm
Adjust drive chain slackness

★ Lift the rear wheel from the ground with a jack (see
“Removing Rear Tire” in the chapter “Wheels/Tires”).
48
●Loosen the rear wheel axle nut [A].
●Unscrew the left and right chain adjuster locknuts

[C].
● Rotate the adjustment nuts of left and right chain
adjusters [B] evenly until the slackness of drive chain
is appropriate. In order to align the drive train and the
wheel, the notch on the right wheel alignment
indicator should correspond to the swing arm mark or
position to which the notch on the left wheel alignment
indicator is aligned.
★ If the drive chain is too loose, adjust the chain
adjuster on the right and the chain adjuster on the left
counterclockwise from the rear view of the vehicle and
average it to the left and right sides.
★ If the drive chain is too tight, adjust the right chain
adjuster and the left chain adjuster clockwise from the
rear view of the vehicle to average the left and right
sides, then kick the wheel forward.
Screw in Increase the slackness
Screw out Reduce the slackness
WARNING
If the wheels are not aligned, abnormal wear
may be caused to the wheels and dangers may be
caused when riding.
●Be sure to tighten the left and right chain adjuster
locknuts [C].
● Tighten the axle nut.
Locking torque of rear axle nut: 150 N•m
● Rotate the wheel and measure the slackness of the
drive chain again at the tightest point of the drive
chain and re-adjust it if necessary.
Warning
If the rear axle nut is not tightened, dangers
may be caused when riding.
49
Check wheel alignment
● Check whether the position of concave scale line [B]
at the right chain adjuster [A] on the rear swing arm
[C] matches the concave scale line of the left chain
adjuster.
★ If misaligned, adjust the slackness of drive chain
and align the wheel alignment (see “Adjusting the
Slackness of Drive Chain” for details).
Remarks
○ You can also check the wheel alignment with a
ruler or a rope.
WARNING
If the wheels are not aligned, abnormal wear
may be caused to the wheels and dangers may be
caused when riding.
Check the wear of drive chain
● Remove the chain cover (see “Removing the Drive
Chain” in the chapter “Final Drive Transmission” for
details).
● Rotate the rear wheel to check for damaged rollers,
loose split pins and chain links on the drive chain.
★ If any abnormality is found, the drive chain must be
replaced.
● If the drive chain looks dirty, add lubricant.
●Hung a 10kg weight on the drive chain to tighten the
drive chain.
●Measure the length of the 20 links [B] of the drive
chain of the straight section [C] (from the center of the
first cotter pin to the center of the 21st cotter pin).
Since the drive chains are unevenly worn, it is
necessary to measure at different locations.
★ If any of measurement values exceeds the usage
restriction, the drive chain must be replaced.
Meanwhile, replace the front sprocket and the rear
sprocket.
Length of the 20 links of the drive chain
Standard: 317.5 - 318.2 mm
Operating limit: 323 mm
WARNING
If the drive chain wear exceeds the
operating limit, the drive chain must be replaced
or dangers may be caused when riding. If the
drive chain breaks or falls off the sprocket, it
may catch the engine sprocket or lock the rear
wheel, which will seriously damage the
motorcycle and make it out of control.
To ensure safety, a standard drive chain
must be used. The standard drive chain is a
no-link chain and must not be cut off during
installation.
Standard drive chain
Model: 520HO
Link: 110 links
50
Check the wear of chain guide
● Remove the rear swing arm (see “Removing Rear
Swing Arm” in the chapter “Suspension System”).
● Visually inspect the chain guide [A].
★ If the chain guide looks abnormally worn or
damaged, it must be replaced.
Important notice

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Brake
Check brake hoses and brake lines for damage and ensure their installation status
The precautions for models equipped with CBS are as
follows:
●Disassemble:
Fuel tank (see “Removal of Fuel Tank” in the chapter
“Fuel Injection System (EFI)”),
battery (see “Removal of Battery” – “Electrical
System”).
●Check brake hoses, brake lines and fittings for

corrosion, cracks or leaks.
○If the brake hoses and brake lines are not properly
serviced, the high pressure inside the brake lines may
cause brake fluid to leak [A] or the brake hoses and the
brake forming tubes to burst. When checking rubber
hoses, bend and twist them. When checking rubber
hoses, bend and twist them.
★If any cracks [B], swelling [C] or leaks are found on
the brake hose or brake forming tube, they must be
replaced.
●Tighten all hollow bolts of brake hose.
Locking torque for hollow bolt of brake hose: 25 N•m
Locking torque for connecting nut of brake hose: 18
N•m
●Check the winding method of brake hose.

★If the brake hoses and brake lines are not wound
correctly, please arrange brake hoses and brake lines in
accordance with the section "Winding Method of
Cables, Wires and Hoses" of chapter "Appendix".
Free stroke of front brake
●Measure at the tip of front brake lever
at the tip of brake lever.
Free stroke: 10-20mm
Free stroke of rear brake

Measure the free stroke of brake pedal.
Free stroke: 20-30mm.
52
★Adjust if it does not meet the specified value.
○Adjust the free stroke of brake pedal.
1. First loosen the nut [A] on the joint [C].
2. (2) Screw in or out the ejector rob [B] to adjust
the free stroke of brake pedal.
If the ejector rob [B] is screwed in, the free
stroke will be reduced;
If the ejector rob [B] is screw out, the free
stroke will be increased.
3. Tighten nut [A] until the free stroke meets
specified values.
4. After adjustment, the brake dragging
phenomenon shall be avoided.
★If the adjusting rod [B] cannot satisfy the free stroke
of brake pedal, then adjust the limit bolt [D] and adjust
the free stroke of the brake pedal according to the
following steps:
(2) Screw in or out the limit bolt [D] to adjust the
free stroke of brake pedal.
If the limit bolt [B] is screw in, the free
stroke will be reduced.
If the limit bolt [D] is screw out, the free
stroke will be increased.
(2) Screw in or screw out it until the free stroke
meets the specified value.
(3) After adjustment, the brake dragging
phenomenon shall be avoided.
★If the free clearance of brake pedal cannot be
adjusted with the adjuster, please replace the brake
pedal.
Inspection of brake
● Check whether front brake and rear brake are normal
when riding a motorcycle on a dry road.
★ If the brake is abnormal, check the brake system.
WARNING
If you need to test-ride a motorcycle during the
inspection, make sure to do it at a place under safe
traffic conditions.
Inspection of brake fluid level
● Check whether the level of brake fluid in the front
brake fluid pump [B] is higher than the lower limit of
oil lens [A].
Remarks
○ When checking the brake fluid level, rotate the
handle to make the fluid reservoir level.
Important notice

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★ If the liquid level is below the lower limit, add
brake fluid to the reservoir until the liquid level
reaches the high liquid level line [A].
Remarks
○Brake fluid may damage the painted surface or
plastic parts. Therefore, apply absorbent paper
around the pump and immediately clean the spilled
brake fluid.
● Check the brake fluid cylinder diaphragm on the
cover. If there is any damage/wear, please replace the
brake fluid cylinder diaphragm
● Check whether the brake fluid level in the rear brake
fluid reservoir [A] is between the upper limit [B] and
lower limit [C].
★ If the liquid level is below the lower limit, add
brake fluid to the reservoir until the liquid level
reaches the high liquid level line [C].
● Check the brake fluid diaphragm on the fluid
reservoir. If there is any damage/wear, please replace
the brake fluid diaphragm
WARNING
If you need to add brake fluid but are not sure
about the type and brand of brake fluid in the
brake fluid reservoir, you must replace the brake
fluid in the brake fluid tube. After replacing
brake fluid, use only brake fluid of the same type
and brand.
When adding brake fluid, be careful not to allow
any water to enter the container. Water will
significantly reduce the boiling point of the
brake fluid, which will generate steam bubbles
when heated, and thus lead to a reduction in
brake system.
Recommended disc brake fluid
Grade: DOT4
●Properly install the cover of rear brake fluid reservoir
according to the following procedures.
○ First, tighten the cover [B] of rear brake fluid
reservoir with your hands clockwise [C] until you feel
a little resistance, indicating that the cover has been
fixed on the reservoir, then hold the reservoir [A] and
rotate it by 1/6 turn [D].
Inspection of wear of brake pad

●Remove the brake pads (see “Disassembly of
front/rear wheel brake pad” in chapter “Brake” for
details).
●Check the thickness of friction plate of brake pad
inside the caliper [A].
★If the thickness of friction plate of any brake pad is
lower than the operating limit [B], replace the two
brake pads inside the caliper simultaneously.
Thickness of friction plate of brake pad
Standard:
Front wheel brake pad: 4.0 mm
Rear wheel brake pad: 4.0 mm
54
Inspection of brake light switch
●Open the electric door lock.
● When the brake lever is pulled by about 200 mm or
the brake pedal is pressed by about 25mm, the brake
light is on.
★If the brake light is off, check or replace the following

parts:
Battery (see “Inspection of Charging” – “Electrical
System”).
Brake light (see “Removal of Taillight / Brake Light” –
“Electrical System”).
30 A main fuse and 10 A taillight fuse (see “Inspection of
Fuse" – “Electrical System”);
Front brake light switch [A] (see “Inspection of Switch" –
“Electrical System”);
Rear brake light switch (see “Inspection of Switch" –
Wire harness (see “Inspection of Line” – “Electrical
System”).
Check the output voltage of speed sensor
● Check the input voltage before checking the output
voltage (see "Inspection of the Input Voltage of Speed
Sensor" for details).
Remarks
○ The battery is fully charged.
●Close the electric door lock.

●Lift the rear wheel using a parking frame.
● Disconnect the speed sensor joint and connect the sensor
cable adapter between the harness connector and the speed
sensor joint.
● Connect the digital meter to the wire of the sensor cable
adapter.
Output voltage of speed sensor
Connection to the sensor cable adapter:
Electric meter (+) → Y / W (sensor Y) wire [C]
Electric meter (-) → BK / BL (sensor BK) wire [D]
● Measure the output voltage with the engine off and the
sensor line adapter bridged to the power supply.
Output voltage of sensor

Standard: approximately equal to DC0.05-0.09V or
DC4.5-4.9V
● Rotate the rear wheel by hands to see whether the output
voltage is increased or reduced.
★ If the reading is outside the above range, check the speed
sensor (see “Inspection of Speed Sensor” in the chapter
“Electrical System”) and ECU circuit (see the wiring
55
diagram in this section for details).
★ If there is no problem with the readings, speed sensor and
wiring, replace the ECU (see “Removing/Installing ECU”
for details).
Speed sensor (fault code: front: C0080, C0081, C0082, C0083: rear: C0100, C0101, C0102, C0103)
56
Suspension system:
Check front fork / rear shock absorber
● Shake the front fork up and down for four or five
times to check whether the stroke of shock absorber is
smooth.
★ If the front fork does not move smoothly or there is
noise, check the fuel level of the front fork shock
absorber or the fork clamp (see “Replacing Front Fork
Shock Absorber Oil” in the chapter “Suspension
System”).
● Shake the seat cushion up and down for four or five

times to check whether the stroke of shock absorber is
smooth.
★ If the stroke of shock absorber is not smooth or
there is noise, check whether the shock absorber oil
leaks (see “Checking the Rear Shock Absorber for Oil
Leakage”).
Check the front fork shock absorber for oil leakage

● Visually check whether the front fork shock absorber
[A] for oil leakage.
★ Replace or repair any defective parts if necessary.
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Check the rear shock absorber for oil leakage
● Visually check whether the rear shock absorber [A]
for oil leakage.
★ In case of oil leakage, replace the shock absorber.
Important notice

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Steering system
Check steering clearance
● Lift the front wheel from the ground with a jack.
Special tool—jack:
●When the front wheel is straight ahead and the front
wheel is lifted off the ground, just push the left or right
handle [A], the whole handle should be able to slide
freely to the upper left and right steering limits by
gravity.
★ If the entire handle cannot slide freely to the upper
left and right steering limits, the steering system is too
tight.
●Push the front fork and check whether there is a too
large clearance in the steering system.
★ If it is too loose, the steering system is too loose.
Remarks
○Cables and wires must be considered for
connection as they may affect the movement of
front fork.
○Make sure that the wires and cables are wound in
the correct way.
○The state of bearing must be good, and the
lubricating oil has been properly added, otherwise,
the test result is invalid.
Adjust the steering seat properly
●Disassemble:
Handlebar (see "Removing Handlebar" in the chapter
"Steering Gear");
Remove the steering column head bolt [A] with an
Allen wrench [B];
Loosen the fastening bolt [C] of upper bracket[D]
(release)
Remove the upper bracket [D]
Remove locknut of steering stem [E].

Special tools - steering stem nut wrench: four claws
●Adjust the locknut of steering stem [F].
★Tighten the steering stem locknut [F] to the torque
of 30-35N•m
Special tools - steering stem nut wrench: seven claws
★ Rotate the steering stem to the left and right for 2-3
times. When rotating, it cannot be stuck and the
bearing race cannot be loose.
★Loosen the locknut E by 1/4 turn and then tighten,
use the relevant wrench to tighten the locknut F;
★Tighten the steering stem locknut [F] to the torque
of 20-24N•m
●Install the locknut of steering stem [E].
Special tools - steering stem nut wrench: four claws
★Tighten the locknut [E] to the torque of 60N•m
Warning:
Do not fasten the locknut [E] too excessively.
● Check the looseness of steering seat
59
★ Make sure that the pillars are not loose, and
horizontally rotate the front forks to the end of the
stroke to ensure that there are no obstructions. If there
are any blocking points, remove the lower bracket
components and check the upper and lower steering
bearings.
● Install the upper bracket.
● Install the steering stem head.
● Install the steering stem head bolts.
● Install the handlebar.
● Tighten:
Locking torque of steering stem head nut: 78 N•m
Upper bracket fastening bolt (C): 30 N·m
Handlebar fastening bolt: 20N•m
Check the steering gear again.
★ If the steering gear is still too tight or too loose,
re-adjust it.
● Install the handlebar (see "Installing the Handlebar"
in the chapter "Steering Gear").
Lubricate steering stem bearings
Remove the steering stem (see "Removing Steering
Stem, Steering Stem Bearing" in the chapter "Steering
Gear");
● Clean the ball bearings in the upper and lower
holders using the solvent with a high flash point and
wipe the outer races at the top and bottom. The outer
race is pressed into the head section steering column.
Clean grease and dust.
● Visually inspect the outer race and ball bearings.
★ If the bearing assembly appears to be worn or
damaged, it must be replaced.
● Wrap the upper and lower ball bearings [A] in the
holder with grease, and then apply a thin layer of
grease to the outer races at the top and bottom.
Install the steering stem (see "Installing Steering Stem,
Steering Stem Bearing" in the chapter "Steering
Gear");
● Adjust the steering gear (see “Adjusting the Free
Clearance of steering”).
Important notice

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Electrical System
Check lights and switches
Step I
●Various lights will be on in the order of the following table.
Position light (LED)[A] On
Taillight (LED)[B] On
License plate light [C] On
Meter panel (LCD)[D] On
Water temperature warning indicator light
On
(LED)[E]
Fuel alarm indicator light (LED) [F] On
Fault alarm indicator light (LED) [G] On
Neutral position indicator light (LED) [H] On
ABS indicator (LED) [I] (model with ABS) On
★If the light is out, check or replace the following parts:

Battery (see “Inspection of Charging” – “Electrical
System”).
30 A main fuse and 10 A taillight fuse (see “Inspection of
Applicable bulbs (see “Wiring Diagrams” in the chapter
The head part of meter panel (LCD) (see "Checking the
Meter Part" in the chapter "Electrical System");
The head part of water temperature alarm indicator light
(LED) (see "Checking the Head Part" in the chapter
"Electrical System");
The head part of fuel alarm indicator light (LED) (see
"Checking the Head Part" in the chapter "Electrical
System");
The head part of fault alarm indicator light (LED) (see
System");
The head part of neutral position indicator light (LED) (see
System");
The head part of ABS indicator light (LED) (see "Checking
the Head Part" in the chapter "Electrical System");
The head part of ABS indicator light (LED) (see "Checking
the Head Part" in the chapter "Electrical System");
;ECU (see “Inspection of ECU Power Supply” in the chapter
“Fuel Injection System (EFI)”);
Electric door lock (see “Inspection of Switch” – “Electrical
System”).
Gear position switch (see "Inspection of Gear Position
Switch" – “Electrical System”);
System”).
ABS indicator (LED) (model with ABS) [See "Checking the
ABS Indicator (LED)" in the chapter "Brakes")
●At this time, all lights should be turned off.
★ If the light does not go out, replace the electric door lock.
61
Step II
● Turn on the turn signal light switch [A] (left or
right).
●The left or right turn signal light (LED)

(corresponding to the position of switch) (front and
rear) will flash.
●The left/right turn indicator light (LED) [C] in the

meter panel will flash.
★ If the left or right turn signal light is out, check or
replace the following parts:
Turn signal light (LED) (see “Replacing the Turn
Signal Light” in the chapter “Electrical System”);
Turn signal indicator light (LED) (see "Checking the
Head Part" in the chapter "Electrical System");
Turn signal light switch (see “Inspection of Switch" –
System”).
● Push back the turn signal switch.
●The turn signal light and turn signal indicator light
(LED) are dimmed.
★If the light is not dimmed, check or replace the
following parts:
Turn signal light switch (see “Inspection of Switch" –
62
Step III
● Rotate the dimmer switch [A] to the position of
low-beam light.
● Start the engine.
●The low-beam headlight [B] shall be on.

★If the low-beam headlight is out, check or replace
the following parts:
Low-beam bulb of headlight (see “Replacing the Bulb
of Headlight” in the chapter “Electrical System”);
15A fuse of headlight (low-beam) (see “Inspection of
10 A fuse of headlight relay (see “Inspection of Fuse"
– “Electrical System”);
Headlight circuit relay in relay box (see “Inspection of
Relay Circuit" – “Electrical System”);
Headlight relay (low-beam) (see “Inspection of
Headlight Relay" – “Electrical System”);
System”).
●Press the passing light switch [C] (model with
passing light switch) or rotate the dimmer switch to the
position of high-beam light.
● Low-beam headlight [E] and high-beam headlight

[D] should remain on.
63
●The high-beam indicator light (LED)[C] shall be on.
★ If the high-beam headlights and/or high-beam
indicator light (LED) are out, check or replace the
following parts:
High-beam bulb of headlight (see “Replacing the Bulb
of Headlight” in the chapter “Electrical System”);
15A fuse of headlight (high-beam) (see “Inspection of
10 A fuse of headlight relay (see “Inspection of Fuse"
– “Electrical System”);
Passing light switch button (model with passing light
switch button) (see “Inspection of Switch” in the
chapter “Electrical System”;
Dimmer switch (see “Inspection of Switch" –
Headlight relay (high-beam) (see “Inspection of
Headlight Relay" – “Electrical System”);
System”).
● Turn off the emergency stop switch.
● Low-beam and high-beam headlights should remain
on.
★ If the headlights and high-beam indicator lights
(LED) are out, check or replace the following parts:
●The headlight and high-beam indicator light (LED)
shall be out.
Important notice

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Check the headlight accuracy
● Check the accuracy of headlight beam.
★ If the headlight beam is pointing to one side instead
of pointing straight ahead, ajust the beam.
Correctly adjust the beam of headlights as follows:
Park the vehicle about 10 meters in front of the upright
wall and park it on a completely flat surface. Fig. A
Ride on the motorcycle and sit in the rider position.
Make sure that the highest point of beam, such as on
the wall, which is less than 1/10 of the horizontal axis
of the headlights.
If the beam does not fall within these ranges, make
adjustments to make it in the correct position.
Adjustment of headlight beam

● Remove the inner cover (see “Removing the Inner
Cover” in the chapter “Frame”).
● Screw in or out the low-beam adjustment screw [A]
and the high-beam adjustment screw [B] inside the
two headlights, until the beam is directly pointing to
the front.
★ If the headlight beam is too low or too high, adjust
the vertical beam.
Low-beam rotating screw at the left [A]
Rotate the screw counterclockwise to reduce the b
eam
Rotate the screw clockwise to raise the beam
High-beam rotating screw at the right [B]
Rotate the screw counterclockwise to reduce the b
eam
Rotate the screw clockwise to raise the beam
Remarks
○ When the motorcycle is supported by its wheels
and someone is riding on the motorcycle, turn on
the high-beam light, the brightest point should be
slightly lower than the horizontal line. Adjust the
angle of the headlights according to local
regulations.
Important notice

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Check the sidestand flameout switch
●Check the sidestand switch [A] according to the table
below.
Sidestand flameout switch

Clutch operating Engine start
Sidestand Gear position Engine is running
lever switch
Upper Neutral Release Start Continuous running
Upper Neutral Tightening Start Continuous running
Upper Engage a gear Release Not started Continuous running
Upper Engage a gear Tightening Start Continuous running
Lower Neutral Release Start Continuous running
Lower Neutral Tightening Start Continuous running
Lower Engage a gear Release Not started STOP
Lower Engage a gear Tightening Not started STOP
★If the sidestand switch is abnormal, check or replace the

following parts:
Battery (see “Inspection of Charging” – “Electrical System”).
30 A main fuse (see “Inspection of Fuse" – “Electrical System”);
30 A ECU fuse (see “Inspection of Fuse" – “Electrical System”);
10 A ignition fuse (see “Inspection of Fuse" – “Electrical
System”);
Electric door lock (see “Inspection of Switch” – “Electrical
System”).
Sidestand stop switch (see “Inspection of Switch" – “Electrical
System”);
Emergency stop switch (see “Inspection of Switch" – “Electrical
System”);
Start switch button (see “Inspection of Switch" – “Electrical
System”);
Gear position switch (see "Inspection of Gear Position Switch" –
Starter relay (see “Inspection of Starter Relay" – “Electrical
System”);
Relay box (see “Inspection of Relay Circuit" – “Electrical
System”);
Starter circuit relay (high-beam) (see “Inspection of Headlight
Relay" – “Electrical System”);
Wire harness (see “Inspection of Line” – “Electrical System”).
★ If the above parts are normal, replace the ECU.
66
Check emergency stop switch
Step I
● Set to neutral.
● Rotate the emergency stop switch to the stop
position [A].
●Press the starter button.
● At this point, the engine should not be started.
★If the engine has been started, check or replace the
following parts:
Emergency stop switch (see “Inspection of Switch" –
Step II
● Set to neutral.
● Rotate the emergency stop switch to the power
supply position [A].
●Press the starter button to start the engine.
● Rotate the emergency stop switch to the Off
position.
● The engine should stop running immediately.
★ If the engine does not stop, check or replace the
following parts:
Emergency stop switch (see “Inspection of Switch" –
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Others
Lubricate frame parts
● Before lubricating any parts, use a rust remover to
remove the rust on the parts and wipe off grease, oil,
dirt or grime.
● Lubricate the following positions with the specified
lubricant.
Remarks
○ If you use a motorcycle in a humid or rainy day,
especially if you use a high-pressure water spray to
wash the motorcycle, you must lubricate the parts as
follows.
Pivot shaft: lubricate it with grease
Brake handle
Brake pedal
Clutch handle
Rear brake master cylinder pump connecting pin
Sidestand
Wire: lubricate it with grease
Wire rope of throttle cable [A]
Cable: lubricate it with grease

Throttle cable
●Lubricate the cable by placing a rust inhibitor
between the cable and the housing.
○ You can also purchase the spray lubricant on the
market for the throttle cable.
68
● After disconnecting the two ends of the throttle
cable, the cable inside should be free to move [A].
★ If the cable does not move smoothly after adding
the lubricant, the cable is worn [B] or the throttle cable
housing is cracked [C], the throttle cable must be
replaced.
Check the tightness of bolts, nuts and fasteners

Check the tightness of bolts and nuts listed below. In
addition, check whether all cotter pins are in the
proper positions and in good conditions.
Remarks
○Check the tightness of engine fasteners when the
engine is cooled (to the indoor temperature).
★ If the fasteners are loose, tighten them according to
the specified tightening sequence and locking torque.
See the corresponding chapters for the provisions on
torque. If locking torque is not described in the
corresponding chapters, refer to the Standard Torque
Table. When tightening any one of the fasteners, first
tighten it by 1/2 turn and then continue to tighten it.
★ If the cotter pin is broken, it must be replaced with
a new one.
69
Bolts, nuts and fasteners to be checked
Engine:
Clutch lever pivot bolt locknut,
engine mounting bolt and nut,
engine bracket clamp bolt,
engine hanging board clamp bolt,
exhaust pipe flange clamp bolt,
muffler chamber clamp bolt,
Muffler cylinder mounting bolt
Shift rocker arm clamp bolt,
Wheel:
Front wheel axle,
clamp bolt of front wheel axle,
Rear wheel axle,
Rear wheel axle nut,
Brake:
Pivot bolt locknut of brake lever,
brake pedal bolt,
caliper mounting bolt,
clamp bolt of front master cylinder,
clamp bolt of rear master cylinder section,
Rear master cylinder mounting bolt:
Suspension system:
Upper bracket clamp bolt of front shock absorber,
lower bracket clamp bolt of front shock absorber,
upper bolt of rear shock absorber,
lower bolt of rear shock absorber,
rear swing arm shaft,
Nut of rear swing arm shaft,
Steering gear:
Handlebar holder bolt,
Handlebar holder clamp nut
Steering stem head clamp bolt;
Others:
Footpeg bracket bolt
Sidestand bolt
70
Replacement part
Replace of air filter element
Remarks
○ If the motorcycle is used in a dusty environment,
the interval for replacing the air filter element is
shorter than the recommended replacement interval.
○ Immediately replace the air filter element after
riding on a rainy day or riding on a muddy road.
WARNING
If dirt or dust enters the throttle body
assembly, the throttle may be blocked, thereby
causing a safety hazard.
Notes
If dirt enters the engine, it may cause excessive
wear to engine and even damage the engine.
Open the seat cushion lock using the key [A].
●Remove the rear seat [A]
71
●Pull the front seat cushion cable [A] and remove the
front seat cushion [B]
●Remove mounting screw [A]
●Remove the air filter inlet [A]
●Remove air filter element [A].
72
● check filter element [A]:
○Check whether the filter element is contaminated or
damaged.
○If any, please replace it with a new one.
★ Cleaning:
○ Rinse the filter element softly and thoroughly with
cleaner.
○Then apply the oil to the filter element and then
squeeze out the redundant oil, ○so that the filter
element is moist without oil dripping.
Remarks
○Do not use the gasoline so as not to cause fires.
○Do not distort or warp the filter element so as not
to damage the foam materials.
● Install a new filter element.
Notes
Use the recommended air filter element (Benelli
part number: 49202N220002). If other air filter
elements are used, the engine may be damaged
prematurely or its performance may be
reduced.
●Install it in the reverse order of disassembly.
● Tighten:
Locking torque of screw at air filter element inlet: 5
N·m
● Install the removed parts.
73
Replacement of fuel hose
Remove the fuel tank (see “Removing Fuel Tank” -
“Fuel Tank”).
● Remember to wrap the hose joint [A] with a piece of
cloth.
●Press the joint lock claw [A].

● Pull the joint [C] in the direction shown in the figure
[B].
● Remove the fuel hose components from the fuel
tank.
WARNING
If some fuel spills, it must be thoroughly
cleaned.
When the fuel hose is disconnected, the fuel
may overflow from the fuel hose. Therefore,
cover the hose joint with a clean workshop rag to
prevent fuel from overflowing.
● When installing a new fuel hose, properly arrange

the fuel hose (see section "Winding Method of Cables,
Wires and Hoses" of Chapter "Appendix" for details).
● Insert the fuel hose joint directly into the fuel pump
supply hose until the hose joint clicks.
● Push and pull the fuel hose joint back and forth
twice to ensure that it has been locked and will not fall
off.
WARNING
Ensure that the hose joint has been properly
installed on the fuel supply line, otherwise, the
fuel may leak.
★ If the fuel pipe joint is detached, reinstall it.
● Start the engine and check whether the fuel pipe is
leaking.
74
Replacement of coolant
WARNING
Do not remove the radiator cap or replace
the coolant when the engine is still hot to avoid
burns. Wait for the engine to cool before
performing the above operation. If the coolant
splashes on the tire, the tire may slip, which may
cause a motorcycle accident or personal injury.
Therefore, once any coolant splashes on the frame,
engine or other painted parts, wipe/clean them
immediately.
Since the coolant is harmful to the human
body, it is forbidden to be drunk!
●Disassemble:
Radiator cap [A]
○ Remove the radiator cover in two steps: first turn the
radiator cover counterclockwise to the first stop point,
then continue to rotate in the same direction, and push
it to remove the cover.
● Remove the right cowling (see “Removing

Cowling” in the chapter “Frame”).
● Place a container under the drain bolt [A] at the
bottom of the pump cover.
●Remove the drain bolt [A] and drain the radiator and
the coolant inside the engine.
75
●Disassemble:
Clamp [A]
hose [B],
bolt [D],
expansion kettle [C],
overflow hose [F],
● Remove the cover [E] and pour the coolant into a
container.
● Install the expansion kettle [C] and install the hose

[B] and overflow hose [F] of the expansion kettle
correctly.
● Tighten the bolt [D].
Locking torque of expansion kettle bolt: 9.8 N·m
● Tighten the drain bolts (with washers).
○Replace the gasket of drain bolt.
Locking torque of coolant drain bolt: 10 N·m
●Add coolant to the radiator until the liquid level

reaches the filler neck [A] of the radiator, and then
cover the radiator cap.
Remarks
○Pour the coolant slowly to remove the air from the
engine and radiator.
●Pour the coolant until the level reaches the full liquid
level of the reservoir and close the lid.
Notes
Use the recommended coolant first (Benelli part
number: 06109P250000). Use other coolants that
may damage the engine or reduce engine
performance.
Notes
The antifreezing liquid in the cooling system
must be soft water or distilled water.
If hard water is used in the cooling system, scale
may deposit in the water pipe, thus greatly
reducing the efficiency of cooling system.
76
● Discharge the air from the radiator as follows:
Start the engine (the radiator cover has been removed)
and keep the engine running between 3000 RPM and
4000 RPM until there is no air bubble in the coolant
[A].
○Tap the radiator hose to remove air bubbles from the
hose.
○Turn off the engine and add coolant until the liquid
level reaches the filler neck of the radiator.
●Tighten the radiator cover.
●Start the engine and warm it up completely until the
radiator fan rotates and then shut down the engine.
●After the engine has cooled, check the level of the
coolant in the expansion kettle.
★If the coolant level is lower than the low level line,
add coolant until the level reaches the highest level.
Notes
Do not exceed the maximum level line when
adding coolant.
77
Replacement of radiator hose
● Drain the coolant (see "Replacing Coolant" for
details).
●Disassemble:
Engine cowling (see “Removing Engine Cowling” in
chapter “Frame”),
Cover (see “Removing Middle Cover” in chapter
“Frame”).
Clamp [A]
Inlet hose [B]
● Install a new hose and tighten the clamp.
Locking torque of radiator hose (water pipe) lock
screw: 2.0 N·m
● Add the coolant (see "Replacing Coolant" for
details).
● Check whether the cooling system is leaking.
78
Replace oil
●After the engine is warmed up, place the motorcycle
to make it perpendicular to the ground.
● Remove the oil drain bolt [A] to drain the oil.
○ Place a suitable container under the oil drain bolt

[A] to collect the oil.
● Drain: Oil in the crankcase.
●Tighten the oil drain bolt.

Locking torque of oil drain bolt: 22 N•m
● Pour the specified amount of specified type of oil.
Notes
To ensure that the fuel level is in the middle of oil
immersion lens [A]
Recommended oil
Model: API SE, SF or SG
API SH, SJ or SL, JASO MA, MA1 or MA2
Viscosity: SAE 10W-50
Capacity: 1.2 L (when replaced);
1.5 L (completely disassemble the engine)
Remarks
○ Do not add any chemical additives to the oil! The
oils that meet the above requirements are carefully
formulated to provide adequate lubrication action
to the engine and clutch.
○ Although oil with a viscosity of 10W-50 is
recommended for most cases, it is also necessary to
make corresponding changes according to the
atmospheric conditions in the specific use area.
79
Replacement of brake hose
Notes
Brake fluid may quickly corrode the surface of
painted part, so if the brake fluid spills on any
plastic part, it must be thoroughly rinsed
immediately.
●Remove the hollow bolt of brake hose [A].
●When removing brake hose, be careful not to spill
brake fluid on any painted part.
●When removing brake hose [B], temporarily fix the
end of brake hose in a high place to minimize the loss
of brake fluid.
●If brake fluid overflows, clean it immediately.
80
●All sides of brake line fittings are equipped with washers.
They needs to be replaced with new ones when installed.
● Tighten:
● Avoid excessively bending, snarling, squeezing or twisting
the brake hose when installing, and arrange the brake hose
in accordance with the section "Winding Method of Cables,
Wires and Hoses" of chapter "Appendix".
●Fill the brake line with brake fluid after installing brake
hose. (See “replacement of brake fluid” for details).
81
Replacement of rear brake hose
Notes
immediately.
Remove the rear brake hose clamp [A].
●When removing the rear brake hose, be careful not to
spill brake fluid on any painted part.
●When removing the rear brake hose [B], temporarily
fix the end of brake hose in a high place to minimize
the loss of brake fluid.
●If brake fluid overflows, clean it immediately.
●The rear brake fuel hose needs to be replaced with

new ones when installed.
● Avoid excessively bending, snarling, squeezing or
twisting the brake hose when installing, and arrange
the brake hose in accordance with the subsection
"Winding Method of Cables, Wires and Hoses" of
chapter "Appendix".
●Fill the rear brake hose with brake fluid after
installation. (See “replacement of brake fluid” for
details).
82
Replacement of brake fluid
●Park the motorcycle on a flat ground
Remarks
○Support the motorcycle with a parking rack and
make sure that it is upright
●Check brake fluid level
★ If it is lower than the minimum mark of oil
immersion lens [A], add the recommended brake fluid
to the correct level.
● Remove the brake fluid cylinder cover [B] from the
brake pump
● Check the brake fluid cylinder diaphragm on the
cylinder.
If there is any damage/wear, please replace the brake
fluid cylinder diaphragm
Notes
immediately.
● Hold the brake handle and add brake fluid until the
brake fluid level is above the oil immersion lens of
master cylinder
WARNING
Use only the prescribed brake fluid. Other brake
fluids may cause deterioration of rubber gasket,
thus resulting in leakage and improper operation
of brake system.
Use the same brand of brake fluid in the process
of adding brake fluid. The mixture of different
brake fluids may cause harmful chemical
reactions and thus result in the reduction of
brake system performance.
When adding brake fluid, be careful not to allow
any water to enter the container. Water will
significantly reduce the boiling point of the
brake fluid, which will generate steam bubbles
when heated, and thus lead to a reduction in
brake system.
83
Remarks
○ The steps for replacing the front brake fluid are as
follows. The procedures for replacing the rear
brake fluid are the same as the procedures for
replacing the front brake fluid.
●Replacement of brake fluid
1. With the main cylinder level, remove the brake
fluid cylinder head.
2. Install the pipe on the front end of oil drain screw
[C] and prepare the oil pan at the front end of
hose.
3. Loosen the oil drain screws.
4. Operate the brakes for several times until the oil
drain screw no longer discharges the brake fluid.
5. Tighten oil drain screw.
6. Inject the brake fluid above the lower limit.
7. Pull the brake handle to fill the brake fluid hose
with brake fluid.
8. Slowly move the brake handle until no bubbles
appear in the small holes in the brake cylinder
and a force is felt at the the brake handle.
9. Release the air.
After the adjustment is completed, install it in the

reverse order of disassembly.
Remarks
○ Frequently check the brake fluid level of
reservoir and replenish the new brake fluid as
needed. If the brake fluid in the reservoir is used up
during the replacement of brake fluid, the air in the
brake hose must be drained.
● Remove the transparent plastic hose.
● Install the diaphragm and reservoir cap.
●Properly install the rear brake fluid reservoir cap
according to the following procedures.
○ First, tighten the front / rear brake fluid reservoir cap
[B] with your hands clockwise [C] until you feel a
little resistance, indicating that the cap has been fixed
on the reservoir of master cylinder of storage tank,
then hold the brake fluid reservoir cap [A] and rotate it
by 1/6 turn [D].
● Tighten:
Locking torque of fastening screw of front brake fluid
reservoir cap: 1.2N·m
●Tighten the bleeder screw and install the rubber
cover.
Locking torque of bleeder screw: 7.8 N·m
● After replacing the brake fluid, check whether the
84
performance of brake is good, whether the braking is
blocked, and whether the brake fluid leaks.
★ If necessary, blow out the air in the brake hose.
85
Replacement of rubber parts of master cylinder
Disassemble front master cylinder
● Remove the front master cylinder (see “Disassembly
of Front Master Cylinder” in the chapter “Brakes”).
● Remove the reservoir cap mounting screw [F],
reservoir cap [E] and diaphragm [D].
● Unscrew the locknut [P] and the pivot bolt [G], and
then remove the brake lever [N].
● Remove the dust rubber sleeve [L].
● Remove the circlip [K].
Special tool—inside circlip pliers:
● Pull the piston assembly [J] and the return spring
[H].
Notes
It is forbidden to remove the cup [I] from the piston,
because it may be damaged once removed.
●Replacement
Diaphragm: [D],
Circlip: [K],
Dust rubber sleeve: [L],
Piston assembly: [J].
Disassembly of rear master cylinder
● Remove the rear master cylinder (see “Disassembly
of Rear Master Cylinder” in the chapter “Brakes”).
● Remove the connector [H] and the seal [H].
● Slide the dust cover [A] out
● Remove the circlip [B].
Special tool—inside circlip pliers:
● Remove the piston assembly [D] and the return
spring [F].
Notes
It is forbidden to remove the cup [C] and cup [E]
from the piston, because it may be damaged once
removed.
●Replacement
Dust cover [A]
Circlip: [B],
Piston assembly [D],
Seal [H],
Diaphragm: [I].
86
Assembly of master cylinder
● Before assembly, clean all parts with brake fluid or
alcohol, including master cylinder.
Notes
Except brake pad and disc, other brake parts
can only be cleaned with disc brake fluid,
isopropyl alcohol or ethanol. Dot not clean the
above parts with other liquid. Gasoline, oil or
other gasoline distillates may corrode rubber
parts. If oil spills onto any part, it will be difficult
to clean thoroughly and eventually corrode the
rubber parts inside the disc brake.
●Apply brake fluid to new parts and inner wall of
brake cylinder.
●Be careful not to scratch the piston or the inner wall
of brake cylinder.
●Apply silicon grease to the brake lever pivot bolt.
●Tighten the brake lever pivot bolt and locknut.
Locking torque of fastening screw of front brake
fluid reservoir cap: 1.2N·m
Locking torque of front brake lever pivot bolt: 3.0
N·m;
Locking torque of locknut of front brake lever
pivot bolt: 6 N·m;
87
Replacement of rubber parts of caliper
Disassembly of front caliper
● Before removing the front caliper, first drain the
front brake fluid.
●Loosen front caliper mounting bolt [A] and hollow
bolt [B], and then gently remove them.
●Disassemble:
Front caliper [C] (see “Removing the Front Caliper” in
the chapter “Brakes”),
Front brake pad (see “Removing the front brake plate”
in the chapter “Brakes”),
Front caliper assembly bolt
O-Ring
●Remove the piston with compressed air.
The method for removing piston is as follows:
○ Install a rubber gasket [A] and a wooden board [B]
with a thickness of 10 mm (0.4 in.) or more in the
middle of the caliper, and secure the rubber gasket and
the wood board with the appropriate bolts and nuts, as
shown in the figure. Open one of the oil ports [C].
○Inject the compressed air [D] into oil port slowly,
until the piston touches the rubber gasket. If the caliper
is half open, block the hose joint [E] during operation.
Press bolt [F] and nut: [G].
WARNING
To avoid serious injuries, do not put your fingers
or palms in front of the piston! Otherwise, the
piston may crush your hands or your fingers
when the compressed air is injected into the
caliper.
○ Pull out the piston by hands.
● Remove the dust seal [A] and the oil seal [B].
• Repeat the above steps to remove the piston from the
other side of caliper body.
Remarks
○If compressed air is not available, remove the
piston from both calipers as follows (connect brake
hose to caliper).
○ Prepare a container to hold the brake fluid.
Front brake pad spring and brake pad (see
“Removing the Front Brake Plate” in the chapter
“Brakes”).
○ Press the brake lever until the piston is pushed out
of the brake cylinder, and then remove the caliper.
88
Assembly of front caliper
● Clean the caliper parts (except the brake pads).
Notes
Parts must be cleaned with disc brake fluid,
isopropyl alcohol or ethanol!
● Replace the oil seal [A] with a new one.
○ Add silicone grease to the oil seal and install it into
the brake cylinder by hands.
● If the dust seal [B] is broken, replace it with a new
one!
○ Add silicone grease to the dust seal and install it into
● Replace the O-ring [A].

● Apply brake fluid to the outside of piston and press
it into the brake cylinder by hands.
● Remember to install an O-ring seal.
● Apply some thread fastening glue to the threads of
the front caliper mounting bolts and tighten the bolts.
Locking torque of front caliper mounting bolt: 27 N·m
Install front brake pad (see “Removing front brake

pad” in the chapter “Brakes”).
●Wipe the brake fluid splashed onto the caliper with a
damp cloth.
89
Disassembly of rear caliper
●Loosen the hollow bolt of rear caliper [A], and then
gently tighten them (Tighten them a little bit, and do
not tighten too much).
●Disassemble:
Front caliper [B] (see “Removing the Rear Caliper” in
the chapter “Brakes”),
Brake plate (see “Removing rear brake pad” in the
chapter “Brakes”),
Rear caliper assembly bolt,
O-Ring
● Remove the piston on the caliper as follows.

● The method of removing the piston on the caliper is
the same as the method of removing the front caliper.
● Use a piece of wood against the piston on the
caliper, blow compressed air into the brake hose joint
to squeeze the piston of caliper
WARNING
To avoid serious injuries, do not put your fingers
or palms behind the piston! Otherwise, the
piston may crush your hands or your fingers
when the compressed air is injected into the
caliper.
●Disassemble:
Oil seal [A],
Dust seal [B],
Guide post dust cover I [C],
Guide post dust cover II [D],
Dust cover of bleed screw [E]
Remarks
○If compressed air is not available, remove the
piston from both calipers as follows (connect brake
hose to caliper).
○ Prepare a container to hold the brake fluid.
Front brake pad spring and brake pad (see
“Removing rear brake pad” in the chapter
“Brakes”).
○ Press the brake lever to remove the caliper piston.
90
Assembly of rear caliper
● Clean the caliper parts (except the brake pads).
Notes
Parts must be cleaned with disc brake fluid,
isopropyl alcohol or ethanol!
● Install the bleed screw and bleed screw cap.
Locking torque of bleeder screw: 7.8 N·m
●Apply brake fluid to the inner wall of brake cylinder.
● Replace the oil seal [A] with a new one.
○ Add silicone grease to the oil seal and install it into
● Replace the dust seal [B] with a new one.
● Apply brake fluid to the outside of piston and press
it into the brake cylinder by hands.
● Replace the guide post dust cover II [C] and the

guide post dust cover II [D].
● Apply grease to the guide post dust cover I [C] and
the guide post dust cover II [D], and install the guide
post [A] and the guide post [B].
● Apply some thread fastening glue to the threads of
the rear caliper mounting bolts and tighten the bolts.
Locking torque of rear caliper mounting bolt: 37 N·m
Install brake pad (see “Installing rear brake pad” in the

chapter “Brakes”).
●Wipe the brake fluid splashed onto the caliper with a
damp cloth.
91
Replace spark plug
● Remove the ignition coil (see “Removal of Ignition
Coil” – “Electrical System”).
●Remove the spark plug [A] vertically using special
spark plug wrench
●Replace the spark plug with a new one.

