Royal Alloy GP125S Maintenance Manual Download Page 3 | Manualshive

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Dear users:
Thank you for choosing your Royal Alloy

GP125S/GP200S

scooter. In order to make you drive more safe and

comfortable, please read carefully and fully understand the contents of this manual.
This manual explains the main information, such as the structure, characteristic, basic inspection and maintenance, and
the structure and maintenance of EFI etc for your scooter, so that you can carry out regular maintenance operations on
your vehicle. As it is not possible to include complete mechanical notions in this manual, users should have basic
mechanical knowledge. Without this knowledge, repairing or checking the vehicle may 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 modifications and changes in repair procedures are
communicated to all Sales Outlets and its International Subsidiaries. These changes will be introduced in the subsequent
editions of the manual.
The important information below will appear in this manual:

CAUTION

Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING

Refers to specific procedures to carry out to prevent injuries to the repairer.

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Summary of Contents for GP125S

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Page 3: ...y 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 m...

Page 4: ...3 Contents CHARACTERISTICS 4 TOOLING 18 ELECTRICAL SYSTEM 54 REMOVE ENGINE FROM VEHICLE 61 ENGINE DISASSEMBLY 83 EFI SYSTEM 122 BRAKING SYSTEM 145 COOLING SYSTEM 160 FINAL INSPECTION 165 ...

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

Page 6: ...arts 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 o...

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: ...y if the revision of the chassis number will be invalid even if the warranty is invalid Specifications Vehicle data Engine data Model GP125S GP200S Engine model 1P58MI 125CC 1P63ML 4 200CC Overall size mm 1845 670 1115 Engine idle speed 1900 100rpm 1800 100 rpm Wheel base mm 1390 Engine type 1 cylinder S horizontal Liquid cooling double overhead camshaft 4 Valve ...

Page 9: ... 0 5 1 200CC Max loading weight kg 210 Max net power rate kW r min 10 8000 125CC 13 8250 200CC Fuel tank capacity L 10 5 Max net torque rate Nm r min 12 7500 125CC 16 4 7500 200CC 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 Magneti Marelli Front brake Disc brake Valve clearance mm Intake 0 10 0 15 ...

Page 10: ...rn 90 100dB A Clutch Automatic centrifugal dry clutch Variator Continuous automatic Transmission system description Item Standard Transmission CVT with V belt final reduction unit CVT ratio 2 9 0 89 1 125 2 4 0 86 1 200 Gear ratio 66 14 58 23 11 89 125 66 14 54 27 9 43 200 Engine wheel total ratio 10 6 34 5 125 8 1 22 5 200 ...

Page 11: ...gine oil 900ml Change Engine oil and engine oil filter 950ml Dismantle engine inject oil 1000ml Transmission oil 200ml Brand name 75W 80 Change transmission oil 180ml Dismantle engine inject oil 200ml Fuel system description Item description Fuel number Unleaded fuel 95 or higher Fuel tank capacity 10 5L ...

Page 12: ...glycol antifreeze is mixed with distilled water according to 1 1 The freezing point reaches 40 and boiling point to 108 Chassis and suspensions system Item Standard Chassis type High strength steel tubular chassis single spar at the front superimposed double cradle at the rear Steering rake angle 26 30 Front suspension Adjustable preloading hydraulic action telescopic fork ...

Page 13: ...er and adjustable preloading Rear suspension travel 80mm Front and Rear wheel description Item Standard Wheel 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 ...

Page 14: ...mm disc brake with hydraulic transmission Rear brake Ø220mm disc brake with hydraulic transmission Brake fluid FMVSS DOT4 Electrical system description Item Standard Battery capacity 12V 9Ah Fuses 20 15 15 15A Permanent magnet Alternator 12 V 330W at 8000 rpm Spark plug NGK PMR9B ...

Page 15: ... Tail light bulb LED License plate light bulb LED Brake lamp 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 16: ...engine hanger 1 M10 45 Nut fixing engine 1 M10 45 Front wheel 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 ...

