RK6 Service Manual

Service manual of RK6
KEEWAY Motorcycle Corporation Ltd.

0
Contents
Preface .............................................................................................................................................................. - 1 Preparing Documents ....................................................................................................................................... - 2 General Safety .......................................................................................................................................... - 2 Maintenance Rules ................................................................................................................................... - 3 Specification ........................................................................................................................................... - 13 Failure Diagnosis.................................................................................................................................... - 15 Inspection/Adjustment ........................................................................................................................... - 22 Inspection and Maintenance of the Electrical System .................................................................................... - 43 1. Battery/Charging System ........................................................................................................................... - 44 1.1 Preparing Documents ....................................................................................................................... - 44 1.2 Failure Diagnosis.............................................................................................................................. - 45 1.3 Battery .............................................................................................................................................. - 46 1.4 Charging System .............................................................................................................................. - 47 1.5 Voltage/Current Regulator ................................................................................................................ - 48 1.6 Magnetor Charging Coil ................................................................................................................... - 48 1.7 Magnetor Disassembly ..................................................................................................................... - 49 2. Ignition System .......................................................................................................................................... - 52 2.1 Preparing Documents ....................................................................................................................... - 52 2.2 Failure Diagnosis.............................................................................................................................. - 53 2.3 Ignition System Check ..................................................................................................................... - 54 2.4 ECU Group....................................................................................................................................... - 55 2.5 Ignition Coil ..................................................................................................................................... - 56 2.6 Sensor of the Crankshaft .................................................................................................................. - 56 3. Startup System............................................................................................................................................ - 58 3.1 Preparing Documents ....................................................................................................................... - 58 3.2 Failure Diagnosis.............................................................................................................................. - 59 3.3 Startup Motor ................................................................................................................................... - 59 3.4 Starter Relay ..................................................................................................................................... - 61 4. Bulbs/ Switches / Meters ............................................................................................................................ - 63 4.1 Preparing Documents ....................................................................................................................... - 63 4.2 Failure Diagnosis.............................................................................................................................. - 64 4.3 Replacement of Headlamp Bulbs ..................................................................................................... - 64 4.4 Replacement of Front Position Lamp Bulbs .................................................................................... - 65 4.5 Replacement of Tail Lamp ............................................................................................................... - 66 4.6 Replacement of Rear Registration Plate Lamp Bulbs ...................................................................... - 67 4.7 Replacement of Front Steering Lamp Bulbs .................................................................................... - 68 4.8 Replacement of Rear Steering Lamp Bulbs ..................................................................................... - 68 4.9 Meters ............................................................................................................................................... - 68 4.10 Main Switch ................................................................................................................................... - 69 4.11 Horn ................................................................................................................................................ - 69 4.12 Handlebar Switch ........................................................................................................................... - 70 Inspection and Maintenance of the Motorcycle Body .................................................................................... - 71 5. Brake .......................................................................................................................................................... - 74 1
5.1 Maintenance Instruction ................................................................................................................... - 74 5.2 Failure Diagnosis.............................................................................................................................. - 75 5.3 Front Disc Brake .............................................................................................................................. - 76 5.4 Rear Disc Brake ............................................................................................................................... - 80 6. Body ........................................................................................................................................................... - 84 6.1 Disassembly ..................................................................................................................................... - 84 6.2 Assembly .......................................................................................................................................... - 84 7. Front Wheel/Handlebar/Front Suspension ................................................................................................. - 88 7.1 Preparing Documents ....................................................................................................................... - 88 7.2 Failure Diagnosis.............................................................................................................................. - 89 7.3 Front Wheel ...................................................................................................................................... - 90 7.4 Steering Handlebar ........................................................................................................................... - 95 7.5 Front Fork ......................................................................................................................................... - 97 8. Rear Wheel/Rear Suspension ................................................................................................................... - 101 8.1 Preparing Documents ..................................................................................................................... - 101 8.2 Failure Diagnosis............................................................................................................................ - 101 8.3 Rear Wheel ..................................................................................................................................... - 102 8.4 Rear Absorber................................................................................................................................. - 106 8.5 Chain Drive .................................................................................................................................... - 108 8.6 Rear Swinging Arm ........................................................................................................................ - 110 9. Fuel Tank .................................................................................................................................................. - 113 9.1 Preparing Documents ..................................................................................................................... - 113 9.2 Failure Diagnosis............................................................................................................................ - 113 9.3 Fuel Tank ........................................................................................................................................ - 114 10. Disassembly and Installation of Engine ................................................................................................. - 116 10.1 Preparing Documents ................................................................................................................... - 116 10.2 Disassembly of Engine ................................................................................................................. - 116 10.3 Installation of the Engine ............................................................................................................. - 122 Inspection and Maintenance of Engine ........................................................................................................ - 123 11. Lubricating System................................................................................................................................. - 124 11.1 Preparing Documents ................................................................................................................... - 124 11.2 Failure Diagnosis .......................................................................................................................... - 124 11.3 Fuel Pump..................................................................................................................................... - 125 12. Cylinder Head ........................................................................................................................................ - 130 12.1 Preparing Documents ................................................................................................................... - 130 12.2 Failure Diagnosis.......................................................................................................................... - 130 12.3 Cylinder Head .............................................................................................................................. - 132 13. Crankcase ............................................................................................................................................... - 140 13.1 Preparing Documents ................................................................................................................... - 140 13.2 Failure Diagnosis.......................................................................................................................... - 143 13.3 Upper Box .................................................................................................................................... - 144 13.4 Piston ............................................................................................................................................ - 145 13.5 Lower Box .................................................................................................................................... - 150 13.5 Lower Box .................................................................................................................................... - 151 13.6 Clutch ........................................................................................................................................... - 154 2
13.7 Gearshift Mechanism ................................................................................................................... - 157 13.8 Crankshaft Connecting Rod Assembly Chamber and Variable Speed Chamber .......................... - 161 14. Cooling System ...................................................................................................................................... - 167 14.1 Preparing Documents ................................................................................................................... - 167 14.2 Failure Diagnosis.......................................................................................................................... - 168 14.3 Water Pump .................................................................................................................................. - 168 Inspection and Maintenance of Exhaust Emission System .......................................................................... - 171 15. Exhaust Emission & Control System ..................................................................................................... - 172 15.1 Warranty on the Exhaust Emission & Control System ................................................................. - 172 15.2 Instructions on Periodic Maintenance .......................................................................................... - 173 15.3 Mechanical Function of the Exhaust Control System .................................................................. - 173 15.4 Catalytic Transfer System ............................................................................................................ - 174 15.5 Measures When the Idle Speed Emission Value Exceeds the Standard ....................................... - 176 Inspection and Maintenance of Electronic Fuel Injection (EFI) System ...................................................... - 177 16. Electronic Fuel Injection System ........................................................................................................... - 178 16.1 Introduction of Electronic Fuel Injection System......................................................................... - 178 16.2 Components of Electronic Fuel Injection System ........................................................................ - 178 16.3 Methods for Fault Diagnosis and Maintenance ............................................................................ - 192 16.4 Common Fault Removal Techniques ........................................................................................... - 202 RK6 Circuit Diagram ........................................................................................................................................... 0
Preface
This maintenance manual is used for operating and maintaining Motorcycle
RK6.
Preparing Documents include all necessary instructions and statements.
Please carefully read this manual before operation.
Inspection & Adjustment states how to check and adjust your motorcycle. All
safety rules and maintenance regulations shall be carried out from the beginning of
periodic inspection.
Except for Chapter I, the rest chapters explain the disassembly/ assembly/
inspection of Electronic Fuel Injection System, engine, entire motorcycle and
electrical equipment.
Breakdown drawing, systematic drawing, failure analysis and statements are
contained at the first part of each chapter.
Please note that photos, pictures or instructions are for your reference only.
The actual object may differ from what is mentioned here. We will not make
notification for any discrepancy.
Qianjiang Motorcycle Corporation Ltd.
- 1 -
Preparing Documents
General Safety
Specification Table
Maintenance Rules
Inspection/Adjustment
General Safety
Carbon monoxide
Engine must be started up in a well-ventilated place, not in a closed area.
Note
Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human.
Start up engine in an open place. The exhaust cleaning system shall be adopted if engine is started up in a
closed area.
Petrol
Ventilation is required for working places. Fire is strictly forbidden in any working place or where petroleum is
stored.
Battery
Battery emits explosive gas. Therefore, it shall be far away from fire sources, naked flame or smoking places.
Make sure good ventilation during charging.
Battery contains sulfuric acid (electrolyte). It will burn your skin or eyes when contacted. Therefore, wear
protective clothing and mask.
Clean with fresh water immediately if electrolyte splashes on the skin.
Clean with fresh water at least for 15 minutes immediately and then go to the doctor if electrolyte
splashes on eyes.
Electrolyte is poisonous. Drink a large quantity of fresh water, milk, milk of magnesia (laxative antacid) or
mineral oil if electrolyte is swollen accidentally. Then go to the doctor. It shall be unreachable for children.
Machine Oil
It may trigger cancer if repeatedly expose the hands in the air after contacting with oil. Although there is little
possibility for you to contact with oil in the daily life, wash hands thoroughly with water and soap if you have
contacted. And it shall be unreachable for children.
Thermal Energy
Parts of the engine and cooling system produce heat, which can last for some time before the engine gets
started. Deal with these parts with gloves or after the engine and cooling system cools down.
- 2 -
Maintenance Rules
Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage.
Clean up the surface of components or assembly parts before removing or opening the shield for maintenance,
which can prevent dirt from falling into the engine, the chassis or the braking system.
Wash and dry parts with air compressor after disassembly and
before measurement of attrition value.
Solvent or oil can easily damage aging rubber articles. Check

rubber before reassembly and replace rubber if necessary.
boot
When loosening assembly parts, please start form outside to

inside. Small assembly parts shall be loosened first.
Complex assembly parts, such as gearbox, shall be stored in
proper order for facilitating installation in the future.
Please specially note important connections before disassembly.

Replace parts which will not be in use before disassembly.
- 3 -
Bolts and screws with different length shall be separately used for
different assembly parts and shields, and they shall be correctly
mounted. Insert a bolt into a hole to check whether it is proper if
you are confused.
Fill the groove with grease before mounting an oil seal. Check
whether the oil seal is smooth or damaged during assembly.
When installing a rubber hose (fuel, vacuum or cooling agent),

insert its end into the bottom of the connector so that the hose clip
can properly fix the connector. Rubber or plastic dirt-proof boot
shall be mounted at the original design position.
groove clip connector
During dismantling ball bearings, one or two (inside & outside)

bearing rollers shall be supported by tools. Ball bearings may be
damaged during disassembly and have to be replaced if only one
roller (either inside or outside) is imposed with force.
Bearings will be broken under either

occasion as mentioned.
- 4 -
Loose cables threaten electrical safety. Check each cable

after it is clamped to another for electrical safety;
Wire clamps are not allowed to bend towards welding
point;
Bind cables at the designated place;
Do not deploy cables at the end of frame or at sharp point;
Do not deploy cables at the end of bolts or screws;
Cable deployment shall be far from heat source and where
cables may be clamped during moving;
Cables along the handlebar shall be neither too tight nor
too loose, and do not interface with any neighboring parts
at steering positions;
Cables shall be properly deployed without twist or knot;
Check whether the connector jacket is damaged and
whether the connector is over-stretched before mounting
connectors;
Adopt adhesive tape or hose to protect cables if they are
positioned at sharp point or corner;
Bind cables with tape after repairing;
Control cables shall not be bent or twisted. Clumsy
operation may be caused in light of damaged control
cables.
- 5 -
Identification
1The frame number, see figure
Frame Number
Frame
2Rivets of the frame sign and the frame, see figure
Frame Number
Rivets
3The serial number of the engine, see figure

Engine Number
Significant Notes
1. Please apply valid Qianjiang parts and accessories. Any part or accessory not in accordance with the design
specification of Qianjiang Company may cause damage to engine.
2. Only metric tools are valid for maintenance and repair. Metric screws, bolts and nuts can not be exchanged
with imperial fasteners.
3. New gaskets, O-rings, cotter pins and locking pieces shall be applied for re-assembly.
4. Bolts with large diameter or positioned inside shall be fastened first and then diagonally screw down until
reaching required torque, otherwise there is special instruction.
5. Wash disassembled parts with cleanser. Lubricate all sliding surface before assembly.
6. Check whether all the parts and accessories are correctly mounted and operated after assembly.
7. Clean and remove oil before measurement. Add recommended lubricant to the lubricating areas during
assembly.
8. Apply lubricant to the surface of engine and driving system if they are dismantled for long-term storage,
which can prevent rust and dirt.
- 6 -
Special Tools
Special tools refer to tools which are specially designed for assembling or disassembling some
motorcycle parts on special positions. Applicable special tools are necessary for precise adjustment and
installation. With them, parts and accessories can be mounted safely, reliably and rapidly, which improves
efficiency and saves energy.
1Tools for repairing the engine

Special tools are required for properly disassembling/assembling some engine parts.
Table and drawing (1-1, 1-2) of special tools for disassembling/assembling engine parts are as follows:
Table 1-1
Name
Remark
Special socket spanner
Used for assembling/disassembling bolts for flywheels, Fig. 1-3
Clutch clamp holder
Fig.1-4
Flywheel puller
Fig. 1-4
Feeler gauge
Fig. 1-5
Bearing disassembly tools
Fig. 1-6
Bearing assembly tools
Fig. 1-7
Oil seal remover
Fig. 1-8
Handle for dismantling tools
Fig. 1-9
Piston pin pulling device
Fig. 1-10
Piston pin pliers
Fig. 1-11
Socket spanner for spark plug
Fig. 1-12
Clutch thickness measuring device
Fig. 1-13
Cylinder diameter measuring device
Fig. 1-14
Dial indicator
Fig. 1-15
Dial indicator, V-block
Measuring the inner diameter of the piston pin, Fig. 1-16
Dial indicator
For measuring the bending of the valve rodFig. 1-17
Assembly/disassembly tool for valve catheter
For measuring the external diameter of the valve rodFig. 1-18
Assembly tool for valve catheter
Fig. 1-19
Adjustment tool for valve space
Fig. 1-20
Assembly/disassembly tool for valve spring
Fig. 1-21
Valve catheter reamer
Fig. 1-22
Disassembly tool for crankcase
Fig. 1-23
Fig. 1-24
Table 1-2 (continued)
Fig. 1-3
Fig. 1-4
- 7 -
Fig. 1-5
Fig. 1-6
feeler gauge
Fig. 1-7
Fig. 1-8
Fig. 1-9
Fig. 1-10
handle
Fig. 1-11
Fig. 1-12
pliers piston
- 8 -
Fig.1-13
Fig.1-14
Fig. 1-15
Fig. 1-16
Fig. 1-17
Fig. 1-18
Fig. 1-19
Fig. 1-20
Fig. 1-21
Fig. 1-22
- 9 -
Fig. 1-23
Fig. 1-24
2Tools for repairing the chassis

Table and drawing (1-25, 1-26) of ordinary tools and special tools for disassembling/assembling chassis
parts are as follows:
Fig. 1-25
Name
Remark
Torque spanner
Fig. 1-27
Inner hexagon spanner
Fig. 1-28
Socket spanner
Fig. 1-29
Micrometer
Fig. 1-30
Magnetic rack, V-block
Fig. 1-31
Dial indicator
Fig. 1-32
Vernier calipers
Fig. 1-33
Circlip pliers
Fig. 1-34
Screwdriver with striking cap
Fig. 1-35
Tool for assembling oil seal of front fork
Fig. 1-36
Tool for hammering seal of front fork
Fig. 1-37
Steering nut spanner
Fig. 1-38
(1) Ordinary tools for repairing the chassis

Table 1-26 (continued)
Fig. 1-27
Fig. 1-28
Fig. 1-29
Fig. 1-30
- 10 -
Fig. 1-31
Fig. 1-32
Fig. 1-33
Fig. 1-34
Fig. 1-35
Fig. 1-36
(2) Special tools for repairing the chassis: tool for hammering seal of front fork
Fig. 1-37
(3) Steering nut spanner
Fig. 1-38
3Tools for electric parts

- 11 -
Table and drawings (1-39, 1-40) of special tools for testing electric parts are as follows:
Fig. 1-39
Name
Remark
Multimeter
Fig. 1-41
Ignition tester
Fig. 1-42
Fig. 1-40 (continued)
Fig. 1-41
Fig. 1-42
- 12 -
Specification
Motorcycle Model
RK6
Engine Type
BJ465MS-A
Length mm
2120
Fuel type
Unleaded petrol93/97
Width mm
800
No. of
cylinder
Height mm
1100
ID stroke
65.045.2
Wheelbase mm
1480
Total
displacement
600cc
Petrol tank capacity
15L
Startup
Electric
115
Cooling
Liquid cooling
105
Lubrication
Pressure splash
lubrication
Total
220
Clutch type
Wet multi-chip
Front
tire
120/70
ZR 17
Variable
speed
Six variable speed
Rear tire
180/55
ZR 17
Transmission
Chain
Weight kg
(Curb weight)
Tire Size
Electric
devices
Perfor
mance
Engine
Forward
shaft
Backshaft
Battery
capacity
12V-9AH
Magnetor
Flywheel permanent
magnet
Spark plug
CR9E(NGK)
Spark plug
gap
0.6-0.7mm
Ignition
Primary
transmission
ratio
Transmisson
ratio of gear 1
1.864
2.846
Transmission
ratio of gear 2
1.947
Transmission
ratio of gear 3
1.556
TLI
Transmission
ratio of gear 4
1.333
Max. Hp
60.0kW/11000rpm
Transmission
ratio of gear 5
1.190
Max. torque
55N.m/8000rpm
Transmission
ratio of gear 6
1.083
Compression
ratio
11.51
Final
Transmission
ratio
3.286
Max. speed
185km/h
Dia. of front
liquid brake
discmm
320mm
Dia. of rear
liquid brake
discmm
240mm
Transmission
devices
Brake
Fuel
consumption
limit
5.2L/100km
- 13 -
RK6
- 14 -
Failure Diagnosis
Diagnosis on difficulty or failure in starting up
Failure Diagnosis
Adjustment & Inspection
Causes of Failure
- 15 -
Check if petrol
pump is working
properly
Oil provided to fuel

injector is sufficient
and smooth
No
petrol
provided to
fuel injector
Disassemble
spark
plug into its cap,
ground it with engine
to check if it can spark
Spark-over
Weak sparks
No
Test compression pressure
Normal
No petrol in the tank

Oil tube of fuel injector blocked
Oil tube of petrol pump blocked
Tube of combustion chambers
Evaporation Control System
blocked
Petrol air filter blocked
Low oil pressure of petrol pump
Abnormal spark plug
Polluted spark plug
Abnormal CPU group
Abnormal trigger
Open circuit or short circuit of
ignition coils wire
ignition coil
Abnormal main switch
Abnormal charging coil
Abnormal clutch for startup
Abnormal piston of cylinder and
piston ring
Too low
No
Leakage of cylinder gasket
No ignition
outbreak of
the engine
Ignition outbreak
of the engine but
no sign of startup
Abnormal
actuation
automatic
choke
Intake manifold with air

Incorrect ignition time
Disassemble once agian the

spark plug to check
Dry spark plug
Wet spark plug
Abnormal adjustment to throttle

valve and bolt
Excessive oil injected to fuel

injector
Abnormal automatic choke
actuation
Throttle opens too large
- 16 -
Unsmooth gyration (No speed or weak speed)

Failure diagnosis
Adjustment specification
Causes of failure
Start engine with

soft refueling
accelerated
gyration speed
of engine
Air filter blocked

Abnormal petrol
blocked
Exhaust pipe blocked
Abnormal automatic choke
Abnormal throttle valve
Engine can not

fully speed up
Adjust ignition timing and

use ignition timing light
Correct
ignition time
Abnormal CPU group
Incorrect ignition
time
Abnormal trigger
Test compression pressure
Abnormal piston of cylinder and
piston ring
Normal
Too low
Leakage of cylinder gasket
Blocking check to Carburetor

No
Yes
Contaminant removal
Disassemble the spark plug to
check
No pollution nor
discoloration
Contaminant removal
Polluted and
discolored
Heat value of spark plug does

not conform
Check oil level in crankcase

if it is high or polluted
Normal
Excessive oil
Insufficient oil
No replacement of oil
High oil level

Check the lubrication
cylinder head
Normal
Abnormal
Overheated engine
Yes
No
Accelerated driving or
running
Engine knock
No engine knock
of
Abrasion in piston cylinder
Mixed gas too thin
Abnormal petrol
Too much carbon fouling in the
combustion chamber
Earlier ignition time
Too much carbon fouling in the
combustion chamber
Abnormal petrol
Clutch slipping
Thin mixed gas
Earlier ignition time
- 17 -
Unsmooth gyrationespecially in low speed

Failure Diagnosis
Causes of Failure
Adjust ignition time

Abnormal CPU group
Normal
Abnormal
Abnormal trigger
Adjustment to throttle valve and

bolt
Mixed gas too thin (loosen bolt)

Good
Bad
Mixed gas too dense (tighten
bolt)
Spacer inhaled air or not
Yes
Abnormal spacer of heat

insulation piece
Throttle valve fixed, bolt
loosened
Heat insulation piece ruptured
Negative pressure pipe ruptured
No
Disassemble spark plug

into its cap and ground it
with engine to check if it
can spark
Good
spark-over
Bad spark-over
Spark plug abnormal or polluted

