Zongshen RX3 Owners Manual PDF

宗申产业集团有限公司文件名称维修手册页码
ZONGSHEN INDUSTRIAL GROUP 产品型号 ZS250GY-3(电喷) 1/1
产品代号版本号
阶段标记 01
标记处数更改文件号签字日期 L C S D F P V
维修手册
（英文）
宗技术文件
有效
申日期：
编制母仕会 2013-9-9 标准化甘立顺 2013-9-10 文件编号

校对郭伟 2013-9-10 审定杨庆春 2013-9-11 08210-M954-C100
审核宋全刚 2013-9-10 批准王冲 2013-9-11 基础车型产品代号
会签
https://www.motorcycle-manual.com/
ZS250GY-3 (EFI)MOTOCYCLE
SERVICE MANUAL
THE FIRST EDITION(Aug,2013)
Zongshen industrial group reserves all rights of
this service manual.
The specifications and pictures in this manual
are only for reference.
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INTRODUCTIONS
The manual intruduces the structure,woking principle, disassembly and inspection, fault diagnosis and elimination.
Also, this includes technical specifications,performance parameter and maintenance data. With both the descriptions and
pictures, you may have a comprehensive understanding of the configuration as well as the service and repair skill.We hope
it can bring technical support and guide to all the users and after service staffs.
Technical specifications, performance parameter and maintenance data mentioned in manual are base upon the
latest design features of your motorcycle. Chongqing Zongshen Automobile Industry Co.Ltd. reserves the right to make
changes to the specifications of its vehicles without notification. We sincerely hope you can give us your suggestions
about the design,manufacture and quality of this type of motorcycle,so that we can do the improvement in time.Thank
you for your support and co-operation.
All the specifications,diagram, data and performance index in this manual end in the print of this book. Our
companyreserves the right to change the book without any notification.All rights are reserved by Zongshen.Any people
or companies won’ t copy it if there is no permission.Otherwise,we will go behind the criminal and legal responsiblity.
In this book we take ZS250GY-3 for example to explain the detail of the disassembly,installation,inspection and
troubleshooting of this series models.Due to our limited knowledge, it is very possible to have mistakes or omissions in
this book.And we welcome your comments.
Chongqing Zongshen Automobile Industry Co., Ltd.

Address: CHAOYOUCHANG,BANAN DISTRICT,CHONGQING,CHINA.
Service hotline:4007003088
For more information, visit our website www:zongshenmotor.com
Editor Aug,2013
All rights of this trademark reserved by Zongshen Industrial Group, trademark registration number in china is:1487149;
Zongshen Industrial Group are applying this trademark.
This Logo is the combination of registration trademark of Zongshen Industrial Group and registration trademark of
PIAGGIO & C.S.P.A. All rights reserved by ZONGSHEN PIAGGIO FOSHAN MOTORCYCLE CO.,LTD.
This trademark was registered by Zongshen Industrial Group in more than 20 countries such as Nigeria, Argent-ina
and Vietnam, etc.
This trademark was registered by Zongshen Industrial Group in more than 90 countries such as Japan, New Ze-aland,
Germany, Canada etc.
This trademark was registered by Zongshen Industrial Group in more than 90
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countries such as Germany, Camb-odia and France, etc.

LIMITED: Without written permission by Zongshen Industrial Group, no company and individual is allowed to copy,
duplicate and use above trademarks and logos.
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catalogue
INTRODUCTION
CATALOGUE
CHAPTER 1 GENERAL INFORMATION ....................................................................................1
section 1 vehicle introduction .................................................................................................... 1
section 2 structure .................................................................................................................... 2
CHAPTER 2 MAINTENANCE KNOWLEDGE .............................................................................4
section 1 Attention Items of Maintenance ................................................................................... 4
section 2 General knowledge of Maintenance ............................................................................................ 5
section 3 Adjusting Data of Maintenance .................................................................................... 8
CHAPTER 3 VEHICLE ...........................................................................................................10
section 1 Fuel Supply System ................................................................................................. 10
section 2 EFI System .............................................................................................................. 13
section 3 Intake and Exhaust system ....................................................................................... 20
section 4 Rear Transmission Device ........................................................................................ 24
section 5 Frame and Accessories ............................................................................................ 28
section 6 Steering System ...................................................................................................... 31
section 7 Control Steel Cable ................................................................................................... 32
section 8 Shock Absorber ....................................................................................................... 33
section 9 Rear Fork .................................................................................................................................... 37
section 10 Wheel .................................................................................................................. 38
section 11 Brake ................................................................................................................... 42
section 12 Meter ................................................................................................................... 48
CHAPTER 4 ELECTRICAL .....................................................................................................50
section 1 Basic Knowledge ..................................................................................................... 50
section 2 Power Supply .......................................................................................................... 51
section 3 Control ................................................................................................................... 54
section 4 Power Consumption ................................................................................................................... 57
CHAPTER 5 TROUBLESHOOTING ......................................................................................... 60
APPENDIX： CIRCUIT DIAGRAM .......................................................................................... 74
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CHAPTER 1 GENERAL INFORMATION
section 1 vehicle introduction
ZS250GY-3 is designed for use on road With futuramic appearance and easy operation. It adopt single
cylinder,4-stroke,air cooling engine. This type of engine has the advantages of good cooling,powerful and
good acceleration.The frame is pipe joint which has high tensity and good rigidity.The brake system
adopts the combination of front and rear disc so that it could ensure the stabilization and safety.And rim
type wheel has good appearance and function of anti-abrasion.
FIGURE 1-1 Left view of motorcycle
[1]Front fender
[2]Front shock absorber
[3]Steering 3
[4]Fuel tank
[5]Rear armrest 4 5
[6]Front wheel
[7]Front brake
[8]Gearshift pedal 1 2
[9]Side stand
6
[10]Rear wheel
7 10
8
FIGURE 1-2 Right view of motorcycle

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[1]Taillight assembly
[2]Muffler
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4
5 [3]Seat
[4]Ignition lock
1 [5]Headlight
3 [6]Rear brake
[7]Rear pedal
2
[8]Front pedal
[9]rear brake pedal
7
6
8 9
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Chapter 2 Structure
This motorcycle mainly consists of riding system,operation system,brake system,transmission system,fuel
supply system,electrical system and engine.Refer to Diagram 1-3.
Diagram 1-3 structure
[1]Riding system 3
[2]Electrical system 2 4
[3]Operation and brake system
[4]Fuel supply system
[5]Engine
[6]Transmission system
1
5
6
1 Riding System
The basic function of riding system:
[1]Make motorcycle in a whole and support whole motorcycle.
[2]Receive the torque from transmission setup.Provide traction for motorcycle running through the contact of wheel
and road.
[3]Endure and transmit road function and endure torque made by the outside force of wheel.
[4]Absorb and handle the strike and shake produced during motorcycle running.
Riding system mainly contains frame assembly,front/rear shock absorber,front/rear wheel and some other accesories.
2 Operation and Brake System
The main function of operation system is to control running direction,running speed,brake,illumination and
signals,and to ensure motorcycle running safety.
The operation and brake system mainly consists of steering setup,brake setup and some relative controlling
handlebar,controlling switch,steel cable and accessories.
3 Transmission System
The basic function of transmission system is to augment torque or reduce transmission speed according to the road
condition and running need,After that,to transmit the result to drive wheel and to make motorcycle run.
Transmission system mainly consists of starting device,clutch,gearshift and accessories of rear transmission
device.
[1]Starting Device
The function of starting device is to start engine and to make engine automatic running.The starting device of
motorcycle is divided into two modes.One is kick starting,and the other is electric starting.
[2]Clutch
The function of clutch is to transmit or cut off the power from engine reliably and softly,and to ensure motorcycle抯
stable start and gearshift.The clutch of this motorcycle adopts automatic,wet and multiple.
[3]Gearshift
The function of gearshift is to change the rev and drive torque of motorcycle transmission and to ensure proper pull
and speed of motorcycle,so that it can adapt the changable running condition.The gearshift of this motorcycle adopts
gradational gearshift.
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[4]Rear transmission device
The function of rear transmission device is to transmit the engine power to transmission device,so that
the rev is reduced and the torque is augmented.Then transmit the power to rear wheel to drive motorcycle
run.The transmission of this motorcycle is chain transmission.
[5]Intake and Exhaust System
The function of inlet system is to guide and filtrate air,to control the volume of mixed gas flowing into
cylinder according to the needs of working condition.It mainly consists of inlet pipe and air cleaner.
The function of exhaust system is to vent the exhaust gas in cylinder and to reduce the noise during
exhausting.It mainly consists of exhaust pipe and muffler.
[6]Fuel Supply System
The function of fuel-supplying system is to confect clean gas and air into mixed gas with proper
proportion according to the working condition of engine,and to offer the mixed gas timely and
quantificationally to burning chamber to keep burning.
The fuel supply system mainly consists of fuel tank,fuel pump,fuel injector,fuel filter and fuel pipe.
4 Electrical System
The function of electrical system is to offer electric power to the starting and running of motorcycle,and
to send sound or light signals so that the running safety can be ensured.The electrical system mainly
contains the part of electric power supply,electric power consumption and electric power control.
[1]Electric Supply
The part of electric supply mainly consists of generator and battery.When generator reaches a certain rev
driven by engine,generator will export eletric power,which not only offers the power to electric setup,but also
to the battery so that it can be charged. The battery can transfer chemical power to electric power,which can
support starting,illumination and signal setup.
[2]Electric Consumption
The function of electric consumption part is to offer several kinds of sound or light signals to ensure
running safety,meanwhile it can start engine conveniently and fast.It mainly consists of illuminating
signal device and electric starter device.
[3]Control Part
The function of control part is to ensure and adjust electric supply and electric consumption.It mainly
consists of ECU,rectifier,starter relay,fuse，control switch and main wire.
5 Engine
Engine is a device,which is to make fuel burn in the cylinder and to transfer heat to mechanical power.
it is the power producer of motocycle.(the maintenance of engine please refer to the engine service
manual)
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Chapter 2 Maintenance Knowledge
Section 1 Attention Items of Maintenance

When there are some problems with motorcycle,you can have it repaired at Zongshen after-service station or
professional maintenance station.Meanwhile you also can refer to this maintenance manual.Parts on the motorcycle
will be worn or loose during riding. Lack of regular maintenance can affect the safety and reliability of your motorcycle
and shorten the service life.So a regular maintenance will help to keep your new motorcycle operating at peak
performance.
[1]When motorcycle is being repaired,please use the components,accessories,luboil
and other accessorial materials which produced or recommended by our company or.If you
use the co mponen ts whic h are not su itable for th is mot orcycl e,it wi ll inf luence the
mo ti vi ty ,r el ia bi li ty ,s ta bi li ty a nd c om fo rt o f mo to rc yc le .S er io us ly , th e mo to rc yc le w il l
be destroyed.
[2]After disassembly and reinstallment,please replace new gasket,sealed components
and open pin.
[ 3] Wh en t ig ht en in g bo lt s an d nu ts ,y ou s ho ul d do w it h th e pr in ci pl e of d ia go na l
crossover and completely tighten to the standard torque value during 2 or 3 times.
[4]When cleaning the components,please adopt non-burning cleaning fluid. Paint some
luboil on the moving parts of components before installation.
[5]After installation,check whether components are installed correctly.Check methods
are circumrotate,movement,operation and inspection.
[6]When disassembling motorcycle,normally please use appropriative maintenance tools.
[7]Please repair motorcycle with flameout.If the motorcycle needs to be repaired while
engine is working,please do it at a well ventilated place,because the exhaust gas from
motorcycle contains poisonous CO.
[8]Gas is easy to burn or explode,so do not smoke or ignite at maintenance place.
[9]The electrolyte of battery consists of vitriol.If eyes,skin and clothes are spattered with electrolyte,
completely clean it with water.Seriously,please go to hospital.
[10]There is hydric gas from battery,which is flammable and explosive,so do not smoke,ignite fire near
battery.Especially when it is charging.
Statement in this manual preceded by the following words are of special significance:
WARNING
Indicates a potential hazardous situation, which if not avoid, may cause people hurt or death.
CAUTION
Indicates a potential hazardous situation, which if not avoid, may damage your bike.
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ADVICE
Indicates special information to make maintenance easier or instructions clearer.
Section 2 General knowledge of Maintenance
1 Classification of Maintenance
Maintenance can be divided into 4 parts according to the range and interval period.4 parts contains major
repair,medium repair ,minor repair and assembly repair.
[1]Major repair is a thorough repair,which needs to make motorcycle completely disassembled,cleaned,
measured,inspected,adjusted and so on.After the major repair,motorcycle can reach the standard of origi-
nal motivity,economy,stability and safety performance.
[2]Medium repair is to repair and adjust some parts which influence the performance of motorcycle.
Medium repair can eliminate potentially hazardous,avoid deterioration of problems and keep a good
running condition.
[3]Minor repair is a running repair,which is mainly focus on elimination of some temporary problems
or partial hurts during running.
[4]Assembly repair is a separate repair for assembly,which is caused when the requirement of a certain
assembly or hurt,abrasion or distortion of a certain component influence the performance of motorcycle.
2 Repair Technics
（1）Disassembly of Motorcycle
Disassembly is a very important part during repair.The method of disassembly will directly influence
the quality and efficiency of repair.If components broken or blocked caused by unproper disassembly,it
will not only expand the repair range,but also will delay the repair period.Seriously,it will lead to the
disassembly stop.The basic principle of disassembly is the order and direction opposite to those of
installation.Normally,the order is from outside to inside,from up to down,from big to small.When
disassembling,pay attention to the store environment and order to avoid damnification and confusion.
The order and method of disassembly is not absolute.Different motorcycle has different order and
method of disassembly.You can refer to the following introduction of disassembly,installation and
maintenance.
The basic principle of disassembly of Engine and other components is the same as principle of whole
motorcycle.The order and method of disassembly is different because of different structure and character-
istic of different component.Pay more attention to the store environment and order for all disassembled
parts are components.
Pay attention to the following items when disassembling motorcycle and components:
[1]The components which have high requirement for position should check its position mark first when
disassembling.If the mark is not clear,please re-make a mark.
[2]When dismantling the components which are too tight,please use the special tools.If you have none
special tools,support the motorcycle with some wooden or soft metal,then hammer the right place with
gluey hammer to avoid component damage.
[3]When dismantling the assembly of front/rear shock absorber and front/rear wheel,support motor-
cycle with main stand.Avoid motorcycle falling down to hurt people or damage the components.
[4]Put the components which are dismantled in order.Do not put those components directly on the
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ground.Such as spray components,chromeplate components and high precision components.

[5]The nuts and bolts which are dismantled should be stored carefully,which also can be installed on
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the original place,but don’t tighten them.

