Buddy Kick

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PREFACE
This service manual contains basic instructions in connection with general service and maintenance of the
Genuine Buddy Kick. This manual also contains detailed technical information for Genuine service technicians
who are engaged in maintenance, repair, parts replacement, troubleshooting, and reassembly. The service
manual is complete providing details from simple tear down to detailed disassembly and from a basic
performance introduction to service preparation. The manual also provides complete instructions for
general lubrication, routine inspections and adjustments. Various diagrams provide general views, exploded
views, or actual photos, all necessary items repeatedly cited will reference the previous drawings if
appropriate.
Specifications -
BRAND GENUINE FRAME STEEL TUBE
MODEL Buddy Kick FRONT TELESCOPIC
SUSPENSION
LENGTH 1720 mm 67.7 in REAR UNI-ABSORBER
WIDTH 710 mm 28 in 1ST REDUCTION 0.75~2.6

SCALE
TRANSMISSION
HEIGHT 1060 mm 41.75 in 2ND REDUCTION 47/17*47/15=8.66
WHEEL BASE 1215 mm 47.8 in CLUTCH CENTRIFUGAL
FRONT 41 kg 90.40 lbs GEARBOX C.V.T.

MASS OF VEHICLE
REAR 62 kg 136.70 lbs FRONT 90/90-10

TYRE
TOTAL 103 kg 227 lbs REAR 90/90-10
RIDERS 2 up to 150kg / 330 lbs FRONT DISK

MASS
BRAKE
FRONT 83 kg 183 lbs REAR DISK

TOTAL MASS
REAR 170 kg 375 lbs SPEEDOMETER 140 km/hr 87 mi/hr
TOTAL 253 kg 558 lbs HEADLAMP 12V-35W/35W

LIGHT
TOP SPEED 92 km/hr 57 mph TAIL LIGHT 12V-0.2W/12V-5W
PERFORMANCE
FUEL CONSUMPTION 42 km/L 98.8 mpg BRAKE LIGHT 12V-2W
HILL CLIMB 25°↑ SIGNAL LIGHT 12V- 2W/12V-2W
TYPE J1 HORN DC 12V
FUEL 92 UNLEADED MUFFLER C-D ABSORPTION
CYCLE/COOLING 4T / FORCE D AIR&OILCOOL EXHAUST DIRECTION RIGHT & BACKWARD
BORE 54 mm LUBRICATION COMPRESS & SPLASH

CYLINDER
STROKE 54.5 mm E. E. C. NO
ENGINE
NUMBER SINGLE P. C. V. YES
DISPLACEMENT 124.8 cc CATALYST YES
COMPRESSION RATIO 10.1：1 S. A. I. YES
MAX POWER 8.0kW / 10.73hp @ 8250rpm STARTER ELECTRIC
MAX TORQUE 9.5N-m / 7 ft-lbf @ 6750rpm IGNITION TRANSISTOR
ARRANGEMENT HORIZONTAL FUEL TANK 5.5L 1.45 gal
NOTE FUEL SUPPLY：INJECTION

This manual is a service manual for Genuine Buddy Kick with details specifying methods to
disassemble or install various mechanisms, basic maintenance including inspection and adjustment
of components, notices for operation, and diagnostics, etc. There are 15 sections as referenced
below.
Classification Item Page

Information summary and preparation 1 6~27
Installation or Removal of External Components 2 28~40

Check & Adjustment 3 41~70
Electronic fuel injection system 4 71~106
Lubrication System 5 107~110
Engine disassembly 6 111~116

Cylinder head 7 117~126
Cylinder combination 8 127~135

CVT 9 136~146
Crankcase & Crankshaft 10 147~160
Gear box 11 161~165
Shock absorber / brake system (ABS) 12 166~204
Charge, Ignition, and Start-up 13 205~221
Injection system diagnosis 14 222~238
Wiring 15
Information Summary and Preparation -1
1-1 Exterior parts diagram 1-2 Electrical Parts configuration
1-3 Positions of engine number / vehicle identification number
1-4 Code of practice
1-5 Torque
1-6 Service tools
1-7 Procedure to maintain the Electronic Management System (EMS)
1-1 Exterior parts diagram
HANDLE COVER UPER
HEAD LIGHT COVER

FRONT HOOK
FRONT INNER PANEL COVER SEAT
SIDE REFLECTOR
REAR LUGGAGE BRACKET
FRONT TURN SIGNAL(R/L) FRONT INNER COVER
REAR TURN SIGNAL (R/L)

