Brixton BX125 Service Manual Download Page 34

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I Braking System

Maintenance Instruction-------------------1.1

Fault Diagnosis-------------------------------1.2

Front/rear Hydraulic brake-------------1.3

1.1 Maintenance Instructions

Precautions on operation

* Attentions

•

Please do not contaminate braking assembly with oil

while assembly or disassembly.

•

Please use specified detergent to clean the braking

assembly, or it may reduce braking performance.

*Please check braking system before driving your motorcycle.*

1.1.1 Specifications

Items

Standard Value

Service Limit

Items

Standard Value

Service Limit

Front

Special brake fluid

DOT4

Rear

Special brake fluid

for hydraulic brake

DOT4

Hydraulic brake disc

thickness

Hydraulic brake disc

thickness

4.0

3.0

Brake shoe thickness

9mm

4.5mm

Brake shoe thickness

9mm

4.5mm

Hydraulic brake disc

diameter

φ276mm

Hydraulic brake disc

diameter

φ220mm

Hydraulic brake disc

brake surface runout

0.1mm

Hydraulic brake disc

brake surface runout

0.1mm

Oil pumping cylinder

inner diameter

Ф12.mm

Oil pumping cylinder

inner diameter

Ф16mm

Oil pumping piston

outer diameter

Ф12

Oil pumping piston

outer diameter

Ф16mm

Caliper cylinder

inner diameter

Ф25

Caliper cylinder

inner diameter

Ф25mm

Caliper piston outer

diameter

Ф25

Caliper piston outer

diameter

Ф25

KS MOTORCYCLES - http://ksmotorcycles.com

Summary of Contents for BX125

Page 1: ...0 Model BX125 Motorcycle Service Manual ROHENTWURF DRAFT KS MOTORCYCLES http ksmotorcycles com ...

Page 2: ... Data 50 4 2 Fault Diagnosis 51 4 3 Rear Wheel 52 4 4 Rear Shock Absorber 52 4 5 Rear swing arm 53 4 6 Drive Chain 54 V Battery Charging System 58 5 1 Service Data 58 5 2 Fault Diagnosis 59 5 4 Charging System 61 5 5 Voltage current Regulator 62 5 6 Generator Charging and Lighting Coils 63 5 8 Generator Removal 64 VI Ignition System 65 6 1 Service Data 65 6 2 Fault Diagnosis 66 6 3 Ignition System...

Page 3: ...01 12 2 Fault Diagnosis 102 12 3 Crankcase 103 12 4 Clutch 104 12 5 Gearshift Mechanism 110 13 6 Crankshaft Connecting Rod Assembly 111 13 7 Transmission chamber 114 Exhaust System Inspection and Maintenance 117 XIII Exhaust control system 117 13 1 Exhaust control system Guarantee 117 13 2 Periodical Maintenance Instructions 118 13 3 Mechanical Functions of Exhaust Control System 119 13 4 Catalyti...

Page 4: ...This shall be implemented from the time of periodical inspection The parts after Part 1 demonstrate disassembly assembly and main points of inspection of engine finished motorcycle engine and other components System diagrams disassembly drawings maintenance fault diagnosis and explanations are presented before each part when compiled Notes If patterns or structures of the motorcycles change or dif...

Page 5: ...sed site ventilation system shall be used Gasoline Work in well ventilated site Fire and smoking are strictly forbidden in working sites or gasoline storage places Battery Battery electrolyte contains sulfuric acid so do not let the eyes skin clothes infected with electrolyte Once the skin clothes infected with electrolyte thoroughly rinse with water if infected eyes you should immediately go to h...

Page 6: ...cle Before take down or open protecting plate for maintenance work please clean the dirt on external surface of the component or the assembly to prevent the dirt from falling into the engine chassis or braking system After disassembly and before measuring friction please clean the components and purge with air compressor Do not bend or distort during operation to avoid difficult operation or earli...

Page 7: ...efore disassembly The components that are not used any more shall be replaced on time before disassembly Length of bolts and screws are different for assemblies and protecting plates They shall be installed at correct positions If confused just put the bolt inside the hole and see if it matches Fill lubricating grease into the groove during oil seal installation Check if the oil seal is smooth and...

Page 8: ... Install the rubber or plastic dustproof boot back to its originally designed position Disassembly of ball bearing use a tool to push against one or two inner and external bearing races If the force works only on one bearing race whatever inner or external the bearing may be damaged when disassembled and it must be replaced KS MOTORCYCLES http ksmotorcycles com ...

Page 9: ...ent Cover tire of the rear wheel 120 80 17 Drive Train Clutch type Wet multi plate friction type Fuel tank capacity 14L Gearshift pattern Manual Performance Max speed 101 km h Climbing capacity Maximum climbing angle should not be less than 20 degrees Transmission Chain drive Idle speed rpm 1500 100rpm min Electricals Battery capacity type 12V 10AH lead acid type Max torque 11 4N m 7000r min Max p...

Page 10: ...9 BX125 KS MOTORCYCLES http ksmotorcycles com ...

Page 11: ...spark plug for inspection again No gasoline in the gasoline tank Oil tube blockage of gasoline tank injector Oil tube blockage of gasoline pump Tube blockage of fuel tank evaporation control system Blockage of gas filter Insufficient pressure of gasoline pump Failure of spark plug Polluted spark plug Failure of ECU Assembly Failure of trigger Ignition coil wire is disconnected or under short circu...

Page 12: ...e oil is normal Excessive machine oil Check whether the machine oil in crankshaft tank is excessive or polluted Blockage of air filter Failure of gasoline Tube blockage of fuel tank evaporation control system Blockage of exhaust pipe Failure of automatic choke apparatus Failure of throttle Failure of ECU Assembly Failure of trigger Failure of cylinder piston and piston ring Air leakage of cylinder...

Page 13: ...12 Inflexible rotation especially low speed Fault Diagnosis Adjustment Fault Cause KS MOTORCYCLES http ksmotorcycles com ...

Page 14: ...g Improper sparking of spark plug Improper Proper Air aspirated in gasket Failure of ECU Assembly Failure of trigger Gasoline mixture is too thin release screw Gasoline mixture is too thick lock screw Failure of insulation pad Fixed nut of throttle is loosen Insulation pad is broken Negative pressure tube is broken Spark plug is failure of or polluted Failure of ECU Assembly Failure of ignition co...

Page 15: ...ic force due to breaking of spring Good Injector clogged Failure of ECU Assembly Failure of trigger Small quantities of gasoline in the gasoline tank Gasoline tube gasoline filter blockage Tube blockage of fuel tank evaporation control system Failure of automatic oil ring Remove Failure of spring KS MOTORCYCLES http ksmotorcycles com ...

Page 16: ...d negative pole lines and connecting it to the vehicle body Check the voltage between the pole lines and the vehicle body when connecting the red line of the voltage regulator socket to multimeter positive and negative pole lines and connecting it to the vehicle body Failure of charging and overcharge Normal Poor contact Check whether the wiring of the voltage regulator is properly contacted Test ...

