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Motorcycle Maintenance Manual

All rights reserved! Without the prior written consent of dealer, no part of this Maintenance Manual may be

reproduced, stored in a retrieval system or transmitted in any form (electronic form, mechanical copying,

recording, etc.).

We have made every effort to ensure that this Manual is complete and accurate, but will not assume any

responsibility for any inaccuracies or omissions that may appear in this Manual.

We reserve the right to modify this Manual without prior notice and do not have the obligation to modify

previous products accordingly. For the latest product perfection information prepared after the release of this

Manual, please consult your motorcycle .

The contents of this Manual are compiled according to the latest product information at the time of

compilation. The illustrations and pictures in this Manual are for reference only and may differ from the actual

parts

1

Abbreviations

A

Ampere

lb

Pound

ABDC

After bottom dead center

m

Meter

AC

Alternating current

min

Minute

ATDC

After top dead center

N

Newton

BBDC

Before bottom dead center

Pa

Pascal

BDC

Bottom dead center

PS

Horsepower

BTDC

Before top dead center

psi

Pound per square inch

℃

Degree celsius

r

Revolution

DC

Direct current

rpm

Revolutions per minute

F

Farad

TDC

Top dead center

℉

Fahrenheit degree

TIR

Total indicator reading

ft

Foot

V

Volt

g

Gram

W

Watt

h

Hour

Ω

Ohm

L

Liter

2

Exhaust Emission Control Information

In order to protect our common environment, Zhejiang Qianjiang Motorcycle Co., Ltd. has introduced

crankcase blow-by gas filtration system (1) and exhaust emission control system (2) which conform to the

applicable regulations of the US Environmental Protection Agency and California Air Resources Board, and

equipped the motorcycles sold in California only with fuel vapor recovery system (3) which conform to the

applicable regulations of California Air Resources Board.

1. Crankcase blow-by gas filtration system

This system is used to prevent crankcase gas from being discharged to the atmosphere. The crankcase gas is

forced into the intake side of the engine after passing oil separator. When the engine is working, the gas is fed into

the combustion chamber and then will combust with the fuel and air from the fuel injection system.

2. Exhaust emission control system

This system can reduce the amount of pollutants discharged to the atmosphere in the exhaust generated by

this motorcycle. The fuel injection system, ignition system and exhaust system of this motorcycle are carefully

designed and assembled to ensure efficient engine operation and low emissions of pollutants.

The exhaust system of this motorcycle includes a catalytic converter system.

3. Fuel vapor recovery system

The fuel vapor in the fuel injection system is not discharged to the atmosphere but is forced into the working

engine and will burn out. If the engine is not started, the vapor will be stored in the canister. If it is a fluid fuel, it

will be sucked into oil separator, and then return to fuel tank.

Atmospheric Protection Act is a federal law that deals with motor vehicle pollution and includes provisions

commonly known as “Modification Regulations of Air Pollution Control Act”.

“203(a) No one may do or instigate others to do the following:

(3) (A) Before the final buyer purchases or receives the motorcycle or motorcycle engine, no person shall

dismantle or damage any part mounted on the motorcycle or motorcycle engine according to the regulations of the

manual; the manufacturer or dealer shall not intentionally remove or damage any part after the sale or delivery of

any motorcycle or motorcycle engine to the final purchaser.

(3) (B) After the sale or delivery of any motorcycle or motorcycle engine to the final purchaser, any person

who engages in the repair, maintenance, sale, lease or transaction of motorcycle or motorcycle engine or the

operation of motorcade shall not remove damage any part mounted on the motorcycle or motorcycle engine…”

Remark

It is generally accepted that “the removal or damage of any part” has the following meaning:

1. The temporary removal of any part for maintenance or temporary failure to operate the part does not belong to

“modification”.

2. The following cases belong to “modification”:

a. Incorrectly adjust vehicle components, so that the exhaust emissions exceed the emission standards.

b. Use replacement part or accessory, thus affecting the performance or durability of motorcycle.

c. Add part or accessory, thus making motorcycle out of the standard.

d. Permanently remove, disassemble or damage any part of exhaust emission control system.

It is recommended that all dealers comply with the above regulations of federal law and any violators will

be subject to civil fines.

1

Strictly Prohibiting the Modification of Noise

Control System

Federal law prohibit anyone from doing or instigating others to do the following: (1) Any person removes

any part or make it inoperative before the final buyer purchases or receives any new motorcycle or in the course of

the use of motorcycle, unless there is a need to repair, maintain or replace this part; (2) any person continues to

use the motorcycle after removing any part of any motorcycle or making it inoperative.