[6]The components which are only dismantled by special tools,please operate as regulation.Please
energize equally and pay attention to the direction.
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[7]When dismantling components,please choose suitable tools,energize equally and pay attention to
direction to avoid component damage.
[8]The brake pads which are dismantled should be stored separately,which are also forbidden to
contact luboil,otherwise it will lead to brake failure.
[9]When there are some difficulties to dismantle because of the rust of screw thread components,you
can dip the components in gas for several minutes,then dismantle them.
[10]When dismantling gaskets,you should be much careful to avoid damage.
（2）Cleaning of Components
After the components are dismantled,they must be adhibited some oil or carbon deposit.Clean them to
help maintenance and installation.You can choose gas,coal oil and cleaning liquid to clean.The cleaning
method is adopted according to the speciality of components.
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[1] Oil Stain Cleaning

Cool cleaning and heat cleaning are two methods for metal parts.Use gasoline or coal oil as detergent,
put the metal parts into detergent and scrub them by brush,which is called cool cleaning .Use aqueous
alkali as detergent,put metal parts into detergent ,heat up to 79℃～90℃ and immerse for 10min～
15min,then take out the metal parts and clean,which is called heat cleaning. 5
[2] Carbon Deposit Removing
To remove the carbon deposit on component,we can use mechanical method or chemical method.
Mechanical method is that scrape deposit with bamboo-scraper or spade and clean them with gasoline.
Immerse the component,brush the carbon deposit off and clean them with hot water,which is called
chemical method.
（3）Parts Inspection
Inspect the parts after cleaning.The purpose for inspection is to check whether the parts need to be repaired or
replaced.There are three methods,i.e.direct inspection,instrument inspection and troubleshooting.
[1] Direct Inspection
Direct inspection is to check and judge the condition of parts by individual sensation instead of instrument.It is a
simple and feasible method,which is widely used for maintenance.
[2] Instrument Inspection
Instrument inspection is to measure the size and geometry shape of parts by gauge and apparatus;then compare
the measured value with limiting value to figure out the condition of parts.This method can get an accurate
judgement,but it needs careful inspection for the precision of instrument and reasonable selection of parts.
[3] Troubleshooting
To find the latent fault of parts，we can apply troubleshooting.Usually we adopt the method of oil
immersion and knock during maintenance.The process of this method is as following.First,immerse the
parts into coal oil or diesel oil for several minutes.Second,take out and wipe the parts.Third,spread talcum
powder on the surface of parts. Finally, knock the non-working surface of parts gently with a small hammer
. In this way,the knock can produce vibration and oil that has remained in crack will splash for vibration.
The splashed oil will dye the talcum powder yellow,so we can easily find a yellow mark in crack place.
Cleaning methods for non-metal parts differ in different materials.The best detergent for rubber parts is alcohol.Do not
use coal oil or gasoline to clean rubber parts,because they can cause inflation and deformity of rubber parts.Gasoline is
suitable for clutch disc and brake pads friction disc,while aqueous alkali is forbidden.
（4）Repair methods and skills
After disassembly,cleaning and inspection,the following is the principal stage.Mastering the basic skill
well is the key to ensure a good quality of maintenance.The skills for maintenance are as following:
[1] Chiseling,filing and scraping
Chiseling is to process metal parts by hammer and chisel. The functions are cutting and parting.
Filing is to rasp off the surface of parts by a file.It includes rasp and delicate filing.Teeth of a file directly
decide the roughness degree when filing metal parts.The operation of file is different because of different
shape surface of parts.
Scraping is a process which scrapes off a thin layer from the surface of parts. It is a delicate work, so we
should scrape the parts bit by bit with great care.Usually,scraping off 0.005～0.01mm each time.Before
scraping,we need to spread red lead on the surface of parts.Then,match the parts with standard one.The
unmatched parts are the aim of scraping.After several match and scraping,the contact surface of parts is
bigger.So it reaches the requirement and achieves the purpose.
[2] Rubbing
Rubbing is to rub out a thin layer from the surface of parts by grinder and crocus.This is a fine finish
for the surface of parts,which can provide a precise size ,exact geometrical shape and the lowest degree of
roughness.It includes flat rubbing,internal rubbing and external rubbing.The rubbing tool for flat rubbing
is a plane plate,while internal rubbing tool is a pestle.During maintenance,rubbing methods are usually
used for rubbing the flat of crankcase and internal hole of connecting rod.
[3] Rivet joint and welding
Rivet joint is a process which can join two parts or more together with rivets.It is widely used in
maintenance,such as rivet joint of clutch disc and so on. Classified by its function,rivet joint can be
divided into fixed rivet joint,active rivet joint and seal rivet joint.
Welding is a process which can bring into close union of two metal parts with welding tool and solder.
It is also widely used in maintenance,such as repairing the crack of frame and other metal parts.
[4] Drilling and Reaming
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Drilling is a process which drills holes on parts or materials with drill bit.The drilling tools mainly
include beam drill、bench drill、electric hand drill、rotary hand drill、drill bit and clamp.
Reaming is a fine finish by reamer,which can increase the precision degree of holes on parts and decrease
the roughness degree.It improves the match precision between hole and shaft and the precision can reach
grade 6 to grade 8. The basic tool for reaming is a reamer,such as fixed reamer,adjustable reamer,conical reamer
and so on.Before reaming,we need to drill a bottom hole in advance,which is for the precision requirement of hole
shaped and making room for reaming procedure.
[5]Tapping and thread die cutting
Tapping is to Process internal thread with screw tap and thread die cutting is to process external thread with
threading die. The essential tools for tapping is screw tap. Generally, screw tap consist of master tap and plug tap.
The difference between these Two kinds of tap is that master tap adopt a slight bevel angle on cutting part,instead ,
plug tap adopt a steeply bevel angle. After tapping,we should drill a bottom hole with chamfer.
Please refer to the specialized list or the following formula for the bit diameter of bottom hole :
Diameter of drilling hole outside diameter of screw thread - 1.1mm × screw pitch(appropriate for iron and
copper)
Diameter of drilling hole outside diameter of screw thread-1.2mm × screw pitch(appropriate for steel and brass)
When cutting inside threads,turn master tap into the chamfer-angle hole,then take out and use plug tap to shape
the threads.
The tool for outside screw threads cutting is screw plate.Screw plate includes fixed screw plate,adjustable screw
plate and active screw plate.Usually,we use fixed screw plate,i.e.round screw plate.When cutting outside screw
threads,choose screw plate and diameter of club-shaped material according the required material,diameter of screw
thread and screw pitch.To make proper choice,please refer to the specialized list or the following formula:
Diameter of club shaped materialoutside diameter of screw thread-0.13mm × screw pitch
Bevel the end of club-shaped material in 15 °～20°angle before cutting outside screw threads.To ensure easy
operation,the screw plate and club-shaped material should be in vertical,therefore,the minimum diameter of cone
angle should less than inside diameter of screw thread.
[6]Rectification
The operation that eliminates the unevenness of plane-shaped,bar-shaped and column-shaped parts is called
rectification.。Rectification can reshape the parts.
The rectification depends on the flexibility of metal parts.Therefore,metal parts with good flexibility can be
rectified directly,such as soft steel and red cooper ’metal parts with less flexibility need to anneal before rectification.
The ways for rectification are torsion,extension,bending and expansion.
[7]Bonding
Bonding is widely used in manufacture and repairs because it operates easily and can be done without special
equipment and expensive materials. In addition,the bonding parts don ’t need to be processed by high precision
machine,such as the bonding of handlebar and steering head,bonding of plastic label and spay-paint metal parts,
bonding of brake disc and brake pads.There are various adhesive,such as epoxy adhesive,phenol formaldehyde
adhesive and so on.
（5）Motorcycle assembly
The last procedure in repair is assembly,which is a key to ensure the good quality of motorcycle.
[1]Assembly includes module assembly,parts assembly and overall assembly.In the process of assembly,we
should abide by the principle that assemble module first,then parts and the overall finally.The sequence of assembly
is opposite to disassembly,which is to first assemble the last disassembled components,and to last assemble the first
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disassembled components.
[2]Module assembly is the first stage in whole process,which makes the parts into a single module,such as the
combination of front brake drum cover,the combination of brake pads ,the combination of wheel.
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[3]Parts assembly is based upon module assembly,which assembles the parts and module as a whole,such as
front and rear wheel assembly,front fork assembly,shock absorber assembly and so on.
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[4]Overall assembly is the last procedure to complete the whole working process,which connects parts and
modules with frame according to installation sequence by all means.
[5]The sequences of overall assembly are similar.The operation is as following ：Firstly,finish all modules
assembly and parts assembly,then install engine assembly and gearbox assembly on frame.Secondly,install front fork
assembly,handlebar assembly,front and rear fender assembly,shock absorber assembly,carrier assembly,front and
rear wheel assembly,fuel tank assembly and seat assembly.Thirdly,install headlight,taillight,steering indicator,horn
and battery assembly.The fourth,connect all electric circuit and control cables.The fifth,install driving chain, dentiform
belt,wind shield and chain cover or belt cover.Last,lubricate the whole motorcycle.
[6]Consult the following reference about disassembly,installation and inspection if there is any assembly se-
quence difference which is caused by different type and structure.
[7]Pay attention to the following:：
Choose a clean and wide place ；strictly follow the assembly requirements；parts connecting should accord
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with specification ;avoid misfitting and leaving out of any gaskets,cotter pin and fixing clip.
3 Adjustment after Repair
The interconnection of parts have been affected in some extent after repair.To recover the performance of
motorcycle,adjust them according to the specification of user ’smanual.adjust as follows:
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（1）Ignition Time Adjustment
If there is a wrong ignition advance angle，it will cause a series of problems,such as hard engine starting ,
power decrease,high fuel consumption,engine overheating,uncomplete fuel burning,exhaust value overrun,
short service lifetime and so on.Therefore,adjust ingiton advance angle firstly.
If ignition system cannot work well,check electrical ignition device,high voltage coil,ignition coil and
triggering loop of magneto and so on.
（2）Carburetor Adjustment
Carburetor adjustment is very important,which directly decides the performance of engine,so maintain
it as the following:
Before carburetor adjustment,make sure the operation temperature of engine is in order,open choke
valve,check whether the valve clearance and ignition timing are right,and ensure no leakage or block of
engine and carburetor. Carburetor adjustment includes idle adjustment and fluid level adjustment of float
chamber.The adjustment can make the operation of engine idle stabler and avoid poor or rich oil in
carburetor.
（3）Clutch Adjustment
Clutch is used to transfer power,so it plays an important role in transmission system.Adjust the free stroke
of clutch operation grip within 10mm and 20mm.For some motorcycles,there is a need to adjust adjust-
ing bolts of disengagement parts.
Section 3 Adjusting Data of Maintenance
Table 2-1
operation/ brake/ shock absorber/wheel
items Standard Value (mm) limit Value (mm)
Free stroke of front brake lever 10～20 20～30
Free stroke of rear brake pedal 20～30 30～40
Free stroke of throttle control grip 2～6 10～12
Depth of flower pattern on tire surface 4. 0 2.0
Stroke of front shock absorber 130
Free length of front shock absorber spring 425
Stroke of rear shock absorber 45
Free length of rear shock absorber spring 235
axial 0.8
Wheel hub runout
radial 0.8
Axle runout front 0.8
rear 0.8
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Table 2-2 Maintenance Cycle
Times Items Mileage km
Items Period 1000km 4000km 8000km 12000km
● Fuel system I I I
● Fuel filter A R/I R/I R/I
● Control system I I I I
● Choke valve cable I I I I
Air cleaner element A/R R R R
spark plug gap I I I I
●● Valve clearance I I I I
Driving chain I/L I/L I/L I/L
Battery I I I I
Abrasion of brake pads I I I I
Brake system I I I I
● Brake light switch I I I I
● Headlight adjusting I I I I
Main/side stand I I I I
●● Front/Rear shock absorber I I I I
● nut/bolt/fixing components I I I I
Outter tire of front and rear wheel I I I I
●● steering system bearing I I I I
Maintain the motorcycle according to the period that is listed above.Each capital letter on the list stands
for as follows:
R-clean、A-inspect、L-lubricate、I-inspect、clean、adjust、lubricate or replace
● indicates that maintaining this item by service center of our company.If maintain it by yourself,please
consult this maintenance manual.
●● indicates that maintaining this item only by service center of our company.To ensure riding safety,
please follow our advice.
CAUTION
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Shorten the maintenance period if motorcycle usually runs in dusty region.
table 2-3 Torque tighteningCAUTION

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Items Specification Torque Value(N.m)

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Locknut of main pipe M24×1 25~35

Fixed bolt of handlebar M10 ×1.25 50~60
Front a xle nut M14 × 1.5 70~80
Rear axle nut M14 × 1.5 70~80
Motorcycle
Engine suspension bolt M10 ×1.25 45~55
Fixed nut of rear shock absorber M10 45~55
Locknut of chain wheel M8 28~32
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Nut of rear rocker arm M12 ×1.25 50 ~ 60

f o r k s ha f t n u t M12 ×1.25 55 ~ 65
f o r k s ha f t n u t M10 ×1.25 45~5
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Section 1 Fuel Supply System
Fuel supply system consists of fuel tank,fuel pump,injector,fuel filter and oil pipe.
1 The Structure and Working Principle of Fuel System
[1] Fuel Tank
Fuel tank is jointed by the armor plate which is normally 0.8mm～1.0mm.Some fuel tank is jointed
apertured clapboard inside,which not only strengthens the fuel tank,but also avoids the fuel gurgitation
during riding.Because of the strong erosion of oil,it must be galvanized on the surface of fuel tank.There
is a fuel-adding hole on the top of fuel tank and close the fuel cap which has air hole,so that it can avoid
fuel leakage during riding and ensure the balanced pressure of inner and outer fuel tank.So that fuel can
flow out naturally.
[2]Fuel Pump
The fuel pump consists of pump, support and oil pressure adjuster. Flexible installation can decrease
the vibration on the fuel pump. The pump installed in the fuel tank is to get a simple construction and
non-leakage.
The pump adopts turbo, single stage and electric type. It is driven by a DC motor with 12V and
controlled by ECU through the pump relay. There is a one-way valve at the exit of the pump which can
prevent the oil from flowing back to the bank when engine stops and ensures a good starting performence.
[3] Fuel Injector
Fuel injector injects the proper amount of atomized fuel into the intake pipe of engine by ECU,thus the
atomized fuel can participate in the combustion process in the cylinder.
[4]Fuel Filter
Fuel filter connects with the oil way between the electric fuel pump and fuel rail. This system adopts the
dedicated filter for EFI to make impurities not block the nozzle. The housing of filter has enough intensity and
it never break due to the fuel pressure.
[5]Fuel Pipe
The pressure of the fuel supply system is 250kPa. Its selection must have enough safety factor for security.
ENGLISH
10
2 Disassembly and Maintenance of Fuel System
[1]The capacity of the fuel tank is 16L。
When refueling, please keep air circulation and keep
away from sparks and flame.
Warning
fuel tank cap
Fuel is highly combustible.Smoking and getting
close to the fire are strictly forbidden
Switch off the motorcycle and operate in an airy place.
[2]Check the fuel tank cap for fuel leakage.Replace the

sealing ring of cap if necessary.
open fuel tank

WARNING
The brand of oil allowed is 93#. Do not using
other type of oil.
[3]Check the fuel tank for fuel leakage.Replace or repair it

if necassery.
CAUTION
If the fuel tank is deformed by the collision of
check fuel tank
external force,repair it to original condition with
wooden hammer.If the fuel tank has cracks,
replace the fuel tank without repair.
[4]Check the fuel pipe for fuel leakage or aging. Check

filter for block, repair or replace it if blocked.
ENGLISH
CAUTION
If the fuel pipe has fuel leakage or aging,replace it. check the filter
Before replacing the fuel pipe or filter, Shut up
ignition switch to stop the fuel pump and avoid the
fuel flow out of the fuel tank. 11
[5]First of all, dismantle the left and right side cover and
seat.Then remove fixed bolt and take out the fuel tank.
dismantle the WARNING

fuel tank
Keep the oil away from fire when dumping the oil.
[6]Remove the six fixed bolt(M5×16) of fuel pump

by hexagon wrench.
WARNING
dismantle the
fuel pump Please dump oil first and keep away from
the fire when dismantling the pump.
[7]Take out the pump, and then clean the oil sludge and
water in the tank with oil sludge.
CAUTION
remove the
fuel pump After cleaning, the fuel tank could be used
when drying out.
[8]Check the pump seal ring for aging, breaking or oil

leakage. Replace it if necessary.
ENGLISH
check seal ring

12
[9]Check the motor of fuel pump for running.And clean
or replace the fuel strainer.
check the
fuel pump
ADVICE
Replace the fuel filter when the motorcycle
drives about 8000~10000Km.
3 The cause,trouble description and repair method of fuel supply system