Abnormal CPU
Abnormal ignition coil
spark plugs wire
Negative pressure pipe damaged

Good
Bad
Air pass-hole blocked
- 18 -
Unsmooth gyration (high speed)

Failure Diagnosis
Causes of Failure
Adjust ignition time
Abnormal CUP group

Normal
Abnormal
Abnormal trigger
Little oil in petrol tank

Normal
Petrol filter of the pipe blocked
Abnormal
Blocked oil injector
No
Good
Blocked
Spring broken
Weak elasticity

blocked
Abnormal automatic oil ring
Remove
Abnormal spring
- 19 -
Poor battery charging (over discharge or over charge)

Failure Diagnosis
Causes of Failure
Test the voltage of

batterys two ends, and
stat engine
Battery used up
No voltage rise
Voltage rises to normal

value, and back to
original voltage value
after flameout
Poor battery
Check the plug of voltage

regulator if it is loose
Normal
Poor connection of the plug
Abnormal
Open circuit of the red wire of

the charging wire
Check if the red wire of voltage regulators
socket connects the multimeter, while
anode and cathode wire to the voltage
between parts of the body
Voltage
available
Voltage regulator
No voltage
Open circuit of the white wire of

the charging wire
Test the resistance
alternators coil
Normal
of
Abnormal coil
Poor connection of the joint
Open circuit of alternators
white wire
Poor battery
Abnormal
Poor battery charging

Overcharging
Voltage above
normal value
value
Start the engine, connect the red wire of the

voltage regulators socket to the multimeter,
while anode and cathode wire to the voltage
between parts of the body
Normal voltage
Check if charging wire of the voltage

regulator connects well
Normal
Loose
Bad connection
Use monomer of the voltage regulator

to test impedance
Poor connection of the joint and

charging wire to the ground
Abnormal voltage regulator
- 20 -
No spark-over of the spark plug

Failure Diagnosis
Causes of Failure
Replace on new spark

plug and check again
Weak spark-over or
no spark-over
Strong spark
Original spark plug abnormal
Check again after

checking spark plug
No sign of loose
Loose
Spark plug cap loose
Check plugs of CDI group if they

are loose
Normal
Abnormal
Bad connection of the plug

Check conduction between terminals
of CDI groups plugs, and test
resistance value

Abnormal charging coil
Normal
Abnormal
Abnormal trigger
Check relevant parts
Normal
Abnormal
Breakage of main wire

Bad connection of the plug and
socket
Use CDI tester to check CDI group
Normal
Abnormal CPU group
Abnormal
Use CDI tester to check ignition coil

Abnormal
- 21 -
Inspection/Adjustment
Preparing information
Periodic Maintenance & Inspection Table
Engine oil/ Oil filter
Liquid coolant
Assembly/disassembly of radiator pipes clamp
Fuel injector & Oil-way
Adjustment of throttle cable
Air filter
Spark plug
Battery
Fuse replacement
Cylinder pressure
The slackness of the drive chain
Free stroke of front brake
Free stroke of rear brake
Headlamp
Clutch
Front/rear suspension system
Bolt/nut/fastener
Rim/tire
Fixing steering stem bearing & handlebar
Throttle valve
Components lubrication
Preparing Principles
General
Warning!
Make sure that it is well ventilated before starting the engine. It is forbidden to start it in a closed area.
Exhaust gas, which contains monoxide, may cause unconsciousness or even death of human being.
Petrol is liable to volatile or exploded under certain condition. Ventilation is required and no any fire exists in
working places. Fire is strictly forbidden in working areas or where oil is stored.
- 22 -
Specification
Engine
ID stroke
65.045.2
Total displacement
600cc
Ignition
TLI
Spark plug gap
0.6-0.7mm
Spec. of spark plug
CR9E(NGK)
Type of combustion chamber
spherical
Frame
Free stroke of front brake lever
10-20mm
Free stroke of rear brake pedal
20-30mm
Specification
Tyre pressure unitKpa
Torque
value
RK6
Tire pressure
Front tire
120/70 ZR 17
25010kpa
Rear tire
180/55 ZR 17
29010kpa
Fixing front wheel

spindle
100-140N
m
Fixing nut of rear

wheel spindle
130-150N
m
- 23 -
Periodic Maintenance & Inspection Table

Service cycle and time
Inspection item
*
*
*
*
*
Per
300
Km
Per
1000
Km
Per
3000
Km
Per
6000
Km
Per
12000
Km
Per
14500
Km
New
One Three Six

month months months
Twelve
months
Fifteen
months
R
R
C
Air filter
Petrol filter
Fuel filter
Replacement of engine
fuel
I
I
C
Tire pressure
Battery inspection
Actuation gap inspection
Ordinary tools
Ordinary tools
Inspection of steering
handle fastening
Absorber working
inspection
Screw fastening
inspection
Oil leakage inspection for
gearbox
Inspection or replacement
of spark plug
Replacement of gearbox
oil
C
I
C
Tools
Replacement every 1000KM
Ordinary tools
Ordinary tools
Ordinary tools
Ordinary tools
Tire pressure
gauge, inflator
Densimeter,
multimeter
Ordinary tools
Torque spanner
Ordinary tools
Ordinary tools
I
I
Replacement every 5000KM
Lubrication of each part
Ordinary tools
Lubricator
Muffler
Ordinary tools
Ignition timing
Timing lamp
Carburetor
Exhaust gas inspection at
idle speed
Throttle inspection
Fuel pipeline inspection
Lighting/metering/electric
devices
Main stand bracket
Absorber
Torque force of engine
bolts
Front/rear brake
Tachometer, CO
HC analyzer
I
I
I
I
I
I
I
I
Ordinary tools
Ordinary tools
Visual multimeter
I
I
I
I
Ordinary tools
Ordinary tools
Torque spanner
Ordinary
I
I
I
I
I
I
I
I
I
A
I
I
Ordinary
Ordinary
Feeler
*
*
Drive chain
Clutch
Valve
I
I
I
I
I
I
I
- 24 -
Anticipated Inspection
1
2
3
Ignition systemobviously continuous ignition abnormality, engine fire or overheating, which requires
inspection and maintenance.
Carbon fouling eliminationobviously insufficient horsepower, which requires carbon fouling removal
from cylinder head, piston head and exhaust system.
Piston & cylinderexcessive abrasion; replace cylinder if it is blocked.
Please have your motorcycle inspected and adjusted periodically at Qianjiang distributors for being in best
condition.
The above table is established under the presupposition of 1000 km/month.
IInspection AAdjustment RReplacement CCleaning LLubrication
Note: 1. * Regulations on exhaust emission made by the State Environmental Protection Agency shall be
complied with. Maintenance must be carried out in accordance with the instruction manual supplied by the
company. We are not responsible for any loss rising from private adjustment or maintenance.
2. Increase frequency of washing air filter if your motorcycle runs on the sandy/gravel road or under
heavily polluted environment so as to extend its service life.
3. Motorcycles which often run at high speed or with high mileage shall be maintained frequently.
Engine Oil/Filter
Oil level
* Note
The motorcycle should be parked on a flat ground when
checking its oil level.
After the engine runs for 2-3 minutes or stops running for
about 2-3 minutes, check the oil level.
Check the oil level.
Add oil to the upper limit when there is an alarm from the oil level sensor.
Check oil level

*Note
Do not tighten dipstick when check.
Check the oil level, and lay down the single shoring on the flat
ground so that the body is vertical.
Oil level must be checked regularly when oil is constantly
being consumed, and refuel to a right level.
Oil capacity: 3.0L change oil 3.2L disassemble
The working of engine and clutch will be affected if the oil
level is too high;
(maximum minimum)
And if it is too low that will lead to overheated engine and earlier abrasion of the components.
If refuel with inferior oil or oil of other brand or class will reduce the effect of lubrication.
Disassemble the dipstick after the engine stops, and dry it with a clean cloth.
Put the dipstick into the measurement hole with the engine on the flat ground, but do not tighten it up.
Take out the dipstick and check the oil level.
- 25 -
If it is below or near the minimum level,

Refuel with the recommended oil to the maximum level.
*Note
Check the O-ring.
Assemble the dipstick.
Oil Replacement
* Note
It will be easier to change oil when the engine is warming up.
Preheat the engine.
Place a drip pan under the engine, and disassemble the drain
bolt and the dipstick.
Repeatedly start the engine for several times until the oil is
discharged completed.
When the oil is discharged completely, install back the drain
bolt and the packing washer after cleaning.
Refuel recommended oil to the crankcase to a required capacity.
Assemble the dipstick.
Start the engine to run in an idle speed for 2-3 minutes.
Stop the engine, and check if the dipstick is at the maximum level several minutes later.
The engine should be upright while checking.
Make sure that there is no leakage.
Replacement of the Oil Filter

*Note
It will be easier to change oil when the engine is warming up.
Turn off the engine.
Make the oil filter stuck with special removal tool, spin
anticlockwise and disassemble the oil filter that needs
replacement .
Replace on new oil filter and coat a layer of lubricant on the
O-ring.
Note:
Do not disassemble the O-ring, otherwise it will make the
O-ring out of position while installing, which can lead to
oil leakage or the damage of the engine.
Install the new oil filter to the engine with hands, spin until
it can not be screwed any further, then tighten it with
Torque spanner (torque: 12-20Nm).
Check oil leakage when the engine operates at its idle
speed for minutes.
Oil filter
- 26 -
Cooling Liquid
Check the height of the cooling liquid in the expansion kettle
during maintenance.
Replace in time the cooling liquid when it becomes turbid or it
is time for maintenance.
Recommended model of the cooling liquid: FD-2
Total liquid capacity of the cooling system: about 2.0L
Remove the front shield on the right side. Find the filler mouth
of radiator water tank.
Open the filler cap and inject a right amount of cooling liquid.
Re-install the cap after injection.
Check the cooling liquid of the expansion kettle after the
engine has been turned off and cooled down.
While checking, make sure the motorcycle is on the flat ground
and its body upright.
Observe the capacity of the cooling liquid in the expansion
kettle through the frame hole from the right side of the
motorcycle.
Keep the capacity between the mark of H and L. If the liquid is below H, remove the cap of the expansion
kettle and then add cooling liquid.
Warning:
Add the cooling liquid after the engine is turned off
and cooled down. In case of burns, do not open the filler
cap before the engine has cooled down. The cooling
system is under pressure. In some cases, the cooling
liquid contains substances that are combustible, and
there will be visible flame when ignited. Avoid the
leakage of cooling liquid on hot motorcycle parts,
because it can cause serious burns if combust.
Avoid contact to and inhalation of the cooling
liquid, because it is highly toxic. And keep it away from
the children and domestic animals. If inhaled, seek
medical advises immediately, and if the skin or eyes
have accidentally contacted the cooling liquid, they
must be cleaned with water instantly.
- 27 -
Assembly and Disassembly of the Clamp of the Radiators Conduit

The clamp of the radiators conduit is disposable component, so
the old clamp can not be reused when disassembled. And the
clamp can only be assembled by special clamp pliers, or it
may not in place, which will lead to the breakdown of the
vehicle.
clamp
Fuel Injector and Oil-way

The fuel pump has two connectors, oil passes through
the fuel filter from one of the two connector into the
fuel injector, and finally inject oil into the intake
manifold of the engine. When the oil is under too high
pressure, it will pass through another connector back to
the fuel pump.
Please connect the inlet and outlet oil tubes as shown in
the figure at right.
- 28 -
Adjustment to the Steel Rope of the Throttle

*Note
Adjust the idle speed of the engine right before adjusting
the stroke of the steel rope of the throttle.
Check the free stroke of the steel rope of the throttle, and it
should be 3-5mm.
Adjust if it does not conform to the specified value.
Adjust the free stroke of the steel rope of the throttle.
The motorcycle is configured with two-lane steel rope of
the throttle, among the two ropes, A for throttle forward
(1)Remove the dustproof boot of the steel rope of the
throttle.
(2)Loosen the locking nut.
(3)Screw in completely the adjusting nut.
(5)Rotate the adjusting nut to make the free stroke of
controlling handlebar of the throttle to 1015.
(6)Tighten up the locking nut.
(7)Adjust nut to make the controlling handlebar of the
throttle flexible.
(8)Tighten up the locking nut.
After adjusting the free stroke, the handle should be
twisted left and right to make sure that there is no change
of the idle speed of the engine.
Air Filter
Filter Replacement
Open the rear seat cushion with the key, and remove it.
key
Pull the seat steel rope, open the front seat and take it off.
- 29 -
seat steel rope
Disassemble the shield of the fuel tank and its front fixing
bolt, and open the fuel tank.
front fixing bolt of the fuel tank
Disassemble the cover of the air filter.

Take off its cartridge.
Check whether the cartridge is stained or damaged.
Replace it if necessary.
Clean thoroughly but gently the cartridge with the cleanser.
Do not use petrol, in case of fire.
Do not distort or wring the cartridge so as not to damage
the foam.
Then apply the engine oil to it, and squeeze out the excess
oil to make the cartridge seem moist, but make sure there is
no oil dripping.
cover of the air filter
fuel tank
Cartridge
Replacement Time
Replace it as early as possible if the motorcycle is always running on rainy days or on rugged road.
*Note
- 30 -
Do not start engine when disassemble the cartridge of the air filter, otherwise, the engine will intake unfiltered
air, which may lead to rapid abrasion of other components, and the damage of the engine too.
In addition, rotation without cartridge will cause sequential malfunctions of the carburetor, and it may lead to
overheat of the engine.
Install in reverse order.
Spark Plug
Remove the spark plug:
(1)Lift up the fuel tank.
(2)Disassemble the intake air temperature sensors on both side
of the air filter, and then remove the air filter.
(3)Remove the stators of the spark plug caps on both sides.
(4)Remove four spark plug, and you can see the spark plug.
(5)Remove the spark plug with the spark plug demolition sleeve.
Check
Whether the insulator is cracked or damaged
Whether the electrodes are abrasive
The combustion condition and color
The condition is good in light grey
Combustion color of pale indicates that the ignition system
gets a breakdown or the mixed air is too thin.
The condition of wet or there is black carbon deposition
indicates that the mixed air is too thick.
If there occur any cases mentioned above, please remove with spark
plug cleaner or steel brush, and replace if necessary.
Check the spark plug visually.
Replace the cracked or abrasive insulator if necessary.
Replace the spark plug after 8000 kilometers of each driving.
Check the spark plug gap.
Gap: 0.6-0.7mm
Model: CR9E(NGK)
spark plug gap
*Note
Re-install the spark plug to the cylinder head, and screw tight with a specified torque.
Torque value: 20-25N.m
Manually install the spark plug first, and then tighten with the spark plug sleeve.
Do not make the spark plug too tight or the threads staggered, so as not to damage the threads of the cylinder
head.
When remove the spark plug, avoid impurities from entering into the engine through it.
- 31 -
Battery
Battery Disassembly
Disassemble the front seat.
Remove the mounting plate of the battery.
Remove the negative wire and then the positive wire.

Remove the battery from the battery box.
Take out the battery.
Warning!
When the positive wire is disassembled, do not make the
tool contact with the frame. Otherwise, it may cause
short-circuit spark, which may ignite gasoline and damage
the battery. It is dangerous.
Install it in reverse order.

Warning!
To prevent short circuit, connect the positive wire first and then the negative wire.
Do not remove the battery during commissioning. Otherwise, it may cause damage to inner parts of the
vehicle.
Check the Charging Condition (closed circuit voltage)

Open the front seat.
Remove the battery from the battery box.
Remove the negative wire and then the positive wire.
Take out the battery.
Test the voltage between battery terminals.
Fully charged: 13.1V
Insufficient charging: 12.3V1 hour off work
*Note
Use a voltmeter to check the charging condition.
Charging
Connection: Connect the positive pole of the charger to the positive pole of the battery.
Connect the negative pole of the charger to the negative pole of the battery.
- 32 -
Warning!
The battery should be far away from fire source.
Turn off the charger before or after charging to avoid
explosive danger caused by spark which may exist in any
connection.
Comply with the current and time requirements for charging
as stated on the battery.
* Note
Except emergencies, you should not use emergency charging.
Measure voltage in 30 minutes after the battery is charged.
voltmeter
Charging current: standard: 0.3A
quick: 3.0A
Charging time: standard: 10-15 hours
quick: 30 minutes
charging accomplishedopen-circuit voltage: above 12.8V
Fuse Replacement
The fuse is under the drivers seat, and near the battery.
The main fuse is set on the starter relay, and the fuse box is
near the fuse. As shown in the figure refers to the fuse,
model: 40A, refers to the spare fuse of the main fuse, model:
40A, refers to the fuse box, the configuration of the fuse is
shown in the figure:
Frequent fuse blowout indicates that there is short circuit or
circuit overload.
Note:
Before check or replace the fuse, set the ignition switch to off
, in case of short circuit or damage to other electrical
components.
Use the specified fuse only, or it will cause serious affect to the
electric system, and it can even burn the lamps of the
motorcycle or cause a fire or loss of engine traction, which is
very dangerous.
: light; fuel pump; fan;
power lock; spare fuse
- 33 -
Cylinder Pressure
Warm up the engine.
Insert the pressure gauge.
Turn the choke lever to the fully open position.
Start up the engine repeatedly,
The pressure of the cylinder: 11.2mpa
*Note
Start the engine until the reading does not rise.
Reasons for low pressure:
Incorrect valve adjustment
Leakage of the valve
Abrasive piston ring or cylinder
Reasons for high pressure:
Carbon deposition in the combustion chamber or piston
Turn off the engine, and remove the spark plug/spark plug cap
Looseness of the Drive Chain

The life of the drive chain depends on appropriate
lubrication and adjustment. Improper maintenance could
lead to earlier abrasion of the dive chain and the sprocket.
It must be maintained frequently if harshly used.
Looseness: 10-20mm
Adjustment to the drive chain:
Adjust the drive chain to the sag of 10-20mm in
every 1000 kilometers drive. Regular adjustment may
need which depends on your driving.
Warning:
It is the maximum interval for adjustment as
recommended; in fact, you should adjust the chain
before every drive. Over loosened chain may
cause the accessory chain off the drive chain or
serious damages to the engine.
Adjust the chain according the following methods
mentioned
- 34 -
(1)Put up the motorcycle with the support frame.

(2)Loosen the rear axle nut.
(4)Turn right or left the adjustment bolt to adjust the looseness of the chain, and keep the centers of the
rear and back sprockets into a straight line. There are benchmarks on the swinging arm and each chain
adjuster to facilitate your adjustment, and they can be aligned with each other and the reference from
one side to the other. Align and adjust the looseness of the chain to 1020mm, and then fix again the
rear axle nut for the final check.
Note:
The two sprockets of the newly replaced
chain should be checked to make sure whether
they are abrasive or not, replace if necessary.
Inspect periodically the following condition of the chain:
(1)Loose pin
(2)Damaged idler wheel
(3)Dry and rusty chain
(4)Twisted or blocked chain link
(5)Excessive damage
(6)Adjust loose chain
If the chain has defects as mentioned above, then there is a high possibility that the sprocket will damage the
chain. So the following items should be check to the sprocket:
(1)Excessively abraded gear tooth
(2)Broken or damaged gear tooth
(3)Loose fixing nut of the sprocket
Lubrication of the drive chain
Priority should be given to lubricate by the lubrication grease for the drive chain, and you may buy it or use
engine oil or other lubrication oil instead. Dip every chain joint to make the lubrication grease penetrate to the
space between the chain plates, pins, bushings and rollers.
*Note
Do not assemble new drive chain to abraded sprocket or vice versa.
The sprocket and the chain should all be in good conditions, or it will cause quick abrasion of the newly
replaced chain or sprocket.
- 35 -
Free Stroke of the Front Brake

Free stroke of front brake
Measure the free stroke of front brake at the tip of the
brake lever.
Free stroke: 10-20mm
Regulator of Lever Grip of the Front Brake

Depending on the operating needs for the comfort, the
position of the lever grip of the front brake can be
adjusted by adjusting the knob with the ring nut. There
are four positions for adjustment, and you can adjust to a
desired position just by moving gently forward the lever
of the brake, and then rotating the adjuster of the ring nut
at the arrow A
. And position 1 of the front brake lever is
most remote to the controlling handlebar of the throttle,
while the position 4 nearest to it.
front
Free Stroke of the Rear Brake

Free stroke of the brake pedal
Measure the free stroke of the brake pedal.
- 36 -
If specified value has not been met, it should be adjusted.

Adjust the free stroke of the brake pedal.
First open the nut 1.
Screw in or out nut 2 to adjust the free stroke of the brake pedal.
Screw in 2 to reduce the free stroke;
Screw out 2 to increase the free stroke.
Tighten the fixture 1 until the specified value is met.
After being adjusted, dragging should not occur to the brake.
Headlamp
Disassemble the fixing bolt of the headlamp support.
Disassemble the fixing bolt of the headlamp support.
- 37 -
Unplug the lamp holder connector of the headlamp,

remove the lamp holder, disentwine the snap ring, and take
out the bulb.
*Note
Keep combustible materials and your hands a distance away
from the bulb when it is light. Because the bulb is very hot at
that moment, you should let it cool down before touching it.
Install new headlamp bulb, lamp holder, and screw in the
bulb to the socket.
During the installation, avoid direct touch with the glass of
the bulb, an do not make it oil-stained. Or it will affect the
transparency, life and luminous flux of the bulb.
Once stained with oil, wipe thoroughly with a damp cloth of
alcohol or rubber solution of strong volatility.
Clutch
Check the free stroke of steel rope of the clutch.
Adjust the free stroke of the steel rope of the clutch.

