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10. Front fork assembly

Know Before Service

1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause
damage to parts, peeling of plating, improper assembly, etc.
2. The O-rings, paper gaskets, copper gaskets, and component seals used for sealing must be replaced before
assembly.
3. Fasteners with torque requirements need to use a torque wrench to check the torque; if the torque is not required,
refer to the general torque value recommended by general fasteners.
4. Clean up before assembly; after assembly, check whether the assembly is correct and in place.
5. The vehicle should be parked in a balanced manner and pay attention to safety during disassembly and assembly.
Including but not limited to the use of electric tools, hand tools, pneumatic tools, hydraulic tools, handling; prevent
contact with skin, eyes, burns, etc.
6. The replaced oils, liquids, batteries, etc. must be recycled and handed over to a qualified organization for disposal;
it is forbidden to dump them at will to pollute the environment or water sources.
7. Swallowing or inhaling coolant, brake fluid, etc. will cause certain harm to the human body. Any exposed skin such
as hands and face should be cleaned thoroughly after each addition. If swallowed by mistake, immediately contact the
poison control center or hospital; if inhaled, immediately go to a ventilated environment. If it accidentally splashes into
the eyes, immediately rinse the eyes with a large amount of running water and seek medical advice or consultation in
time. Keep away from children and pets.
8. When replacing the front wheels, jacks or similar devices are needed to support the entire vehicle.
9. Contaminated disc brake discs and disc brake pads will reduce the braking effect. Please replace with new disc
brake discs and clean the contaminated brake discs.
10. When the front wheel is removed, please do not operate the brake handle.
11. After the front wheel is installed, please press the brake handle repeatedly until the brake restores the braking
effect.

Only part of the basic requirements for matters needing attention, prevention of accidental injury, etc. can be listed;

it is not possible to list all situations in detail. Be vigilant during disassembly and assembly to prevent accidents.

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Содержание ZT310T-M

Страница 1: ...1 184 ZT310T M Maintenance Manual 2022 01 22 ...

Страница 2: ... the part codes on the official website of Zontes This manual will not be listed in detail if the part names in this manual are inconsistent with the official website of Zontes please refer to the official website of Zontes If part of the content of this manual is insufficient please refer to the Driver s Manual included with the bike The latest version of the driver s manual can be downloaded as ...

Страница 3: ...s and rubber parts reducing the service life Non woven fabrics should be used for wiping with no residue Ordinary rags may leave cloth scraps or wool etc which may affect the assembly or cause other adverse effects Our company will update this manual as soon as possible after the product changes The following is the meaning of the icons marked in this manual Failure to observe will cause personal ...

Страница 4: ...ccessories 21 6 Oil supply system 22 6 1 Fuel evaporation 22 6 2 Fuel supply 23 7 Distribution map of cooling system accessories 23 8 Electrical device layout 24 9 Intake and exhaust system 26 Tool 27 Expansion nail description 29 2 Maintenance 30 Know Before Service 30 Maintenance schedule 31 Air filter filter element air inlet filter element 32 1 Support the vehicle firmly 32 2 Remove the left e...

Страница 5: ...lant 48 5 Check whether the fins of the radiator water tank are deformed or the air duct is blocked 48 6 Check all water pipes for leaks aging 49 Fuel pipe 51 1 Check the fuel pipe for leaks with the help of an endoscope with LED light 51 2 Replace high pressure oil pipe 51 3 Fuel pump 52 3 1 Use oil pressure gauge to measure fuel pressure 52 3 2 Simple test of fuel pump 52 4 Treatment of abnormal...

Страница 6: ...brake brake fluid 68 2 2 Replace the rear brake fluid 69 3 Brake system exhaust 69 Tire 69 1 Check the tires 70 Steering mechanism 70 1 Check the steering mechanism 71 3 Maintain steering bearings 71 4 Malfunction 72 Front fork 72 1 Check the appearance 72 2 Check the shock absorption performance 73 3 Remove the front shock absorption 73 4 Correct the front fork tube 73 5 Troubleshooting 73 Rear s...

Страница 7: ...ure 90 3 EFI system 91 Know Before Service 91 Error code 93 1 Read the fault code through the meter 93 2 Read the fault code through the diagnostic tool 93 3 Clear fault code 94 3 1 Manually clear 94 3 2 Use the diagnostic tool to clear 94 EFI parts layout 95 Fault diagnosis and elimination of EFI parts 96 1 Dump switch 96 2 OBD port 96 3 Fuel pump 96 4 Carbon canister solenoid valve 97 5 EFI rela...

Страница 8: ...pection 111 Ignition timing 111 Check 111 Installation 112 Ignition coils 112 5 Starting system 113 Know Before Service 113 Troubleshooting 113 1 Starting relay 113 2 Starter motor 114 3 The starter motor runs slowly 114 4 The starter motor is working normally but the engine cannot be started 114 Ignition system layout 114 Starting system electrical schematic diagram 115 Starter motor 115 1 Remove...

Страница 9: ...water tank 129 2 Attention to the water tank filling port 130 2 1 Overall leak check 130 2 2 Check of pressure relief valve 130 3 Auxiliary water tank 130 4 Aluminum inlet pipe and aluminum outlet pipe 130 5 Small water tank 130 6 Water and oil shared sensor 131 7 Thermostat 131 7 1 Inspection 131 7 2 Failure phenomenon 131 7 3 Disassembly 132 7 4 Thermostat core inspection 132 8 Water pipe 132 9 ...

Страница 10: ...he charging voltage 147 3 Inspection of magneto stator charging coil 147 Remove the rectifier 148 10 Front fork assembly 149 Know Before Service 149 Exploded view of front fork components 150 Directional exploded view 150 Front fork exploded view 151 Exploded view of lower link board 152 Change the direction of the handle 153 1 Remove the direction of the handle 153 2 Remove the components 153 3 I...

Страница 11: ... pull out the connection plug 164 4 Disassemble the engine 165 5 Install the engine 166 6 The installation of the corresponding cover 167 6 1 Install the surrounding floor 167 6 2 Install pedal and pedal decorative cover 167 6 3 Install the rear skirt 168 6 4 Installing the side cover 169 6 5 Armrest after installation 169 6 6 Install the device box 169 12 Disassembly and assembly of vehicle cover...

Страница 12: ...y of the left and right tail cover 180 Disassembly of tail light 180 Disassembly of rear fender 181 Disassembly of the left right fuel tank cover 182 Disassembly the middle cover of the fuel tank 182 Disassembly the left and right storage boxes 183 Disassembly the front storage box panel 184 ...

Страница 13: ...hydraulic tools handling prevent contact with skin eyes burns etc 6 The replaced oils liquids batteries etc must be recycled and handed over to qualified institutions for disposal it is forbidden to dump them at will to pollute the environment or water sources 7 Swallowing or inhaling coolant brake fluid etc will cause certain harm to the human body Any exposed skin such as hands and face should b...

Страница 14: ... the rear of the frame The muffler code is on the inner side above the muffler The nameplate is above the radiator PKE OBD interface and water tank filling port position are pasted on the right storage box cover The engine identification code is engraved on the left crankcase The storage box warning label is pasted on the front of the storage box ...

Страница 15: ... ABS Oil consumption Replace fine filter 1 75L 0 46 US gal 0 39 lmp gal Without replacing the fine filter 1 7L 0 45 US gal 0 37 lmp gal Gearbox oil consumption 0 2L 0 05 US gal 0 04 lmp gal Engine Body Aluminum alloy Total number of cylinders Single cylinder Camshaft method Single overhead camshaft SOHC Bore X stroke 72 76mm 2 83 2 99 in cooling method Water cooling Fuel oil 95 and above Compressi...

Страница 16: ...I Front axle runout 0 2mm 0 008 in Rear wheel suspension system Item Standard Limit Tread depth 1 6mm 0 063 in Normal temperature standard tire pressure 260kPa 2 7 kgf cm2 37 7 PSI Rear wheel spline shaft run out 0 2mm 0 008 in V belt Top width 1 26 4mm 1 039 in 25 4mm 1 in Standard position of rear shock absorber and preload regulator Third gear Brake system Item Standard Limit Front brake disc B...

Страница 17: ...1 times the battery capacity Charging time 5 8 hours Charging current charging time must be controlled within the current range of 0 5 to 0 8 times the battery capacity Lamp Speedometer switch description Item Specification Light LED Front headlight High beam 12V 23W Low beam 12V 15W Front position light 2 8W Front turn signal 1 2W Rear turn signal 1W License plate light 0 5W Brake lights tail lig...