Page 17: ... value Normal Abnormal Abnormal Normal Related position inspection Check whether the ECU assembly plug is loose Normal Abnormal Abnormal Use ECU tester to check the ignition coil Use ECU tester to check the ECU assembly Failure of original spark plug Spark plug Poor contact of plug Failure of main switch Failure of charge coil Failure of trigger Failure of ignition coil Breakage of main wiring Poo...

Page 18: ...tem bearing and handlebar fixation Cylinder pressure Drive chain Basic Data General Precautions Warning Before running the engine please make sure if the workplace in is well ventilated You shall never run the engine in an enclosed site Gas exhausted from the motorcycle contains carbon monoxide which may lead to loss of consciousness and even death Under certain conditions gasoline is highly volat...

Page 19: ...ths Air cleaner I C C R C Common tool Gasoline filter I C C R C Common tool Engine oil filter C C C C C C Common tool Engine oil replacement R Every 5000KM R Common tool Tire pressure I I I I I I Tire gauge air inflator Battery inspection I I I I I I Densimeter multimeter Actuating stroke inspection I I I I I I Common tool Inspection of steering handle bar looseness I I I I Common tool Shock absor...

Page 20: ...m I Tachometer CO HC analyzer Idle exhaust gas inspection A I A A A A Throttle inspection I I I I I Common tool Fuel hose inspection I I I I I Common tool Lamps instrument and electric apparatus I I I I I I Visual multimeter Main stand and side stand I I I I Common tool Shock absorber I I I I Common tool Torque of engine bolt I I I I I Torque wrench KS MOTORCYCLES http ksmotorcycles com ...

Page 21: ...nmental Protection Agency Normal maintenance shall be performed according to specifications on the user s manual unauthorized repair and adjustment are forbidden We will not be responsible for the results 2 You shall clean more frequently the air cleaner to extend its service life when your motorcycle is used on sand gravel roads or in severely polluted environment 3 More frequent servicing may be...

Page 22: ...f there is engine oil leakage Start the engine and run the engine on idle for 3 minutes Check engine oil level again Gasoline filter Inspect the deterioration and damage for fuel pipe Replace in case of deterioration damage or fuel leakage Warning No smoke no fire Throttle cable inspection and adjustment Check if the throttle cable is unhindered Check stroke of throttle cable Stroke shall be 2 6mm...

Page 23: ... the air cleaner Check the contamination and damage of paper element If the filter is contaminated or damaged if necessary replace it with a new one If it is contaminated replace it with a new one Replacing Time If driving under adverse conditions or in rainy days frequently replace the air cleaner earlier Attentions Check whether the air cleaner is installed in place before installing the air cle...

Page 24: ...23 Spark plug Remove the spark plug cap Remove the spark plug with a spark plug socket KS MOTORCYCLES http ksmotorcycles com ...

Page 25: ...st and then the positive lead wire Take out the battery Warning During positive lead wire disconnection be sure to prevent the tools being used from touching the frame or it will result in short circuit sparks which may ignite gasoline and damage battery It is dangerous Install the battery in reverse order of removal Warning To avoid short circuit please connect positive lead wire first and then t...

Page 26: ... charger switch first before or after charging in case sparks may be generated at connection parts which may result in explosion During charging please take the current time labeled on the battery as the basic time Attentions Battery quick charging is not recommended except in case of emergency After charging wait at least 30minutes and then measure the battery voltage Charging current Standard 0 ...

Page 27: ...n adjust idle speed Run the engine and connect engine tachometer Adjust the throttle cable lock screw to specified RPM Idle speed RPM 1400 100rpm min If idle speed RPM is unsteady or idle speed is not smooth when the vehicle is gently accelerated adjust idle speed and adjust screws again KS MOTORCYCLES http ksmotorcycles com ...

Page 28: ...1 Prop up the motorcycle with a support 2 Unscrew the rear shaft nut 3 Unscrew the locknut 4 Rotate the adjustment bolt to the right and left to adjust the chain slackness keep the front rear sprockets align the center in a straight line when adjusting the chains To help you make this adjustment process there are reference marks on the swing arms and chain regulators and these reference marks can ...

Page 29: ... install worn drive chains onto the new sprockets Keep both sprocket and drive chain in good conditions or newly replaced chain or sprocket will be worn soon Stroke of front rear brake Front brake stroke Measure stroke of front brake at the tip of front brake handle Stroke 10 20mm Brake pedal stroke Measure stroke of brake pedal at the tip of front brake handle Stroke 20 30mm Adjust the stroke of ...

Page 30: ...e the brake shoe Headlamp Adjustment Unscrew the mounting bolts of headlamp to adjust the headlight optical axis Clutch Start the engine speed up the revolving speed slowly and check the clutch s operating condition Check the friction block of the clutch if the motorcycle does not run or the engine is stalled Replace it with a new one if necessary Stroke of clutch 10 20mm Adjust the stroke of clut...

Page 31: ...e rear shock absorber are loosened or injured Lift and support the rear wheel and swing the wheel to check if engine suspension bushing is loosened Nuts bolts fasteners Inspect whether bolts nuts and fasteners at every part of the motorcycle are loosened If they are loosened tighten them to specified torque Wheel rim tire Check whether there are cracks nails and similar sharp objects and other inj...

Page 32: ...may lead to tire deflation caused by control failure Driving a motorcycle at excessive tire wear situation is a dangerous thing as the adhesive force of the tire is lower than the normal Check whether the front axle fixing nut is loose Check whether the rear axle fixing nut is loose If it is loose it shall be tightened to the specified torque value Torque value front axle 75 85N m Rear axle nut 75...

Page 33: ...te 1 4 Front disc brake hose 1 1 17 Rear disc brake caliper assembly 1 5 Front disc brake upper pump 1 18 Front disc brake lower pump assembly 1 6 Bolt M6 25 1 19 Front disc brake support 1 7 Front disc brake handle 1 20 Bolt M10 35 1 8 Disc brake half overlay 1 21 Front disc brake pad 1 9 Rear disc brake hose 1 1 22 Rear disc brake pad 1 10 Rear disc brake switch 1 23 Bolt M6 16 1 11 Rear disc br...

Page 34: ...id DOT4 Rear Special brake fluid for hydraulic brake DOT4 Hydraulic brake disc thickness 4 3 Hydraulic brake disc thickness 4 0 3 0 Brake shoe thickness 9mm 4 5mm Brake shoe thickness 9mm 4 5mm Hydraulic brake disc diameter φ276mm Hydraulic brake disc diameter φ220mm Hydraulic brake disc brake surface runout 0 1mm Hydraulic brake disc brake surface runout 0 1mm Oil pumping cylinder inner diameter ...