WIND SHIELD COVER
TAIL LIGHT
AIR CLEANER
DISK
CVT
FRONT BRAKE CALIPER SIDE STAND

CENTER STAND
BACK
GRIP MIRROR(R/L)
SPEEDOMETER
HANDLE COVER LOWER
HEAD LIGHT ASSY
MIDDLE COVER
BRAKE LEVER GRIP
BODY COVER,FRONT
BODY COVER WINDSHIELD
FRONT FENDER
REAR SUSPENSION
MUFFLER OUTER FORK TUBE ASSY
REAR BRAKE CALIPER

STEP FLOOR
BRAKE
DISK LOWER COVER (R/L) FRONT UNDER COVER,(UPPER)
1-2 Electrical Parts configuration
10
14
12
13
Number Type Number Type

1 BATTERY 12V*7A 2 STARTER RELAY
3 ECU 4 MAIN / FUEL RELAY

5 IGNITION COIL 6 FLASHER RELAY ASSY
7 HORN 8 TOPPLE SWITCH
9 MAIN SWITCH 10 FUSE
11 RECTIFIER 12 FUEL GUAGE
13 FUEL PUMP 14 THROTTLE BODY

1-3 Positions of engine number / vehicle identification number
J1F00000 125 C.C

1-4 Code of practice
1. Any clamp or cotter pin removed shall be replaced with a new one.
2. Any part to be replaced shall be manufactured by Genuine.
3. Make sure any assembled component is securely fastened and formally activated.
4. Any bolts or nuts with large external diameters rather than small ones shall be secured first and diagonally according
to rated torque values.
5. Any mechanic shall use appropriate tools for any disassembly and wear proper safety gear during maintenance.
6. Any maintenance operation performed by two mechanics shall be completed with each other’s safety in mind.
7. Any electrical parts slightly heated by the motorcycle’s operation are normal and should not be touched by hands directly.
8. Please keep any cable or wire harness properly secured but not excessively tight or loose, and without any sharp angles
or bolts / screws piercing a cable. Check all cables or wire harnesses for any unnecessary twists or kinks.
9. Do not put any tool on the motorcycle, particularly the battery which would cause a short circuit, during maintenance.
10. The battery in a motorcycle which has not been started for a long period should be tested to ensure its voltage is
acceptable and the battery should be charged at least once per month or placed on a maintenance charge.
11. Please follow the correct steps to connect and disconnect a lead acid battery without the short circuit or inflammation.
1-4-1 Directions for maintenance of the Engine Management System (EMS)
1) Directions for General Maintenance