Страница 18: ...king torque Tightening torque range Standard value Breaking torque M4 1 2 1 4 1 5 3 2 5 M5 2 4 2 9 4 5 3 6 4 5 8 M6 4 7 4 9 10 8 12 10 14 5 M8 10 16 12 2 20 18 28 22 34 M10 22 25 24 5 45 40 60 44 76 M12 35 55 43 75 70 100 77 112 M14 50 80 69 123 110 160 124 200 M16 80 130 110 195 170 250 200 300 M18 130 190 150 285 200 280 270 450 Remarks The connection tightening torque of plastic parts is half o...

Страница 19: ...osition light 5 Right daytime running light 6 Headlight 7 Right front turn signal 8 Right hand handle auxiliary switch 9 Right hand handle switch 10 Rear tail light system Moving lamp 11 Rear right turn signal 12 Rear reflector 13 License plate lamp 14 Left rear turn signal 15 Left handle switch 16 Left handle assistant switch 2 Throttle cable 1 Oil return line 2 Fuel line ...

Страница 20: ... wheel speed sensors 1 Brake disc front 2 ABS induction ring gear 55 teeth 3 wheel speed sensor front wheel 4 front disc brake caliper 5 FC HU brake hose 6 ABS induction ring gear 54 Teeth 7 brake disc rear 8 rear disc brake caliper 9 wheel speed sensor rear wheel 10 RC HU brake hose Caution The specifications of the brake disc and wheel speed sensor are the same ...

Страница 21: ...wheel 2 FC HU brake hose 3 RC HU brake hose 4 wheel speed sensor rear wheel 5 rear brake lever 6 rear brake switch 7 RMC HU brake hose 8 rear disc brake main pump 9 FMC HU brake hose 10 front brake switch 11 front disc brake main pump 12 front brake handle 13 hydraulic control unit ...

Страница 22: ...ent pipe 6 a solenoid valve intake pipe 10 a solenoid valve outlet pipe 11 and a vent leakage pipe 13 The carbon canister components are sold as a complete set and are sold separately without being disassembled If the vent tube is damaged you can purchase a reliable and weather resistant hose with the same or similar inner and outer diameters A small amount of gasoline that enters the canister aft...

Страница 23: ...filter screen Fuel pump High pressure fuel pipe Fuel injector Cylinder 7 Distribution map of cooling system accessories 1 Main water tank 2 Water tank filling port 3 Secondary water tank 4 Aluminum water inlet pipe 5 Aluminum water outlet pipe 6 Small water tank 7 Water and oil shared sensor 8 Thermostat 9 Water pump cover assembly ...

Страница 24: ...PKE 6 main cable 7 ignition coil 8 side bracket flameout switch 9 engine controller ECU 10 buzzer 11 cushion lock 12 Dump switch 13 Windshield motor controller 14 USB charging cable 15 Front storage box lock 16 Electronic fuel tank lock 17 Canister solenoid valve 18 Battery 19 Rectifier ...

Страница 25: ...et lock 5 front storage box lock 6 speaker 7 USB charging cable 8 dump switch 1 Cushion Lock 2 Rectifier 3 Buzzer 4 Engine Controller ECU 5 Battery 6 Fuse Box 1 7 Electronic Fuel Tank Lock 8 Fuse Box 2 9 Fuse Box 3 10 Ignition Coil 11 Side Bracket flameout switch ...

Страница 26: ...ter intake pipe Air filter element Air filter outlet pipe Throttle valve assembly body Intake manifold Cylinder Muffler Cylinder head exhaust gas control system red arrow indicates Exhaust gas cylinder head cover oil and gas separator cylinder head exhaust pipe air filter air filter outlet pipe throttle valve body intake manifold cylinder muffler Gearbox exhaust gas control system indicated by the...

Страница 27: ... piece tool set Torque wrench On board tools Claw hammer Pull code Rubber hammer Dynamic Balancing Machine Tire raking machine Oil pan Measuring cup Funnel Taps dies Micrometer Depth gauge Vernier caliper Feeler gauge ...

Страница 28: ...g diagnostic Speedometer 16PIN 17 Inner hexagon Hoop clamp Internal Circlip Pliers External circlip pliers Clamp multimeter Multimeter Dust blow gun Some of the above pictures are from the Internet and the copyright belongs to the author of the original picture Do not use it for other purposes ...

Страница 29: ...the outer ring with two fingers and push the center cylinder up to the initial position Pinch the center cylinder with two fingers to install the expansion nails to the installation position The outer ring is attached to the connected parts if not attached Check whether it is misaligned Press the center cylinder with your fingers or other tools and you can hear a sound or the top of the center cyl...

Страница 30: ... advice or consultation in time Keep away from children and pets 8 If you need to clean or wash the body parts of the vehicle you should use neutral car wash fluid or tap water diesel kerosene etc Acidic or alkaline car wash fluid will cause irreversible corrosion of the surface paint electroplating surface and anodized surface of the parts gasoline will cause premature aging or hardening of seala...

Страница 31: ...ion Front fork inspection Rear shock absorber inspection Bolts and nuts for body and engine installation Fastening Fastening Coolant inspection Replace every 4 years or 40 000 kilometers 24855 mile Gearbox oil replace replace Valve clearance cold inspection In 0 08 0 12mm 0 003 0 005 in Row 0 18 0 22mm 0 007 0 009 in inspection This service is provided by a dealer or a qualified maintenance organi...

Страница 32: ... system electronic fuel injection system shock absorber and wheels are all key components and it is recommended to be carried out by a qualified maintenance organization Air filter filter element air inlet filter element Step 1 Support the vehicle firmly Prop up the vehicle with the main bracket and put down the side brackets as shown in the figure 2 Remove the left engine cover a Use your fingers...

Страница 33: ...inner wall dry with a clean non woven fabric b Replace with 2 new rubber strips one is installed in the air inlet cover the other is installed in the box Take out the new air inlet filter element and install it into the air inlet cover in the direction shown 5 Remove the air filter housing a Use a Phillips screwdriver to remove the 9 screws that fix the housing of the air filter b Remove the air f...

Страница 34: ... back the shockproof sponge d Clip M6 16 bolts flanged bushing flanged bushing cushioning glue to the inner step hole of the engine left cover and then use a 4 inner hexagon to penetrate from the outside and hold the bolt e Align the left bolt with the mounting hole and tighten it f Before installing other bolts install the exposed sponge and plug it back into the left cover g Use 4 inner hexagon ...

Страница 35: ... The new models a If there is a slight air leak first try to tighten the exhaust port nut with 6 inner hexagon if the problem is not solved remove the muffler and replace with a new engine exhaust port gasket b If there is no sign of air leakage use 6 inner hexagon to check whether the M8 nut at the exhaust port of the engine is loose 2 Whether the 3 bolts connecting the muffler cavity of the 14 s...

Страница 36: ...inner hexagon to remove the 2 bolts at the front pedal 1 e Use 4 inner hexagon to remove the 3 bolts that surround the left side 1 and remove the bushing 2 and the cushion rubber 3 f Use your fingers or a plastic crowbar to forcefully break out from the arrow point until the bolt near the arrow point is exposed Because there are still bolts on the upper part that have not been removed it cannot be...

Страница 37: ...uge to inspect the gap between the center electrode and the side electrode d If necessary the gap can be adjusted by bending the side electrodes paying attention to the strength during adjustment e Clean the surface of the spark plug gasket and the joint surface and wipe off the dirt on the thread f First screw it back to the engine by hand and then use the tool to turn it clockwise to the standar...

Страница 38: ...ng the oil dipstick and the filler nut it is necessary to prevent foreign matter from falling into the engine 1 Drain the oil a Start the vehicle and turn off the engine for 3 5 minutes after idling for 3 5 minutes b Use the main bracket to park the vehicle firmly c Rotate the oil dipstick 3 on the right side of the engine counterclockwise and remove the oil dipstick 3 and O ring 4 to accelerate t...

Страница 39: ...r of the left engine Use a 14 sleeve to loosen the oil drain bolt 1 counterclockwise b Rotate the fuel filler nut counterclockwise and remove the nut and O ring c Remove the oil drain bolt and the copper pad d After the gear box oil is completely drained wipe the surface of the drain port with a non woven cloth e Replace with a new copper pad check whether the joint surface of the oil drain bolt i...