Standard spark plug
Model: NGK CR8E
● Insert a new spark plug into the spark plug hole and
then press the spark plug with your fingers.
●Tighten the spark plug [A] vertically using special
spark plug wrench.
Notes
If the wrench is tilted while tightening the spark
plug, the insulator of spark plug may break.
Locking torque of spark plug: 13 N·m
● Firmly fix the ignition coil.
○ Make sure that the fixed ignition coil is not easy to
remove.
92
Chapter III Fuel Injection System (EFI)
Contents
Introduction to EFI......................................................................................................................................... 96
EFI system ......................................................................................................................................................97
EFI part position .............................................................................................................................................99
Fuel tank .......................................................................................................................................................108
Exploded view of fuel tank ..................................................................................................................108
Fuel vapor recovery system ................................................................................................................. 110
Fuel tank ...............................................................................................................................................111
Disassemble fuel tank .................................................................................................................. 111
Check the fuel tank ...................................................................................................................... 112
Install the fuel tank .......................................................................................................................112
Precautions for EFI overhaul ....................................................................................................................... 113
Precautions for EFI overhaul ............................................................................................................... 113
ECU................................................................................................................................................................ 115
Engine controller (MT05 ECU) ........................................................................................................... 115
ECU appearance ...................................................................................................................................115
ECU disassembly ................................................................................................................................. 115
ECU installation ................................................................................................................................... 115
Precautions for ECU ............................................................................................................................ 116
ECU power supply requirements ......................................................................................................... 116
ECU temperature requirements ............................................................................................................116
Fuel pump .....................................................................................................................................................117
Working principle of fuel pump ...........................................................................................................117
Appearance of fuel pump .....................................................................................................................117
Fuel pump composition ........................................................................................................................118
Fuel pump label and logo .....................................................................................................................118
Working environment of fuel pump .....................................................................................................119
Maintenance process of fuel pump: ..................................................................................................... 119
Safety protection: ......................................................................................................................... 119
Fault diagnosis of fuel pump assembly: ...................................................................................... 120
Disassembly of fuel pump assembly: .......................................................................................... 120
Installation of fuel pump assembly: .............................................................................................120
Fuel pressure release process: ......................................................................................................121
Fuel leakage check process: .........................................................................................................121
Notes for use: ....................................................................................................................................... 121
Throttle body: ...............................................................................................................................................123
Working principle of throttle body: ..................................................................................................... 123
Appearance of throttle body: ............................................................................................................... 123
93
Throttle body: ...............................................................................................................................124
Throttle position sensor: .............................................................................................................. 124
Idle air control valve: ...................................................................................................................124
Operating temperature of throttle ........................................................................................................ 124
Disassembly of throttle body ............................................................................................................... 124
Cleaning method of throttle ................................................................................................................. 124
Installation of throttle body ..................................................................................................................124
Notes for the installation of throttle body ............................................................................................125
Notes for the use of throttle body ........................................................................................................ 125
Fuel injector ................................................................................................................................................. 126
Working principle of fuel injector ....................................................................................................... 126
Appearance of fuel injector ..................................................................................................................126
Fuel injector seal .................................................................................................................................. 126
O-ring seal connected to oil rail or oil injection cap ................................................................... 127
O-ring seal connected to intake pipe end.......................................................................................127
List of recommended lubricants .................................................................................................. 127
Overvoltage impact of fuel injector .....................................................................................................127
Temperature range of fuel injector: ..................................................................................................... 127
Fuel contaminants of fuel injector ....................................................................................................... 128
Fuel injector harness arrangement ....................................................................................................... 128
Notes for use of fuel injector ............................................................................................................... 128
Installation requirements for fuel injector ........................................................................................... 129
Replacement method of fuel injector ...................................................................................................129
Replaceability of fuel injector ............................................................................................................. 130
Blocking of fuel injector ...................................................................................................................... 130
Engine water temperature sensor .................................................................................................................131
Working principles of engine water temperature sensor ..................................................................... 131
Appearance of engine water temperature sensor .................................................................................131
Installation requirements for engine water temperature sensor .......................................................... 131
Operating environment of engine water temperature sensor ...............................................................131
Electrical environment of engine water temperature sensor ............................................................... 131
Cleaning of engine water temperature sensor ..................................................................................... 132
Inlet temperature sensor ...............................................................................................................................133
Working principle of intake temperature sensor ..................................................................................133
Appearance of intake temperature sensor ............................................................................................133
Pin position definition and function diagram ...................................................................................... 134
Installation position of intake temperature sensor ...............................................................................134
Cleaning ............................................................................................................................................... 134
Inlet pressure sensor .....................................................................................................................................135
Working principles of inlet pressure sensor .........................................................................................135
Appearance of inlet pressure sensor .................................................................................................... 135
Operating environment ........................................................................................................................ 135
Storage environment ............................................................................................................................ 135
Electrical environment ......................................................................................................................... 136
Pin definition ........................................................................................................................................136
94
Position .................................................................................................................................................136
Cleaning ............................................................................................................................................... 136
Oxygen sensor ..............................................................................................................................................138
Working principle of oxygen sensor ....................................................................................................138
Appearance of oxygen sensor .............................................................................................................. 138
●Oxygen sensor pin definition: ........................................................................................................... 139
Characteristic curve ............................................................................................................................. 139
Requirements for fuel quality .............................................................................................................. 140
Idle speed stepper motor .............................................................................................................................. 141
Working principle of idle speed stepper motor ................................................................................... 141
Appearance of idle speed stepper motor ..............................................................................................141
Pin definition ........................................................................................................................................142
Characteristic parameters: ....................................................................................................................142
Cleaning ............................................................................................................................................... 142
Canister solenoid valve (ECP) .....................................................................................................................143
Overview of working principle ............................................................................................................143
Appearance ...........................................................................................................................................143
Pin of ECP solenoid valve ................................................................................................................... 143
Fault Maintenance and Diagnosis Method of EFI System ..........................................................................145
Conduct diagnosis directly using the flashing fault lamp at meter ..................................................... 145
Diagnose fault using diagnostic apparatus .......................................................................................... 147
Check fault using diagnostic software PCHUD .................................................................................. 148
Common troubleshooting methods for electronic fuel inject system ..........................................................155
Maintenance tool ..................................................................................................................................155
Engine working data flow displayed by diagnostic apparatus ............................................................ 155
Step I ............................................................................................................................................ 155
Step II ...........................................................................................................................................155
Step III ..........................................................................................................................................156
Simple troubleshooting ........................................................................................................................ 156
Daily use and maintenance .......................................................................................................... 156
Fault phenomenon-Start fault ...................................................................................................... 156
Fault phenomenon—Start failure with tempering .......................................................................158
Fault phenomenon—Instable idle speed ..................................................................................... 158
target idle speed) .......................................................................................................................... 158
Fault phenomenon—Instable idle speed with deceleration and flameout .................................. 158
Fault phenomenon—Insufficient power of deceleration .............................................................158
Fault phenomenon—Slight burning phenomenon ...................................................................... 158
Fault phenomenon—Fault lamp is on, but fault code is inconsistent with fault .........................158
Fault phenomenon—Extremely high fuel consumption ............................................................. 158
95
Introduction to EFI
This motorcycle adopts the small engine electronic injection system from Delphi Corporation. For this system,
the closed-loop control is realized by an oxygen sensor and the oil injection and ignition are controlled. A
three-way catalyst is used to carry out after treatment for the gas burnt by the engine to convert it into harmless
gas and discharge it to the air. This system adopts the closed-loop control self-learning system which can
effectively eliminate the manufacturing differences between the system and related mechanical parts, improve
the overall consistency of the motorcycle and remove the errors caused due to wear and other factors after actual
use.
Throttle valve Idle control

Crankshaft position sensor valve
position sensor Burglar alarm
Throttle body
Optional
23X crankshaft
position target Ignition coil
gear
Heating oxygen
sensor ECM
Engine temperature Engine control
sensor module
Nozzle
intake temperature
neutral position
switch
Down switch Serial communication interface

intake pressure of fault diagnosis switch
sensor
Ignition switch
Battery Fault indicator Engine speed

light signal Metal carrier catalytic converter
96
Connect Function Description
or
J1-1 Idle control valve A high
J1-2
Battery power J1-3 Fault light
23 X signal
(high)
Ignition power Main relay output
J1-4
23 X signal
(low) J1-5
Ignition / Stop switch
EFI system
master switch J1-6 Tachometer
Main relay
J1-7 CAN line signal is low
Ignition coil drive A Ignition coil
output (cylinder 1) (non-IGBT) J1-8 CAN line signal is high
Fuse: EFI
Fuel pump control
system should signal J1-9 The power supply (system) is grounded
use Main relay
independent J1-10
fuse-15A
J1-11 Idle control valve A low
Spark plug
Storage Fuel pump control signal
Main relay output circuit J1-12 Idle control valve B high
battery
12V Power (system) J1-13 Idle control valve B low
grounding
Fuel injector J1-14 Vehicle-down sensor signal
J1-15
Analog signal input
Nozzle A
(cylinder 1) J1-16 Diagnosis switch
5V reference voltage J1-17 Fuel pump control signal circuit
Throttle position
Throttle position signal J1-18 Neutral position switch
sensor Main relay output
Signal grounding J2-1 Ignition coil drive A (cylinder 1)
D Idle control valve A (high) J2-2 The power supply (system) is grounded
5V reference voltage B Idle control valve B (high)
Intake pressure signal Idle stepper J2-3 KW2000
motor C Idle control valve A (low) Panel Ignition
power
A Idle control valve B (low) J2-4 23 gear signal is high
97
Intake pressure
Signal grounding J2-5 Nozzle A
and temperature
sensor Intake temperature J2-6
signal
Tachometer
J2-7 Oxygen sensor is heated
Cylinder cover 5V reference voltage
J2-8 intake temperature signal
temperature signal
J2-9 Fuel pump control signal
Cooling water 5V reference voltage grounding (Signal grounding) Fault light
temperature J2-10 5V reference voltage grounding
sensor Signal grounding
J2-11 intake pressure signal
Main relay output KW2000 serial data
Oxygen sensor
J2-12 Throttle position signal
signal Power (system) grounding CAN line signal (high) J2-13 23 gear signal is low
Oxygen sensor Power (system)
Signal Single point grounding CAN line signal (low)
grounding J2-14 Cylinder head temperature signal
grounding to engine module
Oxygen sensor heating Diagnosis switch J2-15 Ignition power supply
Oxygen sensor J2-16 5V reference voltage
(heating type) Storage
battery power J2-17 Oxygen sensor signal
J2-18 Battery power supply
Ignition power
Diagnosis connector
Neutral position switch
Anti-roll
sensor signal
Switch signal input
Connector (harness end) part

No. (Tyco)
Number of ECU connector
Connector Function Description

J1-1 Idle control valve A high
J1-2
J1-3 Fault light
J1-4
J1-5
J1-6 Tachometer
J1-7 CAN line signal is low
J1-8 CAN line signal is high
J1-9 The power supply (system) is
grounded
J1-10
J1-11 Idle control valve A low
J1-12 Idle control valve B high
J1-13 Idle control valve B low
J1-14 Vehicle-down sensor signal
J1-15
J1-16 Diagnostic switch
J1-17 Fuel pump control signal circuit
J1-18 Neutral position switch
J2-1 Ignition coil drive A:
J2-2 The power supply (system) is
grounded
J2-3 KW2000
J2-4 23 gear signal is high
J2-5 Nozzle A
J2-6
J2-7 Oxygen sensor is heated
J2-8 Inlet temperature signal
J2-9 Fuel pump control signal
J2-10 5V reference voltage grounding
J2-11 Inlet pressure signal
J2-12 Throttle position signal
J2-13 23 gear signal is low
J2-14 Cylinder head temperature
signal
J2-15 Ignition power supply
J2-16 5V reference voltage
J2-17 Oxygen sensor signal
J2-18 Battery power supply
98
EFI part position
●ECU[A]
●Throttle body [A]
●Idle stepper motor [A]

●Injector [B]
●Throttle body position sensor [C]
●Throttle body [D]
99
●Starter relay [A]
●Flasher [A]
●Ignition coil [A]
●Headlight relay controller [A]
100
●Fuse box [A]
●Oxygen sensor [A]
●Canister solenoid valve [A]
●Gear sensor [A]
101
●Stop switch [A]
●Front speed sensor [A]
●Rear speed sensor [A]
●Electric door lock key [A]

●Electric door lock [B]
102
●Water temperature switch sensor [A]
●Water temperature sensor [A]
●Fuel pump [A]
●USB interface [A]
103
●Intake air temperature sensor [A]
●Intake pressure sensor [A]
●ABS pump [A]
●Rectifier [A]
104
● Relay unit [A]
●OBD diagnostic interface [A]

●ABS diagnostic interface [B]
105
Item Normal
Electronic Fuel Injection System
Idling 1400 ±100 r/min (rpm)
Throttle valve assembly:
identity Cylinder-shaped
Diameter Φ34 mm
Negative pressure value of throttle 2.7 kPa
valve
Bypass screw –––
ECU：
Manufacturer Delphi
identity Electronic memory type with built-in IC igniter, sealed with resin
Available engine speed range 100 ∼ 11 200 r/min (rpm)
Fuel pressure (high pressure hose): 250 kPa
Fuel pump:
identity Fuel tank built-in friction pump
Oil pump capacity ≥67 mL (2.3 US oz.) every 3 seconds
Fuel injector:
Nozzle type Fine atomization type,
Resistance: ≈11.7 - 12.3 Ω at 20°C (68°F)
Main throttle sensor:
Input supply voltage DC 4.75 ∼ 5.25 V
Output supply voltage DC 0.63 - 3.91 V (throttle opening is idle to fully open)
Resistance 4 ∼ 6kΩ
Inlet air pressure sensor /
atmospheric pressure sensor
Output supply voltage DC 3.80 ∼ 4.20 V [standard atmospheric pressure]
Inlet temperature sensor:
ECU output voltage ≈2.80 - 2.97 V at 20°C (68°F)
Resistance 2.21-∼ 2.69 kΩ at 20°C (68°F);
≈0.322 kΩ at 80°C (176°F)
Water temperature sensor:
ECU output voltage ≈2.80 - 2.97 V at 20°C (68°F)
Speed sensor:
Output supply voltage After the electric door lock is open, it is about DC 0.05 - 0.09 V or DC
4.5 - 4.9 V when the vehicle is stationary.
Motorcycle dump sensor:
Actuation mode Magnetic flux detection trigger
Actuation angle When the side-tipping is out of the range of 60 - 70°
Output voltage Sensor arrow is up: 3.55 - 4.45 V
Sensor tilt angle ≥ 60 - 70°: 0.65 - 1.35 V
106
Continued
Item Normal
Secondary throttle sensor:
Output supply voltage DC 0.63 - 4.14 V (throttle opening is idle to fully open)
Resistance 4 ∼ 6kΩ
Anti-theft device transceiver (model with
anti-theft device transceiver):
Resistance ≈0.6 ∼ 0.9 Ω
Secondary throttle valve disc drive:
Resistance ≈5 ∼ 7 Ω
Input supply voltage ≈DC 10.5 ∼ 12.5 V
Oxygen sensor (model with oxygen
sensor):
Output power supply voltage (peak value ≥DC 0.8 V
at the highest air-fuel ratio)
Output power supply voltage (peak value ≤DC 0.24 V
at the lowest air-fuel ratio)
Heating coil resistance ≈6.7 - 10.5 Ω at 20°C (68°F)
Controller area network cable:
Resistance The resistance of ECU connector is 114 - 126 Ω
Throttle handle and throttle cable
Free clearance of throttle handle 3∼5 mm
Air filter
Element material Wet-type sponge filter element
107
Fuel tank
Exploded view of fuel tank
108
Num Torque
No Chinese name and specifications Remarks
ber of N·m kgf·m
1 Inner hexagon screw M5×30 3 8 0.8
3 Rubber washer of protector 3 — —
4 Hexagon bolt with flange M6×35 3 10 1.0
5 Fule tank mounting washer 3 — —
6 Rubber cover 3 — —
7 Fuel tank mounting shaft 2 — —
8 Fuel tank assembly 1 — —
9 Mounting washer of fuel tank 1 — —
10 Fuel pump assembly 1 — —
11 Bolt M5×16 6 4 0.4
12 Fuse hose assembly 1 1 — —
13 Clamp 14.5-706R 2 — —
14 Filter assembly 1 — —
15 Filter jacket 1 — —
16 Fuse hose assembly II 1 — —
17 Hexagon flange nut M6 4 10 1.0
18 Fuel sensor assembly 1 — —
19 Sensor rubber washer 1 — —
20 Wire clamp 1 — —
21 Leaking pipe 1 — —
22 Dowel pin of rear swing arm 1 — —
23 Fuel tank mounting pad 1 — —
24 Anti-roll switch mounting bracket 1 — —
25 Bolt M6×10 2 10 1.0
26 Plate clamp φ8.5×8×0.6 4 — —
27 Fuel hose 1 — —
28 Check valve components 1 — —
29 Fuel hose 1 — —
30 Wrapping strip 2 — —
109
Fuel vapor recovery system
Num Torque
ber of N·m kgf·m
1 Canister assembly 1 — —
2 Plate clamp 10 4 — —
Connecting plate between canister
3 1 — —
solenoid valve and engine inlet port
4 Canister solenoid valve 1 — —
5 Solenoid valve mounting bracket 1 — —
7 Check valve components 2 — —
8 Plate clamp φ8.5×8×0.6 4 — —
Connecting plate between check
9 1 — —
valve and fuel tank
Connecting plate between check
10 1 — —
valve and canister
Connecting tube between canister
11 6 — —
solenoid valve and canister
12 Canister mounting bracket 1 — —
110
Fuel tank
Disassemble fuel tank
●Remove the rear seat cushion (see "Replacing the Air
Filter Element")
●Remove the front seat cushion (see "Replacing the
Air Filter Element")
●Remove the fuel tank cover (see “Frame” – “Fuel
Tank Cover” for details).
●Remove the mounting bolt at the front of fuel tank
[A]
●Remove the mounting bolt at the rear of fuel tank [A]
● Lift the fuel tank, unplug the oil pipe connected to

the injector; unplug the connecting pipe between fuel
tank and check valve
Note:
When unplugging the fuel hose connected to the
throttler, be careful not to let the fuel flow out.
● Drain the fuel in the fuel tank into the container
prepared in advance.
Warning:
In the process of draining oil, it is forbidden to
approach to the open flame to avoid causing fire.
● Remove the screw [A] and the screw [B] and
remove the fuel tank lock [C].
111
● Remove the four tightening nuts [A] and remove the
fuel level sensor [B] and the fuel level sensor seal [C].
○Check sensor seal
★If the sensor seal is found to be broken or swelled, it
must be replaced!
● Remove the six fastening bolts [A] and remove the

fuel pump [B].
○Check the fuel pump seal
★If the fuel pump seal is found to be broken or
swelled, it must be replaced!
Check the fuel tank

○ Check whether the inside of the fuel tank is rusted.
If the fuel tank is seriously rusted, please replace it.
Install the fuel tank

● Install the parts that have been removed before in the
Locking torque of fuel level sensor fastening nut: 10 N•m
Locking torque of fuel pump mounting bolt: 4 N•m
Locking torque of fuel tank lock decorative screw: 6 N•m
Locking torque of fuel tank lock mounting screw: 8 N•m
Locking torque of fuel pump mounting bolt: 10 N•m
Locking torque of front cover mounting holder mounting
bolt of fuel tank: 10 N•m
112
Precautions for EFI overhaul
Precautions for EFI overhaul

There are the following important precautions in the
process of overhauling the EFI system.
○The power supply of this EFI system must be
supplied by a 12V battery. Do not use any other
battery as a power source for the EFI system.
○Do not connect the battery cable reversely.
Otherwise, the ECU may be damaged.
○ To avoid damage to EFI parts, do not disconnect the
battery cable or any other electrical connectors while
the electric door lock is in the “ON” position or while
the engine is running.
○Be careful not to short-circuit the cable that directly
connect the positive (+) electrode of the battery and
the ground wire of the chassis.
○ Disconnect the connecting wire between battery and
motorcycle during charging to avoid excessive voltage
and damage to the ECU.
○ Turn off the electric door lock before disconnecting
the EFI electrical connection, and then disconnect the
battery (-) pin. Do not pull the wire and only pull the
connector. Conversely, make sure that each EFI
electrical connector has been properly connected
before starting the engine.
○ Connect the connector adapter to the power supply
with bridges properly.
○ Do not open the electric door lock if no EFI

electrical connectors are connected. The ECU will
remember the fault code.
○Do not spray water on electrical parts, EFI parts
connectors, leads and electric wires!
○If the motorcycle is equipped with a transceiver,
ensure that the operation of the EFI system is not
affected by the radio waves emitted by the antenna.
Run the engine at idle speed and check the operating
status of system. The antenna shall be kept away from
the ECU as far as possible.
○ Do not open the electric door lock if any fuel hose is
disconnected. Otherwise, the fuel pump will run,
thereby causing fuel to be ejected from the fuel hose.
○Do not operate when the fuel pump is completely dry
to prevent the fuel pump from getting stuck.
○ Before disassembling the parts of the fuel injection
system, blow off the dirt or dust on the outside of the
113
parts with compressed air.
○ When any fuel hose is disconnected, fuel may be
ejected due to residual pressure in the hose Therefore,
cover the hose joint with a clean rag to prevent fuel
from overflowing.
○ When installing the hose, avoid bending, twisting or
warping the hose, and do not bend the hose as much as
possible to avoid blocking the oil circuit.
Arrange the fuel hose in accordance with section
"Winding Method of Cables, Wires and Hoses" of
chapter "Appendix".
○ Do not add any fuel antifreeze chemicals to the fuel
to avoid corroding the fuel injection system or causing
deposits in the fuel injection system.
○ If the operation method is improper, the high
pressure inside the fuel hose may cause fuel leakage
[A] or fuel hose rupture. Bend and twist when
inspecting the fuel hose.
★If the fuel hose is found to be broken or swelled, it
must be replaced!
○ In order to maintain the correct mixing ratio of fuel

and air (F/A), there must be no air intake leakage in
the EFI system. Always tighten the filler plug [A] after
adding the oil.
Locking torque of filler plug: tighten by hands.
114
ECU
Engine controller (MT05 ECU)

● The engine controller can detect the operating state
of the engine in real time through various sensors.
Ensure the original motorcycle emission and fuel
economy while optimizing the driving performance of
motorcycle under various working conditions through
reasonable calculation and self-learning control output
devices. The engine controller can also wake up the
self-diagnosis when the system is faulty.
ECU appearance
● The upper part of MT05 engine controller housing is
made of plastic and the bottom is made of aluminum
alloy. The picture shows the front and back of MT05
controller.
ECU disassembly
●Disassembly of rear seat cushion
●Disassemble:
ECU[A]
Bolt [B]
●Disassemble:
Bolt [A]
ECU[B]
ECU installation
Install it in the reverse order of disassembly.
Tightening bolt torque of ECU: 3.9N•m
WARNING
The mounting surface must be flat to prevent
generating external force to the controller and thus
making the circuit board bent.
115
Precautions for ECU
Precautions Cause
High temperatures may reduce the service life of ECU

Do not: Place the ECU near the exhaust pipe or engine
and even directly damage the ECU
Do not: place the ECU near water drops, engine oil or
ECU may be damaged by liquid
any liquid
Do not: Allow mud or other contaminants to cover the Mud or other pollutants may cover the ECU and thus
ECU surface affect the heat dissipation
Do not: Connect the additional power voltage to the It may cause problems with ECU performance and
ECU even cause damage to the ECU
Do not: Wash the ECU with solvents or corrosive
It may cause damage to the ECU housing
liquids.
Please: ensure that water or large amounts of moisture The ECU connector may be short-circuited, thus
should not drip or adhere to the ECU connector causing damage to the ECU
Please: Clean the ECU with a damp cloth and dry it It can prevent ECU from being damaged
ECU Power Supply Requirements

 Power supply: If the battery voltage is greater than
6.3 volts, the ECU's power supply module can
start the control chip, and this is automatically
controlled by the ECU.
 Power range: The ECU can operate within the
range of 9 to 16 volts of battery and ignition
voltage.
 Shutdown: Shut down the ECU when its ignition
voltage is below 6.2 volts. The ECU can enter the
shutdown procedures and store important
information in the ECU's memory.
 Restart: All outputs are set to a preset state during
the restart process. The ECU can monitor itself in
real time and automatically enter the restart when
an internal error is detected. After restart, ECU
will follow the normal procedures.
 Overvoltage: The ECU will not be permanently
damaged if it is operated for 1 minute under the
DC voltage of below 26V.
 Reverse voltage: The ECU will not be
permanently damaged if it is operated for 1 minute
under the DC inverse voltage of below 13V.
ECU temperature requirements
● Operating temperature: The ECU is able to work
normally between minus 20 degrees Celsius and minus
85 degrees Celsius.
116
fuel pump
Working principle of fuel pump

● The fuel pump assembly can provide the fuel whose
gasoline pressure meets the system requirements at
250Kpa. It is installed at the bottom of tank to provide
the required fuel oil to engine through the connecting
pipes.
●Fuel pump:
○ The electrical principle of electric fuel pump is that
when the DC motor drives the turbine-type fuel pump
to run, the fuel in the circumferential groove of turbine
rotor will move at high speed along with the turbine
rotor. Due to the action of high-speed centrifugal
force, the fuel pressure at the outlet is increased, and at
the same time, the high-speed rotating turbine
generates a certain vacuum at the inlet of oil pump, so
that the fuel is sucked from the inlet into the space of
turbine blade. The differential pressure of fuel inlet
and outlet may cause the fuel source to be
continuously pumped to the outlet side and transmitted
to the fuel line of system. The fuel transfer pressure
generated by the fuel pump can be up to 250 - 400
kPa.
●Pressure regulating device:
○It is mechanical diaphragm type, and can be used to
make pressure regulation to fuel pump device, so as to
achieve the constant fuel pressure required by the
system.
Appearance of fuel pump:

Reverse side:
117
Fuel pump composition
1. Oil strainer
2. Fuel pump body
3. Sealing washer and fuel pump bracket
4. Fuel pump wiring harness
5. Pressure regulator
Fuel pump label and logo

● Oil pump assembly:
 The production batch and date are marked at
the fuel pump device and pressure adjustor.
 Make it at fuel pump assembly installing
plate in the form of label.
Fuel pump:
 make engraved mark at fuel pump.
Oil pressure regulator:
 make engraved mark at external housing.
118
Working environment of fuel pump
 The fuel pump assembly needs to be
installed at the bottom of fuel tank according
to the requirements.
 The general design of fuel tank is generally
only for gasoline fuel. If the fuel contains
ethanol, please contact the motorcycle
manufacturer to confirm whether it can be
used.
 Make sure that there is enough fuel in the
fuel tank in the first operation of fuel pump
assembly, and do not run it in the absence of
oil.
Maintenance process of fuel pump:

Safety Protection:
●When conducting maintenance operation for fuel system,
care should be taken to ensure personal safety.
● Disconnect the negative electrode of storage battery
of motorcycle.
● Smoking is prohibited and a “no smoking” sign
should be placed near the operating area.
● Ensure that there is a fire extinguishing device.
● The operating environment is well ventilated and
away from open flames.
● Wear safety goggles.
● To release fuel vapors in the fuel tank, open tank
cover and refit it.
● There is still a high pressure in the fuel line after the
engine stops running, then oil may be injected after
disassembling or releasing fuel line. Refer to “Fuel
Pressure Release Process” in this section.
● A small amount of fuel may flow out after
disassembling fuel line, in order to avoid the risk of
occurrence, the blocking device at the fuel pipe
should be used for blockage.
● After maintenance is completed, please ensure that
the fuel line and clamp are properly installed.
119
● After maintenance is completed, check system oil
leakage according to the provisions of “Fuel Leakage
Check Process”.
● After maintenance is completed, please ensure that
there is sufficient fuel in the fuel tank when the fuel
pump is running.
Fault diagnosis of fuel pump assembly:
Step Operation Yes No
If you can hear that the fuel If you cannot hear that the fuel
After ingnition key is started, fuel pump
1 pump is running, please go pump is running, please
will run for 3 seconds.
to Step IV directly. conduct Step II.
Disconnect the connector of fuel pump,
Check the power supply circuit
2 and check whether the supply voltage of Conduct Step III
of fuel pump
fuel pump is within the range of 10-14V
Supply 12V DC current to fuel pump.
1. Check the circuit from
Ensure that there is sufficient oil in the 1. Check fuel pump harness
3 fuel pump to ECU;
tank, to prevent dry running of fuel pump 2. Check fuel pump
2. Check ECU
Is fuel pump running?
Check whether the front fuel supply
pressure of nozzle is within the range of Fuel pump assembly is
4 Perform Step IV
220-270kpa when engine is in idle running normally
running.
1. Check whether there is
1. Check whether the fuel
leakage at fuel pipe
Use the oil pressure gauge to test whether filter is blocked
joint
5 the fuel hose pressure is lower than 2. Check whether fuel pipe is
2. Check fuel pump
220kpa bent and twisted
3. Check pressure
3. Check pressure regulator
regulator
Disassembly of fuel pump assembly:
 Refer to “Fuel Pressure Release Process” to release the fuel
pressure in the fuel line.
 Disconnect the negative electrode line of storage battery.
 Disconnect fuel pump assembly harness connector.
 Remove the remaining fuel from the fuel tank and store it in
a suitable container, to ensure safety and reduce
contamination.
 Remove the connecting fuel hose to fuel pump assembly
using spring compressor assembly
 Remove the fuel tank from the motorcycle.
 Do not invert the fuel tank, to avoid tank scratches and
bumps.
 Affect fuel pump assembly mounting bolt.
 Carefully remove the fuel pump assembly from the fuel
tank
 Be careful to not damage fuel pump filter screen.
Installation of fuel pump assembly:
 Replace the sealing washer of fuel pump assembly
(Used washer may lead to fuel leakage)
 Lightly support the fuel pump strainer and carefully
put the fuel pump assembly into the tank. Avoid
damaging the filter screen of fuel pump.
Installation direction of fuel pump assembly:
Arrange the installing screw holes of fuel pump
assembly asymmetrically, and installed it in the
specified direction. The pressure regulator should
face the rear of fuel tank
to ensure that the installing surface of fuel tank is
clean and flat.
 Install mounting bolts on the fuel pump assembly
Tightening sequence of mounting screw
120
cover plate and tighten them evenly in the order
indicated in the following figure. Installing torque of
screw: 3- 4 Nm
The fuel pump assembly should be secured with
special bolts. It should be tightened according to
specified tightening order and torque during the
installation. Over torque an incorrect tightening
order may cause washer deformation and thus
result in leakage.
 Install the fuel tank on the motorcycle.
 Connect fuel pipe and fix it with a suitable clamp.
 Connect the fuel pump harness connector.
 Check for leaks according to “Fuel Leakage Check
Process” before the operation of engine.
Fuel pressure release process:
● Notes: Do not operate when the engine is in warning-up state.
After confirming that the engine is in cooling state, conduct the
following fuel pressure release operation:
 The motorcycle is in “neutral” state.
 Disconnect the connector between fuel pump assembly
harness and motorcycle harness.
 Turn on motor to start engine until the engine is
automatically extinguished. Then continuously turn on
and off the ignition key for 2-3 times, with an internal
of 3 seconds each time.
 After completing the above operations, connect the
fuel pump assembly harness connector.
Fuel leakage check process:
After performing any fuel system maintenance, perform fuel
leakage check test.
 Fill the tank with sufficient fuel.
 Turn on ignition key for 3 seconds, and then turn off it
for 15 seconds, repeat the above operations for 3-4
times, to establish the oil pressure in the fuel line.
 Check whether there is leakage in the parts of fuel
system (fuel tank, connecting pipes, pipe joint, etc.).
Notes for Use:

Precautions Cause
Do not: throw or touch fuel pump It may cause damage to the internal of fuel pump
Do not: "dry run" fuel pump (there is no oil at fuel pump
inlet and filter screen) It may cause damage to the internal of fuel pump
Please ensure that there is sufficient fuel in the tank
Impurities may go into the fuel pump from damaged
Do not: damage filter screen during the maintenance
filter screen and thus damage the fuel pump body
Do not: disassemble the internal parts of fuel pump and
pressure regulator “Three guarantees” will not be provided after
Do not: regulate fuel pump and pressure regulator disassembly without permission
(except replacement)
Do not: lift fuel pump assembly through fuel pump
assembly harness Harness is damaged / the power supply of fuel pump is
Do not: lift fuel pump harness in the direction vertical to disconnected
fuel pump cover plate
Do not: use damaged pipe clamp Pressure leakage/fuel leakage
Do not: use seriously damaged fuel pump filter screen or Impurities may go into the fuel pump from damaged
cut fuel pump assembly filter screen and thus damage the fuel pump body
Do not: pump oil from fuel tank using fuel pump Fuel pump is not designed for this purpose
121
Do not: Install screws to fix other parts using fuel pump
Affect fuel pump assembly installation
assembly
Do not: Damage fuel pump harness during the The terminal may be damaged and thus poor contact is
maintenance of fuel pump assembly caused / the power supply of fuel pump is disconnected
Do not: Contact fuel pump assembly when fuel pumping
Avoid damaging fuel pump assembly
oil from the tank manually
Please: Ensure that the tank is not damaged during
Avoid oil leakage
maintenance
Please: Only use “original” fuel pump assembly sealing
Fake washer may cause fuel leakage
washer
Ensure that there is no fuel leakage and seepage at pipe
Please: Use designated hose clamp
joint
Please: Fix fuel pump harness at motorcycle Reduce shock
The fuel with poor quality may damage the fuel pump
Please: Use standard fuel
too early
Please: Replace fuel filter within the specified time Blocked filter may reduce fuel supply
Unqualified filter may damage nozzle, oil pressure
Please: Use specified and qualified fuel filter
regulator and fuel pump
Please: Ensure to correctly arrange the ways of fuel
Incorrect ways and interference may damage fuel pipe
pipes and not interfere with other parts
Please: Ensure that there is sufficient fuel in the tank
Avoid “running in dry state” of fuel pump
(submerge fuel pump filter)
Please: During the presure regulator maintenance, Ensure the correct pressure regulation curve of pressure
replace two O rings simultaneously regulator
Please: Take care to connect fuel pump assembly harness
Avoid damaging the terminal of connector
connector
Please: Return any collided , damaged and suspicious Ensure to quickly and correctly find the root cause of
parts and describe the problems problem
Warning:
 Because there is no gasoline in the fuel tank of
new motorcycle at the beginning, a lot of air is
generated at fuel pipe, so it needs to start it for
several times to empty the air in the fuel line, and
then the engine can work properly, which is
normal. Motorcycle will be started easily in the
future.
 Because gasoline can cool fuel pump, do not let
fuel pump work little oil or no gasoline, which
may burn fuel pump.
122
Throttle Body
Working Principle of Throttle Body:
●The throttle body assembly is mainly composed of
the following parts: main casting valve body, bearing,
shaft and valve plate, return spring, throttle cable part,
throttle position sensor system and by-pass flow
control system. All of the above subsystems work
together to meet the requirements for following
functions:
 Intake flow control
 Control of air flow at idle speed
 Throttle position detection – provide throttle
opening feedback signal for engine control
system
The throttle body position sensor provides the ECU
with a throttle opening; the stepper motor on the
throttle body controls the engine idle speed to be
maintained near the target idle speed required by the
ECU;
Appearance of Throttle Body:
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Throttle Body:
 34mm inner diameter: maximum flow: ≥50g/s
@ 2.7kPa vacuum degree
 Throttle body starting torque:
Idle state: 0.12±0.03Nm
Fully open: 0.32±0.05Nm
Throttle position sensor:
 The reference voltage is 5±0.1VDC
 Resistance between T1 and T2: 3kΩ - 12kΩ.
Idle air control valve:

 Operating voltage: 7.5~14.2 VDC
 Winding resistance: 53Ω ± 10%
 Winding inductance: 33mH ± 20%
Operating temperature of throttle
Normal operating temperature: -30 ~120°C
Disassemble throttle body
 Disconnect the negative electrode line of storage
battery.
 Disconnect the connectors on throttle position
sensor, stepper motor, inlet temperature/pressure
sensor (if installed on the throttle body assembly)
 Disassemble the throttle cable
 Disassemble the connecting hose between the air
filter and intake manifold
Cleaning Method of Throttle
●Clean throttle body using carburetor cleaner (3M
product is recommended). Spray cleaner at the inner
wall of throttle body, and gently remove dust and
carbon deposit and other items using a brush. Be
careful to prevent the bypass air duct from being
blocked by dirt.
install throttle body
Note the followings for installing the throttle body:
 Adjust throttle wire
 Ensure that all moved parts have been
installed properly, such as stepper motor
assembly.
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 Install the connecting screw properly
Notes for the Installation of Throttle Body
 Do not immerse the throttle position sensor in the
liquid.
 Always use the throttle cable to open the valve
plate.
 Do not insert tools or other items into the inside of
the throttle body to maintain the opening of the
valve plate. This may deform the valve plate or
scratch the inner wall of throttle body. This damage
may cause the valve to be extremely easy to open or
difficult to open.
Notes for the Use of Throttle Body
Precautions Cause
Please: be careful to install the connectors of all throttle
Avoid damage to wiring terminal.
body
Please: avoid any liquid from entering throttle body Make sure it works properly
Please: Take out one throttle from the part tray and
So as not to damage critical parts
install it every time
Please: send the falling, damaged parts or parts with
suspected problems, and label to specify the existing
Quickly confirm the cause of problem
problems (only for the components within the scope of
“three guarantees")
Do not: use any dropped or squeezed parts May cause damage to the internal of parts
Do not: store or transport near salt water without
Corrosion may affect normal use
protection
Do not: expose it to the environment before the
Corrosion may affect normal use
completion of assembly (such as humid environment)
Do not: test under non-system operating voltage It may cause damage
Do not: use additional fixtures It may cause damage
Do not: remove the packaging so that the parts may It may affect minimum air leakage or cause other
touch each other damages
Do not: release the throttle completely from any position It may cause damage
Do not: block the bypass channel by dust or small
It may affect idle speed stability
particles
Do not: pick up, store or hold parts in a manner that
It may cause damage
might come into collision with other parts.
125
Fuel injector
Additional resistor
Various sensors
Crankshaft position sensor

Air flow meter
Water temperature sensor
Microcomputer
Fuel injector
Throttle position sensor
Ignition switch
Oxygen sensor
Speed sensor
Battery voltage
Working Principle of Fuel Injector:

● The injector is an actuator that injects the
appropriate fuel into the engine inlet in a timely and
accurate manner, and then inhales it into the
combustion chamber and mix it with the oxygen in the
filled fresh air for burning.
The fuel injector should be replaced with that with the
same part number only.
Appearance of fuel injector
● The appearance of fuel injector is shown in the figure below.
O-ring Seal Connected to

Oil Rail or Oil Injection Cap O-ring Seal Connected to
Intake Pipe End
Fuel injector seal

●As shown above, O-ring seal can ensure that leakage
will not occur when fuel injector works within the
range of -40°C -150°C (-40 -302°F), and it can resist
various fuel additives (such as: ethyl alcohol). The
following data is the existing sealing ring design.
126
O-ring Seal Connected to Oil Rail or Oil Injection Cap
●Size:
·Inner diameter: 6.35 mm
·Outer diameter: 14.85 mm
·Section thickness: 4.25 mm
●Materials
•Viton GLT (blue): applications at low
temperature
• Viton A (black): applications other than low
temperature
O-ring Seal Connected to Intake Pipe End
●Size:
·Inner diameter: 9.61 mm
·Outer diameter: 14.49 mm
·Section thickness: 2.44 mm
Materials:●
• Viton A (blue or brown)
List of recommended lubricants
●To facilitate the installation of fuel injector, lubricant
should be applied at O-ring seal. The following table
shows the list of usable lubricants. Tests show that the
following lubricants do not have any impact on the
fuel injector.
List of recommended lubricants

Name of lubricant Manufacturer Viscosity (cSt) @ 40 C
Spindura 10 Equilon 10
Spindura 22 Equilon 21
DTE-24 Mobil 32
DTE-25 Mobil 46
DTE-26 Mobil 68
Norpar 15 Exxon / Mobil <1
Drawsol 60 DA Stewart 1-2
NocoLube AW 46 NOCO Energy 46
NocoLube AW 32 NOCO Energy 32
Advantage Spindle Oil Advantage Lubrication Specialties 10
Overvoltage Impact of fuel injector
The fuel injector can run at the voltage of 26V and the
working conditions of 100ms (pulse) and 200ms (one
cycle time) for 1 minute at most (run with oil). It will
not affect the flow rate, cause permanent damage to
the solenoid coil or weaken the electromagnetic
performance.
Temperature range of fuel injector:
●The standard injector operating temperature range is
as follows. Within the qualified operating temperature
range, the fuel injector flow is within the tolerance
range and fault will not be caused. Meanwhile, in a
reasonable operating environment, leakage,
degradation or reduction of service life will not be
127
caused to fuel injector.
 Operating temperature range: - 30 ~ 125C
 Extreme operating range (may cause some
functional degradation): - 40 ~ 150C
 Storage temperature: -60 ~ 60C
Fuel contaminants of fuel injector
Although the fuel injector has a self-cleaning function,
it is not a serviceable part, because it is designed to
remove only the impurities with small diameter
accumulated in the fuel line from the fuel filter to the
injector. The impurities with large diameter may cause
injector bonding, flow deviation and leakage and other
faults, so fuel filter system is very important.
Fuel injector harness arrangement
 The injector harness should be located away
from heat sources and the harness should be
protected from external wear or damage.
 If not necessary, do not insert or remove the
injector connector.
 There is no positive or negative electrode for
the electrical connector of fuel injector.
Notes for Use of Fuel Injector
Precautions Cause
Do not: Resuse the sea. If it needs to reuse it in special
conditions, please carefully check whether the sealing Avoid leakage
ring is damaged before use.
Do not: Immerse the end of nozzle in the lubricant. It may block spray hole.
Do not: Operate it without load in the case of no oil
It may damage internal mechanical components.
pressure
Do not: Make water go into the fuel way during
It may damage fuel injector.
leakage inspection.
Do not: Apply force to the head of fuel injector during During the installation on nylon intake pipe, allow to
installation apply force in the direction of 45 degrees
Do not: Strike fuel injector when installing it at intake
It may cause fuel injector and sealing ring.
pipe.
Do not: Apply tension to connector. It may cause intermittent power supply.
Do not: Use fuel injector that has fallen It may be damaged.
Do not: Store fuel injector, fuel rail or engine that has
External environment may damage the electronic and
been loaded into fuel injector in an unprotected
mechanical parts of fuel injector.
environment.
Do not: Take fuel injector as a handle when lifting
assembly parts.
Do not: make parts be in touch with each other during
storage.
Do not: Parts are in contact with each other during Collision may be caused and thus fuel injector may be
transportation. damaged.
Do not: Knock fuel injector for troubleshooting when
an fault occurs.
Do not: Repalce the original fuel injector with one
It may seriously affect the performance of nozzle.
with the part number not recommended.
Please: Pay special attention to protect sealing ring
from being cut by the installing seal during the Protect sealing ring.
installation of fuel injector.
128
Please: Use correct lubricant for installation, and
immediately it into the installing hole after applying Protect sealing ring, to reduce pollution.
lubricating oil.
Please: Add tests for the fuel injector whose needle
valve is stuck or cannot be mounted. (Apply the pulse
Confirm the fault form of fuel injector
to fuel injector for less than 5 seconds using 9-15 V
voltage).
It may prevent the needle valve of fuel injector
Please: Before assembling fuel injector, make an
froming returning to the original position during the
oil-free leak test to confirm that the needle valve of
transporation and transfer process, thus resulting in
fuel injector has been mounted.
fuel leakage
Please: Prevent liquid from damaging fuel injector It may casue short circuit of solenoid coil
Please: Be careful to disassemble harness It may cause damage of terminal
Please: Use recommended lubricant when installing
It may cause corrosion to terminal
connector.
Please: Do not use the components that are dropped,
damaged or whose materials have problem, and Ensure to quickly find the root cause of fault.
describe the problem using label.
Installation requirements for fuel injector
●During the installation and removal process, please strictly observe
the following methods to avoid damage to the fuel injector body and
electronic components.
 Lubrication: Apply a small amount of lubricant to the
underside of the sealing ring. ISO 10 light mineral oil or
equivalent product is recommended.
 When conditions allow, apply lubricant to the fuel injector
seat, which is better than the effect of being applied the seal
ring. So that the fuel injector contamination probability will
be reduced to minimum.
 Do not allow the spray plate to come into contact with the
lubricant, which may affect the injection quantity. Do not dip
the top of the fuel injector to into the lubricant.
 All fuel injector sealing rings are factory assembled. In
principle, the sealing seals should not be reused. Before
reusing it in special conditions, please carefully check whether
the sealing ring is damaged before use. Very small damage
may cause leakage. Carefully insert the sealing ring into the
installing seat during installation.
 When installing the fuel injector connector, take care not to
damage the connector, and you can hear a click, indicating
that it has been installed properly.
 Avoid unnecessary disassembly and assembly of connector.
 Harness should not be clamped too tightly, which may cause a
short circuit.
 When installing the fuel injector connector, do not rotate the
fuel injector. This may cause fuel injection target to shift.
Replacement Method of Fuel Injector
●The following is the disassembly and replacement method of fuel
injector.
Note: The injector and the surrounding objects are very hot.
 Turn off the motorcycle.
 Cut off the negative electrode of storage battery, to avoid
accidentally starting the engine.
 Remove the fuel injector connector.
 Release the fuel pressure.
 Remove the fuel pipe from the fuel injector.
 Remove the fuel injector from the throttle valve body.
 Remove the fuel injector retainer and carefully remove the
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fuel injector from the seat ring.
 Carefully clean the impurities at the injector contact surface,
and be careful not to damage the contact surface.
 Apply lubricant to the sealing rings on both ends of the new
fuel injector.
 Carefully put the head of fuel injector into the intake pipe,
and confirm that the installation direction is consistent with
the original one.
 Press it in the fuel injector seat ring and secure the clamp.
 Install fuel injection hose.
 Insert the fuel injector connector.
 Power on the key, do not start the engine and check fuel
injector for leakage.
 Start engine for running check.
Replaceability of fuel injector
●The fuel injector should be replaced with that with
the same part number only.
Blocking of Fuel Injector
●The accumulation of fuel impurities may cause flow offset and
shorten fuel injector life. When the engine is standing, the heat
of engine may produce fuel precipitation through the head of
fuel injector, and the precipitation gathered in the injection hole
may cause flow offset.
 Blockage may cause many problems, such as small
flow, large friction and accumulation of impurities, and
ultimately affect emissions and durability. Ultimately
affect emissions and durability.
 Fuel and environmental factors may cause fuel
crystallisation or fuel injector corrosion, which may
also cause flow offset.
 Poor oxidation stability of fuel may cause precipitation,
so please use high-quality gasoline.
 Add an appropriate amount of fuel cleaner to avoid
precipitation.
 If fuel injector is blocked, please clean injector
according to the following cleaning method.
Warning: Bad Good Bad
 A filter is designed inside the fuel injector, but it is not a
maintainable part, because its design function is to filter
the accumulated impurities from the fuel filter in the oil
line to the fuel injector only. Impurities can cause the
cohesion, flow deviation, leakage and other faults of fuel
injector, so the fuel filter is very significant.
 The fuel injector should be replaced with that with the
same part number only.
Atomization of fuel injector
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Engine water temperature sensor
Working principles of engine water temperature sensor
● The sensor is used for water-cooled engine to
measure the temperature on the engine waterway and
is mounted on the engine block. Within this sensor
temperature range, its resistance may vary with engine
temperature. Its characteristics are negative
temperature coefficient resistance characteristic. It is
an irreparable part.
Appearance of engine water temperature sensor
●The appearance of engine water temperature sensor
is as shown in the figure below
Installation requirements for engine water temperature sensor

 Dynamic torque requirements: It should be
assembled by hands to allow the thread to be
correctly guided, and then tightened to the
specified torque using a manual wrench.
 Static torque requirements: The torque
required to disassemble the sensor from the
engine should not exceed 200% of the
assembly torque.
Assembly torque: 20～25N•m
Operating environment of engine water temperature sensor
 The sensor is mainly used for water-cooled
engine
 Normal operating temperature range: -40
-135°C (continuous work)
 Relative humidity at working environment: 0
~ 100%
 Typical operating pressure: at minimum
installation torque, the sensor is capable of
sealing the engine coolant at an actual
pressure of 206.8 kPa (30 psi) and a
temperature of 135°C.
 Extreme operating conditions: only 1 hour at
maximum temperature of 150°C.
Electrical environment of engine water temperature sensor
 Typical working voltage: The reference
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voltage is 5±0.1VDC
Cleaning of engine water temperature sensor
 If necessary, the sensor can be cleaned with
isopropyl alcohol and then air dried. It should
be soaked in isopropyl alcohol for not more
than 1 minute, and sealing connector should
be installed during cleaning to prevent
cleaner from intruding into the sensor.
132
Inlet temperature sensor
Working principle of intake temperature sensor

●Within the sensor temperature range, the resistance
will change with the temperature of engine and the
temperature characteristic is the negative temperature
coefficient resistance characteristic. It is an irreparable
part.
Appearance of intake temperature sensor

●The appearance of intake temperature sensor is as
shown in the figure below
 Operating voltage: 5DVC
 Response time: <15s
 Operating temperature: -40 ~150°C
 Relative humidity: 0 - 100% RH.
●Resistance measurement
value and temperature curve: Curve of intake temperature and resistance
Resistance
133
Pin position definition and function diagram
5V ECM
R pull-up
Sensor A/D
Converter
GND
● Use a multimeter to measure the resistance between Measured temperature

Resistance value (ohms)
the two pins of sensor. The table of specific (degrees Celsius)
temperature and resistance is shown below: 0 9,399
5 7,263
10 5,658
15 4,441
20 3,511
25 2,795
30 2,240
Installation position of intake temperature sensor

●The intake air temperature sensor [A] is located on
the air filter and can be pulled out with gloves.
Clean
● If necessary, the sensor can be cleaned with
isopropyl alcohol and air dried. It should be soaked in
isopropyl alcohol for not more than 1 minute, and
sealing connector should be installed during cleaning
to prevent cleaner from intruding into the sensor.
134
Inlet pressure sensor
Working principles of inlet pressure sensor

●This sensor is used to measure the absolute pressure
of air intake elbow, reflect the size of intake pressure
according to the difference of resistance, and then
calculate the intake volume in engine combustion
chamber through indirect conversion, and it is also a
non-serviceable part.
Appearance of inlet pressure sensor
Operating environment
 Operating pressure range: 20~102kPa
 Operating temperature range: -40~105°C
 Relative humidity: 0 - 100% RH.
 Extreme operating conditions: only 2 hours
at maximum temperature of 125°C.
Storage environment
 Storage temperature: -50~150°C
135
Electrical environment
●Typical voltage: The operating DC reference voltage
of sensor circuit is 5 ± 0.1 V.
●Characteristic curve
Pin definition
Location
●Intake pressure sensor is installed on the frame
●Intake pressure sensor [A]
Clean
● If necessary, the sensor can be cleaned with
isopropyl alcohol and air dried. It should be soaked in
136
isopropyl alcohol for not more than 1 minute, and
sealing connector should be installed during cleaning
to prevent cleaner from intruding into the sensor.
137
Oxygen sensor
Working principle of oxygen sensor

●Oxygen sensor can be used to detect the oxygen
content in the waste gas of engine exhaust pipe for
internal fuel closed loop control of ECU, thus
maintaining engine combustion at the most reasonable
state of air and fuel ratio (14.7).
Appearance of oxygen sensor
 Partially thick limit of air-fuel ratio: ＞
750mVDC
 Partially thin limit of air-fuel ratio: ＜120
mVDC
 Power of oxygen sensor heater: 7.0W
(The above parameters are measured at engine
bench, the working conditions: exhaust gas
temperature: 450°C; duty cycle: 70%; 10Hz;
voltage: 13.5V).
 The resistance of heater is: 9.6±1.5Ω
(measured at 21°C)
 Operating temperature range: 260-850°C
Installation requirements
 Installation angle (angle with the horizontal
plane): ≥10 degrees
138
Oxygen sensor pin definition:
Characteristic curve
The oxygen sensor is located on the exhaust manifold.

