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3). Quickly compress and loosen the right brake lever several times, then press hard on the right brake lever.

(4). Loose the valve (shown no.2) about 1/4 circle to allow the brake fluid to flow into the container. Release the pressure
on the brake lever until the end of the stroke.

(5)Repeat the above operation until there is no bubble in the brake fluid entering the container.

CAUTION

In the process of operation, always check the liquid level of the brake fluid in the pump storage

chamber, add it in time, and do not drain, otherwise there will be bubbles in the pipeline.

(6)Tighten the vent valve (shown no.2) and remove the pipe (shown no.3) and install the bleed valve rubber cap (shown

no. 1).

(7)Add the brake fluid to the "MAX" scale line in the upper pump.

2. Rear brake fluid circuit

The clearance process is the same as front brake fluid circuit.

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Summary of Contents for GP125i

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Page 3: ...ay be inefficient or even dangerous So you should be extremely cautious so as not to damage components or injure individuals If you can t complete the repair and maintenance independently please contact the local dealer Company reserves the right to make any changes due to the renewal of the product If there is any change no notice will be made please refer to the real scooters The main technical ...

Page 4: ...3 Contents CHARACTERISTICS 4 TOOLING 17 MAINTENANCE 23 ELECTRICAL SYSTEM 50 REMOVE ENGINE FROM VEHICLE 58 ENGINE DISASSEMBLY 80 EFI SYSTEM 1177 BRAKING SYSTEM 141 FINAL INSPECTION 162 ...

Page 5: ...ification Specifications Transmission system description Lubrication system description Fuel system description Chassis and suspensions system Front and Rear wheel description Braking system description Electrical system description Tightening torque ...

Page 6: ...parts when reassembling components 3 When tightening nuts and screws start either from the components with the largest diameter or from the innermost components proceeding diagonally Tighten nuts and screws in successive steps to the specified torque 4 After decomposition clean parts in clean solvents Lubricate any smooth surface before assembly 5 After reassembling check all parts to install and ...

Page 7: ...6 Vehicle identification Chassis number is stamped on the frame right side frame rail Engine number is stamped on the rear of the crankcase assembly ...

Page 8: ...d even if the warranty is invalid Specifications Vehicle data Engine data Model GP125i GP150i GP180i Engine model 1P52QMI 125 1P57QMJ 150 1P61QMK 180 Overall size mm 1845 670 1115 Engine idle speed 1800 100rpm Wheel base mm 1390 Engine type 1 cylinder S horizontal Saddle height mm 780 Bore stroke mm 52 4 57 8 125 57 4 57 8 150 61 57 8 180 Minimum ground clearance mm 145 Total displacement mL 125 1...

Page 9: ...0 5 Max net torque rate Nm r min 9 2Nm 7000rpm 125 11Nm 6000rpm 150 12 5Nm 5500rpm 180 Front tyre size Inflating pressure 110 70 12 32 PSI Start mode Electric Rear tyre size Inflating pressure 120 70 12 34 PSI Ignition mode EFI DELPHI Front brake Disc brake Valve clearance mm Intake 0 12 Exhaust 0 12 Rear brake Disc brake Lubrication type Pressure splash Battery capacity 12V 9Ah Spark plug NGK CR7...

Page 10: ...T with V belt final reduction unit Gear ratio 2 363 0 765 125 150 180 Gear ratio 45 13 41 15 9 46 125 150 180 Engine wheel total ratio 7 24 22 354 125 150 180 Lubrication system description Item Standard Engine oil 1000ml Brand name SAE10W 40 SJ Change Engine oil 850ml Change Engine oil and engine oil filter 950ml Dismantle engine inject oil 1000ml ...

Page 11: ...Item description Fuel number Unleaded fuel 92 or higher Fuel tank capacity 10 5L Chassis and suspensions system Item Standard Steering rake angle 26 30 Front suspension Adjustable preloading hydraulic action telescopic fork Front suspension travel 70mm Rear suspension Hydraulic double acting shock absorber and adjustable preloading ...

Page 12: ...heel Rims material Aluminium alloy Front tyre Tubeless 110 70 12 Rear tyre Tubeless 120 70 12 Front tyre inflation pressure 32 220 Psi kPa Rear tyre inflation pressure 34 234 Psi kPa Braking system description Item Standard Braking system ABS or CBS Front brake Ø220mm disc brake with hydraulic transmission ...

Page 13: ...T4 Electrical system description Item Standard Battery capacity 12V 9Ah Fuses 20 10 10A Permanent magnet Alternator 12 V 200W at 7000 rpm Spark plug NGK CR7HSA Bulbs warning lights High low beam bulb Square lamp 12V 35 35W Round lamp LED Front position lamp LED Tail light bulb LED ...

Page 14: ...LED Front and rear turn indicator bulbs LED Speedometer Instrument panel lighting bulb LED Turn indicator warning light LED High beam warning light LED Engine oil pressure warning light LED Low fuel warning light LED EFI check warning light LED ...

Page 15: ...heel axle nut 1 M12 60 Rear wheel axle nut 1 M14 100 Upper screw fixing rear shock absorber 2 M10 40 Lower screw fixing rear shock absorber 2 M8 25 Upper screw fixing front shock absorber 2 M6 12 Lower screw fixing front shock absorber 2 M12 60 Locking nut fixing direction column 1 M25 70 Nut fixing handlebar 1 M10 45 Screw fixing front brake disc 3 M8 25 ...