First open the clamp nut1.
Then screw in or back to the adjusting device2.
Until the specified value of the free stroke is met.
Finally, tighten the clamp nut.
If adjusting the handle of the inhaul cable of the clutch to its

ultimate position can not meet the requirement of the free
A of the engine and the
stroke, then adjust the locking nut
B with the inhaul cable.
adjusting nut
- 38 -
Front/Rear Suspension System

Front Absorber
Pull the front brake tight; compress the front absorber upwards or downwards for check.
Check whether there is oil leakage in the front absorber and whether any component is damaged or loosened
compress upwards or downwards
Rear Absorber
Compress the rear absorber upwards or downwards for check.
Check whether each part of the rear absorber is damaged or loosened.
Suspend the rear wheel and check shimmy.
Check whether the suspension bushing of the engine is loose or not.
Bolt/ Nut/Fastener
Check whether each bolt, nut and fastener is loose.
If yes, tighten it to required torque.
- 39 -
Rim/Tyre
Check whether tires or rims have any crack, nail or any
other damage.
Check tyre pressure.
*Note
Check tyre pressure when it is cold.
Tyre
Specification
pressure
Front tyre
120/70 ZR 17
25010kpa
Rear tyre
180/55 ZR 17
29010kpa
RK6
When the non-skid depth on the central thread of the tyre

reaches to the figure in the table, the tyre should be
replaced.
Minimum non-skid depth
Front tyre
1.6mm
Rear tyre
2.0mm
Warning:
Do not attempt to repair the damaged tyre.
The balance and reliability of the tyre is likely to
worsen.
Improper tyre inflation will lead to abnormal
abrasion of the tyre and threat the safety. And
insufficient inflation will cause tyre slip, or
disengage the tyre, or lead to the deflation of tyre
which is out of control. It is dangerous to drive
with excessively abraded tires, and it is adverse to
the adhesion or driving.
barometer of the tyre
Check whether the locking nut of the front wheel spindle is loose.
Check whether the fixing nut of the rear wheel is loose.
Tighten it to the required torque value if it is loose.
Torque value: fixing the front wheel spindle
fixing nut of the rear wheel spindle
55-62 N
m
85-108 N
m
- 40 -
Fixing Steering Stem Bearing and Handlebar

Move the handlebar to confirm there is no wire interference.
Rotate the front wheel and move the handlebar freely for check.
If the handlebar moves difficultly, release it and then check the bearing of the fixing steering stem.
Throttle Body
The idle speed of the motorcycle will be reduced to some
extent due to the pollution of the throttle body. It is better to
clean it after every 5000 kilometers drive.
When cleaning, disconnect the negative pole of the battery,
connectors of the sensor installed on the throttle; and
remove the throttle cable, hose connected to the air filter
and the intake manifold, and the throttle body.
Open the lid on the bottom of the throttle body, spray
cleanser to its in-wall and brush the dust and carbon
deposition, etc.
After cleaning, operate in reverse order, install the throttle
and make sure that all parts are in place, and try to start the
engine successfully.
Note:
Do not let impurities block the parichnos nearby.
- 41 -
Components Lubrication
Appropriate lubrication is of great importance to the normal operation of each part of the motorcycle, to an
extended life and to the safety drive. Lubricate the motorcycle after a long time running or exposure in the rain
or after cleaning. As for detailed points for lubrication and maintenance, see the following figure:
motorcycle
lubrication
grease
1 axis of the rear brake pedal
2 single bracket joint and spring hook
3 pin of the
gearshift riding rod
4 throttle cable
5 pin of the front brake handle
6 clutch handlepin
- 42 -
Inspection and Maintenance of the Electrical System
charging system
- 43 -
1. Battery/Charging System
Preparing Documents-----------------------1.1
Failure Diagnosis----------------------------1.2
Battery-----------------------------------------1.3
Charging System-----------------------------1.4
Voltage/Current Regulator -------------------1.5
Charging Coil of Magnetor ------------------1.6
Disassembly of Magnetor -------------------1.7
1.1 Preparing Documents

Work Instructions
*Note
1. Battery can be charged or discharged repeatedly. If it is placed after discharge, its service life will be
shortened and performance is undermined. Normally, the battery performance will be degraded after two or
three years. As for battery of degraded performance (reduced capacity), whose voltage will recover temporarily
after charging but decrease sharply when loading.
2. Battery overcharge: normally, overcharge can be judged upon the battery. In the case of short circuit inside
the battery, its terminal is unable to detect voltage or the detected voltage is very low. Regulator failure: over
voltage inside the battery will shorten its service life.
3. The battery will be self-discharged if being stored for a long time, which reduces its capacity. It shall be
charged about every three months.
4. Check the charging system following the sequence listed on the failure diagnosis table.
5. Do not remove the connector when there is current through electrical parts, otherwise it will cause over
voltage and damage to electrical parts inside the voltage regulator. Please operate it after the main switch turns
off.
6. It is unnecessary to check the maintenance-free battery and add electrolyte and distilled water.
7. Check all electric loads.
8. Emergency charging can only be used under emergency situation.
9. Remove the battery from the motorcycle for emergency charging.
10. Do not use electrolyte-added batteries when interchanging batteries.
11. Use a voltmeter to check charging condition of the battery.
- 44 -
Item
Specifications
Capacity/Type
Battery
Magnetor
Voltage
regulator
Voltage
20
12V-9AH/ dry-charged
Fully charged
13.1V
Necessary
charging
12.3V(not working for 1h)
Charging current
Standard: 0.8A, quick:8A
Charging time
Standard: 10-15 hours, quick: 30 mins
Impedance of the coil

20
Between white-white 1.5-3.5
Type
Three-phase full wave
Charging voltage of the

battery
14.50.5V/5.000rpm
Tightening Torque Force

Rectifier bolt
High-voltage coil fixing bolt
Flywheel fixing nut
Body guard bolt
5.0 N
m
9.0 N
m
5.0 N
m
9.0 N
m
Tools
Universal fixing spanner
Flywheel remover
Test instrument
Multimeter
1.2 Failure Diagnosis

Power Supply Dead
Battery over-discharge
Unconnected battery wiring
Fuse blow
Poor switch
Interrupted Current
Poor contact of the charging wire
Poor contact of the charging system
Poor contact or short circuit of the lighting system
Low Voltage
Poor Charging System
Poor battery charging

Poor contact
Poor charging system
Poor voltage/current regulator
Poor contact, short circuit or open circuit of wire terminals

Poor voltage/current regulator
Poor magnetor
- 45 -
1.3 Battery
1.3.1 Battery Disassembly
As for details, please see page 31.
battery position
Warning!
When the positive wire is disassembled, do not
make the tool contact with the frame. Otherwise, it
may cause short-circuit spark, which may ignite
gasoline and damage the battery. It is dangerous.
*Note
To prevent short circuit, connect the positive wire
first and then the negative wire.
Check the charging condition (closed circuit voltage).
Remove the seat.
Remove cables of the battery.
Test the voltage between battery terminals.
Fully charged: 13.1V
Insufficient charging: 12.3V (not working for 1
hour)
* Note
Use a voltmeter to check the charging condition.
1.3.2 Charging
Connection method: connect the positive pole of the charger with the positive pole of the battery;
connect the negative pole of the charger with the negative pole of the battery.
Warning!
The battery should be far away from fire source.
Turn off the charger before or after charging to
avoid explosive danger caused by spark which
may exist in any connection.
Comply with the current and time requirements
for charging as stated on the battery.
- 46 -
*Note
Except emergencies, you should not use
emergency charging.
Measure voltage in 30 minutes after the battery
is charged.
Charging current: standard: 0.8A
quick: 8.0A
Charging time: standard: 10-15 hours
quick: 30 mins
Charging completed: open circuit voltage: above 12.8V
1.4 Charging System

1.4.1 Short-circuit Test
Remove the earth lead from the battery. Install a voltmeter between the negative terminal and the earth lead.
Turn off the switch. Check the short-circuit.
*Note
Connect the positive terminal of the multimeter
with the negative terminal of the battery.
Check whether there is short-circuit in the main switch or in the main wire in the case of any abnormality.
1.4.2 Charging Check

Use a multimeter to check the charging status of the battery when it is being fully charged.
Install the fully charged battery after the engine warms up.
Connect a voltmeter between terminals.
Remove the main fuse and connect an ammeter between terminals.
Start the engine and increase its speed gradually to measure the limiting voltage and current.
Limiting voltage/speed: 14-15V 5.000rpm
Check the voltage regulator if the limiting voltage is not within its required range.
Check the limiting voltage of the lighting system.
Remove the seat.
*Note
Set the multimeter to the AC voltage position.
Limiting voltage: 13.1+/-0.5V/5.000rpm
Check the voltage/current regulator if the limiting voltage is not within its required range.
- 47 -
1.5 Voltage/Current Regulator

1.5.1 Main Wiring Check
Remove the shield of the body.
Remove 4p plug of the voltage/current regulator.
Check conductivity between main wiring terminals.
Item (wire color)
Judgment
Between Battery(red) and

GND of the body
With battery
voltage
Between GND wire (black)

and GND of the body
With lead
Between charging coil (white)

and the GND of the body
Resistance in the
coil of the
magnetor.
1.5.2 Voltage-current Regulator Check

1. Choose diode file with multimeter.
2. The black probe connects to the red wire terminal of the voltage regulator, and the red probe connects
respectively with the white wire terminal (white 1, white 2, white 3). The pointer gauge shows a certain value,
otherwise it indicates the damage of the voltage regulator and replacement is needed.
3. The red probe connects to the black wire terminal of the voltage regulator, and the black probe connects
respectively with the white wire terminal (white 1, white 2, white 3). The pointer gauge shows a certain value,
otherwise it indicates the damage of the voltage regulator and replacement is needed.
*Note
Do not touch any metal part of the test rod of the
multimeter with your finger for check.
Check with multimeter. Different multimeters
show different impedance and different results.
Replace the voltage-current regulator when the impedance between terminals is abnormal.
1.6 Magnetor Charging Coil
*Note
Check the magnetor charging coil on the engine.
Check
Remove the 6p connector of the magnetor.
Measure the impedance between the three white terminals of the magnetor with the multimeter.
Standard: 1.5-3.520
Replace the magnetor coil when the measured value exceeds the standard value.
- 48 -
1.7 Magnetor Disassembly

Left cover and
the magnetic coil
1.7.1 Disassembly
Loosen the fixing nuts on the left cover, and
remove the left cover and the magnetic coil.
Bolt
Fix the flywheel with the universal fixing

spanner.
Remove fixing bolts of the flywheel.
Remove the flywheel with the flywheel remover.
Remove the solid key.
Remove the conductor joint.
Remove the stator.
Bolt
Loosen the four fixing bolts of the magnetic coil,

and remove the magnetic coil.
Bolt
- 49 -
Loosen the locking nuts of the flywheel with

electric, pneumatic tools or torque spanner.
Remove the flywheel assembly.
Locking nut of
the flywheel
1.7.2 Installation
Install the stator on the body of the engine.

Connect the magnetor joint.
Clean up the crankshaft and the taper part of the flywheel.

Install the solid key into the groove above the upper crankshaft key and confirm it.
Aim the groove in the flywheel at the solid key on the shaft.
* Note
Ensure there is no any bolt in the inner magnetic
side of the flywheel.
Fix the flywheel with the universal spanner and tighten fixing nuts.
Torque force: 9.0 N
m
- 50 -

/2
/2
ECU2
/2
/2
/1
/1
/ /
ECU1
/1
/1
power, trigger, ignition system

black, white, red, orange, green, blue
- 51 -
2. Ignition System
Preparing Documents -----------------2.1
Failure Diagnosis ---------------------2.2
Ignition System Check ---------------2.3
ECU Group----------------------------2.4
Ignition Coil ---------------------------2.5
Trigger ---------------------------------2.6

Work Instructions
1. Check the ignition system following the sequence listed in the table of failure diagnosis.
2. This ignition system is an electronically and automatically angling device. It is solidified in the ECU group
and you dont have to adjust the ignition time.
3. Check the ignition system following the sequence listed in the table of failure diagnosis.
4. Do not make ECU of the ignition system fall down or hang down or hammer it with strong force (primary
causes for failure). Pay special attention during disassembly.
5. Failure of the ignition system is mostly caused by poor contact of the socket. Check whether each connector
is in good condition.
6. Check whether the heat value used for the spark plug is proper. If not, the engine may work abnormally or
the spark plug may be burnt.
7. Check in this chapter is based on the maximum voltage. It also refers to check on the impedance of the
ignition coil.
8. Check the main switch according to the conduction table.
9. Remove the magnetor and the stator according to instructions.
Item
Spark plug
recommended
Standard value
Standard
Spark plug gap

Ignition coil
Primary coil
impedance20
Impedance of trigger20
Measure the maximum primary voltage of the ignition coil
Trigger voltage
CR9E(NGK)
0.6-0.7mm
65050m
100-300
14V
Above 1.7V
Tools
Attachments to the Maximum Voltage Table
Multimeter
- 52 -

No spark-over of the spark plug
Abnormality
Ignition
coil
Too low high-voltage
No or interrupted high voltage

Side
voltage
Normal high voltage, but no spark
Charging
coil
No high voltage
Too low high-voltage

Trigger
Cause (confirm it sequentially as follows)

The inner resistance is too small and it should be
tested by required tester.
Low speed of the crankshaft.
Interfered tester (It is normal that voltage is
always beyond the required value upon several
measurements.)
Poor wiring contact of the ignition system.
Poor ignition coil.
Poor charging coil (measured at the maximum
voltage).
Incorrect connection of the tester.
Poor main switch.
Poor contact of ECU terminal.
Short circuit or poor contact of the GND of ECU.
Poor contact of charging coil (measured at the
maximum voltage).
Poor trigger (measured at the maximum voltage).
Poor terminal of high-voltage wires.
Poor ECU group (when item - is checked to
be abnormal or there is no spark for spark plug.)
Poor spark plug or secondary leakage of the
ignition coil.
Poor ignition coil.
measurements.)
Poor charging coil (Item - is checked to be
normal.)
Poor ignition coil.
Poor charging coil.
measurements.)
Poor trigger (Item - is checked to be
normal.)
Poor ignition coil.
Poor trigger.
- 53 -
2.3 Ignition System Check

*Note
When there is no spark, check whether there is
loose wiring
or poor contact, and make sure all voltage values
are normal.
There are kinds of multimeters with different
impedances and different test values.
Connect a high-pressure shunt or an ammeter with

an input impedance above 10M10CV to the multimeter. multimeter
2.3.1 Primary Voltage of the Ignition Coil (high-pressure shunt)

If you replace the original spark plug with a better one, make ground connection with the engine.
*Note
Make sure all wiring is correct before test.
Cylinder compression pressure normally refers to
the test value when the spark plug is installed on
the cylinder head.
Connect the lead of the ignition coil and also the shunt
between the primary coil terminal (black/red) and the GND.
Press the startup motor or step the actuating lever to
measure the maximum primary voltage of the ignition coil.
Minimum voltage: above 95V
*Note
Never touch any metal part of the test rod with
your finger to avoid electric shock.
- 54 -
2.3.2 Sensor of the Crankshaft

*Note
Install the spark plug on the cylinder head and
carry out measurement when the compression
pressure is normal.
Remove 18 connectors of ECU group. Connect the
peak-voltage shunt between the charging coil
(blue/white terminal) with 18 connector and
the 18 connector (white/green terminal).
Press the startup motor or step the actuating lever to measure
the maximum voltage of the charging coil.
Connection: positive pole to blue/white; negative pole to white/green.
Minimum voltage: above 95V
*Note
Never touch any metal part of the test rod with
your finger to avoid electric shock.
When the maximum voltage measured at the terminal of ECU Group is abnormal; dismantle the shield of the
body and the magnetor terminal.
If the voltage of ECU is measured to be abnormal while the voltage at the magnetor terminal is normal, it is
caused by poor contact or disconnected wiring.
If the voltage at both ECU and magnetor terminal appears to be abnormal, it is caused by poor charging coil.
Please refer to charging coil check.
2.4 ECU Group

2.4.1 System Check
Check the system.
Remove the ECU Group, and check components
of the ignition system at the terminal.
- 55 -
2.5 Ignition Coil

2.5.1 Disassembly
Remove the body.
Remove the spark plug cap.
Remove the primary lead of the ignition coil.
Remove the fixing bolts and then the ignition coil.
Install the ignition coil in reverse order.
*Note
Install the primary coil with black/red
terminal.
2.5.2 Check the Primary Coil

Measure the impedance between terminals of the primary coil.
Standard: (40.2) (20)
It shows good if the impedance is within the range of standard values.
Replace the primary coil if the impedance shows which indicates that the coil breaks.
2.6 Sensor of the Crankshaft

*Note
Check the trigger on the engine.
Check
Remove the shield of the body.
Remove the trigger terminal.
Measure the impedance between the blue/white terminal of
the side wire of the engine and the body GND.
Standard: 100-30020
Replace the magnetor if the measured value exceeds the
standard value.
- 56 -
BATTERY
G/Y
G/Y
Startup Schematic Diagram
- 57 -
3. Startup System
Preparing Documents ----------------3.1
Failure Diagnosis ---------------------3.2
Startup Motor -------------------------3.3
Starter Relay --------------------------3.4
Starter Clutch--------------------------3.5

Work Instructions
Disassemble the startup motor on the engine.
For the disassembly of the startup clutch, please comply with related regulations
Item
Standard
Limit for use
Length of the brush of the

startup motor
12.5mm
8.5mm
Bushing of the startup idler

shaft
8.3mm
Outer diameter of the startup

idler shaft
7.94mm
Tightening torque force

Bolts for the clutch cover of the startup motor
Retaining nut for the clutch of the startup motor
12 N
m
95 N
m
Tools
Spanner for retaining nuts
Universal fixing spanner
- 58 -

Startup failure
Fuse blow
Low battery
Poor main switch
Poor startup clutch
Poor brake switch
Poor starter relay
Poor wiring contact
Poor startup motor
Weak in rotation
No rotation of RE rotary engine
of the startup motor
of the startup motor
Low battery
Poor wiring contact
Gear seized
Poor startup clutch

Reversal rotation of the startup motor
Low battery
3.3 Startup Motor

3.3.1 Disassembly
Loosen the two fixing bolts of the startup motor,
and remove the motor.
Bolt
Startup motor
* Note
Before the startup motor is disassembled, turn off the
main switch, remove the GND wire of the battery, and
then power on to check whether the startup motor
works for ensuring safety.
- 59 -
Remove the wire clip of the startup motor.

Remove the fixing bolts of the startup motor, separate
the front cover and the back cover, and dismantle the
startup motor.
Roll the waterproof rubber case and dismantle the
connector of the startup motor.
commutator
3.3.2 Breakdown
Remove screws in the shell, front cover, motor housing and other parts.
3.3.3 Check
Check other components.

