um DSR EX 125 Workshop Manual Download

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Spark plug

Rocker cover

Camshaft bridge

Timing crown wheel 1

Timing crown wheel 2

Cylinder head

Inlet pipe

Thermostat cover

Coolant temperature sensor

Timing chain tensioner

Timing chain tensioner spring

Water pump cover

Water pump turbine

Clutch control cam

Oil filter cover

Oil pressure sensor

Clutch cover

Clutch spring

Clutch bell housing-ram

Balance shaft

Crankshaft-clutch bell housing gear

Timing chain roller.

Oil pump

Selector drum flor.

Selector drum flor. locking cam

Starter motor

Phase inspection cover

Magneto side oil filter cover

PARTS TO BE TIGHTENED

DESCRIPTION

THREAD

MEASUREMENT

QTY.

TIGHTENING TORQUE

Kgf.m

N·m

Obs.

Bolt

Cover

Bolt

Nut

Bolt

M10

M56x1,5

M10

M12

M10

M12

M18X1,5

M28X1

1,2-1,4

1-1,2

2,5-2,7

2,7+90°

1,1-1,3

1-1,2

0,8-1,0

1,1-1,3

0,8-1

0,5-0,6

0,4-0,6

0,8-1,0

2,4-2,6

1,2-1,4

1,1-1,3

0,35-0,45

3,5-4,5

7,5-8,3

1-1,2

0,5-0,6

0,35-0,45

0,8-1,0

1,1-1,3

0,35-0,45

2,4-3,0

12-14

10-12

25-27

27+90°

11-13

10-12

8-10

11-13

8-10

5-6

4-6

8-10

24-26

12-14

11-13

3,5-4,5

35-45

75-83

10-12

5-6

3,5-4,5

8-10

11-13

3,5-4,5

24-30

TIGHTENING TORQUES

WORKSHOP MANUAL

Summary of Contents for DSR EX 125

Page 1: ...ENGINE 125 4T 4V 6M EURO 4 WORKSHOP MANUAL...

Page 2: ...tely satisfactory work cannot however be carried out without the availability of suitable facilities and tools which is why we ask you to consult the pages of this manual referring to special tools an...

Page 3: ......

Page 4: ...stributor INSPECTION AND REPAIR ASSEMBLING AND ADJUSTING THE ENGINE Transmission gear selector gearchange shaft and selector distributor Crankshaft Crankcases Oil pump Clutch Flyweel magneto Camshaft...

Page 5: ...he specific tools intended for this machine During assembly always use new gaskets oil seals piston rings and keys After dismantling clean the components with solvents that are non inflammable or with...

Page 6: ...R CLASSIC 125 RENEGADE SCRAMBLER SPORT 125 DSR ADVENTURE 125 DSR ADVENTURE TT 125 M6FSC0001Hxxxxxxx M6FDA0001Hxxxxxxx M6FDS0001Hxxxxxxx ENGINE CODE The engine code can be found at the back of the engi...

Page 7: ...tems together This includes gears cylinders pistons and other parts sub mitted to natural wear together Related parts must always be reassembled or replaced together While dismantling the motorcycle c...

Page 8: ...rease to the retaining ring edges TAB SPACER WASHERS AND SPLIT PINS After removing them renew all tab spacer washers 1 and split pins Bend the tabs to fit the flat surfaces of the bolt or nut once the...

Page 9: ...to be applied to it See the figure on the side 4 Shaft SPECIAL TOOLS The following special tools are needed for assembly and for complete and exact adjustments Only use the proper special tools thereb...

Page 10: ...g tool Ref 00H05300041 Clutch bell housing fitting tool Ref 864486 Balance shaft locking tool Ref 864567 Set of camshaft locking keys GENERAL INFORMATION WORKSHOP MANUAL Ref T01010045 Ref T01010042 Re...

Page 11: ...ing tool Ref 864868 Magneto flywheel extractor tool Ref 865261 Piston fitting clamp Ref 865207 Set of tools for 125cc 4 stroke 4 valve engine 10 GENERAL INFORMATION WORKSHOP MANUAL Ref T01010050 Ref T...