Page 17: ... rear brake disc 5 M8 25 Reference bolts for other specifications GB1231 2006 bolt torque standard Engine part Fastening parts Number Thread specification Torque Nm Cylinder head screw A 4 M8 24 26 Cylinder head screw B 2 M6 10 12 Camshaft cover fixing screw 8 M6 10 12 Timing sprocket screw 2 M8 25 30 Exhaust pipe joint fixing screw 2 M6 9 12 Oil filter cover 2 M6 9 12 ...

Page 18: ...leasing screw 1 M12 23 27 Pressure regulating valve screw 1 M18 33 38 Front clutch nut 1 M12 70 80 Rear clutch nut 1 M12 55 65 Generator rotor fixing screw 1 M8 23 27 Water temperature sensor 1 M12 20 24 Spark plug 1 M10 9 11 Oil pressure switch 1 M10 9 11 Reference bolts for other specifications GB1231 2006 bolt torque standard ...

Page 19: ...s 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 2 Threaded bolt for locking crankshaft at TDC Z02 ...

Page 20: ...19 3 Clutch driving wheel locator Z03 4 Shaft bearing punch Z06 1 Z06 8 5 Oil seal punch Z07 1 Z07 9 ...

Page 21: ...20 6 Flywheel extractor Z04 7 Spark plug sleeve Z05 8 Fault diagnosis instrument Z08 9 Shock absorber adjusts handle Z09 ...

Page 22: ...21 2 General tools No Name Picture 1 T sleeve 8 10 12 14 2 Tool case 1 ...

Page 23: ...22 3 Tool case 2 4 Spring pliers 5 Screwdriver ...

Page 24: ...23 6 Pliers 7 Nylon hammer 8 Multimeter ...

Page 25: ...tenance 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 Check and top up the coolant 7 Braking system 8 Headlight inspection and adjustment ...

Page 26: ... Prepare 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 ...

Page 27: ... R R R Engine oil filter New 300R R R R R R R 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 ...

Page 28: ... I I Ignition coil I I I CVT clutch system Drive belt I R Clutch I R Front and back 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 Cooling system Coolant I I I I Valve gap I I I ...

Page 29: ...sorption I I I Wheels tires I I I I Head tube bearing I I I I Battery I I R Safety fastener of important bolt and nut of car body I I I I I I I Basic maintenance 1 Spark plug A Removal and cleaning WARNING In order to avoid the risk of ignition please let the engine and silencer cool down before ...

Page 30: ... 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 2 Remove the spark plug suppressor cap shown no 3 ...

Page 31: ...he engine being careful not to let dust or any other substance enter into 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 ...

Page 32: ...y bending the ground electrode B Assembly fastening 1 Make sure that the washer is in good conditions Once the washer is fitted manually screw the spark plug using spark plug sleeve Z05 2 Ensure that the spark plug suppressor cap is fitted securely so that it will not get detached when exposed to engine vibrations ...

Page 33: ... 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 otherwise engine duration and performance could be compromised 2 Check and replace the gear oil WARNING In order to avoid the risk of ignition please let the engine and silencer cool down before performing the following operations ...

Page 34: ...operations 2 Check that the quantity is within the specified limits SEE TECHNICAL DATA top up with the necessary quantity if required Visual oil color if black or iron filings please immediately change the oil 3 Tighten the drain screw shown no 3 Locking torques 16 20Nm 4 Fill the oil into Gear box from the plug shown no 2 tighten the plug shown no 2 5 Wipe the oil of the surface with a rag to con...

Page 35: ... the engine oil WARNING In order to avoid the risk of ignition please let the engine and silencer cool down before performing the following operations A Check the quantity of engine oil 1 Start the engine let it idle during a few minutes and 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 i...

Page 36: ...nsert the oil cap dipstick shown no 1 into the injection port but do not screw in Remove again and check for the correct oil level it must be between the reference mark H and L Visual oil color if black or iron filings please immediately change the oil ...

Page 37: ...he oil cap dipstick shown no 1 6 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 wear of moving parts and produce irreparable harm B Replacement 1 Park the vehicle on its main stand unscrew and remove oil cap dipstick shown no 1 ...