Page 35: ...nd hydraulic brake disc Improper installation of braking shoe assembly Contamination of braking shoe assembly and hydraulic brake disc 1 2 2 Brake drags or tight handle Improper brake adjustment Wearing of braking shoe assembly and hydraulic brake disc Improper installation of braking shoe assembly 1 2 2 Noisy Braking Wearing of braking shoe assembly and hydraulic brake disc Contamination of braki...

Page 36: ... 5 2 7Hard Brake Handle Pedal Braking system clogged restricted Caliper piston adhesion abrasion Improper sliding of caliper Brake fluid pipe clogged restricted Caliper piston seal wear Master cylinder piston adhesion abrasion Brake pedal disc bending 1 3 Front Hydraulic Brake 1 3 1 Removal Attentions Replacement of brake shoe assembly group If the brake shoe is reused it shall be marked on its si...

Page 37: ...isc from the front wheel 1 3 2 Inspection Check whether the braking shoe is worn out Replace the braking shoe if necessary Measure the braking shoe and brake disc and record the maximum value Measure the thickness of braking shoe Allowable limit brake shoe 4 5mm Specifications Diameter of front hydraulic brake disc φ276mm Attentions The brake disc shall be wrapped with 120 abrasive paper in case o...

Page 38: ... brake lower pump mounting bolts 25 35N m Front hydraulic brake oil pump mounting bolts 7 9N m Front axle 75 85N m 1 4 Rear Hydraulic Brake 1 4 1 Removal Remove the rear brake oil pump body assembly Remove the brake cylinder assembly of rear brake Remove the rear wheel Remove the brake discs from the rear wheel hub Note The brake disc cannot be removed if necessary please remove it after heating A...

Page 39: ... Attentions If the hydraulic brake disc is rusty please polish it with 120 abrasive paper A micrometer shall be used for the measurement If the brake disc and braking shoe are contaminated by grease or their thickness is smaller than the service limit replace them Attentions The vernier caliper and micrometer shall be used for the measurement 1 4 3 Installation Install the rear wheel Install the r...

Page 40: ...le Exteriors Disassemble the motorcycle body in the following sequence Rear view mirror Headlamp Instrument bracket Instrument Front mud fender Seat cushion Left and right cover Fuel tank Left and right pedal Tail lamp Rear mud fender License plate bracket Attentions Do not damage the cover of the motorcycle while removing or installing Do not break the hooks of the cover while removing or install...

Page 41: ...b oil seal 3 Speedometer 6 Front brake disc 4 Front wheel assembly 7 Front axle sleeve 5 Front wheel assembly 8 Front disc brake disc lock sheet 5 1 Front wheel rim 9 Bolt M6 16 5 2 Valve nozzle 10 Front axle self lock nut M14 1 5 5 3 Front hub 11 Axle rubber sleeve 5 4 Front wheel spokes KS MOTORCYCLES http ksmotorcycles com ...

Page 42: ...y from the ground During operation it is important that any grease must not be attached on the braking shoe Reference for motorcycle Reference for motorcycle Measuring position Item Standard value mm Allowable limit mm Front wheel shaft Bending 0 2 Front wheel Wheel rim shimmy Longitudinal direction 2 0 Horizontal direction Not less than 1 0 2 0 Torque force value Tool 方向把固定螺钉 22 29 N m 轴承拆卸杆 Moun...

Page 43: ... deformed Front wheel bearing is worn Front tire has defects Tires or wheels are unbalanced 3 2 4 Wheel failing to rotate Failure of bearing of front wheel shaft Braking failure Failure of wheel shaft Bending of front wheel 3 2 5 Abnormal noises from front shock absorber Inadequate fluid in the shock absorber Friction noise of shock absorber guard Looseness bolts of shock absorber 3 2 6 Only being...

Page 44: ...move the front wheel shaft Remove the front wheel Remove the oil seal and bearing of oil seal remover and shaft bearing replacer 3 3 2 Inspection 3 3 2 1 Inspection of wheel shaft bending Place the wheel shaft onto a V shaped base and the measure eccentricity with a micrometer gauge Service limit replacing in case of exceeding 0 2mm 3 3 2 2 Inspection of wheel disk wobbling Service limit Longitudi...

Page 45: ...ew bearing 3 3 3 Bearing replacement After remove front wheel front wheel shaft and front wheel lining oil seal removing appliance and bearing removing appliance must be used to remove the lower oil seal and bearing respectively Note the removed bearing must be replaced with new bearing During installation apply the lubricating grease onto the bearing And then use the bearing mounting tool to pres...

Page 46: ...ition of speedometer Install the brake disc after the involution of the gear housing assembly of speedometer Attentions The odometer gear housing component will deform if the component is not aligned to the locked front wheel shaft Rotate the wheel after mounting the axle to check whether the drive axle of speedometer to rotate Install the front axle and lock it Torque value Front axle 75 85N m 3 ...

Page 47: ...3 Rear brake return spring 7 1 Clutch cable sleeve 14 Bolt M8 16 8 Clutch handle assembly 3 4 1 Removal Remove front brake handle and left handle assembly Remove the throttle seat and right handlebar assembly Remove the throttle cable assembly Remove the left direction handlebar sleeve Remove the clutch cable assembly and valve cable assembly Remove the mounting bolts of handle and remove the hand...

Page 48: ...le clip 2 7 Nut M8 6 Bolt M6 12 2 8 Steering stem 7 Side reflector 2 9 Steering bearing 8 Front right shock absorber 3 5 1 Removal Remove the front fender Remove the front wheel Remove the brake hose and speedometer cable Remove the front shock absorber Remove the steering fixing nut Remove the steering handle Tools Steering handle fixing screw wrench Fixing nut wrench 3 5 3 Installation Tools Fix...

Page 49: ... Step bolt M8 25 6 5 Rolling bearing 6302 4 Rear brake disc 6 6 Hub seal 5 Rear tire assembly 7 Sprocket 6 Rear wheel assembly 8 Sprocket self lock nut M10 1 25 6 1 Rear rim 9 Real wheel left axle sleeve 6 2 Valve cock 10 Real axle self lock nut M14 1 5 KS MOTORCYCLES http ksmotorcycles com ...

Page 50: ...ft 7 Bolt M6 16 2 Flat fork sleeve 8 Plain washer φ6 3 Flat fork assembly 9 Fanged washer 4 Chain adjuster 10 Chain protecting clamp 5 Drive chain 11 Rear fork dust cover 6 Half chain box 12 Flat fork self lock nut M14 1 5 KS MOTORCYCLES http ksmotorcycles com ...

Page 51: ... Data Precautions Any grease spot is not allowed on the brake disk and brake shoe Reference Item Standard value mm Allowable limit mm Rear wheel wobbling Longitudinal 2 0 Horizontal 2 0 Locking torque force Nut rear wheel shaft 75 85N m Top nut rear shock absorber 35 45 N m Bottom nut rear shock absorber 35 45 N m KS MOTORCYCLES http ksmotorcycles com ...