Page 16: ...read specification Torque Nm Cylinder head fixing nut 4 M8 25 30 Cylinder head fixing bolt 2 M6 8 12 Gear box cover fixing screw 7 M8 25 30 Timing sprocket screw 2 M6 8 12 Oil filter cover 1 M30 25 30 Combined box screw 3 M6 8 12 Intake manifold fixing screw 3 M6 8 12 Crankcase oil releasing screw 1 M12 33 38 Gear box oil releasing screw 1 M8 15 20 Gear box oil Injection hole bolt 1 M8 15 20 ...

Page 17: ...70 Rear clutch nut 1 M12 60 70 Generator rotor fixing screw 1 M12 60 70 Cylinder temperature sensor 1 M8 6 9 Spark plug 1 M10 9 12 Fan fixing bolt 1 M6 9 12 Reference bolts for other specifications GB1231 2006 bolt torque standard ...

Page 18: ...17 TOOLING 1 Special tools The following tools are restricted to professional technicians only consumers must not operate without authorization No Name Tool number Picture 1 Valve spring compressor Z01 ...

Page 19: ...18 2 Tightener Tool Z02 3 Clutch Drive Wheel and Drive Wheel Limiter Z03 4 Shaft bearing punch Z06 1 Z06 8 ...

Page 20: ...19 5 Oil seal punch Z07 1 Z07 9 6 Flywheel extractor Z04 7 Spark plug sleeve Z05 ...

Page 21: ...20 8 Fault diagnosis instrument Z08 9 Shock absorber adjusts handle Z09 2 General tools No Name Picture 1 T sleeve 8 10 12 14 ...

Page 22: ...21 2 Tool case 1 3 Tool case 2 4 Spring pliers ...

Page 23: ...22 5 Screwdriver 6 Pliers 7 Nylon hammer 8 Multimeter ...

Page 24: ...Maintenance Maintenance cycle Basic maintenance 1 Spark plug 2 Check and replace the gear oil 3 Check and replace the engine oil 4 Throttle grip adjustment 5 Clean the air filter 6 Braking system 7 Headlight inspection and adjustment ...

Page 25: ...e the worktable under the engine and tools 4 For threaded fasteners or seals if not specified counterclockwise should be loosened and clockwise should be tightened Maintenance cycle I INSPECT CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE The running in period of motorcycle is 1000km For this reason the driving speed should not exceed 80km h within the mileage 1000km ...

Page 26: ...lter New 300R C C C Gear oil New 300R R R Fuel Fuel filter net R R R Air intake system Air filter CVT sponges C C C R C C Intake manifold and fixed bolt I I I I I I R Air lines I I I I I I R Electric injection system Throttle assembly C C C Injection nozzle I I High pressure oil pipe I R Cylinder temperature sensor I I ...

Page 27: ...k Belt fixed moving plate I R PuLiZhu I R Braking system Brake Liquid I I I I Brake tubing I I I I Brake disc I I I I Valve gap I I Spark plug R R R Control drawing line Throttle line brake line I I I Front and rear shock absorption I I I Wheels tires I I I I Head tube bearing I I I I Battery I I R ...

Page 28: ...g WARNING In order to avoid the risk of ignition please let the engine and silencer cool down before performing the following operations 1 Park the vehicle on its main stand unscrew and remove the 3 screws of right side cover shown no 1 remove the right side cover shown no 2 and find the spark plug suppressor cap shown no 3 ...

Page 29: ...28 2 Remove the spark plug suppressor cap shown no 3 ...

Page 30: ...nto the cylinder 4 Check that the spark plug electrode and centre porcelain shown no 4 are free of carbon deposits or signs of corrosion If necessary clean using suitable spark plug cleaners a wire and or metal brush Blow with a strong air blast to avoid removed dirt getting into the engine 5 Check the electrode gap with a feeler gauge This gap should be 0 7 0 8 mm adjust it if necessary by carefu...

Page 31: ...n exposed to engine vibrations C Technical data Standard spark plug NGK CR7HSA Spark plug electrode gap 0 7 0 8 mm Locking torques 10Nm 7 38 lb ft CAUTION 1 If spark plug insulation material is broken and electrode corrosion is serious spark plugs need to be replaced 2 Tighten the spark plug correctly Otherwise the engine may overheat and be damaged Use only the recommended type of spark plug othe...

Page 32: ...and silencer cool down before performing the following operations A Check 1 Park the vehicle on its main stand unscrew and remove the oil injection hole screw shown no 1 unscrew and remove the oil drain screw shown no 2 then drain off the oil get a collecting container before carrying out these operations ...

Page 33: ...shown no 1 Locking torques 15 20Nm 5 Wipe the oil of the surface with a rag to confirm no leakage CAUTION In the case of insufficient lubrication less oil oil deterioration long running time and no use of recommended oil it will accelerate the wear of moving parts and produce irreparable harm B Replacement The operation steps are the same as the above A inspection process 3 Check and replace the e...

Page 34: ... then switch it off 2 Park the vehicle on its main stand keeps the vehicle in an upright and level position Wait at least five minutes to let the oil that is inside the engine to run back down into the crankcase 3 Remove the left and right cover 4 Unscrew and remove oil cap dipstick shown no 1 ...

Page 35: ... H pour a small quantity of oil and wait approximately five minutes Then check the oil level by step 5 until it close to the mark H screw and tighten the oil cap dipstick shown no 1 7 Wipe the oil of the engine surface with a rag to confirm no leakage CAUTION In the case of insufficient lubrication less oil oil deterioration long running time and no use of recommended oil it will accelerate the we...

Page 36: ...35 2 Unscrew and remove the oil release bolt of left crankcase shown no 2 drain off the oil get a collecting container before carrying out these operations ...