Page 38: ...37 2 Unscrew and remove the oil release bolt of right crankcase shown no 2 remember not to dismantle the bolt shown no 3 drain off the oil get a collecting container before carrying out these operations ...

Page 39: ...tore the original state according to the order shown Otherwise the thermal part of the engine will be damaged due to insufficient lubrication 3 The replacement of engine oil filter Unscrew and remove the 2 screws shown no 7 remove the cover shown no 8 Slide off the engine oil filter don t use anymore Fit a new oil filter and the cover shown no 8 screw and tighten the 2 screws shown no 7 ...

Page 40: ...gine oil through the fill opening of oil cap dipstick shown no 1 6 Screw and tighten oil cap dipstick shown no 1 7 Start the engine and let it run for several minutes Stop the engine and let it cool down 8 Check engine oil level again whether to meet the requirements ...

Page 41: ...tle trim If this is not so proceed as follows 1 Slide off the protection cover shown no 1 2 Loosen the lock nut shown no 3 3 Turn the set screw shown no 2 so as to obtain the specified value 4 After the adjustment tighten the lock nut shown no 2 and check the empty travel again 5 Refit the protection cover shown no 1 ...

Page 42: ...d 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 Undo the 3 screws shown no 1 to remove the left side cover shown no 2 ...

Page 43: ... size with non flammable water soluble cleaning solvent Immerse the filter element 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 fil...

Page 44: ... 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 Filter element Filter element Engine oil Non flammable cleaning solvent ...

Page 45: ...ill increase engine wear 6 Check and top up the coolant WARNING In order to avoid the risk of ignition please let the engine and silencer cool down before performing the following operations Undo the 3 screws shown no 1 to remove the left side cover shown no 2 ...

Page 46: ...he coolant tank cap shown no 2 4 Check the coolant level If you do not see the liquid level or the liquid level is deep top up until liquid level close to the coolant tank cover 5 Screw the coolant tank cap shown no 2 clockwise B Inspect the coolant level in the expansion tank Make sure that the coolant level in the expansion tank shown no 3 is between the MIN and MAX reference marks Otherwise top...

Page 47: ...n no 4 from the expansion tank shown no 3 2 Top up with coolant until the fluid level is close the MAX reference mark Do not exceed this level Otherwise the coolant will spill out when the engine is running 3 Refit the filler cap shown no 4 ...

Page 48: ... cooling system 7 Braking system A Check and top up the brake 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 49: ...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 50: ... TOPPING 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 apply to GP200S 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 51: ...the same time the ABS lamp will not extinguish 1 Check the gap between the front wheel hall sensor shown no 1 and the front wheel counting gear tray shown no 2 and the clearance should be 1 0 1 6mm If there is an excess check and adjust the position of hall sensor shown no 1 ...

Page 52: ... 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 ...

Page 53: ...f the front light beam 1 Place the vehicle 10 m from a vertical wall and make sure the ground is level 2 Turn on the low 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 ...

Page 54: ... 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 55: ...54 ELECTRICAL SYSTEM Components arrangement ...

Page 56: ...55 ...

Page 57: ...1 Taillight 12 Control unit throttle body 13 Spark plug 14 Battery 15 Left grip switch 16 Buzzer 17 Injector 18 STARTER MOTOR 19 Voltage regulator 20 Generator 21 Fuses 22 Oxygen sensor 23 Ignition coil 24 Start up relay 25 Relay 26 Dump valve 27 Instrument adjustment switch 28 Electric lock 29 Acceleration grip right switch 30 Speedometer 31 Oil pump 32 Fuel Level Sensor ...

Page 58: ...57 Instrument Panel Indications 1 Engine RPM Indicator 2 Fuel gauge 3 LH Direction Indicator 4 High beam Low beam indicator ...

Page 59: ...ory When the display is TRIP METER press the MODE button and hold for 5 seconds then release when zero is displayed C MPH to KPH change When the display is ODOMETER press the MODE button and hold for 5 seconds then release 7 Oil indicator If this warning light appears during running check oil level if found to OK Then please consult your dealer 8 ABS indicator If this warning light appears during ...