Page 52: ...chain 4 2 3 Spongy suspension Shock absorber spring is not firm with shake Front suspension regulator is incorrect Oil leakage occurs to shock absorber Tire pressure is too low 4 2 4 Hard suspension Assembly bearing on the shock absorber is damaged Shock absorber cylinder is bent Rear swing arm pivot bearing is damaged Rear swing arm pivot bearing is bent Suspension regulator is incorrect Tire pre...

Page 53: ...centricity with a micrometer gauge Allowable limit Longitudinal direction replacing in case of exceeding 2 0mm Horizontal direction replacing in case of exceeding 2 0mm If the rear wheel wobbling exceeds the allowable limit the rear wheel bearing is loosened and the rear wheel is bent Replace the rear wheel shaft after inspection 4 3 3 Installation Install the rear wheel in reverse sequence of dis...

Page 54: ...wer mounting bolt on the rear shock absorber Lock to the specified torque value Torque value Upper fixing nut 35 45N m Lowe fixing nut 35 45N m 4 5 Rear swing arm 4 5 1 Disassemble the rear swing arm Disassemble the chain guard plate Disassemble the chain tensioning wheel and the rear axle shaft Disassemble the rear wheel and the rear shock absorber Disassemble the rear swing arm installation shaf...

Page 55: ...curely Remove the shifting lever arm left rear cover and drive sprocket Remove the rear wheel chain guard and chain drive 4 5 2 Inspection Clean the drive chain put it into kerosene brush the dirt and then take out the chain from the kerosene and make it dry Check the roller and side panel if damaged or worn replace the drive chain Lubricate the drive chain with the lubricant purchased from the st...

Page 56: ...ke adjustment Unscrew the rear axle nut Adjust the drive chain slack The adjustment steps include Unscrew the lock nut screw or unscrew the adjustment device until the slack meets the specified value Screw the slack may increase Unscrew the slack may reduce Attentions Finally tighten the lock nut 4 5 4 Installation Installation must be initiated in the reverse sequence of removal Adjust the loosen...

Page 57: ...56 Maintain the chain looseness within the specified limits KS MOTORCYCLES http ksmotorcycles com ...

Page 58: ...57 Inspection and Maintenance of Electrical System Charging system KS MOTORCYCLES http ksmotorcycles com ...

Page 59: ...rs inside the battery voltage or very low voltage on the terminals of the battery cannot be inspected If the regulator fails it will have too high voltage on the battery and the life span of the battery will be shortened 3 When the battery is laid aside for a long period it will self discharge and its capacitance will drop The battery should be recharged every three months 5 Charging system inspec...

Page 60: ... current Standard 0 9A Quick 9A Charging time Standard 10 15hours Quick 30minutes Magneto Capacity 150W 1500rpm Coiling impedance value 20 White white 0 5 10Ω Voltage regulator Type Full wave rectification Battery charging voltage 14 5V 0 4V 5 000rpm Tightening torque value Tools Rectifier bolt 5 0 N m Universal non adjustable spanner High voltage coil pinch bolt 9 0 N m Flywheel remover Testing d...

Page 61: ...onnection be sure to prevent the tools being used from touching the frame or it will result in short circuit sparks which may ignite gasoline and damage battery It is dangerous Install the battery in the reverse order of removal Attentions To avoid short circuit please connect positive lead wire first and then the negative lead wire Battery charging open circuit voltage inspection Open the seat cu...

Page 62: ...time Attentions Battery quick charging is not recommended except in case of emergency After charging measure the battery voltage in 30minutes time Charging current Standard 0 4A Quick charging 4 0A Charging time Standard 10 15 hours Quick charging 30 minutes Charging completed open circuit voltage higher than 12 8V 5 4 Charging System 5 4 1 Short circuit test Disconnect the grounding wire from the...

Page 63: ...ns A multimeter shall be set at AC voltage Limited voltage 13 5 0 5V 5 000rpm If limited voltage is beyond the specified range check the voltage and current regulator 5 5 Voltage current Regulator 5 5 1 Loop inspection on main wiring terminals Disconnect the 6P plug on the voltage current regulator Check continuity between main wiring terminals in the following way Item wire color Judgment Between...

Page 64: ...e regulator shall be replaced Multimeter Positive Negative Yellow 1 Yellow 2 Yellow 3 Black Red Unit MΩ Yellow 1 0 1 3 0 1 3 None None Yellow 2 0 1 3 0 1 3 None None Yellow 3 0 1 3 0 1 3 None None Black None None None None Red None None None None 5 6 Generator Charging and Lighting Coils Attentions Inspection of generator charging coil can be performed on the engine Inspection Disconnect the 4P co...

Page 65: ... flywheel puller Disassemble the fixed key Disassemble the generator wire joint Disassemble the generator stator 5 8 2 Installation Install the generator stator onto the engine crankcase Connect the generator terminal Clean the taper of the crankshaft and the flywheel Install the fixed key of the flywheel into the groove on the crankshaft and confirm whether it is properly installed KS MOTORCYCLES...

Page 66: ...listed in the fault diagnosis table 2 The ignition system is solidified in the ECU assembly so ignition time adjustment is unnecessary 3 Ignition system inspection please perform inspection in accordance with the sequence listed in the fault diagnosis table 4 Ignition system ECU shall not be dropped and hung or heavily knocked this is also the main reason for its failure Pay special attention to t...

Page 67: ... Impedance value of trigger 20 100 200Ω Ignition coil primary peak voltage 95 400V Trigger voltage 1 7V 以上工具 Tools Accessories for maximum voltmeter Multimeter 6 2 Fault Diagnosis No sparking of spark plug Ignition coil Symptom Possible causes Determine the cause from 1 in sequence When the high voltage power is too low When inner impedance is too small use the appointed tester to test Crankshaft...

Page 68: ...o test Crankshaft rpm is too low Tester is disturbed it is normal when more than one time s measured voltage is above the basic Poor charging coils when items are proved normal No high voltage power supply or high voltage power is sporadic Poor ignition coil Poor charging coil Trigger High voltage power supply is too low Inner impedance is too low Use appointed tester to test Crankshaft rpm is too...

Page 69: ...oil and a shunt is connected between terminal black white of primary coil and grounding wire of vehicle block Press starter motor button or kick starter pedal to measure primary peak voltage of ignition coil Min voltage higher than 95V Attentions Please do not touch the metal parts of testing probe with your fingers while measuring voltage or you will be shocked Please take care 6 3 2 Charging and...

Page 70: ...nition coil Install it in the reverse order of removal Attentions 一 The primary coil is installed with black white wire connector 6 4 2 Primary coil inspection Measure impedance between terminals of primary coil Standard value 0 4Ω 10 20 Impedance value within the range is good Impedance value indicates broken wire inside the coil The coil shall be replaced 6 4 3 Secondary coil Provided with a spa...

Page 71: ...green white line measure the resistance Connection mode see the right figure Resistance 125 20Ω VII Starting System Service Data 7 1 Fault Diagnosis 7 2 Starter Motor 7 3 Starter Relay 7 4 7 1 Service Data Precautions on operation Starter motor removal can be performed on the engine Removal refers to removal instructions Basic data Item Standard Service Limit Length of starter motor electric carbo...