Replace any part with abraded, damaged or burnt surface.
Clean the commutator surface if there is metal power attached to it.
Check conduction between the surfaces of other components.
Ensure non-conduction between armature shafts of the commutator.
Check the conduction of the shell of the startup motor.
Ensure non-conduction between the conduction terminal and the startup motor shell.
Check conduction between the conduction terminal and the brush.
Replace any abnormal part.
Check conduction of the brush bracket. Replace it when there is conduction.
Measure the length of the brush.
Limit for use: replace it if lower than 8.5mm
Check smooth rotation of the needle bearing inside the front cover and whether it is loose when press-in.
Replace it if there is any abnormality.
Check whether the oil seal is abraded or damaged.
carbon brush
- 60 -
3.3.4 Assembly
Lubricate the oil seal inside the front cover with grease.
Install the brush on the bracket.
Lubricate moving parts at two ends of the brush shaft
with grease.
Press each brush into the bracket,
* Note
Pay special attention that the contact surface between
the brush and the armature shall not be damaged.
Pay attention that the armature shaft shall not damage
lips of the oil seal.
and install the back cover of the electric machine.
Aim the screw hole of the motor shell at the screw hole of the front cover for installation.
Lock screws in the shell.
* Note
When the shell and the front cover are assembled, it is
easy to pull the front cover with magnet to attract the
armature. Press it gently for assembly.
3.3.5 Installation
Install the lead of the startup motor and the dustproof boot.
And then install the startup motor.
Install the wire clip for rear brake.
3.4 Starter Relay

3.4.1 Check
When the main switch is on, check there is click sound at
the time of pressing the startup motor.
With click sound, it is normal.
Without click sound: check voltage of the starter relay;
check the GND loop of the starter relay;
check the movement of the starter relay.
starter relay
- 61 -
3.4.2 Check Voltage of the Starter Relay

Set up the main stand, and measure voltage between the
negative pole of the green/yellow wire of the starter relay
terminal and the body ground connection.
When the main switch is on, hold the brake lever. The
battery voltage shall comply with regulations.
When there is no voltage at the starter relay terminal,
check the conduction of the brake switch and leads.
starter relay
3.4.3 Check GND Loop of the Starter Relay

Remove the starter relay connector.
Check conduction between the black wire of the lead terminal and the body ground connection.
When the startup button is pressed, it shall show good conduction between the black wire of the terminal and
the body ground connection.
Check conduction of the startup button and leads when it is not conducted.
3.4.4 Check
Connect the starter relay to the battery, and the
terminal of the startup motor to the multimeter.
Connect the fully charged battery between the black
wire and the green/yellow wire of the relay. The relay
shall sound click and the multimeter shall indicate
resistance of zero.
- 62 -
4. Bulbs/ Switches / Meters

Preparing Documents -------------------------------------------------------------4.1
Failure Diagnosis ------------------------------------------------------------------4.2
Replacement of Headlamp Bulbs------------------------------------------------4.3
Replacement of Front Position Lamp Bulbs------------------------------------4.4
Replacement of Tail Lamp--------------------------------------------------------4.5
Replacement of Rear Registration Plate Lamp Bulbs-------------------------4.6
Replacement of Front Steering Lamp Bulbs -----------------------------------4.7
Replacement of Rear Steering Lamp Bulbs ------------------------------------4.8
Meters--------------------------------------------------------------------------------4.9
Main Switch -----------------------------------------------------------------------4.10
Horn ---------------------------------------------------------------------------------4.11
Handlebar Switch -----------------------------------------------------------------4.12

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

All plastic connectors have clamping jaws,
lift the clamping jaws and clamps before disassembly,
and make sure that the clamping holes aim at the clamping jaws when installing.
When looking up for electric faults,
check the continuity of the circuit passing through the electronic devices.
The state of the battery must be confirmed before carrying out any inspection,
including the voltage, to confirm that whether it is normal or not.
- 63 -

The ignition switch ON is not light, which due to
Poor bulbs.
Poor switch.
Bad contact or broken wires
Weak battery power or no voltage.
4.3 Replacement of Headlamp Bulbs

Remove the two fixing bolts of the headlamp at
the bottom left and bottom right of the meter.
Lower the headlamp forward, you can see the back

of the headlamp, and remove its dustproof cover.
- 64 -
The figure below shows the bulb of the dipped

headlight, and the bulb of the headlight on full
beam, remove the power cord socket, bulb snap,
fixing bolts and the bulb snap buckle of the dipped
headlight and the headlight on full beam that need to
be replaced, and finally remove the damaged bulb.
Aim the position of the light snap, and replace on a
new one of the same specification.
*Note
Keep combustible materials and your hands a distance
away from the bulb when it is light. Because the bulb
is very hot at that moment, you should let it cool
down before touching it.
Install the bulb in reverse order.
During the installation, avoid direct touch with the
glass of the bulb, an do not make it oil-stained. Or it
will affect the transparency, life and luminous flux of
the bulb.
Once stained with oil, wipe thoroughly with a damp cloth of alcohol or rubber solution of strong volatility.
Install headlamp devices.
4.4 Replacement of Front Position Lamp Bulbs

The front position lamp and the headlamp are in one
lamp body, as shown in the figure, there is a front
position lamp bulb on the right and left sides.
(1) Operate according to the prompts of the above
chapterReplacement of the Headlamp Bulbs.
(2) Remove the damaged bulb, and replace on a new
one of the same specification.
(3) Install the bulb in reverse order.
- 65 -
4.5 Replacement of Tail Lamp

The illuminant of the tail lamp is LED, replace the whole
lamp if necessary.
(1) Remove the passengers seat and the drivers.
(2) Remove the tow fixing nuts of the tail-hood shield,
and then move it horizontally backward to take it
down.
(3) Remove the two fixing nuts of the rear lamp

combination.
(4) Remove the three fixing bolts of the rear lamp

combination.
(5) Remove the cable of the rear lamp combination, take
off the damaged lamp, and replace on a new one of
the same specification.
(6) Install the lamp in reverse order.
- 66 -
4.6 Replacement of Rear Registration Plate Lamp Bulbs

(1) Remove the fixing nuts of the rear registration
plate lamp to take down the tail-hood of it.
(2) Take off the damaged bulb, and replace on a new one
of the same specification.
- 67 -
4.7 Replacement of Front Steering Lamp Bulbs

The illuminant of the front steering lamp is LED,
replace the whole lamp if necessary.
(1) Operate according to the prompts of the above
chapterReplacement of the Headlamp Bulbs.
(2) Remove the fixing nuts of the right or left
steering lamp.
(3) Remove the cable of the front steering lamp, take off the damaged lamp, and replace on a new one of the
same specification.
4.8 Replacement of Rear Steering Lamp Bulbs

The illuminant of the rear steering lamp is LED, replace
the whole lamp if necessary.
(1) Remove the fixing nuts of the right or left
steering lamp from the back of bracket of the rear
registration plate.
(2) Remove the cable of the rear steering lamp, take off
the damaged lamp, and replace on a new one of the same specification.
4.9 Meters
Remove the rearview mirror;
Remove the handle cover, and unplug the connectors.
Remove the nuts the meter.
Install the meter in reverse order.
- 68 -
4.10 Main Switch

4.10.1 Check
Remove the front shield.
Remove the main switch lead terminal.
Check the conduction of the terminal.
POWER LOCK
ON
OFF
LOCK
R/W
4.10.2 Replacement of Main Switch

Remove the front shield.
Remove the fixing bolts, and take off the fixing socket of the main switch.
Remove the fixing bolts, and replace the main switch.
4.11 Horn
Check
Remove horn wires.
It shows good when the horn wire is connected to the battery.
- 69 -
4.12 Handlebar Switch

Switch classification:
1. Light changing switch
2. Start switch
3. Steering switch
4. Horn switch
5. Turn off switch
6. Warning switch
/ /
// /
Schematic diagram of wiring

headlamp switch
start button
blue
/yellow/red
light blue
black
grey
/red/white
/grey/white
green
white
- 70 -
Inspection and Maintenance of the Motorcycle Body

Torque Force Table of the Body
Name of fastening parts and fasteners
Tightening torqueN
m
Fixing bolt of the front absorber M6

Locking screw of the front wheel spindle M6
Front fixing bolt of the fuel tank M6
Fixing bolt of the front fuel pump assembly M6
Fixing bolt of the rear fuel pump assembly M6
Fixing bolt of the fixing seat on the handlebar M8
Fixing bolt of the upper connecting bracket M8
Rear fixing bolt of the fuel tank M6
Mounting bolt of the front brake cylinder assembly M10
Mounting bolt of the rear brake cylinder assembly M8
Fixing bolt of the sprocket M10
Fixing bolt of the rear frame M10
Fixing bolt of the pillar
Top bolt of the rear absorber M10
Bottom bolt of the rear absorber M10
Fixing bolt of the engine M10
Fixing bolt of the rear swinging arm axle M14
Front wheel spindle M16
Fixing nut of the rear wheel spindle M24
5-10
5-10
5-10
5-10
5-10
22-34
22-34
5-10
37-55
22-34
37-55
37-55
50-70
37-55
37-55
37-55
70-105
100-140
130-150
- 71 -
Front Disc Brake

A
C
D
E
G
H
I
Dia. of the front left/right brake

disc:320mm
Thickness of the front left/right brake
disc:4.0mm
Limit for use: 3.6mm
Thickness of the brake shoes:7.8mm
Limit for use:3.8mm
Torque for mounting bolt 4 in the
figure:5-10N
m
figure:30-35N
m
figure:
5-7N
m
figure:30-35N
m
figure:37-55N
m
figure:22-34N
m
1. handlebar assembly of the front brake disc 2.handlebar screw 3.fixing cover 4.bolt M623 5.hexagon
flange screw 6.brake switch 7.screw M412 8.nut M6 9.brake hose assembly 10.11. bleed nipple
12.mounting bolt of the oil tube 13.gasket 14.bolt M101.2555 15.front left brake cylinder assembly
16.brake shoes 17.bolt M816 18.D.320front brake disc 19.front right brake cylinder assembly
- 72 -
Rear Disc Brake

A
B
C
D
E
F
G
Dia of the rear disc brake: 240mm

Thickness of the rear disc brake: 5.0mm
Thickness of the brake shoes: 7.0mm
figure:30-35N
m: 22-34 N
m
figure:30-35N
m: 5-10 N
m
figure:30-35N
m: 30-35 N
m
figure:30-35N
m: 30-35 N
m
1.pin 2.joint M6 3.cotter 4.nut M6 5.pushrod 6.rear fuel pump assembly 7.gasket 8.rear brake
indicator 9.rear brake hose assembly 10.mounting bolt of the oil tube 11.rear brake cylinder assembly
12.brake shoes 13.rear disc brake 14.screw M620 15.bolt M81.2520
- 73 -
5. Brake
Maintenance Instruction ------------------------5.1
Failure Diagnosis --------------------------------5.2
Front Disc Brake ---------------------------------5.3
Rear Disc Drake ---------------------------------5.4
5.1 Maintenance Instruction

Work Instructions
*Note
A stained brake disc or protective gasket will reduce brake force, so discard
stained gasket and clean the brake disc with quality brake degreaser.
Check the brake system through the brake lever and pedals.
Spilled brake liquid is harmful to the focusing and paint of the equipment,
and the rubber parts too. So be careful whenever you remove the cap of the
oil cup, and the first thing you should do is to make sure that the liquid in the
cup is aclinic.
Never let the earth, water or other dirt into an open cup.
Use the DOT4 brake liquid taken out from a sealed container when doing
maintenance, and do not mix it with other type of liquid, since they can not
coexist.
* Check the brake before riding.*
5.1.1Specification
Item
Special brake liquid
Thickness of the left/right
brake disc
Thickness of the left/right
brake shoe
Dia. of the left/right brake disc
The jump of the brake surface
Front
of the left/right brake disc
Standard
DOT4
Limit for use

-
Item
Special brake liquid
Standard
DOT4
Limit for use

-
4.0mm
3.6mm
Thickness of the brake disc
5.0mm
4.5mm
7.8mm
3.8mm
Thickness of the brake shoe
7.0mm
3.7mm
320mm
240mm
0.1mm
Dia. of the brake disc

The jump of the brake
surface of the brake disc
0.1mm
I.D. of the pump oil cylinder
11+0.027
mm
0
I.D. of the pump oil cylinder 16+0.043

mm
0
Rear
O.D. of the oil-pumping

piston
16-0.032
-0.059 mm
O.D. of the oil-pumping

piston
11-0.032
-0.059 mm
I.D. of the caliper cylinder
34+0.08
+0.03 mm
I.D. of the caliper cylinder
32+0.08
+0.03 mm
O.D. of the caliper piston
32-0.032
-0.065 mm
O.D. of the caliper piston
32-0.032
-0.065 mm
- 74 -
5.1.2 Torque Force

Fixing the front wheel spindle
Mounting screw of the front left brake cylinder assembly
Mounting screw of the front right brake cylinder assembly
Fixing nut of the rear wheel spindle
Mounting screw of the rear brake cylinder assembly
100-140N
m
37-55N
m
37-55N
m
130-150N
m
22-34N
m

5.2.1 Poor Brake Performance
1.
2.
3.
4.
Improper adjustment of the brake

Abraded brake shoes assembly or disc brake
Improper installation of the brake shoes assembly
Stained brake shoes assembly or disc brake
5.2.2 Slow Reaction or Tight Lever

1. Improper adjustment of the brake
2. Abraded brake shoes assembly or disc brake
3. Improper installation of the brake shoes assembly
5.2.3 Abnormal Noise

1 Abraded brake shoes assembly or disc brake
2 Stained brake shoes assembly or disc brake
5.2.4 Soft or Flossy Brake Lever/Pedal

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Air in the hydraulic system

Leakage of the hydraulic system
Stained brake pedal/disc
Abraded seal of the caliper piston
Abraded brake pedal/disc
Stained caliper
Abnormal slip of the caliper
Insufficient brake liquid
Blocked brake liquid channel
Bended/fragmentary caliper piston
Bended/fragmentary piston of the main cylinder
Stained piston of the main cylinder
Bending braking lever/pedal
5.2.5 Brake Stuck or Pulled to One Side

1 Stained brake pedal/disc
2 Wheel deviation
- 75 -
3 Blocked or limited joint of the brake hose

4 Bending/fragmentary brake disc
5 Abnormal slip of the caliper
5.2.6 Brake Resistance

1
2
3
4
5
Strained brake pedal/disc

Wheel deviation
Abraded brake pedal/disc
Bending/fragmentary brake pedal/disc
5.2.7 Stiff Brake Lever/Pedal

1
2
3
4
5
6
7
Blocked/limited brake system

Sticked/abraded caliper piston
Blocked/limited brake liquid channel
Abraded sealing gasket of the caliper piston
Sticked/abraded piston of the main cylinder
Bending brake lever/pedal
5.3 Front Disc Brake

5.3.1 Disassembly
*Note
Replace the brake shoes assembly.
If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place.
Remove following assemblies from the right grip and the front absorber.
Front brake:
Nut of the rearview
1. brake handle
mirror
2. fuel pump assembly
3. brake hose assembly
4. left/right brake cylinder assembly Fixing screw of
the fuel pump
5. left/right brake disc
*Note
Do not stain the brake assembly with oil spots during
installation or disassembly.
Clean it with required cleaning agent to maintain the brake performance.
- 76 -
Fixing screw of the handle
Fixing bolt of the brake hose

Brake hose
Bleed nipple
Right brake cylinder assembly
Fixing bolt of the brake cylinder
Loosen the fixing screws of the brake cylinder assembly.
Remove the brake cylinder assembly from the front absorber.
Bleed nipple
Left brake cylinder assembly
Fixing bolt of the brake
cylinder
- 77 -
Remove the front wheel spindle.

Remove the front wheel.
Remove the disc brake off the front rim.
front wheel
front wheel spindle
front left disc brake
fixing screws
5.3.2 Check
Check whether the brake shoes assembly and the brake
disc are abraded. Replace brake shoes if necessary.
Measure the brake shoes and the brake disc. Record
maximum values.
Specification
Diameter of the front brake disc
Thickness of the front brake disc
320mm
4.0mm
*Note
Measure them with micrometer.
- 78 -
Measure the thickness of the brake shoes.

If the thickness of the brake disc or the brake shoe is
below the required value for maintenance or it is stained
with grease, please replace it.
Limit for use:
brake shoe
brake disc
3.8mm
3.6mm
Note:
Replace brake shoes in pair.
5.3.3 Installation
Install the brake disc and the front wheel.
Install the front brake hose assembly and the brake cylinder assembly.
Do not stain shoes and the brake disc with grease.
* Note
Any grease on brake shoes will reduce the brake performance and even lead to failure.
Tighten bolts and nuts to the required torque force.
Torque force:
The bolt of the brake disc
The fixing bolt of the fuel pump assembly
Mounting bolt of the front brake cylinder assembly
120N
m
28N
m
8N
m
50N
m
Do not stain the brake shoes with oil spots.

Use brake cleaning agent to clean brake shoes with oil spots.
*Note
Any grease on brake shoes will reduce the brake performance.
*Note
Do not stain the brake assembly with oil spots during installation or disassembly.
- 79 -
5.4 Rear Disc Brake

5.4.1 Disassembly
*Note
Replace the brake shoes assembly.
If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place.
Remove the following assembly off the frame and the rear swinging arm.
Rear disc brake:
(1) Fuel pump assembly
(2) Brake hose assembly
(3) Brake cylinder assembly
(4) Brake discs
Loosen the fixing screws of the right pedal cover plate.

Right pedal cover
plate
Fixing screws
Loosen the fixing screws of the oil pump assembly.

Remove the oil pump cylinder.
Fuel
pump
assembly
Fixing screws
- 80 -

Remove the brake cylinder assembly off the rear
swinging arm.
Rear brake hose
Fixing bolt
Brake
assembly
cylinder
Fixing screw
Remove the rear wheel spindle.

Then take off the rear wheel.
Remove the bake disc off the rear rim.
rear wheel
rear brake disc
fixing screw
rear wheel spindle
5.4.2 Check
Check whether the brake shoes assembly and the brake
disc are abraded. Replace brake shoes if necessary.
Measure the brake shoes and the brake disc. Record
maximum values.
Specification
Diameter of the rear brake disc
240mm
Thickness of the rear brake disc
5.0mm
*Note
Measure with micrometer.
- 81 -
Measure the thickness of the brake shoes.

If the thickness of the brake disc or the brake shoe is
below the required value for maintenance or it is
stained with grease, please replace it.
Limit for use:
brake shoe
brake disc
3.7mm
4.5mm
Note:
Replace brake shoes in pair.
5.4.3 Installation
Install the rear brake disc.
Install the rear wheel.
Install the brake cylinder.
* Note
Any grease on brake shoes will reduce the brake performance and even lead to failure.
Tighten bolts and nuts to the required torque force.
Torque force:
Fixing the rear wheel spindle
The bolt of the brake disc
The fixing bolt of the fuel pump assembly
Mounting bolt of the rear brake cylinder assembly
120N
m
28N
m
8N
m
50N
m
Do not stain the brake shoes with oil spots.

Use brake cleaning agent to clean brake shoes with oil spots.
*Note
Do not stain the brake assembly with oil spots during installation or disassembly.
- 82 -
Body
*Note:
Do not damage any body part during disassembly.
Do not damage any hook or claw in the body during
disassembly.
Aim panels in the body at each corresponding
groove.
Ensure correct installation of each hook or claw
part during assembly.
Do not damage any part during assembly.
1. right air deflector mounting plate 2. windshield 3. left air deflector mounting plate 4. 5. right front shield 6.
right shield of the tank 7 bottom right shield 8. right shield 9. trim-cover of the right muffler 10. decorative
cover of the right muffler 11. back seat assembly 12. right rear handrail 13. left rear handrail 14. 16. left
assembly of the rear fender 17. right assembly of the rear fender 18. left shield 19. battery box 20. bottom left
shield 21. front seat assembly 22. middle shield of the tank 23. left shield of the tank 24. left front shield 25.
front shield of the tank 26.connecting board of the left/right shield
- 83 -
6. Body
6.1 Disassembly
Disassemble in the following order:
back seat assembly front seat assembly front shield of the tank left shield
of the tank right shield of the tank left front shield right front shield
middle shield of the tank tank assembly
rear connecting board of the left/right shield left rear handrail right rear
handrail bottom left shield left shield bottom right shield right shield
taillight rear bottom fender decorative cover of the right muffler
trim-cover of the right muffler decorative cover of the left muffler trim-cover
of the left muffler barrel assembly of the muffler rear fender assembly
battery box
mounting frame assembly of the headlamp windshield left air deflector

mounting plate right air deflector mounting plate headlamp
*Note
Do not damage any body part during disassembly.
Do not damage any hook or claw in the body during disassembly.
6.2 Assembly
Assembly in reverse order.
*Note
Aim panels in the body at each corresponding groove.
Ensure correct installation of each hook or claw part during assembly.
Do no damage any part during assembly.
- 84 -
Front Suspension
A
Torque for mounting the

fixing bolt 20 of the steering
column in the figure:
50-70Nm
fixing bolt 16 of the upper
base of the steering handlebar
in the figure: 22-34Nm
fixing bolt 13 of the upper
connecting board in the
figure: 22-34Nm
fixing bolt 5 of the front
absorber in the figure:
5-10Nm
Torque for mounting the front
wheel spindle 1 in the figure:
100-140Nm
locking bolt 28 of the head of
the front wheel spindle in the
figure: 5-10Nm
1. front wheel spindle 2. bolt M50.814 3. screw M615.2 .4. front right absorber assembly 5. bolt
M620 6. screw M50.812 7. bolt M6114 8. suspension bush 9. mounting base under the
headlamp 10. spacer bush 11. screw M6116 12. mounting base above the headlamp 13. bolt
M81.2525 14. upper connecting board 15. upper base of the steering handlebar 16. bolt M81.2525
17. locking screw of the inner hexagon flat end M46 18. pin 19. column 20. fixing screw of the upper
connecting board 21. nut 22. locking nut of the upper connecting board 23. steering bearing 24. screw
M68 25. fixing wire clip of the front brake tube 26. bottom connecting board 27 front left absorber
assembly 28. bolt M630 29. left spacer bush of the front wheel
- 85 -
Handlebar
1. balance piece assembly 2. throttle lever 3. mounting base of the balance piece 4. front cover of the throttle
cable 5. screw 6. right switch group 7. handlebar 8. left switch group 9. cover of the left handlebar 10.
handle combination of the clutch 11. clutch cable assembly 12. throttle cable assembly I 13. throttle cable
assembly II
- 86 -
Front Wheel
A
B
C
Tyre size: front tyre: 120/70

ZR17
Pressure of the front tyre:
25010kpa
Minimum
non-skid
depth:
1.6mm
Rim run-out limit:
Vertically: 2.0mm
Horizontally: 2.0mm
Torque for mounting the bolt 1
of the brake disc: 22-34N
m
1. bolt M816 2. front brake disc 3. bearing 6005-2RS/1-C3 4. middle spacer bush of the front wheel 5. front
rim 6. vacuum tyre 120/70 ZR17 7. front brake disc 8. valve
- 87 -
7. Front Wheel/Handlebar/Front Suspension

Preparing Documents--------------------------7.1
Failure Diagnosis-----------------------------7.2
Front Wheel-----------------------------------7.3
Handlebar--------------------------------------7.4
Front Suspension-----------------------------7.5

Work Instructions
Before removing the front wheel, you should use jack to support the body bottom and suspend the front wheel
which shall not be reversely rotated.
Pay attention that the brake shoes and the brake disc shall not be stained with grease during operation.
A stained brake disc or brake shoe will reduce brake force, so discard stained gasket and clean the brake disc
with quality brake degreaser.
Motorcycle Standards
Standard
(mm)
Measurement points
Item
Front wheel spindle
Bending
Front wheel
Rim
shimmy
Limit for use (mm)

0.2
Vertically
Horizontally
Torque Force
Fixing bolt of the upper connecting board assembly
Locking screw of the head of the front wheel spindle
Fixing screw of the front absorber
Fixing bolt of the steering column
Assembling bolt of the front brake cylinder
2.0
Within 1.0
2.0
Tools
22-34N
m
Bearing puller
100-140N
m Locking nut spanner
5-10N
m
5-10N
m
50-70N
m
37-55N
m
- 88 -

7.2.1 Difficulty in Steering
Failure or damage of the steering handlebar.

Damaged bearing of the handlebar.
Too tight of the adjusting bolt of the faucet bearing.
Insufficient tyre pressure.
7.2.2 Unsteady Steering
Damaged steering handlebar.