Please remove the oxygen sensor connector and then remove the
oxygen sensor using 13# open-end wrench. Be careful not to knot
or twist the harness when disassembling.
139
Requirements for fuel quality
 Pb≤0.005g/L
 P≤0.0002g/L
 S ≤ 0.04% (weight ratio) x
 MMT≤0.0085g/L
 Si≤4ppm
140
Idle speed stepper motor
Working principle of idle speed stepper motor

●The function of idle speed control valve is to control
the flow area of bypass air duct of throttle body, so as
to adjust the air volume of engine and control the idle
speed of engine.
Air
1. Valve; 2. Inlet manifold 4. Idle stepper motor 5. Bypass hole
Appearance of idle speed stepper motor

●The appearance of idle speed stepper motor is as
shown in the figure below
141
Pin Definition
Dust cover
When the adjusting head is
extended to the utmost, the Contact pin
adjusting head corresponds
to , it can be moved
from 0.44 to 2.00mm.
Connector
Position where it is fully retracted
Working position
Characteristic parameters:
Rated voltage: 12Vdc
Maximum /
minimum operating 7.5Vdc/14Vdc
voltage:
Resistance per roll
53±5.3
(@27°C):
Minimum resistance
35
(@-40°C):
Inductance per roll
33.5mH±6(1kHz)
(@25°C):
Stepping distance
0.04167mm
(step):
Maximum stroke: 8.5mm(204 steps)
Operating -40°Cto125°C(150°C peak
temperature range: value)
Minimum storage
-40°C
temperature:
Weight: 110 g
Clean
●The stepper motor assembly is integrated on the
throttle valve body. When cleaning, first remove the
stepper motor and clean it with a clean rag
142
Canister solenoid valve (ECP)
Overview of working principle

● The canister solenoid valve is used to prevent
the fuel vapor in the canister from entering the engine
intake system and burning it in the engine. This can
reduce fuel evaporative emissions.
Appearance
●The appearance of canister solenoid valve is as
shown in the figure below:
Pin of ECP solenoid valve

The solenoid valve pin has no positive and negative
electrode. The connection method is as follows:
Charcoal canister
connector
Inlet manifold
connector
Electrical
connector
The electromagnetic
switch is always closed
 Normal operating voltage: 8~16V VDC
 Operating temperature range: -40~120°C
 Operating frequency: 16 Hz
 Maximum flow rate: 25-35L/min
The flow curve is shown in the figure below:
143
Flow (standard L/min)
Duty cycle (%)
Installation requirements
 The canister solenoid valve should be
installed horizontally on the motorcycle
 The canister solenoid valve should be
installed close to the central axis of
crankshaft to reduce vibration
144
Fault Maintenance and Diagnosis Method of EFI System
Conduct diagnosis directly using the flashing fault lamp at meter

The fault light [A] is located on the meter panel
with a mark below. Under normal circumstances, after
the key is turned, if the fault light is on, it indicates
that the electronic injection system is powered and it
can work; if the fault light is off, it indicates that the
electronic injection system circuit is disconnected, it
will not work and the connection of positive and
negative electrodes of fuse and battery should be
checked. If the fault light is off after the engine is
started, it indicates that there is no fault; on the
contrary, if the fault light is still on after the engine is
started, it indicates that the electronic injection system
works abnormally and the fault should be removed if
any.
In the case that a fault is confirmed, after opening
and closing the key for 3 times, namely the operation
of opening---closing--- opening---closing –opening
key, the fault lamp will flash the flash code of
corresponding fault. Then, corresponding fault can be
identified through fault code table.
Of them, when using the method to read fault
using fault lamp, the flash code rule is as follows: for
example, the fault is the open circuit of intake pressure
sensor or short circuit of signal terminal pin to the
negative electrode of storage battery, the fault lamp
will flash for 10 times to represent 0, flash for 1 time
to represent 1 after 1.2 seconds, flash for 10 times to
represent 0 after 1.2 seconds, flash for 7 times to
represent 7 after 1.2 seconds, namely P0107. It can be
seen that except that number 0 is represented by
flashing for 10 times, numbers 1-9 correspond to the
times of flashing. If there are other fault codes, such as
fault P0201, there is fault in the fuel injector of
cylinder 1. After flashing P0107, wait for 3.2 seconds,
continue to flash P0201 fault code; if there is no other
fault, it will flash P0107 and P0201 cyclically. Then,
relevant faults can be queried according to fault code
table.
When using PCHUD software, the software will
report fault code using decimal numbers. In fault code
table, there is an one-to-one correspondence
relationship between decimal numbers and previous
hexadecimal numbers, and thus corresponding faults
may be found according to the correspondence
relationship. For example, MULFCURR (current fault)
= 263 in the software, it corresponds to P0107 in fault
code table, namely intake pressure sensor fault.
145
●MT05 Table of fault codes
DTC Number
HEX DEC Chinese translation of
System or Component DTC Description
(diagnostic (software DTC
unit display) display)
MAP Circuit Low Voltage or
107 263 voltage is low or
Manifold Absolute Open
open-circuited
Pressure Sensor (MAP)
MAP Circuit High Voltage 108 264
voltage is high
IAT Circuit Low Voltage 112 274
voltage is low
Intake Air Temperature
Sensor (IAT) IAT Circuit High Voltage or
113 275 voltage is high or
Open
open-circuited
Coolant/Oil Temperature Water temperature sensor
117 279
Sensor Circuit Low Voltage voltage is low
Coolant/Oil Sensor Coolant/Oil Temperature Water temperature sensor
Sensor Circuit High Voltage or 118 280 voltage is high or
Open open-circuited
TPS Circuit Low Voltage or
Throttle Position Open
open-circuited
Sensor (TPS)
TPS Circuit High Voltage 123 291
voltage is high
Oxygen sensor voltage is
ircuit Low Voltage 131 305
low
Oxygen Sensor
Oxygen sensor voltage is
Circuit High Voltage 132 306
high
Oxygen sensor heating
Heater Circuit High Voltage 31 49
coil voltage is high
Oxygen Sensor Heater
Oxygen sensor heating
Heater Circuit Low Voltage 32 50
coil voltage is low
Fuel Injector A Injector A Fault 201 513 Fuel injector coil fault
Fuel pump relay coil
FPR Coil Circuit Low Voltage
or Open
Fuel Pump Relay (FPR) open-circuited
Fuel pump relay coil
FPR Coil Circuit High Voltage 232 562
voltage is high
Trigger (crankshaft phase
CKP Sensor Noisy Signal 336 822
Crankshaft Position sensor) signal is confused
Sensor (CKP) No trigger (crankshaft
CKP Sensor No Signal 337 823
phase sensor) signal
Ignition Coil A Cylinder A Ignition Coil fault 351 849 Ignition coil fault
Idle Control System Idle Speed Control Error 505 1285 Idle speed control error
System Voltage Low 562 1378 Battery voltage is low
System Voltage
System Voltage High 563 1379 Battery voltage is high
Fault indicator light is out
MIL MIL Circuit Malfunction 650 1616
of order
Tachometer Circuit Low The rotating speed output
1693 5779
Voltage voltage is low
Tachometer
Tachometer Circuit High The rotating speed output
1694 5780
Voltage voltage is high
There is no signal in speed
Vehicle Speed Sensor VSS No Signal 500 1280
sensor
Park Neutral Switch Park Neutral Switch Error 850 2128 Neutral position and
146
Diag clutch switch fault
Canister solenoid valve
CCP short to high 445 1093
output voltage is high
CCP
Canister solenoid valve
CCP short to low/open 444 1092
output voltage is low
Rollover Sensor Rollover Sensor Vehicle-down sensor
1500 5376
Diagnostic malfunction/Triggered signal
Several BLM value hit Long-term learning value
BLM_MaxAdapt 171 369
maximum of fuel is slightly high
Several BLM value hit Long-term learning value
BLM_MinAdapt 172 370
minimum of fuel
PE mode burned AFR keeps Continue to be thin in
PESystLean 174 372
lean power enrichment mode
Diagnose fault using diagnostic apparatus

●Diagnostic apparatus
●Operation method:
a) Find the 6-port diagnose interface at
motorcycle;
b) Connect connecting wire and diagnostic

apparatus interface;
c) Open the key for diagnosis;
147
WARNING
 The XCM-PT100X diagnostic apparatus is
a high-precision instrument that should be
protected from shock and vibration;
 If the apparatus is not working properly or
the display is unstable after it is turned on
for the first time, please disconnect the
power cable and try again;
 Please ensure that the connector is always
fastened in the diagnostic connector;
 It is strictly forbidden to test the electrical
signals that exceed the limit;
 It is strictly forbidden for the driver to
operate the instrument during driving;
 Use and storage conditions:
Environment temperature: 0~50 degrees
Celsius
Relative humidity: less than 90%
Check fault using diagnostic software PCHUD

●PCHUD software is used to detect and record engine
operating data, laptop should be connected to 6-port
diagnostic port of motorcycle through K line before
use, and the diagnosis port is below the rear seat
cushion. Please note that the PCHUD system only
supports 16Bit Microsoft Windows operating system
or a very small number of 32bit Windows operating
systems. It does not support 64bit systems such as
Win7, Win8 or iOS. It is necessary to install K-line
driver software on the notebook before use.
●Operating Instructions for PCHUD Software:
(1) Connect laptop and 6-hole diagnostic port of
motorcycle using K line and open the key;
(2) Click “HUD.EXE” icon and start PCHUD
software;
(3) Select “File” in the software interface, click “open”
to select “PCHUD.HAD”, and then click “OK” for
confirmation.
148
(4) Select “Parameter File” under “Setup”, click
MT05common.par file, select “Comm protocol under
“Setup”, select “Keyword2000” and then click OK, at
the same time select 17 as the Device Code.
149
(5) If the software interface cannot display the
real-time communications data, it needs to conduct the
following work: check whether there is problem in
COM port connection setting under “Setup”, generally
set COM Port: 4. Baud Rate:10400, and do not select
DTR High at startup
And then conduct normal communications, display the

current fault code at MALFCURR, and display
historical fault code at MALFHIST.
And then query the corresponding fault according to fault code table.
●PCHUD Software Parameter Interpretation:
VRPM Engine speed engine speed
VTHROT Throttle opening throtle position
VBARO Atmospheric pressure BARO
VMAP Intake manifold pressure manifold air pressure
Estimated value of intake manifold
VMAPEXP expect manifold air pressure
pressure
VIGN Storage battery voltage ignition key voltage
Temperature of cylinder temperature cylinder temperature or coolant
VCLTS
or coolant temperature
VIAT Intake temperature intake air temperature
STATUSBYTE5 Status flag 5 STATUSBYTE5
VAFCMET Airflow learning conditions are met airflow correction met
Atmospheric pressure updating
VBAROCMET Baro update met
conditions are met
150
VCSINSYNSPRK Sequential ignition flag sequential spark enable
tip-in ignition angle correrction
SATITRIG tip-in Spark Advance retard trigger
condtions are met
CATLOENB Catalyst work logic is enabled catlyst light-off logic enable
Normal working flag position of
IF ENGSTATE=3 engine work in run state
engine
The idle speed conditions for
NISTBLIDLE stable warm idle
warming up machine are met
Long-term learning unit of intake
FCNO block learn memory cell
efficiency
FBLMCOR1 Long-term learning value of cylinder cylinder 1 block learn memory
FCLCINT1 Item I of closed loop learning intergral of close loop correction
FCLCMUL1 Correction of closed loop learning close loop correction
IARDRPM Rotating sped of desired idle speed desired idle rpm
IARPMERR Deviation of idle speed idle rpm error
FPWVC1 Fuel injection pulse width of cylinder base pulse width of cylinder 1
VO2 Oxygen sensor signal Oxygen sensor signal
Concentration mark of oxygen sensor cylinder 1 oxygen sensor signal rich
FO2STAT1
of cylinder lean state
Correction and resetting mark of
FCLREST1 cylinder 1 close loop correction reset
closed loop of cylinder
FOSHTREN Oxygen sensor heater is enabled Oxygen sensor heater enable
Heating completion mark of oxygen
FO2REDY1 cylinder 1 Oxygen sensor ready
sensor of cylinder
Closed loop learning of idle speed idle airflow control valve close loop
IF IACV MODE=0
stepper motor is enabled correction enable
Lost step flag position of idle speed
IAMTRLOST IACV lost
stepper motor
Flag position where the movement of
IACMVIHB IACV move disable
idle speed stepper motor is disabled
VIGNS Ignition state flag position ignition state
FVE1 Cylinder filling efficiency cylinder 1 Volumetric efficiency
VMAPRANG Intake pressure reading angle MAP read angle
AFFNLAFR Target air fuel ratio target air fuel ratio
SAESTA Ignition advance angle of cylinder cylinder 1 Spark Advance
SAIDLDYN Dynamic ignition angle at idle speed idle dynamic Spark Advance
SPDWELL Magnetizing time dwell time
Airflow learning value of idle speed
IAINTEGOFST airflow integral of idle air control valve
stepper motor
Number of desired steps of idle speed desired position of idld air control
IACVDSMP
stepper motor valve
Closed loop correction of cylinder is
FCLCEN1 cylinder 1 close loop correction enable
enabled
Flag position where pilot injection is
PPDSEBL prime pulse disable
disabled
Flag position where fuel pump is
FPENABL fuel pump enable
enabled
Acceleration and enriching are
FTRNSAES acceleration enrich enter
enabled
FTRNSDES Deceleration and thinning are enabled deceleration enlean enter
FTRNSAEDCLOAD Acceleration and enriching exit acceleration enrich exit
FTRNSDEINLOAD Deceleration and thinning exit deceleration enlean exit
151
●Diagnosis process:
1.Insert the key on vehicle and do not start the motorcycle, please check:
Check and
Parameter Min Max Description Units
Record
□Norm
VIGN 11.5 13 battery voltage volt
□Abnormal
□Norm
VTHROT 0 1 fully closed throttle position percent
□Abnormal
□Norm
VTHROT 98 100 fully open throttle position percent
□Abnormal
□Norm
VTHROTRAW 4000 9000 Absolutely throttle body voltage AD None
□Abnormal
□Norm
VBARO 98 103 atmospheric pressure kpa
□Abnormal
□Norm
VIAT -15 40 intake air temperature degC
□Abnormal
□Norm cylinder temperature or coolant
VCLTS -15 40 degC
□Abnormal temperature
2.Starting:
Check and
Record
□Norm
Start - - - -
□Abnormal
□Norm
TERRCNT 0 0 Fly wheel tooth error counter count
□Abnormal
□Norm fuel cut-off enable, the normal flag is
FUELCOFF 0 0 None
□Abnormal white, if not blue
□Norm Rollover sensor enable, normal is
VRLVENBL 0 0 None
□Abnormal white, if not blue
3. Idle The parameters can be checked 1 min for idle speed after vehicle starting. And then check the
stability of EFI parameterafter 3 minutes of long idle.
Check and
Record
□Norm
VRPM 1300 1700 engine speed rpm
□Abnormal
□Norm
VTHROT 0 1 fully closed throttle position percent
□Abnormal
□Norm
MALFCURR 0 0 current MALF code None
□Abnormal
□Norm
VBARO 98 103 atmospheric pressure kpa
□Abnormal
□Norm
VMAP 47 53 intake pressure measured value kpa
□Abnormal
152
□Norm
VIGN 12 16 battery voltage volt
□Abnormal
□Norm Neutral and Clutch switch enable flag,
PNSWTCH 0 0 None
□Abnormal blue is working
□Norm
IACVDSMP 10 60 stepping motor target value step
□Abnormal
□Norm
vehicle speed 0 0 vehicle speed Km/h
□Abnormal
□Norm
FBLMCOR1 0.75 1.15 cylinder 1 block learn memory factor
□Abnormal
□Norm
□Abnormal
□Norm cylinder 1 integral of lose loop
FCLCINT1 -15 15 count
□Abnormal correction
□Norm cylinder 2 integral of close loop
□Norm
FPWVC1 1.5 2.6 base pulse width of cylinder 1 ms
□Abnormal
□Norm
FPWVC2 1.5 2.6 base pulse width of cylinder 2 ms
□Abnormal
□Norm
VO2 45 850 cylinder 1 oxygen sensor voltage mv
□Abnormal
□Norm
VO2B 45 850 cylinder 2 oxygen sensor voltage mv
□Abnormal
4. Run with stable speed
Check and
Record
□Norm
MALFCURR 0 0 current MALF code None
□Abnormal
VCLTS 40 105 degC
□Norm
□Abnormal
□Norm
vehicle speed 0 220 vehicle speed Km/h
□Abnormal
□Norm
□Abnormal
□Norm
□Abnormal
□Norm cylinder 1 integral of lose loop
□Norm cylinder 2 integral of close loop
VO2 □Norm 45 850 cylinder 1 oxygen sensor voltage mv
153
□Abnormal
□Norm
□Abnormal
5. Top speed with full throttle(PE mode, power enrich)
PE mode: 70% < VTHROT < 100%, in this situation，the value of oxygen sensor(VO2 VO2B) is
around 800mv.
Check and
Record
VCLTS 80 105 degC
□Norm
□Abnormal
□Norm
VO2 750 950 cylinder 1 oxygen sensor voltage mv
□Abnormal
□Norm
□Abnormal
154
Common troubleshooting methods for electronic fuel inject system
Maintenance tool
a) Disassembly and assembly of electronic
control system components - common
automotive mechanical parts removal tool
b) Electronic control system circuit and system
electrical signal - digital multimeter (with
buzzer)
c) Electric control system fault diagnosis and
engine working condition detection
 Electronic control system fault
diagnostic apparatus (recommended)
 Fault diagnosis software (PCHUD) and
interface connection (conditional use)
d) Electronic control system fault code table
(emergency use)
e) Fuel pressure gauge, range: 0-300kP
Engine working data flow displayed by diagnostic apparatus

Analyze and determine engine fault using the
engine working data flow displayed by the diagnostic
apparatus.
Step I
a) Engine harness and the vacuum pipeline—may
affect the system to control air flow and fuel
supply
b) Whether oxygen sensor is assembled in
place—may affect the system to determine the air
to fuel ratio
c) Engine fault indicator—may affect the system to
give an alarm for fault
d) Storage battery voltage—determine whether the
power of storage battery is sufficient
e) Determine whether coolant temperature sensor,
intake temperature sensor, intake manifold
absolute pressure sensor and oxygen sensor
display value are normal
f) Working range of throttle position sensor—it
cannot be fully opened or closed, which may
affect engine power performance and some
system functions
Step II
Check whether ECU power is turned off—the
communications between diagnostic apparatus and
system is interrupted after turning off key switch
155
Step III
a) Coolant temperature and coolant temperature
cycle—predicts whether the thermostat is working
properly
b) Storage battery voltage (14V) —Indicate whether the
generator is working properly.
Too high: there may be fault in voltage regulator;
Too low: there may be improper connection of
generator or generator fault
c) Intake manifold pressure—it can predict whether there
is leakage in intake and valve clearance problems.
Valve clearance is too small: this value is too high, so
engine power performance may be affected; in addition,
due to too early opening of exhaust valve and increase
in exhaust temperature, oxygen sensor and three-way
catalytic converter service life may be significantly
shortened;
Valve clearance is too large: it may cause low intake
manifold pressure, and thus affect the system to
determine the working state of engine, thus resulting in
abnormal idle speed during warm-up of motorcycle.
In addition, if the exhaust system is blocked, for
example: a foreign body exists in the outlet; the oil
consumption is too high, thus blocking three-way
catalytic converter; three-way catalytic converter is
blocked due to internal damage, which will cause
slightly high value.
d) Number of cycles of oxygen sensor value—the number
of cycles is too small, indicating fault of oxygen sensor
Simple Troubleshooting
Please follow the following steps to repair EFI system.
To repair fault in one step, the subsequent steps may be
stopped. And then use diagnostic apparatus to conduct
inspection and acceptance and clear fault code according to
“Engine Working Data Flow Displayed by Diagnostic
Apparatus”.
When using diagnostic apparatus, the voltage of storage
battery should not be lower than 8.5 V.
Daily Use and Maintenance
 Gasoline should be high quality without lead.
 ECU has a moisture-proof function, but
high-pressure water gun should not be used to rinse its
shell.
 The petrol filter should be changed every
18000km.
 Under normal conditions of use, clean the throttle
body every 10,000 km or 1 year.
Fault phenomenon-Start Fault
a) Rotate ignition switch to “On” position, and check whether engine fault lamp is on.
If it is off:  Check fuse and grounding wire
 Check whether ECU plug is connected
firmly
 It is able to check whether this lamp and
line is normal using the check function of
156
diagnostic apparatus actuator
 Check and repair bulb and its line
It is be  Connect diagnostic apparatus to system
able to be diagnosis interface
on:
b) Check whether diagnostic apparatus can be connected to system for communications
If not:  Check fuse and grounding wire
 Check whether ECU plug is connected
firmly
 Test whether diagnostic apparatus is
working normally at another normal
motorcycle
If yes:  Remove the fault indicated by diagnostic
apparatus
c) Check ignition system fault—whether normal ignition can be made for spark plug
If not:  Check whether high-voltage line and spark
plug are plugged firmly or damaged
 Use another ignition coil for assembly
judgment
 Judge using ECU
If yes:  Check whether high-voltage line is
connected to ignition coil and spark plug
properly
d) Check oil supply system fault
Check whether fuel pump is working—it is able to hear the sound that the fuel pump is working
near the fuel tank when starting engine
Not work:  Check whether fuel pump relay is working
normally
 Check whether the connection and
working of crankshaft position sensor is
normal
 Judge using ECU
 Check fuel pump line
Be able to 1) Check whether fuel supply pressure is
work: greater than 220Kpa
2) Insufficient  Check whether there is
pressure: sufficient fuel in the fuel
tank
 Check whether fuel
filter needs to be
replaced (note: replace
the fuel filter special for
electronic injection
should be replaced once
every 18000km)
 Check whether fuel
supply pipe and fuel
return pipe are damaged
3) Normal  Check whether there is
pressure: any abnormality in
nozzle control line
 Check whether nozzle
needs to be cleaned
157
e) Confirm whether cylinder is submerged
If yes: After completely opening the throttle and
turning on starting motor, there should be
working sign in engine after several
seconds
f) Check whether crankshaft position sensor clearance is too large
Fault phenomenon—Start failure with tempering
a) Check whether ignition coil is loosened;
b) Check whether timing gear ring is loosened.
Fault phenomenon—Instable idle speed
Idle control Check whether the idle bypass bolt is
system: loose
Oil supply system: Check whether there is leakage in oil
pipeline
target idle speed)
Too high  When the water temperature is lower
idle speed: than 68 degrees, the system will increase
idle speed to accelerate warming-up
process, which is normal phenomenon.
Check the items according to the
following items except that
 Adjust the negative pressure balance of
cylinder before check
 Check whether valve clearance,
especially exhaust valve clearance is too
large
Too low  Check fuel quantity in fuel tank, fuel
idle speed: filter, fuel line pressure and nozzle
 Checking valve clearance and confirm
whether it is too small
Fault phenomenon—Instable idle speed with deceleration and flameout
a) Checking valve clearance;
b) Check whether idle speed bypass hole and throttle body are too dirt.
Fault phenomenon—Insufficient power of deceleration
a) Check whether the parameters are normal at idle
speed and high idle speed;
b) Check fuel quantity in the fuel tank and fuel
filter;
c) Check whether exhaust system is blocked, for
example: whether three-way catalytic converter is
blocked by burning oil or damage;
d) Check fuel line pressure and nozzle;
e) Check whether fault lamp is on, and whether
normal ignition can be conducted for only one
cylinder.
Fault phenomenon—Slight burning phenomenon
Check whether the spark plug clearance meets
specification of 0.6-0.7mm
Fault phenomenon—Fault lamp is on, but fault code is inconsistent with fault
It may be caused due to instable connection of system
grounding wire, reconnect the grounding wire, disconnect
the power cable of battery for 3 minutes and then start the
158
engine.
Fault phenomenon—Extremely high fuel consumption
a) Check whether the oxygen sensors of two cylinders
are assembled in place; if it is in the loose state, the
oxygen sensor may incorrectly judge that the
combustion in the cylinder is thin, and then increase
fuel, which may result in unusually high fuel
consumption.
b) After confirming that the engine mechanical parts and
oxygen sensor are in normal conditions, run the
engine to observe the oxygen sensor reading. If the
reading is always greater than 500 mV at normal
water temperature, check whether there is leakage in
fuel injector.
Precautions
 The vast majority of EFI parts cannot be repaired; after
the confirmation of damaged parts, generally
replacement is taken.
 When starting the engine, do not operate any
mechanism (including the throttle, do not pull the
throttle for start) on the engine.
 If engine fault lamp becomes on during the engine
operation, cause must be checked and eliminated as
soon as possible.
 Do not use leaded gasoline, because lead may damage
the oxygen sensor and three-way catalytic converter.
 If oil consumption is abnormal, the problem should be
resolved as soon as possible, because some of the
substances in the oil may damage the oxygen sensor
and three-way catalytic converter.
 Valve clearance should not be too small, if the exhaust
valve is not shut off tightly, exhaust temperature may
become too high and thus shorten the life of three-way
catalytic converter.
 At the temperature of below 10°C, if the vehicle and
engine run at low speed for a long time, the exhaust
pipe may have carbon deposition and become black,
which is a normal phenomenon. It will be eliminated
after a period of high-speed operation, or appropriate
means should be taken to keep the engine coolant
temperature within the specified temperature range.
159
Sample of diagnostic table
Registration number (license plate
Name of rider: First registration year:
number):
Model: Engine number: Frame number:
Date of fault: Mileage:
Environment where the fault occurs
Weather □ Sunny □ Cloudy □ Rainy □ Snowy □ General □ Others:
temperature □Hot □Warm □Cold □Very cold □General □Others:
Frequency of fault □Usual □Frequent □Only once
Road conditions □Street □Road □Mountain road (□ Uphill, □ Downhill) □ Rugged road □ Gravel road
Altitude □Normal □High altitude (about 1000 m or above)
The state of the motorcycle in the event of fault
□ After the electric door lock is turned on for about 3 seconds, the FI warning message and the FI
Alarm
warning sign (EFI system failure) are alternately displayed on the LCD.
indicator
□ After the electric door lock is turned on for 3 seconds, the FI flashing burglar alarm system warning
light
message and sign are displayed on the LCD screen (anti-burglar control system is faulty).
(LED)
□ After the electric door lock is turned on for 3 seconds, the alarm light will go out.
□The starter motor does not run.
□ The starter motor rotates but the engine does not start.
It is □ The starter motor and engine are not started.
difficult to □Unable to supply oil (□ no fuel in the fuel tank, no running sound of fuel pump).
start □ Submerge cylinder (Do not open the throttle valve when starting to avoid submerging the cylinder).
□The spark plug cannot work properly.
□Other:
□ It will flame out after start.
□ It will flame out after turning on the throttle.
□ It will flame out after turning off the throttle.
Flame-out
□ It will flame out when moving the motorcycle.
of engine
□ It will flame out after stopping the motorcycle.
□ It will flame out when running at a constant speed.
□Other:
□ The idle speed is very low, □ the idle speed is very high, □ and the idle speed is unstable.
□ The battery voltage is low (test after charging).
□ The spark plug is loose (tighten the spark plug).
□ The spark plug is dirty, broken or the gap is improper (corrected).
It cannot □ Tempering.
run
□Blasting.
properly
□It is sluggish when accelerating.
at a low
speed □ The oil viscosity is too high.
□ Brake drags.
□Engine overheating
□The clutch is slipping
□Other:
□ The spark plug is loose (tighten the spark plug).
□ The spark plug is dirty, broken or the gap is improper (corrected).
□ The spark plug model is improper (replace it).
The □ Deflagration (poor or improper oil quality, replace it using the gasoline with high-octane rating).
acceleratio □ Brake drags.
n is □The clutch is slipping
sluggish □Engine overheating
□ There is a lot of oil.
□ The oil viscosity is too high.
□Other:
160
Chapter IV Cooling System
Contents
Exploded view of cooling system ................................................................................................................162
Exploded view of water pump ..................................................................................................................... 164
Coolant flow diagram .................................................................................................................................. 165
Coolant ......................................................................................................................................................... 168
Check coolant for deterioration ........................................................................................................... 168
Check coolant level ..............................................................................................................................168
Drain the coolant ..................................................................................................................................168
Add the coolant .................................................................................................................................... 168
Detect pressure .....................................................................................................................................168
Flush cooling system ........................................................................................................................... 168
Disassembly/installation of coolant reserve tank.................................................................................. 169
Water pump .................................................................................................................................................. 170
Disassembly of water pump .................................................................................................................170
Installation of water pump ................................................................................................................... 171
Check water pump impeller .................................................................................................................171
Radiator ........................................................................................................................................................ 172
Disassembly of radiator and radiator fan .............................................................................................172
Installation of radiator and radiator fan ............................................................................................... 173
Inspection of Radiator ..........................................................................................................................173
Inspection of radiator cover................................................................................................................... 175
Inspection of radiator filler .................................................................................................................. 176
Thermostat ....................................................................................................................................................177
Disassembly of thermostat ...................................................................................................................177
Installation of thermostat ..................................................................................................................... 178
Inspection of thermostat .......................................................................................................................178
Hose and pipeline .........................................................................................................................................180
Installation of hose ...............................................................................................................................180
Check hose ........................................................................................................................................... 180
Water temperature sensor .............................................................................................................................181
Disassembly / installation of water temperature sensor ...................................................................... 181
Check water temperature sensor ..........................................................................................................181
161
Exploded view of cooling system
162
Num Torque
ber of N·m kgf·m
1 Water tank assembly 1 — —
2 Stainless steel screw M6×30 2 10 1.0
3 Radiator mounting collar 4 — —
4 Rubber block 4 — —
5 Stainless steel clamp 2 — —
6 Inlet hose 1 — —
7 Stainless steel clamp 2 — —
8 Outlet hose 1 — —
Outlet water temperature switch
9 1 — —
assembly
Connecting pipe between coolant
10 1 — —
reserve tank and water tank
11 Clamp Φ10 2 — —
12 Expansion kettle 1 — —
Hexagon bolt with flange
13 2 10 1.0
M6×12/polished head
14 Expansion kettle cover 1 — —
15 Plate clamp 1 — —
16 Inlet hose of coolant reserve tank 1 — —
R: Replace the part
163
Exploded view of water pump
Num Torque
ber of N·m kgf·m
1 Retainer 1 — —
2 Washer 1 — —
3 Elastic retainer for shaft φ12 1 — —
4 Washer 1 — —
5 Plastic gear of pump gear 1 — —
6 Pin B3×22 1 — —
7 Water pump shaft 1 — —
8 Washer 1 — —
9 Water pump impeller 1 — —
10 Pump seal 1 — —
11 Pin 2 — —
12 Bolt M6×30 3 10 1.0
13 Water pump cover 1 — —
14 Bolt M6×20 1 10 1.0
15 Washer 1 — —
R: Replace the part
164
Coolant flow diagram
Permanent antifreezing liquid is used as a coolant to prevent the cooling system from being rusted or
corroded. Once the engine is started, the pump will begin to rotate and the coolant will begin to circulate.
The cooling system uses a paraffin-based thermostat that will be turned on or off as the temperature of the
coolant changes. In order to maintain the coolant at the proper temperature, the thermostat constantly changes
the valve opening. If the temperature of coolant is below 75°C, the thermostat will beturned off to limit the flow
of coolant through venting holes, thus allowing the engine to warm up faster. If the temperature of coolant is
higher than 75°- 90°C, the thermostat will be turned on and the coolant will flow.
If the temperature of coolant exceeds 98°C, the radiator fan switch starts to work, thus causing the radiator
fan to rotate. If the air flow is insufficient (such as when the motorcycle is running at low speed), the radiator fan
will draw air through the radiator fins to accelerate the cooling effect of radiator. If the temperature of coolant is
lower than 93°C, the radiator fan relay will be turned off and the radiator fan will stop rotating.
In this way, the cooling system controls the temperature of engine within a narrower range, and the engine
can operate efficiently even if the load of engine changes.
This cooling system is pressurized through radiator cap to prevent the coolant from boiling and creating
bubbles and causing too high temperature of engine. As the temperature of engine rises, the coolant in the
radiator and water jacket will expand. Excess coolant will flow through the radiator cap and hose, then to the
auxiliary tank and is temporarily stored in the expansion kettle. Conversely, as the temperature of engine drops,
the coolant in the radiator and water jacket will shrink and the coolant stored in the expansion kettle will flow
165
back to the radiator.
There are two valves on the radiator cover. One is a pressure valve that controls the pressure in the cooling
system while the engine is running. If the pressure exceeds 93 ∼ 123 kPa, the pressure valve will be opened and
the pressure in the expansion kettle will be released. After the pressure is released, the pressure valve will be
closed and the pressure will be maintained at 93 ∼ 123 kPa. When the engine cools, another small valve
(negative pressure valve) on the radiator cover will be opened. As the temperature of coolant decreases, the
coolant will shrink, thus causing the system to form a vacuum. The negative pressure is tunred on to allow the
coolant to flow from the expansion kettle to the radiator.
166
Item Normal
Coolant prepared when delivering goods
(Recommended) type Permanent antifreezing liquid
Color Green
Mixing ratio 50% soft water, 50% coolant
Freezing point –35°C
Total amount 3.4L (full level of coolant reserve tank, including
radiator and engine)
Radiator cover
Release pressure 93 ∼ 123 kPa
Thermostat
Valve opening temperature 75∼90°C
Valve head ≥7 mm at 75°C
167
Cooling fluid
Check coolant for deterioration
●Visually inspect the coolant inside the reservoir.
★If white cotton-like floats are observed, the
aluminum parts inside the cooling system have been
corroded. If the coolant is brown, the iron or steel parts
are rusting. In either case, flush the cooling system.
★ If the coolant smells, check the cooling system for
leakage. Because exhaust gas may enter the cooling
system.
Check coolant level
● See "Check Coolant Level" in chapter "Periodic Maintenance" for details.
Drain the coolant
● See "Replacing Coolant" in chapter "Periodic Maintenance" for details.
Add the coolant
● See "Replacing Coolant" in chapter "Periodic Maintenance" for details.
Detect pressure
●Remove the radiator cap and install the cooling
system pressure gauge [A] on the filler.
Remarks
○Dampen the sealing surface of the radiator cover
with water or coolant to prevent pressure leakage.
●Gradually increase the pressure in the system until the
pressure reaches 123 kPa
Notes
Do not exceed the designed maximum pressure of
the system when testing pressure. The maximum
pressure is equal to 123 kPa
● Observe the pressure gauge for at least 6 seconds.
★ If the pressure remains stable, the system is normal.
★ If the pressure drops and no external problems are
found, check the internal part for leakage. If a small
amount of oil is found in the coolant, it indicates
internal air leakage. Check cylinder head gasket and
water pump.
●Remove the pressure gauge, replenish the coolant, and
cover the radiator cap.
Flushing Cooling System
●At set intervals, rust, scale and calcium oxide may be
deposited in the pipe chamber and the radiator in the
cooling system. Once you find rust, scale and calcium
oxide, flush the cooling system! Otherwise, the above
deposits may block the water channel, thus greatly
reducing the efficiency of the cooling system.
● Drain the coolant (see "Replacing Coolant" in chapter
168
"Periodic Maintenance" for details).
●Fill the cooling system with a mixture of fresh water
and detergent.
Notes
Do not use the cleaners that can corrode
aluminum engines and radiators! Please strictly
observe the relevant regulations in the product
manual provided by the manufacture!
●Heat the engine up and run it for about ten minutes at
normal operating temperature conditions.
●Turn off the engine and drain the cooling system.
●Fill the cooling system with fresh water.
●Heat the engine up and drain the cooling system.
●Repeat the previous two steps again.
●Add permanent coolant to the cooling system and
drain the air from the cooling system (see "Replacing
Coolant" in chapter "Periodic Maintenance" for
details).
Disassembly/Installation of Coolant Reserve Tank

● Before replacing the coolant, remove the coolant
reserve tank and then install it after replacement (see
"Replacing Coolant" in chapter "Periodic Maintenance"
for details).
169
Water pump
Disassembly of Water Pump

● Remove the bottom cover (see “Removing the
Bottom Cover” in the chapter “Frame”).
● Drain the oil (see "Replacing Oil" in chapter
●Disassemble:
Hose clamp [A]
Inlet hose [B]
Water pump cover bolt [C]
Water pump cover [D]
Note:
Need to be done while cooling the engine
When pulling out the hose, do not splash the
coolant to the personnel.
●Remove the impeller mounting bolt [A].
●Remove the impeller from the shaft [A].
170
Installation of Water Pump
● Replace the seal [A].

● Locking torque
Locking torque of water pump cover bolt: 9.8 N•m
Check water pump impeller

● Visually inspect the impeller of water pump.
★ If the impeller surface has been corroded or the
blade is broken, replace the water pump assembly.
171
Radiator
Disassembly of Radiator and Radiator Fan

● Remove the radiator cowling (see “Removing
Radiator Cowling” in the chapter “Frame”).
●Disassemble:
Engine outlet hose clamp [A],
Engine outlet hose [B],
Upper mounting bolt of radiator [C],
Hose of coolant reserve tank
●Disassemble:
Engine inlet hose clamp [A],
Engine inlet hose [B],
Upper mounting bolt of radiator [C],
Radiator [D
Notes
Do not touch the heat sink fins as this will damage
the heat sink and reduce cooling efficiency.
● When removing the radiator, disconnect the radiator
fan cable connector.
172
●Disassemble:
Radiator fan mounting bolt [A]
Radiator fan [B]
Assembly of Radiator and Radiator Fan

● Properly arrange the radiator fan motor lead (see
section "Winding Method of Cables, Wires and Hoses"
of Chapter "Appendix" for details).
● Install the radiator bracket bushing [A], cushion
bushing [B] and bolts, as shown in the figure below.