Page 37: ...o the filter screen if damaged replace immediately Fit a new oil filter screen and fit the springr shown no 5 check the seal ring shown no 6 screw and tighten the screen cover shown no 3 Locking torques 25 30Nm 4 screw and tighten the bolt shown no 2 Locking torques 33 38Nm 5 Pour approx 950mL cleaning filter screen or 850mL uncleaning filter screen engine oil through the fill opening of oil cap d...

Page 38: ...t it cool down 8 Check engine oil level again whether to meet the requirements 4 Throttle grip adjustment The empty travel of the throttle grip shown no 4 should be 2 3mm measured at the throttle trim If this is not so proceed as follows 1 Slide off the protection cover shown no 1 ...

Page 39: ... The air filter element used in this scooter is a polyurethane foam paper element If the filter element has become clogged with dust intake resistance will increase with a resultant decrease in power output and increase in fuel consumption due to the richer fuel air mixture Check clean and replace the air filter element according to the maintenance cycle 1 Park the vehicle on its main stand Unscre...

Page 40: ... 9 screws shown no 2 Remove the filter box cover 3 Unscrew and remove the 2screws shown no 3 take off the filter element shown no 4 Split the filter element into paper filter element shown no 5 and foam filter element shown no 6 ...

Page 41: ...ment in the solvent and wash it clean Squeeze the solvent out of the washed filter element by pressing it between the palms of both hands Do not twist and wring the filter element as this will lead to tearing Rinse in warm free running water and dry filter element by using compressed air or warm air dryer Immerse the filter element in clean engine oil squeeze excess oil from the filter element to ...

Page 42: ...41 Reinstall the cleaned air filter element in reverse order of removal Be absolutely sure that the filter element is securely in position and is sealing properly ...

Page 43: ...Take off the foam sponge shown no 7 immerse the filter element in the non flammable water soluble cleaning solvent to clean Squeeze the solvent out of the washed filter element by pressing it between the palms of both hands 7 After cleaning the air filter body assemble in reverse order ...

Page 44: ...fluid 1 Park the vehicle on its main stand 2 Check that the level in the reservoir is over the mark LOWER If the fluid does not reach the mark LOWER check brake pads and disc for wear If the pads and or the disc do not need replacing top up the fluid ...

Page 45: ...to remove the brake pump cover shown no 2 CAUTION In order to avoid the risk of brake fluid overflow the brake handle cannot be held after the 2 screws are removed and the pump cover is removed mainly b Top up the fluid to reach the mark MAX ...

Page 46: ...PPING UP DO NOT EXCEED THE MAX LEVEL MARK WHEN BRAKE PADS ARE WORN AS YOU RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS c Assemble the brake pump cover and the 2 screws shown no 1 in sequence of Figure 4 3 and 2 B Check ABS system if the vehicle has ABS Turn on the key the instrument ABS indicator lights on until the front and rear wheels move at the same time the ABS lights will go out ...

Page 47: ...f there is an excess check and adjust the position of hall sensor shown no 1 2 Check the gap between the rear wheel hall sensor shown no 3 and the rear wheel counting gear tray shown no 4 and the clearance should be 0 5 1 6mm If there is an excess check and adjust the position of hall sensor shown no 3 3 Check the resistance for the front wheel hall sensor shown no 1 and the rear wheel hall sensor...

Page 48: ...e whole system tubing is damaged whether the connection is leaking timely replacement or maintenance 2 Operate the front wheel lock of the right brake handle Operate the left brake handle and lock the front and rear wheels Check and confirm the braking performance ...

Page 49: ... ground is level 2 Turn on the high beam light sit on the vehicle and check that the light beam projected to the wall is a little below the headlight horizontal straight line about 9 10 of the total height 3 Turn on the low beam light sit on the vehicle and check that the light beam projected to the wall is below the headlight horizontal straight line 0 6 08H H total height ...

Page 50: ... Adjust the light beam Unscrew and but not remove the screw shown no 1 push the bolt shown no 1 to the R direction to lower the light beam push the bolt shown no 1 to the F direction to raise the light beam ...

Page 51: ...50 ELECTRICAL SYSTEM Components arrangement ...

Page 52: ...51 ...

Page 53: ...Electric lock 13 Left handlebar switch 14 Speedomete 15 Injector 16 STARTER MOTOR 17 Voltage regulator 18 Generator 19 Fuek pump relau 20 Ignition coil 21 Dump valve 22 Oxygen sensor 23 Start up relay 24 CBS speed sensor 25 Instrument adjustment switch 26 Acceleration grip right switch 27 Fuel Level Sensor 28 Spark plug 29 ECU 30 Head light relay 31 ABS speed sensor 32 ABS unit ...

Page 54: ...53 Instrument Panel Indications 1 Engine RPM Indicator 2 Fuel gauge ...

Page 55: ... Direction Indicator 8 Battery Indicator 9 Odometer 10 Speedometer 11 MODE button functions See below With the ignition key turned to the on position A TRIP METER to ODOMETER to change between displays Press the MODE button then release MODE button B Clearing the trip counter history When the display is TRIP METER press the MODE button and hold for 5 seconds then release when zero is displayed C M...

Page 56: ...55 Harness diagram ...

Page 57: ...56 ...

Page 58: ...57 Conceptual diagram ...

Page 59: ...N Before dismantling the engine associated parts clean the engine thoroughly with a suitable cleaner Remove the left and right side cover 1 Undo the 6 screws shown no 1 remove the right side cover shown no 2 and left side cover shown no 3 ...