Page 12: ...ype electronic ignition Gearing Cv 15 5 Kw 11 4 a 9250 at the crankshaft Cv 14 0 Kw 10 3 a 9250 at the rear wheel Type of oil Engine oil Viscosity Total capacity AGIP CITY 4T SAE 10W 40 1150 ml Power...

Page 13: ...mission ratio First gear ratio Second gear ratio Third gear ratio Fourth gear ratio Fifth gear ratio Sixth gear ratio Secondary transmission ratio 12 ENGINE SPECIFICATIONS WORKSHOP MANUAL 2 38 3 2 1 5...

Page 14: ...NED DESCRIPTION THREAD MEASUREMENT QTY TIGHTENING TORQUE Kgf m N m Obs Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Cover Bolt Bolt Bolt Bolt Nut Nut Nut Bolt Bolt Bolt Bolt Bolt M10 M6 M6 M8 M8 M8 M6...

Page 15: ...ick up R P M sensor Starter crown wheel clamp Magneto rotor Magneto rotor starting clutch Semi crankcases joint Bolt Bolt Bolt Bolt Bolt Nut Bolt Bolt M6 M4 M10x1 25 M12x1 5 M5 M5 M6 M14x1 5 M6 M6 10...

Page 16: ...01 8714465002 N B The crankcases available as spare parts are always of the S kind BALANCE SHAFT GEAR SET S CLASS T CLASS MIN 64 03 64 00 64 00 63 97 MAX BALANCE GEAR N B The distances between the bal...

Page 17: ...EFERENCE 8714605001 8714605002 REFERENCE 8714475001 8714475002 N B The crankcases available as spare parts are always of the X kind X CLASS Y CLASS MIN 86 04 86 00 86 00 85 96 MAX BALANCE GEAR N B the...

Page 18: ...kit with the piston Reference 874533 CATEGORY THICKNESS 1 2 3 4 5 6 7 8 9 10 11 12 THICKNESS 2 20 2 25 2 30 2 35 2 40 2 45 2 50 2 55 2 60 2 65 2 70 2 75 REFERENCE CM222701 CM222702 CM222703 CM222704 C...

Page 19: ...864589 If the crankcases have mixed bearings they can be fitted regardless of their initial location CLASS B BLUE BLUE RED BLUE CLASS A RED BLUE RED RED CLASS 1 CLASS 2 MIN 32 480 32 485 CRANKSHAFT D...

Page 20: ...rk plug should fire Components Engine rpm sensor pick up Sensor resistance 105 124 _ at 20 C magneto side connector between R and B cable Ignition coil Resistance of primary winding 0 21 0 025 at 25 5...

Page 21: ...8000 rpm Resistance of stator between phases 0 4 10 Check at the magneto side connector between 1 2 and 3 3 measurements Current leakage With the ignition key in the OFF position connect the ammeter i...

Page 22: ...The pump is driven by the clutch and fitted with two rotors made of sintered material One 13mm thick rotor for oil suction One 8 5 mm thick rotor for pumping The maximum pressure is 4 2 bars and at t...

Page 23: ...ass To bottom of cylinder Oil input to filter To bottom of cylinder Oil input Rises for camshafts Oil to supports Rises for camshafts Oil to supports Rises for camshafts Oil input 22 LUBRICATION CIRCU...

Page 24: ...HOP MANUAL bis 22 Gear Box lubrication circuit 7 holes pipe Lubricate the gear shaft before assembly Always replace pipe OR OIL TO PIPE LUBRICATION PIPE OUTPUT SHAFT LUBRICATION HOLE CHECK THE SIX HOL...

Page 25: ...The pump oil seal is the metal type The thermostat opens at between 80 C and 85 C The radiator is fitted with an electric fan Resistance value of the temperature sensor NTC At 60 C 600 470 At 90 C 21...