Locking torque of radiator mounting bolt (upper side):
10 N·m
Locking torque of radiator mounting bolt (lower side):
10 N·m
Inspection of Radiator
● Check radiator fins.
★ If there are any obstacles that block the flow of air,
please clean up!
★ If the radiator fin [A] is deformed, carefully
straighten it.
★If the obstacle that cannot be removed or the radiator
fin that cannot be repaired blocks the air passage of
20% or more of the radiator, you need to replace it with
a new one.
173
Notes
In order to avoid damage to the radiator, the
following precautions should be taken when
cleaning the radiator with a steam cleaning device:
The steam gun [A] must be at a distance of 0.5
m [B] or more from the radiator fins.
When holding the steam gun, make it vertical
[C] (do not tilt [D]) on the surface of radiator fin.
Use the steam gun according to the direction
of the radiator fin heat sink.
174
Inspection of radiator cover
●Disassemble:
Radiator cap [A]
● Check the base [A], top [B] valve seal and valve
spring [C].
★ If any of the above parts is broken, you need to
replace it with a new one.
● Mount the cover [A] on the pressure gauge of cooling

system [B].
Remarks
○Dampen the sealing surface of the radiator cover
with water or coolant to prevent pressure leakage.
●Observe the pressure gauge, pump up the pressure
gauge, increase the pressure until the pressure relief
valve opens: the pressure gauge pointer pops open.
Stop pumping and immediately measure the pressure
value when the air leaks. The pressure relief valve must
be opened within the limits specified in the table below.
In addition, the gauge pointer must remain in this range
for at least 6 seconds.
Radiator cover release pressure
Standard: 93-123 kPa
★ If the radiator cap cannot maintain the specified
pressure or maintain excessive pressure, you need to
replace it with a new radiator cap
175
Inspection of Radiator Filler
●Disassemble:
Radiator cover
●Check the radiator water filler for damage.
●Check the top and bottom seals [A] inside the filler.
The top and bottom seal sleeves must be smooth and
clean to ensure proper operation of radiator cap.
176
Thermostat
Disassembly of Thermostat
● Remove the radiator cowling (see “Removing
Radiator Cowling” in the chapter “Frame”),
● Remove the radiator (see “Removing Radiator” in the
chapter “Radiator”),
●Remove
Bolt [A],
Thermostat cover [B],
● Remove:
Thermostat [A]
Notes
Perform these steps while the engine is in the
cooling state
177
Installation of Thermostat
●When installing the thermostat [A] into the housing,
the exhaust valve hole [B] should be on the top.
●Install a new O-ring seal into the housing.
Lock torque of thermostat cover mounting bolt: 9.8
N·m
●Install the water pipe and tighten the lock screw.
Lock torque of radiator hose (water pipe) lock screw:
2.0 N·m
● Fill the radiator with coolant (see "Replacing
Coolant" in chapter "Periodic Maintenance" for
details).
Inspection of Thermostat
● Remove the thermostat (see “Disassembly of
Thermostat” for details) and check the thermostatic
control valve [A] under room temperature conditions.
★ If the valve is open, you need to replace it with a
new one.
To measure the valve opening temperature, suspend the

thermostat [A] in a container filled with water and raise
the water temperature.
○The thermostat must be completely submerged in
water and must not touch the inner wall or bottom of
the container. A precise thermometer [B] is suspended
in the container containing the water, and the
immersion depth of part [C] used for sensing
temperature of the thermometer is substantially the
same as that of the part used for sensing temperature of
thermostat. The thermometer should also not touch the
inner wall or bottom of the container.
★When the temperature reaches 75°C, the thermostatic
valve will open and the temperature will reach 90 °C.
The thermostatic valve will open by at least 7 mm.
★ If the measurement result exceeds the specified
temperature range, replace it with a new one.
Thermostat valve opening temperature:

75°~ 90°C
178
Graph when the thermostat is turend on / off
A Completely turned off
A Completely turned on
Notes
A damaged thermostat may cause the engine
to be too hot or too cold.
179
Hose and Pipeline
Installation of Hose
● Install hose and pipeline, and pay attention to the
direction in which the hoses and pipeline are bent.
Avoid substantial bending, kinking, squeezing or
twisting.
● Properly arrange the hose (see section "Winding of
Cables, Wires and Hoses" of Chapter "Appendix" for
details).
The clamp [A] should be as close as possible to the
hose to prevent its end from tilting and prevent the hose
from being loosened.
○Make sure that the lock screws are in the correct
position to prevent the clamps from touching other
parts.
The radiator hose (water pipe) clamp contacts other
parts.
Locking torque of lock screw: 2.0 N·m
Check hose
● See "Inspection of Radiator Hose" in chapter
"Periodic Maintenance" for details.
180
Water temperature sensor
Notes
Prevent the water temperature sensor from falling
on hard surfaces, otherwise, the water
temperature sensor may be damaged.
Disassembly / installation of water temperature sensor

● Remove the radiator (see “Removing Radiator” in the
chapter “Radiator”).
● Remove the water temperature sensor [A]

Locking torque: 20-25 N·m
Check water temperature sensor

● See “Engine Water Temperature Sensor” in the
chapter “Electronic Fuel Injection System (EFI)”.
181
Chapter V Engine
Contents
Lubrication system .......................................................................................................................................184
Exploded view of fuel pump ................................................................................................................184
Oil flow diagram .................................................................................................................................. 186
Fuel pump ............................................................................................................................................ 188
Disassembly of fuel pump ........................................................................................................... 188
Inspection of fuel pump ............................................................................................................... 189
Installation of fuel pump ..............................................................................................................190
Sub-assembly of cylinder head .................................................................................................................... 191
Exploded view of cylinder head .......................................................................................................... 191
Exploded view of camshaft and valve ................................................................................................. 193
Exploded view of timing drive mechanism .........................................................................................194
Special tools and sealants .................................................................................................................... 197
Cylinder head ....................................................................................................................................... 199
Disassembly of cylinder head ......................................................................................................199
Valve decomposition ....................................................................................................................201
Inspection of combustion chamber ..............................................................................................201
Inspection of the cylinder head joint surface ...............................................................................201
Inspection of intake and exhaust springs .....................................................................................202
Inspection of valve stem .............................................................................................................. 202
Inspection of valve guide .............................................................................................................203
Replacement of valve guide .........................................................................................................203
Adjustment of valve seat ring ...................................................................................................... 204
Installation of cylinder head ........................................................................................................ 206
Tensioner ..............................................................................................................................................207
Function of tensioner ................................................................................................................... 207
Disassembly of tensioner ............................................................................................................. 207
Assembly of tensioner ................................................................................................................. 207
Inspection of tensioner .................................................................................................................207
Cylinder block and piston ............................................................................................................................ 208
Exploded view of cylinder body ..........................................................................................................208
Exploded view of piston / crankshaft .................................................................................................. 209
Technical parameters ............................................................................................................................211
Inspection and replacement of cylinder block .....................................................................................212
Disassembly of cylinder block .....................................................................................................212
182
Installation of cylinder ................................................................................................................. 212
Inspection of cylinder block ........................................................................................................ 213
Piston ....................................................................................................................................................213
Disassembly of piston ..................................................................................................................213
Installation of piston .................................................................................................................... 214
Check the piston, piston pin and piston ring ............................................................................... 215
Crankshaft connecting rod ........................................................................................................................... 218
Exploded view of crankshaft connecting rod ...................................................................................... 218
Crankshaft combination .......................................................................................................................222
Disassembly of crankshaft connecting rod combination .............................................................222
Assembly ......................................................................................................................................222
Inspection ..................................................................................................................................... 222
Balance shaft ........................................................................................................................................ 223
Function of balancer shaft ........................................................................................................... 223
Disassembly of balancer shaft ..................................................................................................... 223
Assembly of balancer shaft ..........................................................................................................224
Inspection of balancer shaft ......................................................................................................... 224
Clutch ........................................................................................................................................................... 225
Exploded view of clutch ...................................................................................................................... 225
Special tool ...........................................................................................................................................227
Installation of clutch ............................................................................................................................ 231
Inspection of clutch ..............................................................................................................................231
Gearshift mechanism ................................................................................................................................... 232
Exploded view of gearshift mechanism ...............................................................................................232
Disassembly of gearshift mechanism .................................................................................................. 235
Installation of gearshift mechanism .....................................................................................................236
Inspection of gearshift mechanism ...................................................................................................... 236
Inspection of primary / auxiliary shaft component ..............................................................................240
183
Lubrication System
Exploded view of fuel pump
184
Num Torque
ber of N·m kgf·m
1 Fuel pump components 1 — —
2 Fuel pump body 1 — —
3 Fuel pump shaft 1 — —
4 Pin 3×16 1 — —
5 Inner rotor 1 — —
6 Outer rotor 1 — —
7 Fuel pump cover 1 — —
8 Pin 1 — —
9 Cross recessed pan head screw M4×10 1 — —
10 Plug 2 — —
11 Collar 1 — —
12 Dowel pin 1 — —
13 Roller sprocket 1 — —
14 O-Ring 1 — —
15 Washer 1 — —
16 Bolt M5×10 1 7 0.7
17 Screw M6×25 3 10 1.0
18 Chain 1 — —
R: Replace the part
185
Oil flow diagram
Camshaft oil dust
Oil drain
Oil drain
Crank oil dust
Gearbox oil dust

Main geary
Oil pump Oil filter
Preparatory information
Action of Lubrication System:
The function of the lubricating system of engine is to provide lubricant to the friction surface of workpiece to
make the dry surface friction become into the liquid friction between lubricant particles so as to reduce the wear
of parts; cool the parts with high heat loads; absorb the impacts of bearing and other parts and reduce noise;
increase the sealability between the piston ring and cylinder wall; clean and remove the impurities on the
surfaces of parts.
Operation Precautions:
After disassembling fuel pump, clean the parts carefully and blow the surfaces of parts using high-pressure
gas.
During the disassembly of fuel pump, do not drop the foreign body into the crankcase.
186
Item Normal Allowable limit
Oil capacity:
When replacing the oil 1.2±0.05L ＿
When disassembling 1.5±0.05L ＿
Fuel pump rotor:
Radial clearance between inner
0.05-0.13mm 0.15mm
and outer rotors
Clearance between outer rotor and
0.10-0.16mm 0.2mm
pump
187
Fuel pump
Disassembly of fuel pump
● Loosen the oil pump fixing screw [D], and remove
the roller sprocket [D], fuel pump chain [B] and clutch
housing component [A] on the fuel pump.
●Remove the screw [A].

●Remove fuel pump [B].
●Remove the screw [A], remove the fuel pump seat [B]
and disassemble fuel pump.
188
Inspection of Fuel Pump
● Check the radial clearance between the outer rotor
[A] and the inner rotor [B].
Allowable limit: 0.15mm.
Check the clearance between external rotor [A] and fuel

pump cover [B].
●Check the end clearance of rotor.

189
Installation of fuel pump
●The fuel pump assembly is shown in the figure below
Screw [A]
Chain [B]
Screw [C]
Washer [D]
Roller sprocket [E]
Fuel pump body [F]
Fuel pump shaft [G]
Inner rotor [H]
Outer rotor [I]
Fuel pump cover [J]
Note:
After assembly, the inner and outer rotors should
be able to rotate flexibly without clamping
stagnation.
Locking torque:
Roller sprocket mounting screw: 10N.m
Fuel pump cover mounting screw: 10N.m
Fuel pump mounting screw: 10N.m
190
Sub-assembly of Cylinder Head
Exploded View of Cylinder Head
191
Num Torque
ber of N·m kgf·m
1 Bolt M6×12 1 10 1.0
2 Washer 6.2×14×2.2 1 — —
3 Spark plug 1 — —
4 Valve seal components 4 — —
5 Conical plug M10×1 1 — —
6 Cylinder head processing assembly 1 — —
7 Clamp assembly 2 — —
8 Intake tube components 1 — —
9 Fuel injector 1 — —
10 Fuel Injector seat 1 — —
11 Hexagon socket cap screw M6×15 1 10 1.0
12 Cylinder head sealing components 1 — —
13 Stud M6×25 2 10 1.0
14 Hexagon nut M6 2 10 1.0
16 Stud 1 — —
17 Water temperature sensor 1 — —
18 Thermostat cover 1 — —
20 Thermostat 1 — —
21 Bolt M6×40 4 10 1.0
22 Cylinder head bolt component I 2 — —
23 Cylinder head bolt component I 2 — —
24 Bolt M6×40 4 10 1.0
R: Replace the part
192
Exploded view of camshaft and valve
Num Torque
ber of N·m kgf·m
1 Lifter 4 — —
2 Valve shim 4 — —
3 Valve lock clamp 8 — —
4 Upper spring seat of valve 4 — —
5 Valve spring 4 — —
6 Valve lower spring seat [5] 4 — —
7 Inlet camshaft component 1 — —
8 Intake valve 2 — —
9 Exhaust valve 2 — —
10 Exhaust camshaft component 1 — —
11 Snap ring 2 — —
193
Exploded view of timing drive mechanism
Numb Torque
er of N·m kgf·m
Auxiliary guide chain plate
1 1 — —
component
2 Timing chain 1 — —
3 Primary guide chain plate component 1 — —
4 Bolt M6×14 2 10 1.0
5 Bolt M6×25 2 10 1.0
6 Washer 1 — —
7 Plug 1 — —
8 Camshaft chain regulator 1 — —
9 Washer 1 — —
194
Function of Cylinder Head:
Cylinder head is used to seal the cylinder and it forms a combustion chamber with the piston to withstand the
high temperature and high pressure gas. And it can also complete the intake and exhaust through the distribution
mechanism.
In order to ensure the sealing of cylinder head and cylinder block, the cylinder head withstands great bolt
pretightening force. Tighten it by three times, 15NM for the first time, 30NM for the second time and 90 degrees
for the third time
Before the inspection and measurement, all parts shall be cleaned and blown with high-pressure air.
195
Planeness of cylinder head 0.03mm 0.05 mm
Valve and valve guide
Valve clearance:
Intake 0.13-0.15 mm ＿
Exhaust 0.15-0.17 mm ＿
Outer diameter of valve stem
Intake 4.465-4.475 mm 4.455 mm
Exhaust 4.465-4.475 mm 4.455 mm
Inner diameter of valve guide:
Intake 4.5-4.512 mm 4.54 mm
Exhaust 4.5-4.512 mm 4.54 mm
Clearance between valve seam and
valve guide:
Intake 0.025-0.047 mm 0.09 mm
Exhaust 0.025-0.047 mm 0.09 mm
Width of valve seat:
Intake 1-1.2 mm 1.5 mm
Exhaust 0.9-1.1 mm 1.4 mm
Valve spring
Free length:
Intake 37 mm 36 mm
Exhaust 37 mm 36 mm
Camshaft
Matching clearance between
0.04-0.074 mm 0.1 mm
camshaft and cylinder head
196
Special tools and sealants
Pressure gauge 20 kgf/cm²; Valve seat cutter 60°:
Valve spring compressor assembly: Valve seat holder bar:
Valve seat cutter 45°: Valve seat cutter 45°:
Valve seat cutter 32°: Valve guide arbor:
Valve seat cutter 32°: Valve guide reamer:
Valve seat cutter holder: Pressure gauge adapter:
197
Valve seat cutter 60°: L-shaped hose:
Valve guide driver: Valve guide driver accessory E:
Valve spring compressor adapter: Binder:
Valve oil seal compaction tooling:
198
Cylinder head
Disassembly of cylinder head
●Remove the ignition coil.
Loosen mounting bolt [A], and remove the washer and
cylinder head cover [B].
Loosen the mounting bolt [A] and remove the camshaft

chain regulator [B].
● Use the feeler gauge [C] to measure the fit clearance

between the cylinder head [A] and the camshaft [B].
● Loosen the camshaft support lock screw [A], and

remove the camshaft support [B] and the camshaft limit
ring.
199
● Remove the guide chain plate, chain
● Remove the camshaft.
● Loosen the cylinder head bolt [A].

● Remove the cylinder head [B].
200
●Remove the top pillar, compress the valve spring with
valve spring compression tool and remove valve cotter.
● Remove the valve adjustment washer, valve spring,

valve spring upper seat, valve spring lower seat, valve.
Valve decomposition
Valve [A]
Valve lower spring seat [B]
Valve spring seat [C]
Valve upper spring seat [D]
Valve cotter [E]
Valve adjustment gasket [F]
Top pillar [G]
Inspection of combustion chamber

●Check the combustion chamber and clear the carbon
deposits inside the combustion chamber.
Inspection of cylinder head joint surface
● Measure the planeness of the cylinder head joint
surface [C] with the test gauge [A] and the ruler [B].
When the flatness of the cylinder head joint surface
exceeds the use limit, place a fine sandpaper on the flat
plate, make the cylinder head joint surface fit the
sandpaper and sand the surface in 8 shape.
201
Inspection of intake and exhaust springs
● Use the caliper [A] to measure the free length of the
valve inlet and exhaust springs [B].
Allowable limit: intake spring: 36mm.
Exhaust spring: 36mm.
● Measure the gradient of inner / outer spring of valve

[a].
Allowable limit: 1.6mm
Inspection of valve stem

●Use the micrometer [A] to measure the outer diameter
of the valve stem [B].
Allowable limit: Intake valve: 4.455mm.
Exhaust valve: 4.455mm.
Measure the run-out of valve stem

Allowable limit:0.04 mm
202
Inspection of valve guide
●Check the valve guide and remove the carbon deposits
in the valve guide with a reamer before check.
Notes Valve reamer
Rotate the reamer clockwise and do not rotate the
reamer counterclockwise.
●Measure the inner diameter of each valve guide with a

tester [A].
Allowable limit:
Intake / exhaust: 4.54mm.
Allowable limit of clearance between valve and valve
guide:
Intake valve: 0.09mm.
Exhaust valve: 0.09mm.
Replacement of Valve Guide

Notes
If the clearance between valve and valve guide
exceeds the limit, replace the valve guide. After the
valve guide is replaced, the valve seat ring surface
must be finished.
●Put the valve guide in the freezing cavity of
refrigerator to cool it for an hour.
●Use the electric furnace or oven to heat the cylinder
head to 100-150℃.
Fix the cylinder head and remove the valve guide from
the upper side of cylinder head with the valve guide
disassembly tool [A].
203
●Put a new O-ring on the new valve guide.
●Install the valve guide from the top of cylinder head.
○Install new valve guide using valve guide mounting
tool [2] and guide using valve guide remover [1].
Note:
Do not damage the cylinder head when installing the
valve guide.
After the valve guide is embedded, carry out the

finishing by using the valve guide reamer.
Note: Valve reamer
Add an appropriate amount of cutting oil during
cutting with a reamer. The reamer shall be rotated
clockwise.
Adjustment of Valve Seat Ring

●Clean the carbon deposits in the combustion chamber
and valve, and thoroughly rinse the intake and exhaust
valves.
● Check the width of valve seat contact surface [A].
Allowable limit: intake: 1.5mm.
Exhaust: 1.4mm
●Use a 45°cutter to remove the rough or uneven parts

[A] on the surface of valve seat ring.
Notes
Apply a layer of transparent or Prussia blue coating to
the valve seat ring. so that it can be seen more clearly.
204
●Remove 1/4 of outer end of valve seat ring with a 25°
cutter.
●Remove 1/4 of bottom of valve seat ring with a 60°

cutter. Take the cutter and check the positions which
have been disposed.
●Grind the valve seat ring with a 45° finishing cutter to

reach an appropriate width. Make sure to remove all
dents and uneven parts.
Standard valve seat ring width: intake: 1mm
exhaust valve: 1.0mm
If the contacted position is in the too high part of valve, Contact surface with higher valve
please lower the valve seat ring with a 25° flat cutter.
●If the contacted position is in the too low part of
valve, raise the valve seat ring with a 60° internal
cutter.
●Use the 45° finishing cutter to finish the valve seat
ring again to make it meet the required specification. Contact surface with lower valve
●After the valve seat ring is grinded, apply polish to the
valve surface and gently polish the valve.
Installation of Cylinder Head

●Installation shall be carried out in the order contrary to the disassembly order.
Precautions for Installation of Valve:
205
●When the valve is installed, apply appropriate amount New product
of engine oil to the surface of the valve stem and then
install the valve stem into the valve guide.
Valve spring retainer①
Valve oil seal②
Valve③
Valve spring④
Spring plate⑤
Note:
Before installation, check whether there are burrs at
the end of the valve.
If there are burrs at the end of the valve, polish the
end of the valve stem with an oilstone.
●When installing the valve spring, install the end of
spring with smaller pitch toward the combustion
chamber.
●Use the valve spring compression tool ② when

installing the valve lock clip ①.
●Knock the valve lock plate gently with a soft hammer

to fix it on the valve stem.
Note:
Knock
the valve lock plate overly to avoid damaging
the valve.
Tensioner
Function of tensioner
●A commonly used retaining device on a chain drive system,
which is characterized in that the chain can maintain an
appropriate tension during the transmission process, thereby
prevent the belt from slipping, or prevent the synchronous belt
from skipping, skidding and dragging, or prevent the chain from
206
loosening, shedding, and reduce the wear of sprocket and chain.
Disassembly of Tensioner
● Open the screw at the tail of tensioner first, use the tensioner
to rotate the tooling to retract the tensioner rack, and use the
tool to clamp the tail groove, remove the fixing screw, and
remove the tensioner.
Tensioner
Assembly of Tensioner
● Rotate the rack back when equipped with the tensioner. Fix it
with the tooling clamp and then install it on the engine, tighten
the fixing screws, slowly release the rotating tooling clamp, and
adjust the tension of the tensioner. Do not pull it out directly.
Rotate the engine crankshaft after aligning at the timing device
and assembling it properly. Check the working conditions of
chain. Do not tighten it too tight and too loose. There is no
positioning phenomenon while timing.
Inspection of Tensioner
●Check whether the tensioner rack is obviously shaking. Use
the tooling to screw in and out to check whether the rack is
stuck.
207
Cylinder Block and Piston
Exploded View of Cylinder Body
Num Torque
ber of N·m kgf·m
1 Bolt M6×35 1 10 1.0
2 Rubber plug 1 — —
3 Cylinder block assembly 1 — —
4 Cylinder block washer 4 — —
R: Replace the part
208
Exploded view of piston / crankshaft
Num Torque
ber of N·m kgf·m
1 First ring 1 — —
2 Second ring 1 — —
3 Oil ring 1 — —
4 Piston 1 — —
5 Piston pin retainer 1 — —
6 Piston pin 1 — —
7 Crankshaft components 1 — —
R: Replace the part
209
Function of cylinder block:
The cylinder block provides a space for gas compression, combustion and expansion and guides the movement
of piston.
It can also transfer some heat in the cylinder to the surrounding cooling mediums.
Function of piston:
1. It can withstand the pressure generated by the combustion of combustible gas mixture in the cylinder and
transmit the pressure to the connecting rod to drive the crankshaft to rotate.
2. Form a combustion chamber together with the cylinder head and other parts.
Function of Piston Ring:
The piston ring is a metal ring embedded into the interior of the piston groove. There are two types of piston
rings: the compression ring and the oil ring. The compression ring can be used to seal the combustible mixture in
the combustion chamber; the oil ring is used to scrape the excess oil from the cylinder. The piston ring is a metal
elastic ring with a large outwardly expanding deformation that is fitted into the section and its corresponding
annular groove. The reciprocating and rotationally moving piston ring can form a seal between the external
circular surface of ring and cylinder as well as ring and the side of ring groove relying on the pressure difference
of gas or liquid.
Before the inspection and measurement, all parts shall be cleaned and blown with high-pressure air. There is no
impurity or foreign matter.
210
Item Standard value Allowable limit
Cylinder:
Inner diameter 72.000-72.015 mm 72.02 mm
Cylindricity - 0.015 mm
Roundness - 0.015 mm
Planeness 0.02 mm 0.08 mm
Piston:
Outer diameter of piston (measurement point) 71.94-71.955 mm
71.93 mm
(8-11mm at the bottom of
piston skirt)
Inner diameter of piston pin hole 16.002-16.008 mm 16.02 mm
Outer diameter of piston pin 15.994-16.000 mm 15.99 mm
Clearance between piston and piston pin 0.002-0.014 mm 0.025 mm
Clearance between piston ring and ring
groove
First ring 0.03-0.07 mm 0.09 mm
Second ring 0.03-0.07 mm 0.09 mm
Piston ring joint clearance
First ring 0.15-0.30 mm 0.4 mm
Second ring 0.20-0.35 mm 0.4 mm
Oil ring 0.20-0.70 mm -
Connecting rod:
Inner diameter of connecting rod small end 16.020-16.034 mm 16.04 mm
Clearance between connecting rod and piston
0.020-0.04 mm 0.05 mm
pin
211
Inspection and replacement of cylinder block
14.3 Disassembly of Cylinder Block
● Remove the parts above the cylinder head and loosen
the cylinder block fixing bolt [A].
● Vertically remove the cylinder block [B].
●Remove
Washer [A].
Dowel pin [B].
Installation of Cylinder
●Install the washer [B] and dowel pin [A] on the
crankcase.
★ The gasket shall be prevented from folds and
unevenness.
★ Do not allow misalignment. Apply a small amount of
oil to the inside of cylinder block and put it on the piston.
Shake the cylinder up and down and left and right to fully
fit the piston into the cylinder block. Then press down it
firmly into place. Install the cylinder head gasket.
●Apply oil to the inner wall of cylinder evenly.
Install the piston ring into the cylinder carefully. The
assembly should be conducted smoothly; if it is stuck, the
installation should not be conducted with large force.
Check whether the piston ring is misaligned.
Notes
Do not damage the piston ring. It can rotate
flexibly after installation
212
Check cylinder block
●Check the wear situation of inner wall of cylinder.
Check whether there is obvious scratch, bright concave
and convex phenomena
★ If the wear is serious, please replace it.
Piston
Disassembly of Piston
● Remove the piston pin retainer [A], take out the
piston pin [B], and remove the piston [C].
Notes
During disassembly, do not drop the retainer into
the crankcase.
●Remove the piston ring.
213
Installation of Piston
●To replace the piston, it is necessary to select the
cylinder and piston of the matching group for assembly,
and also check the size requirements such as the
clearance of cylinder.
●Apply oil to the piston ring and piston evenly, make
the piston ring mark side up and install it properly.
When assembling, the height between three piston rings
is 120 degrees in the opening direction, and the two
steel sheets of the combined oil ring are staggered by
30°.
Notes
Do not scratch the piston and do not break the
piston ring.
After the piston ring is installed, it can rotate
freely in the piston ring groove.
●Clean the washers attached to the crankcase before

installing piston.
Notes
Foreign matters shall not fall into the crankcase.
●Install the piston, piston pin and piston pin retainer.
★ When assembling with a new piston pin retainer,
the opening of retainer should not overlap with the
dowel pin of piston pin.
Notes
Install the piston into the intake valve according to
the “IN” mark at the top.
The piston pin retainer should completely fall into
the piston retainer groove, without upsiding down
edges.
214
Check the piston, piston pin and piston ring
●Check the piston, piston pin and piston ring.
★ Clear the carbon deposits inside the piston ring
groove.
Notes
Do not break or damage the piston ring.
●Install the piston ring after cleaning. Push the piston

ring to one side using hands, and measure the gap
between the piston ring [A] and the piston ring groove
[B] using the feeler gauge [C].
Allowable limit: top ring: 0.09mm. Push-in
Second ring: 0.09mm.
●Remove the piston ring and install the piston rings at

the bottom of cylinder.
Notes
Press the piston ring [B] in the cylinder by using
the piston head [A].
●Measure the piston ring joint clearance using the plug

gauge [C].
●Measure the inner diameter of piston pin hole using

the tester.
●Inner diameter of piston pin hole
215
●Measure the outer diameter of piston pin.
●Clearance between piston pin hole and piston pin.
●Measure the outer diameter of piston pin.

Notes
The measurement position forms an angle of 90
degrees with the piston pin and it is 8-11mm below
the piston skirt part.
Allowable limit: 71.93 mm.
● Check the piston skirt and head for obvious scratches.

★ The piston will be considered as damaged if there
are obvious deep scratches, bumps and top ablation.
●Measure the inner diameter of cylinder with a tester

[A].
Notes
Measure the inner diameter of cylinder in the
upper, middle and lower positions in the direction
which forms a right angle (90 degrees) with the
piston pin.
●Check the damage and wear on the inner wall of
cylinder.
●Measure the clearance between cylinder and piston ,
whichever is the greater
● Need to be selected according to grouping
requirements.
216
●Measure the roundness of inner wall of cylinder (inner
diameter difference between X and Y directions).
●Measure the cylindricity of inner wall of cylinder Top
(inner diameter difference between X and Y directions

in upper, middle and lower positions). Middle
Bottom
●Measure the planeness of cylinder surface [C] using

feeler gauge [A] and ruler [B].
●Measure the inner diameter of small end of

connecting rod [A].
●If the above measurement exceeds the allowable limit

rule, new parts need to be replaced. The new parts to be
replaced need to be cleaned. The inside of the cylinder
block should be coated with oil, piston pin and piston
pin hole and the small hole of connecting rod should be
coated with oil.
217
Crankshaft connecting rod
Exploded view of crankshaft connecting rod
218
Num Torque
ber of N·m kgf·m
1 Hexagon nut M20×1.5 1 65 6.5
2 Lock washer with double ears 1 — —
3 Clutch drive gear 1 — —
4 Belleville spring 1 — —
5 Straight key 1 — —
6 Balancer shaft gear components 1 — —
7 Balancer shaft drive gear 1 — —
8 Damping spring 6 — —
9 Damping block 6 — —
10 Balancer shaft collar 1 — —
11 Crankshaft components 1 — —
12 Washer 1 — —
13 Nut M12×1.25 1 70 7.0
14 Woodruff key 1 — —
Balancer shaft driven gear
15 1 — —
components
16 Lock washer with double ears 1 — —
17 Hexagon thin nut M14×1 1 60 6.0
18 Balancer shaft combination 1 — —
19 Straight key 1 — —
R: Replace the part
219
Function of Crankshaft:
Convert the reciprocating motion of piston into a rotary motion and generate torque, and simultaneously
drive the valve distributing mechanism and other auxiliary mechanisms, which are the carrier and power source
for the timing sprocket, the drive gear, the bearing, the crank pin and other parts. As seen from the outside, the
crankshaft consists of a crankshaft and a connecting rod. A combined crankshaft is used for this motorcycle. It is
mainly composed of a crank, a connecting rod, a crank pin and needle bearing. Its crank pin is pressed into the
crank wall with an interference fit. Meanwhile, the big ends of two rods pass through the crank pin. The crank is
circular and has a large thickness in the direction opposite to the crank wall to balance the inertial force
generated due to the rotation of balanced crankshaft. If the engine is overloaded or it is used for a long time,
wear and deformation may be caused. Let us introduce the maintenance method of crankshaft connecting rod.
220
Item Standard value Allowable limit
Lateral clearance of big end of connecting
0.10-0.35 mm 0.5 mm
rod
Crankshaft
Radial clearance of big end of connecting
components 0.012-0.024 mm 0.035 mm
rod
Run-out 0.03 mm 0.1 mm
Crankshaft is disconnected 61.9~62 mm -0.2 mm
221
13.6 Crankshaft Connecting Rod Combination
Disassembly of Crankshaft Connecting Rod Combination
●Open the assembling screw, remove the right case and
the crankshaft and the other accessory parts on the case,
and remove the crankshaft connecting rod combination
[A] from the left crankcase [B].
Notes
Do not damage assembling surface. Do not knock
the crankshaft down with a slam, and please
slowly knock the crankshaft using the same force.
Assembly
● Install the crankshaft into the crankcase and install Crankshaft Right
the main and auxiliary shafts into the specified Left crankcase component crankcase
positions. Finally assemble the case.
Notes
Assemble the crankshaft in the reverse order of
disassembly.
Assembling bolt
Check
● Measure the side clearance of connecting rod:
★ Put the crankshaft together with the bearing on the Plug gauge
V-shaped iron, push the big end of connecting rod to
one side by hand, and measure the left and right
clearance of the big end of the connecting rod by using
the plug gauge.
222
●Measure the radial clearance of big end of connecting
rod:
★ Fix a dial indicator at the connecting rod and
measure the clearance of big end of connecting rod in
X-Y direction. In addition, an inner diameter dial gauge
is required to verify the inner diameter of small side of
connecting rod.
●Measure the run-out of crankshaft.

★ Fix the crankshaft together with the bearing on the Measuring point
V-shaped iron, and fix two dial gauges on the left and
right crankshaft journals so that the dial indicator is
perpendicular to the main journal. Then rotate the
crankshaft to read the maximum and minimum readings
of dial gauge. The difference between the two is used as
the runout value of crankshaft. If the value exceeds the
specified value, the crankshaft is bent and deformed,
the bending direction should be ascertained and
corrected.
●Check whether the crankshaft bearing rotates with

abnormal noise or whether it is loose. Check whether
the big end of connecting rod is stuck or not, it
becomes black or blue. Check the crankshaft journal for
serious wear and tear and the crankshaft bearing for
damage.
If there is abnormal noise or it is loose, replace the
crankshaft assembly.
Crankshaft
bearing
Balance shaft
Function of balancer shaft
The balancer shaft is used to balance the imbalance of
engine, improve the stability of engine and improve the
vibration comfort of engine.
Disassembly of balancer shaft
● Loosen the assembling screw, remove the right case
and take balancer shaft combination from the left
crankcase.
223
Assembly of balancer shaft
●Assemble the balancer shaft in the reverse order of
disassembly.
● Pay attention to the alignment of the gear marks
when assembling.
Align it with the

marked point
Inspection of balancer shaft

● Check the balancer shaft gear surface for wear and
pitting.
●Check whether the balancer shaft journal has become

black or yellow due to obvious wear and tear.
● Check the runout of end of balancer shaft, the method

of which is the same as that for detecting the
crankshaft.
224
Clutch
Exploded view of clutch
225
Num Torque
ber of N·m kgf·m
1 Clutch housing assembly 1 — —
2 Spline washer 1 — —
3 Clutch wheel hub 1 — —
4 Washer 2 — —
5 Belleville spring 1 — —
6 Friction pad I 1 — —
7 Clutch plate 5 — —
8 Friction pad II 2 — —
9 Friction pad 3 — —
10 Lock washer 1 — —
11 Nut 1 — —
12 Bearing block 1 — —
13 Rolling bearing 1 — —
14 Pressure plate 1 — —
15 Filter spring 5 — —
16 Assembling bolt 5 — —
17 Slotted head adjusting screw 1 — —
18 Hexagonal thin nut M6 1 10 1.0
19 Steel ball 1 — —
20 Pulling plate 1 — —
21 Operating lever component 1 — —
22 Bolt M6×12 1 10 1.0
23 Return spring 1 — —
24 Clutch return damper 1 — —
25 Push rod component 1 — —
R: Replace the part
226
Special tools
Clutch locking tool:
227
Disassembly of clutch
Remove the bolt [A] and open the clutch cover on the
right crankcase [B]
●Loosen the five bolts [A] of plate [B] in the way of

diagonal cross.
● Remove the plate, clutch spring and bearing block.
Remove the slotted head adjusting screw [A] and nut

[B].
●Lock the clutch and remove the locknut and washer

[B] using special tools [C].
228
●Remove the clutch pads and fiction pads.
●Remove the clutch wheel hub.

●Remove the spline washer.
Remove the fuel pump locking screw [A].
● Remove the oil pump sprocket, clutch housing

component and chain.
229
Disassembly of Clutch
Clutch housing component [A]

Slotted head adjusting screw [B]
Bolt [C]
Clutch spring [D]
Nut [E]
Plate [F]
Bearing block [G]
Lock nut [H]
Friction pad [I]
Clutch hub [J]
230
Installation of clutch
●Install the clutch in the reverse order of disassembly.
Inspection of clutch
●Check the housing groove of clutch for the trace of
any burr or damage. If any, polish it using a file, and
replace it when the polishing amount is too large.
Check the tooth shape of plate and clutch wheel hub for
damage, if any, it should be replaced.
●Measure the free length of pressure spring.
Allowable limit I: Replace it if its length is less than
41mm.
Free length
●Measure the thickness of friction plate with a vernier

calipers. Thickness
Allowable limit I: Replace it if its thickness is less
than 2.6mm.
Allowable limit II: Replace it if its length is less than
2.8mm.
231
Gearshift Mechanism
Exploded View of Gearshift Mechanism
232
Num Torque
ber of N·m kgf·m
1 Screw M4×16 2 — —
2 Gear indicator 1 — —
3 O-Ring 1 — —
4 Shifting prod 1 — —
5 Prod spring 1 — —
6 Shift drum 1 — —
8 Stopper lever component 1 — —
Arm shaft of gear shift positioning
9 1 — —
roller
10 Pin 4×9 1 — —
11 Star locking plate 1 — —
12 Separation block 2 — —
13 Separation block pin 2 — —
14 Pawl spring 2 — —
15 Separation seat 1 — —
16 Separation seat roller 1 — —
17 Star locking plate pin 1 — —
18 Star wheel plate 1 — —
19 Bolt M6×10 2 10 1.0
20 Pivot 1 — —
21 Shift rod assembly 1 — —
22 Shift rod welding assembly 1 — —
23 Collar 1 — —
25 Washer 12x18x1 1 — —
26 Five-position shift fork shaft 1 — —
Five-position shift fork of auxiliary
27 1 — —
shaft
28 Shift fork shaft of primary shaft 1 — —
29 Shift fork of primary shaft 1 — —
Six-position shift fork of auxiliary
30 1 — —
shaft
31 1 — —
shaft
31 1 — —
shaft
32 Nut M18×1 1 60 6.0
34 Output sprocket 1 — —
35 Output sprocket collar 1 — —
36 O-ring seal 19×1.8 1 — —
233
37 Auxiliary shaft assembly 1 — —
37 Auxiliary shaft assembly 1 — —
38 Auxiliary shaft 1 — —
39 Plug 1 — —
40 Two-position gear of auxiliary shaft 1 — —
41 Washer 1 — —
42 Retainer for shaft 1 — —
43 Six-position gear of auxiliary shaft 1 — —
43 Six-position gear of auxiliary shaft 1 — —
44 Four-position gear of auxiliary shaft 1 — —
45 Washer 1 — —
46 Three-position gear of auxiliary shaft 1 — —
48 Retainer for shaft 4 — —
49 Five-position gear of auxiliary shaft 1 — —
One-position gear component of
50 1 — —
auxiliary shaft
51 Two-position gear of primary shaft 1 — —
52 Washer 1 — —
53 Primary Shaft Assembly 1 — —
54 Primary shaft 1 — —
55 Five-position gear of primary shaft 1 — —
Three and four-position gear of
56 1 — —
primary shaft
57 Six-position gear of primary shaft 1 — —
58 Spline collar 1 — —
R: Replace the part
234
Disassembly of Gearshift Mechanism
Remove the shift shaft component [A] and return
spring.
●Remove the bolt and star wheel plate

●Remove the shift positioning roller arm shaft, the shift
positioning roller arm component and the return spring
●Remove the star positioning plate dowel pin,
separating seat and star positioning plate
● The removed parts are shown in the exploded view.
Shift rod component [A]

Return spring [B]
Star wheel plate [C]
Arm shaft of gear shift positioning roller [D]
235
Gear shift positioning roller arm component [E]
Return spring [F]
Star locking plate [G]
Separation seat [H]
Installation of Gearshift Mechanism

Inspection of Gearshift Mechanism

Before disassembly, the shift lever should be able to
return flexibly without clamping;
● Check the wear of the shift lever component. If the
wear is serious, replace the component.
Check the shift shaft for bending; in case of
overbending, replace it;
●Check whether the elasticity of return spring is

weaken, and replace it if necessary;
● Check the wear of start-type positioning plate. If the

wear is serious, replace it.
236
● Check the wear of separation seat. If the wear is
serious, replace the component.
237
Disassembly of primary / auxiliary shaft component
●Loosen the assembling bolt.
●Separate the crankcase.
Notes
Do not damage washer and assembling surface.
●Remove the left case.
Primary shaft component[A]

Shift fork of primary shaft [B]
Five-position shift fork of auxiliary shaft [C]
Shift drum [D].
Six-position shift fork of auxiliary shaft [E]
Auxiliary shaft component [A].
238
●Pull out the shift fork shaft
●Remove the shift fork
Pull out shift drum, primary shaft component, auxiliary shaft component
● The removed parts are shown in the exploded view.
Primary shaft component[A]

Auxiliary shaft component [B].
Shift fork shaft [C]
Shift drum [D].
Shift fork [E]
Output sprocket [F]
Disassembly of primary / auxiliary shaft component

239
Inspection of primary / auxiliary shaft component
●Use the micrometer [A] to measure the outer diameter
of shift fork shaft [B].
Allowable limit: 9.97 mm
●Use the tester [A] to measure the inner diameter of

shift fork [B] hole.
●Use the vernier calipers [A] to measure the thickness

of shift fork [B].
●Use the micrometer [A] to measure the diameter of

shift drum [B].
Allowable limit: 41.5mm Width of shift fork
groove
●Measure the width of shift fork groove with a

vernier calipers
240
Chapter VI Finished Motorcycle
Contents
Wheel/tire .....................................................................................................................................................246
Exploded view of front wheel/tire ....................................................................................................... 246
Exploded view of rear wheel/tire .........................................................................................................247
Special tool ...........................................................................................................................................250
Wheel (rim) .......................................................................................................................................... 251
Disassembly of front wheel ......................................................................................................... 251
Installation of front wheel ............................................................................................................252
Disassembly of rear wheel ...........................................................................................................253
Installation of rear wheel ............................................................................................................. 254
Inspection of wheel ......................................................................................................................255
Inspection of wheel axle .............................................................................................................. 256
Adjustment of static balance of rim .............................................................................................256
Adjustment / inspection of tire pressure ......................................................................................258
Inspection of tire .......................................................................................................................... 258
Disassembly of tire ...................................................................................................................... 258
Installation of tire .........................................................................................................................259
Hub bearing ..........................................................................................................................................262
Disassembly of hub bearing .........................................................................................................262
Installation of hub bearing ........................................................................................................... 262
Inspection of hub bearing ............................................................................................................ 263
Hub bearing lubrication ............................................................................................................... 263
Drive mechanism ......................................................................................................................................... 264
Exploded view of drive mechanism .................................................................................................... 264
Special tool ...........................................................................................................................................267
Drive chain ...........................................................................................................................................268
Inspection / adjustment of wheel alignment ................................................................................268
Insppection of wear of drive chain .............................................................................................. 268
Drive chain lubrication ................................................................................................................ 268
Disassembly of drive chain ..........................................................................................................268
Installation of drive chain ............................................................................................................ 269
Sprocket, collar, collar bearing ............................................................................................................ 271
Disassembly of rear sprocket .......................................................................................................271
Installation of rear sprocket ......................................................................................................... 271
Disassembly of collar bearing ..................................................................................................... 272
Installation of collar bearing ........................................................................................................272
Inspection of collar bearing ......................................................................................................... 272
241
Lubrication of collar bearing ....................................................................................................... 273
Inspection of damper of collar .....................................................................................................273
Inspection of wear of drive chain ................................................................................................ 273
Check the deformation of rear sprocket ...................................................................................... 274
Brake ............................................................................................................................................................ 275
Exploded View of brake .......................................................................................................................275
Special tool ...........................................................................................................................................278
Brake lever, brake pedal .......................................................................................................................279
Adjustment of position of brake lever ......................................................................................... 279
Disassembly of brake pedal ......................................................................................................... 280
Installation of brake pedal ........................................................................................................... 280
Caliper ..................................................................................................................................................282
Disassembly of rear caliper ......................................................................................................... 282
Installation of caliper ................................................................................................................... 282
Assembly of front caliper ............................................................................................................ 283
Diassembly of rear caliper ........................................................................................................... 283
Assembly of rear caliper .............................................................................................................. 283
Inspection of fluid sea of caliper for damage .............................................................................. 283
Inspection of dust seal of caliper for damage ..............................................................................283
Inspection of the caliper piston and brake cylinder for damage ................................................. 284
Brake pad ............................................................................................................................................. 284
Disassembly of front brake pad ................................................................................................... 284
Installation of front brake pad ......................................................................................................285
Disassembly of rear brake pad .....................................................................................................285
Installation of rear brake pad ....................................................................................................... 286
Inspection of wear of brake pad ...................................................................................................286
Master cylinder .................................................................................................................................... 286
Installation of rear master cylinder ..............................................................................................289
Assembly of master cylinder ....................................................................................................... 289
Check the master cylinder (visual inspection) .............................................................................289
Brake disc .............................................................................................................................................289
Disassembly of front brake disc .................................................................................................. 290
Disassembly of rear brake disc .................................................................................................... 290
Installation of brake disc ..............................................................................................................291
Inspection of wear of brake disc ..................................................................................................291
Inspection of deformation of brake disc ......................................................................................292
242
Brake fluid ............................................................................................................................................292
Inspection of level of brake fluid .................................................................................................292
Replacement of brake fluid ..........................................................................................................292
Exhaust the air inside the brake line ............................................................................................292
Brake hose ............................................................................................................................................293
Disassembly / installation of brake hose and brake line ............................................................. 293
Inspection of brake hoses and brake lines ................................................................................... 293
Anti-lock brake system (ABS) .............................................................................................................294
Part position ................................................................................................................................. 294
ABS system circuit diagram ........................................................................................................ 295
Pin name .......................................................................................................................................296
ABS overhaul ...............................................................................................................................297
ABS diagnostic flow chart ...........................................................................................................301
Questions need to be asked for the rider ..................................................................................... 302
ABS hydraulic mechanism .......................................................................................................... 310
Speed sensor .................................................................................................................................314
Suspension system ....................................................................................................................................... 318
Exploded view of front suspension system ......................................................................................... 318
Exploded view of rear suspension system ...........................................................................................320
Special tool ...........................................................................................................................................323
Front shock absorber ............................................................................................................................324
Installation of front shock absorber ............................................................................................. 324
Replacement of front shock absorber fluid ................................................................................. 325
Inspection of inner tube and outer tube ....................................................................................... 330
Inspection of dust seal ..................................................................................................................330
Inspection of spring tension .........................................................................................................331
Rear shock absorber .............................................................................................................................332
Adjustment of pretightening force of spring ............................................................................... 332
Disassembly of rear shock absorber ............................................................................................ 333
Assembly of rear shock absorber .................................................................................................334
Inspection of rear shock absorber ................................................................................................ 334
Rear swing arm .................................................................................................................................... 335
Disassembly of swing arm ...........................................................................................................335
Installation of swing arm ............................................................................................................. 336
Disassembly of swing arm bearing ..............................................................................................337
Installation of swing arm bearing ................................................................................................ 337
Inspection of swing arm bearing ................................................................................................. 337
Inspection of chain guide .............................................................................................................338
Control system ............................................................................................................................................. 339
Exploded view of control system ........................................................................................................ 339
Special tool ...........................................................................................................................................341
Control system ..................................................................................................................................... 342
Inspection of control system ........................................................................................................342
243
Adjustment of control system ......................................................................................................342
Handlebar ............................................................................................................................................. 343
Disassembly of handlebar ............................................................................................................343
Installation of handlebar .............................................................................................................. 344
Steering stem ........................................................................................................................................346
Disassembly of steering stem and steering stem bearing ............................................................ 346
Installation of steering stem and steering stem bearing .............................................................. 347
Lubrication of steering stem bearing ........................................................................................... 349
Inspection of deformation of steering stem ................................................................................. 349
Frame ............................................................................................................................................................350
Exploded view of frame .......................................................................................................................350
Exploded view of left footpeg ............................................................................................................. 352
Exploded view of right footpeg ........................................................................................................... 354
Exploded view of muffler .................................................................................................................... 356
Exploded view of rack and luggage carrier ......................................................................................... 358
Exploded view of fender ......................................................................................................................360
Exploded view of headlight cover ....................................................................................................... 362
Exploded view of cowling ................................................................................................................... 364
Exploded view of fuel tank cover ........................................................................................................366
Exploded view of seat cushions and covers ........................................................................................ 368
Exploded view of engine accessories .................................................................................................. 370
Seat cushion ......................................................................................................................................... 371
Disassembly of seat cushion ........................................................................................................371
Installation of seat cushion .......................................................................................................... 371
Cover .................................................................................................................................................... 372
Rear rack and side case bracket ........................................................................................................... 374
Disassembly of side case bracket ................................................................................................ 374
Installation of side case bracket ...................................................................................................374
Disassembly of rear rack ............................................................................................................. 375
Installation of rear rack ................................................................................................................ 376
Side cover .............................................................................................................................................377
Disassembly of side cover ........................................................................................................... 377
Installation of side cover ..............................................................................................................377
Rear fender ...........................................................................................................................................378
Disassembly of rear fender .......................................................................................................... 378
Installation of rear fender .............................................................................................................378
Front fender ..........................................................................................................................................379
Disassembly of front fender .........................................................................................................379
244
Installation of front fender ........................................................................................................... 379
Windshield and cowling .......................................................................................................................380
Disassembly of windshield .......................................................................................................... 380
Disassembly of cowling ...............................................................................................................381
Installation of windshield and cowling ........................................................................................381
Headlight cover and left and right front panel .....................................................................................382
Disassembly of headlight cover ...................................................................................................382
Installation of headlight cover and left and right panel ...............................................................385
Fuel tank cover.......................................................................................................................................386
Disassembly of fuel tank cover ....................................................................................................386
Installation of fuel tank cover ...................................................................................................... 386
Frame ....................................................................................................................................................387
Disassembly of frame .................................................................................................................. 387
Installation of frame .....................................................................................................................387
Inspection of frame ...................................................................................................................... 388
Sidestand .............................................................................................................................................. 389
Disassembly of sidestand .............................................................................................................389
Installation of sidestand ............................................................................................................... 389
Left front footpeg .................................................................................................................................390
Disassembly of left front footpeg.................................................................................................. 390
Installation of left front footpeg ...................................................................................................390
Left rear footpeg .................................................................................................................................. 392
Disassembly of left rear footpeg....................................................................................................392
Installation of left rear footpeg .................................................................................................... 392
Front right footpeg ............................................................................................................................... 393
Disassembly of front right footpeg ..............................................................................................393
Installation of front right footpeg ................................................................................................ 393
Rear right footpeg ................................................................................................................................ 394
Disassembly of rear right footpeg ............................................................................................... 394
Installation of rear right footpeg ..................................................................................................394
Muffler ................................................................................................................................................. 395
Disassembly of muffler ................................................................................................................395
Installation of muffler .................................................................................................................. 397
Disassembly/installation of engine ...................................................................................................... 398
Exploded view of disassembly/installation of engine ................................................................. 398
Disassembly of engine ................................................................................................................. 400
Installation of engine ................................................................................................................... 404
245
Wheel/tire
Exploded view of front wheel/tire
Num Torque
ber of N·m kgf·m
1 Front wheel left collar 1 — — Si
2 Bolt M10×1.25×20 9 22 #
2.2 L
3 Front wheel gear ring 1 — —
4 Front brake disc component 1 — —
5 Dust seal assembly 2 — — Si、R
6 Rolling bearing 6204-2RS 2 — — Si
7 Front wheel middle shaft sleeve 1 — —
8 Front rim 1 — —
9 Tubeless tire 110/70R17 1 — —
10 Air valve Z2-01-1/straight 1 — — R
11 Front rim cover 1 — —
12 Front wheel right collar 1 — — Si
13 Front wheel axle 1 107 10.7
R: Replace the part
Note: In the table #, the locking torque of the liquid brake disc side bolt is 22N·m, and there are no torque requirements for other
three bolts.
246
Exploded view of rear wheel/tire
247
Num Torque
ber of N·m kgf·m
1 Rear wheel axle 1 — — Si
2 Left collar of rear wheel 1 — — Si
5 Chain drive collar 1 — — Si
6 Self-locking nut M10×1.25 6 45 4.5
7 Washer 10 6 — —
8 Spring washer φ10 6 — —
9 Chain 520HO-1×108 1 — —
10 Sprocket / 43-gear 1 — —
11 Sprocket hub 1 — —
12 Sprocket mounting bolt 6 — —
13 Rear wheel damper 6 — —
15 Bearing collar 1 — —
17 Front wheel right seal assembly 1 — — Si、R
18 Air valve 1 — —
19 Rear wheel rim 1 — —
20 Tubeless tire 150/60R17 1 — —
21 Rear brake disc 1 — —
22 Brake disc mounting bolt M6×16 6 10 1.0 L
23 Collar II 1 — —
24 Rear brake bracket 1 — —
25 Speed sensor component 1 — —
26 Bolt M6×1×16 1 10 1.0
Rear small fender bracket welding
27 1 — —
component
28 Headlight bushing 3 — —
30 Rear small fender 1 — —
31 Bolt M6×20 3 10 1.0
R: Replace the part
248
Wheel (rim)
Oscillating quantity of rim:
Axial ≤TIR 0.5 mm TIR 1.0 mm
Radial ≤TIR 0.8 mm TIR 1.0 mm
Oscillating quantity of wheel axle: ≤TIR 0.03 mm TIR 0.2 mm
Wheel balancer ≤10 g –––
Balance weight 10 g、20 g、30 g –––
Rim size:
Front wheel 17×MT3.50 –––
Rear wheel 17×MT4.00 –––
Tire
Tire pressure (when cooling tire) :
Front wheel 220±10kPa –––
Rear wheel 250±10kPa –––
Tread depth:
Front wheel 3.8 mm 1.6 mm
Rear wheel 4.8 mm 2.0 mm
Standard tire: Manufacturer, model Specifications
CORDIAL/CY156A/CCC/E4
Front wheel 110/70-17
75R-0005102
CORDIAL/CY185A/CCC/E4
Rear wheel 140/60-17
75R-0006820
METZELER(elephant
Front wheel brand)/M/C/CCC/E3 110/70R17 54H/radial-ply Tire
75R-0056965/DOT
METZELER(elephant
Rear wheel brand)/M/C/CCC/E3 150/60R17 66H/radial-ply Tire
75R-0056678/DOT
WARNING
Front and rear tires must be made by the same
manufacturer!
249
Special tools
Bearing driver set: Bearing puller shaft:
Bearing puller head
250
Wheel (rim)
Disassemble front wheel
●Disassemble:
Front caliper mounting bolt [A]
Front caliper [B]
●Loosen:
Wheel axle mounting bolt [B](right)
Front wheel axle [A]
● Lift the front wheel from the ground with a jack.