Table 4-1
Maintenance of Fuel Supply System
component cause trouble description trouble description of repair method
description of component motorcycle
Fuel tank body is broken. leakage of fuel tank Repair or replace fuel tank.
f u e l t a n k The venthole of fuel Fuel supply is not good. Motorcycle cannot start. Unblock the venthole of
tank cap is blocked. fuel tank cap.
Fuel tank is deformed. Fuel tank is accidented. The appearance of mo-
torcycle is bad.
Repair or replace fuel
tank.
Motorcycle is hard to be
oil-filter screen is dirty
or small holes are Fuel supply is not good. started or cannot be
started.The engine power Clean oil-filter screen.
blocked.
is not enough and the
idle speed is not stable.
fuel pump The fuel pump body is Fuel supply is not good. Motorcycle cannot be Clean or replace fuel pump.
blocked. started.
The motor of fuel pump Fuelcannotbesupplied. Motorcycle cannot be Replace the motor.
does not run started.
ENGLISH
Fuel pressure regula- Fuel can not be back. Oil duct is cracked
tor is blocked.
Motorcycle is hard to be Clean or replace the
Fuel pressure regulator is
normally open. The pressure of oil started or cannot be pump assembly.
supply is low. started.The engine power
is not enough and the
idle speed is not stable.
13
Section 2 EFI system
The main effect of EFI system is to convert the fuel which is supplied from fuel tank into a mist, then
mixture of the mist and air import into the combustion chamber.
1 The Structure and Working Principle of EFI system
EFI system consists of ECU,nozzle,throttle valve,intake air temperature,integrated pressure sensor,
engine temperature sensor,ignition coil,CKP,fuel pump,oxygen sensor.
EFI system could control the ratio of fuel-air mixture which import into the engine cylinder, combustion
process and exhaust gas conversion accurately .So as to optimize engine performance and driveability ,and
control the exhaust emission strictly.
ECU is a microprocessor as a core of SCM. By sensor and working request switch installed in the engine
and body of motorcycle, ECM could analyse mode of operation and estimate operating conditions.Finally,
controlling engine and relevant mechanisms accurately through actuator in the engine and body of motorcycle.
The type of engine speed and crankshaft angle sensor is magnetoelectricity. The function of this sensor
is to determine the position of the rotating and revolving speed for crankshaft.
Crankshaft angle sensor is installed on the clutch housing and it works with 24x gear ring from
flywheel.
MAP sensor is installed in the intake manifold to measure the pressure,so ECU could judge air enter into
the engine from this signal.
MAP sensor consists of an elastic diaphragm seal and a magneticcore. Diaphragm seal and magneticcore
is placed in the coil accurately.When they sense pressure, they could produce a 0～5v output signal in
direct proportion to input pressure.
Throttle position sensor is installed on the throttle body and has a same axle with throttle lever and
throttle valve. The structure is a linear variable resistor and its sliding terminal is drived by throttle axle.
Resistance signal,which is passed to the ECU through this sensor, depends on the opening of throttle.
EFI could judge the real-time load of engine and dynamic variation according to the signal and its rate of
changes which output from the sensor.
Sensor of intake air temperature is installed on the pipe of intake system. The function of it is to test air
temperature enter into the engine. It also use thermistor of NTC coefficient as a sensing element.
The change of gas temperature directly affects its density fluctuation, therefore, intake air temperature
is one of the importance parameters for computing actual amount of air,which enters into the cylinder.
Nozzle is an electromagnetic switch device.Two poles elicite from coil connect with ECU through
engine wires. Voltage is applied to coil under the control of ECU, and the coil produces magnetic force to
overcome spring force, fuel pressures and a vacuum suction of intake manifold, suck up iron core, that could
enables fuel to traverse the seal surface of ball valve which is the one with the iron core ,then the fuel
sprays from nozzle and forms a mist spray; After interruption of power supply, magnetic disappears and
nozzle shuts.
The top of fuel injector adopts rubber sealing for forming a reliable leakproofness of fuel pressure with
the port of fuel channel;The bottom of it adopts rubber sealing for forming a aeroseal with engine intake
manifold. Nozzle spray the fuel as mist into the inlet valve.
Throttle body is installed in the front of the intake manifold. It consists of valve body,throttle position
sensor and ISCV. The main function is to control air inflow when engine is working.
Oxygen sensor is installed on the exhaust pipe of engine.It is a important part of closed-loop fuel control
system.
The main sensitive materials of oxygen sensor is zirconia. Zirconia is heated to 300℃ by exhaust and
is activated, then oxygen ion traverses the zirconia part and gets to its external electrode. Ultimately,
zirconia part induct content of oxygen from engine exhaust emission and change the output voltage value.
ENGLISH
Oxygen sensor adopts Teflon insulated wires and stainless steel materials of component.Air for refer-
ence is imported through wire,so it is non-blocking.
When AFR becomes thin， oxygen content of exhaust increases and the output voltage of oxygen
sensor reduces;Otherwise, the output voltage valve rises, it provide feedback of the real-time condition of
AFR to ECU.
14
2 Disassembly and Maintenance of EFI system
The EFI of motorcycle has been calibrated before leaving the factory. When EFI system has failure, adjust
idle screw of throttle voluntarily and replace or adjust parts of EFI are strictly prohibited.Please go to our
service station to maintain for any queries.
EFI failure indicator is equipped in the meter.When ignition system is opened, the indicater lights up.
when the indicator does not light up, that means there is failure. When engine starts, the indicator puts out.
When the indicator keeps the light on or flashing ,that means there is failure.
idle air control valve

throttle position sensor
24X aiming crankshaftposition sensor optional
wheel of burglaralarm
crankshaft throttle body
position optional
LSH igniton coil
engine temperature
sensor engine con-
trol module
Inlet tempera-
ture/pressure
sensor
M3.5 nozzle
neutral switch
fault diagnosis
dumping switch switch SCI WCPR fuel
pressure regu-
lator
ignition switch fuel pump
fault indi- highTempera- rev signal

catinglamp ture indicator of engine
battery of engine catalytic converter
optional for metal carrier
Structural drawing of EFI system
3 The trouble description of EFI system

Check the EFI system by the test instrument.If it has fault，replace homologous
component of EFI. If not, please check the system as following:
1.Check the line connection;
2.Check whether or not the voltage reaches 9V.
3.Check the vehicle and EFI safe system
4.Check whether the oil-ways are blocked,extruded or broken.
ENGLISH
15
Section 3 Inlet and Exhaust System
The inlet system of engine mainly consists of air cleaner and inlet pipe.The main function of which
is to guide and filtrate air,reduce inlet noise and control the volume of mixed gas which is going to engine.
The exhaust system mainly consists of exhaust pipe and muffler.The main function of which is to
transfer the exhaust gas to atmosphere,reduce the noise when exhausting and the temperature of exhaust
gas and eliminate the spark in exhaust gas.A good exhaust system can advance the inlet and exhaust
system,increase engine power and reduce the fuel consumption,so it is also called exhaust muffler.
1 The Structure of Inlet System
[1]The Structure and Working Principle of Air Cleaner
Air cleaner is the important component of inlet system.The function of which is to filtrate,purify the
air entering into cylinder,avoid dust,sand entering into cylinder so that it will reduce the abrasion of
cylinder,piston and piston ring.Its performance has a big effect on the motivity of engine,noise of inlet and
service lifetime.Experiences indicate the abrasion of cylinder will increase 8 times ,the abrasion of piston
will increase 3 times and the abrasion of piston ring will increase 9 times if air cleaner is not installed.In
this way,the reliability of engine will reduce and the service lifetime will be shortened.Therefore,motor-
cycle must be installed with air cleaner. The requirement of air cleaner is not only to filtrate the air,but also
the resistance of air flowing must be small so that the volume of engine inlet will enhance.More require-
ments are reliable working performance,simple structure,small dimension of appearance,light body and
easy to maintain.The air cleaner mainly consists of element and sealed box.When engine runs,air will
enter into the front cavity of air cleaner through air pipe,then flow into the rear cavity after filtration.and
finally enter the throttle.
[2]The Structure and Working Principle of Inlet Pipe
Inlet pipe is the important component to con-
nect throttle and engine inlet.Meanwhile,it has a
function of supporting throttle and has a simple
structure.Its bending shape depends on the posi-
tion which the throttle should be corresponding to the
engine inlet,but you should think about the influ-
ence of inlet resistance.If the pipe is long,it has an
advantage of fuel pulverization,but air resistance is
big.If the pipe is short,which is not good for fuel
pulverization,but air resistance is small.
The mixed gas after pulverization of throttle
flows into cylinder through inlet pipe and engine
inlet.The inlet pipe reduces the heat which engine
has transferred to throttle and separates the shake of
engine from throttle.
2 The Structure and Working Principle of Exhaust

System
The exhaust pipe in exhaust muffler is made of
bending steel pipe.It locates between exhaust vent of
engine and muffler.Its funtion is to guide the exhaust
gas from engine to the muffler.
ENGLISH
16
3 Disassembly and Maintenance of Intake System
[1]Dismantle suspension bolt of air cleaner
and clamp screw of inlet pipe.Remove air
cleaner assembly.
air cleaner
[2]Dismantle lock screw of air cleaner element. Take out

the element of air cleaner and check whether there is too
element much dust on it.Clean it if too much dust.
[3]Remove filter sieve of air cleaner and check whether

it is damaged or dusty.Clean the filter sieve.
filter sieve
ENGLISH
17
4 Disassembly and Maintenance of Exhaust System
[1]Dismantle the locknut of exhaust pipe of muffler
and suspension bolt of muffler.Check whether the
suspension bracket is broken.Re-joint it if broken.
Locknut
CAUTION
When the suspension bracket of muffler is
broken,replace or re-joint it.
[2]Remove muffler and check whether the muffler is

broken or damaged.Re-joint or replace it when bro- muffler
ken or damaged.
[3]Remove the seal gasket of muffler and check whether

the gasket is damaged.Replace it if damaged. Seal gasket
CAUTION
The seal gasket must be replaced every disassembly
of muffler.
[4]Check whether there is carbon deposit in the muffler

pipe.Clean it.
ENGLISH
Muffler
pipe
CAUTION
Check Whether muffler is rusty or broken.Replace or
18 maintain it if necessary.
[5]Check whether there is carbon deposit at the
muffler tail.Clean it.
muffler tail
5 The cause,trouble description and repair method of inlet and exhaust system
Table4-3 Maintenance of Inlet and Exhaust System

component trouble description of description of repair method
description cause component motorcycle
Engine is hard to be started
or cannot be started.poor Clean or replace
Element is dusty. engine power,unstable idle element.
speed,high fuel consump-
inlet system tion and black smoke from
exhaust muffler.
The body of air The noise of engine in- Replace air cleaner
cleaner is broken. let is big. body.
ENGLISH
leakage at vent of The noise of engine exhaust Replace seal gasket

exhaust pipe becomes louder. of exhaust pipe.
exhaust The body of ex-
system The noise of engine ex- Repl ace exh aust
haust muffler is haust becomes louder. muffler.
broken. 19
Section 4 Rear Transmission Device
Because the export torque of engine is small and its rev is fast,it only can enhance the torque of engine to ensure
the good working condition of motorcycle by 3-time deceleration.The first time is through the drive and driven gear of
cluth.The second time is through the drive and driven bearing of derailleur.The third time is through the drive and driven
gear of rear transmission device,so that the export power and rev of engine can economically and properly be used.
1 The Structure and Working Principle of Rear Transmission Device
The rear transmission device of this motorcycle adopts
chain.It mainly consists of drive gear,driven gear,drive chain,
chain tie-in,drive chain box,chain adjuster and rubber dead
block.
First,it exports power through the end of countershaft
of engine derailleur(power-exporting bearing),then trans-
fers the power to driven chain through drive chain and
makes 3-time deceleration.The driven chain is fastened
on the cushion body by bolts.The cushion body con-
nects with rear hub through rubber dead block.So when
changing the speed during running,power is transferred
flexibly through rubber cushion,so it avoids the abrasion
of parts and enhances the comfort and stability of
motorcycle.
2 Disassembly and Maintenance of Rear Transmission Device

[1]Dismantle the fixed bolt of gearshift pedal and remove
the gearshift pedal.
gearshift axle
[2]Dismantle bolts of left rear cover of left crankcaseand

remove left rear cover of left crankcase.
re ar co ve r of
ENGLISH
left crankcase
20
[3]Check the abrasion of small drive chain and replace the
chain assembly if necessary.
Small drive
sprocket
wheel
[4]Dismantle fixed bolt of chain box,and remove the chain

box.
chain box
[5]Dismantle the spring clamp of drive chain.

Remove tie-in of drive chain and drive chain.Check
the abrasion of the tie-in of drive chain and replace
it if necessary.
CAUTION
When installing,the open end of spring clamp of

Chain tie-in chain tie-in should be opposite to the running
direction of chain.
[6]Check the abrasion and distortion of drive chain.

Wholly replace the big and small sprocket wheel
and drive chain if necessary.
ENGLISH
drive chain
21
[7]Remove left gasket of rear wheel and check its
abrasion.Dismantle the locknut of rear axle, then
take rear wheel off.
Left
gasket
[8]Remove the oil seal of cushion body of rear drive

sprocket wheel and check its abrasion.
Oil seal
[9] Remove the rear drive sprocket and check it for

wear.
CAUTION
Rear drive
When both big and small drive sprocket wheel sprocket
are worn,wholly replace them,including big and wheel
small drive sprocket and drive chain.
[10]Remove the gasket of rear drive sprocket wheel

and check the abrasion of rear drive sprocket wheel
axle.Replace it if necessary,otherwise it will influ-
ence the working of transmission system.
ENGLISH
WARNING
rear
When rear drive sprocket wheel axle is worn, wheel
replace it in time,otherwise it will lead to a big berring
swing of rear wheel and a dead rear wheel.
22
3 The cause,trouble description and repair method of rear transmission device
Table 4-4 Maintenance of Rear Transmission Device
component trouble description of trouble description of
description cause component repair method
motorcycle
Gear teeth are worn. Drive chain disen- D r i v e c h a i n h a s Wholly replace drive
gages from gear. strange sound and is and driven sprocket
drive sprocket easy to break off. wheel and drive chain.
wheel The inner teeth of gear strange sound from Drive chain is easy to Wholly replace drive
are worn. drive chain break off. and driven sprocket
wheel and drive chain.
Drive chain disen- D r i v e c h a i n h a s Wholly replace drive
Gear teeth are worn. strange sound and is and driven sprocket
gages from gear. wheel and drive chain.
driven easy to break off.
sprocket wheel The inner teeth of gear Wholly replace drive
strange sound from Drive chain is easy to and driven sprocket
are worn. drive chain break off. wheel and drive chain.
Drive chain is too dirty Drive chain has strange Clean and lubricate
or has bad lubrication. sound. chain.
Drive chain is too improper tightening D r i v e c h a i n h a s Adjust the tightness
adjustment of chain strange sound. of dr iv e c hai n to
tight. 15mm~25mm
improper tightening D r i v e c h a i n h a s Adjust the tightness
drive chain Drive chain is too adjustment of chain strange sound or is of dr iv e c hai n to
loose. easy to break off. 15mm~25mm
Chain is worn. Drive chain disen- Drive chain is easy to Wholly replace drive
and driven sprocket
gages from gear. break off. wheel and drive chain.
drive chain Drive chain box is sound from drive chain Replace drive chain
box damaged. box box.
Readjust left and right
improper adjustment of Drive chain is easy to adjuster and keep the
adjuster left and right adjuster Rear wheel inclines. break off. left mark the same as
the right mark.
Adjuster is damaged.Adjuster cannot be Drive chain is easy to Replace adjuster.

adjusted. break off.
rubber Rub ber cu shion is Rubber cushion is strange sound from R e p l a c e r u b b e r
cushion worn. damaged. rear wheel cushion.
ENGLISH
23
Section 5 Frame and Accessaries
Frame is the supporting framework of motorcycle.It is the main supporting part of motorcycle.Because
motorcycle should bear mighty shake during running,its component and structure must have high
intensity and the frame is required to be light.In this way,it is good for motorcycle to have a high-speed
running.
1 Structure and Working Principle of Frame and Accessaries
The frame of this motorcycle adopts pipe joint-
ing and crooked girder.It has high intensity,good
firmness and good suitability.It mainly consists of
head pipe,main frame,tail pipe,rear supporting pipe
and low bending pipe.It is made through the meth-
ods of jointing,riveting and so on.
Frame is used to support engine,transmission
system,operation system,seat,fuel tank,brake sys-
tem and so on.Meanwhile,it also offers the install-
ing point for other accessories.It makes motorcycle
as an integrated part.
2 Disassembly and Maintenance of Frame and Accessories
[ 1] Ch e ck re a rv i ew m i rr o r f or lo o se n es s
and damage. Fasten or repair it if loose or
damaged.
Check
rearview
mirror
CAUTION
Keep the rearview mirror clean and dustless.
Adjust it to its best angle before riding.
[2 ]Ch eck wh eth er side st and is be nd or

d is to rt e d. Re pa i r or r e pl ac e i t if be nd o r
distorted.
Side stand
ENGLISH
24
[3]Check all the covers of motorcycle.Re-
place them if damaged.
Cover
ADVICE
Replace the covers if damaged.
[4]Check whether the seat is damaged.Re-

place it if damaged.
Seat
ADVICE
Replace seat if damaged.
[5]Check whether the rubber cover of front

pedal is damaged.Replace it if damaged.
Front pedal
ADVICE
Replace rubber cover of front pedal if damaged.
[6]Check whether rear armrest is broken.