Страница 40: ... scratching the cushion skin b Use 4 inner hexagon to press down 4 expansion nails center cylindrical pins and then a total of 4 expansion nails on the left and right sides c Grasp the rear of the battery cover assembly turn it up and then pull it out toward the rear of the vehicle Note that there are buckles on both sides of the front The rebate position needs to be inserted in the front when re ...

Страница 41: ...o pry the glove box rubber strip from one end and remove it Remove the decorative buckle of the M6 hexagon socket bolt remove the bolts on both sides with 4 hex socket remove the bushing and the cushion rubber Remove the 3 bolts with a Phillips screwdriver j Remove the decorative buckle of the M6 hexagon socket bolt remove the bolts on both sides with 4 hex socket remove the bushing and the cushio...

Страница 42: ...nch both ends of the circlip with your hands and move it out and then pull out the desorption tube 3 d Loosen the bolt of the clamp with a 4 inner hexagon and pull out the air filter outlet pipe and clamp in the direction of the arrow to pull out the throttle valve body e Use 5 inner hexagon to remove 2 bolts and then remove the valve body assembly from the engine f Remove the heat insulation pad ...

Страница 43: ...etermine idle speed adjustment bolt position and fix replace recoil spring or cleaning throttle valve body disc Throttle body sensor performance check Fault lights are always on druing riding Check the corresponding sensor according to the fault code if the circit is normal the sensor can be judged to be faulty and need to be replaced The diagnostic instrument eads the data stream and requires the...

Страница 44: ...que 3 8 N m 0 4 kgf m 2 8 lbf ft b If the above adjustment fails to achieve the desired effect please refer to the description in Remove the throttle valve body assembly to clean up carbon deposits to remove the throttle valve body assembly Use a 10 open end wrench to loosen the 2 nuts on the bracket to adjust Torque 3 0 N m 0 3 kgf m 2 2 lbf ft c If the above two adjustments are invalid replace t...

Страница 45: ...ance The limit screw on the valve body is not allowed to be adjusted privately Check idle speed Check the idling speed of the engine when the engine is warm The idle speed range of the engine should be 1500 1700 rpm If the idling speed is not within the standard range or the idling speed is stalled it should be checked and handled by professional service personnel at the designated maintenance poi...

Страница 46: ...lve outlet pipe 11 The carbon canister components are sold as a complete set and are sold separately without being disassembled If the vent tube is damaged you can purchase a reliable and weather resistant hose with the same or similar inner and outer diameters The fuel evaporative pollutant control system can only be checked after the cover is removed Check the carbon canister for cracks or damag...

Страница 47: ...ing antifreeze liquid according to the lowest possible local temperature The vehicle added to the factory is Total 35 C 31F green antifreeze The total amount of coolant is 1 64L 1 73 US qt 1 44 lmp qt 0 43 US gal 0 36 lmp gal Coolant may damage the paint surface Pay attention when adding it A small amount of splash should be wiped off with a clean soft cloth immediately 1 Check the coolant a Press...

Страница 48: ...verflowed with coolant the coolant level can be seen at the water filling port e Tighten the filler cap of the Radiator Tighten the exhaust bolt torque 8 10N m 0 8 1 kgf m 6 7 lbf ft 4 Put coolant a Place an oil pan underneath wear waterproof gloves and use a 10 sleeve to remove the drain bolt and O ring b Remove the filler cap of the Radiator to accelerate the flow of coolant c Wipe all the joint...

Страница 49: ...crewdriver If the deformed fins exceed 20 a new heat sink needs to be replaced 6 Check all water pipes for leaks aging 1 Radiator 2 Coolant expansion tank 3 Aluminum water inlet pipe 4 Aluminum water outlet pipe 5 Small radiator 6 Water and oil shared sensor 7 thermostat 8 water pump assembly ...

Страница 50: ... 3 Small radiator outlet pipe 4 Water inlet pipe 5 Secondary water tank connection pipe 6 Main water tank outlet pipe 7 Engine inlet pipe 8 Small radiator inlet pipe 9 Small circulation outlet pipe 10 Water pump cover inlet pipe 11 Cylinder inlet pipe ...

Страница 51: ...irst remove the cushion and storage box components and remove them as shown in the figure below b Remove a total of 6 expansion nails indicated by the arrow For instructions on disassembly and assembly of expansion nails please refer to the pre service instructions in this chapter c Use 4 inner hexagon to remove the bolts on both sides and remove the bush and the cushion rubber d Press the blue pa...

Страница 52: ... and storage box components and remove them as shown in the figure below b Unplug the fuel pump and start the engine to idle until the engine stops Turn the engine stop switch to power off the vehicle and lock the vehicle After putting on waterproof and oil proof gloves press the anti trip lock and pull out the high pressure oil pipe in the direction of the arrow c Connect the high pressure oil pi...

Страница 53: ...ump is faulty e Whether the fuel is insufficient When pulling out the high level oil pipe be sure to pull it toward the axis and do not press or push or pull The protruding part of the fuel pump and nozzle holder It is forbidden to smoke dial mobile phones and other actions that may cause a fire at the demolition site The fuel pump is a precision component that needs to be assembled in a dust free...

Страница 54: ... 11 M14 1 Hexagon Flange Nut Grade 10 Environmental Protection Color Zinc 1 3 Driving wheel drive disc 1 12 φ21 8 φ1 8 Acrylic O ring 2 4 Distance tube 1 13 φ14 5 φ25 16 driven wheel bushing 1 5 V shaped transmission belt 1 14 Driven wheel clutch cover 1 6 Driving wheel sliding plate 1 15 Driven wheel clutch shoe 1 7 Pulizhu 8 16 Sliding plate of driven wheel 1 8 Boot block 1 17 Driven wheel fixed...

Страница 55: ...r outward with one hand and press the rear inner mud plate inward with the other hand Separate the air filter from the rear inner mud plate e Use an 8 sleeve to remove the 12 M6 30 hexagonal flange bolts as shown in the figure The two box bolts at the bottom of the air filter need to be removed to expose the air filter f Remove the left crankcase cover and the left crankcase cover gasket The left ...

Страница 56: ...en wheel bushing e Remove the positioning fixture for the main and driven wheels and remove the driving wheel drive plate from the crankshaft f Remove the driven wheel clutch cover from the drive shaft g Pinch the middle part of the V shaped drive belt and remove the belt and the driven pulley pulley together h Pinch the sliding plate of the driving wheel and the ramp plate inside and remove it to...

Страница 57: ...asure the diameter of the outer cylindrical surface of the Puli beads It needs to be replaced when the diameter is less than or equal to φ24 5mm 1 in d Check whether the V shaped transmission belt is damaged such as cracks broken wires or missing teeth If it does it needs to be replaced Use a vernier caliper to detect the widest part of the V shaped drive belt It needs to be replaced when the widt...

Страница 58: ...on direction Otherwise it is easy to cause the failure of the embedded steel sleeve of Pulizhu to fall off when the engine is running c Turn over the driving wheel slide plate with Puli beads and ramp plate as a whole and then install the distance tube into the inner hole of the driving wheel slide plate Then squeeze the sliding plate and the ramp plate with one hand to prevent the spread of the P...

Страница 59: ...heel inward into place on the drive shaft use When installing φ14 5 φ25 16 a section of the optical shaft of the driven wheel bushing is exposed and the other part of the V shaped transmission belt is sleeved on the outer ring of the exposed crankshaft spline f Put the side of the driving wheel drive disc with the wind blades facing outwards align the spline holes in the middle with the splines on...

Страница 60: ...of the driven wheel is damaged d The spline of the clutch cover and the drive shaft is damaged 3 2 Engine stall or lack of power a The V belt is slipping b The large spring of the driven wheel is damaged 3 3 Insufficient high speed power a V shaped transmission belt is worn or slipped b The clutch cover and the clutch shoe slip c The large spring of the driven wheel fails d Ply ball wear 3 4 When ...

Страница 61: ...ose 9 ABS hydraulic control unit 10 FC HU brake hose 11 wheel speed sensor rear wheel 12 rear disc brake caliper 13 RC HU brake hose Caution In order to facilitate after sales tracking those who need to purchase brake hoses disc brake calipers disc brake main pumps and hydraulic control units must be reviewed by our company before they can be purchased Domestic customers can fill in the frame code...

Страница 62: ...and to observe whether there are obvious damages on the surface such as pits deep scratches grooves etc Replace it if necessary Feel with your hands whether there is a noticeable sound of grinding the brake disc when turning the front wheel Observe from the front whether the brake disc swings when turning the front wheel if there is any swing please remove it according to the steps of dismantling ...