Page 60: ...59 Harness diagram ...

Page 61: ...60 Conceptual diagram ...

Page 62: ...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 63: ...down the cushion shown no 1 unscrew and remove the 2 screws shown no 3 2 Unscrew and remove the screw shown no 4 take down the battery cover shown no 5 unscrew and remove the 2 screws shown no 6 3 Unscrew and remove the 4 screws shown no 7 take down the hand holder shown no 8 ...

Page 64: ...63 4 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 main cover shown no 11 ...

Page 65: ...the Fuel evaporation system 1 Loosen the clamp shown no 1 pull out the trachea shown no 2 2 Unscrew and remove the screw shown no 3 take down the air valve shown no 4 dump valve shown no 5 and bracket shown no 6 ...

Page 66: ...65 3 Cut the tie band shown no 7 loosen the clamp shown no 8 pull out the trachea shown no 9 and remove the carbon canister shown no 10 ...

Page 67: ...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 10 ...

Page 68: ...lug shown no 18 and the oil level sensor plug shown no 19 2 Take down the 3 relays shown no 16 unscrew and remove the 2 screws shown no 17 2 screws shown no 20 and 2 screws shown no 21 Remove the battery bracket Connecting Fuel Tank Connecting Canister ...

Page 69: ...68 ...

Page 70: ... ignition key shown no 22 into the cap shown no 23 and turn the fuel cap tab clockwise undo the screw fixed to ABS shown no 24 pinch and pull out the fast joint of the high pressure oil pipe shown no 25 with the hand remove the fuel tank ...

Page 71: ...ter 1 Remove the clamp shown no 1 and no 3 separate the trachea shown no 4 and take down the return valve shown no 2 CAUTION Reassemble and remove the oil in the return valve shown no 2 The UP arrow points to the air filter ...

Page 72: ...71 2 Loosen the clamp shown no 5 and separate the air filter outlet pipe shown no 6 3 Unscrew and remove the 2 screws shown no 7 and no 8 ...

Page 73: ...72 4 Unscrew and remove the 2 screws shown no 9 5 Take down the air filter and front fender ...

Page 74: ... Remove the exhaust system 1 Undo but not remove the two Hoop screws shown no 3 2 Undo and remove the screw shown no 4 3 Undo but not remove the two screws shown no 5 remove the exhaust system shown no 6 ...

Page 75: ...sleeve shown no 6 1 every time after removing the muffler and replace it when the inner hole is damaged or broken 4 Loosen the clip shown no 7 disconnect the oxygen sensor connector shown no 8 and remove the oxygen sensor shown no 9 ...

Page 76: ... 10 remove the exhaust pipe shown no 11 CAUTION When reassembled the 2 nuts shown no 10 and bolt shown no 4 are first swirled but not locked when the clamp bolt shown no 3 is locked then lock the 2 nuts shown no 10 and bolt shown no 4 ...

Page 77: ...no 4 and slide out the water pipe shown no 5 so that the coolant is collected in the well prepared container CAUTION Remove the expansion box cap to help the coolant evacuate Rising the front wheel at least 55cm can make the coolant in the system loop empty ...

Page 78: ...hown no 36 2 Disconnect water temperature sensor plug shown no 37 3 Disconnect oil temperature sensor plug shown no 38 4 Disconnect the start motor line plug shown no 39 5 Disconnect the ECU plug shown no 40 6 Disconnect generator wire plug shown no 41 and no 42 ...

Page 79: ...rottle body shown no 2 Remove the rear wheel 1 Unscrew and remove the screws shown no 7 and no 8 take down the right rear shock absorbers shown no 9 2 Unscrew and remove the 2 screws shown no 10 and nuts shown no 11 take down the rear fork shown no 12 ...

Page 80: ...79 3 Hold the left brake lever shown no 1 unscrew and remove the 5 screws shown no 13 and take down the rear wheel shown no 14 ...

Page 81: ...ning torque is 60Nm 4 Hold the left brake lever shown no 1 unscrew and remove the 5 screws shown no 16 CAUTION When reassembling the bolt thread part of Figure 13 is coated with Loctite 243 thread adhesive and the tightening torque is 25Nm 5 Unscrew and remove the 2 screws shown no 15 take down the brake disc shown no 17 ...