Insufficient tyre pressure.
Bending of the front fork or the front wheel spindle.
Deformed or unbalanced front tyre.
7.2.3 Front Tyre Shimmy
Deformed rim.
Abraded front wheel bearing.
Flawed front tyre.
Unbalanced tyre or wheel.
7.2.4 Difficulty in Wheel Rolling
Failure in the front wheel spindle bearing.

Braking fault of the brake.
Failure in the front wheel spindle.
Bending of the front wheel.
7.2.5 Abnormal Noise of the Front Absorber
Insufficient liquid in the absorber.

Fricative sound of the absorber guard.
Loose bolts in the absorber.
7.2.6 Operation Only Available in One Side or Move in Curve
Unbalanced adjustment of the left and right forks

Bending absorber
Bending wheel
Incorrect installation of the wheel
Bending frame
Broken wheel bearing
Broken central axis of the swinging arm
7.2.7 Soft Front Absorber
Insufficient liquid in the absorber

The spring of the absorber is not firm.
Too low of the tyre pressure
- 89 -
7.2.8 Too Stiff of the Front Absorber
Improper weight of the liquid

Blocked pathway of the liquid in the absorber
7.3 Front Wheel

7.3.1 Disassembly
Note:
Support the motorcycle firmly.
Support the motorcycle with a safety frame or firm crane.
Disassemble the front fender, and loosen the fixing screws.
Bleed nipple
Fixing bolt of the bake hose
Fixing bolt of the brake
cylinder
Disassemble the braking caliper of the front disc brake.
Remove the brake cylinder assembly off the front absorber.
- 90 -
Bleed nipple
Fixing bolt of the bake hose
Fixing bolt of the brake cylinder
Remove the clamping screw of the front wheel spindle

(right front absorber)
Disassemble the front wheel spindle
- 91 -
Disassemble the front wheel assembly

Remove the left spindle sleeve of the front wheel
Disassemble the bearing with the bearing remover.
Note:
Do not operate the brake controlling lever after the removal of the brake caliper.
- 92 -
7.3.2 Check
7.3.2.1 Check the Bending of the Wheel Spindle
Place the wheel spindle on the V-base and measure the
eccentricity ratio with a dial indicator.
Limit for use: replacement when beyond 0.2mm
axle
7.3.2.2 Check the Rim Shimmy

Place the rim on a precision bracket
and check the rim shimmy.
Rotate the wheel by manual and read indication.
Limit for use:
Vertically: replacement when beyond 2.0mm
Horizontally: replacement when beyond 2.0mm
Balance of the wheel
Warning
The balance of the wheel directly affects the stability,
operation and safety of the motorcycle. Check the stability of
the wheel when it is removed.
Note:
In order to keep balance, mark on the tyre near the bleed
nipple by drawing a dot at the rim. Assemble the tyre when
necessary.
7.3.2.3 Balance of the Front Wheel

Note:
Paste marks of the rotating direction on wheels and tires.
Remove the dust-proof sealing ring off wheels;
Install the wheels, tires and brake disc assembly at the Checkpoints;
Stop the rotating wheels, and mark the lowest (highest) point with the chalk.
Verify the most important sector in this way for 2 or 3 times.
If the wheel is in balance, it will not stop at one point.
In order to keep the wheel in balance, put on weight to it at the higher side of the rim, and mark with the chalk
at the other side. Add enough weight to the wheel when it is on rotation until it does not stop at one point.
Do not add weight above 60g to the wheel.
- 93 -
7.3.2.4 Check the front wheel bearing

Remove the bearing, and the middle sleeve of
the front wheel.
Check the rolling of the bearings.
Replace it if the bearing does not roll, or the
rolling is unsmooth or unstable, or the it is abraded
or loose.
7.3.3 Bearing Replacement

Remove the front wheel spindle, front wheel, left
spindle sleeve and the middle spindle sleeve. Then
remove the oil seal and the bearing respectively with
the oil seal remover and the bearing puller.
Note:
Replace dismantled bearings with new ones.
Lubricate the bearings with grease during installation.
Then press the bearings in with bearing installation
tools.
*Note
Bearings must be pressed in horizontally.
clearance
axially
radial
7.3.4 Installation
Note:
Lubricate the front wheel spindle, left spindle sleeve of the front wheel, bearing 6005-2RS/1-C3, and the
middle spindle sleeve.
Albany grease is suggested.
When tighten the front wheel and the caliper assembly of the disc brake, make sure that the brake disc is
between the brake pads.
The free stroke of the front brake lever can not be adjusted.
*Note
Torque of fixing the front wheel spindle: 100-140N
m
- 94 -
7.4 Steering Handlebar

7.4.1 Disassembly
Remove the left/right rearview mirror assembly.
Right rearview mirror
Left rearview mirror
Remove the oil pump assembly of the front brake.

Remove the right switch group.
Remove the mounting base assembly of the throttle
cable.
Oil pump assembly
Mounting base assembly of the throttle
cable
Fixing screw
Right switch group
Fixing screw
- 95 -
Remove the left handle assembly.

Remove the left switch group.
Left handle
assembly
Fixing screw
Left switch group
Remove the balance block assembly.

Remove the right handle assembly.
Remove the balance block.
Remove the fixing bolts of the upper base of the

steering handlebar.
Turn the upper base of the steering handlebar.
Remove the tube of the handlebar.
7.4.2 Installation
Install in reverse order.
Note:
Fixing screw of the upper base of the steering handlebar
Torque: 22-34N
m
- 96 -
7.5 Front Fork

7.5.1 Disassembly
Support well the middle bracket of the motorcycle.
Disassemble the front wheel.
Disassemble the brake caliper and the brake pipe clamp.
Remove the steering handlebar.
Remove the pillar bolt.
Remove the meter and the meter bracket.

Loosen the fixing bolts of the upper connecting
board.
Remove the upper connecting board.
Remove the headlamp and its bracket.

Loosen the clamping bolts of
connecting board.
Remove the front absorber.
the
upper
- 97 -
Tools:
Fixing nut spanner.
Special disassembly tool for bearing cup.
*Note:
The opening of the body guard shall be cleaned with cloth.
The upper/lower bearing cup shall be dismantled with a special disassembly tool for bearing cup.
7.5.3 Installation
Note:
Make sure that the hole of the front wheel spindle is concentric when installing the left and right
absorber.
Steps are contrary to the process of disassembly.
Note:
Fixing screws for the bottom connecting board:
Fixing screws for the upper connecting board:
10N.m
28N.m
- 98 -
Rear Wheel/Rear Suspension

A
B
C
E
F
G
Tyre size: rear tyre: 180/55 ZR

17
Pressure of the rear tyre:
29010kpa
Minimum
non-skid
depth:
2.0mm
Rim run-out limit:
Vertically: 2.0mm
Horizontally: 2.0mm
Torque for mounting the bolt 2 in
the figure: 5-10N
m
Torque for mounting nut 19 in the
figure: 37-55N
m
Torque for mounting nut 20 in the
figure: 130-150N
m
1. rear wheel spindle 2. screw M620 3. right spacer bush of the rear wheel 4. DIA.240 disc brake 5.
bearing 6006-2RS1-3C 6. spacer bush of the rear wheel 7. valve 8. rear rim 9. vacuum tyre 180/55 ZR17 1.
bearing 6006-2RS1-3C 11. buffer bushing 12. left spindle sleeve of the rear wheel 13. bearing 306223.8
14. spindle sleeve of the sprocket wheel 15. fixing bolt of the sprocket wheel 16. sprocket wheel rim 17.
sprocket wheel 18. retaining ring 62 19. self-locking bolt M101.25 20. self-locking bolt M241.5
- 99 -
Rear Suspension/Rear Absorber

A
Torque for mounting bolt 1

in the figure: 70-105 N
m
Torque for mounting nut
10 in the figure: 37-55
N
m
Torque for mounting nut
10 in the figure: 37-55
N
m
1. screw 2. mounting sleeve of the rear swinging arm 3. rolling bearing 61905-2RS 4. straight pin 48 5.
middle spacer bush 6. mounting sleeve of the rear swinging arm 7. sleeve 8. rear absorber assembly 9.
mounting gasket of the rear absorber 10. fixing spindle of the rear absorber 11. nut M101.25 12. supporting
board of the brake clamp 13. rear chain cover 14 bolt M68 15. bolt M6114 16. chain protecting block 17
bolt M6114 18 front chain cover 19 bolt M6114 20 fixing spindle of the rear absorber
- 100 -
8. Rear Wheel/Rear Suspension

Preparing Documents --------------------8.1
Failure Diagnosis -------------------------8.2
Rear Wheel --------------------------------8.3
Rear Absorber -----------------------------8.4
Chain Drive--------------------------------8.5
Rear Swinging Arm----------------------8.6

Work Instructions
The surface of the disc brake and the brake shoes shall not be stained with oil spots.
Item
Rear wheel
shimmy
Standard (mm)
Limit for use (mm)
Vertically
2.0
Horizontally
2.0
Locking torque force

Fixing nuts for the rear wheel spindle
Top bolts for the rear absorber
Bottom bolts for the rear absorber
Fixing bolts for the rear swinging arm
Fixing nuts for the sprocket wheel
Fixing bolts for the rear brake disc
130-150N
m
37-55N
m
37-55N
m
70-105N
m
37-55N
m
5-10N
m

8.2.1 Rear Wheel Shimmy
Deformed rim
Abraded rear wheel spindle
Tyre failure
- 101 -
Abraded or damaged bearings of the swinging arm spindle

Incorrect adjustment of the drive chain
Unbalanced tires and wheels
Bending frame or the rear swinging arm
8.2.2 Inflexible Rolling of the Wheel
Bending rear disc brake

Abraded bearings of the rear wheel spindle
Too tight of the drive chain
8.2.3 Too Soft of the Suspension
Insecure or shaking damping spring

Incorrect front suspension regulator
Oil leakage of the absorber
8.2.4 Too Stiff of the Suspension
Damaged assembly bearing of the absorber

Bending tube of the absorber
Damaged bearing of the rear swinging arm axis
Bending of the rear swinging axis
Fault in the suspension regulator
Too high of the tyre pressure
8.2.5 Operation Only Available in One Side or Move in Curve
Bending rear wheel spindle

Incompetent of the axle arrangement/chain regulator on both sides
8.3 Rear Wheel

8.3.1 Disassembly
Support the motorcycle firmly with the rear
wheel above the group.
- 102 -
Caliper of the rear disc brake

Fixing screws of the caliper of
the rear disc brake
Adjusting screw of the rear wheel
Remove the caliper of the rear disc brake.
Loosen the adjusting screws of the rear wheel.
Remove the nuts of the rear wheel spindle and left adjusting block of the chain.
Nut of the rear wheel spindle
Left chain adjusting block

Adjusting screw of the rear wheel
Remove the rear wheel spindle and the right adjusting block of the chain.
rear wheel
rear disc brake box
fixing screws
rear wheel spindle
Take the chain off the big sprocket wheel.

Chain
Big sprocket
wheel
- 103 -
Remove the rear wheel assembly.
Remove the supporting board of the brake clamp.
Supporting board of the brake

clamp
Remove the sprocket wheel assembly.

Remove the fixing bolts of the sprocket wheel.
Fixing bolts of the sprocket
wheel
- 104 -
8.3.2 Check
8.3.2.1 Check the Rim Shimmy
Rotate the wheel by manual and measure the
eccentricity ratio with a dial indicator.
Limit for use:
Vertically: replacement when beyond 2.0mm
Horizontally: replacement when beyond 2.0mm
When the rear wheel indication goes beyond the limit for
use, the rear wheel bearing is loosened leading to the rear
wheel shimmy. Replace the rear wheel bearing after check.
8.3.3 Installation
Install the rear wheel in reverse order, and lock the nuts.
Fixing nuts for the rear wheel spindle
Torque force: 130-150 N
m
- 105 -
8.4 Rear Absorber

8.4.1 Disassemble the Rear Absorber
Remove the upper/lower fixing nut of the rear absorber.
Remove the rear absorber.
8.4.2 Check the Rear Absorber

Visually inspect of the absorber for damage.
Check the following items:
whether the absorber tube is bent or damaged
whether the absorber has signs of deformation or oil leakage
whether the rubber block is abraded or damaged.
whether the spring is damaged
Check all other parts for damage or abrasion
If necessary, replace the absorber
8.4.3 Install the Rear Absorber

Install the upper fixing nut and lower fixing bolt of the rear absorber.
Lock to the specified torque force.
- 106 -
Fixing bolts
m
- 107 -
8.5 Chain Drive

8.5.1. Disassembly
Put the motorcycle on level ground, and firmly support it.
Remove the left rear cover.
Fixing bolt of the left rear cover
Engine left rear cover
Disassemble the rear wheel, rear absorber, the drive

chain shade and drive chain.
8.5.2 Check
Measure the length of ten chain links
if the length doesnt meet the specified value, replace

the drive chain.
The limit value of the length of ten chain links is
1587.5mm.
- 108 -
* Note:
Measure after stretching the chain by hand.
Range from chain link roller (1) to the inside of roller (11).
Measure the length of ten chain links.
Measure the length of ten chain links of different parts 2-3 times.
Clean the drive chain, put it into the kerosene,
and wash off the dust as much as possible,
then take the chain out of kerosene and dry it.
Check the rotor and side panels ,

if damaged or frayed, replace the drive chain.
The lubricant for drive chain can be purchased from the
shop to lubricate the drive chain.
Check the hardness of drive chain,

clean, lubricate or replace it if hard.
- 109 -
Check the drive sprocket and driven sprocket.

If one-fourth of the teeth of a cogwheel
is frayed,
replace the sprocket,

the bending of the teeth of a cogwheel also requires
the replacement of sprocket.
8.5.4. Installation
Fixing nuts
m
Note:
Adjust the laxation degree of the drive chain and the free stroke of the brake pedal.
If the laxation degree of the chain is too small, engine and other vital parts will be overloaded.
The laxation degree of the chain should be kept within the prescribed limit value.
8.6 Rear Swinging Arm

8.6.1 Disassemble the Rear Swinging
Arm
Put the motorcycle on level ground, and firmly support it.
Disassemble the rear wheel.
Disassemble the lower fixing nut of the absorber.
Disassemble the bolt and drive chain shade.
Disassemble the fastening bolt of the swinging arm spindle

from the frame.
Disassemble the rear swinging arm spindle and rear swinging
arm assembly.
- 110 -
Disassemble the rear swinging arm spindle bearing and the

rear swinging arm spindle
8.6.2 Check the Rear Swinging Arm

Check the rear swinging arm mounting spindle, rotate the
spindle on a flat surface or measure with a dial indicator, if
bent, replace it.
*Note
Dont attempt to straighten the spindle already bent.
Clean the parts of the rear swinging arm mounting spindle
in the solvent.
Check the sleeve of the rear swinging arm and the middle
sleeve, if damaged, replace them.
Rear swinging arm
Check the bearing for the damage

Use your finger to rotate in the inner bush of the right-pivot
bearing
The bearing shall rotate smoothly and steadily, and the
installment of the bearing's outer ring on the wheel hub
should be checked for security
If the ring can not rotate smoothly and steadily, or it is
flexible in installation on the pivot, please disassemble and
discard it
Bearing
8.6.3 Install the Rear Swinging Arm

Spindle bush of the pivot should be greased,
Note:
Bolts for the rear swinging arm spindle
Torque force: 70-105N
m
- 111 -
Fuel Tank
Gasoline capacity of the
A
gasoline tank:
150.2L
Torque force of bolt 3:

5-10Nm
5-10Nm
5-10Nm
5-10Nm
16
22-37Nm
1.fuel tank body assembly 2.gasket 6.412.51.6 3.bolt M670 4.fuel pump seal gasket 5.fuel pump
assembly 6.petrol pump screw 7.fuel pipe assembly 8.filter assembly 9.bolt M6 10.gasket 5,3101
11.oil level sensor assembly 12.bolt M625 bolt M625 13. rubber gasket tube 14.fuel tank front
mounting pad 15.fuel tank front mounting board 16.bolt M81.2520 17.fuel tank cover support
assembly 18.fuel tank lock 19.socket head cap screw M530 20.socket head cap screw M514 21.fuel
tank cover seal gasket
- 112 -
9. Fuel Tank
Preparing Documents -----------9.1
Failure Diagnosis -----------9.2
Fuel Tank -----------------9.3
Work Instructions:
It shall be dismantled far from fire sources.
Tighten all the bolts and screws to the required torque value for assembly.
After assembly, check whether all the parts are correctly installed and operated.
Item
Standard
Limit for use
Gasoline tank capacity
150.2L
Tightening torque force

Front fixing bolts for the gasoline tank
Rear fixing bolts for the gasoline tank
Fixing bolts for the fuel tank front mounting pad
Fixing bolts for the fuel pump
Fixing bolts for the oil level sensor
22-37N
m
5-10 N
m
5-10 N
m
5-10N
m
5-10N
m

9.2.1 Decreasing Gasoline
Natural consumption of gasoline

Leakage of gasoline
- 113 -
9.3 Fuel Tank

9.3.1 Disassembly
Remove the rear seat and the front seat
Remove the upper body of the fuel tank.
Remove the front fixing bolt of the fuel tank.
Remove the high-pressure oil pipe assembly.

Remove the fuel pump connector jacket.
Remove oil level sensor connector jacket
Front fixing bolt of the fuel tank.
Oil level sensor

Fuel pump
High-pressure oil pipe assembly
Fuel pump connector jacket
Oil level sensor connector jacket
- 114 -
Remove the rear fixing bolt of the fuel tank.