The following acts belong to “modification of motorcycle”:



Replace the original exhaust system or muffler with parts that do not comply with federal regulations.



Remove muffler or any of its internal components.



Remove air filter or its cover.



Modify muffler or inlet system by means of cutting, drilling or otherwise, to increase noise level.

2

Contents

Exhaust Emission Control Information ..................................................................................................................... 1

Strictly Prohibiting the Modification of Noise Control System ................................................................................ 2

Preface ..................................................................................................................................................................... 19

Chapter I Basic Information ................................................................................................................................ - 20 -

Notes before Maintenance ........................................................................................................................... - 21 -

Battery Grounding ............................................................................................................................... - 21 -

Sharp Edge of Part ............................................................................................................................... - 21 -

Solvent ................................................................................................................................................. - 21 -

Cleaning Motorcycle before Disassembly ........................................................................................... - 22 -

Collecting and Cleaning Removed Part ............................................................................................... - 22 -

Storing Removed Part .......................................................................................................................... - 22 -

Check ................................................................................................................................................... - 22 -

Replacement Part ................................................................................................................................. - 23 -

Assembly Order ................................................................................................................................... - 23 -

Fastening Order ................................................................................................................................... - 23 -

Tightening Torque ................................................................................................................................ - 23 -

Force .................................................................................................................................................... - 24 -

Gasket and O-Ring Seal ....................................................................................................................... - 24 -

Mould Closing Glue and Threaded Fastening Glue ............................................................................. - 24 -

Press Fitting ......................................................................................................................................... - 24 -

Ball Bearing and Needle Bearing ........................................................................................................ - 26 -

Oil Seal and Grease Oil Seal................................................................................................................ - 26 -

Circlip and Cotter Pin .......................................................................................................................... - 27 -

Lubrication ........................................................................................................................................... - 27 -

Rotation Direction of Engine ............................................................................................................... - 27 -

Wire ..................................................................................................................................................... - 27 -

Cable Connector Check ....................................................................................................................... - 28 -

1. Disconnection .......................................................................................................................... - 28 -

2. Check ....................................................................................................................................... - 28 -

3. Check ....................................................................................................................................... - 28 -

4. Check ....................................................................................................................................... - 29 -

5. Check ....................................................................................................................................... - 29 -

Cable Arrangement .............................................................................................................................. - 30 -

Tool ...................................................................................................................................................... - 30 -

Model Information ....................................................................................................................................... - 31 -

China .................................................................................................................................................... - 31 -

Europe .................................................................................................................................................. - 33 -

Non-Europe ......................................................................................................................................... - 35 -

Basic Specification ...................................................................................................................................... - 38 -

General Technical Parameter ....................................................................................................................... - 40 -

Unit Conversion Table ......................................................................................................................... - 43 -

Chapter II Regular Maintenance .......................................................................................................................... - 44 -

Regular Maintenance Table ......................................................................................................................... - 46 -

3

Torque and Locking Agent .......................................................................................................................... - 48 -

Main Locking Torque Specifications ................................................................................................... - 48 -

Nut, Bolt, Screw Fastening Torque and Relative Parameters .............................................................. - 52 -

Technical Parameters ................................................................................................................................... - 53 -

Special Tools ................................................................................................................................................ - 55 -

Regular Maintenance Procedures ................................................................................................................ - 56 -

Electronic Fuel Injection System (EFI) ............................................................................................... - 56 -

Checking Throttle Control System .............................................................................................. - 56 -

Checking Idle Speed .................................................................................................................... - 57 -

Checking Fuel Hose (Fuel Leakage, Hose Break and Hose Installation Situations) ................... - 58 -

Checking Fuel Evaporation and Recovery System (Chinese, European and US Models) .......... - 59 -

Engine Cylinder Head and Cylinder Head Cover ................................................................................ - 61 -

Checking Valve Clearance ........................................................................................................... - 61 -

Adjusting Valve Clearance ........................................................................................................... - 63 -

Clutch ................................................................................................................................................... - 64 -

Checking Whether Clutch Control System is Normal ................................................................. - 64 -

Checking Free Travel of Clutch Handle ...................................................................................... - 64 -

Wheel/Tire ........................................................................................................................................... - 65 -

Checking Tire Pressure ................................................................................................................ - 65 -