Page 82: ...6 Unscrew and remove the screw shown no 28 take down the sensor shown no 29 CAUTION After the sensor 29 is removed fix it with the strap temporarily to the appropriate position of the frame to avoid damage ...

Page 83: ...no 43 do not remove the fixed shaft shown no 43 2 Reconfirm that the connection of the engine has been removed remove the fixed shaft shown no 43 and take down the engine Assemble again CAUTION Reassembly according to the above reverse procedure and tighten to the required torque ...

Page 84: ...sed more than 2 years should replace the rubber parts such as oil seal O ring and so on In 2 years the crankshaft oil seal shown no 2 and the drive shaft oil seal shown no 1 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 stan...

Page 85: ...aced 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 Press the bearin...

Page 86: ...el injector shown no 2 2 Remove the 3 screws shown no 3 and take down the intake manifold shown no 4 Discharge oil fill oil 1 Discharge oil from gear box Unscrew and remove gear box oil discharge screw shown no 3 release oil prepare suitable containers in advance to collect gear oil ...

Page 87: ...icating oil of 75W 80 2 The tightening torque of the oil discharge screw shown no 3 is 25Nm 2 Discharge oil from crankcase Unscrew and remove crankcase oil discharge screw shown no 2 release oil prepare suitable containers in advance to collect engine oil ...

Page 88: ...1 Crankcase Add 1000CC lubricating oil of 10W 40 it is recommended to use the grade APL SJ above 2 If the pressure regulating valve screw shown no 3 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 oil discharge screw shown no 2 is 33 38Nm The tightening torque of the pressure regulating valve scr...

Page 89: ... 1 Remove the air duct 1 Unscrew and remove the 2 screws shown no 1 and 3 screws shown no 2 remove the air duct 2 Unscrew and remove the screw shown no 4 take down the air box cover shown no 5 3 Clean or replace the air filter ...

Page 90: ...89 2 Remove the CVT cover 1 Unscrew and remove the screw shown no 1 Take down the CVT cover shown no 2 by using screwdriver shown no 3 ...

Page 91: ...90 Disassemble front and back clutch 1 Take down the plastic cover shown no 10 2 Remove the 2 nuts counter clockwise shown no 8 3 Take down the figure 7 4 3 9 5 6 2 1 in turn ...

Page 92: ...hamfering of the inner hole 4 Assembly sequence 1 2 6 9 5 3 4 7 8 10 5 Check and confirm the seal face of clutch roller PuLiZhu is opposite to clutch rotation 6 Front off nut Coated with Loctite 243 thread adhesive tightening torque 70 80Nm Back off nut Coated with Loctite 243 thread adhesive tightening torque 55 65 Nm Disassemble Gear box 1 Rotate the engine and remove the screw of the gear box 2...

Page 93: ...r the locating pin is on the gear box cover or the left box body and then place the sealing gasket Disassemble water pipe and sensor 1 Undo the water pipe clamp shown no 3 and remove the water pipe shown no 4 2 If not necessary do not disassemble the water temperature sensor shown no 1 and the oil pressure switch shown no 2 ...

Page 94: ...knocking or beating is allowed during demolition or assembly 2 The water pipe clamp shown no 4 is disposable parts and it is not reused as far as possible after dismantling Reassembly attention 1 Water temperature sensor shown no 3 tightening torque 20 24Nm 2 The oil pressure switch shown no 5 tightening torque 9 11Nm ...

Page 95: ...94 Disassemble generator cover 1 Remove the generator cover screws in turn and Take down the generator cover and gasket ...

Page 96: ...ing gasket If oil immersion damage and folding occur it must be replaced 2 Check whether the locating pin is on the gear box cover or the left box body and then place the sealing gasket 3 Special tooling detection trigger gap 0 7 0 1mm 4 Align the position and direction of the oil pump shaft and the pump shaft according to the figure below ...