Page 26: ...be changed together BEFORE EVERY START UP NOTE Engine trans Cycle Electrical ENGINE OIL Check the level Top up if necessary DRIVE CHAIN Check the tension Adjust if necessary COOLANT Check the level To...

Page 27: ...guides Change if necessary COOLANT Check the level Top up if necessary BRAKE PADS Check the wear Renew if necessary BRAKE LEVER CABLES Check condition BRAKE LEVERS AND THROTTLE TWIST GRIP Check the co...

Page 28: ...d test drive paying attention to the general operation of the brakes steering clutch suspensions engine lights and instru ment panel lights SYSTEM Note 2 Note 1 INSPECCI N TIPO 3 NOTE Engine trans Cyc...

Page 29: ...IS STOPPING Loosen the throttle cable locknut 2 Turn the adjuster 3 inwards or outwards until the speci fied play is obtained 1 Turning inwards Increasing the clearance Turning outwards Reducing the c...

Page 30: ...our is a light brown 4 Clean Spark plug Clean the spark plug with a spark plug cleaner or a wire brush 5 Measurement Gap between the electrodes a using a feeler gauge Outside that specified Adjust Dis...

Page 31: ...G THIS FROM FALLING INTO THE ENGINE Fit q PNQSFTTJPO NFUFS Measurement Compression pressure If it exceeds the permitted maximum pressure Inspect the cyulinder head valve surfaces and piston head for c...

Page 32: ...0 4 kg cm 2 Steps for removal Start the engine with the throttle completely open until the comprerssion reading stabilises WARNING BEFORE STARTING THE ENGINE CONNECT THE SPARK PLUG WITH HANDLE TO PREV...

Page 33: ...iller hole without screwing in Remove it again immediately Check The engine oil level The oil level should be between the MAXIMUM and MINI MUM marks Oil below the minimum level Add oil up to the corre...

Page 34: ...Dipstick Pre filter cap 2 4 3 0 Kgf m 24 30 N m Replenish Oil in the crankcase Quantity of oil 1 150 ml Type of oil AGIP CITY 4T 4 STROKE Check The engine oil level See INSPECT THE ENGINE OIL LEVEL s...

Page 35: ...PIECE OF WIRE TO THE TIMING CHAIN TO STOP IT FROM FALLING INTO THE CRANKCASE 9 Extract The 2 bolts 6 and 2 washers 7 from the camshaft crown wheels The camshaft distribution crown wheels 8 Extract Th...

Page 36: ...starter motor The starter motor 7 N B REMOVE THE STARTER MOTOR TO ENABLE EASY EXTRAC TION OF THE TIMING CHAIN TENSIONER Extract The 2 timing chain bolts the tensioner and the seal 8 N B PLACE A CONTA...

Page 37: ...chapter Extract The fixed timing chain roller 15 Fit The crankshaft sprocket locking tool 16 Crankshaft sprocket locking tool Ref 864487 Extract The nut 17 The crankshaft sprocket 18 Extract The timi...

Page 38: ...key b to turn the crankshaft in an anti cloc kwise direction until the mark a is aligned with the statio nary point N B GIRE EL CIG E AL EN SENTIDO ANTIHORARIO N B REMOVE THE STARTER MOTOR TO ENABLE...

Page 39: ...timing chain tensioner The tensioner seal Extract The 2 bolts and the thermostat cover 8 Extract The thermostat 9 Extract The spark plug 10 The 4 cylinder head cover bolts 11 Cylinder head side cover...

Page 40: ...ING INTO THE ENGINE Extract The camshaft see chapter Extract The 6 bolts 16 securing the cylinder head to the cylinder The cylinder head 17 Extract The top cylinder gasket 18 Renew when refitting The...

Page 41: ...P FROM THE GUDGEON PIN COVER THE BASE OF THE CYLINDER WITH A CLOTH TO PREVENT OBJECTS FROM FALLING INTO THE ENGINE Extract The 2 circlips 23 one on each side securing the piston gudgeon pin Extract Th...