Special tool—jack and its accessories:
●Remove the front axle, pull out the front axle to the
right, and separate the front wheel and front fork.
Notes
Do not place the motorcycle on the side, please
make the wheel press against the brake disc,
otherwise, the brake disc may be damaged or
deformed. Place a wood block under the wheel to
prevent the brake disc from touching the ground.
251
Install front wheel
Remarks
○ Direction of wheel rotation [A].
● Check the rotation of front wheel and install the front
wheel.
● Apply high-temperature grease to the edge of oil seal

[E].
● Put the left collar of front wheel [A] on the left side
of hub.
● Put the right collar of front wheel [B] on the right
side of hub.
●Remove the wheel axle [D] from the right side.
●Tighten the wheel axle [D]
Right wheel axle clamp screw [C]
Rear view from the front of motorcycle [F]
Locking torque of front wheel axle nut: 107 N·m
● Before tightening the wheel axle fastening screw at
the bottom of front fork on the right front side, shake
the front fork up and down for four or five times to
align the bottom of right front fork with front axle.
Remarks
○ Put a stopper in front of the front wheel to prevent
the motorcycle from shifting.
● First lock the wheel axle fastening screw at the
bottom of right front fork.
Locking torque of front wheel axle fastening screw: 8
N·m
Remarks
○ Alternatively tighten the two fastening screws
twice to ensure a uniform locking torque.
Check whether the front brake is normal (see “Periodic
Maintenance” – “Checking whether the brake is able to
work normally” for details)
WARNING
Grasp the brake lever until the brake pad is
against the brake disc, thus allowing the brake
lever to perform its normal function. Do not ride
a motorcycle before completing the above
operations! If the above operations are not
completed, the brake may not work properly
when used for the first time.
252
Disassemble rear wheel
● Lift the rear wheel from the ground with a bracket
[A].
●Disassemble:
Rear caliper mounting bolt [A],
rear caliper [B]
●Remove the rear wheel speed sensor from the caliper

bracket [A]
●Loosen:
Chain adjuster locknut [A]
Left chain adjuster [B]
253
●Loosen:
Chain adjuster locknut [A]
Right chain adjuster [B]
●Disassemble:
Rear wheel axle nut [A],
●Disassemble:
Rear wheel axle [A],
● Remove the drive chain of rear sprocket to the left
● Rotate the rear wheel backwards and remove it.
Notes
Do not place the wheel on the ground, please
make the brake disc downward, otherwise, the
brake disc may be damaged or deformed. Place a
wood block under the wheel to prevent the brake
disc from touching the ground.
Installation of rear wheel
● Apply high-temperature grease to the edge of oil seal.
●Put the collar on both sides of the hub.
Collar at right side [A]
Collar at left side [B]
254
● Mount the drive chain to the rear sprocket.
● Attach the caliper bracket [A] to the swing arm stop
block [B].
● Insert the rear axle from the left side of the wheel and
tighten the rear axle nut.
Locking torque of rear axle nut: 150 N•m
● Adjust the slackness of the drive chain after installing
the rear wheel (see “Periodic Maintenance” –
“Checking the slackness of the drive chain”).
● Install the rear caliper (see “Brake” – “Installing
Caliper”).
●Install rear wheel speed sensor.
Check whether the rear brake is normal (see “Periodic
Maintenance” – “Checking whether the brake is able to
work normally” for details)
WARNING
Stamp on the brake pedal until the brake pad is
pedal to perform its normal function. Do not ride
Check wheel
● Lift the front /rear wheel from the ground.
Special tool—jack and its accessories:
●Gently rotate the wheel to check whether the wheel
can run smoothly.
★ If the wheel does not rotate smoothly, replace the
hub bearing (see “Removing/Installing the Hub
Bearing” for details).
● Check for small cracks, dents, bends or deformations
on the wheels.
★ If the wheel is damaged, please replace it!
● Remove the wheel and support the wheel and tire
with the axle.
● Measure the axial oscillating quantity [A] and the
radial oscillating quantity [B] of the rim with a dial
gauge.
★ If the rim oscillating quantity is out of the operating
limit, check the hub bearing (see “Checking the Hub
Bearing” for details).
Rim oscillating quantity (in case of tire installed)
Standard:
Axial oscillating quantity ≤TIR 0.5 mm
Radial oscillating quantity ≤TIR 0.8 mm
Operating limit:
Axial oscillating quantity TIR 1.0 mm
Radial oscillating quantity TIR 1.0 mm
WARNING
Do not repair damaged wheels! If the wheel is
broken (except that the wheel bearing is broken), the
wheel must be replaced to ensure safe riding on the
motorcycle.
255
Check the axle
● Remove the front and rear wheel axles (see
“Removing the front/rear wheels” for details).
● Visually inspect the front and rear axles for damage.
★ If the axle is damaged or bent, please replace it!
● Place the axle on two V-shaped blocks with a spacing
of 100 mm [A] for the two V-shaped blocks. Place a
dial gauge [B] in the middle of the two V-shaped
blocks. Rotate the [C] axle to measure the oscillating
quantity. The difference between the maximum and
minimum readings of the dial gauge is the oscillating
quantity of axle.
★ If the wheel axle oscillating quantity is out of the
operating limit, please replace the axle!
Oscillating quantity of wheel axle/100 mm
Standard: ≤TIR 0.03 mm
Operating limit: TIR 0.2 mm
Adjustment of static balance of rim

Notes
After replacing the tire, rim or both, adjust the
static balance of rim.
When adjusting the rim static balance, the brake
disc should be installed in place.
● Remove the front and rear wheel (see “Removing the
front/rear wheels” for details).
●Remove the balance weight
● Looking for the gravity point of rim
Notes
Place the front wheel on the appropriate
balancing frame
a. Rotate the rim;
256
b. When the rim stops rotating, draw an “X1” mark at
the bottom of the front wheel;
c. Rotate the front wheel by 90° to make the “X1” mark

at the position as shown below;
d. Release the rim;
e. When the rim stops rotating, draw an “X2” mark at

the bottom of the front wheel;
f. Repeat steps [c] to [e] for several times, until all mars
fall at the same point;
g. The place where all the marks fall is the gravity point
"X" of this rim;
●Adjust static balance
a. Load the weight "1" to the lower side of the hard
point "X" on the rim.
Notes
Start with the lightest balance weight.
257
Remarks
○ Benelli dealers sell the balance weights of 5 and 10
grams respectively. An imbalance of less than 10
grams generally does not affect the driving stability
of the motorcycle.
○ Do not use more than 9 balance weights (including
4 balance weights with a total weight of over 90
grams). If you need more than 9 balance weights to
balance, please disassemble the wheel to find the
cause of problem.
b. Rotate the rim by 90° to make the gravity point at the
position as shown below.
c. If the gravity point does not stop at that position,

please load a heavy balance weight;
d. Repeat steps [b] and [c] until the rim is balanced.
●Check static balance
a. Rotate the rim to confirm that it will stop at each
position shown. As shown in the figure
b. If the front wheels do not remain stationary at each

position, rebalance it.
Adjustment / inspection of tire pressure
● See "Inspection of Tire Pressure" in chapter "Periodic
Maintenance" for details.
Check tire
● See "Inspection of Wheel / Tire for Damage" in
chapter "Periodic Maintenance" for details.
Disassemble tire
●Disassemble:
● Wheel (see “Removing the front/rear wheels” for
258
details).
Valve core (air bleeding)
• To maintain wheel balanced, use chalk to mark the
position of the valve stem on the tire so that the tire can
be installed in its original position later.
Pink or yellow mark [A],
Valve core [B],
aligner [C]
● Apply soapy liquid or rubber lubricant to the bead
and the rims on both sides to make it easier for the bead
to slip out of the rim.
Notes
Never use oil or gasoline distillate as a
lubricant because oil or gasoline distillate may
corrode the tire.
● Use a tire changer to remove the tire from the rim.
Remarks
○ Since the tire is tightly fitted to the rim, it cannot
be removed with a hand tool.
Mount tire
WARNING
Front and rear tires must be the products of
the same manufacturer.
● Check the rim and tires and replace if necessary.
● Clean the sealing surface of the rim and the tire. If
necessary, use a fine abrasive cloth to smooth the
sealing surface of the rim.
●Remove the valve core and throw it out.
Notes
The valve core must be replaced when
changing tires! Do not reuse the valve core!
● Install a new valve core on the rim.
○Remove the valve core cover, apply the seal of valve
core stem [A] with soap liquid or rubber lubricant, and
pull out the valve core stem from the inside of the rim
[B] to adjust the position of valve core stem.
Notes
Never use oil or gasoline distillate as a
lubricant for valve stem, because oil or gasoline
distillate may corrode the tire.
259
○ The structure of valve is as shown in the figure.
Valve core cover [A],
Valve core [B],
valve stem seal [C],
valve stem [D],
valve core seat [E],
Open the valve core [F]
● Check the tire rotation marks on the front and rear

tires and mount the tires on the corresponding rims.
Tire rotation mark [A]
Direction of rotation [B]
● Place the tire on the rim so that the valve core [A] is
aligned with the balance mark on the tire [B] (marks
made of chalk when removing the tire or yellow paint
marks on the new tire).
● Mount the bead to the edge of the rim with a tire
changer.
● Lubricate the bead and rim edge with soap or rubber
lubricant when inflating the tire to mount the bead to
the sealing surface of the rim.
• Align the bead with the rim and inject compressed air
into the tire until the bead engages the sealing surface
on the inside of the rim.
WARNING
Be sure to install the valve core when inflating
the tire, and the pressure inside the tire does not
exceed 400 kPa (4.0 kgf/cm2). Excessive inflation
may result in a puncture, thus causing casualties.
● Check that the rim line [A] on both sides of the tire
sidewall is parallel to the rim edge.
★ If the rim edge is not parallel to the rim line of the
tire sidewall, remove the valve core.
● Apply lubricant to the edges and beads of the rim.
● Install a valve core and re-inflate the tire.
● Check the tire for leaks after installing the bead
inside the rim.
○ The air inflated to the tire should be slightly higher
than the standard inflating volume.
○ Apply soap to the tires or soak the tires in the water.
If there are air bubbles, the tires are leaking.
● Adjust the tire pressure according to the specified
standard (for details, see “Periodic Inspection” –
“Checking the Tire Pressure”).
260
●Install valve core.
● Adjust the static balance of wheel (see "Adjustment
of static balance of rim" for details).
Repair tire
● Two methods are currently used to repair tubeless
tires. One of them is called “temporary (external)
maintenance”: the tire can be repaired without the need
to remove it from the rim; the other is called
“permanent (internal) maintenance”: the tire needs to
be removed before repair.
● It is generally believed that permanent (internal)
maintenance ensures that the tire is more durable and
stable than temporary (external) maintenance. In
addition, there is another advantage of permanent
(internal) repair: in the process of thorough inspection,
collateral damage that cannot be found by external
inspection can be identified.
● In view of this, Benelli does not recommend
temporary (external) repairs, only reasonable
permanent (internal) repairs are recommended.
●The repair methods recommended by each
manufacturer may be slightly different. To ensure safe
ride, perform repairs using repair tools and materials
recommended by the manufacturer.
261
Hub bearing
Disassemble hub bearing
● Remove the wheel (see “Removing the front/rear
wheel” for details) and take out the following parts:
Collar,
Bushing (taken from the rear hub),
Oil Seal
● Remove the hub bearing [A] with the bearing puller.
Notes
stopper under the wheel to prevent the brake disc
from touching the ground.
Special tools - bearing puller head φ25 × φ28
Bearing puller shaft φ13
Install hub bearing
●Before installing the hub bearing, use compressed air
to blow the dust or foreign matter away from the hub to
avoid contaminating the bearing.
● Replace the bearing with a new one.
● Install the bearing with a full set of tools for bearing
(do not touch the inner race of the bearing).
● Press the bearing [A] until it reaches the bottom.
Special tools- a full set of tools for bearing [B]
● Replace the oil seal with a new one.

● Press the oil seal [A] so that the oil seal surface is
flush with the end of the hole [B].
Special tools- a full set of tools for bearing [C]
262
Inspection of hub bearing
Since the error of hub bearing is extremely small, it is
generally impossible to measure the clearance.
Remarks
○ Do not remove any bearings for inspection, as they
must be replaced with new ones once removed.
● If you need to check whether there is an axial
clearance in the bearing, whether it will get stuck or
blocked when rotating, please rotate each bearing back
and forth [A] in the hub!
★ If the bearing does not rotate smoothly, please
replace it with a new one!
● Check whether the bearing seal [B] is damaged or
leaking.
★ If the bearing seal is damaged or leaking, please
Hub bearing lubrication
Remarks
○ Since there is lubricant in the hub bearing and it is
sealed, it is not necessary to lubricate the hub
bearing.
263
Transmission mechanism
Exploded view of drive mechanism
264
Num Torque
ber of N·m kgf·m
1 Rear wheel axle 1 150 15.0 Si
2 Gasket 16 2 — —
3 Left collar of rear wheel 1 — — Si
6 Chain drive collar 1 — — Si
8 Washer 10 6 — —
10 Sprocket / 43-gear 1 — —
11 Sprocket hub 1 — —
12 Sprocket mounting bolt 6 — —
13 Rear wheel damper 6 — —
14 Chain 520HO-1×108 1 — —
15 Chain adjuster assembly 2 — —
16 Chain adjuster retainer 2 — —
18 Drive chain cover 1 — —
19 Inner hexagon screw 3 — —
20 Rear lower fender 1 — —
21 Pedal rubber mounting bolt 1 — —
22 Upper stop block of chain 1 G
23 2 10 1.0
24 Chain protective block 1 — — G
25 Washer 5 1 — —
Cross recessed pan head screw
26 1 10 1.0
M5×16
G: Apply grease.
R: Replace the part
R: Replace the part
265
Item Normal Lower operating limit
Drive chain
Drive chain slackness 32 ∼ 38 mm –––
Drive chain wear (length of 20 317.5 ∼ 318.2 mm 323 mm
links)
Standard drive chain:
Manufacturer –––
Model 520HO –––
Number of links 108 –––
Sprocket
Rear sprocket deformation ≤TIR 0.4 mm TIR 0.5 mm
266
Special tools
Chain assembling and disassembling tool: Bearing driver set:
267
Drive chain
Check the slackness of drive chain
● See "Inspection of Slackness of Drive Chain" in
chapter "Periodic Maintenance" for details.
Inspection of slackness of drive chain
● See “Periodic Maintenance” – “Adjusting the
Slackness of Drive Chain” for details.
Inspection / adjustment of wheel alignment
● See “Periodic Maintenance” –"Inspection of Wheel
Alignment" for details.
Inspection of wear of drive chain
● See “Periodic Maintenance” – "Inspection of Wear of
Drive Chain" for details.
Drive chain lubrication
● See “Periodic Maintenance” –"Inspection of
Lubrication of Drive Chain" for details.
Disassembly of drive chain
● Remove the drive chain cover screw [A] and the
drive chain cover [B].
●Open the stop gasket [A] using slotted screwdriver
268
●Disassemble:
Drive sprocket lock bolt [A]
Drive sprocket of engine [B]
● Remove the drive chain [C]

● The drive chain used in this chain, the main link rod
equipped with safety side panel.
● Type used according to the specifications of chain
manufacturer and requirements.
● Use special tools. There are three tools for
disassembling the main chain plate [A], assembling
side plate [B] and fastening it to the pin on the side
plate [C]
●Drive chain:
Main chain plate [A],
rubber O-ring [B],
Side panel of main chain plate [C],
Remarks
○ Insert the main chain plate from the inside of the
drive chain, and then assemble the side plates with
the ID mark facing outward.
WARNING
Do not use old chains, main chain plates, side panel
of main chain plate or rubber O-rings.
Installation of drive chain
●Install:
Engine drive sprocket (see "Removing the Engine
Drive Sprocket" for details)
Rear wheel (see “Wheel/Tire” – “Removing the Rear
Wheel”)
●Installation of chain:
○ Press the side panel of main chain plate [B] against
the main chain plate using the special tools.
269
○ Use a special tool to firmly mount the pin in the main
chain plate [C],
Notes
The surface affected by the nailed main chain plate
must have no openings.
If there is an opening, replace the main chain plate,
seal ring and side panel.
Remarks
○ Do not use a drive chain with a clip main chain
plate.
●Install:
Drive chain cover
● Adjust the slackness of drive chain after installation
(see “Periodic Maintenance” – “Adjusting the slackness
of drive chain”).
270
Sprocket, collar, collar bearing
Disassembly of rear sprocket
● Remove the rear wheel (see “Wheel/Tire” –
“Removing the Rear Wheel”)
Notes
stopper under the wheel to prevent the brake disc
from touching the ground.
●Disassemble:
Rear sprocket nut [A],
Rear sprocket [B],
Note:
When disassembling the clamp nut of rear
sprocket, follow the instructions on the right
figure
Installation of rear sprocket

●When the sprocket is installed, the side with the tooth
number mark [A] faces outward.
271
●Lock rear sprocket nut.
Locking torque of rear sprocket nut: 45 N•m
Note:
When installing the clamp nut of rear sprocket,
follow the instructions on the right figure
● Install the rear wheel (see “Wheel/Tire” – “Installing
the Rear Wheel”)
Disassemble collar bearing

● Knock out the bearing [A] from the other side of the
wheel.
Special tools- a full set of tools for bearing:
Install collar bearing

● Replace the bearing with a new one.
● Press the bearing inward until it reaches the bottom.
Special tools- a full set of tools for bearing [B]:
● Apply high-temperature grease to bearing.
● Replace the oil seal with a new one.
● when pressing the new oil seal, align the sealing
surface with the end of hole.
Check collar bearing

●Since the error of collar bearing is extremely small, it
is generally impossible to measure the clearance.
Remarks
○ It is not required to remove any bearings for
inspection, as they must be replaced with new ones
once removed.
272
● If you need to check whether the bearing is able to
rotate, whether it will get stuck when rotating, please
rotate the bearing back and forth [A] in the collar!
★ If the bearing does not rotate smoothly, please
Lubricate collar bearing

● Apply high-quality bearing grease to the bearing.
Rotate the bearing for several times by hands to ensure
a uniform distribution of grease in the bearing.
Check the damper of collar
● Remove the collar of rear wheel and check the rubber
damper [A].
● If the damper is damaged or corroded, please replace
it!
Check the wear of sprocket

●Visually inspect the wear of the engine and rear
sprocket teeth.
★ If the sprocket teeth wear is shown in the figure,
please replace the sprocket and check the wear of the
drive chain (see “Periodic Maintenance” – “Inspection
of Wear of Drive Chain”).
Worn sprocket (engine drive sprocket) [A],
Worn sprocket (rear sprocket) [B],
Direction of rotation [C]
Remarks
○ If the sprocket needs to be replaced, the drive chain
may also need to be replaced. Therefore, check the
drive chain when replacing the sprocket.
273
Check the deformation of rear sprocket
● Use the bracket to lift the rear wheel from the ground
so that it can rotate smoothly.
● As shown in the figure, place a dial gauge [A] near
the teeth [B] of rear sprocket. Rotate the rear wheel [C]
to measure the oscillating quantity (deformation) of
sprocket. The difference between the maximum and
minimum readings of the dial gauge is the oscillating
quantity (deformation) of sprocket.
★ If the oscillating quantity is out of the lower
operating limit, please replace the rear sprocket!
Rear sprocket deformation
Upper operating limit: ≤TIR 0.4 mm
274
Brake
Exploded View of Brake
275
Num Torque
ber of N·m kgf·m
1 Front fuel pump assembly 1 — —
2 Washer 8 — — R
3 Fuel hose mounting bolt 8 30 3.0 B
4 Front fluid brake fuel hose assembly I 1 — —
5 Front fluid brake fuel hose assembly II 1 — —
6 Front left brake cylinder assembly 1 — —
7 Brake pad assembly 1set — — R
8 Inner hexagon screw M10×1.25×40 2 45 4.5
9 Double channel ABS assembly 1 — —
10 Bolt M6×14 1 10 1.0
11 Oil cup assembly 1 — —
12 Rear fuel pump assembly 1 — —
13 Rear brake cylinder assembly 1 — —
14 Component of rear friction pad 1set — — R
15 Rear fluid brake fuel hose assembly I 1 — —
16 Rear fluid brake fuel hose assembly II 1 — —
17 Bolt M10×1.25×20 2 22 2.2
18 Spring washer 8 2 — —
B. Apply brake fluid.
G: Apply grease.
R: Replace the part
276
Item Normal Lower operating limit
Brake lever, brake pedal
Brake lever position 4-way adjustable (for riders to choose) –––
Free clearance of brake lever Nonadjustable –––
Free clearance of pedal Adjustable –––
Pedal position Approximately 45 mm below the top of –––
footpeg
Brake pad
Thickness of friction pad:
Front brake pad 5.0 mm 1 mm
Rear brake pad 5.0 mm 1 mm
Brake disc
Thickness:
Front brake disc: 4.8 ∼ 5.0mm 4.5 mm
Rear brake disc: 4.8 ∼ 5.0 mm 4.5 mm
Oscillation ≤TIR 0.15 mm TIR 0.3 mm
Brake fluid
Class DOT4 –––
277
Special tools
Inner circlip pliers: Multimeter:
278
Brake lever, brake pedal
Adjustment of position of brake lever
●The brake lever adjuster has 4 positions so that the
rider can adjust the position of the brake lever
according to the size of his hand. Front
● Push the brake lever forward and rotate the adjuster
[A] so that the number is aligned with the arrow mark
[B] on the brake lever.
○ When the arrow mark is aligned with the number 4,
the distance between the brake grip and the brake lever
is the smallest; when the arrow mark is aligned with the
number 1, the distance between the brake grip and the
brake lever is the largest.
Inspection of position of brake pedal
● Check whether the brake pedal [A] is in the correct
position.
Footpeg [B]
Pedal position [C]

Standard: approximately 15 mm above the top of
the footpeg
★ If the position of pedal is not correct, adjust the

position of brake pedal.
Adjustment of position of brake pedal
Remarks
○ Generally, it is not necessary to adjust the position
of the pedal, but if the push rod lock nut is removed,
the position of the pedal must be adjusted.
● Loosen the lock nut [A] and rotate the push rod [B] to
make the pedal n the correct position.
● Locking torque
Locking torque of push rod locknut of rear master
cylinder: 10 N·m
Check whether the brake light switch is normal (see
“Periodic Maintenance” – “Checking whether the brake
light switch is able to work normally” for details)
279
Disassembly of brake pedal
●Disassemble:
Brake pedal return spring [A],
Rear brake pedal mounting screw [B]
Brake pedal component [C]
●Disassemble:
1 Bolt M6×25
2 Brake pedal mounting seat
3 Self-locking nut M6
4 Bolt M6×35
5 Joint M6
6 Nut M6
7 Foot pump piston screw
8 Upper spring pin
9 Nut M6
10 Brake pedal
11 Bolt M6×25
12 Self-lubricating collar
Installation of brake pedal
●Assembly of brake pedal component:
1 Bolt M6×25
2 Brake pedal mounting seat
3 Self-locking nut M6
4 Bolt M6×35
5 Joint M6
6 Nut M6
7 Foot pump piston screw
8 Upper spring pin
9 Nut M6
10 Brake pedal
11 Bolt M6×25
12 Self-lubricating collar
Locking torque of fastening bolt at brake pedal
mounting base: 10 N·m
Locking torque of bolt on fastening joint M6: 10
N·m
Locking torque of nut on fastening limit bolt
M6×35: 10 N·m
280
● Apply grease to the rear brake pedal mounting screw
[A]
●Install:
Rear brake pedal mounting screw [A]
Washer [B]
Locking torque of brake pedal bolt: 22 N•m
● Hang the lower end of the brake pedal return spring

[A] on the lower spring pin [B] of pedal.
●Hang the upper end of the brake pedal return spring
[A] on the mounting bolt [B] of rear brake cylinder.
● Apply grease to the rear brake pedal mounting screw

[A]
●Install:
Rear brake pedal mounting screw [A]
Washer [B]
○Press the brake pedal [C], align the joint hole of

master cylinder [B], and install and fix the mounting
screw [A] of rear brake pedal.
Locking torque of rear brake pedal mounting screw:
22 N·m
● Check the position of brake pedal (see "Checking the
Position of Brake Pedal" for details).
281
Caliper
● Loosen the hollow bolt [C] at the lower end of the
brake hose and tighten it slightly.
● Unscrew the caliper mounting bolt [B], separate the
caliper [A] and the brake disc.
Notes
Do not remove the caliper mounting bolts. To
remove the caliper, simply remove the caliper
mounting bolts, as brake fluid may leak after
removing the caliper mounting bolts.
● Remove the hollow bolt and the brake hose on the
caliper [D]
Notes
If brake fluid spills out, rinse it immediately!
Remarks
○If you need to disassemble after removing the
caliper and there is no compressed air available,
please disassemble the caliper before removing the
brake hose (see “Removing the Front Caliper” for
details).
Disassembly of rear caliper
● Loosen the hollow bolt [C] at the lower end of the
● Unscrew the caliper mounting bolt [B], separate the
caliper [A] and the brake disc.
Notes
● Remove the hollow bolt and the brake hose on the
caliper [D]
Notes
Remarks
○If you need to disassemble after removing the
caliper and there is no compressed air available,
please disassemble the caliper before removing the
brake hose (see “Removing the Rear Caliper” for
details).
Installation of caliper
● Install the caliper and the lower end of the brake
hose.
○ Replace the gaskets on both sides of the hose joint
with new ones.
● Locking torque
Locking torque of caliper mounting bolt:
Front caliper: 34 N·m
Rear caliper: 25 N·m
Hollow bolt of brake hose: 25 N•m
● Check the level in the brake fluid reservoir.
● Discharge the air inside the brake line (see
“Exhausting the Air inside the Brake Line” for details).
● Check whether the performance of brake is normal
and the brake fluid leaks.
282
WARNING
Clench the brake lever or step on the brake pedal
until the brake pad is against the brake disc, thus
allowing the brake pedal or brake pedal to
perform its normal function. Do not ride a
motorcycle before completing the above
completed, the brake lever or pedal may not work
properly when used for the first time.
● See "Periodic Maintenance" - "Replacing Rubber
Parts of Caliper" for details).
Assembly of front caliper
Diassembly of rear caliper
Assembly of rear caliper
Inspection of fluid sea of caliper for leakage
●In order to maintain a gap between the brake pad and
the brake disc, an oil seal (piston seal) [A] is placed
around the piston. If the oil seal is damaged, the brake
pads may be excessively worn and the brakes may fail,
thus causing the temperature of the brake pad or brake
fluid to rise.
● If any of the following conditions occur in the fluid
seal, please replace it!
○ The brake fluid leaks around the brake pads.
○The brake temperature is too high.
○ The wears of the inner and outer surfaces of brake
pad vary greatly.
○ The oil seal and the piston are stuck together.
★ If you replace the oil seal, please replace the dust
seal [B]. In addition, all oil seals must be replaced each
time when the brake pads are replaced.
Inspection of dust seal of caliper for damage

● Check the dust seal [B] for cracks, wear, expansion
or other damage.
★ If any dust seal is damaged, please replace it with a
new one!
Piston [C],
Oil seal [A]
283
Inspection of the caliper piston and brake cylinder for damage
• Visually inspect the piston [A] and the brake cylinder
surface [B].
★ If the brake cylinder and piston are severely worn
or rusted, please replace the caliper!
Brake pad
Remove the front brake pad
●Disassemble front caliper
● Remove the mounting pin [A] of brake pad.
●Disassemble:
Mounting pin of brake pad [A],
Brake pad spring [B],
Mounting pin of brake pad [C],
Notes
When the pin A is pulled out, the safety spring B
should be pressed
284
●Disassemble:
Front brake pad
Installation of front brake pad

● Push the caliper piston by hand as far as possible.
●Install:
Check: brake fluid level [B]; if it is below the minimum
score, add the recommended brake fluid to the correct
level.
● Check: Brake lever operation; if the brake lever is
soft or slight, exhaust the air in the brake circuit.
Warning
Disassembly of Rear Brake Pad
● Screw out the caliper mounting bolt [A]
● Remove the bolt [B] from the brake caliper and rotate
the rear caliper [E] in the C direction.
●Disassemble:
Brake pad [D]
285
Installation of Rear Brake Pad
● Push the caliper piston by hand as far as possible.
●Install:
● Install the caliper (see “Installing Caliper” for
details).
●Check brake fluid level [A]; if it is below the
minimum score, add the recommended brake fluid to
the correct level.
● Check: Brake pedal operation; if the brake pedal is
soft or slight, exhaust the air in the brake circuit.
WARNING
Inspection of wear of brake pad
Brake Pad" for details.
Master cylinder
Disassemble front master cylinder
● Loosen the hollow bolt [A] at the lower end of the
Notes
●Disconnect the front brake light switch connector [A].
286
●Disconnect the front master cylinder mounting bolt
[A].
● Remove the hollow bolt [A] and the brake hose on

the caliper [B]
Notes
● Remove the front master cylinder component.
●Disassemble:
Brake handle pivot shaft bolt [B] and lock nut [C]
Brake lever [A],
Front brake light switch mounting screw [B], flat
washer [F] and spring washer [G]
Front brake light switch [D]
Front master cylinder [H]
Installation of front master cylinder

●Install:
●Lock the upper clamp bolt [A] first, and then tighten
the lower clamp bolt [B].
Locking torque of front master cylinder fastening bolt:
10 N·m
with new ones.
● Locking torque
287
●Remove brake pedal return spring [A]
●Remove the two screws for installing the right cover
[B], and remove the right cover [C].
●Install the two removed screws [A].
●Remove the reservoir [A]

● Discharge the brake fluid into a container.
Notes
288
●Disassemble:
Rear brake light switch sensor [A]
Brake hose [B],
Fuel pump mounting screw [C]
Rear master cylinder [D]
Notes
Installation of rear master cylinder

with new ones.
●Install:
● Locking torque
Locking torque of rear master cylinder mounting screw:
10 N·m
Locking torque of rear brake light switch sensor: 10
N•m
Disassembly of front master cylinder
Parts of Master Cylinder" for details).
Assembly of master cylinder
Check the master cylinder (visual inspection)
● Remove the master cylinder (see “Disassembly of
Front / Rear Master Cylinder” for details).
● Remove the front and rear master cylinders (see
"Periodic Maintenance" - "Replacing Rubber Parts of
Master Cylinder" for details).
●Inspect the inner wall of each master cylinder and the
outer surface of each piston for scratches, rust or dents.
★ If any master cylinder or piston is damaged, please
replace them!
● Check the primary cup and secondary cup.
★ If the cup is worn, damaged, softened (corroded) or
swelled, the entire piston (including cup) should be
replaced.
289
★ If you find that brake fluid is leaking from the brake
lever, replace the the entire piston (including cup)!
●Check the dust cover for damage.
★ If the dust cover is damaged, please replace it!
● Check whether the piston return spring is damaged.
★ If the piston return spring is damaged, please
replace it!
● Check whether the relief port and supply port are
blocked.
★If the relief port is blocked, the brake pad may
produce resistance to the brake disc. Clean all oil holes
using the compressed air
Brake disc
Disassembly of front brake disc
●Remove front wheel (see “Wheel/Tire” – “Removing
Front / Rear Wheel”).
●Remove the mounting bolt [A] and remove the brake
disc [B].
○Remove the sensor rotor.
Disassembly of rear brake disc

●Remove rear wheel (see “Wheel/Tire” – “Removing
Front / Rear Wheel”).
●Remove the mounting bolt [A] and remove the brake
disc [B].
290
Installation of brake disc
● Mount the brake disc on the wheel with the marked
side facing outward.
○ Mount the sensor rotor on the brake disc with the
marked side [A] facing outward
● Apply locking agent to the threads of mounting bolts
of front and rear brake discs.
●Tighten the bolt to the brake disc in the form of a

cross
● Locking torque
Locking torque of brake disc mounting bolt: 22 N·m
Inspection of wear of brake disc

● Measure the thickness of brake disc at the place
where the brake disc is most severely worn.
★ If the wear of brake disc is out of the lower
operating limit, please replace it!
Thickness of brake disc
Standard:
Front brake disc: 4.8 - 5.0 mm
Rear brake disc: 3.8 - 4.0 mm
Lower operating limit:
Front brake disc: 4.5 mm
Rear brake disc: 3.5 mm
291
Inspection of deformation of brake disc
● Lift the front /rear wheel from the ground.
○ In order to facilitate the inspection of front brake
disc, the handlebars can be completely rotated to one
side.
● Rotate the [B] wheel by hand and place the dial
gauge on the brake disc [A] (as shown in the figure) to
measure the oscillating quantity of brake disc.
★ If the oscillating quantity of brake disc is out of the
upper operating limit, please replace it!
Oscillating quantity of brake disc
Upper operating limit: TIR 0.3 mm
Brake fluid
Inspection of level of brake fluid
● See Periodic Maintenance" - "Inspection of Level of
Brake Fluid".
Replacement of brake fluid
● See "Periodic Maintenance" - "Replacing Brake
Fluid" for details.
Exhaust the air inside the brake line
The brake fluid has a very small compression
factor, so almost all operations of brake lever or brake
pedal are transmitted directly to the caliper, thus
producing a braking effect. But the air is easy to
compress. If air enters the brake line, part of the
operations of brake lever or brake pedal will be used to
compress the air, thus causing the brake lever or brake
pedal to become soft and reducing braking
performance.
WARNING
If the brake lever or brake pedal is soft after
replacing the brake fluid or loosening the brake line
joint, the air inside the brake line must be exhausted.
Remarks
○ The steps for exhausting the air from the rear brake
line are as follows. The steps of for exhausting the
air from the front brake line are the same.
Order of releasing the air

1. Remove the brake fluid cylinder head.
2. Remove the brake fluid cylinder diaphragm.
3. Install the pipe on the front end of oil drain screw
and prepare the oil pan at the front end of hose.
4. After braking for a few times, grasp the brake
lever and loosen the oil drain screw by about 1/2
turn, and then tighten it again.
5. Repeat the above operations until all bubbles are
removed from the oil drain screw.
6. Install the brake fluid cylinder diaphragm
7. Install the brake fluid cylinder head
Remarks
○ The level of brake fluid must be checked
frequently in the process of exhausting the air, and
replenish the fluid as needed. If the brake fluid in the
reservoir is completely exhausted in the process of
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exhausting air, the exhaust operation must be
repeated because the air may have entered the brake
line.
○ To exhaust the air more thoroughly, tap the brake
hose between the caliper and reservoir.
WARNING
The precautions for handling disc brakes are as
follows:
1. It is forbidden to reuse brake fluid!
2. If the container containing the brake fluid is not
sealed or has been opened for a long time, the brake
fluid inside the container must not be used!
3. Do not mix brake fluids of different types or
brands. This will reduce the boiling point of the
brake fluid, resulting in brake failure or corrosion of
rubber brake parts.
4. Do not open the reservoir cap for a long time to
prevent the brake fluid from getting wet.
5. Do not replace brake fluid in rain or strong winds!
6. In addition to brake pads and brake discs, only
disc brake fluid, isopropyl alcohol or alcohol can be
used to clean the brake parts. Do not clean the above
parts with any other liquid! Gasoline, oil or other
gasoline distillates may corrode rubber parts.
Gasoline, oil or other gasoline distillates may
corrode rubber parts. If oil is splashed on any part, it
will be difficult to completely clean and eventually
corrode the rubber parts inside the disc brake.
7. When handling brake pads or brake discs, prevent
any brake fluid or other oil from splashing on them.
If you accidentally spill any brake fluid or other oil
on the brake pads or discs, clean them using solvent
with a high flash point! Do not use any solvents that
may leave oily residues! If the brake fluid or oil
cannot be completely removed from the brake pad,
8. The brake fluid may quickly corrode the surface of
painted part, so if any brake fluid spills, it must be
wiped!
9. The air in the brake line must be drained whenever
the brake line connector or exhaust valve is opened!
Brake hose
Disassembly / installation of brake hose and brake line
● See "Periodic Maintenance" - "Replacement of Brake Hose and Brake Line" for details.
Inspection of Brake Hoses and Brake Lines
● See Periodic Maintenance" - "Inspection of Damage
and Installation of Brake Hoses and Brake Lines".
293
Anti-lock brake system (ABS)
Part position
1. Front wheel speed sensor

2. Gear ring of front wheel speed sensor
3. Rear wheel speed sensor
4. Gear ring of rear wheel speed sensor
5. Check the ABS indicator (LED)
6. ABS hydraulic mechanism
7.ABS Qianjiang self-diagnosis system connector
8.ABS fuse box
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ABS system circuit diagram
1. ABS Switch
2. Ignition Switch
3. Installation of Ground Wire
5. Ignition Fuse
6.ABS Fuse (40A)
7. Meter panel
8.ABS Diagnostic System Connector
9. Front Wheel Speed Sensor
10. Rear Wheel Speed Sensor
295
Pin name
296
ABS overhaul
Precautions for ABS overhaul
process of overhauling the ABS system.
○The power supply of this ABS system must be
supplied by a 12V sealed battery. Do not use any other
power source!
○Do not connect the battery cable reversely. Otherwise,
the ABS hydraulic mechanism will be damaged.
○ To avoid damage to ABS parts, do not disconnect the
battery cable or any other electrical connectors while
the ignition switch is in the “ON” position or while the
engine is running.
○Be careful not to short-circuit the wire that directly
connect the positive (+) electrode of the battery and the
ground wire of the chassis.
○If any ABS electrical connector is disconnected, do
not turn the ignition switch to “ON”! The ABS
hydraulic mechanism will remember the fault code.
○Do not spray water on electrical parts, ABS parts,
joints, wires and electric wires!
○If the motorcycle is equipped with a transceiver,
ensure that the operation of the ABS system is not
affected by the radio waves emitted by the antenna. The
antenna shall be as far away as possible from the ABS
hydraulic mechanism.
○Turn the ignition switch to “OFF” before the ABS
electrical connector is disconnected.
○Do not hit the ABS parts with a hammer or drop the
ABS parts on a hard surface. Otherwise, the ABS parts
will be damaged.
It is not allowed to disassemble the ABS parts! Even if
it is found that the ABS parts are faulty, do not
disassemble the ABS parts for repair. Please replace
them directly!
ABS has many brake tubes and wires. And ABS can not
detect the faults of traditional brake systems (wear of
brake disc, uneven wear of brake pad and other
mechanical faults). In order to prevent faults, please
check whether the brake tube is properly connected,
whether the electric wires are arranged correctly, and
whether the brake performance is normal. Remember to
check the brake fluid for leakage and completely
discharge the air from the brake tube!
WARNING
If any brake tube connectors are loosened, including
the coupling nut or bleeder screw of the ABS
hydraulic mechanism, the air in the brake tube must
be discharged.
Notes
If there is air in the brake tube, do not ride the
motorcycle, otherwise the ABS will fail.
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○If the tire pressure is incorrect and the other tires or
wheels installed instead of those recommended by the
manufacturer are deformed, the ABS indicator (LED)
[A] will be on. If the indicator is on, please remove the
faults and delete the fault code!
WARNING
If the other tires are used instead of those
recommended by the manufacturer, the ABS will fail
and the braking distance will increase, resulting in a
traffic accident for the rider. Therefore, this
motorcycle must use the standard tires
recommended by the manufacturer. If the other
tires are used instead of those recommended by
the manufacturer, the ABS will fail and the
braking distance will increase, resulting in a
traffic accident for the rider. Therefore, this
motorcycle must use the standard tires
recommended by the manufacturer.
○If the engine is started when the motorcycle is
supported by the bracket and it is not in the neutral
position, the ABS indicator (LED) will be on. If the
indicator is on, turn the ignition switch to “OFF” and
clear the fault code (front wheel speed sensor failure).
○ ABS will make noise when it is running, and the rider
will feel the reaction force of the brake rod and brake
pedal. This situation is normal and is intended to alert
the rider that ABS is running normally. ○ ABS will
make noise when it is running, and the rider will feel
the reaction force of the brake rod and brake pedal.
This situation is normal and is intended to alert the
rider that ABS is running normally.
○ Once the ABS hydraulic mechanism detects a fault
code, it will remember the fault code. Therefore, after
the overhaul is completed, remember to delete the fault
code! However, do not delete the fault code during
troubleshooting. Please delete the fault code until all
inspections and repairs have been completed to avoid
the repeated entry of the previous fault code and
unnecessary overhaul work.
○ All the fault codes stored in the ABS hydraulic
mechanism must be deleted before the motorcycle is
delivered to the customer. Ensure that the ABS
indicator (LED) will be on by using the diagnosis
features. In order to make the diagnosis accurate, make
sure that the battery is fully charged. Try riding the
motorcycle (driving speed: above 20km/h (12mph))
and observe whether the ABS indicator (LED) will be
on. Finally, try riding the motorcycle (driving speed:
above 30km/h (20mph)), slam the brake and observe
whether the motorcycle can stop smoothly, and whether
the ABS works normally (you can feel the reaction
force of the brake pad and brake pedal). So far, the
inspection process is finished.
298
Overview of ABS fault removal
If an error occurs to ABS, the ABS indicator (LED) will
be on to alert the rider. In addition, the fault
information will be stored in the memory of the ABS
hydraulic mechanism. Therefore, after faults are
removed, you must delete the fault code and start the
diagnostic program to confirm that the signal output is
normal. If the ABS fault indicator (LED) is constantly
on, first thoroughly find out the background of the fault
and then start the repair work. For example, ask the
rider about the current situation [B] when the fault
occurs and try to determine the cause of the fault [C].
Do not completely rely on the ABS self-diagnosis
function, and combine common sense to remove faults.
For example: Check whether the brake performance is
normal, whether the brake fluid level is correct and
whether the brake fluid leaks.
Under the following circumstances, the ABS

indicator (LED) will be on even if ABS is running
normally. At that time, please turn the ignition switch to
“OFF” to turn off the indicator. If you ride the
motorcycle again without deleting the fault code, the
indicator will become on again.
○ The rider rides the motorcycle on the undulating road
all the time.
○ When the motorcycle is supported by the bracket, the
engine is started and is not in the neutral position, and
the rear wheel is rotated.
○ The front wheel leaves the ground due to sudden
acceleration.
○ ABS is suffered from severe electrical interference.
○ The tire pressure is abnormal. Please adjust the tire
pressure!
○ The tires with different specifications from those of
standard tires are used. Please replace them with
standard tires!
○ The wheels are deformed. Please replace the wheels!
Most ABS fault removal work involves verifying

whether the circuit is normal. The ABS parts have been
assembled and adjusted by the manufacturer, so there is
no need to disassemble or repair the ABS parts.
However, the ABS hydraulic mechanism can be
replaced if necessary.
The basic fault removal steps are shown below:
● Carry out the pre-diagnosis inspection (preliminary
inspection).
● Determine the fault by using the self-diagnostic
function.
● Check the joints of the ABS hydraulic mechanism
and the circuits and connectors between the suspected
faulty ABS parts with a multimeter.
Special tool: Multimeter:
299
● Visually check whether the electric wires are burnt or
worn.
★ If any electric wires are damaged, please replace
them!
● Disassemble each connector [A] and check whether
the inside is corroded, dirty or damaged.
★ If any connector is corroded or contaminated,
carefully clean it! If the connector is damaged, replace
it!
● Check whether the circuit is normal.
○ Find both ends of the wire that may fail by using the
circuit diagram.
○ Connect the multimeter with both ends of the wire.
Special tool—multimeter:
○ Set the range of the multimeter to ×1Ω, and then read
the reading of the multimeter.
★ If the reading of the multimeter is not 0Ω, it
indicates that the wire is damaged. Replace the main
cable [B] if necessary.
● Repeat the conduction detection of the circuit to

reduce the number of the parts that may fail and then
detect the ABS parts.
★ If the circuit and the connectors are normal, the
next suspect object is the ABS parts, and they shall be
detected one by one.
★ If it is found that any ABS part is abnormal, please
replace it!
300
ABS diagnostic flow chart
A fault occurs
Identify the fault
Collect information from the rider
Carry out the pre-diagnosis

inspection (Phase 1 and Phase 2).
Make diagnosis
Check by other means than diagnosis Check by diagnosis
If there is a problem with the cable or connector If there is a problem with the ABS part
Repair or replacement Check ABS parts
With Replacement
NG
Final inspection
OK
End
301
Questions need to be asked for the rider
○ Each rider reacts differently to the fault, so it is necessary to confirm which problem the rider is experiencing.
○ By asking the rider, find out what went wrong and under what circumstances. Only by knowing clearly about
the faults can you help yourself to reproduce the problem in the workshop.
○ Diagnostic tables can help you avoid ignoring any key points, so you must use a diagnostic table.
Sample of diagnostic table
Name of rider: Registration number (license plate number):
First registration year: Model:
Engine number: Frame number
Date of fault: -Frequency:
Weather Mileage:
□The brake
□The brake □The indicator
lever
lever vibrates or light is
□Brake moves □ABS can
makes noise flashing □ ABS runs
Pheno distance abnormally □ABS run, but the
too
menon is too □ The failure indicator
□The brake □The indicator frequently
long brake pedal light is out
pedal vibrates or light is always
is moving
makes noise on
abnormally
□ At startup
The state of engine in the
□ After startup
event of a fault
□Speed: ≥5000r/min
□The road surface is very slippery (□ snow road, gravel road, □ other)
Road conditions □The road is undulating
□Other
□Turn a corner at high speed
□ Driving speed ≥10km/h (6mph)
Driving conditions □ Driving speed ≥10km/h(6mph)
□ Parking
□Turn a corner
□ Gentle braking
Brake
□ Sudden braking
□The brake lever stroke is large
Other conditions
□ The pedal stroke is large
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Carry out the pre-diagnosis inspection (Phase 1)
● Level in the brake fluid reservoir. NG Replenish brake fluid.