Rear fixing bolt of
the fuel tank
Remove the fuel tank.
9.3.2 Installation
Torque force for mounting:

Front fixing bolts for the gasoline tank
Rear fixing bolts for the gasoline tank
Fixing bolts for the fuel tank front mounting pad
Fixing bolts for the fuel pump
Fixing bolts for the oil level sensor
22-37N
m
5-10 N
m
5-10 N
m
5-10N
m
5-10N
m
- 115 -
10. Disassembly and Installation of Engine

Preparing Documents -------------10.1
Disassembly and Installation of Engine ----------10.2

Work Instructions
It shall be dismantled far from fire sources.
Tighten all the bolts and screws to the required torque value for assembly.
After assembly, check whether all the parts are correctly installed and operated.
Locking torque force

Gearshift rod bolt:
Engine fixing bolt:
10N.m
50N.m
10.2 Disassembly of Engine

Support the motorcycle firmly to make its rear
wheel above the ground.
- 116 -
Unscrew the clamp of the engine water pump

inlet/outlet, remove the cooling water-pipe and
exhaust the coolant
Disassemble the front and rear seats

Disassembly of the rear seat
Insert the key into the guard lock, and open it
clockwise;
Slightly push the back of the rear seat with your
right hand, pull the rear seat upwards and
backwards
Remove the rear seat;
Disassembly of the front seat

Remove the rear seat;
Hold the front seat cable with hands;
Slightly push the back of the front seat with
your left hand, pull the front seat upwards and
backwards
Remove the front seat;
Note:
Confirm the left and right limits are set at
positions when installing the front seat.
- 117 -
Disassemble the fuel tank assembly

See 9.3.1 Disassembly of the fuel tank
Disassemble the air filter assembly

Disassemble the air filter fixing bolt
Disassemble the air filter hoop
Disassemble the connector jacket of the intake air
temperature sensor;
Disconnect the breather rubber pipe from the vent
of cylinder cover;
Remove the air filter
Note:
The stepper motor of the throttle body should be
set well to position when installing the air filter.
Disassemble the throttle body assembly
Remove the throttle cable assemblyI and throttle
cable assembly II;
Disassemble four throttle body hoops in 1-2-4-3
order;
Remove the connector jacket of the intake air
pressure sensor.
Remove the ejector connector jacket;
Remove the connector jacket of the idle stepper
motor;
Remove the canister desorption rubber pipe;
Remove the intake oil pipe;
Remove the throttle body assembly
Note:
Confirm the throttle cable assemblyI and throttle
cable assemblyII are set at positions;
Confirm the oil pipe is connected well to place
without oil leakage after the correct installation of
the throttle body assembly.
Confirm the electric components are connected at
positions;
- 118 -
Disassemble the canister assembly
Canister assembly
Disassemble the clutch steel rope assembly
Clutch steel rope assembly
Disconnect the battery wire, disassemble the starter motor wire

and the ground wire
Disassemble the FBT connector jacket, rectifier
and outlet water temperature switch connector
jacket
Battery wire
- 119 -
Disassemble the anterior segment of muffler exhaust

pipe
Disassemble the radiator filler, water tank, and

disconnect the fan switch connector jacket
Disconnect the crankshaft position sensor, neutral
switch connector jacket
Disconnect the single-kickstand flameout switch

connector jacket and disassemble the single-kickstand
flameout switch
Single kickstand flameout switch
- 120 -
Disassemble gearshift lever swing arm and the left cover of

the engine
Disassemble the small sprocket and detach the chain from the
sprocket
Release the engine fixing bolt and lift the engine
- 121 -
10.3 Installation of the Engine

Note:
Place an appropriate holder under the frame in case of rollover when disassembling the engine.
Engine fuel: 3.2L when assembling.
Start the engine and check it for abnormal vibration, noise and engine lubrication.
After the engine works properly at idle speed for a period of time, turn the throttle handle to maximum
level, then completely relax the throttle handle, at this time if the idle speed changes, it shows that the
throttle cable hasnt been regulated well. Therefore, attention should be given to the regulation in this
regard prior to the testing the engine.
a.
b.
c.
d.
Checking method of engine fuel

Pull out the fuel rod, wipe it off with a clean cloth.
Insert the rod into the oil and remove it to check the oil level, if the oil level is lower than the
lowest limit, increase the fuel.
Heating up for 5 minutes and cooling for 3 minutes, then check the oil level again, if the oil level
is lower than the lowest position, increase the fuel.
The oil level should always be kept between the lowest limit and the toppest limit.
- 122 -
Inspection and Maintenance of Engine

Table of Torque Force of Fasteners
Name of fastening parts and fasteners
Tightening torque (N
m)
Magnetic bolt M14
20~25
Oil pan bolt M6
10~12
cylinder double-end bolt
60~62
Flywheel locking bolt
100~110
Gearshift positioner bolt M6
10~12
Crankcase bolt M6
10~12
Crankcase bolt M8
22~24
Crankcase bolt M10
35~39
Connecting rod bolt
23~27
Left/right crankcase cover bolt M6
10~12
Flywheel bolt M8
20~24
Fuel filter
18~22
Fuel filter connecting bolt
40~45
Fuel filter bolt M14
40~45
Round nut M20
95~105
Clutch release plate bolt M6
10~12
Cylinder cover shade bolt M6
10~12
Camshaft sprocket bolt M7
20~25
Fuel pump bolt M6
10~12
Gearshift positioning plate bolt M6
10~12
Spark plug
22~25
- 123 -
11. Lubricating System

Preparing Documents ------------11.1
Failure Diagnosis ------------11.2
Fuel Pump ---------------11.3

Function of the lubricating system:
The lubricating system of the engine is to provide lubricating oil to the frictional surface of each part, which
transforms dry friction into liquid friction between lubricating oil particles and also reduces abrasion of parts.
It also cools components with high thermal load, absorbs shock from bearings and other parts, reduces noise,
increases sealing between piston ring and cylinder wall, and cleans and removes particles in the surface.
Work Instructions:
Clean all parts carefully and blow the parts surface clean with high-pressure gas after disassembly of the fuel
pump.
Foreign matter shall not fall into the crankcase when the carburetor is disassembled
Standard of benchmark items and table of limit for use
Item
Fuel capacity
Fuel pump rotor
Standard
Limit for use
When oil change
3.0L
When disassembling
3.2L
The radial clearance between

inner and outer rotors
0.04-0.11mm
0.15mm
The clearance between

outer rotor and pump body
0.04-0.11mm
0.15mm

Decreasing fuel
Natural consumption of fuel
Fuel leakage
Burnt engine
No fuel pressure or low fuel pressure
Blocked fuel pipes
- 124 -
11.3 Fuel Pump

11.3.1 Disassembly
Remove the clutch cover, loosen the fuel pump fixing bolt, take down
the fuel pump drive sprocket and the fuel pump drive chain.
Fuel pump chain

Screw
Fuel pump drive sprocket
Remove the screw.

Remove the fuel pump body.
Screw
Fuel pump body
Remove the screw, take down the fuel pump cover, and decompose
the fuel pump.
Screw
Fuel pump cover
- 125 -
Check the radial clearance between inner and outer rotors

Limit for use: 0.15mm.
Gauge
Check the clearance between outer rotor and fuel pump cover
Gauge
- 126 -
11.3.2 Assembly of Fuel Pump

Fuel pump
drive sprocket
As shown below
Fuel pump cover
Outer rotor
Inner rotor
Pump body
Pump shaft
Note: After the combination, the inner and outer rotors should rotate flexiblely without stagnation.
Installation
- 127 -
11.3.3 Lubricating Systematic Drawing
Piston cooler
--- exhaust camshaft --- intake camshaft ---piston cooler

--- crankshaft connecting rod mechanism --- main oil channel --- oil cooler
---main shaft --- fuel pump --- fuel filter --- fuel strainer --- relief
valve ---countershaft
- 128 -
- 129 -
12. Cylinder Head

Preparing Documents --------------------12.1
Failure Diagnosis -------------------------12.2
Cylinder Head / Valve--------------------12.3

Function of the cylinder head:
The cylinder head is used to seal the cylinder and form the combustion chamber with the piston. It bears HPHT
gas, and achieves air intake and exhaust through distribution mechanism.
Work Instructions:
The cylinder cover bears large bolt pretension to ensure sealing between the cylinder head and the upper
cylinder block. Pretension: 12 N
m, torque force: 60 N
m. All components must be cleaned and dried with
high-pressure air before check.
Unit: mm
Item
Standard
Limit for use
Flatness of cylinder cover
0.03
0.05
Intake
013-0.19
__
Exhaust
0.19-0.25
__
Intake
3.97-3.98
3.96
Exhaust
3.97-3.98
3.96
Intake
4.03-4.04
4.07
Exhaust
4.03-4.04
4.07
Intake
0.05-0.07
0.11
Exhaust
0.05-0.07
0.11
Intake
1.0-1.1
1.5
Exhaust
1.0-1.1
1.5
Intake
38.8
37.3
Exhaust
41.6
40.1
0.041-0.054
0.08
Valve gap
Outer diameter of valve stem

Valve
Valve catheter
Inner diameter of valve catheter

Clearance between valve stem
and valve catheter
Width of valve seat
Valve spring
Camshaft
Free length
Fitting clearance between camshaft and
cylinder head

Low compression pressure
Valve clearance maladjustment
Noise in Cylinder head

Valve clearance maladjustment
- 130 -
Burnt or bent valve

Poor air-tightness of valve seat
Cylinder head gasket leaks gas
Poor installation of spark plug
Damaged valve spring

Over high compression pressure
Too much carbon fouling in the combustion chamber.
- 131 -
12.3 Cylinder Head

12.3.1 Disassembly
Remove the ignition coil.
Loosen six locating bolts, remove the gasket and cylinder cover shade.
Cylinder
cover shade
Locating bolt
Loosen the fastening bolt, and remove the air-distributing

chain regulator.
Fastening bolt
Air-distributing chain regulator
Loosen the four sprocket bolts of the camshaft.
Sprocket bolt of the camshaft

Measure the fitting clearance between camshaft and cylinder
head.
Gauge
- 132 -
Loosen the camshaft holder.
Camshaft holder
Remove the camshaft, camshaft sprocket and chain.
Camshaft
Camshaft chain
Camshaft sprocket
Guide chain
plate
Cylinder
cover
Loosen the cylinder cover locking bolt.
Remove the cylinder cover.
Remove the top stem, compress the valve spring with valve
spring compression tools, and remove the valve block.
Remove the valve adjusting gasket, valve spring, valve spring
upper/lower seat and valve.
- 133 -
12.3.2 Cam Assembly Breakdown
Seal cover D13
Camshaft
Camshaft sprocket
Bolt
12.3.3 Valve Breakdown

Valve
Valve spring
Valve spring
lower seat
Valve block
Valve spring
upper seat
Top
stem
Valve adjusting
gasket
Ruler
Gauge
Check
Eliminate carbon deposit in the cylinder cover.
Measure the flatness of the joint surface of the cylinder cover.
When the flatness of the joint surface of cylinder cover
exceeds the limit for use, place the fine-sand paper on the flat
plate, with the joint surface of cylinder cover fitting the sand
paper, and mill it according to 8-shape.
- 134 -
Vernier calipers
Measure the free length of valve intake/ exhaust spring.
Limit for use: intake spring: 37.3mm.
exhaust spring: 40.1mm.
Measure the outer diameter of the valve stem.

Limit for use: intake valve 3.96mm
Micrometer
exhaust valve 3.96mm
Check the valve catheter after eliminating the carbon deposit

in it with a reamer.
Note: The reamer should be rotated clockwise, and mustnt be
rotated anti-clockwise.
Tester
Measure the inner diameter of each valve catheter.
Limit for use: intake/ exhaust: 4.07mm.
Limit for use of the clearance between valve and valve catheter:
Intake valve: 0.11mm.
Exhaust valve: 0.11mm.
- 135 -
Screwdriver
12.3.4 Replace the Valve Catheter
Note: When the clearance between valve and valve catheter
exceeds the limit, replace the valve catheter. After the replacement,
trim the surface of the valve seating.
Put the valve catheter in the freezer of the refrigerator to cool for
one hour.
Heat the cylinder head to 100-150 with an electric furnace or a
hot oven.
Fix the cylinder head, disassemble the valve catheter from the
upper side of cylinder head with valve catheter disassembly tools.
Put a new o-ring on the new valve catheter.

Install the valve catheter from the top of the cylinder head.
Note: The cylinder head shall not be damaged when installing
the valve catheter.
Valve
reamer
After inserting the valve catheter, trim with a valve catheter

reamer.
Note: Add proper amount of cutting oil when cutting with an
reamer. And the reamer should be rotated clockwise.
Eliminate the carbon deposit in the combustion chamber and

valve, clean thoroughly the intake/exhaust valve. Check the
width of the contact surface of the valve seat (width of the
valve seating).
Limit for use: intake/ exhaust: 1.5mm.
Contact surface of the valve seat
- 136 -
12.3.5 Trim of Valve Seating

Remove the rugged or ragged parts of the valve seating
surface with a milling cutter at 45angle.
Note: Coat a transparent or prussian-blue cladding on the
valve seating to get a better view.
Rugged part
Remove 1/4 of the outer end of valve seating with a milling

cutter at 25angle.
25
Remove 1/4 of the bottom of valve seating with a milling

cutter at 60angle. Take down the milling cutter and check the
parts treated.
60
Grind the valve seating with a refining milling cutter at

45angle to achieve the proper width.
All dents and ragged parts must be removed.
1.0mm
Standard width of the valve seating: intake: 1.0mm

exhaust: 1.0mm
45
- 137 -
If the contact is the part where the valve is too high, please
lower the valve seating with a flat milling cutter at
25angle.
If the contact is the part where the valve is too low, raise
the valve seating with a inner milling cutter at 60angle.
Refine the valve seating again with a refining milling cutter
at 45angle to meet the specifications required.
After grinding the valve seating, please coat the polish on
the surface of valve to gently polish the valve.
High contact surface

25
Low contact surface
60
12.3.6 Installation
Note:
When installing the valve spring, the end with smaller pitch of the spring shall be installed towards the
combustion chamber.
When installing the valve collet, install it by compressing the valve spring with valve spring compression
tools
When installing the valve, the surface of the valve stem shall be coated with proper amount of fuel prior
to installing to the valve catheter.
- 138 -
- 139 -
13. Crankcase
Preparing Documents------------------------------------------------------13.1
Failure Diagnosis-----------------------------------------------------------13.2
Upper Box-------------------------------------------------------------------13.3
Piston------------------------------------------------------------------------13.4
Lower Box------------------------------------------------------------------13.5
Clutch-----------------------------------------------------------------------13.6
Variable Speed Gear Transmission---------------------------------------13.7
Camshaft Connecting Rod Assembly-------------------------------------13.8

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

1. It bears pressure arising from mixed gas combustion inside the cylinder and transfers such pressure to the
connecting rod for driving the crankshaft.
2. It forms combustion chamber along with the cylinder cover.
Function of the crankcase:

The crankcase is the load-bearing part of the engine. Its main function is to support the crankshaft, clutch,
gearbox, cylinder block and cylinder cover, sustain combustion shock and inertia force from the movement of
the connecting rod, and form part of closed space (oil sealing, gas sealing).
Suspension holes in the crankcase are linked with suspension holes in the body, which connects the engine to
the frame and other parts.
Work Instructions:
- 140 -
All components must be cleaned and blown with high-pressure gas before test.
The crankcase is thin-section casting thus shall not suffer impact during operation which may cause
deformation or fracture.
Lubricant in the crankcase should be drained out before operation.
- 141 -

Item
Standard
use
Cylinder I 65 (0.025, 0.03)
65.100
Cylinder II 65 (0.03, 0.035)
65.110
Cylindricity of the cylinder
0.008
0.050
Roundness of the cylinder
0.006
0.050
Flatness of the cylinder
0.03
0.05
Diameter of the cylinder
Outer diameter of piston (measured in piston skirt)
Upper box
Limit for
Piston I 65 (-0.03, -0.025)
64.90
Piston II 65 (-0.025, -0.02)
64.91
Inner diameter of piston pin hole
16 (0.002, 0.008)
16.04
Outer diameter of piston pin
16-0.008, 0
15.96
0.002-0.016
0.04
Ring 1
0.05-0.09
0.11
Ring 2
0.04-0.08
0.11
Ring 1
0.15-0.30
0.5
Ring 2
0.25-0.45
0.65
Fuel ring
0.20-0.70
1.0
16 (0.016, 0.034)
16.04
Clearance between connecting rod and piston pin
0.016-0.042
Thickness
1.5 (0-0.09)
1.48
0.025-0.05
0.065
0.1-0.25
0.5
0.008-0.016
0.05
1.5 (0-0.012)
1.44
0.03-0.05
0.07
2.8 (-0.05, +0.05)
2.45
3-0.1, 0
2.6
24.3-0.15, +0.15
22.8
23.5-0.2, +0.2
22.4
Outer diameter of fork shaft
11.973-11.984
11.96
Diameter of fork inner hole
12-12.018
12.03
Thickness of fork
5.80-5.90
5.75
Outer diameter of gearshift drum
41.9-42.1
41.5
5.45-5.55
5.65
Clearance between piston pin hole and piston pin

Clearance between piston ring
and ring groove
Joint gap of the piston ring
Inner diameter of the smaller head of connecting rod.
Connecting-rod
Clearance
bearing
connecting-rod
between
bearing
the
and
crankshaft
Left-right clearance of the larger
Connecting rod
end of the connecting rod

Radial clearance of the larger
Thickness
Main-shaft
Clearance between main shaft
bearing
Lower box
and crankshaft
Thickness of friction disc
Clutch
Length of pressure spring
Variable
speed
transmission
gear
Width of gearshift drum lock

groove
- 142 -

Abrasive, burnt or ruptured piston
Abrasive or damaged cylinder or piston
Damaged spacer or crankcase leakage
Over-high compression pressure
Too much carbon deposit in the combustion chamber
White smoke from the exhaust pipe

Abrasive or damaged piston ring
Abrasive or damaged cylinder or piston
Abnormal noise of the piston

Damaged cylinder, piston or piston ring
Abrasive piston pin hole and piston pin

Abnormal noise in the crankcase
Crankcase leakage
Loose or broken parts inside the crankcase
Engine overheating
Engine automatic stopping
Clutch slipping
Seized clutch
Poor lubricating
Not in gear
Gear skip shift
Broken or deformed variable speed fork
The clutch isnt completely released
Broken fork guide pin
Abnormal transmission return spring
Abrasive gear convex claw
Abrasive gearshift drum lock groove
Out of gear automatically
Abrasive joint claw, round edge
Decreasing elasticity of variable speed gear return spring
Abrasive spline gear of spline shaft and spline groove of sliding gear, leading to higher axial force when the
gear works
Abrasive gearshift drum and fork
- 143 -
13.3 Upper Box

BJ465MS/QJ465MS Engine cylinder block
Namely it is part of the upper box.
Upper box
Check
Check the abrasion of the inner wall of the cylinder.
If it is serious, replace it.
Spacer
Remove the spacer and locating pin.
Locating pin
- 144 -
13.4 Piston
13.4.1 Disassembly
Remove the retainer ring of the piston pin.
Note: during assembly, do not make the retainer ring fall
into the crankcase.
Remove the piston pin and the piston.
Retainer ring of the piston

Piston pin
Remove the piston ring.

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

Measure the clearance between piston ring and piston ring
groove.
Limit for use: ring 1: 0.11mm.
ring 2: 0.11mm.
Piston
Push into
Piston ring
Gauge
- 145 -
Remove the piston ring, and install each piston ring on the
cylinder bottom.
Note:
Press the piston ring into the cylinder with piston head.
Measure the joint gap of the piston ring.
Limit for use: ring 1: 0.5mm.
Piston ring
ring 2: 0.65mm.
Gauge
Measure the inner diameter of the piston pin hole.

Tester
Measure the outer diameter of the piston pin.

Clearance between piston pin hole and piston pin.
1
2
3
- 146 -
Measure the outer diameter of the piston I and piston II.

Note:
The measuring point shall be at 90with the piston pin, and
at the piston skirt.
Limit for use of the piston I: 64.90mm.
Limit for use of the piston II: 64.91mm.
90
11mm
Check whether cylinder I/II inner wall is scratched or

abraded.
Note:
It is at 90 degree with the piston pin. Measure the inner
diameter of the cylinder at the top, middle and bottom
points.
Limit for use of the cylinder I: 65.100mm.
Limit for use of the cylinder II: 64.110mm.
Tester
Measure the roundness of the inner wall of the cylinder (inner

diameter difference at X direction and Y direction).
Measure the cylindricity of the inner wall of the cylinder
(inner diameter difference at the top, middle and bottom
points of X direction and Y direction).
In
Ex
Top
Middle
Bottom
- 147 -
Check the flatness of the cylinder surface..

Ruler
Gauge
Upper box
Measure the inner diameter of the smaller end of the

connecting rod.
Inner diameter of
smaller
end
of
connecting rod
the
the
Tester
Measure the clearance between connecting-rod bearing and crankshaft.

Connecting-rod bearing
- 148 -
Measure the clearance between main shaft bearing and crankshaft.

Main shaft bearing
Plastic gauge
13.4.2 Piston Installation
Top ring
Install the locating pin.

Apply fuel to each piston ring and piston. Install the piston
ring in place.
Ring 2
Fuel ring
Note:
Do not scratch the piston or break the piston ring.
After the piston ring is installed, it shall be able to rotate
freely in the piston ring groove.
- 149 -
Remove any residual spacer attached to the crankcase.
Note:
Do not make any object fall into the crankcase.
Install the piston, piston pin and retainer ring.
Note:
The dot mark on the top of the piston shall be installed
towards the intake valve.
Dot mark
- 150 -
13.5 Lower Box

13.5.1 Disassembly of the Crankcase Left Cover
Lossen the fixing bolt of starter motor, remove the starter motor.
Lossen the bolt of the crankcase left cover.
Remove the left cover.
Remove the electric starting bear, needle bearing and spacer.
Motor idle gear

Starter motor
Locating pin hole
Remove the starter motor idle gear.

Remove the spacer and locating pin hole.
Loosen the flywheel locking nut with the electric or pneumatic tool.
Pull the flywheel assembly (including the star wheel )
Flywheel assembly
- 151 -
13.5.2 Disassembly of the Clutch Cover

Loosen the fixing bolt, and remove the clutch cover.
Bolt
Clutch cover
Remove the clutch release stem from the right cover.
Right cover
Release stem assembly
Remove the fixing bolt, clutch, gearshift arm assembly and fuel pump sprocket.
Clutch assembly
Gearshift arm assembly
Fuel pump sprocket

Driven gear
- 152 -
Loosen the locking nut with the electric or pneumatic

tool, and remove the clutch.
Loosen the fuel pump screw, and remove the fuel pump
gear.
Gearshift drum assembly

Fuel pump chain
Fuel pump sprocket
- 153 -
13.6 Clutch
13.6.1 Disassembly
Unscrew the four bolts of the release plate in diagonally staggered sequence.
Loosen the clutch nut.
Remove the sleeve, bearing, release plate
and the clutch spring.
See the breakdown drawing for the disassembly of parts.
.
Release plate bolt
Clutch nut
Unscrew the clutch locking nut with the special tool, and remove the locking nut and gasket.
Remove the center holder of clutch.
Remove the clutch disc and friction disc.
Remove the clutch pressure plate.
See the breakdown drawing for the disassembly of
parts.
Remove the spline gasket.
Remove the shell assembly.
Four-claw socket spanner

Universal holder
Shell assembly
- 154 -
13.6.2 Clutch Breakdown
---needle bearing ---sleeve ---spacer ---drive hub assembly ---driven

hub ---friction disc ---clutch disc ---dish-shaped spring ---gasket
---drive hub housing assembly ---pressure spring ---pressure plate ---bolt
--- rolling bearing
- 155 -
13.6.3 Check
Check the shell groove for burrs and brakeage, if
trimmed excessively by the file, replace it.
Check the pressure plate and the tooth profile of the
center holder for damage, if damaged, replace it.
Drive hub assembly
Driven hub
Measure the free length of the pressure spring.