Страница 63: ...ake handles of the main pumps of the front and rear disc brakes respectively and observe whether the rear brake lights are on If it does not light you need to investigate whether the brake switch is faulty whether the rear brake light is faulty whether the fuse has blown whether the circuit is open 2 2 Replace the brake switch Take the replacement of the rear brake switch as an example to explain ...

Страница 64: ... longer than the original braking distance after replacing the new brake pads It needs to be used for about 300 kilometers 186 mile and the best braking effect can be achieved after the brake disc and the brake pads are fully run in Allow enough braking distance before running in sufficiently to ensure driving safety The brake pads must be replaced in pairs only replacing one side will cause uneve...

Страница 65: ...e then insert the pin to the end and use the 5 inner hexagonal lock pin Be careful not to install it backwards the grooved side faces the brake disc the black metal back plate faces the caliper e After adjusting the position of the brake pad reinstall the bolt and lock it with a 12 sleeve Standard torque 24N m 2 4 kgf m 18 lbf ft f Use a flat blade screwdriver to put back the nut and tighten it g ...

Страница 66: ...ust be completely cooled before it can be operated b One person pinches the rear brake handle and one person uses 21 sleeve impact wrench to remove the rear wheel nut 3 Standard torque of nut 3 125N m 12 8 kgf m 92 lbf ft c Use 4 hex socket to remove the bolt on the right middle of the rear inner mudguard remove the bushing and cushion rubber use 4 hex socket to remove the front bolt and the rear ...

Страница 67: ...the main pump with high pressure water After disassembly make sure that all parts are installed correctly It is strictly forbidden to mix in water dust impurities and silicic acid or petroleum based liquids otherwise it will cause serious damage to the brake system This vehicle uses DOT 4 brake fluid and it is forbidden to mix it with other brake fluids Wear protective gloves protective clothing p...

Страница 68: ...le of the main pump of the disc brake or the piston will become stuck which will cause the braking effect to deteriorate or fail which will affect driving safety 2 1 Replace the front brake brake fluid a Wrap around the front brake main pump with oil resistant plastic film as shown in the previous section b Pull out the rubber cap of the vent nozzle and put on 8 torx wrench Use a 6mm 0 23 in hose ...

Страница 69: ... liquid level in the main pump during operation and replenish it in time to prevent air from entering the brake hose Tire Check the tire condition and tire pressure before driving When the tire is worn to the limit or there are cracks or wounds on the surface it should be replaced in time Pay special attention to driving safety when using new tires New tires that have not run in well may slip and ...

Страница 70: ...r If the wear reaches the mark point it means that it has been worn to the limit If you continue to drive there will be a safety hazard You must replace with new tires of the same specification c The inspection of the rear tires is the same as that of the front tires and will not be repeated here 2 Replace tires a Replace the front tire The front wheel assembly can be removed by referring to the d...

Страница 71: ... the adjusting nut 1a move the lock washer up and then loosen the adjusting nut 1b c If the steering is heavy loosen the adjusting nut 1c counterclockwise First screw it clockwise to 35N m 3 6 kgf m 26 lbf ft then loosen 1 4 turn counterclockwise and then screw it to 15N m 1 2 kgf m 11 lbf ft d If thre is any looseness screw it clockwise to 35N m 3 6 kgf m 26 lbf ft then loosen it counterclockwise...

Страница 72: ...ust and make other parts of the vehicle rust Coastal areas should have more frequent pre maintenance damping than inland areas After wiping clean spray a small amount of anti rust oil to prevent rust 1 Check the appearance a After parking the vehicle firmly let the front wheel hang in the air and turn the direction knob to observe whether the front shock absorber is leaking whether there are scrat...

Страница 73: ...ron block and soft rubber rubber copper etc should be placed on the contact surface to prevent the front fork tube from being scratched Use the press slowly and slightly straighten the pressure and small stroke several times and measure while straightening The radial run out after correction should be less than 0 05mm 0 002 in If the original bending deformation part is out of round after correcti...

Страница 74: ...makes the shock absorption harder otherwise the shock absorber becomes softer The two rear shock absorbers need to be adjusted to the same gear 2 1 Adjust the right rear shock absorption a Use 6 inner hexagon to tighten the exhaust port nut use a 14 sleeve to remove the bolts at the position connecting the muffler and the rear rocker arm Note that the muffler must be completely cooled before it ca...

Страница 75: ...bolt at the front of the left tail skirt with a 5 inner hexagon and remove the bush and cushion rubber Remove the 2 expansion 3 nails at the bottom Grasp the left tail skirt and remove the expansion nail 3 and take off the left tail skirt Remove the right tail skirt in the same way e Pull down the front part of the rear mud plate fix the nut with a 14 sleeve or a torx wrench loosen the bolt comple...

Страница 76: ...displaced 2 Check engine fasteners Standard torque of 5 M12 nuts of engine cradle 65N m 6 6 kgf m 48 lbf ft a Refer to the steps for removing the rear storage box and tail skirt to remove it to the extent shown in the figure b Check if the four nuts on the rear cradle of the fixed engine as shown in the figure are loose The nut on the right front part a in the figure needs to be pulled out or pull...

Страница 77: ... 2N m 1 3 Tools measuring tools accessories a 8 and 14 T shaped socket wrenches 5 and 10 hexagon wrenches magnet sticks tweezers rags b Feeler gauge c Thread fastening glue and sealing silica gel 2 Operation steps a Use an 8 T shaped socket wrench or a wind batch to remove the 6 M6 30 hexagonal flange bolts of the cylinder head cover and then remove the cylinder head cover assembly b Use 5 and 10 ...

Страница 78: ...the side of the timing driven sprocket to expose the valve adjusting gasket Then according to the standard value of valve clearance intake valve 0 08 0 12mm 0 003 0 005 in exhaust valve 0 18 0 22mm 0 007 0 009 in determine the specifications of the adjusting gasket that needs to be replaced For example test The left side intake valve clearance value is 0 04mm 0 002 in which is less than the standa...

Страница 79: ... other side in the same way h After replacing the four valve adjusting gaskets check and confirm the four valve gaps again If there is a deviation from the standard repeat step and to adjust again until it meets the standard range i Set the two valve rocker arm limit blocks on the M5 15 5 hexagon socket head bolts and then apply a proper amount of thread locker on the threads of the M5 15 5 hexago...

Страница 80: ...er head cover 6 M6 30 hexagon flange bolts the torque value is 10 2N m 1 0 2 kgf m 7 4 1 5 lbf ft k Put the 13 2 8 O ring on the M14 1 5 screw plug screw it into the corresponding screw hole of the right crankcase cover and tighten it with a 5 Allen key The torque value is 10 2N m 1 0 2 kgf m 7 4 1 5 lbf ft After putting the 27 4 2 65 O ring on the M30 1 5 aluminum screw plug screw it into the cor...

Страница 81: ...r brake handle After starting the vehicle put down the side brackets and the flame should be automatically turned off otherwise it is necessary to troubleshoot the flameout switch or brake switch failure d Check whether the side bracket mounting plate is deformed or cracked 2 Lubrication a Put away the side bracket so that the spring is in the shortest position for easy disassembly b The thick ste...

Страница 82: ...and remove the gasket Knock out the main support shaft 3 from right to left Pay attention to the protection measures at the spring of the main support to prevent the spring of the main support from suddenly loosening and flying out and causing personal injury It can be covered by a hard object or the spring can be tied up with a rope or thin iron wire b Remove the spring from the main support c Ap...

Страница 83: ...ock is normally opened FUEL Press to check whether the fuel tank cover is normally opened c The left switch button test If you need a more detailed understanding of each button function you can check the driver s manual Here is only a brief description of how to test whether it is normal SET key Short press SET to enter the main menu confirm selection Long press to return to the main interface Ope...

Страница 84: ...e charger provided with the car into the PKE charging port then connect the charger input AC terminal to 110 220V household AC is the protective cap for the charging DC interface is the charging insurance is the PKE insurance which must be unplugged when charging the battery through the DC interface with the charger is the TEST button which function is same as the unlock button on the auxiliary sw...

Страница 85: ... to judge whether it has been blown or use a tool to unplug and observe Refer to the previous steps to remove the battery cover and then pull up the fuse box After opening the fuse box cover check whether the fuse is normal No Name Function Specification Main insurance Protect all circuits 25A ECM Protect ECM ECM relay oil pump relay and other electrical devices 15A Regular power supply Protect fa...