Rear armrest Repal ce or repa ir them i f is.
ENGLISH
ADVICE
Repl ace re ar armr est if it pa rts. 25
3 The cause,trouble description and repair method of frame and accessories
Table4-5 Maintenance of Frame and Accessories

component trouble description of trouble description of repair method
description cause component motorcycle
Frame is struck or has Frame is distorted. Motorcycle cannot run Correct or replace
fallen down. normally. frame.
frame Frame is struck or has Frame parts or crazes. Motorcycle cannot run. Joint or replace frame.
fallen down.
Frame is infuenced by The jointing of frame Motorcycle shakes or Joint frame.
road and is shaken. breaks off. cannot run normally.
Side stand is distorted Side stand cannot Motorcycle makes sound
return normally. during running and park- Correct or replace side
or parts. ing is influenced. stand.
side stand Motorcycle makes sound
Returning spring loses Side stand cannot during running and park- Replace returning
springiness. return normally. spring.
ing is influenced.
left cover Left cover is damaged for Left cover is damaged. Appearance is influenced. Replace or repair left
being struke. cover.
right cover Right cover is damaged Right cover is damaged. Appearance is influenced. Replace orrepairright
for being struke. cover.
front fender Front fender gets strike Front fender is dis- Motorcycle makes R e p l a c e f r o n t
or shake. torted or damaged. sound during running. fender.
rear fender Front fender gets strike Rear fender is dis- Motorcycle makes R e p l a c e r e a r
or shake. torted or damaged. sound during running. fender.
seat Seat cover is damaged. The comfort of riding Replace seat.
declines.
Front pedal is dis- R i d i n g s a f e t y i s Replace front pedal.
front pedal torted or damaged. influenced.
rear pedal Rear pedal is dis- Comfort for rider declines. Replace rear pedal.
torted or damaged.
starting lever Starting lever is dis- Starting performance Replace starting
torted or damaged. is influenced. lever.
rear view Rear view mirrior gets Rear view mirrior is R i d i n g s a f e t y i s Replace rear view
mirrior strike or shake. distorted or damaged. influenced. mirrior.
rear carrier Rear carrier gets strike Rear carrier is distorted Setting of loads is Joint or replace rear
or shake. or jointing breaks off. influenced. carrier.
=
ENGLISH
26
Section 6 Steering System
The direction of motorcycle is operated by steering handlebar.The steering handlebar connects with direction pole.It sees
the frame as the center and run the front shock absorber and operate the front wheel through the rotation of direction pole.
1 The Structure and Working Principle of Steering System
[1]Steering handlebar
The right steering handlebar of motorcycle is the throttle control grip, Control oil flow rate.The right holding lever
is the front brake lever.Also,there are left and right controlling switches,rear view mirrior and choke switch
respectively installed on the left and right handlebar.
[2]Direction pole assembly
Direction pole assembly is the important part of steering system.It mainly consists of direction pole,lower
connecting board,bearing and bearing ring.Normally,the direction pole is jointed with lower board(wholly called
direction pole) and installed within the frame pipe.The weight of motorcycle and rider transfers to front wheel
through the direction pole.However,the weight caused by the strike of road for the front wheel transfers to
motorcycle body through the direction pole. Therefore,direction pole not only must bear the big loads strike,but also
ensure the flexible turning during running.
2 Disassembly and Maintenance of Steering System
In order to make motorcycle keep a good operation,you should maintain the steering system termly.For the first time,
disassemble vehicle after 1500km,and then disassemble it every 600km.Check the abrasion of inner and outer bearing and
rolling ball.Replace them if necessary.When replacing rolling ball,you must replace it completely.Don ’t mix the new parts with
the old ones.
The maintenance of direction pole should stress on bearing.If the bearing is always lack of
lubrication and adjusting nut is loose,the clearance
of bearing will be too big,so that the steering handle-
bar will shake during running,which influences the
stability and safety of motorcycle.On the other hand,if the bearing is
damaged or adjusting nut is too tight,the turning resistance of steer-
ing handlebar will be too big,so that the steering handlebar will be
locked,which is hard to be operated or cannot be operated.Therefore
it influences riding safety.
Support motorcycle with main stand and make front
wheel off the ground.Rotate the front fork and front
shock absorber and check whether the bearing is loose.
Turn the steering handlebar and check whether the
bearing is flexible.Adjust it if the bearing is too
loose or tight.First,unscrew the locknut of direction
pole,rotate adjusting nut and check the tightness of
bearing.Re-tighten the locknut until the bearing is
normal.
The cause,trouble description and repair method of direction pole
Table 4-6 Maintenance of direction pole

The match clear- Turning handlebar is not Adjust nut with lock
Adjusting nut is too ance of bearing wrench until the
tight. flexible.
and bearing ring is handlebar is flexible
bearing too small. and there is no bear-
ring ing rolling between
direction pole and
frame pipe.
Bearing ring is too
worn or damaged Turning handlebar is not Wholly replace bear-
and has pit,press flexible and shakes during ring.
mark and spit. ing running.
ENGLISH
Bearing is worn, Turning handlebar is not Wholly replaceball bearing

bearing distorted or flexible and shakes dur-
damaged. ing running.
direction Direction pole is Direction pole is Turning handlebar is not Correct or replace di-
pole distorted. distorted. flexible. rection pole.
27
Section 7 Operating Steel Wire
1 Structure and Working Principle of Operating Steel Wire

Operating steel wire mainly consists of steel wire,wire head and metal spring plastic hose.The steel
wire should be soft so that it doesn’t break off easily and it can bear big pressure.It is normally made
of several thin wires,which ensure the intensity of steel wire and make it soft.The wire hsead is
connected with steel wire through the method of stannum jointing ,zins alloy die-casting and so on.The
outside of metal spring plastic hose is plastic and inside is a spring hose made of steel wire,which can
bear any bending and won’t change the length when suffers axial pressure.There is a nylon bushing
between the steel spring plastic hose and steel wire,which avoids the direct friction of steel wire and
spring hose.
2 Maintenance of Operating Steel Wire
In order to keep operating steel wire working well and
prolong its sevice lifetme,termly cleaning and lubricat-
ing is necessary.For the first time,you can do it after
1500km,and then every 3000km.Here are two meth-
ods for lubrication:one is dip in,the other is injection.
Dip In Lubrication
Operate as follows:
[1]Dip the whole steel wire in coal oil for 5-10min.
Pull the steel wire to clean out the deposit in hose.
[2]Dip the whole steel wire in the mixed oil which
has persentage of 1:1 of coal oil and luboil.Pull the
steel wire to make mixed oil flow into the hose.
[3]Remove operating steel wire and clean the
mixed oil outside.
Injection Lubrication
Operate as follows:
wire head
[1]Enlace the end of metal spring plastic hose of operat-
steel wire
ing steel wire with transparent adhesive tape.Make it as o i l k e tt l e
a pipe.as the picture: adhesive tape
[2]Raise the end with adhesive tape and pull out of steel
head.
[3]Dip luboil in the hose with oil kettle until there is oil
dripping from the lower steel wire. metal hose
The cause,trouble description and repair method of operation system

Table4-7 Main tenance of Oper ation Sy stem
component
cause trouble description of trouble description of repair method
description component motorcycle
handlebar H a n d l e b a r i s Handlebar is distorted. Motorcycle runs towards one side. Correct or replace
distorted. handlebar.
Steel wire cannot Clutch handlebar is hard Clutch slides or cannot Clean,lubricate or re-
Operating f l e x i b l y p u l l e d to be operated or cannot disengage completely. place operating steel
steel cable outside the cable. be returned well. cable.
of clutch
ENGLISH
Steel wire breaks off. Clutch cannot disen- Replace operating

gage completely. steel cable.
rear brake The free stroke is Rear brake pedal cannot
pedal too small. be returned to the origi- Readjust the free stroke.
nal place.
The free stroke is Rear brake loses control. Readjust the free stroke.
28 too big.
Section 8 Shock Absorber
Front shock absorber is the spring connecting part between front wheel and vehicle body.Rear shock
absorber mainly bear axial pressure of rear wheel.Both of them support the weight of the whole vehicle
body.During motorcycle running,it reduces the concussion and shake for motorcycle and rider,reduces
the pressure for components,prolongs the service lifetime of motorcycle and enhances the comfort,
operation and stability for rider.
1 The Structure and Working principle of Front/Rear Shock Absorber
[1]Front Shock Absorber
The front shock absorber of this motorcycle adopts compound of hydraulic pressure and spring.It
mainly consists of front shock absorber spring,seal ring,dustproof cover,piston ring,front shock absorber
pole,piston lever,buffer spring,one-way valve spring socket,one-way valve spring,one-way valve,one-
way valve socket,front shock absorber pipe and piston lever socket.
When the front wheel of motorcycle gets strike and shake,the front shock absorber pipe rises,the
damping oil flows up through the one-way valve and small holes on piston lever.The resistance power
is small at this time.When absorber pipe continues going up,the clearance between one-way valve
socket and the cone-shaped surface of piston lever becomes smaller and smaller,so that the resistance
becomes bigger,which avoids the bump of front shock absorber pipe and front shock absorber.When
front shock absorber pipe goes down for the returning of front shock absorber spring,the damping oil only
can flow from the small holes of piston lever because of the close of one-way valve,which causes a big
resistance,so that it reduces the shake of front shock absorber spring.
[2]Rear Shock Absorber
The rear shock absorber of this motorcycle adopts compound of hydraulic pressure and spring.It
mainly consists of upper tie-in,rubber cover,gasket,rear shock absorber spring,rear shock absorber lever,
piston,damper and lower tie-in.
Rear shock absorber mainly gets the axial pressure of rear wheel.When the rear wheel gets the strike
or shake for the road condition,rear shock absorber will compress and expand.The hydraulic pressure oil
of damper is forced to flow through the damping hole,so it reduces the shake of rear shock absorber
spring.
2 Disassembly and Maintenance of Front Shock Absorber
[1]Check the effective stroke and performance of
front shock absorber,and check whether there is
leakage from front shock absorber.
Check front
shock
a bs or b er .
CAUTION
Maintain front shock absorber in time if it has

some problems in order to ensure the riding
safety.
[2]Dismantle four fixed bolt of front shock absorber，

and remove the front shock absorber.
ENGLISH
Dismantle the
bolt of front
shock absorber.
29
[3]Dismantle bolt of front shock absorber and drain
front shock absorber oil.Check whether the oil is
bad.Replace it if bad.
Drain shock
a bs o r be r oi l
[4]Remove the oil seal and spring clamp of front

shock absorber and check whether the edge of oil
seal is worn.Replace it if necessary.
Spring clamp
Oil seal
[5]Dismantle front shock absorber pole and lower pipe.

Check their abrasion.Replace them if worn.
Lower pipe
Shock absorber
pole
[6]Remove the returning spring of shock absorber pole and

check its abrasion and distortion.Replace it if distorted.
ENGLISH
Returning
spring
30
[7]Measure the inner diameter of lower pipe of front shock
absorber with callipers.Check whether it exceeds the
limit value of maintenance.Replace it if exceeds.
Measure the
lower pipe.
[8]Remove the returning spring of front shock absorber and

check its abrasion.Replace it if worn.
Spring of
shock
absorber
[9]When installing front shock absorber,add front shock

Add shock absorber oil according to the stated.The standard volume
a bs o r be r oi l
of front shock absorber is (330 ± 5)mL.
Lower pipe of
shock absorber
3 Disassembly and Maintenance of Rear Shock Absorber

[1]Check whether the spring of rear shock absorber
becomes soft and its damper has leakage.Replace shock
absorber assembly if the rear damper has leakage.
ENGLISH
Rear
shock
absorber
31
[2]Check whether the left one has the same length as the
right one and check whether the spring surface of shock
absorber is damaged.Replace it if damaged. Rear shock
absorber
CAUTION
When rubber components have abrasion or
aging,replace them.
4 The cause,trouble description and repair method of front/rear shock absorber

Table 4-8 M ai nt en an ce o f Fr on t/ Re ar S ho ck A bs or be r
component cause trouble description of trouble description of
description component motorcycle repair method
The front shock absorber Front shock absorber The comfort,stability Replace front shock
spring has poor elasticity i s s o f t o r m a k e s and safety of riding absorber or spring.
or breaks off. strange sound. decline.
Motorcycle runs to- Correct and replace
Front shock absorber Left pole and right pole wards one side and front shock absorber
pole is distorted. are not at the same comfort,stability and and front shock ab-
level. safety are influenced. sorber pole.
The surface of front The oil seal of front shock The comfort,stability Replace front shock
s h o c k a b s o r b e r i s a bs or be r p ol e ha s and safety of riding absorber or its pole.
damaged. decline.
leakage.
The chromeplating tier Motorcycle runs to-
of front shock absorber The oil seal of front wards one side and Replace front shock
is worn so that the shock absorber pole comfort,stability and absorber or its pole.
front shock metal part appears. has leakage. safety are influenced.
absorber The lower pipe of front Front shock absorber Motorcycle runs to-
shock absorber is worn has leakage. wards one side and Replace front shock ab-
comfort,stability and sorber or its lower pipe.
or breaks off. safety are influenced.
Piston lever is worn Front shock absorber The comfort,stability Replace front shock ab-
and safety of riding sorber or piston lever.
or damaged. is too soft. decline.
Piston ring is worn or The comfort,stability Replace front shock ab-
Fr on t sh oc k ab - and safety of riding
damaged. sorber is too soft. sorber or piston ring.
decline.
The edge of oil seal is Oil seal has leakage. The comfort,stability Replace oil seal of
worn or damaged. Front shock absorber and safety of riding front shock absorber.
is too soft. decline.
The oil of front shock Front shock absorber The comfort,stability Add or replace front
absorber is not enough becomes soft. and safety of riding shock absorber oil ac-
or bad. decline. cording to the stated.
The spring of rear shock Motorcycle runs to-
absorber breaks off or Rear shock absorber wards one side and Replace rear shock
has poor elasticity. is too soft. comfort,stability and absorber.
safety are influenced.
R e a r d a m p e r h a s Rear shock absorber The comfort,stability Replace rear shock
leakage. is too soft. and safety of riding absorber.
rear shock decline.
ENGLISH
absorber The piston lever of rear Motorcycle runs to-

damper is distorted or Rear shock absorber wards one side and
comfort,stability and
Replace rear shock
breaks off. is distorted. absorber.
The upper and lower Rear shock ab- The comfort,stability Replace upper and
connecting rubber cover sorber is distorted and safety of riding lo we r co nn ec ti ng
32 are worn or have aging. or makes sound. decline. rubber cover.
Section 9 Rear Fork
The rear fork connects rear wheel with frame.It makes rear wheel rotate around a fixed point through rear shock absorber
to reduce the strike and shake of rear wheel.
1 The Structure and Working Principle of Rear Fork
Because rear fork gets big strike and shake,the
requirement on material and jointing is very high.It
is made through the method of jointing and so on.
It mainly consists of rear fork,dust seal,dustproof
seal cover and rear cover of bearing.
In order to keep rear fork rotating up and down
around the vehicle body,there is bearing shaft or
bearing installed at the connection of rear fork and
vehicle body.When rear fork rotates,it will make
rear wheel more flexibly and more stably.
2 Disassembly and Maintenance of Rear Fork