Any check to the Electronic Management System shall be made with a multi-meter only.
1. To make sure of the Electronic Management System is properly running, please use parts supplied by Genuine
during maintenance.
2. Any operation to clean parts during maintenance shall be executed in a well-ventilated place.
3. Please follow the given instructions for all maintenance and diagnosis operations.
4. Do not disassemble or remove parts from the Electronic Management System during maintenance.
5. Please prevent any electronic element (electronic control unit, sensor, etc.) from falling to the ground during
maintenance; establish an environmental protection plan for any hazardous waste generated from maintenance.
2) Directions during maintenance
1. Do not arbitrarily remove any part or connector of the Electronic Management System from its initial location; avoid
any accidental damage or introduction of foreign material such as water and greasy dirt to any connectors as this can
negatively affect a properly running Electronic Management System.
2. In order to prevent any electrical device from damage, the battery power supply shall be disconnected prior to
removing or connecting electrical couplings or components.
3. During any operation which simulates the thermal state of a defective unit or increase in temperature, the
electronic control unit temperature should be less than 80 degrees Celsius.
4. All fuel hoses shall be high pressure-tolerant pipes because of the high fuel pressure in the Electronic
Management System (300kPa or so) which may be present even when the engine is stopped. Because of the high
fuel pressure, the fuel hose shall not be disassembled arbitrarily. In the event of fuel system maintenance, the
pressure in the fuel system shall be released prior to removal of a fuel hose in the following order: Remove the fuel
pump relay; start the engine; keep the engine at the idle speed until the engine stops. Any maintenance operation
requiring removal of a fuel hose and/or replacement of a clamp shall be executed by a professional mechanic in a
well-ventilated area.
5. Disconnect all power supplied to the electric fuel pump when servicing or removing the pump from the fuel tank
to prevent any spark or fire.
6. Do not test the fuel pump empty or by using water else the service life of the pump will be curtailed. The positive
and negative poles of the fuel pump shall be properly connected to prevent damage.
7. Unless otherwise required, a spark test shall not be conducted or completed quickly during inspections of the ignition
system. Additionally, the throttle shall be kept closed during inspections otherwise unburnt gasoline will feed into the
exhaust system and damage the three-way catalytic converter.
8. The idle speed has been adjusted by the Electronic Management System in advance and should not be changed
manually. The initial position of the throttle stop screw adjusted by Genuine shall not be changed by a user without
permission unless otherwise required by Genuine.
9. The battery cables connected to the positive and negative poles on the battery shall be properly linked otherwise
damage will occur to the vehicle electronic devices.
10. Any cable connected to a battery shall not be disconnected while the engine is running.
11. The battery shall be removed from the motorcycle for charging and should not be directly charged with the
battery installed in the vehicle unless it is on a maintenance charge.
12. The cables connected to the battery’s positive & negative poles and the electronic control unit shall be removed
from the motorcycle prior to any electrical repair operation.
13. Do not cut a cable’s insulation layer to test for electrical signals.
14. Screws with thread lock that are unsecured during maintenance procedures should be cleaned and re-secured using
the same grade thread lock compound.
1-5 Torque
Rated values
Type Torque (ft-lbf) Type Torque (ft-lbf)
5 mm bolt 3.5 ft-lbf 6 mm nut 9 ft-lbf
6 mm bolt 7 ft-lbf 8 mm nut 18 ft-lbf
8 mm bolt 15 ft-lbf 10 mm nut 25 ft-lbf
10 mm bolt 25 ft-lbf Pin / bolt 12 ft-lbf
12 mm bolt 40 ft-lbf
Body／Engine
Torque Torque Torque
Type Type Type
(ft-lbf) (ft-lbf) (ft-lbf)
Disk 18 Cylinder head–(stud bolt)IN 4 Handlebar 38
Rear fork 23.5 Cylinder head-( stud bolt DOWN 5 Engine hanger 29
Brake caliper 18 Crank case cover (right) 7 Front shock absorber 29
Flywheel 30 CVT nut 40 Spark Plugs 8
Fan shroud 7 Rear axle 75 Rear shock absorber(UP) 27
Drain plug bolt 20 Camshaft sprocket 4 Rear shock absorber(DOWN) 18
(engine oil)
Drain plug bolt (gear oil) 20 Cylinder head cover 7 MUFFLER ASSY-FRONT BOLT 13
Oil strainer cover 13 Oil pump 7 MUFFLER ASSY–REAR BOLT 24
Stator comp 7 one-way clutch 70 Front axle 40
Stator comp- Pulse 6 Stud bolt (cylinder head) Oil line 7 Left side cover 7
Temperature Sensor 5 Cylinder head nut 16 Sound-proof cover 6
Oxygen Sensor 13 Oil cooler - joint bolt 24 Crank case (left & right) 6
Injector 7 Crankcase -(stud bolt) 7 Gearbox 7
Brake hose- joint bolt 20 Brake caliper--joint bolt 20 Screw, timing chain 7
tensioner assy
Center stand 27 Support bracket，pedal 18 Chain adjuster comp 7
Oil cooler assy 7 Crank angle sensor 6 Fuel gauge comp 2.5
Ignition coil comp 5
1-6 Service tools
1. Front fork - Bearing cage 2. Brake oil-pumping unit 3. Bearing puller tool
disassembly, tools
4. Clutch compression tool 5. Clutch Fixator 6. feeler gauge
7. Bearing Striking Tools 8.Cylinder pressure gauge 9. Test line group
10. Hook type, wrench 11. flywheel puller 12. Crankshaft bearing removal tool
13. multimeter 14. Gasoline pressure gauge 15. Valve compression tool
16. spark plug gap gauge 17.EMS diagnostics - dedicated 18. Hose clamp removal tool
19. Fuel injector cleaning tool 20. Oil seal removal tool - small 21. Dial gauge + Magnetic Base
22. Up crankshaft tools - dedicated 23. crankshaft demolition tool - 24. Fork oil seal into the tool
dedicated
25. Oil seal removal tool - Large

1-7 Maintaining the Electronic Management System (EMS)
Systematic procedure to diagnose any trouble condition
Items below are to be checked first prior to any detailed diagnosis for engine troubles:
Make sure the engine trouble indicator light is functioning normally;

Connect diagnostic tool to determine if any trouble code information has been recorded;
Record any trouble phenomenon provided by the vehicle owner and determine possible trouble-related
conditions. External check:
(1) Check for any fuel hose leakage.