OK
Check the brake fluid for leakage. NG Repair the brake line.
OK
Check the function of the brake lever and brake pedal. NG Repair or replace the master cylinder.
OK
Check the brake pads and brake discs. NG Replace the defective parts.
OK
The front and rear wheels should be able to rotate NG Repair or replace the caliper.
smoothly without any braking resistance.
OK
The free clearance of the wheel bearing should not be too NG Replace the wheel bearing or rear axle.
large.
The bending amount of rear axle or the runout of brake
disc should not be too large.
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Carry out the pre-diagnosis inspection (Phase 2)
Check the ABS indicator (LED). No Check power cables and meter panels
○ Is the indicator light on after the ignition (not be on)
switch is turned "on"?
Yes No
Check whether the light is flashing after (not flash) Check the cable line, check whether the
pressing and holding the ABS switch for connector is plugged in properly, and check
3-5 seconds. whether the front and rear wheel speed
Yes sensors are damaged.
○ Is the indicator light on after the No
ignition switch is turned "off" and then (not be on) Check power cables and meter panels
"on"?
Yes (on)
Drive for more than 1 minute (including 1
minute) at ≥6km/h (3.7mph)
Is the indicator light off when the motorcycle is Yes ABS is normal
running?
No
Make a diagnosis and find the fault code for repair Ask the rider whether the fault has occurred
or replacement. again.
Overview of diagnosis
The ABS hydraulic mechanism will remember and store the fault code so that the service personnel can
easily troubleshoot it. The fault code memory is directly powered by the battery and cannot be removed by the
ignition switch.
The ABS hydraulic mechanism is able to remember all the fault codes (6 codes). If there are more fault
codes, all the existing fault codes (6 codes) must be deleted before they can be stored in the ABS hydraulic
mechanism. If there is no fault, the ABS indicator (LED) light will be on, indicating that "ABS is OK".
Self-diagnostic procedures
○If any fault occurs in ABS, the ABS indicator (LED)
[A] will be on.
Remarks
○ A fully charged battery must be used for diagnostics,
otherwise, the indicator light may flash very slowly or
not flash.
○The motorcycle is in a stopped state.
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Check the ABS indicator (LED).
● Rotate the ignition switch to "ON".
★ If the ABS indicator light (LED) [A] is on for a
while and automatically goes out, it is normal.
★ If the ABS indicator light (LED) is always on, skip
to the following steps: “ABS indicator light (LED) is
on (motorcycle is driving – no fault code)”.
● Rotate the ignition switch to "OFF".

★ If the ABS indicator light (LED) [A] is out, it is
normal.
★ If the ABS indicator light (LED) is always on, skip
to the following steps: “ABS indicator light (LED) is
on (rotate the ignition switch to "OFF")”.
ABS indicator (LED) is on (rotate the ignition switch to "OFF")

● Conduct the Step I of test.
○ Check the pin voltage between the black/white lead
terminal of the meter connector [A] and the ground
wire.
● Rotate the ignition switch to "ON".
Pin Voltage
Standard: about 10V
★ If the pin voltage is not within the specified range,

perform the Step II.
★ If the pin voltage is correct, replace the meter.
● Conduct the Step II of test.
○ Disconnect the meter connector.
○ Check the line between the black/white lead terminal
of the connector at main cable side [A] and the ground
wire.
★ If the line is normal, replace or repair the main
cable.
★ If the line is abnormal, perform Step III.
● Conduct the Step III of test.

○ Disconnect the ABS hydraulic mechanism connector.
of connector at the main cable side [A] and the
black/white lead terminal of connector at the main
cable side [B].
305
★ If the line is normal, replace the ABS hydraulic
mechanism.
★ If the line is abnormal, replace or repair the main
cable.
ABS indicator (LED) is on (motorcycle is driving - no fault code)
●Test
○ Disconnect the ABS hydraulic mechanism connector
and meter connector.
of ABS connector at the main cable side [A] and the
black/white lead terminal of wheel speed sensor
connector at the main cable side [B].
Check the front/rear wheel speed sensor and gear ring
for damage.
Check whether the ABS fuse on the cable is normal.
★ If the line, front/rear wheel speed sensor and gear

ring are normal, and the fuse is also normal, replace the
ABS hydraulic mechanism.
★ If the line, front/rear wheel speed sensor and gear
ring, fuse are not normal, replace or repair them.
Battery terminal voltage
Standard: battery voltage ≥ 12V
★ If the battery terminal voltage is not within the

specified range, replace the battery.
★ If the battery terminal voltage is normal, perform
the next step.
The difference between front and rear wheel speeds is abnormal (fault code: front: C0084-C0088; rear:
C0104-C0108)
○Perform the following checks and repair defective
parts.
The tire pressure is abnormal;
Non-recommended standard tires are installed on
motorcycles (tire specifications are incorrect);
Deformation of wheel or tire;
the rotating teeth of sensor rotor are cracked or blocked
by foreign matters.
★ If the above parts are normal, perform Step II.

○ Recheck the fault code; delete the fault code and
regain the fault code.
★ If the ABS indicator light (LED) [A] is on, the ECU
fault code indicates that the ABS hydraulic mechanism
is faulty. Therefore, the ABS should be replaced.
★ If the ABS indicator light (LED) is out, the ABS is
306
normal (no fault code is stored; temporary fault).
Wheel speed sensor is open or shorted (front: C0080-C0083; rear: C0100-C0103)
○ Check whether the ABS sensor connector is loose or
not inserted properly
○ Check whether the ABS sensor is damaged
★ If the wheel speed sensor is damaged, replace the
wheel speed sensor.
Check the line of wheel speed sensor (fault code: front: C0080-C0083; rear: C0100-C0103)
and the front wheel speed sensor connector.
○ Connect the two lead terminals of connector at the
main cable side with a jumper and check the line
between the two lead terminals of connector at the main
cable side.
★ If the line is not normal, perform Step II.
cable.
○ Connect the two lead terminals of connector at the
main cable side with a jumper and check the line
between the two lead terminals of connector at the main
cable side.
★ If the line is normal, replace the front wheel speed
sensor.
cable.
Relay fault (C0044-C0046)

★ Replace ABS.
ABS normally open valve solenoid circuit is open-circuited or the resistance is too large (front: C0121; rear:
C0161)
★ Replace ABS.
ABS normally closed valve solenoid circuit is open-circuited or the resistance is too large (front: C0131; rear:
C0171)
★ Replace ABS.
ABS voltage is too high, ABS voltage is too low (too high: C0053; too low: C0047, C0052)
Standard: battery voltage ≥ 12V
★ If the battery terminal voltage is not within the
specified range, replace the battery or charge and
discharge.
ABS pump or motor fault (C0070-C0074)

★ There is still a fault after ensuring the line is
normal. Please replace the ABS.
307
Intermittent signal of wheel speed sensor (front: C0084-C0088; rear: C0104-C0108)
○ Check whether the clearance between the wheel
speed sensor and the gear ring surface is between
0.5-1.2 mm.
○Check whether the wheel speed gear ring is deformed
or any tooth is missing
★If the clearance is not within the range, adjust the
clearance
★ If wheel speed gear ring is damaged, replace wheel
speed gear ring
ABS wheel speed difference is too high

○ Check whether the wheels or tires with different
specifications have been replaced
○Check whether the tire is winded in situ
★Use the wheel and tires the same as the originals
★Please turn off the electric door lock after the tire is
winded in situ, then open the electric door lock
Brake diode breakdown (C0062)

○Check whether the diode of the main cable of the
motorcycle body harness is intact
★ If the diode is damaged, replace it
Brake switch line fault (C0060-C0061)

○ABS function will not be affected. Please disconnect
the ABS hydraulic mechanism connector and check the
line between brake signal cable to the ABS connector.
★ If the line is normal, please repair the main cable.
★ Test it for several times; if the line is normal, please
clear the fault code and retest the ABS.
ABS indicator light (LED) fault (C0210-C0213)
and check the line between ABS indicator cable to the
ABS connector terminal.
★ If the line is abnormal, please repair the main cable.
★If the line is normal, please replace the meter panel
and retest.
Speed output port fault (C0230-C0231)

and check the line between wheel speed output port to
the ABS connector terminal.
★ If the line is abnormal, please repair the main cable.
★ If the line is normal, please replace the meter panel
and retest.
308
Front wheel speed sensor signal is abnormal (fault code: C0084-C0088)
○ Measure the clearance between the front wheel speed
sensor and the sensor rotor.
Feeler gauge [A]
Clearance
Standard: 0.5-1.2mm (0.02-0.047in.)
★ If the measured value is beyond the above

standards, check each part for deformation or looseness
and adjust accordingly.
Re-measure the clearance.
★ If the measured value is normal, perform Step II.
○ Check whether there are iron filings or other
magnetic deposits between the sensor [A] and the
sensor gear ring [B], and whether the groove of sensor
gear ring is clogged.
○ Check the installation of the sensor and observe
whether it is loose.
○ Check the tip of the sensor and sensor gear ring for
deformation or damage (eg, the teeth of the sensor gear
ring are notched).
★ If the sensor and sensor gear ring are in poor
conditions, clean the deposit on it and reinstall or
replace the defective parts correctly.
★ If the above parts are normal, perform Step III.

○ Recheck the fault code; delete the fault code, perform
the pre-diagnosis check (Phase I and II), and re-read the
fault code.
is faulty. Therefore, the ABS hydraulic mechanism
should be replaced.
Rear wheel speed sensor signal is abnormal (fault code: C0104-C0108)

○ Measure the clearance between the rear wheel speed
sensor and the sensor gear ring.
Feeler gauge [A]
Clearance
Standard: 0.5-1.2mm (0.02-0.047in.)
★ If the measured value is beyond the above

standards, check each part for deformation or looseness
and adjust accordingly.
Re-measure the clearance.
★ If the measured value is normal, perform Step II.
309
○ Check whether there are iron filings or other
magnetic deposits between the sensor [A] and the
sensor gear ring [B], and whether the groove of sensor
gear ring is clogged.
○ Check the installation of the sensor and observe
whether it is loose.
○ Check the tip of the sensor and sensor gear ring for
deformation or damage (eg, the teeth of the sensor gear
ring are notched).
★ If the sensor and sensor gear ring are in poor
conditions, clean the deposit on it and reinstall or
replace the defective parts correctly.
★ If the above parts are normal, perform Step III.
○ Recheck the fault code; delete the fault code.
should be replaced.
Check ECU (fault code: C0044-C0046)

○ Recheck the fault code; delete the fault code, perform
the pre-diagnosis check (Phase I and II), and re-gain the
fault code.
should be replaced.
ABS hydraulic system

Disassemble ABS hydraulic mechanism
Notes
The ABS hydraulic mechanism have been precisely
set and adjusted before leaving the factory, so care
must be taken during operation. Never use a hammer
to strike it or drop it on a hard surface and prevent
it from touching or be stuck to the mud.
● Discharge the brake fluid from the front brake line
and the rear brake line.
○Press the brake lever and pedal to release the brake
fluid through the bleed screw.
●Disassemble:
Fuel tank (see “Fuel Tank” – “Removing Fuel Tank”).
Right cover (see “Covering Parts” – “Removing Right
Cover” for details).
battery (see “Electrical System” - “Removal of
Battery”).
310
●Disassemble:
Bolt [A]
●ABS cover [B]
● Clean the ABS hydraulic mechanism.
Notes
Clean all connectors on the ABS hydraulic
mechanism and the rear master cylinder, as the dirt
around the hollow bolts may contaminate the brake
fluid during the removal/installation of brake line.
Before removing the brake hose, lay a rag
around the ABS hydraulic mechanism to prevent the
brake fluid from seeping into the parts.
● Remove the brake line connecting bolts [A], [B], [C],

[D].
● Seal the opening of brake hose with a tape to prevent
brake fluid from leaking or foreign matter from
contaminating the brake fluid.
Notes
Brake fluid may quickly corrode the painted
part, so if the brake fluid spills on any plastic
part, it must be thoroughly rinsed immediately.
● Disconnect the connector [A].

○ Loosen the connector [B] by the method as shown on
the right.
●Remove the bolt [A].

● Remove the ABS hydraulic mechanism and bracket
[B].
311
●Remove the bolt and bracket.
Notes
ABS hydraulic mechanism has been precisely set
and adjusted before leaving the factory, so do not
disassemble and repair the ABS hydraulic
mechanism!
Install ABS hydraulic mechanism

● Install the ABS hydraulic mechanism on the bracket
[B].
Notes
Brake fluid may quickly corrode the painted
part, so if the brake fluid spills on any plastic part,
it must be thoroughly rinsed immediately.
●Lock the bolt [A] to the frame.
● Arrange the wires correctly and securely fasten the

connector [A].
○ Mount the joint [B] by the method as shown on the
right.
312
● Install the brake line correctly, as shown in the figure.
● Lock the brake line connecting bolts [A], [B], [C],
[D].
Locking torque for connecting nut of brake line: 17
N•m
“Exhausting the Air inside the Brake Line” for details).|
Check ABS hydraulic mechanism

● Remove the ABS hydraulic mechanism (see
“Removing the ABS Hydraulic Mechanism” for
details).
● Visually inspect ABS hydraulic mechanism.
★ If the ABS hydraulic mechanism is cracked or
damaged, please replace it!
● Visually inspect the connector terminal [A].

★ If the ABS hydraulic mechanism or main cable is
cracked, bent or damaged, please replace it!
★ If the ABS hydraulic mechanism connector is
blocked by mud or dust, blow it off with compressed
air.
313
Speed sensor
Remove front wheel speed sensor
Notes
Wheel speed sensors are precisely machined,
so care must be taken during operation. Never
use a hammer to strike it or drop it on a hard
surface and prevent it from touching or be stuck
to the mud.
Do not disassemble or repair the wheel speed
sensor!
●Disassemble:
Bolt [A]
Front wheel speed sensor [B]
Install front wheel speed sensor

● Properly arrange the wire (see "Appendix" -
"Winding Method of Cables, Wires and Hoses" for
details).
Remove rear wheel speed sensor
Notes
Wheel speed sensors are precisely machined,
so care must be taken during operation. Never
use a hammer to strike it or drop it on a hard
surface and prevent it from touching or be stuck
to the mud.
Do not disassemble or repair the wheel speed
sensor!
●Disassemble:
Seat cushion [see "Removing Seat Cushion" for
details],
Connector [A]
● Remove the connector.
314
●Disassemble:
Bolt [A],
Rear wheel speed sensor [B]
Install rear wheel speed sensor

● Properly arrange the wire (see "Appendix" -
"Winding Method of Cables, Wires and Hoses" for
details).
Check front wheel speed sensor
●Remove the front wheel speed sensor [A] from the
front fork.
●Remove the rear wheel speed sensor from the caliper

bracket [B]
●Visually inspect wheel speed sensor.
★ If the wheel speed sensor is cracked, bent or
damaged, please replace it!
315
Check the clearance of wheel speed sensor
★ Lift the front / rear wheel from the ground with a

jack (see “Wheels/Tires” - “Removing Front / Rear
Wheel”).
●Slowly rotate the wheel and measure the clearance at
several different points between the sensor and the
sensor gear ring.
Feeler gauge [A]
Clearance
Standard:
Front wheel: 0.5-1.2mm
Rear wheel: 0.5-1.2mm
Remarks
○ Sensor clearance cannot be adjusted.
★ If the clearance is not within the specified range,
check the hub bearing (see “Wheel/Tire” – “Checking
Hub Bearing”), the installation and function of sensor
(see “Checking Wheel Rotation Sensor” for details).
Check the gear ring of wheel speed sensor

●Disassemble:
Wheel (see “Wheel/Tire” – “Removing Front / Rear
Wheel”)
Brake plate mounting bolt [A],
Sensor gear ring [B]
316
● Visually inspect the gear ring of wheel speed sensor.
★ If the rotor is deformed or damaged (there is a
notch [A] on the rotating tooth), please replace it with a
new one!
★ If there are iron filings or other magnetic deposits
on the rotor [B], please clean!
317
Suspension system
Exploded view of front suspension system
318
Num Torque
ber of N·m kgf·m
2 Upper grip positioner 2 — —
3 Lower grip positioner 2
4 Damper 4 — —
5 Handlebar positioning double-end stud 2 45 4.5 L
6 Clamp screw of upper bracket 1 78 7.8
7 Bolt M8×25 2 22 2.2
8 Upper bracket 1
9 Handlebar positioning washer 2 — —
Hexalobular socket head cap screw
11 2 22 2.2
M8×16
12 Clamp nut of upper bracket 1 23 2.3
13 Clamp nut 1 2.5 0.25
14 Dust ring 2 — — R
15 Steering bearing 2 — — R、G
16 Column 1 — —
17 Locking ring 1 — — R
18 Lower bracket 1 — —
19 Bolt M8×30 4 22 2.2
20 Front inner fender 1 — —
21 Bolt M6×10 4 10 1.0
22 Front left shock absorber assembly 1 — —
23 Front right shock absorber assembly 1 — —
24 Bolt M6×30 2 10 1.0
25 Front reflector 2 — —
26 Clutch clamp assembly 2 — —
G: Apply grease.
R: Replace the part
319
Exploded view of rear suspension system
320
Num Torque
ber of N·m kgf·m
1 Rear rocker arm mounting shaft 1 108 10.8 G
2 Dust seal assembly 2 — — G、R
3 Needle bearing HK2020 4 — — G
4 Bearing oil seal 2 — — G、R
5 Rear swing arm collar 2 — —
7 Rear rocker arm welding assembly 1 — —
8 2 10 1.0
9 Upper stop block of chain 1 — — R
Cross recessed pan head screw
10 1 — —
M5×16
11 Chain protective block 1 — — R
12 Bolt M6×30 2 10 1.0
13 Support sleeve 2 — —
14 Self-locking nut M10×1.25 1 — —
15 Washer 2 — —
16 Chain adjuster assembly 2 — —
17 Chain adjuster retainer 2 — —
19 Drive chain cover 1 — —
20 Inner hexagon screw 4 10 1.0
21 Rear lower fender 1 — —
22 Pedal rubber mounting bolt 1 10 1.0
24 Rear shock absorber assembly 1 — —
Lower mounting bolt of rear shock
25 1 45 4.5
absorber
26 Mounting bolt of shock absorber 1 45 4.5
27 Nut M10×1.25 1 45 4.5
28 Washer 5 1 — —
G: Apply grease.
R: Replace the part
321
Item Normal
Front shock absorber (each)
Diameter of inner tube of front φ41 mm
shock absorber
Air pressure Atmospheric pressure (not adjustable)
Front shock absorber: 32# shock absorber oil
Viscosity 28.8~35.2
Oil quantity 390 ±5 ml (after disassembling and completely emptying)
Liquid of front shock absorber fluid: 80 ± 2 mm (fully compressed, without front shock absorber spring; top
of inner tube)
Free length of front shock absorber 345±2 mm (lower operating limit: 343mm)
spring
Rear shock absorber
Spring preload setting: Double nut adjustment
Normal Spring length: 217.5 mm
Scope Spring length: 225.5-217.5mm
(from weak to strong)
322
Special tools
Inner caliper: Front shock absorber piston rod puller
Oil seal and bearing puller: Front shock absorber level gauge:
Bearing driver set: Hook wrench T=3.2 :
323
Front Shock Absorber
Disassembly of Front Shock Absorber
●Disassemble:
Front wheel (see “Wheel/Tire” – “Removing the Front
Wheel”)
Front fender (see "Frame" - "Removing the Front
Fender")
Front caliper (see “Brakes” - “Removing the Front
Caliper”),
★ Before removing the front shock absorber mounting
base, remove the front fork clamp bolt at the top [A]
Remarks
○ Remove the front fork clamp bolt and remove the
top cover.
● Remove the front shock absorber clamp bolts [A] on

theupper and lower side.
●Rotate the front shock absorber mounting seat and

remove it.
Installation of Front Shock Absorber
●When the front shock absorber is installed, the
direction and position of the top [A] of the outer tube
are as shown on the right.
1 mm [B]
● Locking torque
Front shock absorber clamp bolt (lower side): 22 N·m
Top cover of front shock absorber: 15-20 N·m
Front shock absorber clamp bolt (upper side): 22 N·m
Remarks
Lock the top cover before locking the front shock
absorber clamp bolt on the upper side.
○ Alternatively tighten the two clamp screws twice to
ensure a uniform locking torque.
324
Replacement of Front Shock Absorber Fluid
Remove the front shock absorber (see “Disassembly of
Front Shock Absorber”).
Clamp the lower end of inner tube with a vise.
Remove the head cover [A] from the outer tube.
Install the fixing tool [A], as shown in the figure

Remarks
○The upper part protecting device shall not touch the
inner tube when installing the fixing tool; pull up the
outer tube, clamp the outer tube with the tool, and
then lock the two bolts. The outer tube plays a
guiding role.
325
●After the spring is pressed with the special tool,
disassemble the front shock absorber bolt [1] and nut [B]
with a wrench
Remarks
○This is the right shock absorber. The left shock
absorber bolt is not equipped with an adjustment lever
(X). The removal method is the same.
●Disassemble:
Shock absorber spring [A]
Spring seat [B]
Adjusting sleeve[C]
Damper and adjusting sleeve [D]
●Pour the shock absorber oil into a suitable container.

○Pull the piston rod up and down for at least ten times and
pour out the shock absorber oil in the front shock absorber.
Special Tool—Shock Absorber Piston Rod Puller [B]:
●Hold the outer tube vertically and press the inner tube [A]
and piston rod to the bottom.
●Pour the shock absorber oil of the specified model and
specified quantity.
32# shock absorber fluid
Viscosity: 28.8-35.2 40℃
Oil quantity (each shock absorber): 390L
When the shock absorber oil is replaced: ≈300 mL
Oil quantity after it is disassembled and dried
completely: 390 ±5 mL
326
★If necessary, measure the oil level of shock absorber oil
according to the following methods.
○It is best to use a three-jaw chuck oiling paper to wrap the
inner tube and fix it vertically.
○Pull the piston rod [B] up and down for more than ten
times by using the piston rod puller [A] to drain the air in
the shock absorber oil thoroughly.
Special Tool—Shock Absorber Piston Rod Puller
○ Remove the piston rod puller.

○Wait for the fluid level to stabilize.
○When the shock absorber is compressed to the end and
the piston rod is pushed to the bottom, insert the tape or
ruler into the inner tube and measure the distance between
the top of inner tube and the shock absorber fluid surface.
Fluid level (when the shock absorber is compressed to

the end and shock absorber spring is taken out)
Standard: 80±2mm
(from the top of the inner tube)
Remarks
○ The level of shock absorber fluid can also be
measured with the shock absorber fluid level gauge.
Special Tool—Shock Absorber Fluid Level Gauge [A]:
○When the shock absorber is compressed to the end and
shock absorber spring is taken out, insert the pipette of
shock absorber fluid level pipe into the inner pipe [B], and
then place the limiting stopper on the top of the inner pipe
[C].
○ Make the scale of fuel level gauge limiting block [D]
display the standard fluid level distance [E].
○ Pull the handle slowly and pump out the excess shock
absorber fluid until the shock absorber fluid is no longer
leaking.
★ If the shock absorber fluid is not pumped out, the
shock absorber fluid inside the inner tube is insufficient.
Pour enough shock absorber fluid and then pump excess
shock absorber fluid as described above.
327
●Rotate the shock absorber piston rod puller to the end of
piston rod.
Special Tool—Shock Absorber Piston Rod Puller:
●Pull the puller above the top of outer tube.

●Install the front shock absorber spring [A], and make the
smaller end [B] face down.
●Install:
Adjusting sleeve,
Damper and other parts
Please replace with new parts!
●Fix the bolt at the top with a wrench and lock the piston
rod nut [A].
Locking torque of piston rod nut: 18-20 N·m
●Clamp the washer by using the holder and loosen the

front shock absorber spring compressor nut.
●Remove the front shock absorber spring compressor.
●Pull up the outer tube and cover the outer tube with the
bolt at the top.
●Install the front shock absorber (see “Installation of Front
Shock Absorber”).
Disassembly of Front Shock Absorber

Remove the front shock absorber (see “Disassembly of
Front Shock Absorber”).
●Discharge the shock absorber oil (see “Replacement
of Shock Absorber Oil”).
328
●Clamp the inner tube of shock absorber with the tool.
●Remove the mounting seat of shock absorber.
●Separate the outer tube and inner tube.

●Pull out the dust ring.
●Remove the retainer ring of outer tube [A].
●Remove oil seal [B] and washer [C].
●Replace the following parts with new ones:
Oil seal
Lock torque of hexagon bolt at the bottom of front
shock absorber: 8-23 N•m
●Install the following parts on the inner tube [A].

Dust seal [B],
Retainer ring [C],
Oil seal [D],
Washer [E]
●Insert the inner tube into the outer tube.

●After the gasket is installed, install the oil seal [A]
with the shock absorber oil seal installer [B].
Special Tool—Shock Absorber Fuel Seal Installer:
●Install the retainer ring and dust seal in the outer tube.
●Pour the shock absorber oil of the specified type (see
“Replacement of Shock Absorber Oil”).
●Install the disassembled damper component on the
assembled inner and outer tubes.
329
Inspection of inner tube and outer tube
●Visually check the inner tube [A] and replace it if
there is any damage.
●If there are cracks or rust on the inner tube, the sharp
edge and tilted part can be worn with a millstone. The
sharp edges or raised parts will damage the oil seal.
★If the inner tube cannot be maintained, please replace
it with a new one! The oil seal will be damaged after
the inner tube is damaged, so the oil seal must be
replaced when maintaining or replacing the inner tube.
Notes
If the inner tube is severely bent or wrinkled,
please replace it! The strength of inner tube will be
reduced when correcting the inner tube after
excessive bending.
●Assemble the inner and outer tubes and pull the inner
and outer tubes back and forth with hands to see
whether the inner tube and outer tube can operate
smoothly.
●If clamp stagnation is felt, the inner and outer tubes
must be replaced.
WARNING
The straightened front shock absorber inner or
outer tube will break down in the using process,
which will cause accidents. Therefore, the seriously
bent or damaged inner or outer tube must be
replaced and the other pipe shall be checked
carefully before use.
Inspection of Dust Seal
●Check whether the dust seal [A] is corroded or
broken.
★If necessary, please replace the dust seal!
330
Inspection of Spring Tension
●The length of spring will be reduced after it is
weakened, so the state of spring can be checked by
checking its free length [A].
★If any shock absorber spring is shorter than the use
limit, it must be replaced! If the length of new spring
and the other shock absorber spring differs
considerably, the other spring must be replaced at the
same time so as to keep the balance of left and right
shock absorbers to ensure the stability of motorcycle.
Free length of spring

Standard: 345mm
331
Rear shock absorber
Adjustment of pretightening force of spring
Remove the rear shock absorber from the frame (see
“Removing the Rear Shock Absorber” for details).
● Loosen the locknut [A], rotate the adjusting nut [B]
and then release the spring.
Special tool - hook wrench:
● Adjust the spring pretightening force, rotate the

adjusting nut [B] to the proper position, and then
tighten the locknut [A].
Spring length [C]
Setting of pretightening force of spring
Standard: spring length: 230 mm
Applicable scope: spring length: 216.5-203.5 mm
○ Standard adjustment nut setting for the rider (without
passengers or accessories) of ordinary body [weight of
68 kg (150 lb)]: the spring length is equal to
207.5-212.5mm.
●Adjust the pretightening force of spring on the frame

using rear shock absorber.
● Remove the footpeg bracket [A] to easily rotate the
hook wrench.
332
● To adjust the spring pretightening force, loosen the
locknut [B] with a hook wrench [A] and rotate it into
the proper position.
● Use the hook wrench [A] to rotate the adjusting nut

[B] to the proper position, and then tighten the locknut
[C] with the hook wrench [A] (the rear shock absorber
is fixed on the frame).
Special tool - hook wrench
★ If you feel the spring is too soft or too hard, please
adjust!
Adjustment of spring
Dampi insulat Road
Spring
ng ed Load conditi Speed
length
force flange ons
196mm Weak Soft Soft Good Low
↑ ↑ ↑ ↑ ↑ ↑
↓ ↓ ↓ ↓ ↓ ↓
184mm Strong Hard Heavy Bad High
Disassembly of Rear Shock Absorber
●Disassemble:
Right cover (see “Frame” – “Removing Right Cover”
for details).
Rear lower fender (see “Rear Swing Arm” –
“Removing the Rear Lower Fender”)
● Lift the rear wheel from the ground with a jack.
Accessories of jack:
●Remove the rear shock absorber clamp bolt on the
upper side [A]
333
●Remove the rear shock absorber clamp bolt on the
lower side [A]
●Remove the shock absorber
Assembly of Rear Shock Absorber

● Locking torque
Upper clamp bolt of rear shock absorber: 45 N·m
Lower clamp bolt of rear shock absorber: 45 N·m
Inspection of Rear Shock Absorber
●Remove the rear shock absorber (see “Removing the
Rear Shock Absorber” for details).
● Visually check:
Whether the stroke is smooth;
Whether there is oil leakage;
Whether there is crack or dent
★ If the rear shock absorber is damaged, please
replace it!
● Visually check rubber collar.
★ If the rubber collar is damaged, please replace it!
334
Rear rocker arm
Disassembly of Swing Arm
● Lift the rear wheel from the ground with a jack.
Accessories of jack:
●Disassemble:
Rear wheel (see “Wheel/Tire” – “Removing the Rear
Wheel”)
●Disassemble:
Clamp bolt [A] on the lower side of rear shock absorber
[B] (see "Removing the Rear Shock Absorber" for
details)
● Remove the lower swing arm mounting shaft nut [A].
●Pull out the mounting shaft [A] from the right side of
the motorcycle to the left side and remove the swing
arm.
335
Installation of Swing Arm
● Apply a proper amount of grease to the edge of the
oil seal [A].
●Install collar [B].
● Install the mounting shaft [A] into the frame from the
left side.
●Lock the swing arm mounting shaft nut [A].

Locking torque of swing arm mounting shaft nut: 108
N·m
Disassembly of Swing Arm Bearing

●Disassemble:
● Rear swing arm (see “Removing Rear Swing Arm”).
Dust seal [A],
Oil seal [B],
Sleeve [C],
336
● Remove the needle bearing.
Special tool - oil seal and bearing puller [A]:
Installation of Swing Arm Bearing

● Replace the needle bearing [A] with a new one.
● When installing the needle bearing, the
manufacturer's mark should face outward.
Needle roller bearing mounting tool [B]:
Gasket:
Check swing arm bearing

Notes
Do not remove the bearing for inspection,
otherwise, the bearing may be damaged.
●Check the needle bearing [A] installed inside the
swing arm.
○The wear of the roller inside the bearing is generally
small, so it is difficult to measure the wearing capacity.
Therefore, only the bearings can be visually inspected
for wear, discoloration or other damage.
★ If there is any abnormal wear, discoloration or
damage in the needle bearing, please replace it as a
whole!
Check the chain guide

Chain Guide" for details.
337
Control System
Exploded View of Control System
338
Num Torque
ber of N·m kgf·m
1 Left rear view mirror assembly 1 — —
2 Right rear view mirror assembly 1 — —
3 Handlebar 1 — —
Hexagon socket cap screw M6×35/half
4 2 10 1.0
tooth
5 Washer Φ6 2 — —
7 Grip end 2 — —
8 Grip end mounting base 2
9 Grip end 2 — —
10 Left handlebar jacket 1 — —
11 Left combination switch 1 — —
12 Right combination switch 1 — —
13 Right grip assembly 1 — —
14 Throttle cable assembly 1 — —
15 Clutch cable assembly 1 — —
16 Clutch handle component 1 — —
17 ABS switch assembly 1 — —
18 Bolt M6×30 4 10 1.0
19 Rear brake pedal mounting screw 1 22 2.2 G
20 Self-lubricating collar 1 — —
21 Washer 1
22 Brake pedal 1 — —
23 Bolt M6×35 1 10 1.0
24 Nut M6 1 10 1.0
25 Bolt M6×25-8.8-ZG 2 — —
26 Brake pedal mounting seat 1 — —
27 Bolt M6×1 2 10 1.0
28 Joint M6 1 — —
29 Nut M6-8-ZG 1 10 1.0
30 Foot pump piston screw 1 — —
31 Mounting bolt of rear brake cylinder 1 10 1.0
32 Brake spring 1 — —
33 Upper spring pin 1 7 0.7
34 Brake pedal spring rubber cover 1 — —
35 Meter adjusting switch 1 — —
AD: Apply adhesive.
AL: Alternatively tighten the two clamp bolts twice to ensure a uniform locking torque.
G: Apply grease.
R: Replace the part
339
Special tools
Bearing driver set: Screwdriver for outer race of head tube:
Mounting tools for steering tube bearing: φ35.5: Four-jaw 300-QCLM4-001
Seven-jaw 300-QCLM7-001
340
Control System
Inspection of Control System
● See “Periodic Maintenance” –"Inspection of
Clearance of Control System" for details.
Adjustment of Control System

● See “Periodic Maintenance” –"Adjustment of
Clearance of Control System" for details.
341
Handlebar
Disassembly of Handlebar
●Disassemble:
Handlebar grip end [A]
Left rearview mirror [D]
Clutch handlebar lock bolt [E],
Left combination switch [C],
Left handlebar cover [B],
●Disassemble:
Handlebar grip end [A]
Master cylinder lock bolt of front fluid brake [E]
Right combination switch [C]
Throttle handlebar [B]
● Remove the bolt [A] of handlebar mounting bracket.

● Remove the mounting bracket [B] and the handlebar
[C] in all directions.
342
Installation of handlebar
● Install the handlebar mounting bracket and handlebar
on the upper bracket.
● Fasten the bolt of handlebar mounting bracket.
Remarks
○ First tighten the front handlebar mounting bracket
bolt [A], then lock the other handlebar mounting
bracket bolt [B].
○ Alternatively tighten the two handlebar mounting
bracket bolts twice to ensure a uniform locking
torque.
Locking torque of handlebar mounting bracket bolt: 25
N·m
●Install:
Front fluid brake master cylinder (see “Master
Cylinder” - “Installation of Front Master Cylinder”).
Right combination switch [B]
Throttle handlebar [C]
Throttle cable [D]
● Apply locking agent to the threads of handlebar grip
end bolt, and then tighten the bolts.
●Install:
Grip end [E]
Right rearview mirror [F]
●Install:
Clutch handlebar.
Remarks
○ First tighten the upper handlebar mounting bracket
bolt [A], then lock the other handlebar mounting
bracket bolt [B].
343
●Install:
Left handlebar [A]
Left combination switch [B]
● Apply locking agent to the threads of handlebar grip
end bolt, and then tighten the bolts.
●Install:
Grip end [C]
Locking torque of combination switch fastening

screw: 3.5 N·m
344
Steering stem
Disassembly of Steering Stem and Steering Stem Bearing
●Disassemble:
Handlebar (see "Removing Handlebar" for details);
Cowling (see “Frame”-“Removing Cowling” for
details),
Front wheel (see “Wheel/Tire” – “Removing the Front
Wheel”)
Front fender (see "Frame" - "Removing the Front
Fender")
Front shock absorber (see "Suspension System" -
"Removing the Front Shock Absorber"),
● Remove the upper bracket locknut [B] with the Allen
wrench [A], and then remove the upper bracket [C].
Remove locknut of steering stem [E].

Special tool - steering stem locknut wrench
(four-claw):
●Remove nut of steering stem [E].
Special tool - steering stem nut wrench
(seven-claw):
●Disassemble:
Steering stem [A],
Inner race of upper ball bearing [B] and ball bearing
345
e●In order to remove the ball bearing outer race that is
pressed into the head tube, it is necessary to insert a rod
[A] into the inner cavity of the head tube, alternately
tap the sides of ball bearing, and take out the outer race.
Remarks
○ If any of the upper and lower bearings of the
steering stem is damaged, it is recommended to
replace the upper and lower bearings (including the
outer race of bearing) with new ones.
● Use a chisel [B] (purchasable) to remove the inner
race of the lower ball bearing (and the oil seal of inner
race) that is pressed onto the steering stem.
Installation of Steering Stem and Steering Stem Bearing

● Replace the outer race of bearing [A] with a new one.
● Install the steering stem and steering stem bearing
into the head tube.
Special tool - special tooling for installing the outer
race of head tube:
Bearing driver set:
● Apply grease to the outer race.
● Replace the inner race of bearing and oil seal with

new ones.
●Apply grease to oil seal.
● Put the oil seal [A] on the steering stem, then install
the inner race of lower ball bearing [B] and apply
grease to the steering stem [D].
Special tool - special tooling for installing the steering
tube bearing [C]:
346
● Install the lower ball bearing [A] to the steering stem.
● Apply grease to the following parts.
Inner and outer races,
lower and upper ball bearings
○The lower ball bearing is the same as the upper ball
bearing.
● Insert the steering stem [A] into the head tube, and
then install the ball bearing [B] and the inner race [C].
●Install:
Washer [D]
Steering stem nut [E]
● Install the bearing to the appropriate position as

follows.
○ First lock the steering stem nut according to the
locking torque of 10 N·m, then loosen it by a small turn
(less than one turn) to make the nut rotate slightly. Then
use the steering stem nut wrench [A] to lock it
according to the specified locking torque.
Special tool - steering stem nut wrench (seven-claw):
Locking torque of steering stem nut: 2.5 N•m
● Manually tighten the steering stem locknut until the

locknut hits the steering stem nut.
● Tighten the steering stem locknut.
Special tool - steering stem nut wrench (four-claw):
Locking torque of steering stem nut: 23 N•m
347
●Install the upper plate and tighten the steering stem
lock bolts.
●Install the front shock absorber (see "Suspension
System" - “Installation of Front Shock Absorber”).
Remarks
○ First lock the front shock absorber lock bolt on the
upper side, then lock the upper bracket locknut, and
finally lock the front shock absorber lock bolt on the
lower side.
○ Alternatively tighten the two front shock absorber
lock bolts on the lower side twice to ensure a
uniform locking torque.
Locking torque:
Front shock absorber lock bolt (upper side): 22 N·m
Upper bracket lock bolt: 78 N·m
Front shock absorber lock bolt (lower side): 22 N·m
WARNING
Properly arrange the cable, wire harness and hose
(see section "Winding Method of Cables, Wires
and Hoses" of Chapter "Appendix" for details);
otherwise, the handlebar may be unable to rotate
normally.