Page 97: ... generator rotor 1 Removing the starter motor Unscrew and remove the two screws take out the starter motor 2 Rotate the crankshaft to make the piston reach the TDC and lock the crankshaft with the special tool below ...

Page 98: ...97 3 Remove the screws of the generator rotor undo the generator rotor with special tools take off the rotor assembly and take out the semicircle key if the crankshaft is not replaced do not take out ...

Page 99: ...er plane is parallel to the centerline of the crankshaft 2 The key slot on the rotor is aligned with the upper half key of the crankshaft 3 The inner hole chamfering edge of the rotor fastening bolt gasket is headed towards the bolt head 4 The rotor fastening bolts are coated with Anaerobic Thread Locking adhesive and the tightening torque is 23 27Nm ...

Page 100: ...99 Disassemble engine oil pump 1 Unscrew and remove the 4 screws Take down the Oil baffle 2 Unscrew and remove the 2 screws take off the chain sprocket and engine oil pump ...

Page 101: ...ad cover 1 Remove the screw shown no 4 Figure 5 is a seal sleeve 2 Remove cylinder head cover shown no 1 gasket shown no 2 and sealing ring shown no 3 All 2 3 and 5 of the drawings are rubber seals If they are damaged or increased they should be replaced ...

Page 102: ...shaft to make the piston reach the TDC and lock the crankshaft with the special tool below 3 Remove the tensioner Unscrew and remove the screw shown no 1 close the spring remove the screw shown no 2 and remove the tensioner ...

Page 103: ...102 4 Remove the timing sprocket To facilitate assembly mark the chain and 2 sprockets before removing remove the screws shown no 3 and Take down the washers shown no 2 and sprockets shown no 1 ...

Page 104: ...e bolt shown no 3 are coated with Anaerobic Thread and then fastened the tightening torque is 25 30Nm 5 Remove the intake and exhaust camshaft Remove 8 screws shown no 6 Take down camshaft cover shown no 5 intake camshaft shown no 2 and exhaust camshaft shown no 3 6 Use a sucker or magnet to remove the valve tappet shown no 1 CAUTION It is better to mark the 1 2 and 3 of the picture when removing ...

Page 105: ...104 ...

Page 106: ...e and replace the valve tappet with a thickness mark on the inside until the requirement is met Intake valve clearance 0 10 0 15 exhaust valve clearance 0 20 0 25 2 Use auxiliary tool 6 3mm pin shown no 7 through the camshaft cover shown no 5 to fix the intake camshaft shown no 2 and the exhaust camshaft shown no 3 Intake camshaft marked A blue Exhaust camshaft marked S white ...

Page 107: ...and reload the outer ring The tightening torque is 9 11Nm 7 Remove the 2 bolts shown no 4 and 4 bolts shown no 5 no 6 take down the head of the cylinder shown no 3 and seal shown no 2 and the positioning pin shown no 1 connected to the head of the cylinder shown no 3 If not necessary do not remove 7 8 9 10 11 and 12 in the figure ...

Page 108: ...107 ...

Page 109: ... no 6 needs to be pretwisted diagonally first B Pre tighten the bolt shown no 4 The tightening torque is 5Nm C Tighten the bolt shown no 6 The tightening torque is 24 26Nm 90 D Then tighten the bolt shown no 4 The tightening torque is 10 12Nm 3 Figure 11 or 12 is not allowed to use two times as much as possible If maintenance is not necessary 11 and 12 in the Figure are not dismantled 8 Disassembl...

Page 110: ...109 2 Use special tool to compress valve spring and take out valve lock clip ...

Page 111: ...110 3 Take down the relevant parts connected with the valve in turn If there is no need do not Take down the valve oil seal ...

Page 112: ...y attention After the above procedure is assembled the tightness of the valve seat must be tested Import gasoline from intake and exhaust port observe leakage from intake and exhaust valve seat do not leak too much ...

Page 113: ...sassemble cylinder Remove the cylinder shown no 7 and the seal pad shown no 6 10 Disassemble piston Remove the retaining ring shown no 3 and remove the piston pin shown no 2 and take down the piston shown no 1 ...