Страница 86: ...switch failure Y Whether the flameout switch is on N Troubleshoot the main cable N Disassemble the handle switch and short circuit the switch line of the flameout switch button can it be started Y N Faulty right handle switch Turn to Y N Y b When the light switch is turned on the headlight does not turn on check whether the light fuse is blown if it is blown check the cable fault if it is normal d...

Страница 87: ...ar away Whether the sensor key has sufficient power Y Bring the induction key close to N Replace the battery the model is CR1225 N Disassemble the right auxiliary switch and short circuit the unlocking switch wire Y Y Right auxiliary switch failure N Fill in the quality feedback form and assist in the investigation by the engineer 4 3Left hand handle auxiliary switch Left hand handle Auxiliary swi...

Страница 88: ...aise the speed but abnormal low speed can also be judged as insufficient battery power The battery needs to be charged If the power is sufficient check whether the horn adjustment bolts and nuts are loose If they are loose tighten them and check again If the fault cannot be eliminated after tightening try to loosen the nut and then use a Phillips screwdriver to fine tune the bolt If the horn does ...

Страница 89: ... see if the turn signal is on Light failure Y Check whether the meter is on Y Press the double flash button is it on There is also a problem with the double flash button The chances are small The near high beam does not light up Disassemble the handle switch and short circuit the light switch line Is it on N Y N Troubleshoot cable faults Check whether the secondary insurance powder is burned Doubl...

Страница 90: ...process of lamp troubleshooting After power on turn on the left right hand switch and the lamp does not light up Check whether the lighting terminal is plugged in N Reconnect the terminals Y Unplug the plug connect the lamp and the battery with a wire N Damaged lights Troubleshoot switch or cable failure Y Check if the insurance is blown N Replacement insurance Y 4 7 Windshield failure When the wi...

Страница 91: ...ng speed is abnormal and the insurance is re plugged The specific method is as follows a Unlock the vehicle and support the main bracket b Pinch the brake and start the vehicle c Pull the engine speed above 3000 rpm d After releasing the throttle turn off the flameout switch and lock the car e After waiting for 5 seconds unlock the vehicle again to complete the reset of the EFI system 7 Pay attent...

Страница 92: ...ar or a vehicle that is about to run out of fuel Be sure to replenish enough fuel before turning it on otherwise the fuel pump will be damaged if it runs dry without fuel Do not insert or unplug the plugs of various parts at will and it is forbidden to clean the plugs directly with water After plugging and unplugging be sure to check whether it is plugged back correctly ...

Страница 93: ...he fault light will start to flash b The fault code has 4 digits Read the fault code according to the number of flashes For example P0201 flashes in the following way continuous flashing 10 times intermittent 1 second continuous flashing 2 times intermittent 1 second continuous flashing 10 times intermittent second Flashes once in a row c If there is more than one fault the next fault code will fl...

Страница 94: ...ontrol circuit is shorted to the power supply P0261 1 cylinder injector control circuit is shorted to ground P0650 MIL lamp driver stage circuit failure P0262 The 1 cylinder injector control circuit is shorted to the power supply P0444 Canister solenoid valve open P0322 No speed sensor pulse signal open circuit or short circuit P0459 Canister solenoid valve is shorted to the power supply P0480 Fan...

Страница 95: ...sappear later EFI parts layout 1 2 3 4 5 6 Dump switch OBD diagnostic interface main cable Fuel pump Carbon canister solenoid valve EFI relay Fuel injector 7 8 9 10 11 12 Ignition coils Throttle valve body Water and oil shared sensor Oxygen Sensor ECU Crankshaft position sensor Throttle valve body components include three in one sensor idle speed control valve stepper motor The crankshaft position...

Страница 96: ...bidden to disassemble it by yourself The engine of this vehicle is designed with a high compression ratio It is recommended to add 95 and above unleaded gasoline for a long time In order to extend the service life of the vehicle please be sure to go to a regular gas station to refuel It is forbidden to run the fuel pump in dry state or in water otherwise its service life will be shortened and it w...

Страница 97: ...the air fuel ratio is incorrect the carbon canister solenoid valve should be checked Use a multimeter to measure the resistance between the two inserts of the canister solenoid valve plug should be 35 2Ω otherwise it can be judged that the solenoid valve is faulty 5 EFI relay There are two PVC sheaths at the battery each sheath covers 4 relays Cable end Relay 3 and 5 are normally closed contacts w...

Страница 98: ...gh voltage spark the high voltage spark is weak when the engine is started without dust check whether the ignition coil is normal Common faults of general ignition coils such as short circuit open circuit or grounding of the coil will cause no high voltage In addition the material of the ignition coil insulation layer is aging the insulation performance is deteriorated and the leakage of the ignit...

Страница 99: ...ll the left cover plate outward with one hand and press the front part of the tail skirt with the other hand pull out the upper part of the left cover plate after pulling out the bottom Then grasp the middle of the cover press down the back of the cover and pull out the left cover at the same time d Refer to the section Maintenance Removal of Spark Plug to remove the left pedal Steps are not repea...

Страница 100: ... tool to confirm whether the three in one sensor is faulty For details on the disassembly and assembly of the three in one sensor please refer to the description in Maintenance Throttle Valve Body Disassembly of the Three in One Sensor The resistance of the two terminals T and G can be measured to determine whether it is abnormal The resistance value at 25 C 77F is 1940 2040Ω 9 Water and oil share...

Страница 101: ... a 22 open end wrench to remove it counterclockwise Install after cleaning the installation surface The thread of the new sensor is coated with a special paste like thread anti sintering agent to prevent air leakage and facilitate subsequent disassembly If there is no problem after removing the old inspection you need to apply a proper amount of anti sintering agent to the thread before installati...

Страница 102: ...osis process to troubleshoot the cause of the fault Unable to start Check the high voltage spark of the ignition coil N No spark or weak strength Check the ignition system Y With car signs Y Check if the air filter element is blocked N Check whether the fuel pump is working N Check for leaks Y replace Y Check whether the injector is normal N Check fuel pump and cable N Check the injector and wirin...

Страница 103: ...Do not add fuel check whether the cable is broken or open the circuit check whether the fuse is blown check the fuel pump Y Check the three in one sensor N Replace the sensor Y Check the spark plug and check the valve clearance if necessary if the spark plug is wet check whether the injector is abnormal and whether it is dripping Use a multimeter to check the EFI system Check cables relays ECU ins...

Страница 104: ...the free stroke of the throttle cable remove the throttle valve body assembly for cleaning Y Check for leaks at the intake manifold Y Replace Y Check the water and oil shared sensor Y Replace N Check whether the exhaust pipe of the engine is leaking Y Replace N Check whether the idle speed control valve is normal N Replace Y Check the wires N N Unsteady idle speed of cooling car Cold car idling is...

Страница 105: ...ic field should be installed as far away as possible from the relay wiring harness and electrical device box or not installed Y Check whether the black and white wire and red wire of the ECM main relay are back to normal after short circuiting N N The flameout switch is faulty replace the right handle switch Y Turn off the flameout switch and check whether the engine crankshaft position sensor and...

Страница 106: ...d The EFI parts are damaged Y After checking the route judge according to the process There has been a power outage in the whole vehicle Reset the EFI system Y High idle speed The throttle body has a large leakage and needs to be replaced Throttle position sensor bounces and needs to be reinstalled N Throttle leakage is too small and needs to be replaced N Loose wire plug Troubleshooting If it is ...

Страница 107: ...107 184 Electrical schematic diagram of EFI system ...

Страница 108: ...e battery has sufficient power If the power is insufficient it may result in a slow start speed or weak spark intensity of the spark plug or no spark Tool Multimeter 7 The driving conditions and maintenance conditions of each vehicle are different so it is impossible to list all the fault phenomena and troubleshooting procedures one by one Only some of the more common faults can be listed Maintena...

Страница 109: ...guide Check whether the gap is normal If it is abnormal replace the corresponding parts The accumulated gasoline may be caused by the mixture being too thick when the cold engine is started and it can be cleaned before trying to ignite 3 The spark plug skirt is damaged The high voltage current breaks down and leaks from the damaged part of the skirt and the spark plug needs to be replaced 4 The el...

Страница 110: ...s with the main wiring harness and there are 3 in total For detailed illustrations please refer to the EFI relay section in the Electronic Injection System chapter of this manual The magneto stator and crankshaft position sensor are integrated in one part and cannot be replaced separately For details about the troubleshooting of the crankshaft position sensor please refer to the section Crankshaft...