[1]Check whether rear fork is distorted or crakes because
of the outside force,whether the match clearance of each
component of rear fork becomes big,and whether the
rotating times of rear fork is too much.
CAUTION Check rear fork

Replace or maintain rear fork in time if it has the
problems above to ensure the comfort and safety of riding.
3 The cause,trouble description and repair method of rear fork
Table4-9 Maintenance of Rear Fork

Motorcycle runs to- Correct or replace
Rear wheel gets strike. Rear fork is distorted. wards one side and rear fork.
comfort,stability and
Motorcycle falls down Rear fork breaks off. Motorcycle cannot run Joint or replace rear
and rear fork breaks off. normally. fork.
rear fork
ENGLISH
The strike and shake to The jointing of Rear The comfort,stability Joint rear fork.
rear wheel is too big. fork breaks off. and safety of riding
decline.
The road is bad and the The dust seal of bear- The seal of bearing Replace dust seal of
strike and shake to rear ing cover of rear fork cover or bearing of re ar f or k be ar in g
wheel are too big. is worn. rear fork is bad. cover.
33
Section 10 Wheel
Front/rear wheel is the running component of motorcycle.It supports the weight of whole motorcycle
and ensures a friction made by wheel and road to make wheel avoid sliding.Wheel can reduce and absorb
the strike and shake caused by the road.The front wheel cooperates with operating part,which fixes on the
direction of running.The rear wheel is transferred power by engine,which drives motorcycle to run.Wheel
mainly consists of outer tire,inner tire,aluminium tire,tire hub,bearing,bush,oil seal and axle.
1 The Structure and Working Principle of Wheel
[1]Tire
The tire of motorcycle is the important component of riding system.Its function is to touch road surface
directly,support the weight of whole motorcycle,reduce strike and shake during running with its elasticity,
ensure balanced motorcycle running and avoid sliding.Tire consists of outer tire,inner tire and gasket.
Outer Tire
Outer tire consists of tire surface,tire body,gasket and tire ring.The surface of outer tire directly touches
road surface.There are different thread on tire surface,which helps motorcycle avoid sliding on different
road.The tire body has a certain intensity,but in order to emit heat,it had better not be too thick.The tire ring
is packed by the edge of curtain and steel ring,which makes outer tire fix on the rim.If the perimeter of tire
ring is too short,which will make the disassembly of outer tire more difficult and if the perimeter is too long,
which will make outer tire spring out.The curtain tier is the framework of outer tire.But the curtain tier of
outer tire crosses with the transect of tire,which makes an angle.But the curtain tier of meridian tire arrays
as the direction of earth meridian.The meridian tire has the good characters of reducing power consumption,
fuel consumption and prolonging service lifetime.
Inner tire and Gasket
Inner tire is made of rubber.It is a circle.There is a valve on it,which can adjust the pressure of inner
tire.The main requirement of inner tire is seal.The pressure of inner tire is the main reason of influencing
the usage of wheel and tire.The gasket is a round rubber cincture,which separates inner tire and rim,
protects the seal of inner tire and prevents the break caused by the spiculate thing.
[2]Rim
Rim is the framework for supporting and fixing the tire.The rim of this motorcycle has two types, die-
casting rim and spoked rim.The former is made from aluminum alloy,which integrates the rim and hub by
casting and then machining.This kind of rim has high intensity,simple arts and crafts,convenient
installation,but poor elasticity and cannot be adjusted.If the rim is distorted or damaged,you should
replace the whole rim.The spoked rim is made from steel strip.In the wheel rim,there is a lot of hole seats,
in which a spoke and spoke nut are installed.The other end of spoke connects the wheel hub.Therefore,
the spoked rim has a good shock resistance,adjustable characteristic and convienent maintenance.In this
part, it mainly discusses the die-casting rim.
[3]Wheel Hub
The wheel hub of motorcycle is divided into front hub and rear hub.The structure of front hub and rear hub is very
familiar.The rear wheel is drive wheel,so there is power transmission device installed on rear hub.There are bearing,
bearing gasket,oil seal and axle installed in the front and rear hub,which is good for the operation of wheel hub.
2 Disassembly and Maintenance of Wheel
[1]Check whether tire pressure is within the normal
scale.Clean out the deposit of outer tire thread.Avoid
inner and outer tire damaged.
Check front
wheel.
ENGLISH
CAUTION
Check the abrasion of outer tire.Replace it if it
34 exceeds the limit value:2.00mm.
[2]If front wheel is deformed by stricking or vibration,
so that the bike run out of way or steering control
trembling or vibrating. The wheel need to be re-
placed or adjusted.
Check front wheel
CAUTION
Replace the wheel when it trembling over the
maintainence limit value。
[3]Before dismantling front wheel, fix the bike

first and leave the wheel of ground, then take off
tighting nut of front wheel shaft（M14） and
Remove the take out front wheel shaft and front wheel
front wheel
assembly.
[4]Take out front wheel shaft bush to check whether

it was abraded. If it was worse,replace it.
Remove the liner

CAUTION
Add grease when assembling the bush。
[5]Take out the oil seal to check whether the blade is

abraded. Replace it when needed.
ENGLISH
Remove the
oil seal
35
[6]Put front wheel on rectification desk and rotate
it in high speed to check the abrasion condition
and free strock. if it is abraded, dismantle it and
replace.
CAUTION
check front
When there is noise or free strock turn wide, replace wheel shaft
it with new beering. And assemble beering with the oil
seal inside.
[7]If front wheel shaft abrade badly, knock it out by

using shaft disassembling tools and replace it with
the new one.
disassem-
CAUTION bling front
wheel shaft
When assembling front wheel shaft, add grease
on it and assemble beering with the oil seal inside.
[8]Put front wheel on rectification desk to check the

vibration of it. Rotate it with hand and use dial
indicator to test the value and read the value.
Maintainance limit value：
Radial 2.0mm
Axial 2.0mm
measure the
vibration of
CAUTION front wheel
If the vibration value is over maintainance limit value
above, rectify or replace it.
[9]Check the abrasion of front outer tyre. The maintainance

limit value of front outer tyre thread is 2.00mm. If the
pressure of front wheel is insufficient, check whether
inner tyre valve core has leakage,then check whether in-
ner tyre has leakage.
ENGLISH
CAUTION
If inner tyre valve core has leakage, repair or

replace the core, If inner tyre has leakage, fix or check
inner/ouer
replace inner tyre. tyre
36
[10]Dismantle the locknut of rear axle .Remove rear axle
and rear wheel assembly.
Check rear axle.
[11]Dismantle rear wheel and check whether rear wheel

Check rear hub is damaged.Replace it if damaged
wheel hub.
[12]Check whether rear axle is worn.Replace it if

worn.
Check rear
axle.
CAUTION
Smear lubricant when installing.。
[13]Check whether the front and rear rim are distorted.

Correct or replace them in time.Check whether the
outer tire thread of rear wheel is worn.Replace outer
tire if the abrasion value exceeds 2mm.
ENGLISH
Check rear rim.
37
3 The cause,trouble description and repair method of wheel
Table4-10 Maintenance of Wheel
component cause trouble description of trouble description

description component of motorcycle Repair method
Front wheel is distorted. F r o n t w h e e l i s Motorcycle runs towards one
distorted. side and turning handlebar
shakes during running. Replace front wheel.
The bearing hole of The match of bearing Motorcycle runs towards
wheel hub is worn. hole of wheel hub one side and turning
front wheel and bearing is too handlebar shakes dur-
loose. ing running.
Bearing is worn or The axial and radial Motorcycle runs to- Replace bearing
clearance of inner
damaged. and outer bearing is wards one side and
too big or its rotation turning handlebar
is not flexible. shakes during running.
Tire is worn. It is easy to slide during

front wheel running and it is hard Replace outer tire.
to avoid side sliding.
Gear is damaged. S peed om et er f in ger Replace the gear box of
gear box of cannot swing. speedometer.
speedometer The transmission ring of Speedometer finger Replace the gear box
gear wheel is damaged. cannot swing. of speedometer.
Rear wheel is distorted. Rear al uminium
wheel is distorted.
rear wheel Rear wheel is damaged.
The bearing hole of The match of bearing Motorcycle runs to-
wheel hub is worn. hole of wheel hub and wards one side and
rear wheel shakes Replace bearing.
bearing is too loose. during running.
Bearing is worn The axial and radial
or damaged. clearance of inner
and outer bearing is
too big or its rotation
is not flexible.
It is easy to slide
rear tire Rear tire is worn. during running and Replace outer tire.
it is hard to avoid
side sliding.
ENGLISH
38
Section 11 Brake
Motorcycle usually needs to decelerate and stop during riding,so brake is used to make resistance to wheel
to achieve that purpose.For normal motorcycles,front brake is operated by right hand and rear brake is
operated by right foot.However,among some motorcycles with automatic clutch,such as moped or scooter,
the rear brake can be operated by left hand.The brake of motorcycle consists of drum brake and disc brake.
This motorcycle adopts front disc brake and rear drum brake.
1 Structure and working principle of brake
Disc brake consists of mechanism type and hydraulic
type.At present,hydraulic brake is in common use on
motorcycle.The hydraulic brake normally consists of brake
handle(brake pedal),main oil reservoir,reserve oil reservoir
(The reserve oil reservoir and main reservoir are usually
integrated),brake caliper,brake disc and brake oil pipe.
When operating brake,brake handle compresses the main
oil reservoir,which enhances the pressure in hydraulic
pressure system,drives the main piston in brake caliper
and tighten the friction pieces on brake disc.Therefore,
the brake disc fixed on wheel can get the braking power.
The characters of disc brake is soft working ,automatic
cleaning and hard to lose control.
Structure drawing of disc brake
2 Disassembly and maintenance of brake
[1]Hold front brake control with right hand to check the

Check brake handle brake performance of front brake. The standard free stroke
is: 10mm～20mm
注意
CAUTION
If front brake control can not reach the
standard value, readjust front brake.
[2]Disassemble the front brake pliers locking bolt,

remove the front brake caliper
ENGLISH
Disassemble the front

brake caliper
39
[3] Disassemble disc brake friction plate and check
the piston of brake caliper for working condition.If
it cannot work well ,repair or replace hydraulic brake.
Remove front brake
friction plate
[4]Disassemble locking nut of front axle and Mile-

age line, then remove the front wheel.
Remove wheel
[5]Remove the speed counter and check the wear breaking

of the seal blade. Replace it if necessary
Remove
speed counter
[6]Remove the front wheel, remove the front brake disc

fixed bolt, remove the front brake disc.
ENGLISH
Disassemble the
WARNING locking bolt
Please smear glue on the bolt before installing
40 the front brake disc to avoid bolt looseness.
[7]Measure the thickness of front brake disc with micrometer.
The limit value of repair is 2.0mm.
Check the
th ic kn es s
CAUTION
If the thickness of brake disc exceeds the limit
value of repair 2.0mm,replace the brake disc.
[8]Measure brake disc run-out with dial indicator, and the

limit value of repair is 0.3mm.
Check the
run-out
CAUTION
If the run-out of brake disc exceeds the limit
value of repair0.3mm,replace the brake disc.
[9]Step rear brake pedal by foot, check it for

performance. The standard free stroke of brake pedal
is:20mm～30mm.
Check rear
brake arm
[10]If the free stroke of rear brake pedal cannot reach

the standard value, readjust the nut of rear brake
rod.
Adjust free stroke
[A]Regulate adjusting nut of rear brake and adjust
the free stroke of rear brake pedal to 20mm～
30mm.
[B]Step rear brake pedal for several times and re-
ENGLISH
lease it.Rotate the rear wheel assembly and check

the rear wheel for free rotation.
41
[11]Disassemble the nut of rear wheel axle and
remove the wheel axle and rear wheel assembly.
locking nut
[12]Remove friction lining and Measure the thick-

ness of it with the limit value of repair is 2.0mm.
Check the piston of brake caliper. If it cannot run
normally, fix or replace hydraulic brake.
Check friction lining
[13]Disassemble the fixed bolt of brake disc and remove

it.
Disas-
WARNING semble the
fixed bolt
Please smear glue on the bolt before installing
the rear brake disc to avoid bolt looseness.
[14]Check the wear for bake disc.

measure the inner diameter by callipers. The limit value
of repair is 131.0mm.
measure the
th ick ne ss
ENGLISH
WARNING
If the value of inner diameter exceed the limit
42 value, replace it.
[15]Measure the run-out of brake disc by dial
indicator and the limit value is 0.3mm.
Measure
the run-
out
CAUTION
If the value of run-out exceed the limit
value,replace it.
3 The cause,trouble description and repair method of front/rear brake see Table 3-13:
Table 3-11 Maintenance of Front/Rear Brake
Component Cause Trouble description Trouble description Repair method

of component of motorcycle
Friction plates are Brake is out of con-
worn. trol or brake pads
cannot return. Replace brake
pads as a set.
Brake The end of brake pad is Rear brake makes ab-
pads worn to a slot. normal sound or is
out of control.
The area of brake shoe Brake is out of control Repair or replace fric-
touching with brake
drum is too small. tion plates of brake pads
The elasticity of brake Brake pads cannot Replace return
ENGLISH
shoe spring is not

enough or broken. return. spring.
Moving parts are rusty The rotation of brake Brake is out of control Clean and lubricate
cam is not flexible. or cannot return. brake cam.
Brake cam or have foreign things.
The circle surface of Brake is out of control Replace brake cam.
brake cam is worn. 43
Section 12 Meter
The meter of motorcycle is to indicate the working condition of motorcycle.