Page 114: ...asket shown no 6 4 If the crankshaft the crankcase the piston and the cylinder are replaced at the same time or part do not install the sealing gasket press the cylinder with auxiliary tools measure the height from the upper plane of the cylinder to the top of the piston and select the thickness of the sealed gasket according to the table below Thickness grouping of cylinder seal Engine capacity V...

Page 115: ...ston diameter Tolerance clearance 125CC M 58 01 58 017 57 963 57 970 0 04 0 054 N 58 017 58 024 57 970 57 977 0 04 0 054 O 58 024 58 031 57 977 57 984 0 04 0 054 P 58 031 58 038 57 984 57 991 0 04 0 054 200CC M 63 01 63 017 62 958 62 965 0 045 0 059 N 63 017 63 024 62 965 62 972 0 045 0 059 O 63 024 63 031 62 972 62 979 0 045 0 059 P 63 031 63 038 62 979 62 986 0 045 0 059 ...

Page 116: ...15 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 Grouping Mark Grouping Mark ...

Page 117: ...116 Disassemble crankcase 1 Remove the 3 bolts 2 Tapping the right crankcase with a nylon hammer and separating the right crankcase ...

Page 118: ...117 3 Tapping the left crank with a nylon hammer and taking the crankshaft out 4 It is not recommended to remove the bush ...

Page 119: ...ot disassemble and replace it without authorization It is suggested to return to the seller or the production plant for maintenance Reassembly attention 1 The tightening torque of the 3 bolts in the figure is 10 12Nm 2 After the assembly is completed the crankshaft stop pin must be used to move the crankshaft to the TDC This step is especially important ...

Page 120: ...119 Disassemble engine oil filter Remove the 2 bolts shown no 6 Remove the oil filter cover shown no 5 O circle shown no 4 and filter element shown no 3 ...

Page 121: ...ing shown no 4 not to be damaged When reinstalling the 5 and 4 combinations the surface is coated with lubricating oil and pressed from the middle 3 After fastening Bolts shown no 6 clean the lubricant around the oil filter cover shown no 5 so as not to bring the illusion of oil leakage Assembly 1 Assemble the engine by the above reverse process 2 Focus on oil pressure inspection 1 Remove hydrauli...

Page 122: ...hen the idle speed is 1700 100rpm the oil pressure is more than 0 18MPa When the speed is 6000rpm the oil pressure is 0 35 0 65MPa 3 If the engine oil pressure is not within the specified limits check oil quantity oil filter oil pressure regulating valve and oil pump in turn ...

Page 123: ...122 EFI SYSTEM The vehicle uses the Magneti Marelli EFI system The schematic diagram as follows ...

Page 124: ...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 125: ...ances 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 pressure of the fuel system before dismantling the tubing Lift the main...

Page 126: ...ttle body has been adjusted when it is released from factory It does not allow users to replace their initial position at will When the engine is running dismantling the battery is not allowed OBD system introduction Vehicle diagnostics system referred to as OBD On Board Diagnostic When the system fails the fault light MIL or the engine Check Engine warning light is lit The OBD system will save th...

Page 127: ...ability detection is carried out by voltage control etc Once a fault occurs in a link or a signal is not trusted the ECU immediately sets up a fault information record in the RAM s fault memory The fault information record is stored in the form of a fault code The fault code is called current fault code the transient fault caused by bad contact and the current lost record is the history fault code...

Page 128: ...35 Lambda sensor heater O2 Sensor Heater Circuit P0201 Injector Injector Circuit Open Cylinder 1 P0230 Fuel pump relay Fuel Pump Primary Circuit P0335 Engine rpm sensor Crankshaft Position Sensor A Circuit P0351 Coil high tension Cylinder 1 Ignition Coil Malfunction P0480 Fan relay Fan 1 Control Circuit P0505 Idle control actuator Idle Speed Control Error P0530 Light relay Light relay P0560 Batter...

Page 129: ...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 130: ...129 4 OBD diagnostic connect and use OBD diagnostic function Read fault code clear fault code data flow display status identification display etc ...