Lubrication of Steering Stem Bearing
● See “Periodic Maintenance” –"Lubrication of
Steering Stem Bearing" for details.
Inspection of Deformation of Steering Stem

● If the steering stem is removed or it cannot be
adjusted for smooth rotation, check the straightness of
steering stem!
★ If the steering stem [A] is bent, please replace it!
348
Frame
Exploded View of Frame
Num Torque
ber of N·m kgf·m
1 Sidestand mounting bolt 1 45 4.5
2 Washer 1 — —
3 Sidestand welding assembly 1 — —
4 Sidestand spring 1 — —
5 Nut M10×1.25 1 45 4.5 AL、S
6 Bolt M10×1.25×125 1 45 4.5 AL、S
7 Nut M10×1.25 6 45 4.5 AL、S
8 1 — —
M10×1.25×165
Front left bracket component of
9 1 — —
engine
Front right bracket component of
10 1 — —
engine
11 Engine end cover 4 — —
12 Hexagon socket cap screw M10×40 4 40 4.0 AL、S
13 Washer 10 4 — —
Voltage regulator connecting
14 2 — —
mounting plate
15 4 10 —
349
16 Hexagon bolt with flange M6×50 2 10 —
17 Self-plugging rivet 3.2×7 2 — —
18 Nameplate of frame 1 — —
Headlight cover bracket welding
19 1 — —
component
20 Screw M6×20 2 10 —
21 Guard bush 3 — —
22 Rubber washer of cover 3 — —
23 Cap nut M6 2 10 —
25 Self-locking nut M8 2 22 —
Windshield bracket welding
27 1 — —
component
28 Mounting washer of fuel tank 4 — —
29 Frame welding assembly 1 — —
30 Screw M6×25 4 10 —
31 Rack plug 2 — —
32 Rear fender bracket welding assembly 1 — —
34 Bolt M6×20 4 10 —
35 Seat cable assembly 1 — —
36 Stainless steel screw M6×25 1 10 —
37 Pipe clamp ZT-35 3 — —
G: Apply grease.
350
Exploded view of left footpeg
351
Num Torque
ber of N·m kgf·m
1 Pedal mounting pin 1 — —
2 Left front pedal bracket 1 — —
3 Pedal limit plate 2 — —
4 Left front pedal assembly 1 — —
5 Circlip φ5 2 — —
6 Bolt M8×25 2 22 2.2
7 Screw M6×12-8.8-ZG 2 10 1.0
8 Left cover 1 — —
10 Left rear pedal 1 — —
11 Left pedal rubber pad 1 — —
12 Bolt M4×10 1 3 0.3
13 Straight arm torsion spring 1 — —
14 Front pedal spring 1 — —
15 Pedal ball 1 — —
16 Pedal mounting bracket 1 — —
17 Bolt M8×30 2 22 2.2
18 Left pedal rubber 1 — —
19 Left rear footpeg bracket 1 — —
G: Apply grease.
R: Replace the part
352
Exploded view of right footpeg
353
Num Torque
ber of N·m kgf·m
2 Right front pedal assembly 1 — —
3 Pedal limit plate 1 — —
4 Right front pedal bracket 1 — —
5 Circlip φ5 2 — —
6 Bolt M8×25 2 22 2.2
7 Right cover 1 — —
8 Bolt M6×1×20 1 10 1.0
9 Pedal mounting bracket 1 — —
10 Front pedal spring 1 — —
11 Right rear footpeg bracket 1 — —
12 Bolt M4×10 1 3 0.3
13 Right pedal rubber pad 1 — —
14 Right rear pedal 1 — —
16 Bolt M8×30 2 22 2.2
17 Right pedal rubber 1 — —
18 Straight arm torsion spring 1 — —
19 Pedal ball 1 — —
G: Apply grease.
R: Replace the part
354
Exploded View of Muffler
355
Num Torque
ber of N·m kgf·m
1 Cylinder component 1 — —
2 Bolt M8×25 1 22 2.2
4 Exhaust pipe gasket assembly 1 — —
5 Oxygen sensor 1 — —
7 Bolt M8×25 2 22 2.2
8 Guard bush 3 — —
9 Rubber cover II 3 — —
10 Muffler mounting bracket 1 — —
12 Cylinder component II 1 — —
14 Self-locking nut M8 2 22 2.2
R: Replace the part
356
Exploded View of Rack and Luggage Carrier
357
Num Torque
ber of N·m kgf·m
1 Rear rack welding component 1 — —
4 Left side case bracket component 1 — —
5 Self-locking nut M8 5 22 2.2
6 Bolt M8×75 2 22 2.2
7 Side case mounting bushing 4 — —
8 Rear rack mounting collar 2 — —
10 Side case bracket mounting bushing II 2 — —
12 Middle connecting rod 1 — —
13 Right side case bracket component 1 — —
14 Bolt M8×25 1 22 2.2
15 Bolt M8×25 2 22 2.2
Turn signal light bracket welding
16 1 — —
component
17 Rear left turn signal light 1 — —
18 Rear right turn signal light 1 — —
19 Plug 2 — —
20 Left side case component 1 — —
21 Right side case component 1 — —
22 Rear tail case component 1 — —
R: Replace the part
358
Exploded View of Fender
359
Num Torque
ber of N·m kgf·m
1 Front fender 1 — —
2 Screw M6×15.2 6 10 1.0
3 Bolt M6×14 4 10 1.0
4 Front fender mounting plate 2 — —
5 Grey nylon 6 — —
6 T-type bushing 5×7×6×10×0.8 2 — —
7 Nut M5 2 6 0.6
8 Front small fender 1 — —
9 Bolt M5×0.8×14 2 6 0.6
10 Screw M5×12 1 — —
12 Washer φ5 1 — —
13 Clamp nut for mounting protector 1 — —
14 Front part of rear fender 1 — —
Small cover at front part of rear
15 1 — —
fender
16 Self-tapping screw ST4.2×13 9 — —
17 Screw M6×15.2 2 10 1.0
18 Rubber washer I of rear fender 1 — —
19 Taillight 1 — —
20 Clamp ST4.2 1 — —
21 Rear fender 1 — —
22 Buffering rubber ring of seat cushion 1 — —
23 Rear reflector assembly 1 — —
24 Rear license plate light 1 — —
26 Nut M6 2 10 1.0
27 Rear license holder 1 — —
28 Bolt M6×16 2 10 1.0
29 Rear license plate 1 — —
30 Bolt M6×12 2 10 1.0
R: Replace the part
360
Exploded View of Headlight Cover
361
Num Torque
ber of N·m kgf·m
1 Front headlight panel 1 — —
2 Left cover of front headlight panel 1 — —
3 Right cover of front headlight panel 1 — —
4 Stainless steel bolt M5×16 4 6 0.6
6 Clamp nut M5 12 — —
7 Left front panel 1 — —
8 Front left turn signal light 1 — —
14 Bracket of left front panel 1 — —
15 Left deflector of radiator 1 — —
16 Right deflector of radiator 1 — —
17 Bracket of right front panel 1 — —
18 Front right turn signal light 1 — —
19 Right front panel 1 — —
R: Replace the part
362
Exploded View of Cowling
363
Num Torque
ber of N·m kgf·m
2 Cowling collar 4 — —
3 Rubber cover 8×18×4×12×4×4 4 — —
4 Windshield 1 — —
5 Cowling 1 — —
6 Headlight 1 — —
8 Screw M6×20 3 1.0 1.0
11 Meter mounting plate 1 — —
14 Meter assembly 1 — —
15 Clamp nut 1 — —
R: Replace the part
364
Exploded View of Fuel Tank Cover
365
Num Torque
ber of N·m kgf·m
1 Middle cover of tank 1 — —
4 Left cover of fuel tank 1 — —
8 Left lower cover of fuel tank 1 — —
11 Right lower cover of fuel tank 1 — —
12 Right cover of fuel tank 1 — —
R: Replace the part
366
Exploded View of Seat Cushions and Covers
367
Num Torque
ber of N·m kgf·m
1 Side cover 1 — —
5 Screw M6×14 8 10 1.0
6 Left protector 1 — —
8 Right protector 1 — —
10 Clamp ST4.2 2 — —
11 Left cover 1 — —
12 Screw M6×8 2 10 1.0
13 Right cover 1 — —
14 Front seat cushion assembly 1 — —
15 Rear seat cushion assembly 1 — —
R: Replace the part
368
Exploded View of Engine Accessories
Num Torque
ber of N·m kgf·m
1 Engine 1 — —
2 Left rear cover component 1 — —
4 Shift pedal component 1 — —
5 Screw M6×25-8.8-ZG 1 10 1.0
6 Plate clamp 2 — —
7 MAP pipe 1 — —
8 Inlet pressure sensor 1 — —
9 Throttle valve subassembly 1 — —
R: Replace the part
369
Seat Cushion
Disassembly of seat cushion
● Insert the ignition switch key [A] into the seat
cushion lock, rotate the key counterclockwise, and open
the seat cushion lock.
●Remove the rear seat [A]
●Pull the front seat cushion cable [A] and remove the
front seat cushion [B]
Installation of seat cushion

●Press the back of seat cushion until you hear a click
from the seat cushion lock seat.
370
Cover
Disassembly of Left Cover
●Remove the seat cushion (see "Cushion" - "Removing
Seat Cushion")
●Disassemble:
Screw M6×14 [A]
Stainless steel bolt M5×12 [B]
Left cover [C]
Installation of Left Cover

Locking torque of left cover mounting screw [A]: 10
N·m
Locking torque of left cover mounting screw [B]: 6
N·m
Disassembly of Right Cover
Seat Cushion")
●Disassemble:
Screw M6×14 [A]
Right cover [C]
Installation of Right Cover

Locking torque of right cover mounting screw [A]:
10 N·m
Locking torque of right cover mounting screw [B]: 6
N·m
371
Disassembly of left cover
●Disassemble:
Screw M6×14 [A]
Bolt M6×8[B]
Left cover [C]
Installation of left cover

Locking torque of left cover mounting screw [A]: 10
N·m
Locking torque of left cover mounting screw [B]: 10
N·m
Disassembly of right cover
●Disassemble:
Screw M6×14 [A]
Bolt M6×8[B]
Right cover [C]
Installation of right cover

Locking torque of right cover mounting screw [A]:
10 N·m
Locking torque of right cover mounting screw [B]:
10 N·m
372
Rear rack and side case bracket
Disassembly of side case bracket
●Disassemble:
Bolt [A]
Middle connecting rod [B]
●Disassemble:
Hexagon bolt with flange M8×70[A]
Side case mounting bushing Ⅳ[B]
Hexagon bolt with flange M8×75[C]
Hexagon bolt with flange M8×20[D]
Self-locking nut M8 [E]
Rear rack mounting collar [F]
Side case bracket mounting bushing II [G]
Left side case bracket [H]
●Disassemble:
Side case mounting bushing Ⅳ[B]
Hexagon bolt with flange M8×75[C]
Hexagon bolt with flange M8×20[D]
Self-locking nut M8 [E]
Rear rack mounting collar [F]
Side case bracket mounting bushing II [G]
Right side case bracket [H]
Installation of side case bracket
Locking torque of middle rod mounting bolt: 22N·m
Locking torque of left side case bracket mounting
bolt: 22N·m
Locking torque of right side case bracket mounting
bolt: 22N·m
373
Disassembly of rear rack
●Remove the rear seat cushion (see "Cushion" -
"Removing Seat Cushion")
●Remove side box bracket (for the one equipped with
side box) (see “Rear Rack and Side Box Bracket” –
“Removing Side Box Bracket” for details)
● Remove the right mounting bolt of rear rack [A].
● Remove the left mounting bolt of rear rack [A].
● Remove the mounting screw on the rear rack [A] and

take down the rear rack [B].
374
●Disassemble:
Self-locking nut M8 [B]
Turn signal light bracket welding component [C]
Installation of rear rack

Locking torque of rear rack mounting bolt: 22N·m
Locking torque of turn signal light bracket welding
component bolt: 22N·m
375
Side cover
Disassembly of side cover
Seat Cushion")
●Remove rear rack (see "rear grab rail and rear cover" -
"removing rear grab rail")
●Disassemble:
Screw M6×14 [A]
Stainless steel screw M6×25[B]
Self-tapping screw ST4.2×13[C]
Side cover [D]
Installation of Side Cover

Locking torque of taillight cover mounting screw: 10
N·m
376
Rear fender
Disassembly of rear fender
● Remove the screw [A] and remove the rear fender
bracket [B] from the frame
●Unplug the rear turn signal light and rear license plate
light connectors
●Disassemble:
Rear license plate light [A]
Rear reflector [B]
●Disassemble:
Rear right turn signal light [C]
Rear left turn signal light [D]
Rear license plate bracket [E]
Rear fender bracket [F]
Rear fender [G]
Installation of rear fender

Torque of fastening screw of rear fender bracket: 10
N·m
377
Front fender
Disassembly of Front Fender
● Remove the screw [A] and remove the front fender
[B] from the front shock absorber
●Disassemble:
Screw [A]
Screw [B]
Front small fender [C]
Front fender [D]
Installation of Front Fender

Torque of fastening screw of front fender: 10 N·m
378
Windshield and cowling
Disassembly of windshield
●Disassemble:
Stainless steel screw M6×25[A]
Windshield [B]
●Disassemble:
Hexagon bolt with flange M8×20[B]
Windshield bracket welding component [C]
379
Disassembly of cowling
●Disassemble:
Stainless steel bolt M5×12 [A]
Meter mounting plate [B]
●Disassemble:
Screw M6×20 [A]
Collar [B]
Rubber washer [C]
Meter mounting plate [D]
Meter assembly [E]
●Disassemble:
Self-tapping screw ST4.2×16[A]
Headlight [B]
Cowling [C]
Installation of windshield and cowling

Torque of fastening screw of meter: 10 N·m
Torque of fastening screw of meter mounting plate:
6N·m
Torque of fastening screw of windshield: 10N·m
Torque of fastening screw of windshield bracket:
22N·m
380
Headlight cover and left and right front panel
Disassembly of headlight cover
●Disassemble:
Left cover of front headlight panel [C]
●Disassemble:
Right cover of front headlight panel [C]
●Disassemble:
Headlight collar [B]
Rubber washer of guard [C]
Bracket of right front panel [D]
381
●Disassemble:
Headlight collar [B]
Bracket of left front panel [D]
●Disassemble:
Headlight cover panel [B]
●Disassemble:
Right front panel [D]
●Disassemble:
Right front panel [D]
382
●Disassemble:
Left deflector of radiator [B]
●Disassemble:
Front left turn signal light [B]
●Disassemble:
Right deflector of radiator [B]
383
●Disassemble:
Front right turn signal light [B]
Installation of headlight cover and left and right panel

Torque of fastening screw of left / right cover of
headlight panel: 6 N·m
Torque of fastening screw of bracket of left / right
front panel: 10 N·m
Torque of fastening screw of headlight cover panel:
6N·m
Torque of fastening screw of left / right front panel:
6 N·m
384
Tank cover
Disassembly of Fuel Tank Cover
●Remove the front seat cushion (see "Cushion" -
"Removing Seat Cushion")
●Remove the left and right front panels (see “Front
Large Cover and Left and Right Front Panels” –
“Removing the Front Cover and Left and Right Front
Panels”)
● Remove the left and right covers (see "Covers" -
"Removing Left Cover" and "Removing Right Cover")
● Disconnect the USB cable connector.
● Remove the fuel tank cover component [A].
Remove the mounting screw [A] and disassemble the

fuel tank cover component [B].
Exploded view (see "Expanded View of Fuel Tank
Cover" for details)
Installation of Fuel Tank Cover

385
Frame
Disassembly of Frame
● Drain the oil (see "Periodic Maintenance" - "Replacing Oil" for
details),
● Drain the coolant (see "Periodic Maintenance" -"Replacing Coolant"
for details).
●Disassemble:
Seat cushion (see “Frame” – “Removing Seat Cushion”)
Rear shelf and side box bracket (see “Rear Shelf and Side Box
Bracket” – “Removing Rear Rack and Side Box Bracket” for details)
Fuel tank (see “Fuel Tank” – “Removing Fuel Tank” for details)
Cover (see “Covers” – “Removing Cover)
Side cover (see "Side Cover" - "Removing Side Cover")
Rear fender (see "Rear Fender" - "Removing Rear Fender")
Windshield and cowling (see "Windshield and Cowling" - "Removing
Windshield and Cowling")
Front large cover and left and right front panels (see “Front Large
Cover and Left and Right Front Panels” – “Removing the Front Cover
and Left and Right Front Panels”)
Radiator (see “Radiator” - “Removing Radiator” for details).
Muffler (see “Muffler” – “Removing Muffler” for details)
Engine (see "Engine" - "Removing Engine" for details)
Brake (see "Front Calipers" - "Removing Front Calipers", "Rear
Calipers" - "Removing Rear Calipers", "Front Master Cylinder" -
"Removing Front Master Cylinder", "Rear Master Cylinder" -
"Removing Rear Master Cylinder")
Rear wheel (see “Rear Wheel” – “Removing Rear Wheel”)
Front wheel (see “Front Wheel” – “Removing Front Wheel”)
Suspension system (see “Front Shock Absorber” – “Removing Front
Shock Absorber”, “Rear Shock Absorber” – “Removing Rear Shock
Absorber” for details)
Rear swing arm (see “Rear Swing Arm” - "Removing Rear Swing
Arm" for details).
Sidestand (see "Sidestand" - "Removing Sidestand")
Front and rear footpegs (see "Front Left Footpeg" - "Removing Front
Left Footpeg", "Front Right Footpeg" - "Removing Front Right
Footpeg", "Rear Left Footpeg" - "Removing Rear Left Footpeg",
"Rear Right Footpeg" - "Removing Rear Right Footpeg")
● Remove cables and other electrical components.
Installation of Frame
● Install the parts that have been removed before in the reverse order
of disassembly (see the corresponding chapters).
386
Inspection of Frame
● Visually check the frame [A] for cracks, dents, bends
or deformations.
★ If the frame is damaged, please replace it!
WARNING
A repaired frame may fail during use and thus
cause an accident. Therefore, if there is any
crack, dent, bend or deformation on the frame,
please replace it!
387
Sidestand
Disassembly of Sidestand
● Lift the rear wheel from the ground with a bracket
[A].
●Remove the screw [A], and remove the sidestand stop

switch [B].
●Disassemble:
Sidestand spring [A]
Nut [B]
Sidestand bolt [C]
Washer [D]
Sidestand [E]
Installation of Sidestand
● Apply grease to the movable parts of sidestand [E].
● Apply locking agent to the threads of sidestand bolt
[C].
● Tighten the bolt and lock it with the nut [B].
Locking torque:
Sidestand bolt [A]: 45 N·m
Locknut of sidestand bolt [B]: 45 N·m
● Install the spring [A] with the long one facing up.
388
Left Front Footpeg
Disassembly of Left Front Footpeg
●Disassemble:
Screw [A]
Left cover [B]
●Disassemble:
Screw [A]
Left front pedal bracket [B]
●Disassemble
Cotter pin [A]
Footpeg mounting pin [B]
Left front pedal component [C]
Pedal limit plate [D]
Left front pedal bracket [E]
Installation of Left Front Footpeg

●Add grease to the footpeg mounting bushing before
installation.
389
Locking torque:
Left cover mounting bolt: 10 N·m
Left front footpeg bracket mounting screw: 22 N·m
390
Left Rear Footpeg
Disassembly of Left Rear Footpeg
●Disassemble:
Screw [A]
Left rear footpeg bracket [B]
●Disassemble
Left rear footpeg bracket [A]
Clip [B]
Pedal mounting bracket [C]
Footpeg ball [D]
Footpeg spring [E]
Left rear pedal [F]
Left pedal rubber pad [G]
Screw [H]
Footpeg mounting pin [J]
Left pedal rubber [K]
Installation of Left Rear Footpeg

●Add grease to the footpeg mounting pin before
installation.
Locking torque:
Left rear footpeg bracket mounting screw: 22 N·m
391
Front Right Footpeg
Disassembly of Front Right Footpeg
●Disassemble:
Screw [A]
Right front footpeg bracket [B]
●Disassemble
Right front footpeg bracket [A]
Footpeg mounting pin [B]
Right front pedal component [C]
Front pedal spring [D]
Pedal mounting bracket [E]
Footpeg mounting bushing [F]
Steel ball [G]
Washer [H]
Cotter pin [J]
Installation of Front Right Footpeg

●Add grease to the footpeg mounting bushing before
installation.
Locking torque:
Right front footpeg bracket mounting screw: 22 N·m
392
Rear Right Footpeg
Disassembly of Rear Right Footpeg
●Disassemble:
Nut [A]
●Disassemble:
Screw [A]
Right rear footpeg bracket [B]
●Disassemble
Right rear footpeg bracket [A]
Clip [B]
Pedal mounting bracket [C]
Footpeg ball [D]
Footpeg spring [E]
Left rear pedal [F]
Right pedal rubber pad [G]
Screw [H]
Footpeg mounting pin [J]
Left pedal rubber [K]
Installation of Rear Right Footpeg
●Add grease to the footpeg mounting pin before
installation.
Locking torque:
Right rear footpeg bracket mounting screw: 22 N·m
Muffler barrel bracket mounting nut: 22 N•m
393
Muffler
Disassembly of muffler
WARNING
Do not remove the muffler while the engine is
heated up, to avoid burns. Do not disassemble the
muffler before it has cooled down.
● Disconnect the oxygen sensor cable connector.
●Disassemble:
Nut [A]
● Loosen the clamp bolt [A] and remove the muffler

barrel component [B].
● Remove the front exhaust pipe retainer screw [A] and

the mounting nut [B].
394
●Remove the exhaust pipe cavity on the left side and
the frame mounting bolt [A]
●Remove the exhaust pipe cavity on the right side and

the frame mounting bolt [A].
● Remove the muffler exhaust pipe component [B].
●Disassemble:
Oxygen sensor [A].
Installation of Muffler
reverse order of disassembly (see the corresponding
chapters).
● Replace the exhaust pipe gasket [A] with a new one.
Locking torque:
Front exhaust pipe mounting screw: 22 N·m
Front exhaust pipe mounting nut: 22 N·m
Left and right mounting bolts of exhaust pipe
cavity: 22 N·m
Rear mounting nut of muffler barrel: 22 N•m
395
Disassembly/Installation of Engine
Exploded View of Disassembly/Installation of Engine
396
Num Torque
ber of N·m kgf·m
1 Frame welding assembly 1 — —
3 Washer 10 2 — —
5 Nut M10×1.25 1 45 4.5 AL、S
Front right bracket component of
6 1 — —
engine
7 Nut M10×1.25 1 45 4.5 AL、S
8 1 45 4.5 AL、S
M10×1.25×165
Front left bracket component of
9 1 — —
engine
10 Bolt M10×1.25×125 1 45 4.5 AL、S
11 Rear rocker arm mounting shaft 1 108 10.8 G
13 Washer 10 2 — —
M: Apply the grease containing molybdenum disulfide.
G: Apply grease.
397
Disassembly of Engine
●Support the rear part of rocker arm using a support
[A].
● Slowly grab the brake rod, and fasten it using a tire.

WARNING
When disassemble the engine, the worker must
grip the brake rod, otherwise, the motorcycle may
topple and fall, thus causing accidents and
resulting in personal injury.
● Drain the oil (see "Periodic Maintenance" - "Replacing Oil"

for details),
● Drain the coolant (see "Periodic Maintenance" -"Replacing
Coolant" for details).
●Disassemble:
●Seat cushion (see "Cushion" - "Removing Seat Cushion" for
details),
cover (see “Frame” – “Removing Cover” for details).
front large cover and left and right front panels (see "Frame" -
“Removing the Front Large Cover and Left and Right Front
Panels” for details),
fuel tank (see “Electronic Fuel Injection System (EFI)”
-“Removal of Fuel Tank” for details),
coolant reserve tank (see "Periodic Maintenance" - "Replacing
Coolant" for details),
radiator (see “Cooling System” - “Removing Radiator and
Radiator Fan” for details),
muffler (see “Frame” – “Removing Muffler” for details),
Drive chain (see "Drive" - "Removing Drive Chain")
●Support the engine with a suitable frame to keep the
engine in balance.
398
● Loosen the nut [A] and remove the clutch wire
connector [B]
● Loosen the nut [A] and remove the throttle cable

connector [B].
●Disconnect each air tube [A]
Remove the spark plug cap [A].
399
● Disconnect the oil pipe joint [A] from the fuel
injector.
●Loosen the clamp between throttle and air filter [C]
●Remove the rocker arm of shift rod.
● Disconnect the connectors of each cable.
●Loosen:
Front mounting bolt of engine [A].
400
●Disassemble:
Front left bracket component mounting bolt of engine
[A].
●Disassemble:
Front right bracket component mounting bolt of engine
[A].
●Disassemble:
Remove the rear lower mounting bolt of engine [A].
●Disassemble:
Rear swing arm shaft [A].
401
●Remove the engine with a frame.
Installation of Engine
●Support the engine with a suitable frame.
● Install the front left mounting bracket component [B]
and do not tighten the screws [A] too tightly.
● Install the front right mounting bracket component

[B] and do not tighten the screws [A] too tightly.
● Install rear swing arm shaft [A] and do not tighten it

too tightly;
402
●Install the rear lower mounting bolt of engine [A], and
do not tighten it too tightly;
●Install the front mounting bolt of engine [A], and do

not tighten it too tightly;
●Tighten the bolts, screws or nuts as follows:

○Step I: Lock the rear swing arm shaft
○Step II: Lock the rear lower mounting bolt of engine
○Step III: Lock the front mounting bolt of engine
○Step IV: Lock the left engine bracket screw and the
right engine bracket screw.
○Step V: Mark each fastening bolt, screw and nut that
locked to the specified torque.
Remarks
○ Fasten the mounting bolts, screws or nuts in three
steps
○Locking torque:
Rear swing arm shaft: 108 N·m
Rear lower mounting bolt of engine: 45 N·m
Front mounting bolt of engine: 45 N·m
Left bracket mounting screw of engine: 40 N·m
● Properly arrange the wire, cable and hose (see
"Appendix" - "Winding Method of Cables, Wires and
Hoses" for details).
●Adjustment:
○ Throttle cable (see “Periodic Maintenance” –
“Checking Throttle Control System”),
403
● Drive chain (see “Periodic Maintenance” –
“Inspection of Slackness of Drive Chain” for details)
● Fill the engine with oil (see "Periodic Maintenance" -
"Replacing Oil" for details),
●Add coolant to the engine and drain the air from the
cooling system (see "Periodic Maintenance"
-"Replacing Coolant" for details).
404
Chapter VII Electrical System
Contents
Precautions ................................................................................................................................................... 410
Special tool ...................................................................................................................................................412
Electrical wiring ...........................................................................................................................................413
Wiring check ........................................................................................................................................ 413
Charging system ...........................................................................................................................................414
Charging system circuit diagram ......................................................................................................... 414
Battery ..................................................................................................................................................415
Disassembly of battery .................................................................................................................415
Installation of battery ................................................................................................................... 415
Activation of battery .................................................................................................................... 416
First charge ...................................................................................................................................417
Inspection of charging state ......................................................................................................... 419
Alternator ............................................................................................................................................. 421
Disassembly of alternator ............................................................................................................ 421
Inspection of alternator ................................................................................................................ 422
Installation of alternator ...............................................................................................................422
Voltage regulator/rectifier .................................................................................................................... 423
Disassembly of rectifier ............................................................................................................... 423
Inspection of circuit at main wiring terminal .............................................................................. 423
Inspection of rectifier ...................................................................................................................423
Installation of rectifier ................................................................................................................. 423
Ignition system .............................................................................................................................................424
Ignition system circuit diagram ........................................................................................................... 424
Precautions for operation ..................................................................................................................... 424
Crankshaft sensor .................................................................................................................................425
Disassembly of crankshaft position sensor ..................................................................................425
Inspection of crankshaft position sensor ..................................................................................... 425
Ignition coil .......................................................................................................................................... 426
Disassembly of ignition coil: ....................................................................................................... 426
Inspection of ignition coil ............................................................................................................ 426
Installation of ignition coil ...........................................................................................................426
Spark plug ............................................................................................................................................ 427
Inspection of spark plug ...............................................................................................................427
Inspection ..................................................................................................................................... 427
Inspection of IC igniter ................................................................................................................ 428
ECU unit .............................................................................................................................................. 428
Ignition system troubleshooting .......................................................................................................... 429
Starter system ...............................................................................................................................................430
405
Starter system circuit diagram ............................................................................................................. 430
Starter motor ........................................................................................................................................ 431
Disassembly of starter motor ....................................................................................................... 431
Inspection of starter motor ...........................................................................................................431
Inspection of brush .......................................................................................................................431
Cleaning and Inspection of commutator ......................................................................................432
Inspection of brush lead ...............................................................................................................432
Inspection of right end cover assembly ....................................................................................... 433
Installation of starter motor ......................................................................................................... 433
Starter relay .......................................................................................................................................... 434
Disassembly of starter relay .................................................................................................................434
Inspection of action of starter relay ..................................................................................................... 434
Installation of starter relay ................................................................................................................... 434
Lighting system ............................................................................................................................................435
Headlight ..............................................................................................................................................435
Disassembly of headlight relay controller ...................................................................................435
Inspection of headlight relay controller .......................................................................................435
Installation of headlight relay controller ..................................................................................... 435
Disassembly of headlight .............................................................................................................436
Replacement of headlight bulb .................................................................................................... 436
Replacement of night light bulb .................................................................................................. 436
Installation of headlight ............................................................................................................... 436
Turn signal light ................................................................................................................................... 436
Disassembly of front turn signal light ......................................................................................... 436
Disassembly of rear turn signal light ...........................................................................................437
Replacement of turn signal light bulb ..........................................................................................437
Installation of turn signal light .....................................................................................................437
Disassembly of flasher .................................................................................................................437
Inspection of flasher .....................................................................................................................438
Installation of flasher ................................................................................................................... 438
Taillight ................................................................................................................................................ 438
Disassembly of taillight ............................................................................................................... 438
Replacement of taillight bulb .......................................................................................................439
Installation of taillight ..................................................................................................................439
License plate light ................................................................................................................................ 439
Disassembly of license plate light ............................................................................................... 439
Replacement of license plate light bulb .......................................................................................439
Installation of license plate light ..................................................................................................439
Meters ...........................................................................................................................................................440
Disassembly of meter ...........................................................................................................................440
Installation of meter ............................................................................................................................. 441
Switch and sensor and other parts ................................................................................................................442
Power lock switch ................................................................................................................................ 442
Disassembly of power lock ..........................................................................................................442
Inspection of power lock ............................................................................................................. 442
Installation of power lock ............................................................................................................ 442
406
Handlebar switch ................................................................................................................................. 443
Switch state (non-headlights are always on) ............................................................................... 443
Switch state (headlights are always on) .......................................................................................444
Inspection of time for turning on brake light .......................................................................................445
Adjustment of time for turning on the brake light ...............................................................................445
Inspection of switch ............................................................................................................................. 445
Connection of rear brake light switch ..........................................................................................445
Connection of sidestand switch ................................................................................................... 445
Speed sensor .........................................................................................................................................446
Disassembly of speed sensor ....................................................................................................... 446
Inspection of speed sensor ........................................................................................................... 446
Installation of speed sensor ..........................................................................................................447
Oxygen sensor ......................................................................................................................................448
Disassembly of oxygen sensor .....................................................................................................448
Inspection of oxygen sensor ........................................................................................................ 448
Installation of oxygen sensor ....................................................................................................... 448
Fuel level sensor .................................................................................................................................. 449
Disassembly of fuel level sensor ................................................................................................. 449
Inspection of fuel level sensor ..................................................................................................... 449
Installation of fuel level sensor ....................................................................................................449
Horn ......................................................................................................................................................450
Disassembly of horn .................................................................................................................... 450
Inspection of horn ........................................................................................................................ 450
Installation of horn .......................................................................................................................450
Fan ........................................................................................................................................................451
Disassembly of fan .......................................................................................................................451
Inspection of fan .......................................................................................................................... 451
Installation of fan ......................................................................................................................... 452
Water temperature switch .................................................................................................................... 453
Disassembly of water temperature switch ...................................................................................453
Inspection of water temperature switch .......................................................................................453
Installation of water temperature switch ..................................................................................... 453
Relay and fuse box ...............................................................................................................................454
Disassembly of relay and fuse box .............................................................................................. 454
Inspection of relay circuit ............................................................................................................ 455
Inspection of relay circuit (disconnect battery) ........................................................................... 455
Inspection of relay circuit (with battery) ..................................................................................... 455
Internal circuit of relay box ......................................................................................................... 456
Fuse ...................................................................................................................................................... 458
Disassembly of fuse ..................................................................................................................... 458
Installation of fuse ....................................................................................................................... 459
Inspection of fuse .........................................................................................................................460
407
Precautions
process of overhauling the electrical system. Learn and
follow all of the following rules.
○ Do not reverse the positive and negative terminals of
battery, otherwise, the diodes of electrical
components may be burned out.
○ Check the battery status before checking other parts
of the electrical system. The battery must be fully
charged before conducting accurate electrical
system testing.
○The electrical components should be protected from
severe impact by hammers, and are not allowed to
fall on hard surfaces. This impact on electrical
components may cause damage.
○To prevent damage to electrical components, do not
disconnect the battery cable or any other
electrical connections while the ignition switch is
on or while the engine is running.
○ When the starter motor cannot rotate due to large
current, do not press the start button all the time,
otherwise, the current may burn out the starter
motor coil.
○ Be careful not to short connect the cable between the
positive terminal of battery and the ground wire
of frame.
○Sometimes a fault may involve one project, and
sometimes it may involve all projects. Do not
replace the faulty part if the exact cause of fault is
not found. If the fault is caused by other causes, it
must be repaired or replaced immediately,
otherwise, the new parts may be damaged again.
○ Ensure that all circuit connectors are clean and tight,
and check the wires for signs of burnout or wear.
Broken wires and poor contact may affect the
operation of power system.
○Measure the coil and winding resistance after the
component is cooled (at room temperature)
408
Item Normal
Battery
identity Maintenance-free battery
Model YTX7L-BS
Capacity 12 V 6 Ah
Voltage 12V
Charging System
identity Three-phase alternating current
Alternator output voltage 55V or higher at 5000 r/min (rpm)
Stator coil resistance 0.05 to 0.5 Ω (normal temperature of 20℃)
Charging voltage 14〜15V
(Regulator / rectifier output voltage)
Ignition System
Crankshaft position sensor resistance 150±10Ω
Ignition coil:
Primary coil resistance 0.58Ω±10%
Primary coil resistance 8.kΩ±15%
Primary maximum operating voltage 15V
Spark plug:
identity CR8E
Clearance 0.7 〜0.8 mm
Electric Starting System
Starter motor:
Brush length 10 mm (lifetime: 5.0 mm)
Commutator diameter 28 mm (lifetime: 27 mm)
Meter, gauge, indicating device
Power voltage of speed sensor About 12 V
Switch and Sensor
Rear brake light switch actuation clearance Turn it on after the pedal stroke is up to about 20mm
Engine oil pressure switch connector Engine is stopped: ON
Engine is running: OFF
Water temperature sensor resistance In the text
Fuel level sensor component:
Full fuel level 9 〜11 Q
Empty fuel level 213 〜219 Q
409
Special tool
Multimeter: Needle meter probe:
410
Electrical wiring
Wiring check
● Visually check signs such as wire melting and wear.
★ If the wire is broken, the damaged wire must be
replaced.
● Pull out each joint [A] to check for corrosion, dirt
and damage.
★ If the joint is corroded or dirty, carefully clean it. If
the connector is damaged, replace it.
● Check whether the circuit is normal.
○ Use the wiring diagram to find the power cable
terminal that may be defective.
○ Connect the multimeter between the power cable
terminals.
Special tool - multimeter:
○ Set the multimeter to the x 1Ω range and read the
multimeter reading.
★ If the multimeter has no reading and display 0 Ω,
there is a problem with the power cable. Replace the
lead and main cable [B] if necessary.
411
Charging System
Charging system circuit diagram
412
Battery
Disassemble battery
●Turn off the power lock
●Remove seat cushion (see "Frame" - "Removing Seat
Cushion")
● Remove right cover (see “Frame” – “Removing
Right Cover” for details).
● Remove the negative electrode of battery
*Note
○ Make sure to disconnect the negative electrode (-)
of cable first
● Remove the positive electrode of battery
● Remove the battery strap [A].

● Take the battery [B] out of the battery holder.
Install battery
●Load the battery into the bracket
●Connect the negative electrode (-) of cable to the battery
● Apply a thin layer of grease to the terminals to prevent
corrosion
●Connect the positive electrode (-) of cable to the battery
● Cover the (+) terminal block with the red cover [A]
● Install the battery cover on the battery and hook the strap
●Connect connector
●Connect the negative electrode (-) of cable to the frame
413
Activation of battery
●Fill the electrolyte
○ Make sure that the model number [A] marked on the
electrolyte bottle matches the model number [B] of the
battery. These models must be the same.
Battery model: YTX7L-BS
WARNING
Always use the same type of electrolyte as the one
marked on the battery. Because of different
battery types, the volume and density of the
electrolyte used are different. This is to prevent
overfilling the electrolyte and shorten battery life
and battery performance.
WARNING
Do not tear the aluminum sealing piece [A] from the
filling port [B] before use. Ensure that a dedicated
electrolyte storage container is used to ensure the
correct volume of electrolyte is filled
○ put the battery on the horizontal surface
○ Check the seal for peeling, cracks or holes
○Removing the sealing strips
*Note
○ The battery is vacuum sealed. If the seal leaks air
into the battery, the first charge may take longer.
●Take out the electrolyte bottle from the plastic bag
●Remove the strip cover [A] from the container and
set it aside, and later use these to seal the battery later.
*Note
Do not puncture or open the seal layer [B] of
electrolyte bottle. Do not attempt to separate a single
reservoir.
● Lay the electrolyte bottle down and place the six

sealing slots into the filling port of battery. Keep the
electrolyte bottle level and push down to puncture the
seal of all six reservoirs. As the seal reservoir is
inserted into the filling port, you will see bubbles
rising in the reservoir.
*Note
○ Do not tilt the electrolyte bottle
414
●Check the electrolyte flow
★ If there is no air bubble rising in the filling port
[A], or if the electrolyte is not completely injected into
the battery, tap the electrolyte bottle [B] for several
times.
● Keep the electrolyte bottle in this position for 20
minutes or longer. Do not remove the container from
the battery before it becomes empty. The normal
operation of battery requires all the electrolyte in the
container.
WARNING
If the electrolyte in the electrolyte bottle is not
completely injected into the battery, the battery
life may be shortened. It takes at least 20 minutes
for the electrolyte to completely fill the battery. Do
not remove the electrolyte bottle until then.
● Gently remove the electrolyte bottle from the battery
● Allow the battery to stand for 60 minutes before
charging so that the electrolyte penetrates into the
metal plate for optimum performance.
*Note
○ If the battery is charged immediately after filling,
the battery life may be shortened. Allow the battery
to stand for at least 60 minutes after filling.
First charge
● Gently cover the strip [A] cover on the filling port, do not
press it completely
●The newly activated maintenance-free battery needs to be
charged for the first time.
Standard charging: 0.9A x 5-10 hours
*Note
○ Charging rate depends on the storage time and
temperature of battery and the type of charger used
○ After the first charge, allow the battery to stand for
30 minutes, then check the voltage with a voltmeter.
If the voltage is less than 12.6V, repeat the charging
cycle.
● After charging is completed, press firmly with both hands to
make the strip cover [A] enter the battery (do not hit or beat).
When properly installed, the strip cover will be flush with the
top of battery.
WARNING
Once the strip cover is installed in the battery,
do not move the lid or add water or electrolyte to
the battery.
415
*Note
○ To ensure maximum battery life and increased customer
satisfaction, it is recommended to perform a 15-second
load test on the battery at the speed that is three times
greater than the ampere-hour rate of battery. Recheck the
voltage; if it is less than 12.6V, repeat the charge cycle and
load test. If it is still below 12.6V, the battery is faulty.
Precautions
1) It is not required to replenish liquid
This battery does not require replenishing liquid and can
be used before the end of its life under normal use. It is very
dangerous to pry up the sealing cap and add water. Never do
this.
2) Replenish power
If the engine fails to start, the horn sound is very weak
and the lights are dim, which means that the battery has lost
power. Replenish the power for 5-10 hours using the
charging current specified in the instruction manual (see the
section "Replenishment of Power").
If a fast charge is necessary, strictly follow the maximum
charge current and time conditions indicated on the battery.
WARNING
If the charge is replenished according to the method
specified above, quality problems will not be caused to
the battery under normal conditions. However, if the
charging is not performed under the conditions
described above, the performance of battery will be
greatly degraded. Do not disassemble the seal cap
during the period of replenishing the power.
If excessive gas is inadvertently generated due to
overcharging, the safety valve will release gas to keep
the battery normal.
3) When you do not use a motorcycle for more than one
month
Recharge the battery before storing it, then remove the
negative cable. The power shall be replenished once a month
during storage.
4) Battery life
If the engine still fails to start after the battery power has
been replenished for several times, the battery has exceeded
its service life. The battery needs to be replaced at this point
(but first make sure there is no problem with the starting
system of motorcycle).
416
WARNING
Keep the battery away from sparks and open flames
during charging as the battery may release an explosive
gas mixture containing hydrogen and oxygen. When
using the battery charger, you need to connect the
battery to the charger before turning on the charger.
This process can prevent causing sparks at the battery
terminals and avoid igniting any battery gas.
There should be no fire source near the battery,
otherwise, any locked terminals should not be loosened.
The electrolyte contains sulfuric acid. Be careful not to
let it touch your skin or eyes. If case of skin or eye
contact, rinse using a plenty of water. If the situation is
serious, seek medical attention.
Exchange
Full play can be given to the performance of
maintenance-free battery only when it is connected to a
suitable vehicle electrical system. Therefore, the battery can
be replaced with a maintenance-free battery when the
motorcycle is originally equipped with a maintenance-free
battery.
Inspection of charging state
● The battery can be inspected by measuring the battery
terminal voltage using a voltmeter [A].
●Disassemble battery
●Measure the voltage between battery terminals.
*Note
○ Use a digital voltmeter that can read a decimal place to
measure voltage
● If the reading is 12.6V or higher, there is no need to

replenish the battery; however, if the reading is below the
specified value, it is required to replenish the power.
Battery terminal voltage
Standard: 12.8V or above
Terminal voltage (V) [A]
Battery charging ratio (%) [B]
Need to replenish power [C]
Note [D]
Good [E]
Replenish power
417
Remove the battery [A] (see battery removal section)
● Make sure to replenish the power based on the battery
terminal voltage in the following way.
WARNING
The battery is sealed. Do not remove the sealing
cap [B] even while charging. Do not add water.
Charging is performed according to the current
and time described below.
Terminal voltage: between 11.5 and 12.6V

Standard charging: 0.9A × 5-10h (see the right figure)
Fast charging: 9A×1h
WARNING
Do not charge quickly if possible. If fast
charging is unavoidable, standard charging will
be performed later.
Terminal voltage: less than 11.5V
Charging method: 0.9A×20h
Notes
If the battery cannot be charged initially, the
charging voltage shall be increased to 25V. After
increasing the voltage, charge for no more than 5
minutes, then check whether current is flowing to
the battery. If the battery has received current, the
voltage should be reduced back to the standard
voltage and continue the operation in the ways as
described in the battery packing. If there is no
current flowing to the battery after 5 minutes, please
replace the battery.
Battery [A]
Battery charger [B]
Standard value [C]
Current begins to flow [D]
• Determine battery state after replenishing power
• After charging is completed, let the battery stand for 30
minutes and then determine the battery state by measuring
the terminal voltage according to the following table.
Normal Judgment
12.6V or above Good
12.0-less than 12.6V Undercharge→Recharge
Less than 12.0V Unavailable→Replacem
ent
● When the battery is inspected, it should be tested with a
multimeter under the state of full charge.
●After the engine is warmed up, install the fully charged
batteries.
●Connect a voltmeter between battery terminals.
●Start the engine, slowly increase the speed and measure the
limit voltage.
Limit voltage/speed: 15V (5000rpm) (DC voltage)
●When the limit voltage is not within the specified value
range, check the voltage regulator.
418
Alternator
*Note
○Check the alternator charging coil and operate at
the engine.
Remove alternator
●Alternator power cable connector
● Place a suitable container under the magnet cover
● Loosen the left cover mounting bolt and remove the
left cover and coil
● Pull the alternator power cable from the engine and
bracket
●Remove stator coil:

Alternator cover (see "Removing alternator cover)
Stator coil [A]
Stator coil bolt [B]
Alternator lead wire sleeve [C]
Bracket and bracket bolt [D]
●Remove the flywheel:

Remove alternator cover (see "Removing alternator
cover)
Use the flywheel remover to remove the flywheel
mounting bolts.
Remove it from the crankshaft using the flywheel
puller
●Remove the flywheel
419
Check the alternator
● There are three types of alternator faults: short circuit,
open circuit (wire is burnt out) or the magnetic property of
rotor disappears. A short or open circuit of coil will result in
low output or even no output. The disappearance of the
magnetic property of rotor will result in a low output that
may be caused by falling of alternator or hitting, or by being
placed near the electromagnetic field, or simply because of
aging.
● Turn off the ignition switch
●Remove alternator 3P connector.
●Use a multimeter to measure the impedance between the
three black terminals of alternator.
Standard value: 0.05 - 0.5 Ω (normal temperature of 20℃)
★ If the resistance is greater than the above, or if any two
power cord multimeters have no reading (infinite value), the
stator line is broken and must be replaced. It the value is far
below this resistance, the stator is shorted and must be
replaced.
● Measure the resistance between each black power cord
and the chassis ground wire using the maximum resistance
range of the multimeter.
★ If the tester coil is used to test whether the engine body
is conducting or not; if it is conductive, there is a short
circuit between the coil and the engine, and the charging coil
needs to be checked.
★ If the resistance of stator coil is normal, but the voltage
check indicates that the alternator is faulty, it is possible that
the rotor is magnetically weakened and the rotor must be
replaced.
●Start the engine
○Run according to the revolutions per minute (rpm) given in
Table 1.
○ Keep a record of voltage readings (total of 3
measurements)
Table 1 Output voltage of alternator
Wring
Tester Reading at
range Connect Connect 5000 rpm
tester (+) to tester (-+) to
Another
A black
750V AC black power 55V or higher
power cable
cable
★ If the value displayed on the output voltage is the value
in the table, the alternator is operating normally.
★ If the reading is much lower than the value in the table,
the alternator is faulty.
Install the alternator
● Install the parts that have been removed before in
the reverse order of disassembly.
Locking torque of stator coil bolt: 10 N·m
Locking torque of bracket bolt: 5N·m
Locking torque of alternator cover bolt: 5N·m
Locking torque of flywheel mounting bolt: 9N·m
420
Voltage regulator/rectifier
Remove rectifier
●Remove the right front panel
●Disassemble:
Joint [A]
Bolt [B]
Voltage regulator/rectifier [C]
Inspection of Circuit at Main Wiring Terminal

● Remove the body protector.
● Remove the 3P plug of the voltage and current
regulator. Check the continuity between the main
wiring terminals by the following method.
Check rectifier
1. Rotate the multimeter to: the position of diode;
2. Connect the black probe to the red terminal of
regulator, and connect the red probe to the yellow
terminals (yellow 1, yellow 2, yellow 3) of regulator
respectively. The pointer gauge will display a certain
value (within the range from 0.1 to 0.5V), otherwise, it
indicates that regulator is damaged and needs to be
replaced.
3. Connect the red probe to the green terminal of
regulator port, and connect the black probe to the yellow
terminals (yellow 1, yellow 2, yellow 3) of regulator
respectively. The pointer gauge will display a certain
value (within the range from 0.3 to 0.8V), otherwise, it
indicates that regulator is damaged and needs to be
replaced.
Install rectifier
Locking torque:
Voltage regulator mounting bolt: 10 N•m
421
Ignition System
Ignition system circuit diagram
黑/红1
Black / red 1
Black / white 1
黑/白1
白and
White 蓝 blue
/ /
ECU
Green绿白white
and
Trigger
触发头 probe
点火电源
Ignition power
Ignition system
Precautions for operation
1. Ignition system should be inspected step by step in the
order of fault diagnosis table.
2. The ignition system is an electronic automatic angle
feeding device and it has been solidified in the ECU group, so the
ignition time does not need to be adjusted.
3. Ignition system should be inspected in the order of fault
diagnosis table.
4. The main reason for ignition system fault is poor contact
of connector, so first check whether the connectors are in poor
contact.
5. Check whether the heat value of spark plug is
appropriate, because improper spark plug may cause the engine to
run unsmoothly or burn the spark plug.
6. Check the main switch according to the conduction table
of switch part. (Attached)
7. Alternator and stator should be removed according to the
disassembly instructions.
WARNING
Ignition system may generate an extremely high voltage. Do
not touch the spark plug or coil while the engine is running;
otherwise, you may be exposed to a serious electric shock.
*Note
Do not disconnect battery cable or any other electrical
connections while the ignition is on or the engine is running.
422
This is to prevent damage to ECU. Do not reverse the electrodes
of battery. The side of negative electrode should be grounded.
This is to prevent damage to ECU.
423
Crankshaft sensor
Remove crankshaft position sensor
●Crankshaft position sensor [A] cannot be
disassembled separately, because it is integrated with
alternator.
●Use the tester