Page 42: ...inder head side cover 3 The cover gasket Renew when refitting Fit The magneto flywheel 4 locking tool Magneto flywheel locking tool Ref 865259 Fit The magneto flywheel extractor 5 Magneto flywheel ext...

Page 43: ...4 N B PLACE A CONTAINER UNDER THE ENGINE AND DRAIN THE OIL FROM THE CRANKCASE Extract The engine oil plug 5 The spring 6 The oil filter 7 Extract The 10 bolts 8 from the clutch cover The clutch cover...

Page 44: ...The clutch disks and separators 12 Abrir The seal tab 13 Extract The nut 15 The seal 13 Extract Use the clutch housing extraction tool 15 to remove it Clutch housing extraction tool Ref 00H05300041 E...

Page 45: ...e intermediate starter gear clip and washer 1 The intermediate starter gear 2 Extract The oil pump gear clip 3 The oil pump gear 4 Extract The 3 oil pump bolts 5 The oil pump 6 Extract The oil pump ga...

Page 46: ...rankshaft sprocket using the locking tool 4 Crankshaft sprocket locking tool Ref 864487 Extract The nut 5 The fitting tool 4 The crankshaft sprocket 6 Extract The timing chain 7 from the top The timin...

Page 47: ...see the chapter Extract The balance shaft 1 Extract The 6 outer bolts 2 from the left hand crankcase The outer bolt 3 from the left hand crankcase longer The 6 inner bolts 4 from the left hand crankca...

Page 48: ...selector fork rods Long rod 1 Short rod 2 The 3 gear selector forks 3 Extract The gear selector shaft 4 by pulling it out N B THE INTERMEDIATE GEAR MUST BE REMOVED TO BE ABLE TO EXTRACT THE GEAR LEVER...

Page 49: ...Extract The gear selector 9 by pulling it upwards Extract The main shaft 10 The intermediate shaft 11 N B LENGTH OF SECONDARY SHAFT 92 2mm 010 0 18mm 11 10 9 47 DISMANTLING THE ENGINE WORKSHOP MANUAL...

Page 50: ...ar damage Renew Steps for measuring distortion and for rectification Place a ruler 1 and a thickness calliper 2 on the head cylinder surface as in the figure to the side Place a 400 600 emery paper on...

Page 51: ...ted 1 In the event of the clearance being incorrect continue by calculating the appropriate pad s in accordance with the fo llowing calculation Thickness of new pad A B C mm Where A Clearance indicate...

Page 52: ...nst the guide and against the seat to make a visible mark Measure the width of the valve seat Where there was contact between the seat and the valve face the dye will be removed If the valve seat widt...

Page 53: ...SHAKE SOFTLY IN THE VALVE SEAT WHILE TWISTING BACKWARDS AND FORWARDS BY HAND Apply a coarse abrasive paste to the valve face and repeat the above steps N B MAKE SURE THAT ALL TRACES OF GRINDING PASTE...

Page 54: ...ring free length 44 90 mm 2 Measurement Spring contact face Wear damage scratches Renew I NSPECTING THE CAMSHAFT 1 Check Cam salients Grooves scratches blue colouring Renew 2 Inspect Oil passage in th...

Page 55: ...ew chain and sprockets 2 Inspect Drive sprockets Damage wear Renew the sprockets and the timing chain 1 1 4 of the tooth 2 Correct 3 Roller 4 Sprocket 3 Inspect Timing chain guide exhaust 1 Timing cha...

Page 56: ...asurement Cylinder Piston clearance Steps for removal Step 1 Measure cylinder diameter C with an internal calliper N B MEASURE THE DIAMETER C OF THE CYLINDER ACROSS AND AT A RIGHT ANGLE TO THE CRANKSH...

Page 57: ...isks assembly 2 Inspect Separators Damage Renew the separators assembly 3 Inspections Clutch springs Damage Renew the springs assembly 4 Inspect Claws of the bell housing 1 Rough edges wear damage Eli...