Страница 111: ... adjustment is required the engine can only be returned to the factory for repair If the right crankcase cover and cylinder head cover of the engine are removed to check the timing the crankcase cover gasket must be replaced it is recommended that the cylinder head cover gasket is also replaced and the sealant should be applied to the position shown in the figure Because professional tools and equ...

Страница 112: ...g big tooth upwards the axial clearance is about 0 7mm 0 028in it is qualified b Tighten the timing chain check again and align the line immediately after the T mark on the flywheel with the triangle mark on the box c Rotate the camshaft to align the dots with the camshaft pressing plate bolts insert the timing driven sprocket into the timing chain and assemble it on the camshaft and at the same t...

Страница 113: ...arged and in good condition Check whether the main fuse 25A and ECM fuse 15A are blown If the fuse is replaced with a new one and it is blown out you need to troubleshoot the line first The starting motor should work under the following conditions a Unlock the vehicle b Retract the side bracket c Turn the engine flameout switch to d Press the start button Starter motor does not run troubleshooting...

Страница 114: ... slowly Check whether the battery power is insufficient Check whether the battery cable connector is in poor contact Check whether the starter motor cable is in poor contact Check whether the starter motor is abnormal 4 The starter motor is working normally but the engine cannot be started Check whether the starter gear train is faulty Check the ignition system for malfunctions Ignition system lay...

Страница 115: ... diameter of 3mm 0 12in 1 Remove the starter motor a Refer to the steps of removing the rear storage box to remove the rear storage box For the removal steps refer to the stepping motor removal and cleaning carbon deposits in the section of the throttle valve body in the Maintenance chapter b Cut off the two grade 0 flame retardant cable ties as shown in the figure c Loosen the clamp bolt shown in...

Страница 116: ...for fixing the starter motor 12 1 5 N m 1 2 0 2 kgf m 9 1 lbf ft And mark with a marker 2 Disassemble the starter motor Caution If the magnet tile pulls the electric pole towards the motor housing the coil may be damaged When installing the electric motor from the slot of the starter motor housing to the housing make the commutator bar face the rear side When installing the back cover of the start...

Страница 117: ...o check whether the outer ring fits tightly with the front cover Motor back cover Check whether the bushing of the back cover is worn or damaged Check whether the brush is damaged measure the length of the brush and use the limit11 5mm 0 45in Check the connectivity of the back cover as follows The positive brush is connected to the end of the cable the cable end is not connected to the back cover ...

Страница 118: ...d the ground wire should be the battery voltage 2 2 Ground wire The vehicle is powered off and locked Set the multimeter to the buzzer position connect one test lead to the green red wire and one to any bolt connected to the frame It should be conductive when the start button is pressed 3 Check the starting relay Use a thicker wire to directly connect the 12V battery to the relay Use the buzzer fi...

Страница 119: ... with a marker on the throttle which may cause abnormal throttle opening and closing and idle speed control 9 Cannot use carburetor cleaning agent 10 Throttle valve body parts not specified in this manual shall not be disassembled After reinstalling the battery or EFI components reset the EFI system For specific operations please refer to the precautions in the driver s manual or the throttle valv...

Страница 120: ...ve the 4 bolts 1 that fix the fuel tank g After confirming that the high pressure oil pipe vent pipe and oil level sensor plug have been unplugged stand on the right side of the vehicle to facilitate the removal of the fuel tank assembly Hold up the fuel tank assembly and turn it clockwise as shown in Figure 1 while turning let the seam welding on the right side of the fuel tank go down to the bot...

Страница 121: ...emove the 4 bolts and pull the sensor out Be careful not to pull it forcibly to avoid the deformation of the float connecting rod which will cause the deviation of the oil volume display to increase When reassembling you need to pre tighten the corners and then tighten the 4 bolts Otherwise the uneven compression of the sealing rubber ring of the oil level sensor may cause leakage and cause safety...

Страница 122: ...ng the engine after the pressure accumulation is completed check whether the fuel pump relay is normal If the relay is normal the fuel pump needs to be replaced if it is abnormal 3 Oil level sensor Use the resistance file of a multimeter to measure the resistance The lowest position empty oil 287 313Ω the highest position full oil 27 79Ω Pull the float connecting rod there should be no jamming phe...

Страница 123: ...nd the small water tank When the engine is not completely cooled opening the water tank cover may cause the coolant to spray out and cause burns The water tank cover must be opened after the water tank and engine have cooled down Troubleshooting 1 The engine temperature is too high a The coolant temperature of the meter is abnormal or the water temperature sensor is abnormal b The thermostat is ab...

Страница 124: ...tribution map 1 Main water tank 2 Water tank filling port 3 Secondary water tank 4 Aluminum water inlet pipe 5 Aluminum water outlet pipe 6 Small water tank 7 Water and oil shared sensor 8 Thermostat 9 Water pump cover assembly ...

Страница 125: ...lation outlet pipe water pump cover inlet pipe Big loop indicated by the green arrow Water pump cylinder inlet pipe cylinder thermostat small water tank inlet pipe small water tank small water tank outlet pipe main water tank inlet pipe main water tank main water tank outlet pipe engine water inlet pipe water pump cover inlet pipe Caution The hoop indicated by the red arrow in the figure should fa...

Страница 126: ...about 40mm 1 6 in in the direction of the arrow and separate the inlet pipe of the small water tank from the thermostat Use an oil pan to receive the coolant that may remain in the pipe c Press the buckle indicated by the arrow to pull out the plug of the cooling fan of the small water tank d Use an 8 sleeve to remove the 3 M6 22 bolts 1 shown in the figure e Use an 8 sleeve to remove one M6 22 bo...

Страница 127: ...ut the water tank assembly to the left Grasp both sides of the main water tank and pull it up in the direction of the arrow to remove the radiator assembly from the vehicle j If you need to remove the water filler fixing bracket you can use an 8 sleeve to remove the bolt Grasp the bracket and use an 8 sleeve to remove the bolt and remove the lower mounting bracket of the main water tank k After lo...

Страница 128: ...p φ22 3 7 Water pump cover inlet pipe 8 Water pipe hoop φ24 3 9 Cylinder inlet pipe 10 Water pump cover assembly Caution The bolt 5 at the thermostat is an exhaust bolt and the bolt at the water pump cover is a bolt for cooling liquid There are O rings of φ5 6 φ1 at both locations which need to be replaced once they are disassembled a Use the hoop pliers to remove the hoop and hoop in the directio...

Страница 129: ...ssed air of 160kPa 1 63 Kgf cm2 23 2 psi shall be introduced and the parts shall be immersed in water and left for 10s without bubbles If there are bubbles the air leaks and needs to be replaced The heat dissipation fins are allowed to have a small amount of lodging deformation If the lodging area is too large it will affect the heat dissipation effect and it is recommended to replace it A small a...

Страница 130: ... water tank seeps If there is seepage it is unqualified Pour out the water after checking the tightness remove the plug and let the auxiliary water tank dry naturally or blow it dry with a dust blower 4 Aluminum inlet pipe and aluminum outlet pipe Check whether the weld is cracked or cracked check whether the buffer rubber is aging and cracked If the appearance is good then check the air tightness...

Страница 131: ...e the pump or waterway will be blocked When the temperature reaches 80 C 176 F the heating rate slows down and the thermostat works normally If the water temperature has been rising rapidly when the internal pressure reaches a certain level the sudden overflow of boiling water indicates that the valve is stuck If it is stuck or closed loosely it can be removed and cleaned or repaired first otherwi...

Страница 132: ...pour it into boiling water and soak for a period of time take out the core body with pliers and observe whether the valve can be fully opened Until all closed The joint surface should be cleaned before rematching and no O ring should be installed 8 Water pipe Check whether there are cracks bulges and other defects on the surface of each water pipe Block one end of the water pipe ventilate the othe...

Страница 133: ... pads or brake discs have oil stains the braking force will be reduced The contaminated brake pads should be replaced and the oil stains on the brake discs can be removed with a good quality degreasing cleaner 8 After removing the oil cup cover of the main pump prevent dust and water from entering 9 If you need to add brake fluid after maintaining the brake system you must use the newly opened DOT...

Страница 134: ...ganizations The replaced brake fluid should be recycled by a professional unit and properly disposed of The operator is responsible for the consequences caused by manual disassembly or improper assembly and is not within the scope of the three guarantees Operate in a dry dust less or dust free environment Disassemble the front disc brake main pump a Remove the cover according to the steps in the r...