Checking Whether Wheel/Tire is Broken .................................................................................... - 65 -

Checking Wear Situations of Thread ........................................................................................... - 66 -

Checking Whether Wheel Bearing is Damaged ........................................................................... - 66 -

Final Drive Mechanism ....................................................................................................................... - 68 -

Checking Lubrication State of Drive Chain ................................................................................. - 68 -

Checking Whether Drive Chain is Loose .................................................................................... - 68 -

Adjusting Slackness of Drive Chain ............................................................................................ - 69 -

Checking Wheel Alignment ......................................................................................................... - 70 -

Checking Wear of Drive Chain .................................................................................................... - 70 -

Checking Wear of Chain Guide ................................................................................................... - 71 -

Brake .................................................................................................................................................... - 72 -

Check Whether Brake Hose and Brake Pipe are Damaged and Their Installation States ............ - 72 -

Free Travel of Front Brake ........................................................................................................... - 72 -

Free Travel of Rear Brake ............................................................................................................ - 72 -

Checking Brake ........................................................................................................................... - 73 -

Checking Brake Fluid Level ........................................................................................................ - 73 -

Checking Wear of Brake Pad ....................................................................................................... - 76 -

Checking Brake Light Switch ...................................................................................................... - 76 -

Suspension System .............................................................................................................................. - 77 -

Checking Front Fork/Rear Shock Absorber ................................................................................. - 77 -

Check for Oil Leakage of Front Fork Shock Absorber ................................................................ - 77 -

Check for Oil Leakage of Rear Shock Absorber .......................................................................... - 78 -

Steering System ................................................................................................................................... - 79 -

Checking Steering Clearance ....................................................................................................... - 79 -

Adjusting Tightness of Steering Seat ........................................................................................... - 79 -

Applying Lubricant to Steering Column Bearing ........................................................................ - 81 -

Electrical System ................................................................................................................................. - 82 -

Checking Light and Switch .......................................................................................................... - 82 -

4

Checking Accuracy of Headlight ................................................................................................. - 87 -

Checking Emergency Flameout Switch ....................................................................................... - 88 -

Others ................................................................................................................................................... - 89 -

Applying Lubricant to Frame Parts.............................................................................................. - 89 -

Check Tightness of Bolt, Nut and Fastener ................................................................................. - 92 -

Replacement Part ................................................................................................................................. - 94 -

Replacing Air Filter Element ....................................................................................................... - 94 -

Replacing Fuel Pipe ..................................................................................................................... - 96 -

Replacing oil ................................................................................................................................ - 98 -

Replacing Brake Hose and Brake Pipe ...................................................................................... - 100 -

Replacing brake fluid ................................................................................................................. - 103 -

Replacing Rubber Parts of Master Cylinder .............................................................................. - 107 -

Replacing Rubber Parts of Calipers ........................................................................................... - 109 -

Replacing Spark Plug................................................................................................................. - 117 -

Chapter III Electronic Fuel Injection System (EFI) ........................................................................................... - 118 -

Introduction to EFI .................................................................................................................................... - 122 -

EFI System ................................................................................................................................................ - 123 -

EFI Part Position ........................................................................................................................................ - 125 -

Technical Parameters ................................................................................................................................. - 131 -

Fuel tank .................................................................................................................................................... - 133 -

Exploded View of Fuel Tank ............................................................................................................. - 133 -

Evaporative Emission Recovery System of Fuel ............................................................................... - 135 -

Disassembly of Fuel Tank .................................................................................................................. - 136 -

Check ................................................................................................................................................. - 138 -

Installatation of fuel tank ................................................................................................................... - 140 -

Notes for EFI Overhaul ............................................................................................................................. - 141 -

Notes for EFI Overhaul ..................................................................................................................... - 141 -

ECU ........................................................................................................................................................... - 143 -

Engine controller (MT05.2ECU) ....................................................................................................... - 143 -

ECU Appearance ............................................................................................................................... - 143 -

ECU Disassembly .............................................................................................................................. - 143 -

ECU Installation ................................................................................................................................ - 144 -

Notes for ECU ................................................................................................................................... - 144 -

ECU Power Supply Requirements ..................................................................................................... - 144 -

ECU Temperature Requirements ....................................................................................................... - 145 -

Fuel pump .................................................................................................................................................. - 146 -

Working of Fuel Pump ....................................................................................................................... - 146 -

Appearance of Fuel Pump.................................................................................................................. - 147 -