Page 58: ...Gear change selector 5 Guide pin 6 Roll the guide bar on a flat surface Warping Renew WARNING DO NOT TRY AND STRAIGHTEN A WARPED BAR 4 Check Movement of the gear change forks in the guide bar Uneven m...

Page 59: ...change shaft 1 Damage warping wear Renew Return spring gear change shaft 2 Return spring limiter rod 3 Wear damage Renew I NSPECTING THE OIL PUMP 1 Inspect Rotary filter Cracks damage Renew Contamina...

Page 60: ...contact surfaces well 3 Inspect Casings Cracks damage Renew Oil passages Obstructions Blow through the passages with com pressed air B EARINGS AND RETAINING RINGS 1 Inspect Bearings Clean and lubricat...

Page 61: ...t 2 Fit Gear change shaft assembly 3 Fit Gear change shaft assembly 4 The gear change selector bolt 5 situated on the other side of the right hand crankcase Fit The 2 gear change forks rods Long rod 6...

Page 62: ...selector shaft 11 N B FIT THE GEAR CHANGE SELECTOR SHAFT BY ALIGNING THE ENDS OF THE RETURN SPRING WITH THE POSITIO NING BRACKET 12 ON THE CRANKCASE N B THE INTERMEDIATE GEAR REMOVED IN DISMANTLING MU...

Page 63: ...secondary gear 6 2nd secondary gear 2 Adjustment washer Needle bearing assy Adjustment washer Safety ring Adjustment washer Washer Bush Washer Primary shaft assy Secondary shaft assembly 1 2 3 4 5 6...

Page 64: ...ecuring plate Gear selection lever Selector shaft assembly Spring D12 safety ring Washer Bolt Washer Drum control head Gear selection spring Special bolt Gear lever assy 6M100x25 bolt D6 washer 1 2 3...

Page 65: ...ENT OBJECT FROM FALLING INTO THE ENGINE Fit The crankshaft key The balance shaft gear 2 The crankshaft gear 3 N B ALIGN THE CRANKSHAFT AND BALANCER GEARS USING THE GUIDE POINTS Fit The balance shaft l...

Page 66: ...9 Crankshaft sprocket locking tool Ref 864487 Fit The crankshaft gear nut 10 Crankshaft gear nut 7 5 8 3 kgf m 75 83 N m N B THERE ARE SETS OF BALANCER SHAFTS CRANKSHAFT GEARING N B See chapter ident...

Page 67: ...CRANKSHAFT PARTS Crankshaft connecting rod assy Counterweight shaft Key Intermediate gear counterweight Counterweight gear Nut 1 2 3 4 5 6 65 ASSEMBLING THE ENGINE AND ADJUSTMENTS WORKSHOP MANUAL...

Page 68: ...TAP THE CRANKCASE LIGHTLY WITH A PLASTIC HAMMER IMPORTANT TIGHTEN THE BOLTS ON THE BLOCK IN SUCCESSION CROSSWISE GOING FROM ONE TO ANOTHER TWO OR THREE TIMES Fit The 6 outer bolts 5 on the left hand...

Page 69: ...Bolt Key M6x75 hex bolt Key m6x60 bolt Clamp Selector lever shaft oil seal Centring stud Secondary shaft needle bearing assy Primary shaft bearing 5 2x15x1 5 washer M5x14 bolt Centring stud 5 2x15x1...

Page 70: ...ion One 8 5 mm thick ro tor for pumping Fit The oil pump gear 5 Fit The oil pump 6 The 3 oil pump bolts 7 The oil pump bolts 0 5 0 6 kgf m 5 6 N m Fit The oil pump gear 8 The oil pump gear clip 9 Fit...

Page 71: ...ump gear Bolt Circlip Oil pump gear Oil pump gear Crankcase oil pump gasket Oil pressure valve spring Oil by pass valve Oil filter Oil filter gasket Plug gasket Oil filter plug 1 2 3 4 5 6 7 8 9 10 11...