1 The Structure and Working Principle of Meter
[1]Speedometer
Speedometer is to indicate the running speed of motorcycle and the total mileage.It is driven by front wheel.The
rev of front wheel is sent to speedometer through gearshift system and soft axle,which makes magnetic cylinder
rotate.Coil cuts magnetic wire,which makes whirlpool and magnetic field to cooperate with the magnetic field of
magnetic cylinder,makes whirlpool disc get a torque,overcomes a resistance and drives the finger to rotate.The
higher the speed is,the stronger the magnetic field of whirlpool disc is.The torque is bigger,so the angle of finger
swing augments and it can reach the higher mark on board.Meanwhile,the rotating main axle drives counter
through whirlpool lever.Therefore,the total mileage of motorcycle is indicated by the counter. Maintain speedom-
eter once a year.Add luboil to where it needs.
[2]Fuel Meter
Fuel meter is to indicate the fuel volume in fuel
tank.It guides the resistance changes in sensor which
caused by the change of fuel level to fuel volume
indicator and indicates the change of fuel volume
through fuel volume indicator.
2 Disassembly and Maintenance of Meter
[1]When fingers of meter don’t work,dismantle speed-

ometer and check it.
Check meter
[3]Check whether the connection of speedometer is

looseness.
ENGLISH
Check connection
44
3 The cause,trouble description and repair method of meter
Table4-12 Main tenanc e of M eter

component cause trouble description of trouble description of repair method
The filament of indicator Indicator doesn’t work. Replace bulb of indicator.
The filament of indi-
cator is burned-out.
is burned-out.
meter The filament of The filament of meter head M e t e r h e a d l a m p Replace the bulb of
assembly meter head lamp lamp is burned-out. doesn’t work. meter indicator.
is burned-out.
Speedometer is Speedometer is damaged. Speedometer doesn’t Replace speedometer
damaged. work.
ENGLISH
45
CHAPTER 4 ELECTRICAL SYSTEM
Part 1 Basic Knowledge
In order to get a further understanding of structure and working principle of motorcycle electrical system,you
should have a general conception about basic knowledge of electrics firstly.
1 Electricity、electric current、voltage and resistance
The basic component of any substance is atom.There exists electropositive atomic nucleus and electronegative
electron inside the atom.The quantity of nucleus is the same as electron,so which makes the positive electricity
counteract the negative electricity and causes atom to be neutral.If the substance is influenced for friction or
magnetic field,this balance will be broken.So the electron will increase or decrease because of moving.At that time,
the substance has electric charge because the atom is not neutral.The electric charge of substance has the
relationship with the increasing and decreasing of atom.When the atom increases,the substance will be electronegative.
When the atom decreases,the substance will have positive electricity.
Electric charge moves regularly in conductor along a stated direction,which is called electric current.The quantity
of electric charge per second is used to scale the strength of electric current.In electrics,we use I to stand for electric
current.Its strength unit is Amp(A).Normally,the stated direction of electric current is from the anode of battery to the
cathode.
There is an interaction force between electric charge.In order to make electric charge move,such force must be
overcome. When moving the positive charge,the work for conquering the force between electric charge is called
potential.The differential potential between any two points is called voltage.We use U to stand for and its unit is V.
When electric current flows in a substance,the substance will produce a resistance,which is called electric
resistance.We use R to stand for,its unit is Ω.Different substance has different resistance.For example,the resistance
of copper,iron,aluminium is small,which is called conductor.However,the resistance of wood,china,plastic is big,
which is called dielectric.Also,there are some other substances,such as silicon,whose electric performance is between
conductor and dielectric,which is called semiconductor.
2 Ohm’s Law
Ohm’s law indicates the relationship among voltage,resistance and electric current.Viz.Electric current(I) and
voltage(U) have direct proportion and electric current(I) and resistance(R) have inverse proportion.Its formula is I=U/
R：Also,U=IR ，R=U/I.
3 Electric apparatus,direct current(DC),alternating current(AC) and electrical source
Electric apparatus is usually called load,which is an equipment that can consume electric power and transfer the
power to other kind of power.
The device which offers power to electric apparatus is called electrical source or power supply.
The electric current what electrical source offers to electric equipment has two types:One type whose intensity and
direction don’t change according to the change of time is called direct current(DC).The other one whose intensity
and direction change periodically according to the change of time is called alternating current(AC).
4 Circuit、series circuit and parallel circuit
The closed circuit which is made up of electrical source,electric apparatus and connecting lead is called circuit.The
circuit is divided into two basic types:series circuit and parallel circuit.In series circuit,several electric apparatuses
connect with each other and there is no cut in the middle.At this time,the electric current which is through each
electric apparatus is the same.But in parallel circuit,the beginning and the end of each equipment connects between
the two points and the voltage of two end is the same.In the complicated circuit of motorcycle,both series circuit and
parallel circuit coexist.
5 Short circuit and open circuit
In a normal circuit,if two leads,of which electrical source passes electric apparatus,don ’t pass electric appara-
tus and connect with each other,which is called short circuit.In the circuit which is made up of electrical source,electric
apparatus and connecting lead,because of the cut of lead,it makes electric current not form a closed circuit,which is
called open circuit.
6 Left-hand rule and right-hand rule
In the magnetic field which can produce electromagnetism induction,stretch out the left hand,make palm flat,
make thumb plumb the other four fingers,let magnetic line plumb and get through the center of palm and make four
fingers towards the direction of electric current.At this time,the direction which thumb points to is the direction of
magnetic field power,which is called left-hand rule.
Unwind the thumb of right hand,hold coil along the direction of electric current with the other four fingers.At this
time,the direction which the thumb points to is the direction of magnetic wire which coil produces magnetic field,
which is called right-hand rule.
ENGLISH
Electrical system is an important part of motorcycle.Its structure and function directly influence the performance and riding
comfort of motorcycle.The electric system is divided into three parts:power supply,control and power consumption.Because the
ignition system of electrical system is the core of motorcycle,it is described in the engine part.During the common usage,you
should maintain the electrical system frequently.The common trouble of electrical system of motorcycle can be looked up
46 through the circuit diagram,so the circuit diagram is attached both in user ’s manual and mainienace manua.
Section 2 Power Supply
1 The structure and working principle of power supply

Power supply part mainly consists of generator and battery.Its function is in the closed circuit of
motorcycle,generator and battery has parallel connection and offers electric current to the electro-equipment
in electrical system,then stores the rest power in battery.
According to the character of electric current export,generator can be divided into DC generator and AC
generator.According to the different structure,the AC generator can be divided into AC flywheel generator,
AC magnet rotor generator and AC three-phase generator.The magnetic pole of first two has permanent
magnet,so it is also called AC permanent magnet generator.However,the last one produces magnetic pole
through electricfying the coil,so it is called AC excitation generator.Usually,the generator we talk about is
AC flywheel generator.
According to the different rated voltage of battery,it can be divided into 6V battery and 12V battery.If the
rated voltage is the same,according to the different volume,it can be divided into big and small.According
to the different structure,it can be divided into plumbum acid battery and complete seal and maintenance-
free battery.
[1]The Structure and Working Principle of DC Generator
DC generator works according to the principle of electromagnetism induction.Viz.when lead plumbs
magnetic wire and moves in the well-proportioned magnetic field,there is inductive electromotive force
produced in the lead.If the lead forms a closed circuit with other outer circuit,there is inductive electric
current produced in the lead.The direction of this electric current can be estimated through right-hand rule.
[2]The Structure and Working Principle of AC Generator
AC generator mainly consists of AC flywheel generator,AC magnet rotor generator and AC three-phase
generator.Like DC generator,it also works according to the principle of electromagnetism induction.But it
doesn’t produce electric current through the method that lead plumbs magnetic wire and moves in the
well-proportional magnetic field.It produces inductive AC through the method that the rotor which made
of permanent magnet rotates continously and comes into being a rotating magnetic field,then makes
magnetic wire continously and alternately pass the fixed coil.
[3]The Structure and Working Principle of Storage Battery
This kind of storage battery has light weight,small bulk,good seal and shockproof performance.and the
plumbum acid storage battery has small inner resistance and stable voltage.It mainly consists of battery
body,cover,plate,electrolyte and clapboard.The battery body is made of hard rubber or plastic which is
acidproof,heat-resistant and shock-proof.The battery is divided into 3 or 6 unattached parts according to
the different stated voltage.There must be marked two marks outside the battery body.The upper mark is
H and the lower one is L,which respectively indicate the upper limit and lower limit.Meanwhile,there are
anode and cathode marked on battery.“＋”is anode and “－”is cathode.
Plate is the main substance,where storage battery does chemistry of charging and discharging.It is
made of plumbum antimony alloy pieces which are painted active substance and processed through
electrochemistry.The plate is divided into anode plate and cathode plate.The active substance on anode
plate is PbO2 and on cathode plate is Pb.
Electrolyte is liquid mixed vitriol with distilled water.The temperature of electrolyte density for stan-
dard measurement is 20℃.When battery is at the standard temperature and in full charge condition,its
density is between 1.24～1.29g/cm3.In each independent part of battery body,there is a set of plates and
electrolyte installed inside.Each set of plates respectively does the chemistry with electrolyte,and makes
ENGLISH
up of an independent battery.Its voltage is about 2V.3 or 6 batteries are series-wound and come into being
a storage battery with the 6V or 12V voltage.The battery cover is made of high insulative hard rubber and
hard plastic,which forms an integrated inner space with battery body.
47
[1]Remove fuse tube and check whether it melts
down.Replace it with the same type.
Fuse tube type：12V/20A
Check fuse
tube.
CAUTION
When fuse tube is damaged,replace it with the same type.
[2]Remove storage battery and measure whether its

voltage is above 12V.When it’s lower than 12V,
remove and charge it.
CAUTION
Screw down connecting bolt of storage battery
when it is loose.
Add distilled water when the electrolyte level of Battery
storage battery is lower than the lower limit mark.
Keep away from fire while battery is charging.
Because it will diffuse combustible and explosive
gas during charging.
[3]Dismantle the socket of charging coil of generator
and measure the charging coil with multimeter.
Check whether the coil has short circuit.Replace it
if short circuit.
Joint of
charging coil
[4]Remove left cover of engine and the stator of

generator.Measure the resistance of generator stator
with multimeter and check whether the resistance
has short circuit or open circuit.Replace it if short
or open circuit.
Resistance Value
ENGLISH
Genera-
tor coil
48
[5]Check whether the magnetic cylinder of gen-
erator rotor fades magnet.Replace magnetic cyl-
inder if fades.
Check
magnetic
cylinder.
3 The cause,trouble description and repair method of power supply part
Table5-1 Maintenance of Power Supply Part

Headlight cannot illuminate.
Engine is hard to be started
short circuit Battery has poor power. and poor engine power and
charging coil
unstable idle speed. Replace charging coil.
open circuit（limit There is no spark spurt be- Engine cannot be started.
value ∞) tween piston electrode.
Engine is hard to be started or
distorted no electric current export or cannot be started.The electric
generator poor export of generator power of motorcycle is not enough.
rotor Electroequipment cannot work
normally. Replace generator rotor.
fades magnet no electric current export of Engine cannot be started.
generator Headlight cannot illuminate.
damaged no power Starting motor doesn’t run. Replace storage battery.
Storing time is too Electric power is not enough Starting motor doesn’t Charge or replace
long. and voltage is too low. run or runs feebly. storage battery.
storage Signal system is deviant.
battery
ENGLISH
Starting motor doesn’t Add distilled water or

Electrolyte is not Electric power is not enough run or runs feebly. replace storage battery.
enough. and voltage is too low. Signal system is deviant.
fuse tube Fuse tube is dam- no power Starting motor doesn’t Replace fuse tube.
aged or melts run. 49
Section 3 Control Part
1 Composing and Function of Control Part
In electrical system of motorcycle,control part is to ensure the good working condition of power supply
part and power consumption part,and ensure their harmony.It can make rider control the electrical system
momentarily.
Control part mainly consists of adjuster,rectifier,flash relay,starting relay,fuse tube,control switch and
cable assembly.
(1)Adjuster
Adjuster is the important component of power supply part of motorcycle electrical system.It can be
divided into DC generator adjuster and AC generator adjuster according to the engine type.
[1]DC generator adjuster
Because the voltage export of DC generator adjuster and the rev has direct proportion,it will bring some
problems:[A]When motorcycle runs with high speed,the engine rev is very fast and the voltage export of
DC generator is very high,which will easily make the electro-equipment burn out and make the storage
battery over charge.[B]When motorcycle runs with low speed,the engine rev is very low,which makes
storage battery export power to DC generator with strong electric current so that the DC generator is burned
out.So it is necessary to make adjuster cooperate with generator.
[2]AC generator adjuster
The motorcycle with generator not only needs the rectifier to transfer the AC to DC,but also it needs AC
adjuster to stabilize the export of generator.At present,the AC adjuster which is usually used is AC
electronic adjuster.
AC adjuster mainly consists of transistor,diode and thyristor.When generator works,the lighting and
signal coil will produce AC.
(2)Rectifier
Rectifier is normally divided into two types:single-phase half wave rectifier and full-wave bridge
rectifier.These two rectifiers work as the principle of one-way electric character of silicon diode.It is like an
electronic valve,which only allows one side electric current to go through.
(3)Flash Relay
Flash relay is called flasher.It is mainly divided into three types:thermal resistance,capacitance and
transistor.
(4)Starting Relay
When starting electromotor works,the electric current will be very strong.It can reach tens of amp.
Starting relay is an electromagnetic switch.When pressing the starting switch of right handlebar,
electric current will connect with the cathode of battery through storage battery,battery connection,relay
coil and connection of starting switch,then it will make a closed circuit.
(5)Tube
Generally, fuse is composed of plastic fuse boxes fitted up with the fuse tube.
(6)Control Switch
The control switches of electrical system are centralized on the left and right handlebar.Normally,from
up to down,there are switches of high/low beam light,turning light and horn on the left handlebar.Also,
from up to down,there are switches of position light,headlight and electric starter on the right handlebar.
The general electrical switch is in the middle of handlebar.
(7)Main Cable
Each part of electrical system of motorcycle is connected by lead.In order to avoid leads in a mess and
be propitious to arrange on the frame,leads with the same direction are usually bound by insulative
rubberized fabric.This is cable assembly.
2 Disassembly and Maintenance of Control Part
[1]Measure the voltage export of relay with multimeter
and check whether it is within 13.0V～14.0V.Re-
place the voltage -adjusting relay when the voltage
export is lower than 13.0V.
Joint of
voltage-
adjusting relay
ENGLISH
CAUTION
Replace the rectifier when the cooling fins of it are
50 broken.
[2]Remove the flasher socket of signal system and
measure the flasher with multimeter.Check whether
it has short circuit.Replace it if short circuit.
Flasher
[3]Check whether starting relay is in good working

condition.Replace it with the same type if it is not
in good working condition.
Starting
relay
[4]Dismantle the switches of left and right controls.

Check whether they are damaged or have short
circuit.Repair or replace them if have problems.
CAUTION
Check whether front/rear brake switches are in good
Control working condition.Readjust or replace them if they are
switch not in good working condition.
If front/rear brake light do not shine when braking,
then there is no electric power to start.
[5]Remove fuse tube and check whether it melts.