Composition of Fuel Pump ................................................................................................................ - 148 -

Label and Mark of Fuel Pump ........................................................................................................... - 148 -

Working Environment of Fuel Pump ................................................................................................. - 149 -

Fuel pump Maintenance Process ....................................................................................................... - 149 -

Safety Protection: ....................................................................................................................... - 149 -

Fault Diagnosis of Fuel Pump Assembly: .................................................................................. - 150 -

Disassembly of Fuel Pump Assembly: ...................................................................................... - 150 -

Installation of Fuel Pump Assembly: ......................................................................................... - 151 -

Fuel Pressure Release Process: .................................................................................................. - 151 -

5

Fuel Leakage Check Process: .................................................................................................... - 152 -

Notes for Use: .................................................................................................................................... - 152 -

Throttle Body ............................................................................................................................................. - 154 -

Working Principle of Throttle Body: ................................................................................................. - 154 -

Appearance of Throttle Body: ........................................................................................................... - 154 -

Technical Parameters ......................................................................................................................... - 154 -

Throttle Body: ............................................................................................................................ - 154 -

Throttle Position Sensor: ........................................................................................................... - 155 -

Air Control Valve of Idle Speed: ............................................................................................... - 155 -

Working Environment of Throttle...................................................................................................... - 155 -

Disassembly of Throttle ..................................................................................................................... - 155 -

Cleaning Method of Throttle ............................................................................................................. - 155 -

Installation of Throttle ....................................................................................................................... - 155 -

Precautions for Installation of Throttle .............................................................................................. - 155 -

Notes for Use of Throttle ................................................................................................................... - 156 -

Idle speed stepper motor .................................................................................................................... - 156 -

Working Principle of Idle speed stepper motor.......................................................................... - 156 -

Appearance of Idle speed stepper motor .................................................................................... - 156 -

Definition of pin ........................................................................................................................ - 157 -

Characteristic parameter: ........................................................................................................... - 157 -

Fault determination of idle speed stepper motor:....................................................................... - 157 -

Circuit inspection of idle speed stepper motor: ......................................................................... - 158 -

Cleaning ..................................................................................................................................... - 158 -

Resetting of idle speed stepper motor ........................................................................................ - 158 -

Fuel injector ....................................................................................................................................... - 159 -

Working Principle of Fuel Injector .................................................................................................... - 159 -

Appearance of Fuel Injector .............................................................................................................. - 159 -

Sealing Ring of Fuel Injector ............................................................................................................. - 160 -

O-ring Seal Connected to Oil Rail or Oil Injection Cap ............................................................ - 160 -

O-ring Seal Connected to Intake Pipe End ................................................................................ - 160 -

Recommended Lubricant ........................................................................................................... - 160 -

Overvoltage Impact of Fuel Injector .................................................................................................. - 160 -

Temperature Range of Fuel Injector: ................................................................................................. - 161 -

Fuel Contaminants of Fuel Injector ................................................................................................... - 161 -

Fuel Injector Harness Arrangement ................................................................................................... - 161 -

Notes for Use of Fuel Injector ........................................................................................................... - 161 -

Requirements for Installation of Fuel Injector ................................................................................... - 162 -

Replacement Method of Fuel Injector ............................................................................................... - 163 -

Fuel Injector Replaceability ............................................................................................................... - 164 -

Blocking of Fuel Injector ................................................................................................................... - 164 -

General Failure Mode and Prevention and Solving Measures in Using Process ............................... - 165 -

Intake Pressure Sensor ............................................................................................................................... - 166 -

Working Principle of Intake Pressure Sensor .................................................................................... - 166 -

Appearance of Intake Pressure Sensor ............................................................................................... - 166 -

Working Environment ........................................................................................................................ - 166 -

Storage Environment ......................................................................................................................... - 166 -

Electric environment .......................................................................................................................... - 166 -

6

Pin definition ..................................................................................................................................... - 167 -

Position .............................................................................................................................................. - 167 -

Cleaning ............................................................................................................................................. - 167 -

Fault Determination ........................................................................................................................... - 167 -

Oxygen Sensor ........................................................................................................................................... - 168 -

Working Principle of Oxygen Sensor ................................................................................................ - 168 -

Appearance of Oxygen Sensor .......................................................................................................... - 168 -

Technical Parameters ......................................................................................................................... - 168 -

Installation Requirements .................................................................................................................. - 168 -