Page 60: ...hown no 5 3 Remove the belt shown no 14 remove the battery screw shown no 12 then remove the screw shown no 13 and remove the battery 4 Unscrew and remove the 2 screws shown no 6 5 Unscrew and remove the 4 screws shown no 7 take down the hand holder shown no 8 6 Unscrew and remove the 2 nuts shown no 8 take down the taillight shown no 9 unscrew and remove the 2 screws shown no 10 take down the mai...

Page 61: ...60 ...

Page 62: ...Remove the Fuel evaporation system 1 Loosen the clamp shown no 1 pull out the trachea shown no 2 2 Take off the air valve shown no 3 pull out the bracket shown no 4 then take off the dump valve shown no 5 ...

Page 63: ...shown no 6 and the negative pressure pipe clamp shown no 8 connecting the carbon tank and pull out the desorption pipe shown no 7 and the negative pressure pipe shown no 9 4 Cut the tie band shown no 10 remove the carbon canister shown no 11 ...

Page 64: ...e trachea of the system should not be disassembled If it is disassembled attention should be paid to the dumping valve shown no 5 The arrow direction should be connected with TANK port of the carbon tan shown no 11 ...

Page 65: ...he oil pump plug shown no 1 and the oil level sensor plug shown no 2 2 Remove two bolts shown no 3 disconnect plug and remove ECU Remove two bolts shown no 4 loosen and remove two bolts shown no 5 two bolts shown no 6 remove battery bracket ...

Page 66: ...65 ...

Page 67: ...lockwise with the lock cover to remove the tank lock Hold and pull the high pressure tubing quick connector shown no 25 by hand if the CBS system removes the tank directly Remark If ABS system is used remove two bolts that fix ABS unit shown no 24 Lower ABS unit and remove fuel tank ...

Page 68: ...ove cylinder head clamp shown no 1 and gear box pipe clamp shown no 3 separate air filter pipe shown no 2 and shown no 4 2 Loosen the clamp shown no 5 and separate the air filter outlet pipe shown no 6 3 Loosen the clamp shown no 7 ...

Page 69: ...68 4 Remove the screw shown no 9 two bolts shown no 8 and remove the air filter ...

Page 70: ...emove the throttle body 1 Disconnect the intake pressure temperature sensor plug shown no 1 2 Disconnect the throttle position sensor plug shown no 2 3 Disconnect the plug of idle stepping motor shown no 3 ...

Page 71: ...70 4 Release the nut shown no 5 from the thread and remove the throttle line shown no 6 5 Release the two bolts of the rubber sleeve of the intake pipe shown no 4 and remove the throttle body ...

Page 72: ...Loosen and remove two bolts shown no 1 and bolts shown no 2 2 Disconnect the plug of the oxygen sensor shown no 3 and dismantle the oxygen sensor shown no 4 If it is not necessary it is not recommended to dismantle the oxygen sensor ...

Page 73: ...the connection plug 1 Disconnect the fuel injector plug shown no 1 2 Disconnect the plug of the cylinder temperature sensor shown no 2 3 Cut the strap Figure 3 and disconnect the magneto plug shown no 4 and shown no 5 4 Disconnect the starting motor wire shown no 6 5 Remove the spark plug cap shown no 7 ...

Page 74: ...73 ...

Page 75: ... brake lever shown no 3 unscrew and remove the 5 screws shown no 1 and take down the rear wheel shown no 2 CAUTION When reassembling the bolt thread part of Figure 1 is coated with Loctite 243 thread adhesive and the tightening torque is 60Nm ...

Page 76: ... 3 Remove tubing clamp bolts shown no 4 and clamp fixing bolts shown no 5 Remove rear brake disc brake pump shown no 6 and brake disc shown no 8 CAUTION When reassembling the nut thread part of Figure 7 is coated with Loctite 243 thread adhesive and the tightening torque is 100Nm ...

Page 77: ... remove the bolt shown no 28 remove the sensor shown no 29 If CBS system does not have this content CAUTION After the sensor 29 is removed it is temporarily fixed in the proper position of the frame with a tie belt to avoid damage ...

Page 78: ...wn no 1 do not remove engine fixed axles shown no 2 Release middle stand axle nuts shown no 3 do not remove middle axle shown no 4 and middlestand shown no 5 When reassembling Torque of engine fixed shaft nut M10 45Nm Torque of middle stand axle nut M8 25 30Nm ...

Page 79: ...78 3 Unscrew and remove the bolts shown no 6 separate the rear shock absorber shown no 7 from the engine ...

Page 80: ...have been removed remove the fixed shaft of the engine shown no 2 remove the engine remove the mid brace shown no 4 and remove the mid brace shown no 5 Reassembly CAUTION Reassembly according to the above reverse procedure and tighten to the required torque ...

Page 81: ...arts such as oil seal O ring and so on In 2 years the crankshaft oil seal and the drive shaft oil seal should have no breakage or aging otherwise change them 2 Fastener torque by standard To the tightening torque of the nut that is not indicated see reference list of tightening torque for screws and GB1231 2006 bolt torque standard 3 Principle of bearing assembly When the bearing is replaced the p...

Page 82: ... a little anaerobic adhesive is applied to the surface of the A surface The bottom B surface of the oil seal is a force surface When the seal is knocked down a uniform force should be guaranteed and a little butter is applied to the lip when the seal is replaced especially it should be noted that the oil seal spring should be checked to be intact when the oil seal is assembled ...

Page 83: ...ge oil from gear box Unscrew and remove gear box oil injection holes crew shown no 1 and oil discharge screw shown no 2 release oil prepare suitable containers in advance to collect gear oil screw the bolts and gaskets into place in time ...