Page 72: ...e seal 4 The nut 5 The clutch housing nut 3 5 4 5 kgf m 35 45 N m Closing The seal tab 4 Use the clutch housing 7 fitting key 6 Bell housing extraction tool Ref 00H05300041 N B See chapter identificat...

Page 73: ...ver bolts 10 with washer and spring The clutch closing cover bolts 0 35 0 45 kgf m 3 5 4 5 N m Fit The cover gasket 11 new gasket Fit The clutch cover 12 The 10 clutch cover bolts 13 The clutch cable...

Page 74: ...2 6 kgf m 24 26 N m Fit The water pump turbine 18 The water pump turbine 0 4 0 6 kgf m 4 6 N m Fit The water pump cover 19 and the 3 bolts 20 The coolant pipe 21 The water pump cover 0 5 0 6 kgf m 5 6...

Page 75: ...closing cover Clutch spring Bolt with washer Washer M6 hexagonal nut Clutch bolt Separator Washer Nut with tapered spring Engine gear Key Seeger ring Washer Needle bearing assy Separator bush 1 2 3 4...

Page 76: ...er cartridge M5x14 bolt Water pump cover O ring Complete drive shaft Water pump oil seal Clamp M6x35 bolt Oil seal Pump cylinder head pipe Oil pressure sensor Washer Water pump shaft assy 20x30x5 oil...

Page 77: ...to flywheel using the magne to fl ywheel locking tool 7 Magneto flywheel locking tool Ref 865259 Magneto flywheel rotor nut 8 3 9 0 kgf m 83 90 N m N B POSITION A RUBBER PAD BETWEEN THE TOOL FIXING PO...

Page 78: ...se cover bolts 1 1 1 3 kgf m 11 13 N m IMPORTANT TIGHTEN THE BOLTS ON THE BLOCK IN SUCCESSION CROSSWISE GOING FROM ONE TO ANOTHER TWO OR THREE TIMES Fit The engine oil pre filter The pre filter plug 1...

Page 79: ...lt M 5x16 bolt Bolt Washer Rotor Free wheel inner ring Free wheel Electric start crown wheel Starter motor takeoff gear Starter motor M6x25 bolt 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 S...

Page 80: ...THE CRANKSHAFT DURING THE FITTING OF THE CAMSHAFT TO DO SO MAY CAUSE DAMAGE OR THE ENGINE TIMING TO BE INCORRECT Fit The inlet camshaft 1 ref 0906 A The inlet camshaft 2 ref 0906 S N B POSITION THE CA...

Page 81: ...WN WHEEL BOLTS UNTIL THE TIMING CHAIN TENSION HAS FIRSTLY BEEN SET Adjust Press the tab 11 Push the timing chain tensioner 12 Release the tab 11 Fit The tensioner seal The timing chain tensioner 13 Th...

Page 82: ...ket locking tool 17 The camshaft sprocket locking tool Ref 865260 Fifar Fit the 2 bolts onto the camshaft crown wheels The camshaft sprocket bolts 2 3 2 7 kgf m 23 27 N m Fit The cylinder head cover 1...

Page 83: ...ROM THE SPROCKET Fit The timing chain 2 from the top Fit The fixed roller 3 Timing chain fixed roller 1 1 2 kgf m 10 12 N m Fit The crankshaft sprocket locking tool 4 Crankshaft sprocket locking tool...

Page 84: ...3 N m N B TO HELP THE COVER TO FIT THE WATER PUMP SHOULD BE TURNED UNTIL THE 2 GEARS COINCIDE Fit The water pump cover 10 and the 3 bolts 11 The coolant pipe 12 The water pump cover bolts 0 5 0 6 kgf...

Page 85: ...ve top casing Exhaust camshaft Intake camshaft Seal washer Camshaft cover M6x40 bolt Rocker cover gasket Rocker cover Rocker cover bolt Valve cover rubber washer NGK CR8EB spark plug 1 2 3 4 5 6 7 8 9...