Replace it with the same type.
Fuse tube type：12V/20A
Check fuse
ENGLISH
tube.
CAUTION
Replace fuse tube with the same type when it
is damaged. 51
[6]Check whether the main cable is damaged.
Bundle the leads in time if the insulative rubber-
ized fabric is damaged.
3 The cause,trouble description and method repair of control part
Table 5-2 Maintenance of Control Part

Storage battery cannot be
Rectifier has short circuit or charged.Illuminating
rectifier damaged open circuit. light illuminates dimly Replace rectifier.
or cannot illuminate,and
is easy to be burned out.
Inner coil has short Starting motor doesn’t work.
starting circuit or open Motorcycle cannot be
relay circuit. started with electric Replace starting relay.
starter.
Inner connecting Starting motor runs feebly.
point is burned-out.
Inner connecting Motorcycle cannot be started Replace button.
point connects bad Starting motor doesn’t with electric starter.
starting or is damaged. work.
button
Inner connecting Starting motor doesn’t work Motorcycle cannot be started
point is burned-out. or runs feebly. with electric starter. Check storage battery.
fuse tube Fuse tube is dam- no electric power Starting motor cannot run. Replace fuse tube.
aged or melts down.
illuminating/ Inner connecting Illuminating light is not in Repair or replace illu-
light-changing point connects bad Inner connecting point con- good working condition or minating/light-chang-
switch or is damaged. nects bad or is damaged. cannot work. ing switch.
Direction indi- Inner connecting Inner connecting point con- Direction indicator lamp Repair or replace direc-
cator switch point connects bad. nects bad or is damaged. doesn’t illuminate. tion indicator lamp.
flasher The inner flasher is The inner flasher is burned-out. Direction indicator lamp Replace flasher.
burned-out. doesn’t illuminate.
brake light The inner con-
necting point can- Brake switch cannot be re- Brake light illuminates for a Repair or replace brake
ENGLISH
switch not be returned or turned or is damaged. long time or doesn’t light switch.
is damaged. illuminate.
Inner connecting Inner connecting point of horn Electric horn doesn’t work Repair or replace horn
horn button point connects bad button connects bad or is or its sound is not normal. button.
or is damaged. damaged.
52
Section 4 Power Consumption Part
The power consumption part of electrical system of motorcycle consists of following:：
(1)Light-signalling Device
Illuminating signal device consists of headlight,position light,taillight and meter indicator.Its main function is
when motorcycle runs at night,they illuminate and have motorcycle noticed by other vehicles in order to ensure the
riding safety.
Signal device consists of turning indicator,horn,gear indicator and brake light.It is used to indicate the running
condition of motorcycle and express the operation of rider through sound and light signal.
(2)Electric Starter Device
Electric starter device consists of starting motor and mesh setup.It is mainly used to start engine.(for the details,
please refer to section 7,chapter 2).
1 Light-signalling Device
(1)Headlight and Position Light
Headlight illuminates the front road for rider.It makes rider see the road condition and other running vehicles and
also,it can send signal to the coming people and vehicles.Its flash can make the front vehicles noticed its overtaking
intention.When motorcycle runs on a fog day,headlight is also usually opened to ensure its riding safety.
Position light is used to indicate the position of motorcycle and make motorcycle noticed by other people at a
district where the illuminating condition is good or motorcycle passes other vehicles at night.It is usually installed in
headlight assembly.
Headlight mainly consists of focus lamp,glass cover,bulb,lamp holder and cover.
The function of focus lamp is to make the light from bulb gather into a bright beam of light.Its material is
aluminum board,which is made through pressing.
The main function of glass cover is to diffuse the beam of light which reflected by spotlight mirrior and ensure
front road to have enough area to be illuminated.It avoids making the coming drivers have the feeling of swimming.
Bulb is divided to single filament and double filament.
Bulb holder is made of galvanizing sheet iron after pressing.It is cylindrical.There are 3 uneven bulge at the edge
of holder and there is a hole which lead can get through.
Lampshade and cover make up of a complete space,which contains the other parts of headlight.
(2)Taillight and Brake Light
Taillight is used to indicate the position of motorcycle to the back vehicles when running at night and make the
registration mark seen clearly.
Taillight mainly consists of lampshade,cover,lamp holder and bulb.The lampshade is made of red organic glass.
There is transparent organic glass window embeded at lower part so that the registration mark can be illuminated.
The light cover is made of plastic.There are two side stands with holes at the buttom.The lampshade and light
cover can be connected by screw.
(3)Horn
During motorcycle running,rider can let horn make sound and make motorcycle noticed by passer-by and other
vehicles to ensure running safety.
According to the different way of power supply,electric horn can be divided into AC electric horn and DC electric
horn.This motorcycle adopts DC electric horn.
(4)Turning Light
When motorcycle needs to turn,turning light will send out yellow flash signal through flash relay to make other
people notice this motorcycle is going to turn.Normally,the turning light consists of cover,holder,bulb and lampshade.
2 Disassembly and Maintenance of light Signalling Device
[1]Dismantle the cover of headlight and check whether

the holder and bulb are in good working condition.
Remove the bulb and check whether it is burned-
out.Replace it with the same type if burned-out.
Bulb type：HS1 12V 35/35W
ENGLISH
Bulb of
headlight
53
[4]Check whether the taillight is burned-out.Re-
place it with the same type if burned-out.
Taillight
[3]Check whether the turning light is burned-out.

Replace it with the same type if burned-out.
Turning
light
[4]Check whether the bulb of meter indicator is

burned-out.Replace it if burned-out.
Bulb of gear
in dic at or
[5]When the sound of electric horn is hoarse and

electric horn has no sound,adjust the horn volume
acccording to the actual situation or replace the
horn with the same type.
ENGLISH
Adjust
horn.
54
3 The cause,trouble description and repair method of power consumption part
Table5-3 Maintenance of Power Consumption Part

component cause trouble description of trouble description repair method
description component of motorcycle
The adjustment of The beam of light of headlight is Adjust the beam of light
beam of light is too far or too close. of headlight.
headlight imporper.
assembly
The filament of head- The filament of headlight is H e a d l i g h t d o e s n ’t Replace the bulb of
light is burned-out. burned-out. illuminate. headlight.
taillight / The filament of The filament of brake light/ The filament of brake light/ Replace the bulb of
brake light brake light/brake brake light is burned-out. brake light is burned-out. brake light/brake light.
light is burned-out.
turning light The filament is The filament of turning light is Turning light doesn’t Replace the bulb of turn-
burned-out. burned-out. illuminate. ing light.
gear The filament is The filament of gear indicator Gear indicator doesn’t Replace the bulb of gear
indicator burned-out. is burned-out. illuminate. indicator.
The inner horn is The inner horn is burned- Electric horn has no sound Replace electric horn.
electric horn burned-out
damaged.
or out or damaged. or the sound is not normal.
ENGLISH
55
Chapter 5 Analysis of Motorcycle Troubles
Section 1 Analysis of Engine Trouble
1.1 Analysis of Poor Idle Speed of Engine
poor idle speed of

engine
The idle speed of en- The idle speed of en-

No idle speed of engine gine is too high. gine is unstable.
Check the compressing Check whether engine ignition is

pressure of cylinder. Pull the valve of with hands timing.
and check whether it is com-
pletely closed.
Check it by fault diagnosis tester.
The comprssing The comprssing Yes No Yes
pressure of cylin- pressure of cylin- No
derisnotenough. der is normal. Shut off ignition Check whether the steel wire of
switch and hold for throttle control cable can be flex- [1]Check whether the CDI de-
10s of downtime, ibly pulled outside the cover of
then restart switch cable and whether valve spring is vice has problems.
when idling stepping too soft. [2]Check whether the flywheel
motor returns. of generator and the triggering
coil are loose.
Check by fault diagnosis

[1]Check whether the outer connection part of tester if idling is still high. No
engine has leakage.
[2]Check whether valve timing is normal. Check the mixed ratio of combus-
[3]Check whether the valve clearance is too narrow. tible mixed gas.
[4]Check whether the seal between valve and valve
seat is good.
[5]Check whether the piston ring is broken off or Check whetherthe elec-
dead or has poor elasticity. trode clearance of spark
[6]Check the abrasion of piston ring and cylinder. plug is too small.
Yes
Check air passage of
throttle valve Adjust electrode
clearance.
Air passage has carbon depo-

sition seriously.
Clean the passage.
There is no idling output after

cleaning.
ENGLISH
Check it by using fault di-

agnosis tester.
56
1.2 Analysis of Insufficient Engine Power
Engine power is
insufficient.
Support motorcycle with main stand,make it off the

ground and rotate wheel with hands.
Wheel rotates freely. Wheel rotates hardly.
Check the pressure [1]Check whether brake is dead.

of tire. [2]Check whether the axle of wheel is damaged or
worn.
[3]Check whether the insulator between the wheel
The pressure The pressure

is too low. is normal.
Check whether the valve element Dismantle spark plug and put your finger on the screw
of wheel has leakage and whether thread hole of spark plug,then press down the starting
wheel is broken off. button or rapidly step the starting lever.
Finger cannot feel strong gas rush

Finger can feel strong gas rush outward. outward and the compressing pres-
Meanwhile there is sound of flop,flop. sure of cylinder is not enough.
The compressing pres- The compressing pressure

sure is normal. is not enough.
Start engine and gently turn throttle con- [1]Check whether the outer connection of engine has leakage.
trol grip inward.Observe the rev change [2]Check whether the valve ia timing.
of engine. [3]Check whether the valve clearance is too small.
[4]Check whether the seal between valve and valve holder is good.
[5]Check whether piston ring breaks off or is dead or whether its
elasticity is not enough.
The engine rev will en- The engine rev won’t en- [6]Check the abrasion of piston ring and cylinder.
hance when the gun is hance when stepping on the
bigger accelerator.
Check whether engine ignition

is timing.
Yes No
① Check whether oil supplying is blocked and [1]Check whether there is something wrong with CDI.
oil pressure value is between 240-250KPa. [2]Check whether the flywheel of generator and trigering
② Check whether fuel filter ,air filter and muffler coil are loose.
are blocked.
ENGLISH
57
1.3 Analysis of Engine Start
Engine cannot be started or is hard
to be started.
Checkignitionsystem.
Remove piston and check whether there is carbon deposit

between the electrode of spark plug.
No Yes
Check whether there is spark spurt Clean out car-
between the electrode of spark plug. bon deposit.
poor spark or no spark between electrode There is strong blue and blue purple spark spurt be-
tween electrode.
Unscrew the cap of piston and check whether Check whether the engine igni-
there is spark spurt with high-voltage coil. tion is timing.
No Yes
There is strong poor spark or no
blue spark spurt spark [1]Check whether there is some- Pull out fuel injector, start ,
thing wrong with CDI device. check whether fuel
[2]Check whether the flywheel spurted is atomised.
of generator and triggering coil
Check whether there is some- are loose.
thing wrong with spark plug
and spark plug cap.
Yes No
Check the compressing Check whether
pressure of cylinder with there is gas in fuel
Barometer tank.
Check the Check whether Check whether the Ch ec k w he th er
power supply the ignition coil inner circuit of ig- the re i s so me- ON
of ignition elec- has short circuit nition system has thing wrong with
trical source or open circuit. short circuit or CDI device. The cylinder Add gas.
open circuit. pressure is
sufficient.
The cylinder Yes
Generator ignition pressure is
system has no con- insufficient. ① Check whether venthole of fuel
necting point. tank cap is blocked.
② Check whether fuel filter is
blocked.
[1]Check whether the outer connection of engine has leakage. ③ Check whether fuel nozzle is
[1]Check whether igni- [2]Check whether valve is timing. blocked.④Check whether fuel tube
tion coil has short circuit [3]Check whether valve clearance is too small. is broken.
or open circuit. [4]Check whether the seal of valve and valve holder is good. ⑤ Check whether connector of fuel
[2]Check whether trig- [5]Check whether piston ring breaks off or is dead or has insufficient nozzle and fuel pump assembly is loose.
elasticity.
gering coil has short cir- [6]Check the abrasion of piston ring and cylinder.
cuit or open circuit.
Dismantle spark plug

and check it.
The electrode of spark The electrode of spark

plug is wet. plug is dry.
Check whether air filter is blocked. Dip a little gas in cylinder and try to start.
The running time is too Enginecancontinue

short or engine has flame- working after
ENGLISH
out after starting. starting.
Check with fault di- Check with fault diagnosis

agnosis tester tester
58
1.4 Analysis of engine overheating
Engine overheats.
Check whether the operation is correct.
Yes
No
[1]Check whether the gas no. is correct or has
stored for a long time. Check cooling system.
[2]Check whether engine always runs with the
high speed or with loads.
air cooling engine liquid cooled

engine
Check whether there is sand or smeary deposit Check whether there is sand or smeary deposit on radiator.
on radiator.
Yes Yes No
Clean Clean Check whether there is enough fluid in the
channel.
Yes No
Check whether the con- Supply the same type of liquid.
necting pipe is loose or
damaged.
No Yes
Check whether the pump Tighten or replace.
is damaged.
Check whether the chan-

nel is unblocked.
No
Check whether the engine ignition
is timing.
No Yes
Yes
[1]Check whether CDI device Check whether clutch slips. Clutch slides. Refer to 1.6.
has problems.
[2]Check whether the flywheel No
of generator and triggering coil
are loose. Dismantle piston and check the color of piston dielectric.Estimate the
mixed ratio of mixed gas according to all kinds of exceptional phenomena.
Spark plug dielectric is dark black.Exhaust muf- spark plug dielectric spark plug dielectric is white.
fler emits black smoke when engine runs with is brown. When accelerating,engine has
the medium/low speed.The accelerating perfor- intermission.The engine power
mance is bad and idle speed is unstable.But it is is insufficient.
normal when with high speed.
The ratio of Combustible mixed gas is normal.
Combustible mixed gas is thick. Combustible mixed

Check whether cylinder ex- Check lubricating gas is too thin.
haust port and exhaust system.
muffler are blocked with car-
bon deposite.
Check whether air filter is blocked.
Check whether oxygen sensor is work- Check whether fuel filter is
ing well. blocked.
Check fuel nozzle is in working order. [1]Check whether the oil volume in crankcase Check whether fuel nozzle
is insufficient. is blocked.
ENGLISH
[2]Check whether the oil in crankcase is dirty Check the oxygen sensor
or its mucosity is too bad. is working well.
[3]Check whether oil cleaner is blocked.
[4]Check whether oil pump is in good working
condition.
[5]Check whether lubricating way is blocked.
1.5 Analysis of over consumption of engine fuel
Engine fuel exceeds

consumptive standard.
Check whether the operation is correct.
Yes No
Support vehicle with side stand and rotate [1]Check whether motorcycle runs with loads or without
wheel with hands. economical speed or with low speed.
[2]Check whether the oil no. is correct.
Wheel turns hard. Wheel turns normally.
[1]Check whether brake is blocked. Check the tire

[2]Check whether the axle is worn. pressure.
[3]Check whether the clapboard of wheel Pressure is too low.
hub has installed or is too short.
Pressure is
normal.
Inflate according to
the stated standard.
Check whether fuel tank,fuel tube
is leakage and hoop of tube is
fastened.
Yes
No
Deal with it according to the Check the mixed ratio of combus-
actual situation. tible mixed gas.
The mixed ratio of combustible Combustible mixed gas Combustible mixed gas
mixed gas is normal. is too thick. is too thin.
Check whether the rev of engine is ①Check whether air filter is blocked. ① Check whether fuel filter is
too fast. ②Check wheher oxygen sensor is work- blocked.
Yes ing well. ② Check whether fuel nozzle is
No ③Check whether fuel nozzle is in work- blocked.
According to 1.1 Check whether en-
gine ignition is timing.
ing order. ③Check whether oxygen sensor
is working well.
Check ignition system.

ENGLISH
60
1.6 Analysis of exhaust muffler of 4-stroke engine
The exhaust muffler of 4-stroke engine emits blue and

white thick smoke.
Check whether the oil level of crank-

case exceeds the upper mark.
Yes No
The oil in crankcase is too much.The redundant oil Start engine.When it runs with high speed,remove oil
should be discharged and let the oil level not exceed ruler and check whether the oil adding hole emits smoke.
the upper mark.
No Yes
Check whether the match clear- [1]Check whether cylinder,piston
ance of valve and valve pipe is and piston ring are worn.
too big. [2]Check whether piston ring has
poor elasticity or is dead.
Yes No [3]Check whether the opening of
piston ring has 120°to another
Check whether valve and Oil seal of valve is opening.
valve pipe are worn. damaged.
1.7 Analysis of gearshift
Gearshift of derailleur
is difficult.
Start engine and check whether the idle speed of engine

is too fast.
Yes No
Readjust it. Check whether operation of gearshift
is harmonious.
Check whether cluth disengages Improve operation

uncompletely. method.
Yes No
[1]Check whether the elasticity of cluth spring is well- Check whether the gearshift axle is
distorted or whether gearshift arm Yes
proportioned. is distorted or worn.
[2]Check whether drive or driven hub tooth of clutch is worn
to sawtooth. No
[3]Check whether friction steel pieces of clutch are distorted. Replace it.
[4]Check whether the components of operation system of [1]Check whether camshaft of gearshift or
clutch are worn. cam trough inside is worn or damaged.
[2]Check whether the fork is worn.
[3]Check whether the fork is distorted.
[4]Check whether the fork axle is distorted
or worn.
ENGLISH
61
1.8 Analysis of derailleur gearshift
derailleur gearshift
Check whether the positioning spring breaks off

or its elasticity is insufficient.
Yes No
Replace it. Disassemble crankcase and check
whether its mesh of gear is correct
according to the standard.
Yes No
Th e d e p th o f ge a r
The depth of gear mesh mesh is not enough.
is enough.
Check whether convex pawls of mesh gear are worn to Check whether the fork is worn or distorted.
cone-shaped and whether opposite groove of gear end
is worn to be bell-mouthed. Yes No
Replace fork. [1]Check whether fork hole and fork axle
are worn.
Yes No [2]Check whether the installation of de-
Rep lace gear. railleur is correct.
Check whether the spline of
main and secondary axle and
the spline trough of slip gear
are worn.
1.9 Analysis of slide and uncomplete disengagement of clutch
Clutch slides and disengages uncompletely.
Automatic,wet and multiple clutch slides.
Check whether the clutch adjuster is adjusted to the

best state.
No Yes
Readjust it. Check whether the elasticity of cluth spring
is well-proportioned.
No
Yes No
Clean,lubricate or re-
place it. Check whether drive and driven Wholly replace cluth spring.
hub trough are worn to be zigzag.
No
Yes
Repair or replace [1]Check whether the pressing bolt of clutch spring is
them. loose.
[2]Check whether the friction pieces of clutch are worn or
ablate.
[3]Check whether the elasticity of clutch spring is poor.
[4]Check whether drive hub of clutch and the connecting
surface of pressing plate and friction pieces are worn.
ENGLISH
[5]Check whether the driven pieces of clutch are distorted.