Страница 135: ...e main pump are mirrored and symmetrical Please refer to the steps for disassembling the front disc brake main pump for disassembly Disassemble the front disc brake caliper a Use 5 inner hexagon to remove bolt and remove the wire clamp First use a 12 sleeve to loosen the disc brake oil pipe bolt pay attention to loosen it and then tighten it slightly to avoid leakage otherwise it will be more diff...

Страница 136: ...terproof gloves and loosen the bolt with a 12 sleeve remove the copper pad and remove the RC HU oil pipe Refer to the steps for adding brake fluid to the main pump of the rear disc brake Remove the upper cover of the main pump to accelerate the discharge of the brake fluid Bolt Standard torque 32N m 3 3kgf m 24 lbf ft b Use a 14 sleeve to remove the bolt 3 Standard torque of bolt 3 24N m 2 4kgf m ...

Страница 137: ...hose remove the upper cover of the front and rear disc brake main pump loosen the disc brake oil pipe bolts from the front and rear disc brake calipers to drain the brake fluid The discharged brake fluid needs to be properly disposed of and it is forbidden to continue to use it It is forbidden to dump at will to pollute the environment or put it at will etc It should be handed over to a qualified ...

Страница 138: ...the front disc brake caliper c Cut off the 2 cable ties remove the 3 wire ties and remove the wheel speed sensor wire Check whether the cable is damaged If the cable sheath is frayed wrap it with electrical tape to avoid short circuit and cause vehicle failure The front wheel speed sensor is also responsible for providing a speed signal to the meter to display the speed per hour Use an 8 sleeve to...

Страница 139: ...ut the wheel speed sensor from the clamp remove the bolt with a 4 inner hexagon and then remove the wheel speed sensor from the car If you need to remove the clamp you can use 4 inner hexagon to remove the bolt that fixes the clamp g Check whether the surface of the removed hose is aging cracked damaged abraded etc Wipe up the remaining brake fluid with a non woven cloth and then wrap the ends of ...

Страница 140: ...t be pulled out forcibly After removing the hose prevent foreign matter from entering Before reassembling the hose connector at the hydraulic control unit apply a small amount of brake fluid to the thread After replacing the new hydraulic control unit you need to refill the brake fluid and exhaust the air to ensure that the brakes are restored to normal before driving the vehicle Disassemble a Ref...

Страница 141: ...ic control unit and bracket assembly from the car e After holding the hydraulic control unit firmly use 4 inner hexagon to remove the bolt then the hydraulic control unit can be removed If you need to replace the bracket you need to remove the flanging bushing and the cushion rubber ...

Страница 142: ...dicator light is always on and the ABS function is invalid When the vehicle is powered on the ABS indicator on the meter flashes continuously for 30 seconds the indicator light is always on Press the ABS switch on the left deputy handle switch the switch is invalid Replace the left deputy handle switch Check whether the cable ground wire is tight If loose Tighten the bolts Check if front and rear ...

Страница 143: ...is loose No rear wheel speed Check whether the rear wheel sensor is damaged or the connector is loose Unplug the diagnostic device restart the power supply of the vehicle ride normally and use the brakes the maximum speed should preferably exceed 100km h 62mph no need to brake at the maximum speed 5043H 5042H 5045H 5044H 5025H 5052H 5053H 5223 Explanation Front wheel speed sensor disconnected grou...

Страница 144: ...the throttle turn off the flameout switch and lock the car e After waiting for 5 seconds unlock the vehicle again to complete the reset of the EFI system 4 The vehicle should be powered off before disassembling the battery 5 Before troubleshooting the charging system check whether the battery is in normal use and maintenance Check with the owner whether you often use high power electrical applianc...

Страница 145: ...tifier failure N Faucet lock failure or short circuit Measure the battery voltage first then measure the charging voltage after starting the engine Battery voltage charging voltage 14 5 14 9 V N Check the magneto Y Battery failure Measure the magneto 3P plug the resistance of any 2 pins should be 0 55 0 85Ω 25 77 F N Magneto coil failure Y Measure whether the voltage of the red wire and green wire...

Страница 146: ...6 184 Charging system layout diagram 1 Charging port PKE 2 Main fuse 25A 3 Battery 4 Magnetic motor 5 Rectifier Electrical schematic diagram Letter G R Y Chinese green Red yellow English Green Red Yellow ...

Страница 147: ...unplugging the PKE fuse For specific steps please refer to the section Checking the battery voltage in the chapter Inspection of sound light and electrical devices in the chapter Maintenance or the instructions delivered with the car Charging system check 1 Leakage test a Turn off the vehicle and cut off the power supply and remove the negative wire of the battery b Adjust the multimeter to the cu...

Страница 148: ...ollow the steps to remove the storage box after removing it first Unplug the two plugs of the rectifier and cut off the cable tie 1 b Refer to the steps of removing the armrests and rear skirts to remove them first Remove the bolts fixing the rear fender on both sides with 5 inner hexagon respectively and remove the bush and the rubber pad c Remove 2 bolts 5 from the bottom with 8 short sleeve and...

Страница 149: ...ute the environment or water sources 7 Swallowing or inhaling coolant brake fluid etc will cause certain harm to the human body Any exposed skin such as hands and face should be cleaned thoroughly after each addition If swallowed by mistake immediately contact the poison control center or hospital if inhaled immediately go to a ventilated environment If it accidentally splashes into the eyes immed...

Страница 150: ...150 184 Exploded view of front fork components Directional exploded view ...

Страница 151: ...151 184 Front fork exploded view ...

Страница 152: ...152 184 Exploded view of lower link board ...

Страница 153: ...cover in the direction of the arrow The direction of the upper cover 2 Remove the components a Use 5 inner hexagon to remove 4 M6 30 bolts and remove the left auxiliary handle switch the rear disc brake main pump the right auxiliary handle switch and the front disc brake main pump b Use 5 inner hexagon to remove 1 non standard M6 16 bolt remove spring washer take out the mobile phone bracket mount...

Страница 154: ...hes you need to align the bolts 8c and 9c with the positioning holes and then tighten them with a cross screw Use a 5 inner hexagon to tighten the bolts 8a that fix the left and right handle switches in turn 8b 9a 9b c When installing the auxiliary handle switch align the joint surface of the auxiliary handle switch and the main pump of the disc brake with the triangle mark on the handle switch an...

Страница 155: ...bushings 2 Install the front wheel assembly a Separate the two brake pads in the brake caliper with a single size batch If the resistance is too large and the two brake pads cannot be separated please refer to the method of Adding Brake Fluid to remove the upper cover of the disc brake oil cup and then separate it 2 brake pads b Put the front wheel in the middle of the front shock absorber shake t...

Страница 156: ...e owner s travel habits whether you like sudden braking road conditions maintenance intervals and other factors but if the following three conditions are reached If any of them they must be replaced a Use a vernier caliper to measure the thickness of the disc brake disc less than 4 mm 0 16 in b Hang the front wheel in the air observe from the front that the disc brake disc swings when the front wh...

Страница 157: ...ters but if the following situations occur the rims must be replaced a The rim is deformed or warped b Cracks or breaks in the rim Under normal conditions the front tires can be used for about 20 000 kilometers Normal conditions mean that the road conditions are not bad and there is no tyre puncture Because the tires are made of rubber there will be aging Generally the tires need to be replaced in...

Страница 158: ...out the gasket d First press the two sides of the front mud board according to the small arrow press the protrusion on the front mud board arrow inward and then move the front mud board up to a suitable position and then pull it out in the direction of the big arrow 2 Remove the left and right front shock absorbers a Use a 14 sleeve to remove the 4 M10 1 5 43 bolts pry open the gap on the lower li...

Страница 159: ...sher The vehicle must be parked on a level and stable ground or on a lifting platform After the front wheel is installed please press the brake handle repeatedly until the brake restores the braking effect Replace the lower link board Caution After the front wheel is disassembled please do not press the brake handle When the disc brake oil cup is removed it must be vertically upward to prevent air...

Страница 160: ...se a four jaw sleeve to remove the direction column adjustment nut on the uppermost layer of the lower link plate take out the cassette washer the middle direction column adjustment nut and the adjustment nut rubber gasket Then use a four jaw sleeve to remove the lowermost direction column adjusting nut Refer to the exploded view of the lower link board b One person supports the lower link plate w...