Page 72: ...or motor gear stuck by Low battery Defective starter clutch foreign substances Defective braking switch Defective starter relay Defective connecting wire contact Defective starter motor 7 3 Starter Motor 7 3 1 Removal Attentions Before removing starter motor the ignition switch must be set at OFF position Disconnect battery grounding wire and then turn on the power supply to check if the starter m...

Page 73: ...rmality exits Inspect carbon brush holder for continuity If there is continuity replace it Measure carbon brush length Service limit replace it when it is shorter than 8 5mm Check rotation smoothness of the needle bearing in the front cover and whether it is loosened when it is pressed in If there is abnormality replace it with a new one Check whether the oil seal is worn or damaged 7 3 4 Assembly...

Page 74: ...1 Actuation Inspection Remove the right cover When the ignition switch is set at ON position press starter motor and a Click sound can be heard Click sound indicates normal No sound Check starter relay voltage Check starter relay ground wire loop Inspect starter relay actuation 7 4 2 Starter relay voltage inspection Lift and support the main stand Measure the voltage between negative pole green ye...

Page 75: ... vehicle ground wire shall be fine If there is no continuity inspect starter button continuity and lead wire 7 4 4 Actuation inspection Connect starter relay with battery and connect terminal of starter motor with multimeter Connect fully charged battery between black wire and green yellow wire of relay A tap sound of operation can be heard on the relay and resistance displayed by multimeter is ze...

Page 76: ... Turning Signal Lamp Bulb Replacement 8 5 Instrument 8 6 Main switch 8 7 Electric Horn 8 8 Handle Switch 8 9 8 1 Service Data Precautions on operation Remove switches from the motorcycle and perform continuity test 8 2 Fault Diagnosis ON lamp of main switch is not lit Defective bulb Defective switch Poor contact of connector or broken wire KS MOTORCYCLES http ksmotorcycles com ...

Page 77: ...nt turn signal light 8 4 1 Removal Loosen the light fixing screw Take off the light 8 4 2 Installation Install the light back in the reverse order of removal 8 5 Replacement of taillight license plate light rear turn signal light 8 5 1 Removal Remove the screws and take off the lampshade Remove the bulb from the socket 8 5 2 Installation Install the bulb in the reverse order of removal 8 5 3 Repla...

Page 78: ...t Remove the meter connectors Remove the screws Remove the meters Install the instrument orderly in the reverse order of removal 8 7 Main Switch 8 7 1 Inspection Remove the headlamp Disconnect connector of main switch lead wire Check the connector terminal for continuity 4 7 2 主开关更换拆下车体前护板拆下固定螺栓取下主开关固定座拆下固定螺栓主开关更换 KS MOTORCYCLES http ksmotorcycles com ...

Page 79: ...nds it indicates the horn is in good condition 8 9 Handle Switch Screw off mounting bolt on the brake lever and take down the bracket Remove throttle handle and bolts Take down the throttle handle from the handle and remove the throttle cable Remove mounting bolt on the handle and take down the handle KS MOTORCYCLES http ksmotorcycles com ...

Page 80: ... screw M6 10 15 12 Oil pump mounting screw M6 6 10 13 Rotor cover screw M5 4 6 14 Clutch cover bolt M6 10 15 15 Bearing thrust bolt torque M6 8 12 16 Sprocket bolt torque M6 10 15 17 Gear switch screw M4 1 3 18 Magneto stator bolt M6 5 8 19 Trigger coil bolt M5 4 6 20 Magneto rotator fixing bolt torque M10 40 50 21 Magneto cover bolt M6 10 15 22 Starter motor bolt M6 8 12 23 Cylinder block side bo...

Page 81: ... 34 Starting shaft limit bolt M12 25 30 35 Bearing retainer plate and press plate tightening torque M6 8 12 36 Balance shaft bearing press plate fastening torque M6 8 12 37 Balance shaft nut tightening torque M16 25 35 KS MOTORCYCLES http ksmotorcycles com ...

Page 82: ...ubricating system Engine lubricating system is to supply lubrication oil to friction surface of engine elements Crank pin Oil pan Piston orifice Camshaft hole 2 Camshaft hole1 Main and auxiliary shaft Engine oil filter Engine oil pump Right crank Primary strainer Cylinder head Cylinder body Clutch cover KS MOTORCYCLES http ksmotorcycles com ...

Page 83: ...s important to prevent any foreign matter from falling into crankcase Standard Value and Allowable Limit of Reference Items Item Standard Allowable limit Engine oil capacity For changing oil 1L For disassembly 1 2L Pump rotor Radial stroke between inner and outer rotors Oil pressure pump 0 025 0 175 0 23 Oil suction pump 0 025 0 175 0 23 Stroke between outer rotor and pump Oil pressure pump 0 11 0...

Page 84: ...emove screws remove the oil pump cover and break down oil pump Assembly Assemble in the reverse order of disassembly Inspection Check radial stroke between inner and outer rotors Allowable limit 0 15 mm Check stroke between outer rotor and pump body Allowable limit 0 15 mm Check rotor end surface stroke Allowable limit 0 15 mm 测试规平板测试规测试规 KS MOTORCYCLES http ksmotorcycles com ...

Page 85: ...r head left cover 12 Observation hole cover 4 Hexagon flange bolt 13 Spark plug 5 Crankcase right cover screw washer 14 Cap nut 6 Plain washer copper 15 Plain washer 7 Cross recessed hexagon screw 16 Engine temperature sensor 8 Cylinder head seal gasket 17 Metal plain washer 9 Locating pin KS MOTORCYCLES http ksmotorcycles com ...

Page 86: ...value 30Nm All parts must be cleaned before being checked and purged with high pressure air Standard Value and Allowable Limit of Reference Items Unit mm Item Standard Allowable limit Valve Valve guide Valve stroke Intake 0 04 0 06 Discharge 0 09 0 11 OD valve rod Intake 4 975 4 990 4 955 Discharge 4 955 4 970 4 958 OD valve rod Intake 5 5 012 5 03 Discharge 5 5 012 5 03 Clearance of valve rod and...

Page 87: ...of spark plug Abnormal noise in cylinder head Bad valve stroke adjustment Valve spring damaged Too high compression pressure Too much carbon deposits in combustion chamber 10 3 Cylinder Head Disassembly Loosen the mounting bolts and remove the cylinder head cover swing arm and its shaft Remove the tightener loosen chain and take down the camshaft KS MOTORCYCLES http ksmotorcycles com ...

Page 88: ...emove the screws nuts and remove the cylinder head Remove the tappet compress the valve spring with a valve spring compression tool and remove valve cock clamp Remove the valve adjustment shims valve springs valve spring upper and lower seats and valves 配合轴颈进气凸轮轴排气凸轮轴 KS MOTORCYCLES http ksmotorcycles com ...