Page 131: ...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 132: ...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 133: ...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 134: ...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 135: ...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 136: ...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 137: ... 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 whether the fuel label and whether it contains ethanol meets the requ...

Page 138: ... 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 bypass air duct 2 idle speed regulator 3 coolant temperature sensor 4 Ignition timin...

Page 139: ...lated 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 parts 1 fuel has ...

Page 140: ...t fuel system 3 Check spark 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...

Page 141: ...ace the exhaust pipe 10 Remove the 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 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 ...

Page 142: ...embly and installation 1 Disconnect the oil pump connector start the engine until the engine goes out automatically remove the fuel tank 2 The two fingers press the plug button at the same time and pull out the quick connector ...

Page 143: ...142 3 Disconnect the injector connector 4 Remove the bolt and take off the fuel injector 5 Assembly according to the above reverse process ...

Page 144: ...143 Throttle valve disassembly and installation 1 Remove the fuel tank 2 Disconnect the plug ...

Page 145: ...4 Unscrewing the clamp between air filter and throttle body shown no 2 unscrewing the throttle body and the hoop connected to the intake manifold shown no 3 5 Take off the throttle body shown no 4 6 Assembly according to the above reverse process ...

Page 146: ...ipped with ABS brake system a front disc brake a rear disc brake and ABS 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 147: ...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 148: ...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 149: ...148 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 150: ...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 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 but not remove the bolt shown no 3 3 Unscrew and remove the bolt shown no 4 4 Unscrew but not remove the 2 bolts shown no 5 and take down the muffler shown no 6 ...

Page 152: ...bolts shown no 7 and no 8 and remove right rear shock absorbers shown no 9 6 Unscrew and remove the 2 bolts shown no 10 and nut shown no 11 and remove the rear fork shown no 12 the tightening torque of the nut shown no 11 is 100Nm ...

Page 153: ...orque is M12 CAUTION When reassembling the bolt thread part of Figure 4 is coated with Loctite 243 thread adhesive and the tightening torque is 60Nm 8 Hold the left brake lever shown no 1 unscrew and remove the 5 bolts shown no 16 9 Unscrew and remove the 2 bolts shown no 15 remove the brake disc shown no 17 The tightening torque M8 is 25Nm ...

Page 154: ... clip shown no 18 pull out the pin shaft shown no 19 take off the spring leaf shown no 20 and pay attention to the spring leaf shown no 20 in accordance with the direction of the picture 11 Take down the pad shown no 21 ...

Page 155: ...ill come out of the caliper to cause the leakage of brake fluid 12 Inspection and replacement of pad and brake disc are described in part Ⅲ CAUTION Reassembly is carried out according to the above reverse process Inspection of front and rear pad and brake disc 1 Brake disc inspection and replacement ...

Page 156: ...mit 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 2 Brake pad inspection and replacement 1 Figure 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 ...

Page 157: ...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 158: ...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 159: ...eplacement 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: ...ion 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 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...

Page 161: ...160 COOLING SYSTEM System composition ...

Page 162: ...Coolant emptying 1 Remove the 6 bolts shown no 1 remove the right cover shown no 2 and the left cover shown no 3 2 Release clamps shown no 4 Slide off the water pipe shown no 5 Collect the coolant into the pre prepared container ...

Page 163: ...162 CAUTION Remove the expansion box cap to help the coolant evacuate Rising the front wheel at least 55cm can make the coolant in the system loop empty ...

Page 164: ...let pipe shown no 5 again tighten the clamps shown no 4 2 Fill the expansion tank with coolant until the liquid level reaches the MAX reference line 3 Fill the water tank with coolant until it is full and cover the water tank cover shown no 2 ...

Page 165: ...til the fan works 5 Turn off the engine and cool it down fully about 12 hours 6 Check the liquid level of expansion tank and water tank again if necessary add to the correct level 7 Reinstall the right cover shown no 2 and left cover shown no 3 ...

Page 166: ...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 167: ...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 168: ...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 GP200S with ABS GP125S with ABS or CBS 6 Front and Rear shock absorption effect 7 Is there any abnormal noise ...

Page 169: ...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 170: ...169 ...

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