Страница 161: ...stall the semi circular key in the groove of the lower link plate then align the gap between the spacer and the base with the semi circular key and finally screw in the cap nut torque 100N m 10 2 kgf m 74 bf ft 6 Install other disassembly components a Refer to Replace the front shock absorber to replace the front shock absorber b Refer to Replace the front wheel to reinstall the front wheel assemb...

Страница 162: ...ver and then use 4 inner hexagon to remove the 2 expansion nails connected to the storage box on the middle cover of the fuel tank green mark c Use 4 hex socket to remove the two M6 16 bolts next to the battery take out the bushing the buffer rubber take out the battery negative rubber sleeve at the arrow use a cross shaped batch to remove the battery negative electrode and then take out the batte...

Страница 163: ...de the tail skirt and next to the rear taillight marked by the green circle e Press down the part where the front part of the tail skirt is in contact with the right part of the fuel tank cover golden and pull the right part golden of the fuel tank cover with one hand until the front of the tail skirt is pulled out then hold the middle part of the fuel tank with the other hand Press the cover blue...

Страница 164: ...el will flow out when the high pressure oil pipe is pulled out and it is forbidden to drip onto the surface of the part e Locate and unplug the crankshaft position sensor and the oxygen sensor in the frame position on the right Caution One end of the crankshaft position sensor is connected to the inside of the engine one end is connected to the main cable one end of the oxygen sensor is connected ...

Страница 165: ...r filter on the left side of the throttle body l Use a 4 inner hexagon to remove one M6 12 bolt that fixes the wheel speed sensor on the rear rocker arm take out the wheel speed sensor and take it out of the fixed clamp Then use a 14 sleeve to remove the two M8 37 bolts that fix the brake caliper and pass the brake caliper and wheel speed sensor in the direction of the arrow from the middle of the...

Страница 166: ...r aligning use a suitable tool to penetrate a M12 1 5 290 bolt b One person holds the whole car and slightly lifts the rear part of the frame and one person rotates the two rear shock absorbers to the frame installation groove and then rotates the right shock absorber until it is aligned with the frame installation hole Pass one M10 1 5 55 bolt use one M10 nut on the left side to tighten torque 30...

Страница 167: ...tom with one hand and install the surround forward big arrow and the groove at the bottom must be surrounded Clamp into the frame and fix it when the two grooves are clamped into the frame shoot the front part of the surrounding bottom plate up small arrow until the front part of the surrounding bottom plate is locked into the shock absorbing sleeve of the small water tank 6 2 Install pedal and pe...

Страница 168: ...Grasp the tail of the right tail skirt green mark with one hand and buckle the tail buckle green mark into the bottom of the tail skirt align the buckle on the lower part of the tail skirt orange mark on the front of the rear mud board Click the right part of the fuel tank cover gold with one hand and buckle the upper part of the tail skirt dark blue mark into the middle cover of the fuel tank lig...

Страница 169: ...ector on the upper side then assemble the rear of the storage box in place When installing the rear of the storage box pay attention to the position of the middle cover of the fuel tank to prevent the storage box from crushing the middle cover of the fuel tank b Remove the 2 bolts on the battery using a cross shaped screw first install the battery positive wire red use the cross shaped screw to in...

Страница 170: ... battery cover When installing the battery cover you need to align the buckle position red mark of the battery cover with the corresponding buckle position of the storage box Then install two expansion nails green mark and arrange the skirt of the battery cover ...

Страница 171: ...e cover 7 Right fuel tank cover plate 8 Right pedal 9 Right side cover 10 Cushion 11 Tail skirt right part 12 Rear rack 13 Rear mudguard 1 Windshield 2 Left front turn light 3 Left cover front storage box 4 Front left panel 5 Front storage box panel left decorative cover 6 Left pedal decorative cover 7 Left fuel tank cover plate 8 Left pedal 9 Left side cover 10 Cushion 11 Tail skirt left part 12 ...

Страница 172: ...ate 3 Front right pedal pad 4 Rear right pedal pad 5 Rear right pedal pad presser 6 Fuel Tank Outer Cover 7 Fuel tank cover middle part 8 Front left pedal pad pressure plate 9 Front left pedal rubber pad 10 Rear left pedal rubber pad 11 Rear left pedal pad presser ...

Страница 173: ... affecting the function of each part Windshield removal a Remove the 4 decorative buckles on the windshield b Use 4 inner hexagon to loosen the 4 M6 16 bolts on the left and right decorative covers of the windshield c Take out the left and right decorative covers of the windshield the windshield and the rubber pads of the windshield bracket in turn Removal of the front sun visor a Use 4 inner hexa...

Страница 174: ...ushroom head blue circle on the right side of the front front cover is pulled out use the same method to remove it The mushroom head on the left side of the front front cover c Grasp the mark on the front cover green rectangle with your hands and pull it up in the direction of the arrow until the two positioning buckles blue circles of the front front cover and both sides of the front front cover ...

Страница 175: ...ter panel with one hand and lift it up in the direction of the big arrow With the other hand press the front storage box panel at the junction of the front storage box panel and the Speedometer panel Until the 8 buckles Yellow area 4 places on the left and right connecting front storage box panel and the Speedometer panel are separated c Grasp the Speedometer panel with one hand and lift it up sli...

Страница 176: ... front part of vent Use 4 inner hexagon to remove the 2 expansion nails on the inside of the front part of vent Then unplug the 3 connectors on the upper left side of the front vent Caution When unplugging the connector you need to press down the lower tip of the connector before pulling it out otherwise the connector buckle will be damaged Use 5 inner hexagon to remove 4 non standard M6 16 bolts ...

Страница 177: ...ge box panel are connected yellow area the 3 buckles are separated and then the left decorative cover of the front storage box panel is surrounded by the front storage box panel in the order of the small arrows The connection of the middle and left pedal decoration cover yellow area 7 buckles on the front storage box panel 3 buckles on the left pedal decoration cover blue area surrounds the 4 poin...

Страница 178: ...ve bushing and buffer glue Caution one of them is only with bushing without buffer glue c Remove the two M6x16 bolts of the left pedal decorative cover with 4 inner hexagon and take out the bushing and buffer glue d Remove an M6x16 bolt from the bottom plate and the decorative cover of the left pedal with a 4 inner hexagon and remove the bushing and buffer glue then remove the 1 nail of the left p...

Страница 179: ... cushion cannot be pulled out do not use brute force to forcibly pull out the cushion to prevent damage to the threads on the cushion installation studs Disassembly of the storage box a Use the 4 inner hexagon to remove the 2 expansion nails on the battery cover buckle the mark green rectangle of the battery cover by hands break it diagonally upward in the direction of the arrow and take out the b...

Страница 180: ...tail skirt is red With the other hand grab the tail skirt mark green rectangle 2 and pull it up until the two buckles at the junction of the tail skirt and the middle part of the fuel tank cover yellow area are separated Hold the mark on the tail skirt green rectangle 4 with one hand and then hold the mark on the right part of the fuel tank cover green rectangle 3 with one hand and pull it out unt...

Страница 181: ...one person uses 14 sleeve ratchet wrench or box wrench to remove the non standard M10 1 5 nut from the upper part of the rear shock absorption of the frame inside nut torque 30N m 3 1 kgf m 22 lbf ft Remove bolts and nuts on the other side using the same method d Use the ratchet wrench 8 sleeve to extend under the rectifier and remove the 2 outer hexagon M6x22 bolts of the rectifier Caution the re...

Страница 182: ...assembly of the left right fuel tank cover a Remove a non standard M6x16 bolt on the right part of the fuel tank cover with 5 inner hexagon and remove the bushing and buffer glue Grasp the mark on the right part of the fuel tank cover green rectangle and pull it upward in the direction of the arrow Until the right part of the tank cover plate and the middle part of the tank cover plate yellow area...

Страница 183: ... Caution Only the upper 2 bolts have bushing buffer glue while the lower bolts do not have bushing buffer glue Remove 1 nail of the front right storage box with the 4 inner hexagon finally remove the front right storage box b There are three ways to open the front left storage box 1 Before removing the battery press the switch next to the front right storage box switch to open it 2 Use the battery...

Страница 184: ...inner hexagon and remove the bushing and buffer glue b Find out the the 3 connectors on the left side of storage box panel and unplug them on the next to the tap lock c Find out and unplug the PKE bullet connector PKE connector and PKE antenna connector on the right side of the front storage box panel d Remove the front storage box panel ...

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