Page 84: ... bolts and replace them in time according to the situation 3 The tightening torque of theoil injection holes crew shown no 1 and oil discharge screw shown no 2 is 15 20Nm 2 Discharge oil from crankcase A Remove the crankcase oil gauge shown no 1 and the oil release bolt shown no 2 release oil prepare suitable containers in advance to collect gear oil and put the oil gauge and bolt in place in time...

Page 85: ...CC lubricating oil of 10W 40 it is recommended to use the grade APL SJ above 2 When the filter screen shown no 4 is is disassembled and assembled check the parts no 3 no 4 no 5 and no 6 are fully loaded otherwise it may damage the engine The tightening torque of the filter screen screw shown no 2 is 33 38Nm The tightening torque of the pressure regulating valve screw shown no 3 is 25 30Nm ...

Page 86: ...ke manifold 1 Force the removal of the anti disassembly nut shown no 2 with the screwdriver If it is not necessary it is not recommended to remove the intake manifold 2 Remove nuts shown no 1 and remove intake pipe connectors shown no 3 ...

Page 87: ... no 1 the bakelite pad shown no 2 and the paper pad shown no 1 Reassembly attention According to the order of paper cushion bakelite cushion paper cushion and ensure that the bakelite cushion has a gap side towards the cylinder head ...

Page 88: ...ommended to demolish it if it is not necessary CAUTION Cylinder temperature sensor shown no 1 is a high precision object It is strictly forbidden to knock or smash when disassembling or assembling Cylinder Temperature Sensor shown no 3 Tightening Torque 6 9Nm ...

Page 89: ...88 Disassembly and assembly the fan cover and plastic parts 1 Loosen and remove 5 screws remove the fan cover 2 Loosen and remove 5 screws remove plastic A and B covers ...

Page 90: ...89 Disassembly and assembly the CVT cover Remove 8 bolts then remove the left cover gasket and positioning pin in turn ...

Page 91: ...1 Loosen and remove the nut shown no 1 remove the retaining disc shown no 2 2 Remove nuts shown no 1 remove clutch driven wheel assembly shown no 2 and belt shown no 3 3 Remove clutch drive wheel assembly shown no 1 and bushing shown no 2 ...

Page 92: ...d the belt otherwise it can not be assembled 2 Check and confirm that the sealing surface of clutch roller Puli bead is opposite to the direction of clutch rotation 2 Front clutch nut Coated with Loctite 243 thread adhesive tightening torque 60 70Nm Back clutch nut Coated with Loctite 243 thread adhesive tightening torque 60 70 Nm ...

Page 93: ...92 Disassembly and assembly the generator 1 Remove four bolts shown no 1 remove the fan shown no 2 2 Remove the flywheel nut shown no 1 remove the flywheel shown no 2 with the special tool shown no 3 ...

Page 94: ...bly attention 1 Special tooling detection trigger gap 0 7 0 1mm 2 Gently tap the semicircle key with a copper hammer and the upper plane is parallel to the center line of the crankshaft The key slot on the rotor is aligned with the upper half key of the crankshaft 3 Flywheel nut coated with anaerobic thread locking glue and the tightening torque is 60 70Nm 4 Four bolts tightening torque of fan 8 1...

Page 95: ...94 Disassembly and assembly the cylinder head 1 Remove 4 bolts and remove cylinder head 2 Remove two bolts and remove chain tensioner ...

Page 96: ...e the key clockwise shown no 2 or similar iron sheet and return the tensioner jack rod from position A to position B before assembling otherwise it can not be loaded 3 Tighten 2 bolts again 4 Re confirm that the O ring on the cross head screw is in good condition and tighten the screw shown no 1 ...

Page 97: ...96 3 Remove 2 bolts shown no 1 remove timing sprocket shown no 2 remove 2 bolts shown no 3 and 4 nuts with gaskets shown no 5 and remove cylinder head shown no 6 ...

Page 98: ...and the intake rocker arm please ensure that they are in accordance with the disassembly Otherwise please readjust the clearance between the intake and exhaust valves intake clearance 0 12mm exhaust clearance 0 12mm 4 Installation of timing sprockets ensures that the center line of the sprocket round hole is parallel to the cylinder surface and the marking is upward the flywheel T line is aligned ...

Page 99: ...e positioning plate bolt shown no 1 remove the positioning plate shown no 4 remove the exhaust rocker shaft shown no 2 and the intake rocker shaft shown no 3 remove the intake rocker arm shown no 6 and rocker arm spring shown no 8 exhaust rocker arm shown no 7 and rocker arm spring shown no 9 remove the camshaft shown no 5 ...

Page 100: ...ith special tools shown no 11 remove the upper seat of the intake valve spring shown no 12 and the intake valve spring shown no 10 remove the lock clamp of the exhaust valve with special tools shown no 14 remove the upper seat of the exhaust valve spring shown no 15 and the exhaust valve spring shown no 13 ...

Page 101: ...100 3 Remove the intake valve shown no 16 and exhaust valve shown no 17 remove the valve oil seal shown no 18 and valve spring seat shown no 19 ...

Page 102: ... If there is no burning oil in the valve oil seal try not to remove it otherwise it must be replaced after removal B Valve umbrella seal face and cylinder head seal face clean up carbon deposit visual inspection before assembly ...

Page 103: ...the above reverse process the sealing of the valve seat must be tested Gasoline is introduced into the intake and exhaust ports separately Leakage can be observed from the intake and exhaust valve seats but only through excessive leakage ...

Page 104: ...03 Disassembly of cylinder and piston 1 Remove the cylinder shown no 7 and the seal pad shown no 6 2 Remove the retaining ring shown no 3 remove the piston pin shown no 2 and remove the piston shown no 1 ...