Page 89: ...ppet adjustment screw E07 13 Adjusting washer E07 3 2 Valve lash lock nut E07 14 Adjusting washer E07 4 Torsion spring E07 15 Intake valve E07 5 Exhaust valve rocker arm shaft E07 16 Exhaust valve E07 6 Camshaft sprocket E07 17 Intake valve rocker shaft E07 7 Hexagon bolt E07 18 Rocker shaft baffle E07 8 Valve spring plate E07 19 Cross recessed screw E07 9 Valve locking clip KS MOTORCYCLES http ks...

Page 90: ...f valve spring Free length of the inner valve spring 39mm Free length of the outer valve spring 41 8mm Measure the outer diameter of valve rod Allowable limit air inlet Ф4 955 mm Air exhaust Ф4 948 mm Check the valve guide Prior to check use a reamer to eliminate carbon accumulated within the guide Attention the reamer shall be turned clockwise and do not turn it counterclockwise 测试规游标卡尺千分尺 KS M...

Page 91: ...r the guide is replaced trim surface of the valve washer Place the guide into the freezing chamber of electrical refrigerator for one hour cooling Heat the cylinder head to 100 150 with an electric oven or thermal oven Fix cylinder head and use the guide disassembly tool to remove the guide out of the head Place a new O ring onto the new guide Fit the guide from the head top Attention Do not damag...

Page 92: ...valve and thoroughly clean the intake and discharge valves Check width of valve contact surface valve race width Allowable limit Intake discharge 1 6mm Valve Race Fixing and Adjustment Use a 45 cutter to clear coarse or uneven parts on the surface of valve race Notes apply a layer of transparent or Prussian blue coating across the race for more visibility 气门铰刀气门座接触面粗糙不平部位 KS MOTORCYCLES http ksm...

Page 93: ...ace Remove the cutter and check the processed locations Use a 45 trimming cutter to grind the race so that it meets the suitable width Make sure all caves and unevenness are eliminated Standard valve base width Intake 1 1 1 3 mm Discharge 1 0 1 2mm 30 45 0 9mm 70 KS MOTORCYCLES http ksmotorcycles com ...

Page 94: ...in the reverse sequence of disassembly Attentions To install the valve spring it shall be such installed that the end with smaller spring pitch faces the combustion chamber To install valve locking clamp compress the spring with its compression tool To install the valve apply a right amount of engine oil across the valve rod and then place the rod into the guide Valve lash adjustment Install the c...

Page 95: ...S N Name S N Name 1 Cylinder block composition 6 Piston ring combination 2 Cylinder block gasket 7 Piston 3 Cylinder stud B 8 Retainer ring for holes 4 Locating pin 9 Piston pin 5 Cylinder stud KS MOTORCYCLES http ksmotorcycles com ...

Page 96: ...chamber along with the cylinder cover Precautions All parts must be cleaned before being checked and purged with high pressure air Standard Value and Allowable Limit of Reference Items Item Standard value Allowable limit Cylinder ID 57 3 57 301 57 351 Cylindricality 0 007 0 027 Roundness 0 005 0 007 0 025 Flatness 0 05 0 055 Piston OD measuring point 57 270 57 275 57 26 Piston pin hole ID 14 002 1...

Page 97: ...ng worn or damaged Cylinder and piston worn or damaged Abnormal noise from piston Cylinder piston and piston ring damaged Piston pin hole and piston pin worn 12 3 Cylinder Block Disassembly Remove the cylinder block Inspection Check wearing of inner wall of cylinder If serious wearing is found replace it Remove the gasket and locating pin Piston Disassembly Remove the piston retaining ring Attenti...

Page 98: ...nd install the piston rings at the bottom of cylinder Attentions Use the piston head to press the piston ring into the cylinder Measure piston ring closure stroke Allowable limit Ring 1 0 4 mm Ring 2 0 5 mm Measure piston pin hole ID Allowable limit 14 04mm Measure piston pin hole OD Allowable limit Ф13 966mm Stroke between piston pin hole and piston pin Allowable limit 0 062mm 测试规推入活塞活塞环测试规活...

Page 99: ... lower positions at 90 with the piston pin Allowable limit Φ57 351mm Measure the stroke between the cylinder and piston and the maximum value prevails Allowable limit 0 07mm Measure the roundness of cylinder inner wall difference between X ID and Y ID Allowable limit 0 01mm Measure the cylindricality of cylinder inner wall ID difference at the upper middle and lower positions between X and Y Allow...

Page 100: ...t their positions with the marking face upward Attentions Do not scratch the piston and do not break the piston ring After the piston ring is installed the piston ring is capable to rotate within the piston slot freely Clear all of gaskets attached on the crankcase Attentions Any foreign matter shall not fall into the crankcase Install piston piston pin and its retaining ring 连杆小端内径测试规直尺气缸顶环第...

Page 101: ... valve Installation of Cylinder Install the gasket and locating pin on the crankcase Apply engine oil across the cylinder inner wall piston and piston ring Care shall be excised to locate the piston ring into the cylinder Attentions Do not damage piston ring KS MOTORCYCLES http ksmotorcycles com ...

Page 102: ...tion for fear of deformation or breaking All parts must be cleaned before being checked and purged with high pressure air Prior to any operation release lubricating oil from the crankcase Standard Value and Allowable Limit of Reference Items Unit mm Item Standard value Allowable limit Crank linkage assembly clutch Right left stroke of connecting rod large end 0 1 0 30 0 5 Radial stroke of connecti...

Page 103: ...chanism return spring deflation Wear of the spline shaft spline teeth and sliding gear spline groove results in the occurrence of a greater axial force during the working of the gear Wear of shifting drum and fork Abnormal sound from crankcase Scattered or broken parts in crankcase Automatic shutdown of engine Clutch stuck Shifting difficulties Incomplete release of clutch Malfunction of transmiss...

Page 104: ...s and remove the left cover Use electric or pneumatic tools to loosen the flywheel lock nut Pull out the flywheel assembly including star wheel remove the starter motor idler gear Remove the gasket Removal of crankcase right cover Loosen the fixing bolts and remove the crankcase right cover gaskets and locating pin KS MOTORCYCLES http ksmotorcycles com ...

Page 105: ...e Loosen the clutch lock nut with special tools then remove the lock nut and washer Disassemble the clutch center support Disassemble the driving and driven friction plates of clutch Remove the parts as per the disassembly diagram Remove the thrust washer Remove the housing component The clutch is assembled in the reverse order of removal 万能固定器套筒扳手外壳组件 Housing component KS MOTORCYCLES http ksmot...

Page 106: ... spline washer 3 7 Clutch driven plate 3 Clutch hub composition 3 8 Clutch compression disk 3 1 Hexagon flange bolt 4 Lock washer 3 2 Clutch putt disc 5 Lock nut 3 3 Clutch spring 6 Bearing 16003 3 4 Clutch hub 7 Clutch push block 3 5 Clutch driving plate 8 Clutch putt KS MOTORCYCLES http ksmotorcycles com ...