Page 86: ...g 1 Secondary ring scraper 2 Top ring compression 3 N B FIT THE RINGS IN SUCH A WAY THAT THE MANUFACTURER S MARK IS TOWARDS THE TOP LUBRICATE THE PISTON AND THE RINGS WELL WITH EN GINE OIL Position Ri...

Page 87: ...HE BASE OF THE CYLINDER WITH A CLOTH TO PREVENT OBJECTS FROM FALLING INTO THE ENGINE N B APPLY ENGINE OIL TO THE GUDGEON PIN THE MARK MUST FACE TOWARDS THE EXHAUST SIDE Fit The piston 2 The piston gud...

Page 88: ...le N B THE CYLINDER GASKET THICKNESS MUST BE CALCULATED TO ESTABLISH THE APPROPRIATE COMPRESSION RATIO THERE ARE THREE THICKNESSES OF GASKET AVAILABLE 0 3 0 4 AND 0 5 MM PERFORM THE CALCULATION WITH T...

Page 89: ...G THE CYLINDER HEAD TO THE CRANKCASE Fit The 6 bolts 11 and the 4 washers 12 securing the cylinder head to the cylinder The bolts securing the cylinder head to the cylinder 1 1 1 3 kgf m 11 13 N m Fit...

Page 90: ...Fit The thermostat 14 Fit The 2 thermostat cover bolts The thermostat cover 15 The thermostat cover bolts 1 1 2 kfg m 10 12 N m 15 14 88 ASSEMBLING THE ENGINE AND ADJUSTMENTS WORKSHOP MANUAL...

Page 91: ...piston assy Cylinder cylinder head gasket Cylinder crankshaft gasket First piston ring Scraper ring Piston gudgeon pin Piston gudgeon pin circlip Chain tensioner Gasket M6x16 bolt 1 3 4 5 6 7 8 9 10...

Page 92: ...the EFI to the inlet manifold Bolt Intake connector O ring Thermistor Thermostat Thermostat cover 6 3x8x6 8 bush M6x20 bolt Studs Carburettor clamp 1 2 3 4 5 6 7 8 9 10 11 90 ASSEMBLING THE ENGINE AN...

Page 93: ...24 25 26 27 28 29 30 31 32 33 34 IGNITION COIL NEUTRAL GEAR DUMPING SWITCH ENGINE STOP SWITCH STARTING IGNITION GND GND BATTERY START RELAY O2 SIGNAL TEMPERATURE SENSOR O2 SIGNAL FAST ACTING SHIFTING...

Page 94: ...R O B W BR Y R O Y R B PU GR B W G G R LG B LB O W BL GR R Y BL W B W R B B L H MAX SPEED SENSOR WATER TEMPERATURE BACK BOARD LIGHT FUEL NEUTRAL GEAR LEFT INDICATOR PU PU W W R B ECU INTERFACES 7 15...

Page 95: ...TURE LEFT INDICATOR RIGHT INDICATOR IGNITION COIL NEUTRAL GEAR DUMPING SWITCH ENGINE STOP SWITCH STARTING IGNITION GND GND BATTERY START RELAY O2 SIGNAL TEMPERATURE SENSOR O2 SIGNAL FAST ACTING SHIFTI...

Page 96: ...ne CAN1L CAN Bus low 15 NC NC NC 16 Power BAT KL30 permanent power EMS Link This file is in Glasscubes or ask through e mail download in your computer and via USB cable put the file in your android ph...

Page 97: ...n go to settings and unlock it Now you can start The diagnostic cable part number EXEC EMSLinkMIU Only for Android Phone 1 Download into your computer the Magneti Marelli apk file 2 Save it into a new...

Page 98: ...5 3 2 Step of use 05 3 2 1 Connection between the smart phone and vehicle 05 3 2 2 Operation of vehicle 05 3 2 3 How to use EMS Link APP 05 3 3 Note 12 4 Feature description 13 4 1 DashBoard 13 4 2 Tr...