Page 105: ... A little lubricant is applied to the parts before assembly 2 The piston pin should be missed out of the piston gap The piston top arrow points to the exhaust direction 3 If the seal pad shown no 6 is damaged or soaked in oil it needs to be replaced ...

Page 106: ...ce 125CC Yellow 52 39 52 395 52 37 52 375 0 015 0 025 Blue 52 395 52 4 52 375 52 38 0 015 0 025 Green 52 4 52 405 52 38 52 385 0 015 0 025 150CC Yellow 57 39 57 395 57 37 57 375 0 015 0 025 Blue 57 395 57 4 57 375 57 38 0 015 0 025 Green 57 4 57 405 57 38 57 385 0 015 0 025 180CC Yellow 60 99 60 995 60 97 60 975 0 015 0 025 Blue 60 995 61 60 975 60 98 0 015 0 025 Green 61 61 005 60 98 60 9885 0 01...

Page 107: ...106 6 The letter of the piston ring top ring and the second ring must point to the top of the piston and the opening of each ring is stagger 90 degrees See the following figure ...

Page 108: ...er 1 Remove two bolts shown no 1 and shown no 2 and remove the starting motor shown no 3 When reloading the motor you must first put the motor on the bottom and then lock the bolt otherwise the O ring on the motor will be damaged ...

Page 109: ...cover and seal gasket Reassembly attention 1 Check the sealing gasket and replace it in case of oil immersion damage and folding 2 Check whether the positioning pin is on the right cover or the right box and then place the sealing gasket ...

Page 110: ...109 3 Remove the four groove nut clockwise shown no 3 take down the gasket shown no 4 the overrunning clutch body shown no 5 the idler axle shown no 1 and the idler wheel shown no 2 ...

Page 111: ...110 4 Remove two bolts shown no 6 remove cover plate shown no 7 remove bolts shown no 1 and 2 and remove oil pump shown no 3 ...

Page 112: ...x bolts Remove gear box cover sealing pad and positioning pin Be careful that the gear chamber cover and internal gear fall off a bolt can be left when disassembled The bolt tightening torque is 25 30Nm when the gear housing cover is reinstalled ...

Page 113: ... with interference If it is not necessary it is not recommended to dismantle it Otherwise the bearing will be damaged and special tooling will be needed for reassembly Reassembly attention 1 Check the sealing gasket and replace it in case of oil immersion damage folding etc 2 Check whether the positioning pin is on the gear box cover or the left box body and then place the sealing gasket ...

Page 114: ...113 Disassembly of crankshaft 1 Remove two bolts shown no 1 and 2 tap the right box several times with nylon hammer and remove the right box ...

Page 115: ...114 2 Tap left crankshaft with nylon hammer remove crankshaft ...

Page 116: ...115 3 Remove the chain shown no 1 When reinstalling the crankshaft insert the chain into the left box as much as possible to prevent the crankshaft from pressing into the chain ...

Page 117: ...arious oil seals butter on inner ring 3 Inspection of sealing gaskets if oil immersion damage folding and other conditions must be replaced 4 Check whether the positioning pin is on the cover or body of the box and then place the sealing gasket 3 Clean the surface lubricant after assembly so as to avoid oil leakage ...

Page 118: ...117 EFI SYSTEM The vehicle uses the DELPHI MT05 EFI system The schematic diagram as follows ...

Page 119: ...supply system consists of oil pump assy including filter pressure regulators high pressure oil pipe and injector The ignition system consists of ECU high voltage coil high voltage wire spark plug cap and spark plug ...

Page 120: ...itch must be switched off otherwise it may damage the electrical appliances The fuel injection pressure of the EFI system is high about 250kPa and all fuel pipelines are made of high pressure oil pipes After the engine has stopped running for a long time the fuel pressure in the oil circuit is also kept high Therefore do not remove the tubing easily during the maintenance process and relieve the p...

Page 121: ...connected When the fuel pump is removed from the fuel tank do not turn on the electricity so as to avoid producing electric sparks and causing fires Fuel pumps are not allowed to run tests under dry conditions or in water The regulation of idle speed is completely cured by the EFI system without manual adjustment Throttle limit screw of throttle body has been adjusted when it is released from fact...

Page 122: ...termine the nature and location of the fault 1 Fault information record The ECU continuously monitors sensors actuators related circuits fault indicator lights and battery voltage and even the ECU itself and to the sensor output signal actuator drive signal and internal signal such as lambda closed loop control cylinder temperature coolant temperature idle speed control and battery Reliability det...

Page 123: ...y 2 Fault code table MT05 Fault code table Fault code description P0107 MAP Circuit Low Voltage or Open P0108 MAP Circuit High Voltage P0112 IAT Circuit Low Voltage P0113 IAT Circuit High Voltage or Open P0117 Coolant Oil Temperature Sensor Circuit Low Voltage P0118 Coolant Oil Temperature Sensor Circuit High Voltage or Open P0122 TPS Circuit Low Voltage or Open P0123 TPS Circuit High Voltage P013...

Page 124: ...Voltage or Open P0232 FPR Coil Circuit High Voltage P0336 CKP Sensor Noisy Signal P0337 CKP Sensor No Signal P0351 Cylinder 1 Ignition Coil Malfunction P0352 Cylinder 2 Ignition Coil Malfunction P0505 Idle Speed Control Error P0562 System Voltage Low P0563 System Voltage High P0650 MIL Circuit Malfunction P1693 Tachometer Circuit Low Voltage P1694 Tachometer Circuit High Voltage ...