Limit for use I: replace it if lower than 22.8mm.
Limit for use II: replace it if lower than 22.4mm.
Free length
Measure the thickness of the friction disc with vernier
calipers.
Limit for use I: replace it if lower than 2.45mm.
Limit for use II: replace it if lower than 2.6mm.
Thickness
- 156 -
13.7 Gearshift Mechanism

13.7.1 Disassembly
Remove the gearshift shaft assembly.
Remove the bolt and gearshift locating plate.
Remove the bolt, stop arm and spring.
Remove the locating pin.
See the breakdown drawing for the disassembly of
parts.
Gearshift shaft assembly
13.7.2 Gearshift Shaft Mechanism Breakage

Fork shaft spring
Fork
Fork shaft
Pressure plate
Gearshift drum
Gearshift drum bearing
Ratchet
Gearshift arm assembly
13.7.2.1 Check
Before the breakage, the gearshift plate should flexibly return without being seized.
Check the gearshift plate and gearshift shaft assembly for abrasion. If heavily abrasive, replace the assembly.
Check the gearshift locating plate for abrasion, If heavily abrasive, replace the assembly.
- 157 -
Check whether the gearshift shaft is bent, if excessively bent, replace it.
Check the return spring for decreasing elasticity, if necessary, replace it.
- 158 -
Loosen the crankcase bolt.

Upper box
Separate the crankcase.
Note: Do not damage the spacer and crankcase surface.
Remove the upper box.
Crankcase bolt
Lower box
Main shaft assembly
Countershaft assembly
Remove the main-/ countershaft.

Loosen the pressure plate bolt, and remove the pressure plate.
Pull the fork shaft.
Remove the gearshift drum.
Remove the gearshift fork.
Gearshift drum
Fork
Fork shaft
- 159 -
13.7.2.2 Check
Fork shaft
Measure the outer diameter of the fork shaft.

Micrometer
Measure the inner diameter of the fork hole.

Tester
Vernier calipers
Measure the thickness of the fork.

Width of the lock groove

Measure the outer diameter of the gearshift drum.
Measure the width of the gearshift drum locking
groove.
- 160 -
13.8 Crankshaft Connecting Rod Assembly Chamber and Variable

Speed Chamber
Depository for
the main shaft
Depository
for
the
crankshaft connecting rod
Depository for
the countershaft
Gearshift chamber
- 161 -
Main shaft
assembly
Gearshift drum
assembly
Gearshift arm
assembly
Fork shaft
- 162 -
13.8.1 Crankshaft Connecting Rod Assembly

13.8.1.1 Disassembly
Remove the upper box.
Remove the crankshaft connecting rod assembly from the lower box.
Countershaft
assembly
asseml
Main shaft
assembly
Drive gear
Note: Do not damage the spacer and crankcase surface.
- 163 -
13.8.1.2 Check
Measure the left-right clearance of the larger end of the connecting rod.
Measuring point at the
clearance between the larger
Measuring point at the larger

Measure the clearance of the larger end of the connecting rod (X-Y
direction).
- 164 -
13.8.1.3 Assembly
Assemble in reverse order of breakdown and disassembly.
Remove the main shaft assembly
Remove the countershaft assembly.
13.8.2 Main-/Counter Shaft Breakdown

13.8.2.1 Main-/Counter Shaft Breakdown
Main shaft assembly
- 165 -
13.8.2.2 Check
Check the abrasion of gear surface and driving-claw point of the gear respectively.
If it is seriously abraded or damaged, replace it.
Gear surface
Check whether the bearing and oil seal are damaged, If yes,
replace it.
Driving claw
Note:
Removed bearing cannot be used any more. It shall be
replaced.
Use special tools to dismantle the bearing and the oil seal.
13.8.2.3 Main-/Counter Shaft Assembly

Note:
Lubricate all gears and shafts with grease when assembling.
Ensure all gears without being seized after assembling.
Note:
Install the crankcase in reverse order.
- 166 -
14. Cooling System

Preparing Documents -------------------------14.1
Failure Diagnosis ------------------------------14.2
Water Pump ------------------------------------14.3

Function of the cooling system:
The cooling method of the engine is water cooling. Water cooling, in which the water is used as the heat
conductor, is a method of cooling high-temperature components and then transferring heat to the outside air,
thus keeping the engine working under the optimum temperature.
Specific cooling circuit:
The cooling water entering from the crankcase goes to the cylinder water jacket through the water channel
of crankcase, then goes upward through the cylinder cover, finally enters into the radiator through the pipe to
- 167 -
dissipate heat, and transfers heat to the outside air with the help of radiators fin.

Water leakage
Damaged seal ring
Broken pump assembly
Broken water pipe
Over high temperature in cylinder block
Damaged blade of the water pump
Blocked water pipe
Damaged cooling fan
Damaged water temperature switch
14.3 Water Pump

Disassembly
Loosen the bolt, and remove the water pump sub assembly.
Bolt
- 168 -
Water pump sub assembly
Bolt
Loosen the bolt, and remove the water pump cover.
Water pump cover
Remove the blade.

Blade
Check
Check the abrasion of the blade assembly.
If it is serious, replace it.
Note: Dont damage the spacer and the joint surface of box
during operation.
Installation
- 169 -
Cooling Systematic Drawing
Reservoir
465 cooling system piping drawing

thermostat
t
Cylinder cover
Thermostat
Pressure valve
Oil
cooler
Water pump
Radiator
Cylinder block
Water direction
- 170 -
Inspection and Maintenance of Exhaust Emission System
1 exhaust pipe gasket assembly 2 screw M830 3 gasket 8 4 spring gasket 8 5 muffler assembly 6
muffler buffer rubber 7 muffler decorating panel 8 heat-insulating spacer
9 combined screw M610
- 171 -
15. Exhaust Emission & Control System

Warranty on the Exhaust Emission & Control System ----------------------------15.1
Instructions on the Periodic Maintenance / Compliance with Standards -------15.2
Mechanical Function of the Exhaust Control System -----------------------------15.3
Catalytic Conversion System --------------------------------------------------------15.4
Measures When the Idle Speed Emission Value Exceeds the Standard ---------15.5
15.1 Warranty on the Exhaust Emission & Control System

15.1.1 The exhaust emission & control system of this motorcycle is in conformity with the GB 14621-2011,
GB 14622-2007, GB 19758-2005 and GB 20998-2007 standards prescribed by the state. We warrant that the
exhaust emission & control system works normally during its effective period provided that users completely
comply with all operation and maintenance requirements.
15.1.2 Warranty Range
Function warranty of the exhaust emission & control system
We warrant that it satisfies all periodic or non-periodic inspection by the related government authorities within
riding of (30000 kilometers).
15.1.3 This provision is not applicable under any following condition. However, our distributor or service store
would like to provide maintenance or repair services at reasonable prices.
(1) Users fail in periodic maintenance within the required period or kilometers.
(2) Periodic maintenance, adjustment or repair is not carried out at our distributor or service center, or there is
no evidence of maintenance record.
(3) Overload or improper operation.
(4) Refit the motorcycle, remove original parts or replace with other devices in private.
(5) Ride the motorcycle on race tracks or on any non-motorized vehicle lane frequently.
(6) Damage to the motorcycle due to extreme weather such as typhoon or flood, or damage or failure due to
negligence, crash or impact.
(7) Users fail in periodic maintenance since it is out of service for a long time.
(8) The odometer is not repaired immediately after being damaged, or it is refit, stopped, or replaced in
private.
All new motorcycles delivered by our company have satisfied the noise test and comply with the GB
4569-2005 and GB 16169-2005 standards prescribed by the state.
- 172 -
15.2 Instructions on Periodic Maintenance
It is the national requirement that all motorcycles produced domestically shall comply with exhaust
emission standards to lessen environmental pollution. We strictly accord with these exhaust emission
standards and also make great effort in purifying air and reducing pollution.
This motorcycle has been strictly examined before delivery and is in conformity with all exhaust emission
standards. We provide the following periodic inspection table for exhaust emission in consideration of
different use by customers. Users shall carry out periodic inspection, adjustment or maintenance
according to the schedule to ensure normal emission.
For any problem, please contact Qianjiang distributors or Qianjiang service center.
Relevant emission provisions are shown as follows:
Emission regulation
CO
HC
NOX
Emission standard
2.0g/km
0.3g/km
0.15g/km
The latest national regulation shall prevail if there is any change.
We are not responsible for any problem due to failure in periodic maintenance at our distributor or service
center. Please carry out necessary inspection to ensure its best condition.
Note: Clean the air filter frequently if the motorcycle runs in sandy road or under seriously polluted
condition to extend the service life of the engine.
Increase maintenance if the motorcycle often runs at high speed or frequently.
Pay attention to following items to ensure meeting emission standards:
(1) Please use lead-free gasoline #93 or #97.
(2) Please use fuel with stipulated specification.
(3) Please comply with periodic maintenance requirements.
(4) For the exhaust control system, it is forbidden to make any adjustment or replacement at random
(including use of spark plug, adjustment of idle speed, ignition timing, throttle adjustment, etc.)
(5) Notes:
Since any problem in the ignition system, the charging system or the fuel system has significant
effect on the muffler device, please go to our designated distributor or service center for inspection,
adjustment or repair immediately when there is any problem found in the engine.
Please use lead-free gasoline #93 or #97. Otherwise, the muffler device (four-stroke system) will be
affected.
(6) The exhaust control system of this motorcycle is in accordance with the national regulation. For
replacement of any component, please use our original parts and have our designated distributor or
service center carry out such replacement.
15.3 Mechanical Function of the Exhaust Control System

General
This system adopts four-stroke single-cylinder engine, EFI and air conduction device to maintain
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qualified exhaust gas. Meanwhile, active carbon canister is used for exhaust gas evaporated from fuel.
Engine improvement
As the spark plug, spherical combustion chamber, compression ratio, ignition time, exhaust system and
other engine components are improved, as well as the intake/exhaust efficiency is enhanced, the combustion
efficiency is raised.
15.4 Catalytic Transfer System

15.4.1 Structure:
Catalytic
15.4.2 Instruction:
(1) Function of transfer catalyst is to transfer completely burnt HC, CO and NOX to harmless gas such as H2O,
CO2andN2 for discharge.
(2) Transfer catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used.
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Note that lead gasoline may invalidate catalyst.

Notes in maintaining motorcycles (gas discharge tube) with catalytic transfer:
a) For motorcycles with transfer catalyst, when the motor is running or just shut, it shall not be touched
because of high temperature.
b) Motorcycle with transfer catalyst shall not be near flammable material.
c) There is CO inside gas discharge tyre, which is harmful to health. So do not run the motor in closed
space.
d) Motorcycle with transfer catalyst shall not use lead gasoline. (prevention for catalytic poison.
e) Do not push motorcycle to run motor. If it is necessary, you must stop for temperature of motor and
catalyst to lower down.
f) Do not shut the motor with gear up when running downward.
g) Do not drive motorcycle with bad ignition.
h) Do not remove spark plug and run motor to see whether there is spark in maintain motor ignition system.
If necessary, the time shall be short.
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15.5 Measures When the Idle Speed Emission Value Exceeds the
Standard
Qualified
Periodic inspection (maintenance plan)
Qualified
Measure idle emission (note 1)
Qualified
Adjust Carburetor (note2)
Qualified
Remove and clean the
carburetor
Qualified for
delivery
Qualified
Replace the carburetor
Dismantle and repair

engine
Valveleakage
Pistonabrasive
Combustorcleaning
Qualified
Notes:
1. Measure it with the idle speed measurement program.
2. Adjust the engine speed with stop screws to live up to requirements and measure CO/HC at the idle speed.
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Inspection and Maintenance of Electronic Fuel

Injection (EFI) System
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16. Electronic Fuel Injection System

Electronic Fuel Injection System ---------------------------------------16.1
Components of Electronic Fuel Injection System---------------------16.2
Failure Diagnosis ----------------------------------------------------------16.3
Common Troubleshooting Methods-------------------------------------16.4
16.1 Introduction of Electronic Fuel Injection System

RK6 adopts the small-scale engine electronic fuel injection system manufactured by Delphi Company, which
is controlled with four oxygen sensors within a closed loop. Besides, it is equipped with four-cylinder
independent fuel injection and ignition control functions. The three-way catalytic converter would go through
treatment with the gas after combustion in the engine, turn it into harmless gas and discharge it into the air.
This system adopts the closed-loop independent function that can efficiently eliminate the manufacturing
differences within the system and the other corresponding components, highly improving the integrity of the
motorcycle, which can also reduce the deviations of the motorcycle after a some time of actual using.
16.2 Components of Electronic Fuel Injection System

16.2.1 Engine Controller (MT05.2 ECU)
The engine controller can test the operation conditions of the engine with various sensors at any time and
guarantee the emission and economy of fuel by proper computing and self-study control output mechanism
with the driving performance optimized. Once failures are found within the engine, the control would go
through automatic diagnosis. The normal working of the system requires two ECU.
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16.2.1.1 ECU Appearance
ECU 12 is located on the left of battery and ECU 34 is behind the battery.
16.2.1.2 Definition of ECU Connector Pin

1) ECU 12
J1-1
J2-1
Pin for activating 1-cylinder ignition coil
J1-2
Headlight control pin
J2-2
Pin for system grounding
J1-3
Pin for trouble light
J2-3
Pin for K line communication
J2-4
Pin for crank signal high potential
Pin for heating 2-cylinder oxygen

J1-4
sensor
Pin for activating 1-cylinder fuel injector
Pin for signal 2-cylinder oxygen

J1-5
J2-5
sensor
J1-6
Connector pin for tachometer
J2-6
J1-7
CAN line low signal 1 pin
J2-7
Pin for heating 1-cylinder oxygen sensor
J1-8
CAN line high signal 1 pin
J2-8
Pin for intake temperature sensor signal
J1-9
J2-9
J1-10
Pin for activating 2-cylinder ignition

coil
J2-10
Pin for 5V system reference voltage grounding
J1-11
J2-11
Pin for intake pressure sensor signal
J1-12
J2-12
Pin for throttle position sensor signal
J1-13
J2-13
Pin for crank signal low potential

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J1-14
J2-14
Signal pin for water temperature sensor
J1-15
J2-15
Ignition power (12V positive voltage after key)
J1-16
J2-16
J1-17
J2-17
Pin for signal 1-cylinder oxygen sensor
J2-18
Battery power supply (battery 12V positive voltage)
J1-18
Dump switch (efficient at low)
Pin for neutral gear switch
Remarks:
J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey
connector.
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2) ECU34
J1-1
Idle speed stepper motor high A pin
J2-1
Pin for activating 4-cylinder ignition coil
J1-2
Canister solenoid valve pin
J2-2
J1-3
Pin for trouble light
J2-3
Pin for K line communication
J2-4
Pin for crank signal high potential
Pin for heating 3-cylinder oxygen

J1-4
sensor
Pin for signal 3-cylinder oxygen

J1-5
J2-5
sensor
J1-6
J2-6
J1-7
CAN line low signal 2 pin
J2-7
Pin for heating 4- cylinder oxygen sensor
J1-8
CAN line high signal 2 pin
J2-8
Pin for intake temperature sensor signal
J1-9
J2-9
Pin for oil pump control signal
J2-10
Pin for 5V system reference voltage grounding
J1-10
Pin for activating 3-cylinder ignition

coil
J1-11
Idle speed stepper motor low A pin
J2-11
Pin for intake pressure sensor signal
J1-12
Idle speed stepper motor high B pin
J2-12
Pin for throttle position sensor signal
J1-13
Idle speed stepper motor low B pin
J2-13
Pin for crank signal low potential
J1-14
Dump switch (efficient at low)
J2-14
Signal pin for water temperature sensor
J1-15
Pin for vehicle speed sensor
J2-15
Ignition power (12V positive voltage after key)
J1-16
J2-16
5V reference voltage
J1-17
J2-17
Pin for signal 4-cylinder oxygen sensor
J2-18
Battery power supply (battery 12V positive voltage)
J1-18
Pin for neutral gear switch
Remarks:
J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey
connector.
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16.2.1.3 Circuit Diagram of Electronic Injection System
Notes:
a) Keep ECU away from places of high temperature, like muffler or engine;
a) Keep ECU away from water, engine oil or any places of liquid;
b) Keep ECU away from mud or other dirt that would affect the heat dissipation function of ECU;
c) Connect with M8 bolts and make sure the tightening torque is around 3.9Nm, keep the surface neat to
prevent outside force to ECU in case of circuit board bending;
d) The DC power supply voltage of ECU of normal working is between 9V and 16V. when it's working
under a voltage not over 26V for one minute, permanent damage would not happen to ECU, neither when the
backward voltage is not over 13V.
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16.2.2 Fuel Injector

16.2.2.1 Working Principle of Fuel Injector:
The fuel injector is designed with magnet coil surrounding iron core inside. Two electrodes from magnet
coil are input control connectors of the fuel injector. When magnet coil is energizing, electromagnetic
attraction generated by magnet coil will conquer spring force and fuel oil pressure of ball valve to uplift the
ball valve. Then high pressured fuel oil (250Kpa) in fuel pipes can inject cone-shaped fuel oil to the air inlet
through value seat hole and orifice plate. After power of the fuel injector, magnetic force of the magnet coil
will automatically disappear. The ball valve closes by the action of return spring and fuel injection stops.
16.2.2.2 Appearance:
Fuel injector is designed with a filter which is not a repairable component because it is designed for only
filtering impurities between fuel filter to fuel injector. The impurities may cause failures such as injector
bonding, flow deviation and leakage. Thus, fuel filter system is very important.
Replace the fuel injector with parts of the same models.
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16.2.3 Throttle Body

16.2.3.1 Working Principle:
The throttle body assembly is comprised of the main casting valve body, return spring, throttle position
sensor system and idle adjusting screws.
Throttle position sensor system offers accelerograph opening for ECU; idle adjusting screws controls and
idle speed and the stability by clockwise reducing the ventilation to lower the idle speed and anticlockwise
increasing the ventilation to higher the idle speed, which is normally required around 2 circles.
16.2.3.2 Appearance:
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16.2.3.3 Cleaning
Clean the throttle body assembly with carburetor cleanser by spraying it on the inner wall of the throttle
body and brush the dusts and carbons away gently.
Notice:
Make sure the side channel is not blocked by the dirty.
16.2.4 Engine Cylinder Head Temperature Sensor

16.2.4.1 Working Principle:
This sensor is used on the air cooled engine for measuring the engine cylinder head temperature. Within
the temperature scope of the sensor, the electric resistance would vary with different temperature of the engine,
which is a negative temperature coefficient resister. It is a not a repairable part.
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16.2.4.2 Appearance
16.2.5 Intake Air Temperature Sensor

16.2.5.1 Working Principle
It is used for measuring the temperature of the intake air. Within the temperature scope of the sensor, the
electric resistance would vary with different temperatures of the engine, which is a negative temperature
coefficient resister. The intake air temperature sensor is not a repairable part.
16.2.5.2 Appearance
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16.2.6 Intake Pressure Sensor

This sensor is mainly used for measuring the absolute pressure of the intake bend tube, which, in
compliance with the change between the resistance value and the intake pressure, can measure the air input of
the engine's combustion chamber indirectly.
16.2.6.1 Appearance
16.2.7 Oxygen Sensor

Oxygen sensor is mainly used for measuring the oxygen content within the exhaust pipe of combustion
engine and for the fuel closed loop controlling in the engines, which can make sure the combustion of the
engine is maintained at a reasonable air-gasoline ratio (14.7).
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16.2.7.2 Appearance
16.2.8 Ignition Coil

The ignition coil can provide energy to the spark plug. The high voltage wire is used to connect the
ignition coil and the spark plug.
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16.2.8.1 Appearance
16.2.9 Idle Speed Stepper Engine

The idle speed control valve is used to control the ventilation circulation area aside the throttle body so as
to adjust the intake air to the engine, realizing controlling of the idle speed of the engine.
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16.2.9.1 Appearance
16.2.10 Fuel Pump Assembly