(2) Check for any leakage from a vacuum pipe.
(3) Check for any jam, leakage, flattening, or damage to an air inlet.
(4) Check the ignition system for breaks or aging of any high-voltage cables and ignition status.
(5) Check the grounding of any wire harness to make sure it is clean and securely fixed.
(6) Check to determine if any sensor or actuator’s connector has loosened or is poorly connected.
Note: Repair any trouble specified herein first which may affect the subsequent diagnoses or repair.
 Diagnosis:
1. Make sure there are no engine-related trouble records;
2. Make sure you list any offered troubles provided by owner;
3. Follow the said procedure to complete the vehicle inspections and determine any fault conditions;
4. Do not ignore any possible effects from maintenance, cylinder compression, mechanical timing, or fuel quality on
the system;
5. Replace ECU for tests.
In the event all other trouble sources have been eliminated, the ECU should be the source of trouble; if not, re-
install the original ECU and repeat the procedure to recheck.
 Trouble:
 Engine not turning over or difficulty running during start-up
 Engine running but start-up failing during start-up
 Difficulty starting when hot
 Difficulty starting when cold
 Trouble of start-up anytime despite RPM normal
 Start-up normal but idle speed unstable anytime
 Start-up normal but idle speed unstable during warm-up
 Start-up normal but idle speed unstable with warm-up finished
 Start-up normal but idle speed unstable or stall with load such as front lamp applied
 Start-up normal but idle speed too high
 RPM low or stall during acceleration
 Acceleration slow
 Acceleration powerless; performance bad
(1) Engine not turning over or difficulty during start-up
General trouble location: 1. Battery; 2. Start motor; 3. Main wiring or power switch; 4. Engine oil viscosity; 5. Engine
mechanism.
Procedure for general diagnoses:
Detection
No. Operating Procedure Subsequent Steps
Results
Check the voltage between two battery terminals with Yes Next step
1 a multi-meter to ensure the voltage is between 11 and
12V during start-up of the engine. No Replace the battery.
Yes Next step
Turn the power switch “ON” and check the voltage at
2 Fix or replace wiring
the positive terminal on the start motor is over 8V. No
harness.
Remove the starter motor and check its status for Fix or replace the
Yes
3 open circuits or jams attributed to insufficient start motor.
lubrication. No Next step
Change applicable
For trouble in winter only, check the lubricant viscosity Yes
4 lubricant.
in the engine for increased resistance of the starter
motor. No Next step
Correct resistance
Check for mechanical resistance inside the engine Yes
5 inside the engine.
preventing the motor from turning or slowly
running. No Repeat the said step.
(2) Engine running but stalling during start-up

General trouble location: 1. Fuel pump; 2. RPM Sensor; 3. Ignition coils; 4. Compression 5. Short Circuit.

Detection
Results
Connect a fuel pressure gauge prior to the fuel inlet of the Yes Next step
1 nozzle; press the power switch repeatedly if necessary or
Repair the fuel supply
start the engine to check the fuel pressure at 300kPa or so. No
system.
Yes Next step
Connect the EMS diagnosis tester and check “Engine RPM”;
2 Correct circuits of the
start the engine to check any RPM signal output. No
RMP sensor.
Yes Next step
Disconnect the ignition cable and connect a spark tester;
3
start the engine and check any high-voltage flash (blue/ Repair the ignition
No
white). system.
Eliminate any
Check pressure of the engine cylinder and find any possibility Yes mechanical trouble of
4 the engine.
of insufficient compression.
No Next step
Connect an EMS adapter and press the power switch to check Yes Diagnosis assist
5 voltages at Pins 5#, 10#, and 23#; check grounding at Pins 2#
and 21#. Repair the relevant
No
circuits.
(3) Difficulty starting when hot

General trouble location: 1. Fuel Pump; 2. Ignition Coils; 3. Engine temperature sensor; 4. Fuel Quality; 5. Electrical
Detection
Results
Yes Next step

Connect a fuel pressure gauge before the fuel inlet of the
1
nozzle; start the engine to check the fuel pressure at 300kPa or Repair the fuel
so. No
supply system.
2 Yes Next step

Disconnect the ignition cable and connect a spark tester; start
the engine and check any high-voltage flash (blue/white).
Repair the
No
ignition system.
Correct circuits
Press the engine temperature sensor connector and start the Yes or replace the
engine; check if the engine successfully started. (Or install a sensor.
3 series-connected resistor (300Ω) in lieu of the engine
temperature sensor at the engine temperature sensor No Next step
connector. Check if the engine is successfully started.)
Yes Replace fuel.