Oxygen Sensor Pin Definition: .......................................................................................................... - 169 -

Fault Determination ........................................................................................................................... - 169 -

Characteristic curve ........................................................................................................................... - 170 -

Requirements for Fuel Quality .......................................................................................................... - 170 -

Temperature Sensor of Engine Cylinder Head .......................................................................................... - 171 -

Working Principle of Temperature Sensor of Engine Cylinder Head ................................................ - 171 -

Appearance of Temperature Sensor of Engine Cylinder Head .......................................................... - 171 -

Working Environment ........................................................................................................................ - 171 -

Electrical environment ....................................................................................................................... - 171 -

Fault Determination and Characteristic of Output Resistance ........................................................... - 172 -

Canister Solenoid Valve (ECP) .................................................................................................................. - 173 -

Overview of Working Principles........................................................................................................ - 173 -

Appearance ........................................................................................................................................ - 173 -

ECP Pin .............................................................................................................................................. - 173 -

Technical Parameters ......................................................................................................................... - 174 -

Installation Requirements .................................................................................................................. - 174 -

Ignition Coil ............................................................................................................................................... - 175 -

Appearance of Ignition Coil .............................................................................................................. - 175 -

Fault Description: .............................................................................................................................. - 175 -

Fault Maintenance Diagnosis Method of EFI System ............................................................................... - 176 -

Diagnosis Directly Using the Flashing Fault Lamp at Instrument ..................................................... - 176 -

Diagnosing Fault Using Diagnostic Apparatus .................................................................................. - 179 -

Checking Fault Using Diagnostic Software PCHUD ........................................................................ - 180 -

Common Troubleshooting Methods of Electronic Fuel Injection System ................................................. - 185 -

Maintenance Tool .............................................................................................................................. - 185 -

Engine Working Data Flow Displayed by Diagnostic Apparatus ...................................................... - 185 -

Step I .......................................................................................................................................... - 185 -

Step II ......................................................................................................................................... - 185 -

Step III ....................................................................................................................................... - 186 -

Simple Troubleshooting ..................................................................................................................... - 186 -

Daily Use and Maintenance ....................................................................................................... - 186 -

Fault phenomenon-Start fault .................................................................................................... - 187 -

Fault phenomenon—Start failure with tempering...................................................................... - 188 -

Fault phenomenon—Instable idle speed .................................................................................... - 188 -

Fault phenomenon—Too high or too low idle speed (idle speed is obviously inconsistent with

target idle speed) ........................................................................................................................ - 189 -

Fault phenomenon—Instable idle speed with deceleration and flameout .................................. - 189 -

Fault phenomenon—Insufficient power of deceleration ............................................................ - 189 -

7

Fault phenomenon—Slight burning phenomenon ..................................................................... - 189 -

Fault phenomenon—Fault lamp is on, but fault code is inconsistent with fault ........................ - 189 -

Fault phenomenon—Extremely high fuel consumption ............................................................ - 190 -

Fault diagnosis instructions for Delphi .............................................................................................. - 191 -

Chapter IV Engine ............................................................................................................................................. - 193 -

Main Parameters of Engine ....................................................................................................................... - 197 -

Lubrication System .................................................................................................................................... - 198 -

Diagram of Lubrication System ......................................................................................................... - 198 -

Position of Fuel pump ........................................................................................................................ - 200 -

Preparation Information ..................................................................................................................... - 202 -

Conventional Information .......................................................................................................... - 202 -

Technical Parameters ......................................................................................................................... - 203 -

Torque Value .............................................................................................................................. - 203 -

Special Tools ...................................................................................................................................... - 204 -

Troubleshooting ................................................................................................................................. - 205 -

Oil level is too low ..................................................................................................................... - 205 -

Oil pressure is low ..................................................................................................................... - 205 -

There is no oil pressure .............................................................................................................. - 205 -

Oil pressure is high .................................................................................................................... - 205 -

Oil is polluted ............................................................................................................................ - 205 -

Oil is emulsified ......................................................................................................................... - 205 -

Checking Fuel pump .......................................................................................................................... - 206 -

Cylinder Head / Distribution ..................................................................................................................... - 207 -

Exploded View of Cylinder Head / Distribution ................................................................................ - 207 -

Preparation Information ..................................................................................................................... - 208 -

Technical Parameters ......................................................................................................................... - 208 -

Torque Value .............................................................................................................................. - 208 -

Fault Diagnosis .................................................................................................................................. - 209 -