Page 107: ...file Replace the clutch if too much such work needs doing Check whether it is damaged in the dents of the pressure plate and the center bearing support Replace it if it is damaged Measure the free length of the pressure spring Allowable limit replace in case of below 29 7mm 自由长度 KS MOTORCYCLES http ksmotorcycles com ...

Page 108: ...replace in case of below 2 5mm Measure the flatness of the driven friction disc with a plug gauge Allowable limit replace in case of below 0 2mm Measure the thickness of the plane needle roller bearing Allowable limit replace in case of below 1 8mm 厚度 KS MOTORCYCLES http ksmotorcycles com ...

Page 109: ...nt shims 19 1 Balance shaft driven gear inner ring 6 Balance shaft driving wheel 19 2 Balance shaft gear cushion 7 Primary driving gear 19 3 Adjusting washer 8 Primary driving gear spring 19 4 Compression spring 9 Primary driving gear 2 19 5 Straight pin 10 Lock washer 19 6 Circlips for shaft 11 Oil filter combination 20 Bushing 11 1 Oil filter rotor 21 Spherical bearing 11 2 Oil filter cover asse...

Page 110: ...olt 20 Hexagon flange bolt 6 Hexagon flange bolt 21 O ring 7 Oil dipstick 22 O ring 8 O ring 23 Magneto outer cover 9 Clutch release shaft composition 24 Magneto cover 10 Release rod seal 25 Top dead center stopper gasket 11 Spring pin 26 Hexagon flange plug screw 12 Torsion spring 27 Hexagon flange bolt 13 Clutch cable bracket 28 Magneto cover gasket 14 Sprocket cover 29 Locating pin 15 Locating ...

Page 111: ...and the gearshift mechanism Replace it if it is seriously worn Check the wearing of the locating plate of the gearshift Replace it if it is seriously worn Check whether the gearshift shaft is bent Replace it if it is excessively bent Check the elasticity of the restoring spring Replace it if necessary Unscrew the bolt and washer on the right crank shaft with electric or compression tools Remove dr...

Page 112: ...3 6 Crankshaft Connecting Rod Assembly Removal Remove the balance shaft assembly and crankshaft connecting rod assembly from the right crank case Note do not damage the surface of the case Inspection Measure the stroke on the left and right side of the big end of the collecting rod Allowable limit 0 5mm KS MOTORCYCLES http ksmotorcycles com ...

Page 113: ...big end of the connecting rod Allowable limit 0 002 0 010mm Measure the dislocation of the crank shaft Allowable limit 0 03mm Check if the crank shaft is noisy or loose while restoring Replace it if so 曲轴轴承连杆大端测量位置 KS MOTORCYCLES http ksmotorcycles com ...

Page 114: ...fork Remove the gearshift drum Remove the gearshift fork Inspection Measure the shifting fork hole OD Allowable limit 11 95mm Measure the shifting fork hole ID Allowable limit 12 05mm 千分尺测试计 KS MOTORCYCLES http ksmotorcycles com ...

Page 115: ...easure the gearshift drum OD Allowable limit 35 75mm Measure gearshift drum lock groove width Allowable limit 7 35mm 13 7 Transmission chamber Remove the primary shaft assembly Remove the secondary shaft assembly 锁槽宽度游标卡尺主轴组件副轴组件 KS MOTORCYCLES http ksmotorcycles com ...

Page 116: ...eel shim 5 Gear shifting cam positioning plate 15 3 Gearshift shaft return spring 6 Locating pin 15 4 Gearshift shaft composition 7 Needle bearing 15 5 Compression spring 8 Gear shifting cam 15 6 Circlip 9 Compression spring 16 Gearshift fork shaft 10 Cam gear positioning pin 17 Right gearshift fork 11 O ring 18 Intermediate gearshift fork 12 Cross recessed pan head screw 19 Left gearshift fork 13...

Page 117: ...and oil seals replace them if any Attentions Abandon the outgoing bearings and replace with new products Disassemble the bearings and oil seals with special tools Primary Secondary Shaft Assembly Attentions Coat the gears and shafts with lubricating oil when assembling Protect the gears against jamming upon assembly Notes The crankcase is assembled in reverse procedures of removal 齿面传动爪 KS MOTORC...

Page 118: ...iodical Maintenance Instructions Ensuring Emissions Standards 13 2 Mechanical Functions of Exhaust control system 13 3 Catalytic Conversion System 13 4 Solutions to the problem of idle exhaust exceeding specified value 13 5 13 1 Exhaust control system Guarantee 1 This exhaust control system is in accordance with the requirements of 134 2014 EU Our guarantee is set for products in effective service...

Page 119: ... in our company comply with the requirements of 134 2014 EU 13 2 Periodical Maintenance Instructions To prevent deterioration of environmental pollution the government requires all the manufacturers to ensure their products meet the emissions control standards Our products meet those standards We are also making our due contribution to air purification and reducing air pollution This vehicle has p...

Page 120: ... service centers 13 3 Mechanical Functions of Exhaust Control System Overview The exhaust solution is based on the use of the four stroke single cylinder engine and the throtle air inhaling device high standards of emission control and use of charcoal canister for emission evaporation Improvements in the engine Central spark plug are improved by improving the compression ratio ignition time and ex...

Page 121: ...due to the high temperature in short time 2 Vehicles equipped with catalytic converters shall be kept away from the combustibles 3 Do not start the engine in the airtight space as CO which is insalubrious remains in the exhaust pipe 4 Vehicles equipped with catalytic converters shall not use leaded gasoline in case of catalytic poisoning 5 Do not start the engine by pulling the vehicle If necessar...

Page 122: ...Adjust throttle Note 1 Remove and wash injector Replace injector Dismount and repair the engine Valve leakage Piston abrasion Combustion cleaning Qualified finished product Qualified Qualified Qualified Qualified Qualified KS MOTORCYCLES http ksmotorcycles com ...

Page 123: ... 122 Notes 1 Test it according to the idling testing procedure 2 Adjust the engine idle speed to the specific value and test CO HC in idling KS MOTORCYCLES http ksmotorcycles com ...

Page 124: ... 123 Inspection and Maintenance of Electronic Fuel Injection System Electrical Schematic Diagram KS MOTORCYCLES http ksmotorcycles com ...

Page 125: ... 124 KS MOTORCYCLES http ksmotorcycles com ...

Page 126: ...d self learning system effectively eliminating the manufacturing differences of the system and relevant mechanical parts and components enhancing the overall consistency of the whole vehicle and eliminating the error caused by wear and other reasons after the vehicle is operated 14 2 Parts of Electronic Fuel Injection System 14 2 1 Engine controller ECU MT05 14 2 1 1 ECU working principles Engine ...