[6]Check whether the operation components of clutch
(separatory cam,separatory handspike and so on)are worn.
62
Section 2 Analysis of electrical part
2.1 Analysis of battery
Battery cannot be
charged.
Remove the connecting part between the generator lead and vehicle cable.
Measure the resistance with ohmic meter and check whether the resistance
between export lead of charging coil accords with the standard value.
Resistance value is smaller than Resistance value accords Resistancevalueisinfinite.

standard value. with standard value.
Charging coil has Install the connecting component between generator Charging coil or other ex-
s h o r t c i r c u i t. lead and vehicle cable.Remove rectifier or the connect- port lead has open circuit.
ing component between commutated adjuster and
vehicle cable.
Measure the resistance between the export lead of charg-

ing coil with ohmic meter.Check whether the resistance
accords with the own resistance of charging coil.
Yes No
Set multimeter to 0 ～20V DC voltage.Measure the voltage The circuit from generator to rectifier or
between the lead ends from the connecting component to between commutated adjuster has open
battery(normally it’s red wire) and ground circuit or bad connection.
There is no voltage show. There is voltage show.
The lead from con- Measure the rectifier and com-

nectingcomponentto mutated adjuster with ohmic
battery has open meter.Check whether they have
circuit. problems.
2.2 Analysis of battery

Battery cannot be full
charged .
Check whether brake light al-

ways illuminates.
Yes No
Adjust or replace brake switch. Set ignition switch to OFF position.Remove cathode wire from
storage battery.Connect the cathode end of current meter to the
cathode of storage battery and anode end to the anode of storage
battery.Check the leakage of electric current.
The value of electric current leakage is The value of electric current leakage is bigger than
smaller than the stated value. the stated value.(Normally,the electric current is
required to be below 1mA）
Check whether the charging coil of generator has
short circuit.
ENGLISH
The circuit from rectifier or

No Yes commutated adjuster or
storage battery to ignition
[1]Check whether the electrolyte of storage battery is enough. Replace illuminat- switch has short circuit.
[2]Check whether the electrolyte density of storage battery is too small. ing coil.
[3]Check whether plate of storage battery has too much pbso 4 or has
short circuit.
63
2.3 Analysis of starting motor
Starting motor
doesn’t run.
Turn on ignition switch and press the horn button or turn on/
off turning light switch.
Eletric horn cannot make sound or make poor sound. Electric horn makes rotund sound.Turning light illuminates brightly.
Turning light illuminates dimly.
The power of storage battery is Press starting button and the Press starting button and the
not enough or the connecting stor- sound at the beginning of elec- sound at the beginning of elec-
age battery lead has poor tric starting cannot be heard. tric starting can be heard.
connection.
Remove the connecting component of starting relay from vehicle cable. Make short circuit of the connnection of battery
Connect the anode/cathode of storage battery with two down-leads of start- on starting relay and the connection of starting
ing relay coil with two leads. motor with screwdriver and thick lead.
After connection,starting motor still cannot run and After connection,starting motor can After short circuit connection,
the sound at the beginning of electric starting After short circuit
run normally. starting motor can run connection,starting motor
cannot be heard. normally. still cannot run.
The coil of starting relay has open Check the circuit of electric con-
c ir cu it or s h or t ci r cu it. trol system.
Disassemble starting motor and check as follows:
[1]Check whether carbon brush is worn.
The connecting [2]Check whether the spring of carbon brush
[1]Check whether the connecting point of inner clutch switch has bad connection. poi nt o f s ta rt- breaks off or its elasticity is poor.
[2]Check whether the connecting point of starting button has bad connection. ing relay is dam- [3]Check whether armature comb is worn.
[3]Check whether the circuit of inner electric starting system has open circuit or aged or ablates. [4]Check whether armature coil has open circuit
short circuit. o r sh or t c ir cu it.
2.4 Analysis of starting motor

The running of starting
motor is weak.
Turn on ignition switch and press horn button or turn on/off

turning light switch.
Electric horn cannot make sound or make weak sound. Electric horn makes rotund sound.Turning light illuminates brightly.
Turning light illuminates dimly.
The power of storage battery is not

enough or the lead of connecting stor- Check whether the lead end from starting relay to starting motor has poor
age battery has poor connection. connection.
No Yes
Dismantle the connecting lead of starting motor from starting Check and
relay and the connecting lead of storage battery.Press start- deal with it.
ing button.When starting relay makes sound,measure the resis-
tance between the battery connection of starting relay and
connection of starting motor with ohmic meter.Check whether
the resistance gets through.
ENGLISH
Yes No
Measure the resistance of motor with The connecting point of starting re-
ohmic meter and check whether it gets lay is damaged or ablates.
64
2.5 Analysis of illuminating light
All illuminating light

don’t illuminate.
AC power supply illumi-

nating system
Remove the connecting component between the

lead bundle of generator and vehicle cable.
Check whether there is power export from the
export lead of illuminating coil with a bulb.
The bulb doesn’ Thebulbilluminates.

t illuminate.
The the illuminating coil of Replace rectifier

generator or its export lead has
open circuit or short circuit.
Illuminating light Illuminating light still

can illuminate. cannot illuminate.
The inner of rectifier has short

circuit.
Disassemble head light assembly,
a nd ch e ck wh e th e r i ts b ul b i s
burned-out.
Yes No
Replace the bulb of head light and check Check whether there is power export from
whether other bulbs are burned-out. the powerimport lead of illuminating switch
with the method of connecting a bulb.
Yes No
With a lead,make short circuit be- Generator or the circuit between igni-
tween electric source lead of illumi- tion switch and illuminating switch
nating switch and export lead . has open circuit or short circuit.
Yes No
After short circuit connecting, After short circuit connecting,illumi-
illuminating light will illuminate. nating light still doesn’t illuminate.
The connecting point of The circuit between illuminating

inner illuminating switch switch and illuminating light has
has bad connection. open circuit or short circuit.
ENGLISH
65
2.6 Analysis of illuminating light bulb
The bulb of illuminating

light is easy to burn out.
Replace rectifier
No
Normal Short circuit or
tanct is not good.
Rectifier has trouble
2.7 Analysis of illuminating light
Illuminating lamplight
is weak
AC supply illuminating
system
Replace rectifier
Illuminating Illuminating lamplight is

lamplight becomes still weak
normal.
Check whether the charging coil and
charging system of magneto is short
Rectifier is bad circuit.
Check and
eliminate
ENGLISH
66
2.8 Analysis of turning light
Turning light doesn’
t illuminate.
Some turning lights of one side All turning light of one side All turning light don’t
don’t illuminate. don’t illuminate. illuminate.
Remove the cover of turning light Remove the cover of turning light Press horn button and check
and check whether of turning and check whether of turning el ec tri c h or n.
light is burned-out. light is burned-out.
Yes No Yes No Electric horn makes Electri c ho rn

Replace of Measure the voltage of makes no sound or
Replace of Remove the connecting compo- retund sound. is barbarous.
turning light. connecting point of light turning light. nent of turning light switch.Mea-
holder power wire to the sure the turning light switch with
groundwithvoltagemeter. ohmic meter and check whether its
problem is solved. The power of stor- The power
age battery is supply of stor-
No poor. age battery is
Yes normal.
The voltage is nor- The voltage is not nor-
mal and there is mal and there isnovolt- The side export power The inner connecting point of
voltage display. age display. wire has open circuit turning light switch has bad
or the light holder has connection.
bad connection. Remove the cover of
The connection of light The power wire of turning light and check
holder is bad or the con- holder has open circuit. whether of turning light
nection between direc- is burned-out.
tion indicator light bulb
and holder is bad.
Yes No
Turn on/off turning light switch. Replace of turning light
Make short circuit for two ends and check whether the com-
of flasher with a lead or a mutated adjuster works
screwdriver. well.
Yes No
After short circuit,turning Aftershortcircuit,turninglight
light still cannot illuminate. can illuminate.
Remove the connecting component of turning lights. Flasher is damaged.

With a lead,make short circuit from the power import of
turning light switch to the power lead of left/right turning
light.
Yes No
After short circuit,turning After short circuit,turning light
light will illuminate. still cannot illuminate.
The inner connecting point of turning light Check whether the power import lead of
switch has bad connection. turning light switch has power export with
a method of connecting a bulb.
Yes No
The bulb can The bulb can-
illuminate. not illuminate.
The power lead of turn- The circuit between ignition switch and
ing light has open cir- flasher or between flasher and turning light
cuit or short circuit. switch has open circuit or short circuit.
ENGLISH
67
2.9 Analysis of electric horn
Electric horn can-
not make sound.
Turn on ignition switch,turn on/off turning light switch and check the turning light.
Turning light cannot illuminate or Turning light can illuminate brightly.

illuminate dimly.
The power of storage battery is not Power supply of storage

enough or the circuit between storage battery is normal.
battery and ignition switch has open
circuit or short circuit.
Remove the power lead from the power connection of electric horn,
then rub the power lead with cathode wire.Check the spark or
measure the voltage with multimeter.
When rubbing,there is spark or the When rubbing,there is no spark or the

voltage is normal. voltage is not normal.
The power wire between

Connect the power lead of electric horn.Connect ignition switch and electric
the non-power connection of electric horn horn has open circuit.
(connection of button)with the cathode wire.
After connection,the electric After connection,the electric

horn can make sound. horn still cannot make sound.
The inner connecting point of horn Adjust the volume and

has bad connection or the lead be- tone of electric horn.
tween electric horn and button has
open circuit.
After adjustment,electric horn After adjustment,the

still cannot make sound. horn sound is normal.
Electric horn is
damaged. Electric horn is adjusted
unproperly.
ENGLISH
68
2.10 Analysis of brake light
Brake light doesn’t

illuminate.
Dismantle the cover of brake light and check whether its

bulb is burned-out.
Yes No
Replace the bulb of With a lead,make short circuit between two
brake light. connection end of brake light switch or two
lead end.
After short circuit,brake light After short circuit,brake light

still doesn’t illuminate. can illuminate.
Rub the power lead of brake light switch with cathode The switch of brake light is ad-
wire with a screwdriver or a lead.Check the spark. justed unproperly or the inner con-
necting point has bad connection.
Yes No
When rubbing,there When rubbing ,
is spark. there is no spark.
The lead between brake light The power lead between ignition
switch and brake light has short switch and brake light switch has
circuit or open circuit. short circuit or open circuit.
2.11 Analysis of ignition system

Engine starts hard.
Dismantle high-voltage wire and check

whether there is spark spurt.
Fire No fire
Spark plug is dagmaged. Cut off the connecion of charging coil of
generator and triggering coil and respectively
measure the voltage.
Repair or replace it.
Reconnect it.Turn off the ignition switch and observe Measure the DC resistance of two coils.
the high voltage coil.
The flywheel rotor of gen- Charging and triggering

Ignition switch is Cut off the power export end of igni- erator loses magnetism coil have short circuit or
damaged. tion and measure the voltage. seriously. open circuit.
ENGLISH
has voltage no voltage

Ig nition coi l h as ope n ci rcu it Add magnetism or re- Repair or replace it.
Electronic ignitor is damaged. place it.
o r sh or t c ir cu it.
Replace it. Replace it.

69
APPENDIX：CIRCUIT DIAGRAM
ENGLISH
70
Copyright reserved by
Zongshen group
Format160mm × 230mm
The 1st edition Aug,2013
The 1st print Aug,2013
ENGLISH
71

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宗申产业集团有限公司 文件名称 维修手册 页码

ZONGSHEN INDUSTRIAL GROUP 产品型号 ZS250GY-3(电喷) 1/1

编 制 母仕会 2013-9-9 标 准 化 甘立顺 2013-9-10 文 件 编 号

Chongqing Zongshen Automobile Industry Co., Ltd.

countries such as Germany, Camb-odia and France, etc.

section 1 vehicle introduction

FIGURE 1-1 Left view of motorcycle

FIGURE 1-2 Right view of motorcycle

Diagram 1-3 structure

Section 1 Attention Items of Maintenance

ground.Such as spray components,chromeplate components and high precision components.

the original place,but don’t tighten them.

[1] Oil Stain Cleaning

Section 3 Adjusting Data of Maintenance

Shorten the maintenance period if motorcycle usually runs in dusty region.

table 2-3 Torque tighteningCAUTION

Items Specification Torque Value(N.m)

Locknut of main pipe M24×1 25~35

Nut of rear rocker arm M12 ×1.25 50 ~ 60

[2]Check the fuel tank cap for fuel leakage.Replace the

open fuel tank

[3]Check the fuel tank for fuel leakage.Replace or repair it

[4]Check the fuel pipe for fuel leakage or aging. Check

dismantle the WARNING

[6]Remove the six fixed bolt(M5×16) of fuel pump

[8]Check the pump seal ring for aging, breaking or oil

check seal ring

3 The cause,trouble description and repair method of fuel supply system

idle air control valve

LSH igniton coil

fault indi- highTempera- rev signal

Structural drawing of EFI system

3 The trouble description of EFI system

2 The Structure and Working Principle of Exhaust

[2]Dismantle lock screw of air cleaner element. Take out

[3]Remove filter sieve of air cleaner and check whether

[2]Remove muffler and check whether the muffler is

[3]Remove the seal gasket of muffler and check whether

[4]Check whether there is carbon deposit in the muffler

Table4-3 Maintenance of Inlet and Exhaust System

leakage at vent of The noise of engine exhaust Replace seal gasket

2 Disassembly and Maintenance of Rear Transmission Device

[2]Dismantle bolts of left rear cover of left crankcaseand

[4]Dismantle fixed bolt of chain box,and remove the chain

[5]Dismantle the spring clamp of drive chain.

When installing,the open end of spring clamp of

[6]Check the abrasion and distortion of drive chain.

[8]Remove the oil seal of cushion body of rear drive

[9] Remove the rear drive sprocket and check it for

[10]Remove the gasket of rear drive sprocket wheel

Adjuster is damaged.Adjuster cannot be Drive chain is easy to Replace adjuster.

2 Disassembly and Maintenance of Frame and Accessories

[2 ]Ch eck wh eth er side st and is be nd or

Replace the covers if damaged.

[4]Check whether the seat is damaged.Re-

Replace seat if damaged.

[5]Check whether the rubber cover of front

[6]Check whether rear armrest is broken.

Table4-5 Maintenance of Frame and Accessories

宗申产业集团有限公司文件名称维修手册页码

编制母仕会 2013-9-9 标准化甘立顺 2013-9-10 文件编号