Compression pressure is low ..................................................................................................... - 209 -

The sound of cylinder head is abnormal .................................................................................... - 209 -

Compression pressure is too high .............................................................................................. - 209 -

Special Tools ...................................................................................................................................... - 210 -

Cylinder Head .................................................................................................................................... - 211 -

Disassembling Cylinder Head ................................................................................................... - 211 -

Checking Cylinder Head ............................................................................................................ - 214 -

Replacing Valve Guide .............................................................................................................. - 216 -

Finishing Valve Seat Ring .......................................................................................................... - 218 -

Cylinder Block / Piston .............................................................................................................................. - 221 -

Exploded View of Cylinder Block / Piston ........................................................................................ - 221 -

Exploded View of Crankshaft ............................................................................................................ - 222 -

Preparation Information ..................................................................................................................... - 223 -

Technical Parameters ......................................................................................................................... - 224 -

Torque Value .............................................................................................................................. - 224 -

Fault Diagnosis .................................................................................................................................. - 225 -

Compression pressure is low ..................................................................................................... - 225 -

Compression pressure is high .................................................................................................... - 225 -

Exhaust pipe is emitting white smoke ....................................................................................... - 225 -

8

The sound of piston is abnormal ................................................................................................ - 225 -

Special Tools ...................................................................................................................................... - 226 -

Cylinder Block ................................................................................................................................... - 228 -

Disassembling ............................................................................................................................ - 228 -

Check ......................................................................................................................................... - 228 -

Piston ................................................................................................................................................. - 228 -

Disassembling ............................................................................................................................ - 228 -

Check ......................................................................................................................................... - 229 -

Installation ................................................................................................................................. - 231 -

Installation of Cylinder Block .................................................................................................... - 232 -

Crankshaft .......................................................................................................................................... - 232 -

Check ......................................................................................................................................... - 232 -

Sub-assembly of Crankcase ....................................................................................................................... - 234 -

Exploded View of Crankcase ............................................................................................................. - 234 -

Dismounting and Mounting Diagram of Crankcase Bearing ............................................................. - 235 -

Preparation Information ..................................................................................................................... - 236 -

Overview.................................................................................................................................... - 236 -

Technical Parameters ......................................................................................................................... - 236 -

Torque Value .............................................................................................................................. - 236 -

Crankcase ........................................................................................................................................... - 237 -

Disassembling Crankcase .......................................................................................................... - 237 -

Checking Crankcase .................................................................................................................. - 237 -

Assembling Crankcase ............................................................................................................... - 239 -

Clutch......................................................................................................................................................... - 241 -

Exploded View of Left Cover ............................................................................................................ - 241 -

Exploded View of Clutch ................................................................................................................... - 242 -

Preparation Information ..................................................................................................................... - 243 -

Conventional Information .......................................................................................................... - 243 -

Technical Parameters ......................................................................................................................... - 244 -

Torque Value .............................................................................................................................. - 244 -

Special Tools ...................................................................................................................................... - 245 -

Troubleshooting ................................................................................................................................. - 246 -

Clutch lever is too hard to pull ................................................................................................... - 246 -

Clutch is slipping when accelerating ......................................................................................... - 246 -

Clutch does not disengage or clutch disengages suddenly during the running of motorcycle ... - 246 -

Right Cover ........................................................................................................................................ - 247 -

Disassembing Right Cover ........................................................................................................ - 247 -

Assembling Right Cover ............................................................................................................ - 247 -

Clutch ................................................................................................................................................. - 248 -

Disassembling Clutch ................................................................................................................ - 248 -

Assembling Clutch ..................................................................................................................... - 249 -

Check ......................................................................................................................................... - 250 -

Subassembly of Cylinder Head Cover ....................................................................................................... - 252 -

Exploded View of Cylinder Head Cover ........................................................................................... - 252 -

Preparation Information ..................................................................................................................... - 253 -

Overview ........................................................................................................................................... - 253 -

Technical Parameters ......................................................................................................................... - 253 -

9

Torque Valve .............................................................................................................................. - 253 -

Cylinder Head Cover ......................................................................................................................... - 253 -

Disassembling Cylinder Head Cover ......................................................................................... - 253 -

Checking Cylinder Head Cover ................................................................................................. - 254 -

Installing Cylinder Head Cover ................................................................................................. - 254 -

Kickstarter Component .............................................................................................................................. - 255 -