*Note
The trigger can be checked on the engine.
Check crankshaft position sensor

● Remove trigger wire connector [A].
● Measure the impedance values of red and yellow
outgoing lines of engine.
Standard value: 150±10Ω (20°C)
★ If the measured resistance value is higher than the
specified value, the coil circuit is disconnected and
needs to be replaced.
★ If the resistance value is lower than the specified
value, the coil is short-circuited and must be replaced.
424
Ignition coil
Remove ignition coil:
●Remove fuel tank (see “Fuel Tank” – “Removing
Fuel Tank” for details).
Remove the spark plug cap [A].
● Remove the screws [A] on the two mounting posts

of ignition coil [B].
Check ignition coil

*Note
• When there is no spark in the spark plug, it is
necessary to check whether the parts of wiring are
loosened or in poor contact;
• There are many brands of multimeter, the internal
impedances are different and the tested values are
different.
●Check the primary coil
●Measure the impedance among the terminals of
primary coil.
Standard value: (4±0.4)Ω (20℃)
★The impedance value is good in the standard value.
★ If the impedance value is “∞”, it indicates that the
wire in the coil is disconnected and the ignition coil
needs to be replaced.
Installation of ignition coil
Locking torque:
Ignition coil mounting bolt: 6 N•m
425
Spark plug
Inspection of spark plug
●Disassemble spark plug (see section “disassembly of
spark plug”)
●Visually inspect the spark plug
○If the center electrode of spark plug [A] and/or side
electrode [A] is corroded or damaged, or insulated
terminal [C] is broken, replace the spark plug
★If the spark plug is dirty or there is carbon deposit,
replace the spark plug
○Use a wire feeler to measure the gap [D]
○If the gap is incorrect, replace the spark plug
Spark plug gap: 0.7-0.8mm
○Use standard spark plugs or their equivalents
Spark plug: CR8E
Check
●Start the engine according to the following
conditions
First check
Condition:
Transmission gear → enter the first gear
Clutch handlebar→grip
Sidestand → upper
○ Turn on the ignition switch and press the start button
○ If the starting system circuit is normal, the starter
motor will not rotate.
●If the engine is started, check the start and power-off
switch, sidestand stop switch, gear switch and relay
box.
●If the component state is normal, replace the ECU •
Start the engine according to the following conditions:
Second inspection
Condition:
Gear position → neutral position
Clutch handle → release
Sidestand → lower
○ Turn on the ignition switch and press the start button
○ Then start the stater motor, but the premise should
be that the starting system circuit is normal.
★If the starter motor does not start, check the start
switch, gear switch and relay box
★If the parts are in normal conditions, replace the
electronic control unit
Third inspection
●Check whether the engine can be safely turned off
after performing the following operations
●Run the engine according to the following conditions
Condition:
Gear position → first gear
Sidestand → up
426
● Place the sidestand on the ground, and shut down the
engine
★If any one is not shut off, check the gear switch,
starting switch, sidestand stop switch and relay box
★If the parts are in normal conditions, replace the
electronic control unit
Check IC igniter
○ IC igniter is built into the electronic control unit.
●Refer to the following items
1. Check the operation of related components
of electrical starter safety circuit related
component (see "Checking the operation of
related components of electrical starter
safety circuit")
2. Ignition system troubleshooting (see section
"Ignition System")
3. Electric control unit voltage check (see
section "Checking Electronic Control Unit
Power" in chapter "EFI System (ECU)")
ECU unit
●System inspection
●Remove ECU and check the parts at wiring terminal
related to ignition system. (See section “ECU” of
electronic injection system for details)
427
Ignition System Troubleshooting
Incorrect ignition (no spark)
Battery inspection Not good Charge or replace battery
Good
Ignition system wire and connector Not good Repair or replace damaged parts
inspection
Good
Spark plug inspection Not good Replace spark plug
Good
Primary coil peak voltage inspection Not good Replace ignition coil
Good
Primary coil peak voltage inspection Not good The voltage is lower than the specified value
Good Not good
If ignition coil fails, replace it The voltage is zero or Check: Not

almost zero good
1. Voltage of multimeter
2. Peak voltage of crankshaft sensor
3. Peak voltage of position sensor of camshaft
Not good Check: Good Replace faulty parts or check them

with a multimeter
1. The adapter is not properly connected or the adapter is
faulty
2. Ignition switch and engine switch flames out
3. Peak voltage of crankshaft sensor
4. Peak voltage of position sensor of camshaft
Good
Replace faulty parts If electronic control unit is faulty, replace it
428
Starter System
Starter system circuit diagram
Clutch
离合开关单撑熄火
switch Sidestand switch 熄火开关
Stop switch Battery
电池 Relay
继电器 Starter motor
起动马达
Start
起动开关 switch
G/Y
LG B
Dg
Gr R
B
O/R
B
G/Y
O/R
R
B
Dg
电源锁
Power lock
R/W LG/B
Gr/R R/W
G/Y
主继电器
Main relay
Neutral空档开关
position
switch
启动示意图
Start diagram
429
Starting Motor
*Note
Before disassembling starter motor, first turn off
the main switch, remove the bond strap of
battery, then turn on the power and check
whether starter motor is running to confirm
safety.
*Note
Do not tap the starter motor shaft or the body,
otherwise, it may cause damage to the motor
body.
Remove the starter motor
●Remove the starter motor cable terminal nut
●Remove the starter motor assembly bolt
● Pull out the starter motor from the left side
Check the starter motor

Run the starter motor according to the following
conditions
Condition:
Gear position → neutral position
Sidestand → lower
● Turn on the ignition switch and press the start button
○When the circuit of other starting system is normal,
the starter motor does not start.
○ Then remove the starter motor and directly connect
the positive and negative electrodes of battery. If it is
running normally, it is the problem of engine
○ engine matching: if the motor is started before the
system is running, it may be damaged.
Check the brush
●Measure the length [A] of each brush [B]
★If any brush has reached the operating limit, the
brush plate assembly should be replaced.
Starter motor brush length:
Standard: 10mm
Operating limit: 5.0 mm
430
Clean and check commutator
● If necessary, polish the commutator surface [A] with
a fine mesh gauze [B] and clean the groove
●Measure the diameter [A] of commutator [B]

★ If the diameter of the commutator is shorter than
the operating limit, replace it with the new starter
motor
Commutator diameter
Standard: 285mm
★ If the resistance between the two commutators is

high or there is no reading, the coil is open circuited
and the starter motor must be replaced.
● Use a multimeter to measure the resistance between
the commutator [A] and the shaft [B]
★ If the reading is 0, the armature is short circuited
and the starter motor must be replaced.
Check the brush lead

● Use a multimeter set to x 1Ω range to measure the
resistance, as shown in the figure
Terminal bolt and positive brush [A]
Right end cover and negative brush [B]
★ If it is not close to zero ohms, the brush lead is
open circuited It is required to replace the carbon
brush plate assembly
431
Check the right end cover assembly
● Use a multimeter set to the highest range to measure
the resistance, as shown in the figure
Terminal and right end cover [A]
★ If there is any reading, the right end cover
assembly is short circuited. Replace the right end
cover assembly
Install the starter motor

Locking torque:
Starter motor mounting bolt: 10 N•m
432
Starter relay
Remove starter relay

● Disconnect the starter motor cable from the starter
relay [A] and the negative (-) cable of battery from
the connector [A]
● Disconnect the starter motor cable from the starter
relay [A] and the positive (+) cable of battery from
the connector [B]
● Pull out the starter relay cable connector
●Disassemble:
Bolt [C]
Starter relay [D]
Inspection of action of starter relay

● Connect the multimeter and 12V battery to the
starter relay, as shown in the figure
●If the relay does not work as specified, the relay is
faulty and needs to be replaced.
Test relay
Tester range: x 1 Ω range
Standard: When the battery is connected 0Ω
When the battery is disconnected →
∞Ω
Install starter relay

Locking torque:
Starter relay mounting bolt: 10 N•m
433
Lighting System
Headlight
Disassemble headlight relay controller
● Disassemble the headlight relay controller and cable
connector [A], and remove the headlight relay
controller [B].
Check headlight relay controller

● Set the multimeter to the x 1Ω range and measure, as
shown in the figure
Headlight relay controller [A]
12V battery [B]
Special tool - multimeter [C]:
★ If the tester reading is not the specified value,
replace the headlight relay controller.
WARNING
Only multimeter can be used in the test. If you use a
high resistance meter or a meter with a high capacity
battery, the headlight relay controller may be
damaged.
Test headlight relay controller
Standard: When the battery is connected 0Ω
When the battery is disconnected → ∞Ω
Install headlight relay controller
434
Remove headlight
●Remove headlight [A] (see "Frame" - "Removing
Cowling" for details).
Replace headlight bulb

● The headlight source is an LED, and the headlight
needs to be replaced as a whole.
Replacement of headlight bulb
● The headlight source is an LED, and the headlight
Install headlight
● After installation, adjust the condensed Light of
headlight (see “Periodic Maintenance" - "Checking
Headlight Condensed Light” for details)
Locking torque:
Headlight mounting bolt: 10N·m
Turn signal light

Remove front turn signal light
●Remove front left turn signal light [A] (see "Frame" -
"Removing Front Left Panel" for details).
435
●Remove front right turn signal light (see "Frame" -
"Removing Front Right Panel" for details).
●Remove rear turn signal light

●Remove rear left and right turn signal lights [A]
(see "Frame" - "Removing Rear Damper" for details)
(in the state of no side case).
●Remove rear left turn signal light [A] and rear right
turn signal light [B] (in the state of side case).
Replacement of Turn Signal Light Bulb

● The front rear turn signal light source is an LED, and
the turn signal light needs to be replaced as a whole.
Install turn signal light
Remove flasher
●Remove rear seat cushion (see "Frame" - "Removing
Rear Seat Cushion")
436
●Remove the connector [A] between flasher and
cable, and remove the flasher [B].
Check flasher
● Connect a 12V battery and install and connect the
turn signal light as shown in the figure to calculate
how many times the light has flashed within one
minute.
Flasher [A]
Turn signal light [B]
12V battery [C]
★ If the light does not flash, replace the flasher
Test flasher
Load Number of time the
Quantity of Watt (W) light has flashed
turn signal (c/m*)
lights
1** 21 or 23 140~250
2 42 or 46 75~95
*: cycle per minute
**: means that "one light is burned out"
Install flasher
Taillight
Remove taillight
●Remove rear rack (see "Frame" - "Removing Rear
Rack and Side Case Bracket" for details).
●Remove side cover [A] (see "Frame" - "Removing
Side Cover" for details).
437
● Remove the self-tapping screws [A], disconnect the
taillight cable connector, and remove the taillight [B].
Replacement of taillight bulb

● The taillight source is an LED, and the taillight
Install taillight
License plate light

Remove license plate light
● Remove the self-tapping screws [A], disconnect the
license plate light cable connector and remove the
license plate light [B].
Replacement of license plate light bulb

Rear license plate light cable [A].
● Remove license plate light bulb [B].
Specifications of license plate light bulb: W5W/12V
Install license plate light

● Replace the license plate light bulb with a new one.
438
Gauge
Remove meter
●Remove windshield mounting bracket [A] (see
"Frame" - "Removing Windshield Mounting Bracket"
for details).
● Remove the screw [A], disconnect the meter cable

connector and remove the meter mounting plate [B].
●Remove the screw [A], and take down the meter.
●The meter of this motorcycle is liquid crystal. If the

meter is faulty or damaged, please replace it as a
whole.
439
Install meter
Locking torque:
Meter mounting bolt: 10 N·m
440
Switch and Sensor and Other Parts
Power lock switch

Remove power lock
●Remove the screw for installing the cover of upper
bracket [A], and remove the cover of upper bracket
[A].
● Remove the power lock mounting screw [A]。

●Remove the main switch wire connector.
●Remove power lock.
Check power lock

●Check the conduction of connector terminal.
★ If it does not match the continuity meter, please
replace the main switch
Schematic wiring
diagram
Line color
Red Red/white
Gear
Install the power lock

Locking torque:
Upper bracket cover mounting screw: 10 N·m
Power lock mounting screw: 10 N·m
441
Handlebar Switch
Switch state (non-headlights are always on)
1. Light control switch
2. Stop switch
3. Starting switch
Red Orange Yellow Blackish Green / blackish
/white / blue / red green yellow green Red
4. Dimmer switch
5. Steering switch
6. Horn switch
7. Passing switch
Dimmer switch Steering switch Horn button
Blue Yellow Light Red / Green / Oran Green Red and Brown
/ red blue white black ge /white white
442
Switch state (headlights are always on)
1. Warning switch
2. Stop switch
3. Starting switch
Green Green and
Orange Stop switch
and white black
Dark Start switch
Red
green
Green and Dark
yellow green
4. Dimmer switch
5. Steering switch
6. Horn switch
7. Passing switch
Dimmer switch Steering switch Horn button
Blue Yellow Light Red / Green / Oran Green Red and Brown
/ red blue white black ge /white white
443
Inspection of time for turning on brake light
● Refer to the "Checking Brake Light Switch
Operation" in the chapter "Periodic Maintenance".
Adjust the time for turning on the brake light

● Refer to the "Checking Brake Light Switch
Operation" in the chapter "Periodic Maintenance".
Check switch
● Use a handheld multimeter to check whether only
the switches in the table have been turned on
○ For the switch housing and main switch, refer to the table in
the wiring diagram section
★ If the switch is open or shorted, repair or replace it
with a new switch
Connect the rear brake light switch
Connect the rear brake light switch
Color BR BL
When the brake pedal
is pressed
is released
Connect the sidestand switch

Connect the sidestand switch
Color BK G
is pressed
is released
444
Speed sensor
Remove speed sensor

WARNING
Do not drop the sensor, especially on a hard
surface. The shock of impact may cause damage
to the sensor.
●Disassemble:
Bolt [A]
Front wheel speed sensor [B]
●Disconnect the speed sensor connector
●Disassemble:
Bolt [A],
Rear wheel speed sensor [B]
●Disconnect the speed sensor connector
Check the speed sensor

● Remove the speed sensor (see the "Removing Speed
Sensor")
●Connect the speed sensor connector [A] and battery
[B], 10kΩ resistor [C] and handheld multimeter [D], as
shown in the figure
●Set the multimeter to the range of DC 20V (digital
multimeter)
445
● Use a screwdriver to slide over the entire surface of
speed sensor, and adjust the end voltage from the
battery voltage value to about 0-1V
Install speed sensor

446
Oxygen sensor
Remove oxygen sensor
WARNING
surface. The shock of impact may cause damage
to the sensor.
● Disconnect the oxygen sensor connector.
●Remove the oxygen sensor [A].
Check oxygen sensor

● See section “Checking Oxygen Sensor” in the
chapter “Fuel System (EFI)”.
Install oxygen sensor
WARNING
Do not drop the oxygen sensor [A], especially on a
hard surface. The shock of impact may cause
damage to the sensor. Do not touch the sensing part
[B] of sensor to prevent it from being polluted with
oil stains. Oil on your hands may affect sensor
performance.
● Tighten:
Torque-oxygen sensor: 25 N·m
● Operate the oxygen sensor wires correctly (see
section "Arrangement of Cables, Wires and Hoses" in
Chapter "Appendixes")
447
Fuel level sensor
Remove fuel level sensor
● Remove the four tightening nuts [A] and remove the
fuel level sensor [B] and the fuel level sensor seal [C].
○Check sensor seal
★If the sensor seal is found to be broken or swelled, it
must be replaced!
Check fuel level sensor

● Check whether the fuel sensor float is moving
smoothly and not stuck. It should move downwards
under its own weight.
★ If the float does not move smoothly, the sensor
must be replaced.
When the float is in the position of "full" [A]
When the float is in the position of "empty" [B]
Floating arm stopper [C]
● Use the hand-held multimeter [A] to measure the

resistance around the terminal of fuel level sensor
connector [B].
Special tool - handheld multimeter:
Pointer adapter device:
★ If the multimeter reading does not meet the
requirements, or does not change smoothly according
to the up and down movement of the float, replace the
sensor.
Fuel level sensor component
Standard: full fuel level [C]: 5-12Ω
Empty fuel level: 96-103Ω
Installation of fuel level sensor
Locking torque:
Fuel level sensor mounting nut: 10 N·m
448
Horn
Disassemble horn
Remove the horn wire.
●Remove the horn mounting bolt [A] and remove the
horn.
Check the horn

● The external horn is connected to the battery, and it
is good if a sound is made.
Resistance: 1.4Ω
Install horn
Locking torque:
Horn mounting bolt: 22N·m
449
Fan
Remove the fan
●Remove radiator fan (see “Removing Radiator and
Radiator Fan” in chapter "Radiator" for details),
●Disassemble:
Radiator fan mounting bolt [A]
Radiator fan [B]
Check the fan

●Check the fan blades [A],
★ If fan blade is damaged, change the fan component
● First confirm whether the copper part inside the fan

connector is loosened;
★ If not, connect the fan to the positive and negative
electrodes of power supply separately, as shown on the
right (the blue one is connected to positive electrode of
battery, and black one is connected to the negative
electrode of battery).
● Check whether the fan is rotating and the wind is
blowing toward the mounting bracket. If it is not
rotating, replace the fan;
★ If the direction of rotation is not correct, you need
to change the harness connection position.
450
● Detect the fan motor using the "Ω" range of
multimeter, as shown on the right
★ If “∞” is displayed, the motor is damaged and the
fan component needs to be changed
Install the fan

Locking torque:
Fan mounting bolt: 10 N•m
451
Water temperature switch
Remove the water temperature switch
● Remove right front cover (see “Frame” –
“Removing Right Front Panel” for details).
● Unplug the water temperature switch connector.
● Use an open-end wrench to remove the water
temperature switch [A].
Check the water temperature switch

Conduction temperature: 98±4°C, 9°C≥ on
temperature—off temperature≥3°C
Install the water temperature switch

the reverse order of disassembly. Locking torque:
Water temperature switch: 15 N·m
452
Relay and fuse box
Remove relay and fuse box
● The relay is directly on the wire harness.
● The relay [A] is in the rear end cover area on the

right side of the motorcycle.
●Open the upper cover when disassembling

● Pull out No. 2 with relay [A]
453
● Unscrew the mounting bolts with five large socket
head wrench
●Remove the relay
*Note
The relay is equipped with a diode. The relay diode
cannot be removed
WARNING
surface. The shock on relay may cause damage to
it.
Inspection of relay circuit:
● Disassemble the relay (see the section "Removing
relay").
• Check the conductivity of the terminals with the
following numbers by connecting a hand-held
multimeter and a 12V battery to the relay (see the
internal circuit of relay box in this section).
★ If the reading of multimeter does not meet the
requirements, replace the relay box.
Check relay circuit (disconnect battery)

Connect the Reading of
multimeter multimeter (Ω)
Fuel pump 3-4 ∞
relay 1-2 Not ∞*
7-8 ∞
Main relay
5-6 Not ∞*
11-12 ∞
Light relay
9-10 NOT ∞*
*: Actual readings may vary depending on the handheld multimeter used.
Check relay circuit (with battery)

Battery Connect
Multimeter
connection the
reading (Ω)
(+) (-) multimeter
Fuel
pump 1-2 3-4 0
relay
Main
5-6 7-8 0
relay
Light
9-10 11-12 0
relay
(+): Connect the positive wire
(-): connect the negative wire
454
Internal circuit of relay box
11
10
12
9
8
7
6
5
4
3
2
1
Gr/R
G/R
LG/B
R/W
R/W
B/R
R/W
Y/R
Dg
LR
LR
B
1油泵继电器 2 Main relay 33灯光继电器

1 Fuel pump relay 2主继电器 Light relay
● State 1: relay
455
● State 2: relay
●The headlights are not always on. The relay of the
motorcycle does not contain the No. 3 relay in the state
1. Others are the same as the above-mentioned export
inspection methods.
456
Fuse
Remove the fuse
●Remove seat cushion (see "Frame" - "Removing Seat
Cushion")
● Remove right cover (see “Frame” – “Removing
Right Cover” for details).
● Main fuse [A]
●Open the buckle [A] and lift the cover
● Use a needle-nosed pliers to pull the main fuse [A]

out of the fuse holder in a straight line
Fuse: 30A
457
●Fuse box [A]
●Open the buckle and lift the cover [A] .

● Use a needle-nosed pliers to pull the main fuse [B]
out of the fuse holder in a straight line
Fuse line, as shown in the right figure

A. Power lock: 15A (blue)
B. ABS: 15A (blue)
C. ECU: 15A (blue)
D. ABS：10A (red)
E. Fuel pump: 10A (red)
F. Fan: 10A (red)
G. Spare fuse 10A (red)
H. Spare fuse 15A (blue)
I. Spare fuse 15A (blue)
Installation of fuse
★ If the fuse fails during operation, check the
electrical system to determine the cause and replace it
with a one of suitable amperage
● Install the fuse box on the cover in the original
position as specified.
458
Check the fuse
● Disassemble the fuse (see the section "Removing
Fuse").
●Check the fuse parts
★ If the fuse is burnt out, replace it with a new one.
Check the amperage of the affected circuit before
replacing the blown fuse. If the amperage is equal to or
greater than the rated current of the fuse, check the
wiring and related components to check whether it is
shorted.
Housing [A]
Fuse component [B]
Joint [C]
Blown fuse [D]
Notes
○If the battery is seriously undercharged, the fuse
may be burnt out by a large current after starting the
engine.
WARNING
When replacing the fuse, make sure that the new
fuse matches the rated current of specified fuse in
the circuit. If a fuse whose current is higher than
the rated value is installed, damage may be
caused to the line or components.
459
Chapter VIII Appendixes
Contents
Winding method of cables, wires and hoses ................................................................................................463

Alignment of main cable: .................................................................................................................... 464
Alignment of clutch: ............................................................................................................................ 471
Alignment of brake pipe: ..................................................................................................................... 473
Other matters: .......................................................................................................................................476
Troubleshooting guide ................................................................................................................................. 479
Diagnostic procedure for the fault that engine cannot be started or it is difficult to start the engine: 479
Starter motor does not work: ....................................................................................................... 479
The starter motor is rotating, but the engine does not work: .......................................................479
The engine does not run: ..............................................................................................................479
Fuel does not flow: ...................................................................................................................... 479
No sparks; sparks are weak: ........................................................................................................ 479
Too low cylinder pressure: ...........................................................................................................480
It cannot run properly at a low speed: ................................................................................................. 480
Sparks are weak: .......................................................................................................................... 480
Others: ..........................................................................................................................................481
It cannot run properly at a high speed or the power is insufficient: ....................................................481
Others: ..........................................................................................................................................482
The temperature is too high: ................................................................................................................ 482
The muffler is overheated: ...........................................................................................................482
The cylinder pressure is high: ......................................................................................................482
The output force of engine is insufficient: ...................................................................................482
Not properly lubricated:.................................................................................................................482
The fuel cooler is abnormal: ........................................................................................................ 482
The coolant is abnormal: ............................................................................................................. 482
Overcooling: .........................................................................................................................................483
460
The clutch is not working properly: .....................................................................................................483
The clutch is slipping: ..................................................................................................................483
The clutch cannot be separated properly: .................................................................................... 483
There is a problem with shifting: .........................................................................................................483
It is unable to operate the gear smoothly; control pedal cannot be reset: ................................... 483
Jump ............................................................................................................................................. 483
Excessive speed change: ..............................................................................................................484
The engine makes an unusual noise: ................................................................................................... 484
The piston makes a sound: ...........................................................................................................484
The valve makes noise: ................................................................................................................484
The drive system makes an unusual noise: ..........................................................................................484
Clutch makes a noise: .................................................................................................................. 484
The drive device makes a noise: ..................................................................................................484
The drive system makes a noise: ................................................................................................. 485
The frame makes an unusual noise: .....................................................................................................485
The front fork makes a noise: ...................................................................................................... 485
The rear shock absorber makes a noise: ...................................................................................... 485
The brake disc makes a noise: ..................................................................................................... 485
Other noises: ................................................................................................................................ 485
Excessive exhaust gas: .........................................................................................................................485
White exhaust: ............................................................................................................................. 485
Black exhaust: ..............................................................................................................................485
Brown exhaust:.............................................................................................................................. 485
Poor performance and / or stability: .................................................................................................... 485
It is difficult to rotate the handlebar: ........................................................................................... 485
The handlebars vibrate or shake severely: ...................................................................................485
The handlebar is placed on one side: ...........................................................................................486
The damping effect is not ideal: .................................................................................................. 486
Brake is unable to work properly ................................................................................................ 486
Battery has failed: ................................................................................................................................ 486
Battery has run out: ......................................................................................................................486
Battery is overcharged: ................................................................................................................ 486
Circuit Diagram ............................................................................................................................................487
461
●Winding method of cables, wires and hoses
462
Alignment of main cable:
Arrange the main cable along the

left of headlight bracket and fix it
using strapping tapes

left of headlight bracket
463
Arrange the main cable along the right of
headlight bracket and fix it using
strapping tapes
Arrange the main cable along the right

of headlight bracket and fix it using
strapping tapes
464
Arrange the main cable along the right of headlight
bracket and fix it using strapping tapes; go into the
inside of frame from the right frame tripod

inside of frame and fix it on the
frame using strapping tapes
465
Arrange the main cable at the right of frame
along the frame and fix it with the main cable
Arrange the main cable at the right of frame

along the frame and fix it with the main cable
466
Arrange the main cable along the right lower
side of frame and fix it using strapping tapes
Arrangement of
main cable
467
Fix the main cable on the stiffened pipe of
frame using strapping tapes
Prevent the positive and negative electrodes

of battery from contacting the frame
468
Prevent the positive and negative electrodes
of battery from contacting the frame
Fix the voltage regulator and other joints using

strapping tapes
469
Alignment of clutch:
470
Arrange the clutch along the lower right
inner side of frame
471
Alignment of brake pipe:
Arrange ABS oil pipe along the

inner side of water tank
Fix the ABS on the lower bracket

using a clamp
472
Fix ABS connector using
strapping tapes on ...
Fix the brake hose using strapping tapes; go into the

473
Fix ABS connector using
strapping tapes on ...
Fix the brake hose using strapping tapes; go into the

474
Arrangement of rear Arrange the rear brake hose and rear speed sensor cable
brake hose along the right side of rear rocker arm; fix it using
strapping tapes
Other matters:
475
Arrangement of rear brake hose
Fix the oil hoses using strapping
tapes
Fix leaking water pipe on the pipe clamp

of frame
476
The installation
direction of fuel
level sensor is
shown in the figure
Connect canister to canister solenoid valve pipe: 5×9×150

Connect canister to down valve pipe: 4.5×8.5×300
Connect canister solenoid valve to engine inlet pipe: 5×9×100
MAP pipe: 4.5×8.5×100
Connect fuel tank to down valve pipe: 4.5×8.5×220
Connect coolant reserve tank to water fuel pipeline: 7×11×240
477
Troubleshooting Guide
Remarks
○ For most of the faults of EFI, see the chapter “EFI”.
○ This table is not exhaustive. It is not possible to list
the possible causes of each problem. It can only be used
as a basic guide to help solve some common problems.
Diagnostic procedure for the fault that engine cannot be started or it is difficult
to start the engine:

Starter motor does not work:
The main switch or engine stop switch is not turned on;
The starter lock switch or the gear switch has failed;
The starter motor has failed;
Battery voltage is low;
The starter relay is in poor contact or cannot operate normally;
The contact of start button is poor;
The starting system circuit is shorted or open;
The main switch has failed;
The engine stop switch has failed;
30 A main fuse or main switch fuse is burnt out
The starter motor is rotating, but the engine does not work:
Motorcycle rollover sensor (EFI) is working;
The anti-theft control system has failed;
The overrunning clutch has failed;
The starting idler gear has failed.
The engine does not run:
The valve is seized;
The valve ejector rod is seized;
Cylinder and piston are seized;
Crankshaft is seized;
The small end of the connecting rod is seized;
The big end of the connecting rod is seized;
The drive gear or bearing is seized;
Camshaft is seized;
Starting idler gear is seized;
Balance shaft bearing is seized;
Fuel does not flow:
There is no fuel in the fuel tank;
The fuel pump has failed;
The tank vent is blocked;
Check whether the fuel filter is blocked;
Fuel hose is blocked
No sparks; sparks are weak:
Motorcycle rollover sensor (EFI) is detached;
The main switch is not rotated to "ON".
The engine stop switch is not rotated to "OFF";
The clutch handle is not pinched or the gear position is not in the neutral position;
□The spark plug is dirty, broken or the gap is improper;
Spark plug is not applicable
Short circuit or poor contact of ignition coil;
The ignition coil has failed;
478
The engine control unit (ECU) has failed;
The camshaft position sensor has failed;
The gear switch, starting lock switch or sidestand switch has failed;
The crankshaft sensor has failed;
The main switch or engine stop switch is short circuited;
The starting system circuit is shorted or open;
Main fuse or main switch fuse is burnt out
There is a problem with the fuel/air mixture:
Bypass screw and / or idle adjustment screw is out of
order;
Air duct is blocked;
Air filter is clogged, poorly sealed or missing;
The oil filling port cover, crankcase vent pipe or air
filter drain pipe leaks;
Too low cylinder pressure:
The spark plug is loosened;
The cylinder head is not tightened;
The cylinder or piston is worn;
The piston ring is damaged (worn, weakened, damaged or stuck);
The clearance between piston ring and piston ring groove is too large;
The cylinder head gasket is damaged;
The cylinder head is deformed;
Valve spring is damaged or or its elasticity is poor;
There is no valve clearance;
The valve is not installed properly (valve bending, wear or carbon deposits on the valve seat)
It cannot run properly at a low speed:

Sparks are weak:
The ignition coil has failed;
The spark plug is dirty, broken or the clearance is improper;
Spark plug is not applicable;
The camshaft position sensor has failed;
The crankshaft sensor has failed
Bypass screw is not adjusted properly;
Air duct is blocked;
Exhaust pipe or vent hole is blocked;
The idle air way is blocked;
Air filter is clogged, leaking or missing;
The tank vent is blocked;
Throttle valve assembly holder is loosened;
Breather pipe holder is loosened
The cylinder pressure is low:
The cylinder head is not tightened firmly;
The piston ring is damaged (worn, weakened, damaged or stuck);
The clearance between piston ring and piston ring groove is too large;
479
The valve is not installed properly (valve bending, wear or carbon deposits on the valve seat)
Camshaft or cam is worn
The main switch continues to run after being cut off:
The engine stop switch has failed;
Fuel injector has failed;
The negative terminal (-) of battery or the engine control unit (ECU) ground wire is loosened;
There is carbon deposit on the valve seat;
Engine overheating
Others:
The negative pressure value of throttle valve is out of balance;
The oil viscosity is too high;
The drive system has failed;
Brake drags;
The clutch is slipping;
Engine overheating;
Air suction valve has failed;
Secondary air compensating valve has failed
It cannot run properly at a high speed or the power is insufficient:

Ignition is abnormal:
The spark plug is dirty, broken or not adjusted properly;
The ignition coil has failed
The engine control unit (ECU) has failed
Air filter is clogged, poorly sealed or there is no air filter;
Vent pipe holder is loosened;
There is water or foreign matter in the fuel;
Insufficient fuel supply to fuel injector;
The air duct of tank is blocked;
Fuel hose is blocked;
The cylinder pressure is low:
The cylinder head is not tightened firmly;
The piston ring is poor (worn, weakened, damaged or stuck);
The clearance between piston ring and groove is too large;
The valve is not installed properly (valve bending, wear or carbon deposits on the contact surface)
There is a click sound:
There is carbon deposit in the combustion chamber;
The fuel is inferior or fuel type is not applicable;
Others:
The throttle valve cannot be fully opened;
Brake drags;
Engine overheating;
480
The fuel level is too high;
The fuel viscosity is too high;
Camshaft or cam is worn;
Air suction valve has failed;
Secondary air compensating valve has failed;
Catalyst is melted due to overheating of muffler
The temperature is too high:

Ignition is abnormal:
The spark plug is dirty, broken or not adjusted properly;
The muffler is overheated:
For the Benelli emission control system, do not start the
engine even if the cylinder does not ignite or is not
running properly (must be repaired by the nearest
maintenance point);
For the Benelli emission control system, if the battery
has run out, do not start the motorcycle (connect the
other fully charged battery with a jumper and then
electrically start the engine);
For the Benelli emission control system, do not start the
engine if the ignition is not normal due to dirty spark
plugs or poor contact of ignition coil;
For the Benelli emission control system, when the main
switch is turned "off", do not ride the motorcycle and
taxi using inertia force (turn "on" the main switch and
start the engine);
Vent pipe holder is loosened;
Air filter is poorly sealed or there is no air filter;
The fuel filter is blocked
The cylinder pressure is high:
The output force of engine is insufficient:
Brake drags
Not properly lubricated:
The fuel level is too low;
The fuel cooler is abnormal:
The fuel cooler is blocked
Meter is abnormal:
The water thermometer is broken;
The water temperature sensor is broken
The coolant is abnormal:
The coolant level is too low;
The coolant is deteriorated;
Coolant mixing ratio is incorrect
The components of cooling system are not working properly:
The radiator is damaged;
481
The radiator is blocked;
The thermostat has failed;
The radiator cover has failed;
The radiator fan relay has failed;
The fan motor is damaged;
The fan blade is damaged;
The pump does not run;
Water pump impeller is damaged
Overcooling:
Meter is abnormal:
The water thermometer is broken;
Water temperature sensor is broken
The components of cooling system are not working properly:
The thermostat has failed;
The clutch is not working properly:

The clutch is slipping:
The friction pad is worn or deformed;
The steel sheet is worn or deformed;
Clutch spring is damaged or or its elasticity is poor;
The clutch housing is unevenly worn;
The master cylinder of clutch has failed;
The slave cylinder of clutch has failed;
The clutch cannot be separated properly:
The clutch pad is deformed or too rough;
Clutch spring is not pressed evenly;
Engine oil is deteriorated;
The clutch housing is seized to the drive shaft;
The clutch housing nut is loosened;
The clutch housing spline is damaged;
The friction pad of clutch is not installed properly
The slave cylinder of clutch has failed;
Clutch oil is deteriored;
There is air in the clutch fuel tube;
The primary cup or the secondary cup of master cylinder of clutch is broken;
The inner wall of master cylinder of clutch is damaged;
There is a problem with shifting:

It is unable to operate the gear smoothly; control pedal cannot be reset:
The clutch cannot be separated:
The fork is bent or stuck;
The gear gear is stuck on the shaft;
Gear lever is blocked
The elasticity of shifting and resetting spring is poor or or it is damaged;
The pin of shifting and resetting spring is loosened;
The spring at the claw of shift connecting rod
is damaged;
is damaged;
The shift claw is damaged
Jump
The fork of shift fork is worn or bent;
Shift gear groove is worn;
The joint between the protrusion of the inner edge of gear and recess is worn;
The groove of shift drum is worn;
482
The elasticity of gear lever spring is poor or or it is damaged;
The guide pin of shift fork is worn;
Drive shaft, output shaft and/or gear spline is worn
Excessive speed change:
The elasticity of gear lever spring is poor or or it is damaged;
is damaged;
The engine makes an unusual noise:

There is a click sound:
Engine overheating
The piston makes a sound:
The clearance between the cylinder and the piston is too large;
The connecting rod is bent;
The piston pin or its hole is worn;
The valve makes noise:
The valve clearance is incorrect;
The camshaft bearing is worn;
The valve lifter is worn
Other noises:
The clearance at t he small end of connecting rod is too
large;
The clearance at t he big end of connecting rod is too
large;
The clearance between piston ring and piston ring
groove is too large;
The piston ring is worn, damaged or stuck;
Piston ring groove is worn;
Piston is seized or damaged;
The cylinder head gasket is leaking;
The exhaust pipe of cylinder head connecting portion is
leaking;
The crankshaft runout is too large;
The engine is loosened;
The crankcase bearing is worn;
The main gear is worn or notched;
Camshaft chain tensioner has failed;
The camshaft chain, sprocket or guide is worn;
Air suction valve is damaged;
Secondary air compensating valve is damaged;
The alternator rotor is loose;
The catalyst is melted due to overheating of muffler
(Benelli emission pollution control system)
The drive system makes an unusual noise:

Clutch makes a noise:
The funciton of clutch shock absorber is weak or it is damaged;
The clearance between the clutch housing and the friction pad is too large;
The clutch housing is worn;
The outer friction pad is not installed properly
483
The drive device makes a noise:
The bearing is worn;
The drive gear is worn or notched;
Metal fragments are stuck on the rotating teeth of gear;
Insufficient oil;
The drive system makes a noise:
The chain is not properly adjusted;
Chain is worn;
The rear sprocket and/or the engine sprocket are worn;
The chain is not applied with sufficient lubricant;
The rear wheel is not adjusted evenly
The frame makes an unusual noise:

The front fork makes a noise:
The lubricant is insufficient or the film is too thin;
The elasticity of spring is poor or or it is damaged;
The rear shock absorber makes a noise:
The shock absorber is broken;
The brake disc makes a noise:
The brake pads are not installed correctly;
The surface of brake pad is polished;
The brake disc is deformed;
The caliper has failed;
Other noises:
Brackets, nuts, bolts and other parts are not properly installed or locked.
Excessive exhaust gas:

White exhaust:
Piston oil ring is worn;
The cylinder is worn;
Valve seal is damaged;
Valve guide is worn;
The fuel level is too high
Black exhaust:
The fuel filter is blocked
Brown exhaust:
Breather pipe clamp is loosened
Air filter is poorly sealed or there is no air filter;
Poor performance and / or stability:

It is difficult to rotate the handlebar:
The wires and cables are not wound in the correct way;
The hoses are not wound in the correct way;
The wires are not wound in the correct way;
The steering stem nut is too tight;
The steering stem bearing is broken;
The steering stem bearing is not applied with sufficient lubricant;
The steering stem is bent;
The tire pressure is too low
The handlebars vibrate or shake severely:
The tire is worn;
The main axis bearing of swing arm is worn;
The rim is deformed or unbalanced;
The wheel bearing is worn;
Handlebar holder bolt is loosened;
484
The steering stem nut is loosened;
The runout of front and rear axles is too large;
Engine mounting bolt is loosened;
The handlebar is placed on one side:
The frame is bent;
The wheels are not aligned properly;
The swing arm is bent or twisted;
The runout of main axis of swing arm is too large;
The steering stem is not adjusted properly;
The front fork is bent;
The oil level of left and right front shock absorber is uneven
The damping effect is not ideal:
(too hard)
Excessive front shock absorber oil;
The viscosity of front shock absorber oil is too high;
Rear shock absorber oil is too thick
The tire pressure is too high;
The front fork is bent;
(too soft)
The tire pressure is too low;
The font shock absorber oil is insufficient and / or leaking;
The viscosity of front shock absorber oil is too low;
Rear shock absorber oil is too thin
The front fork and rear shock absorber springs have poor elasticity;
Rear shock absorber is leaking
Brake is unable to work properly
There is air in the brake tube;
The friction pad or brake disc is worn;
The brake fluid is leaking;
The brake disc is deformed;
The friction pad is polluted;
The brake fluid is deteriorated;
The primary cup or the secondary cup of master cylinder is broken;
The inner wall of master cylinder is damaged
Battery has failed

Battery has run out:
Power is insufficient;
There is a problem with the battery (voltage is too low);
Poor contact of battery cable;
The load is too large (eg, the power of bulb is too large);
The alternator has failed;
There is a problem with the line;
The regulator/rectifier has failed
Battery is overcharged:
The alternator has failed;
The regulator/rectifier has failed
There is a problem with battery;
485
Circuit Diagram
Intake air
Intake air pressure sensor
Startup switch tempeature sensor Carbon canister
Lamp control switch Battery Coolant
Rear Front Relay solenoid valve
Turn lamp switch Engine stop Fuse box temperature Speed
Horn brake brake Idle speed Throttle sensor Oxygen Fuel pump sensor1
switch Scanner
switch switch switch Fuel
Fan
Power control valve sensor sensor Injector Speed
Indicate Main pump ECU locks ABS1 ABS2
COLOR CODE sensor2
USB
PASS
Black B 30A 10A 10A 15A 25A 15A 10A
Meter
Blue BL
B BL/O
N/B
R/W
Ligt LBL B/G N/R G/BL BL/R R R/W B W/O W/P BL N/B N/W N R/W Dg G/O G/W R B R O/R R R R R R R R
Gr N/Y Y/BL B/N B/O BL W/B L R/W Gr/W Y/R R/W B R/W Dg G/Y R/W R/W R B B G/Y R R BL/B Y/B LR R R G/Y
blue
N/LG W/B R/G O/G W/O B/BL Y/G B/BL R/Gr B/R W/R R/B B Y/Gr LR/W LR/G R/W
Brown N Y/W W/Y B/BL B/BL W/N B/R W/Gr R/G B/BL LBL/R B/R B P/W N/O Gr/R B R
Green G
Orange O
Yellow Y
Red R
Pink LR
N/BL
White R/P
W
N/W BL W/BL N R/W G/Y G/W W/P
N/B R/W B R/W BL Dg R/W
Purple Diagnostic tool
P
LR
Gray Gr R/N
B
Light LG
green
Dark
Dg
green
G/W
G/W Right turn lamp
Right turn lamp N/W
N/W
BL P
Tail/Brake
B B lamp
Y/R R/W
Headlamp
B G/B
Left turn lamp

N/B
R/W
Position Lamp
B
G/B
B License
Left turn lamp
N/B R/W
plate lamp
B
Horn N
BL/B B/R R W/G W W W/BL B/BL G/W W/O G/W R/W B B/R
R/B G/R B BL/W W B G/BL R/G G/B B/O G/B B B/W LBL/R Gr/W R/N Y/W W/Y G/BL O/R B/W R/P W/R W/O B/BL O/G W/N R/G LR B Y/Gr LR/W LR/G G/Y G/W G/O R
N/LG B/N N/BL B/Y W/B BL/O B/R B B/Y BL/W Y/G G/R R/Gr W/G Dg W/Gr B P/W N/O Gr/R BL/O B R/W N/B
Y/B N/LG B
N/G R/W N/G R/W
R W W R LR B R G/R N/R G/BL N/Y
W B B/R Dg Y/R R/W BL/R Y/BL B/G Gr
B Gr/W B B
B/R N/LG R/W G/R O/R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Flasher
Rectifier J1 J2
M ABS
Fuel level
sensor Engine
Fan Headlamp Fuel pump stop switch Ignition coil
Fan relay Key switch Main relay relay
＞98℃ controller Magnetor
coolant temperature switch Headlamp relay
Clutch switch
Gears
486

Trk251 Service Manual

Uploaded by

Trk251 Service Manual

Uploaded by

TRK 251

Dear Benelli riders,

Dear Benelli riders,

Dear Benelli riders,

Exhaust Emission Control Information ................................................................................................................... 4

Sharp edge of part

Sort out and clean the removed parts

Store the removed parts

Liquid gasket, locking agent

Oil seal, grease seal

Apply a specified amount of grease to the edges

Circlip, cotter pin

Dear Benelli riders,

Engine rotation direction

Cable connector check

Dear Benelli riders,

BJ250-18 right view

BJ250-18 (European regulation) right view

BJ250-18 (non-European) right view

Dear Benelli riders,

Item BJ250-18 (China), BJ250-18 (European

Main locking torque specifications

Dear Benelli riders,

Dear Benelli riders,

Jack: Accessories of jack:

Oil filter wrench

Dear Benelli riders,

Fuel Injection System (EFI)

If the free clearance of throttle grip cannot be met after

Check whether the winding method of hose complies

●Check whether the hose joint is connected firmly. .

○Remove the hose [A] connected to the separator and

●Check the canister as follows.

Dear Benelli riders,

● Check the hose of fuel vapor recovery system as

Dear Benelli riders,

Engine cylinder head and cylinder head cover

●Place the crankshaft on the piston TDC

Dear Benelli riders,

● When at the TDC position, measure the valve

★ If the valve clearance is not within the specified

0.19～0.25 Valve clearance / without the need to adjust

1. Measure the valve clearance (the engine has cooled).

Dear Benelli riders,

1. Measure the valve clearance (the engine has cooled).

Dear Benelli riders,

● Start the engine and make it run at idle speed.

★If the handle end of clutch cable is adjusted to the

Check whether the drive chain is slack

Adjust drive chain slackness

●Unscrew the left and right chain adjuster locknuts

Dear Benelli riders,

●Check brake hoses, brake lines and fittings for

●Check the winding method of brake hose.

Free stroke of rear brake

Dear Benelli riders,

Inspection of wear of brake pad

★If the brake light is off, check or replace the following

●Close the electric door lock.

Output voltage of sensor

● Shake the seat cushion up and down for four or five

Check the front fork shock absorber for oil leakage

Dear Benelli riders,

Dear Benelli riders,

Remove locknut of steering stem [E].

Dear Benelli riders,

★If the light is out, check or replace the following parts:

●The left or right turn signal light (LED)

●The left/right turn indicator light (LED) [C] in the

●The low-beam headlight [B] shall be on.

● Low-beam headlight [E] and high-beam headlight

Dear Benelli riders,

Adjustment of headlight beam

Dear Benelli riders,

Sidestand flameout switch

★If the sidestand switch is abnormal, check or replace the