Page 99: ...information Figure 1 is Dongle OBDII connector male figure 1 Table 1 is pinout of OBDII connector Table 1 OBDII connector pinout OBD Connector Pin N I O Type Signal Name Pin Description 1 NC NC NC 2...

Page 100: ...4 10 NC NC NC 11 NC NC NC 12 NC NC NC 13 NC NC NC 14 Comm Line CAN1L CAN Bus low 15 NC NC NC 16 Power BAT KL30 permanent power...

Page 101: ...le to the vehicle s OBD connector as shown in figure 2 figure 2 3 2 2 Operation of vehicle Insert the key to the vehicle and make sure the vehicle s status is key on If you need to test dynamic data p...

Page 102: ...APP as shown in figure 3 figure 3 2 After clicking EMS Link you will enter the Take A Look page as shown in figure 4 In this page you can slip picture to learn how to use APP Click the Skip button yo...

Page 103: ...n you will open the user manual click Take A Look button you will learn how to use app briefly click the Go button you will enter the Main page figure 5 4 When you are in main interface the APP will s...

Page 104: ...PP will list all available devices to user and the user can click the name of device to connect as shown in figure 7 figure 7 6 If the dongle is connected successfully the Connect will become Disconne...

Page 105: ...tton to enter the Settings page as shown in figure 9 figure 9 8 In Settings page you can select the language click Language button you will see the Chinese and English you can select either one as sho...

Page 106: ...e paired device as shown in figure 11 figure 11 10 In Setting page you can select the important parameters which will be shown in Dashboard Click the Important Parameters to select The Engine RPM and...

Page 107: ...d Click the Other Parameters to select as shown in figure 13 figure 13 12 Click the Back button on Smart Phone or Tablet you will go back to the Main page as shown in figure 14 figure 14 Note to perfo...

Page 108: ...ongle only can be connected with one smart phone at the same time 2 If you want to use other smart phone to connect dongle please kill the running EMS Link APP in the running smart phone as shown in f...

Page 109: ...Service Tool function Reflashing function and Scan Tool function as shown in figure 16 4 1 DashBoard figure 16 The DashBoard function can display real time parameters such as RPM SPEED Manifold Press...

Page 110: ...e will be shown in Information page as shown in figure 18 4 2 Trip Meter figure 18 The Trip Meter function through the GPS to display the Max Speed Acceleration Altitude and the Speed on your trip The...

Page 111: ...do the diagnostic function for your vehicle it includes several modules as shown in figure 20 figure 20 1 Read Data The Read Data function is used to read the system parameter as shown in figure 21 C...

Page 112: ...function is shown in figure 22 figure 22 2 Configure Data The Configure Data function is used to read the configuration information such as ECU version Click Start button and Search icon to read data...

Page 113: ...3 Actuator Control The Actuator Control function sends the command to test the actuator of the vehicle as shown in figure 24 figure 24 The test result of Actuator Control is shown in figure 25 figure...

Page 114: ...allow the users to edit the command to test the vehicle as shown in figure 26 figure 26 You can edit the command in edit box and click the Send button to send the command the test result of Monitor Mo...

Page 115: ...the DTC by it as shown in figure 28 Click the Start button to scan DTC click the Clear button to clear DTC 4 4 Reflashing figure 28 The Reflahing function permits to update the engine control softwar...

Page 116: ...l be downloaded into ECU should be stored in the same folder on the smart phone Click Select button to select the bin file as shown in figure 30 figure 30 After selecting the correct bin file click th...

Page 117: ...g In Upload Data Download In Main page click the Log in button to sign in if you have registered before or sign up if have not registered before as shown in figure 33 and figure 34 By this function yo...

Page 118: ...22 figure 33 figure 34...

Page 119: ...og in successfully you can upload ECU data in Settings page as shown in figure 35 Contact us figure 35 Please contact the following email address if you meet any question Email ems link support magnet...

Page 120: ...ummotorcycles eu umglobal com...

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