Page 125: ...immediately after the engine starts successfully When produce the fault code At the time of engine operation if the fault occurs the fault lamp is light on which reminds drivers to have faults When the engine is stopped the fault will be stored in the ECU Have fault code Under the special situation Can turn off the key and keep more than 10 seconds and then fast continuous switch key 5 times to re...

Page 126: ...125 4 OBD diagnostic connect and use OBD diagnostic function Read fault code clear fault code data flow display status identification display etc ...

Page 127: ...le Connect the ignition switch Read fault code Inquire maintenance manual to confirm the fault parts and types formulate the maintenance plan according to the query information and experience After troubleshooting remove the history fault code with the fault diagnostic instrument ...

Page 128: ...ner s complaint and confirm the condition of the failure B And then check appearance Check whether there is leakage in the fuel line Check whether the intake pipe is clogged leaked crushed or damaged Check whether the high voltage line of the ignition system is broken or aged Check whether the wire grounding is clean and firm Check whether all sensors and actuator joints are loose or poorly contac...

Page 129: ...use multimeter to check the positive terminal of starter motor whether have more than 9V voltage Check starting motor related lines 3 Remove starter motor and check starting motor s working condition The key is to check whether there is a circuit breakage or stuck due to poor lubrication Repair or replace the starting motor 4 If the fault occurs only in winter then check the engine oil choose whet...

Page 130: ...he spark plug cap connect the spark plug let the spark plug on the engine block start the engine check whether there was continuous blue and white high pressure fire Inspect ignition system 3 Connect the fuel pressure gauge turn on the key switch and check whether the fuel pressure was around 250KPa If there was no fuel pressure gauge can pinch the high pressure oil pipe by hand judge the hardness...

Page 131: ...t 8 ignition timing 9 spark plug 10 engine mechanical part General diagnosis process No Inspection steps Follow steps 1 Remove the coolant temperature cylinder head temperature sensor connector and start the engine to see if the engine has started successfully Inspect circuit or replace coolant temperature cylinder head temperature sensor 2 Connect the fuel pressure gauge turn on the key switch an...

Page 132: ...ther the air filter is clogged and whether there is a leak in the intake port especially the intake pipe connection Inspect intake system 6 Check spark plug and observe the type and clearance adjust or replace 7 Check engine cylinder pressure to see if there is insufficient cylinder pressure Exclude engine mechanical failure pay attention to check whether engine valve clearance is too small 8 Chec...

Page 133: ...l diagnosis process No Inspection steps Follow steps Remark 1 Check whether the air filter is clogged and whether there is air leakage in the intake system Inspect intake system 2 Check if the throttle is stuck Cleaning or replacing 3 Check spark plug and observe the type and clearance adjust or replace 4 Check whether there is carbon deposition in throttle body and idle bypass Cleaning 5 Check wh...

Page 134: ...eck whether there is leakage blockage or excessive flow in fuel injector replace 9 Remove the coolant temperature sensor connector and start the engine observe whether the idle is stable during the engine warm up process Inspect the circuit or replace the sensor Idling instability during the warm up process 5 starting normal but idle speed too high General fault parts 1 throttle body and idle bypa...

Page 135: ...eaning the related parts 4 Remove the coolant temperature sensor connector and start the engine observe whether the idle is too high Inspect the circuit or replace the sensor 5 Check whether the ignition timing of the engine meets the specifications Inspect ignition timing 6 When accelerate the engine speed won t go to up or flameout Reaction slowly Acceleration performance weak General fault part...

Page 136: ...park plug and observe the type and clearance adjust or replace 4 The idle speed regulator is removed to check whether there is carbon deposition in throttle body idle speed regulator and idle bypass Cleaning the related parts 5 Check whether the ECU unit and its circuit are normal Inspect the circuit or replace the ECU assembly 6 Check whether there is leakage or blockage in the injector replace 7...

Page 137: ...hether there was continuous blue and white high pressure fire Inspect ignition system 11 Check whether there are clutch slipping low tire pressure braking delay and whether the user adjusted the last stage transmission ratio Repair acceleration performance weak Fuel injector disassembly and installation 1 Remove left and right cover 2 The two fingers press the quick connector shown no 2 at the sam...

Page 138: ...137 4 Remove the bolt shown no 4 and take off the fuel injector shown no 1 5 Assembly according to the above reverse process ...

Page 139: ...38 Throttle valve disassembly and installation 1 Remove left and right cover 2 Disconnect intake pressure temperature sensor shown no 1 throttle position sensor shown no 2 idle stepping motor shown no 3 ...

Page 140: ...139 3 Release the nut shown no 5 from the thread and remove the throttle line shown no 6 4 Release the clamp shown no 5 separating air filter outlet pipe shown no 6 ...

Page 141: ...140 5 Remove the throttle body by loosening two bolts shown no 4 6 Assembly according to the above reverse process ...

Page 142: ...is equipped with ABS brake system a front disc brake a rear disc brake and ABS integrated unit front and rear all equiped with counting gear disc and Hall sensor clearance between 0 5 1 6 mm Operate the right brake handle and apply pressure on the front brake caliper Operate the left brake handle and apply pressure on the rear brake caliper ...

Page 143: ...142 ...

Page 144: ...ipped with CBS brake system a front disc brake a rear disc brake and CBS integrated unit Operate the right brake handle and apply pressure on the front brake caliper Operate the left brake handle and apply pressure on the rear brake caliper ...

Page 145: ...144 ...

Page 146: ...s and brake disc 1 First lift the main stand then unscrew and remove the bolt shown no 1 The tightening torque M8 is 25Nm 2 Unscrew and remove the front wheel bolt shown no 2 Take down the front wheel The tightening torque M12 is 60Nm ...