Exploded View of Kickstarter Component ........................................................................................ - 255 -

Preparation Information ..................................................................................................................... - 256 -

Overview.................................................................................................................................... - 256 -

Technical Parameters ......................................................................................................................... - 256 -

Torque Value .............................................................................................................................. - 256 -

Kickstarter Mechnism ........................................................................................................................ - 256 -

Disassembling Kickstarter Mechanism ...................................................................................... - 256 -

Installing Kickstarter Mechanism .............................................................................................. - 257 -

Gearshift Mechanism ................................................................................................................................. - 258 -

Exploded View of Gearshift Mechanism ........................................................................................... - 258 -

Technical Parameters ......................................................................................................................... - 259 -

Torque Value .............................................................................................................................. - 259 -

Troubleshooting ................................................................................................................................. - 259 -

It is difficult to shift gears .......................................................................................................... - 259 -

Shift pedal is not returned .......................................................................................................... - 259 -

Gearshift Mechanism ......................................................................................................................... - 260 -

Disassembling gearshift mechanism .......................................................................................... - 260 -

Checking Gearshift Mechanism ................................................................................................. - 261 -

Installing Gearshift Mechanism ................................................................................................. - 261 -

Drive System ............................................................................................................................................. - 262 -

Exploded View of Drive System ........................................................................................................ - 262 -

Technical Parameters ......................................................................................................................... - 263 -

Troubleshooting ................................................................................................................................. - 264 -

Drive system trips over stop or is out of gear ............................................................................ - 264 -

The noise of engine is too large ................................................................................................. - 264 -

Primary Shaft Component ................................................................................................................. - 265 -

Auxiliary Shaft Component ............................................................................................................... - 265 -

Check ................................................................................................................................................. - 266 -

Installing Drive System ..................................................................................................................... - 268 -

Assembling Primary Shaft Component and Aauxiliary Shaft Component ................................ - 268 -

Installng Drive System............................................................................................................... - 269 -

Starter Mechanism ..................................................................................................................................... - 271 -

Exploded View of Starter Mechanism ............................................................................................... - 271 -

Technical Parameters ......................................................................................................................... - 272 -

Torque Value .............................................................................................................................. - 272 -

Troubleshooting ................................................................................................................................. - 272 -

Engine cannot start .................................................................................................................... - 272 -

Starter Mechanism ............................................................................................................................. - 273 -

Disassembling Starter Mechanism ............................................................................................. - 273 -

Installing Starter Mechanism ..................................................................................................... - 275 -

Chapter V Finished Motorcycle ......................................................................................................................... - 276 -

10

Wheel / Tire ............................................................................................................................................... - 281 -

Exploded View of Front Wheel / Tire ................................................................................................ - 281 -

Technical Parameters ......................................................................................................................... - 284 -

Special Tools ...................................................................................................................................... - 285 -

Wheel (Rim) ...................................................................................................................................... - 286 -

Disassembling Front Wheel ....................................................................................................... - 286 -

Installing Front Wheel ............................................................................................................... - 287 -

Disassembling Rear Wheel ........................................................................................................ - 288 -

Installing Rear Wheel ................................................................................................................ - 290 -

Checking Wheels ....................................................................................................................... - 291 -

Checking Wheel Axle ................................................................................................................ - 291 -

Checking Dynamic Balance ....................................................................................................... - 292 -

Adjusting Dynamic Balance ...................................................................................................... - 292 -

Disassembling Grip End ............................................................................................................ - 292 -

Installing Grip End .................................................................................................................... - 293 -

Checking / Adjusting Tire Pressure............................................................................................ - 294 -

Checking Tire ............................................................................................................................. - 294 -

Disassembling Tire .................................................................................................................... - 295 -

Installing Tire ............................................................................................................................. - 296 -

Hub Bearing ....................................................................................................................................... - 298 -

Disassembling Hub Bearing ...................................................................................................... - 298 -

Installing Hub Bearing ............................................................................................................... - 298 -

Checking Hub Bearing............................................................................................................... - 299 -

Hub Bearing Lubrication ........................................................................................................... - 299 -

Drive Mechanism....................................................................................................................................... - 300 -

Exploded View of Drive Mechanism ................................................................................................ - 300 -

Technical Parameters ......................................................................................................................... - 302 -

Special Tools ...................................................................................................................................... - 303 -

Drive Chain ........................................................................................................................................ - 304 -

Checking the Slackness of Drive Chain ..................................................................................... - 304 -