Page 127: ... 3 Definition of ECU pin J1 Function correspondence table GREY S N Code Description S N Code Description 1 J1 1 Idle speed stepper motor A high 10 J1 10 2 J1 2 11 J1 11 Idle speed stepper motor A low KS MOTORCYCLES http ksmotorcycles com ...

Page 128: ...marks S N Code Description 1 J2 1 10 J2 10 5V voltage reference ground signal ground 2 12 2 Power supply system ground 11 J2 11 Intake air pressure signal 3 J2 3 KW2000 12 J2 12 Throttle valve position signal 4 J2 4 23 teeth signal high 13 J2 13 23 teeth signal low 5 J2 5 Nozzle A 14 J2 14 Cylinder head temperature signal 6 J2 6 15 J2 15 Power supply for ignition 7 J2 7 Heating of 1 cylinder oxyge...

Page 129: ... 128 14 2 1 4 Circuit diagram of electronic fuel injection KS MOTORCYCLES http ksmotorcycles com ...

Page 130: ... to surrounding the iron core Two electrodes of the coil are taken s the input control ports of thee injector When the coil is powered the electromagnetic force can overcome the spring force of the ball valve and the pressure of fuel to make the ball valve raise and then the high pressure fuel 250Kpa in fuel pipe can flow through the valve seat hole to orifice plate further forming conical mist to...

Page 131: ... 2 3 3 Throttle valve cleaning method Throttle valve is cleaned by throttle valve cleaning agent Specifically spray the agent to inner valve wall gently brush off the dust and prevent against dirty matters blocking the bypass channel 14 2 4 Temperature sensor at cylinder end 14 2 4 1 Working principle of temperature sensor at cylinder end Temperature sensor at cylinder end serves at air cooled eng...

Page 132: ...oefficient resistance The sensor is an non repairable part 14 2 5 2 Appearance of intake air temperature and pressure sensor 14 2 7 Oxygen sensor 14 2 7 1 Working principle of oxygen sensor The sensor can detect the oxygen content in the exhaust gas from engine exhaust pipe and is used for closed loop control of inner fuel of the ECU to make the combustion in engine at the most reasonable air gaso...

Page 133: ...otor 14 2 9 1 Working principles of idle speed stepper motor Idle speed control valve is to control the flow area of the bypass airway of throttle valve to adjust the amount of air into the engine thereby realizing idle speed control KS MOTORCYCLES http ksmotorcycles com ...

Page 134: ... pump rotation please directly read Step 4 2 Disconnect the pump connector and inspect whether the power supply voltage of fuel pump is about 12V 3 If there is problem is Step 2 connect the accumulator to provide 12V DC to the fuel pump and inspect whether the pump operates 4 If the pump can normally operate use gasoline pressure gauge to check whether the fuel pipe pressure in the front of fuel i...

Page 135: ...negative electrode After the engine is started the fault indicator goes out indicating there is no fault on the contrary if the engine is started and the fault indicator is still on the EFI system doesn t work properly and has faults which to be excluded There are 3 methods to detect faults 14 3 1 The flicker of fault indicator FI is directly used for diagnosis After it is confirmed that there is ...

Page 136: ...ke air pressure sensor 14 3 2 Diagnosis tester is used to diagnose the faults Operation method 1 Find the 6 hole diagnosis interface of the motorcycle 2 Connect the connection wire to the diagnosis tester interface 3 Turn on the key to diagnose 14 3 3 PCHUD software is used to inspect the faults on the computer PCHUD is used to detect and record engine operating data Before using the software conn...

Page 137: ... Parameter File under Setup then click MT05common par and then select Comm protocol under Setup select Keyword2000 and click Ok and select 17 under Device Code at the same time KS MOTORCYCLES http ksmotorcycles com ...

Page 138: ...COM port is correctly arranged in the state of Setup generally set as COM Port 4 Baud Rate 10400 don t select DTR high at startup Then the software interface will recover communication display current fault code at MALFCURR and past fault code at MALFHIST and inquire the corresponding faults as per the List of Fault Codes KS MOTORCYCLES http ksmotorcycles com ...

Page 139: ... cell FBLMCOR1 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 STATUSBYTE3 FO2STAT1 cylinder 1 oxygen sensor signal rich lean state FCLREST1 cylinder 1 close loop correction reset FOSHTREN Oxygen sensor heater enable FO...

Page 140: ...is short connected to the negative electrode of the accumulator 279 P0118 Intake air temperature sensor at cylinder end is in open circuit or signal port pin is short connected to the passive electrode of the accumulator 280 P0122 Throttle valve position sensor is in open circuit or signal port pin is short connected to the negative electrode of the accumulator 290 P0123 The signal port pin of thr...

Page 141: ...ted to the negative electrode of the accumulator 5779 P1694 The tachometer is short connected to the passive electrode of the accumulator 5780 P0137 The oxygen sensor in rear cylinder is short connected to the negative electrode of the accumulator 311 P0138 The signal port pin of oxygen sensor in rear cylinder is short connected to the passive electrode of the accumulator 312 P0038 The heating por...

Page 142: ...engine Diagnosis tester is used to display thee working data flow of engine further to analyze and judge the faults of the engine 14 4 2 1 Step 1 a Engine cable harness and vacuum line may affect the system to control air flow and fuel supply b Whether oxygen sensor is installed in place may affect the system to judge the air fuel ratio c Engine fault indicator may affect the system to alarm the f...

Page 143: ...status of the engine thereby causing idle speed exception f hot car In addition the pressure will be increased if the exhaust system is blocked e g exhaust port has foreign matter and three way catalytic converter is blocked due to high fuel consumption and further the exhaust port is blocked due to broken catalytic converter d As for the number of oxygen sensor cycles less cycle indicates the fai...

Page 144: ...the other ignition coil assembly to judge Use another ECU to judge If yes Check whether high voltage wire is properly connected to the ignition coil and spark plug d Inspect the fault of fuel supply system Check whether the fuel pump works you can hear the sound of fuel pump operation around the fuel tank when starting the engine If not Check whether the fuel pump relay works properly Check whethe...

Page 145: ...re is lower than 68 the system will increase the idle speed to accelerate the heating process which is normal Besides inspect the system as the following steps Inspect whether the idle bypass hole is too big Whether valve clearance especially exhaust valve clearance is too large Lower idle speed Check fuel level in fuel tank fuel filter fuel path pressure and nozzle Inspect whether the idle bypass...

Page 146: ...lting in abnormally high fuel consumption b After confirming the engine mechanical components and oxygen sensors are in normal state operate the engine to observe the reading of oxygen sensor if always greater than 500 mV at normal water temperature inspect whether the fuel injector has leakage Precautions Most parts of EFI are non repairable and generally replaced if confirmed as being damaged No...

Page 147: ...he exhaust pipe may have carbon deposit and become black which is normal and will be eliminated after a period of high speed operation Optionally appropriate measures can be taken to make the temperature of coolant liquid of the engine within the range of specified temperature KS MOTORCYCLES http ksmotorcycles com ...

Page 148: ... 147 BX125 Circuit Diagram ...

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