Page 147: ...t to prevent loss unscrew and remove the 3 bolts shown no 4 remove the brake disc shown a and the front ring gear shown b CAUTION When reassembling the bolt thread part of Figure 4 is coated with Loctite 243 thread adhesive and the tightening torque M8 is 25Nm ...

Page 148: ...147 4 Unscrew and remove 2 nuts and 2 built in bolts shown no 5 unscrew and remove the bolts shown no 6 5 Take down the 2 pads shown no 7 ...

Page 149: ...r to cause the leakage of brake fluid 6 Inspection and replacement of the pad and brake discs are described in part Ⅲ CAUTION Reassembly is carried out according to the above reverse process 7 Remove the ABS system sensor shown no 1 CBS system does not have the counter shown no 2 and sensor shown no 1 the others are the same ...

Page 150: ...149 Dismantle rear brake calipers and brake disc 1 Lift the vehicle main stand unscrew and remove the 3 screws on the right side cover shown no 1 remove the right side cover shown no 2 ...

Page 151: ...150 2 Unscrew and remove the bolt shown no 1 shown no 2 3 Disconnect the oxygen sensor plug shown no 3 ...

Page 152: ...151 4 Remove two fixed nuts of muffler on cylinder head shown no5 and remove muffler shown no 6 ...

Page 153: ...lever shown no 3 unscrew and remove the 5 bolts shown no 1 remove the rear wheel shown no 2 CAUTION When reassembling the bolt thread part of Figure 1 is coated with Loctite 243 thread adhesive and the tightening torque is 60Nm ...

Page 154: ...bing clamp bolt shown no 4 two caliper fixing bolts shown no 5 take off the brake pump shown no 6 and the brake disc shown no 8 Reassembly attention The nut thread part of Figure 7 is coated with Loctite 243 thread adhesive and the tightening torque is 100Nm Caliper fixing M8bolts tightening torque is 25Nm ...

Page 155: ...n no 20 and pay attention to the spring leaf shown no 20 in accordance with the direction of the picture 8 Take off the brake pad shown no 21 CAUTION Do not operate the brake lever after removing the friction hoof otherwise the piston will come out of the caliper to cause the leakage of brake fluid ...

Page 156: ... brake disc are described in part Ⅲ CAUTION Reassembly is carried out according to the above reverse process 10 Remove the ABS system sensor shown no 3 CBS system does not have the counter shown no 4 and sensor shown no 3 the others are the same ...

Page 157: ... surface and replace it if there is serious scratch or rust 2 Use micrometer to measure the thickness on the brake disc circumference If the minimum thickness is less than or near the minimum limit 3 6mm replace it 3 Use the dial gauge to measure the beating of the brake disc If it exceeds the tolerance limit 0 3mm replace it ...

Page 158: ... 2 is front brake pad Figure 3 is rear brake pad 2 The thickness of the pad material is measured with a vernier depth caliper shown no 2 and no 3 As long as the material thickness of one pad is reduced to 1 5mm need to replace two pads at the same time ...

Page 159: ...rake fluid circuit after retrofitting or restoring the brake system 1 Front brake fluid circuit 1 Pull out the rubber cap of the vent valve shown no 1 2 A clear plastic pipe shown no 3 is inserted on the vent valve shown no 2 and the other end of the tube shown no 3 is connected to a container for collecting the discharged brake fluid ...

Page 160: ...e is no bubble in the brake fluid entering the container CAUTION In the process of operation always check the liquid level of the brake fluid in the pump storage chamber add it in time and do not drain otherwise there will be bubbles in the pipeline 6 Tighten the vent valve shown no 2 and remove the pipe shown no 3 and install the bleed valve rubber cap shown no 1 7 Add the brake fluid to the MAX ...

Page 161: ... shown no 1 2 A clear plastic pipe shown no 3 is inserted on the vent valve shown no 2 and the other end of the tube shown no 3 is connected to a container for collecting the discharged brake fluid 3 Quickly compress and loosen the right brake lever several times then press hard on the right brake lever ...

Page 162: ...n the pump storage chamber add it in time and do not drain otherwise there will be bubbles in the pipeline 6 Add brake fluid to the MAX above scale of the tank 7 Repeat steps 3 4 5 6 8 Observe the liquid in the transparent plastic pipe When the color of the liquid is replaced from black to clear tighten the discharge valve shown no 2 and remove the pipe shown no 3 9 Install the rubber cap of the v...

Page 163: ...The paint surface of a leaking part 2 Assembly of plastic parts with external leakage 3 Scratch Tightening torque check 1 Front and Rear suspending device 2 Front and Rear brake calipers brake discs 3 Front and Rear wheels and wheel shafts 4 Connection between engine and frame 5 Handlebar steering mechanism 6 Plastic parts fastening ...

Page 164: ...Head light High beam low beam position light and warning light 3 Adjust the low beam according regulations 4 Front rear brake switch and stop lamp 5 Direction switch and turning lamp 6 Instrument Panel Indications 7 Horn 8 Starting motor 9 The function of engine emergency stop switch and side stand switch ...

Page 165: ... Engine oil level 4 Engine gear oil level Vehicle road check 1 Vehicle cold start 2 Instrument panel operation 3 The sensitivity of throttle control 4 Stability of acceleration and brake 5 Front and Rear brake effect 6 Front and Rear shock absorption effect 7 Is there any abnormal noise ...

Page 166: ...er driving 1 Vehicle hot start 2 Brake rod stroke 3 Front and Rear tyre pressure 4 Angle of rear view mirror 5 Radiator fan run 6 Possible leaks 7 Abnormal sound of engine When the above check is completed the user can ride normally ...

Page 167: ...166 ...

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