Checking the Slackness of Drive Chain ..................................................................................... - 304 -

Checking / Adjusting Wheel Alignment .................................................................................... - 304 -

Checking the Wear of Drive Chain ............................................................................................ - 304 -

Lubrication of Drive Chain ........................................................................................................ - 304 -

Disassembling Drive Chain ....................................................................................................... - 304 -

Installing Drive Chain ................................................................................................................ - 305 -

Sprocket, Shaft Sleeve, Shaft Sleeve Bearing ................................................................................... - 306 -

Disassembling Rear Sprocket .................................................................................................... - 306 -

Installing Rear Sprocket............................................................................................................. - 306 -

Disassembling Shaft Sleeve Bearing ......................................................................................... - 307 -

Installing Shaft Sleeve Bearing .................................................................................................. - 307 -

Checking Shaft Sleeve Bearing ................................................................................................. - 307 -

Lubrication of Shaft Sleeve Bearing .......................................................................................... - 307 -

Checking the Damper of Shaft Sleeve ....................................................................................... - 308 -

Checking the Wear of Sprocket ................................................................................................. - 308 -

Checking the Deformation of Rear Sprocket ............................................................................. - 308 -

Brake .......................................................................................................................................................... - 309 -

11

Exploded View of Front Brake .......................................................................................................... - 309 -

Exploded View of Rear Brake ........................................................................................................... - 311 -

CBS of Hydraulic Brake .................................................................................................................... - 313 -

Technical Parameters ......................................................................................................................... - 316 -

Special Tools ...................................................................................................................................... - 317 -

Brake Lever, Brake Pedal .................................................................................................................. - 318 -

Checking the position of brake pedal ......................................................................................... - 318 -

Adjusting the Position of Brake Pedal ....................................................................................... - 318 -

Removing the Brake Pedal ........................................................................................................ - 319 -

Installing the Brake Pedal .......................................................................................................... - 319 -

Calipers .............................................................................................................................................. - 321 -

Disassembling Front Calipers .................................................................................................... - 321 -

Disassembling Rear Calipers ..................................................................................................... - 322 -

Installing Calipers ...................................................................................................................... - 323 -

Disassembling Front Calipers .................................................................................................... - 323 -

Assembling Front Calipers ........................................................................................................ - 323 -

Disassembling Rear Calipers ..................................................................................................... - 323 -

Assembling Rear Calipers ......................................................................................................... - 323 -

Checking the Liquid Seal of Calipers for Damage .................................................................... - 323 -

Checking Dust Seal of the Calipers for Damage ....................................................................... - 324 -

Checking the Calipers Piston and Brake Cylinder for Damage ................................................. - 326 -

Brake pad ........................................................................................................................................... - 327 -

Disassembling Front Brake pad ................................................................................................. - 327 -

Installing Front Brake pad ......................................................................................................... - 328 -

Disassembling RearBrake pad ................................................................................................... - 328 -

Installing Rear Brake Pad .......................................................................................................... - 329 -

Checking the Wear of Brake Pad ............................................................................................... - 329 -

Master Cylinder ................................................................................................................................. - 329 -

Disassembling Front Master Cylinder ....................................................................................... - 329 -

Installing Front Master Cylinder ................................................................................................ - 330 -

Disassembling Rear Master Cylinder ........................................................................................ - 331 -

Installing Rear Master Cylinder ................................................................................................. - 331 -

Disassembling Front Master Cylinder ....................................................................................... - 332 -

Disassembling Rear Master Cylinder ........................................................................................ - 332 -

Assembling Master Cylinder ..................................................................................................... - 332 -

Checking Master Cylinder (Visual Check) ................................................................................ - 332 -

Brake Discs ........................................................................................................................................ - 333 -

Disassembling Brake Discs ....................................................................................................... - 333 -

Installing Brake Disc ................................................................................................................. - 333 -

Checking the Wear of Brake Disc .............................................................................................. - 333 -

Checking the Deformation of Brake Disc .................................................................................. - 334 -

Brake Fluid ........................................................................................................................................ - 335 -

Checking the Level of Brake Fluid ............................................................................................ - 335 -

Replacing Brake Fluid ............................................................................................................... - 335 -

Exhausting Air from Brake Pipe ................................................................................................ - 335 -

Brake Hose ........................................................................................................................................ - 337 -

Disassembling / Installing Brake Hose and Brake Pipe ............................................................. - 337 -

12