The electric pump would work together with the pressure regulator to provide 250Kpa fuel pressure for
the engine. It is installed under the gasoline tank.
16.2.10.2 Appearance
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Back side:
Front side:
16.2.10.3 Failure Diagnosis of Fuel Pump Assembly

a)
b)
c)
Turn on the key and run the fuel pump for about 3 seconds. If the fuel pump starts to run, refer to
step d).
Cut off the connector of the fuel pump and check whether the power supply voltage is 12V or so.
If there is nothing wrong with the second step, supply 12V DC to the fuel pump with an external
storage battery. Check whether the fuel pump runs or not.
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d)
e)
If the fuel pump runs normally, check the oil pressure gauge to see whether the front supply pressure
of the nozzle is about 250Kpa when the engine is idling.
If the pipe pressure is lower than 220Kpa, check if there is a leakage in the oil pipe, if the fuel pump
runs backwards, or if the filter is blocked.
16.2.10.4 Common Problems

a)
b)
The reverse connection of the connector of the fuel pump assembly causes the fuel pump run
backwards, thus leading to inadequate fuel pressure for the engine. As a result, the engine
cannot work normally.
The fuel pump is damaged and cannot run.
Note:
1. Since a new motorcycle has no gasoline in its fuel tank at the very beginning, much air remains in the
fuel line after the tank is fueled up. Therefore, it is necessary to turn the motor over for several times to
discharge all the air in the fuel line so that the engine can operate normally. This is a normal process,
which will avoid the engine from taking a long time to start but still in failure in the later startup.
2. The gasoline can cool down the fuel pump, so do no run the pump with little or no fuel, or the fuel
pump will be overheated and damaged.
16.3 Methods for Fault Diagnosis and Maintenance

The trouble light is on the instrument panel, with a sign of FI down blew. In a normal circumstance, when
turning on the key, the trouble light will turn on to indicate the electronic control injection system is power-on
and is ready to work. If the trouble light is off, it indicates that there is no power supply in the electronic
control injection circuit and thus it cannot work. In this case, check the fuse and the connection of both
positive and negative electrodes of the storage battery. After the engine has been started, if the trouble light
turns off, it indicates that there is no fault; otherwise, if the trouble light is still on, it indicates that the
electronic control injection system is abnormal and it is necessary to remove the faults.
There are three methods for fault detection:

16.3.1 Direct Diagnosis through the Flickering Trouble Light (FI) on
the Instrument Panel
When any fault is confirmed, by switching the key for three times, i.e., turning the key on-off-on-off-on,
the trouble light will flash in corresponding fault code. Then check the fault code list for the breakdown in
correspondence.
In case of reading faults with the trouble light, the rules of flash codes are illustrated as below. Take the
open circuit of intake pressure sensor or short circuit of signal end pin to the negative electrode of the battery
as an example, after the key has been switched for three times, the trouble light will flash 10 times standing for
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0, flash once after 1.2 seconds standing for 1, flash 10 times after another 1.2 seconds standing for 0 and flash
7 times after another 1.2 seconds standing for 7, that is P0107. It shows that, except the number 0 is
represented by flashing for 10 times, other numbers from 1 to 9 will flash as the number itself shows. If there
are other fault codes, such as fault P0201, a fault in the fuel injector of front cylinder, the light of fault code
P0201 will flash in 3.2 seconds after the flashing of P0107. The trouble lights of P0107 and P0201 will flash
circularly in case of no other fault. Then faults can be checked according to the fault code list.
Decimal number will be adopted to show the fault code in PCHUD software. The decimal number in the fault
code list is corresponded to the previous hexadecimal, thus faults can be found out in correspondence. If
MULFCURR (current fault) =263, the corresponding fault code in the fault code list is P0107, i.e., a fault of
intake pressure sensor.
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MT05 Fault Code List

Corresponding
Fault code
Description
decimal number
P0107
open circuit of intake pressure sensor or short circuit of signal end

pin to the negative electrode of the battery
263
P0108
short circuit of signal end pin of the intake pressure sensor to the
positive electrode of the battery
264
P0112
short circuit of signal end pin of the intake temperature sensor to

the negative electrode of the battery
274
P0113
open circuit of intake temperature sensor or short circuit of signal

end pin to the positive electrode of the battery
275
P0117
short circuit of signal end pin of the cylinder end temperature

sensor to the negative electrode of the battery
279
P0118
open circuit of cylinder end temperature sensor or short circuit of

signal end pin to the positive electrode of the battery
280
P0122
open circuit of throttle position sensor or short circuit of signal

end pin to the negative electrode of the battery
290
P0123
short circuit of signal end pin of the throttle position sensor to the
positive electrode of the battery
291
P0131
short circuit of signal end pin of the front cylinder oxygen sensor
to the negative electrode of the battery
305
P0132
short circuit of signal end pin of the front cylinder oxygen sensor
to the positive electrode of the battery
306
P0031
short circuit of heating end pin of the front cylinder oxygen sensor
50
P0032
short circuit of heating end pin of the front cylinder oxygen sensor
49
P0201
fault of for fuel injector front cylinder
513
P0202
fault of for fuel injector rear cylinder (plug-in device of the fuel
injector is not plugged)
514
P0230
open circuit of oil pump or short circuit to the negative electrode

of the battery
560
P0232
short circuit of oil pump to the positive electrode of the battery
562
P0336
signal interference of crank shaft position sensor
822
P0337
no signal of crank shaft position sensor
823
P0351
fault of ignition coil for front cylinder
849
P0352
fault of ignition coil for rear cylinder
850
P0562
voltage below level of electronic control injection system
1378
P0563
overtension of electronic control injection system
1379
P0560
fault of trouble light (damage of filament or plug-in device)
1616
P1693
short circuit of tachometer line to the negative electrode of the
5779
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battery
P1694
short circuit of tachometer line to the positive electrode of the

battery
5780
P0137
short circuit of signal end pin of the rear cylinder oxygen sensor
311
P0138
short circuit of signal end pin of the rear cylinder oxygen sensor
312
P0038
short circuit of heating end pin of the rear cylinder oxygen sensor
56
P0037
short circuit of heating end pin of the rear cylinder oxygen sensor
55
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16.3.2 Fault Diagnosis by Diagnostic Apparatus
Operation steps
a) Find the 6-hole diagnostic port on the motorcycle.
b) Connect the connecting line to the port on the diagnostic apparatus.
c) Turn on the key to diagnose the faults.
16.3.3 Fault Diagnosis with the Diagnostic Software PCHUD

PCHUD software is used to inspect and record the operating data of the engine. Before using the software,
connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line. The notebook
computer needs to install the K line driver software before using.
- 196 -
Instructions of PCHUD Software:

1Connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line and turn on
the key.
2Click the icon "HUD.EXE" to start PCHUD software
3Select "File" on the software interface, click "Open", choose "PCHUD.HAD" and select OK.
4Select "Parameter File" within "Setup", click the file MT05COMMON.par, choose "Comm protocol"
within "Setup", then select "Keywork2000" and click OK, meanwhile, choose 17 in Device Code.
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5If the real-time communication data fail to display on the soft ware interface when the power is on, check
whether the connection setting of COM port in "Setup". Under the normal circumstance, set COM Port: 4 and
Baud Rate: 10400, instead of DTR High at startup.
Normal communication is ready to make then. Current fault code is displayed in the position of MALFCURR
and historical fault code displayed on MALFHIST.
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Then check the corresponding fault according to the fault code list
- 199 -
Interpretation of PCHUD Software Parameter

VRPM
engine speed
VTHROT
throtle position
VBARO
BARO
manifold air pressure
expect manifold air pressure
ignition key voltage
cylinder temperature or coolant temperature
intake air temperature
STATUSBYTE5
VAFCMET
airflow correction met
VBAROCMET
Baro update met
sequential spark enable
tip-in
tip-in Spark Advance retard trigger
catlyst light-off logic enable
engine work in run state
stable warm idle
O2 ready
block learn memory cell
cylinder 1 block learn memory
FCLCINT1
intergral of close loop correction
FCLCMUL1
close loop correction
IARDRPM
desired idle rpm
IARPMERR
idle rpm error
FPWVC1
base pulse width of cylinder 1
VO2
Oxygen sensor signal
STATUSBYTE3
FO2STAT1
cylinder 1 oxygen sensor signal rich lean state
FCLREST1
cylinder 1 close loop correction reset
VMAP
VMAPEXP
VIGN
VCLTS
VIAT
STATUSBYTE5
VCSINSYNSPRK
SATITRIG
CATLOENB
IF ENGSTATE=3
NISTBLIDLE
FO2REDY2
FCNO
FBLMCOR1
STATUSBYTE3
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FOSHTREN
Oxygen sensor heater enable
FO2REDY1
cylinder 1 Oxygen sensor ready
idle airflow control valve close loop correction enable
IACV lost
IACV move disable
ignition state
cylinder 1 Volumetric efficiency
MAP read angle
target air fuel ratio
SAESTA
cylinder 1 Spark Advance
SAIDLDYN
idle dynamic Spark Advance
SPDWELL
dwell time
airflow integral of idle air control valve
desired position of idld air control valve
STATUSBYTE2
FCLCEN1
cylinder 1 close loop correction enable
PPDSEBL
prime pulse disable
FPENABL
fuel pump enable
FTRNSAES
acceleration enrich enter
FTRNSDES
deceleration enlean enter
FTRNSAEDCLOAD
acceleration enrich exit
FTRNSDEINLOAD
deceleration enlean exit
cylinder 2 close loop correction enable
IF IACV MODE=0
IAMTRLOST
IACMVIHB
VIGNS
FVE1
VMAPRANG
AFFNLAFR
IAINTEGOFST
IACVDSMP
STATUSBYTE2
FCLCEN2
- 201 -
16.4 Common Fault Removal Techniques

16.4.1 Repair Tools
a)
Disassembling the parts of the electronic control system- common disassembly tools for auto machinery
parts
b)
c)
Circuit of the electronic control system and its electrical signal- digital multimeter (with beep)
Diagnosing the faults in the electronic control system and checking the engine's operation
Fault diagnostic apparatus for electronic control system(recommended)
Fault diagnosis software(PCHUD) and port wire( if available)
d)
Fault code list of the electronic control system( for emergency)
e)
Fuel pressure gauge, range: 0 ~ 300kPa
16.4.2 The Operation Data Flow of the Engine Shown on the

Diagnostic Apparatus
Analyze and check the faults in engine through the operation data flow of the engine shown on the
diagnostic apparatus.
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16.4.2.1 Step One

a)
Engine wire harness and vacuum line- may influence the system in controlling air flow and oil supply.
b)
Assembly of Oxygen sensor- may influence the system in judging the air-fuel ratio.
c)
Engine trouble light- influences the system in fault warning.
d)
Storage battery voltage- judges whether the battery power is adequate.
e)
According to the experience, judge whether the readings of coolant temperature sensor, air intake
temperature sensor, manifold absolute pressure sensor and oxygen sensor are normal.
f)
Working range of throttle position sensor- Failure in completely turning on or off the sensor may
influence the power performance of the engine and part of system function.
16.4.2.2 Step Two

Check whether the power supply of ECU is cut off- the communication between the diagnostic apparatus
and the system halts after turning off the key switch.
16.4.2.3 Step Three

a)
Coolant temperature and its cycling- indicate whether the thermostat operates normally.
b)
Storage battery voltage- shows whether the generator works normally.

Too high: maybe a fault in the generator regulator.
Too lowmaybe the inappropriate connection of generator wires or a fault in the generator
c)
Manifold air pressure- may indicate whether there is an intake air leak or an air valve clearance
The air valve clearance is too small: the overhigh figure may influence the power performance of the
engine. Meanwhile, because the exhaust valve opens too early, the increased temperature of the exhausted
air will significantly reduce the service lives of oxygen sensor and ternary catalytic converter.
The air valve clearance is too large: may cause the manifold air pressure become low, thus influencing the
system in judging the engine's operation and leading to abnormal idling in the engine's warming-up.
Besides, the clogged exhaust system, e.g., foreign materials in the exhaust passage, or the blocked ternary
catalytic converter caused by the over-consumption of the engine oil, or damaged pieces inside of the
ternary catalytic converter, will lead to an overhigh figure.
d)
Cycle number of the oxygen sensor reading- a small cycle number indicates the failure of the oxygen
sensor.
16.4.3 Concise Fault Removal Techniques

Please take the following steps to repair the electronic control injection system. If the fault is removed in
a certain step, the following steps can be suspended. Then check and remove the fault code by diagnostic
apparatus in compliance with the term 14.4.2.
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When using the diagnostic apparatus, the storage battery voltage cannot be lower than 8.5V.
16.4.3.1 Daily Use and Maintenance
Unleaded gasoline #92 or #95 is strongly recommended.
Though ECU is damp-proof, it is forbidden to wash its cover with a high-pressure water gun.
The fuel filter should be replaced every 7,000-10,000km
In common circumstances, the throttle valve should be washed every 10,000km or every 1 year.
16.4.3.2 Fault Description- Startup Failure

a)
Turn the ignition lock to "ON" to check whether the trouble light turns on.
If no
Check the fuse and the ground wire.
Check whether ECU's plug is tightly connected.
Check whether the light and circuit are normal through the inspection function of the
diagnostic apparatus's actuator.
If yes
b)
Check and repair the light and its circuit.
Make the judgment with another ECU.
Connect the diagnostic apparatus to the system's diagnostic port.
Whether the diagnostic apparatus can be connected to the system for communication
If no:
If yes:
c)
Check the fuse and the ground wire
Check whether ECU's plug is tightly connected
Check whether the diagnostic apparatus works normally on another normal motorcycle.
Remove the fault shown by the diagnostic apparatus.
Check the faults in the ignition system- whether the spark plug can ignite normally
If no:
If yes:
Check whether the high-tension cable and spark plug are connected tightly or are damaged.
Make the judgment with another ignition coil assembly
Check whether the high-tension cable is connected with the ignition coil and spark plug in a
correct way
d)
Check the faults in the oil supply system

Whether the fuel pump is working- the working noise of the fuel pump can be heard in its nearby when
starting the engine.

If no:
If yes:
Check whether the fuel pump relay works normally.
Check whether the connection of crankshaft position sensor and its operation are normal.
Check the fuel pump circuit
1) Whether the supplied oil pressure is above 220Kpa

2) Inadequate
Check whether there is enough gasoline in the fuel tank

- 204 -
pressure
Check whether it is necessary to replace the fuel filter (note: the special
fuel filter for the electronic control injector should be replaced every
7,000-10,000km)
3) Normal
pressure
e)
Whether the oil supply line and oil return line are damaged
Check whether the nozzle control line is abnormal
Whether it is necessary to clean the oil nozzle
Check whether the cylinder is flooded with oil
If yes
Press the accelerator pedal to the limit and turn on the starter. After several seconds, there
will be a sign showing the engine running.
f)
Whether the clearance of crankshaft position sensor is too large
16.4.3.3 Fault Description- Startup Failure Accompanied with Backfire

a)
Check whether the high-tension cable of ignition coil is loose
b)
Whether the timing gear is loose.
16.4.3.4 Fault Description- Unstable Idle Speed

Idle speed control
system:
Check whether the idle speed by-pass bolt is too loose or tight. Usually it is necessary to
screw 2 turns.
Oil supply system
Whether there is an oil pipeline leak
16.4.3.5
Fault
Description-
Too
High/Low
Idle
Speed
(Apparent
Non-conformity to Target Idle Speed)

Idle speed
is too high:
Idle speed
is too low:
When the water temperature is lower than 68, the system will increase the idle speed to
accelerate the warming up. Besides this normal process, check according to the following
steps.
Check whether the idle air bypass hole is too large.
Check whether the air valve clearance, especially the exhaust valve clearance, is too
large.
Check the oil amount in the fuel tank, the fuel filter, the oil line pressure and the oil
nozzle.
Check whether the idle air bypass hole is too tiny.
Check whether the air valve clearance is too small.
- 205 -
16.4.3.6 Fault Description- Unstable Idle Speed Slowing Down with Flameout
a)
Check the valve clearance
b)
Check whether the idle air bypass hole and throttle body are too dirty
16.4.3.7 Fault Description-Poor Acceleration

a)
Whether the parameters at idle speed and high idle speed are normal
b)
Check the oil amount in the fuel tank, and fuel filter.
c)
Check whether the exhaust system is blocked, e.g., whether the ternary catalytic converter is clogged
because of burning engine oil or damages.
d)
Check the oil line pressure and the oil nozzle.
e)
Check whether the trouble light turns on and whether it is because only one cylinder can work normally
to ignite.
16.4.3.8 Fault Description- Little Misfire

Check whether the spark plug gap meets the standard between 0.7-1mm.
16.4.3.9 Fault Description- Non-conformity between Fault Code and Fault

When Trouble Light is On
The ground wire of the system may be not connected well. Reconnect the ground wire, turn off the
storage battery power line for 3 minutes and turn it on, then start the engine.
16.4.3.10 Fault Description- Abnormally High Oil Consumption

a)
Check the assembly of the oxygen sensor of two cylinders. If it is in a loose state, the oxygen sensor will
make a wrong judgment of the slight lean burn in the cylinders, and thus add more fuel, leading to
abnormally high oil consumption.
b)
When the engine's mechanical parts and the oxygen sensor are confirmed to be normal, start the engine to
check the reading of the oxygen sensor. If the reading is always above 500 mV in a normal water
temperature, check whether there is a leakage in the oil nozzle.
Note
Most parts of electronic control injection system are non-repairable. Once a part is damaged, usually it
needs to be replaced.
When starting the engine, do not run any other organs of the engine (including the throttle, do not push
the throttle in the startup).
- 206 -
If the engine trouble light turns on when the engine is operating, it is necessary to check the reason and
remove the fault as early as possible.
Do not use leaded gasoline for lead will do harm to the oxygen sensor and ternary catalytic converter.
When there is an abnormal consumption of the engine oil, the fault should be removed as soon as possible,
or some substances in the engine oil will also do harm to the oxygen sensor and ternary catalytic
converter.
The air valve clearance should not be too small. If the air valve does not tightly shut off in the exhaust
process, the exhaust temperature will be too high so that the service life of ternary catalytic converter will
be reduced.
When the temperature is lower than 10, if the motorcycle and the engine run at a low speed for a long
time, the exhaust pipe may have carbon deposits and appear to be black. This is a normal phenomenon. It
will disappear after the engine operates at a high speed for some time or by adopting appropriate methods
to keep the engine coolant temperature in a specified range
- 207 -
RK6 Circuit Diagram
/ /
/ /
10A

10A
15A
ECU1
15A
10A

1 / 1 / / / /
/
2# Gr ECU J1
IN5408
30A
15A
ECU2
2#BLACK ECU J2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
/ /
/
/
/
/
/ / /
/
/
/
/ /
/ 1
// / / /
11

/ / /

/ / /1
/ / /
/1 / / / /
/
/
/ / / / / / /
/ / /
/ / /
/ /
/2
/2
/2
/
/
/
/1 / /
/1
/ /
/1
/
/
/
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
/2
/
/
/
/
/
/
/
/
/
/2
/2
/2
/
/
/2
/
/
/
/
/2
/2
/
/
/
/
/2
/2
/2
/
/
/2
/
/2
/2
/2
/
/1
/2
/
/
/
/2
/
/1
/1
/
/1
/1
/
/ /1 /
/ / / / /
/
/1
/ / /
/ / /
/ /
/ / /
/ / /
3 2 1
103
12 3

/ / / /

/
/
1
1

/
/
1
1

/ /
1 1

/ /
1 1
/ / / /
1 1

/ /

/ / /

/ / /
1 1

/ / / /
11 1
/ /

/ /
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1#Gr ECU J1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1#BLACK ECU J2

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RK6 Service Manual

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Service manual of RK6

KEEWAY Motorcycle Corporation Ltd.

Solvent or oil can easily damage aging rubber articles. Check

When loosening assembly parts, please start form outside to

Please specially note important connections before disassembly.

When installing a rubber hose (fuel, vacuum or cooling agent),

groove clip connector

During dismantling ball bearings, one or two (inside & outside)

Bearings will be broken under either

Loose cables threaten electrical safety. Check each cable

2Rivets of the frame sign and the frame, see figure

3The serial number of the engine, see figure

1Tools for repairing the engine

Special socket spanner

Used for assembling/disassembling bolts for flywheels, Fig. 1-3

Clutch clamp holder

Bearing disassembly tools

Bearing assembly tools

Oil seal remover

Handle for dismantling tools

Piston pin pulling device

Piston pin pliers

Socket spanner for spark plug

Clutch thickness measuring device

Cylinder diameter measuring device

Dial indicator, V-block

Measuring the inner diameter of the piston pin, Fig. 1-16

For measuring the bending of the valve rodFig. 1-17

Assembly/disassembly tool for valve catheter

For measuring the external diameter of the valve rodFig. 1-18

Assembly tool for valve catheter

Adjustment tool for valve space

Assembly/disassembly tool for valve spring

Valve catheter reamer

Disassembly tool for crankcase

Table 1-2 (continued)

2Tools for repairing the chassis

Inner hexagon spanner

Magnetic rack, V-block

Screwdriver with striking cap

Tool for assembling oil seal of front fork

Tool for hammering seal of front fork

Steering nut spanner

(1) Ordinary tools for repairing the chassis

(3) Steering nut spanner

3Tools for electric parts

Fig. 1-40 (continued)

Petrol tank capacity

Six variable speed

Adjustment & Inspection

Oil provided to fuel

Test compression pressure

No petrol in the tank

Leakage of cylinder gasket

Intake manifold with air

Disassemble once agian the

Dry spark plug

Wet spark plug

Abnormal adjustment to throttle

Excessive oil injected to fuel

Unsmooth gyration (No speed or weak speed)

Start engine with

Air filter blocked