4 Check fuel and observe any trouble attributed to fuel just added.
No Next step
5 voltages at Pins 5#, 10#, and 23#; check grounding at Pins 2#
and 21#. Repair the
No
relevant circuits.
(4) Cold start difficulty
General trouble location: 1. Fuel pump; 2. Ignition Coils; 3. Engine temperature sensor; 4. Throttle & idle air bypass; 5.
Nozzle; 6. Fuel Quality; 7. Engine compression / valves; 8. Electrical
Detection
Results
Connect a fuel pressure gauge before the fuel inlet of the Yes Next step
1 nozzle; start the engine to check the fuel pressure at
300kPa or so. No Repair the fuel system.
Disconnect the ignition cable and connect a spark Yes Next step
tester; start the engine and check any high-voltage
2
flash
(blue/white). No Repair the ignition system.
Press the engine temperature sensor connector and start Correct circuits or
the engine; check if the engine successfully started. (Or Yes
replace any sensor.
3 install a series-connected resistor (2500Ω) in lieu of the
temperature sensor at the engine temperature sensor No Next step
connector. Observe if the engine is successfully started.)
Clean the air throttle
Slightly pull the throttle to check if the engine is easily Yes
4 and the idle air bypass.
started.
No Next step
Replace the
Disassemble the nozzle and check any leakage or jam in Yes
5 defective nozzle.
the nozzle with a nozzle cleaner & analyzer.
No Next step
Check fuel and observe any trouble attributed to fuel Yes Change fuel.
6
just added. No Next step
Eliminate any mechanical
Check pressure of the engine cylinder and find Yes
7 trouble of the engine.
any possibility of pressure insufficient.
No Next step
Connect an EMS adapter and press the power switch to Yes Diagnosis assist
8 check voltages at Pins 5#, 10#, and 23#; check grounding
at Pins 2# and 21#. No Repair the relevant circuits.
(5) Start-up difficulty anytime despite normal RPM
General trouble location: 1. Air Intake; 2. Fuel pump; 3. Ignition coils; 4. Spark Plug; 5. Temperature Sensor; 6. Air throttle
and & idle air bypass; 7. Nozzle; 8. Fuel Quality; 9. Compression / Valves; 10. Ignition Timing; 11.Electrical.
Detection
Results
Repair the air
Yes
1 Check any jam of the air filter and leakage of the air intake. intake system.
No Next step
2 nozzle; start the engine to check the fuel pressure at 300kPa
or so. Repair the fuel supply
No
system.
Yes Next step

Disconnect the ignition cable and connect a spark tester;
3
start the engine and check any high-voltage flash (blue/ Repair the ignition
white). No
system.
Yes Next step
Check the spark plug in the cylinder and its model and
4 Adjust or change
gap conformable to specifications. No
the spark plug.
Correct circuits or
Press the engine temperature sensor connector and start Yes
5 replace the
the engine; check if the engine is successfully started. sensor.
No Next step
Clean the air throttle
Yes and the air intake for
6 Slightly pull the throttle to check if the engine is easily started.
idle speed.
No Next step
Change the
7 defective nozzle.
No Next step
8
Eliminate any
Check pressure of the engine cylinder and find any possibility Yes mechanical trouble
9
of pressure insufficient. of the engine.
No Next step
Yes Next step
Check if mechanical ignition timing of the engine is
10 Correct ignition
conformable to specifications. No
timing.
11 check voltages at Pins 5#, 10#, and 23#; check grounding at
Pins 2# and 21#. Repair the
No
relevant circuits.
(6) Start-up normal but idle speed is unstable anytime
General trouble location: 1. Air Intake; 2. Idle Governor; 3. Spark plug; 4. Air throttle and idle air bypass; 5. Nozzle; 6. Fuel
Quality; 7. Compression / Valves; 8. Ignition Timing; 9. Electrical.
Detection
Results
Repair the air
Yes
No Next step
Yes Change
2 Check the Idle governor for the control valve jammed.
No Next step
Check the spark plug and its model and gap conformable Yes Next step
3
to specifications. No Adjustment or change
Check the air throttle and the idle air bypass for any Yes Cleaning
4
carbon deposition. No Next step
Replace the
5 defective nozzle.
No Next step
Yes Change fuel.
No Next step
Eliminate any
Check pressure of the engine cylinder and find any big Yes mechanical trouble of
7
difference in pressure. the engine.
No Next step
Yes Next step
Check if mechanical ignition timing of the engine is conformable
8
to specifications. No Correct ignition timing.
9 voltages at Pins 5#, 10#, and 23#; check grounding at Pins 2# and
21#. Repair the
No
relevant circuits.
(7) Start-up normal but idle speed is unstable during warm-up
General trouble location: 1. Air Intake; 2. Spark Plug; 3. Idle Governor; 4. Temperature sensor; 5. Nozzle; 6. Fuel quality;
7. Engine compression / Valves; 8.Electrical.
Detection
Results
Repair the air
Yes
No Next step
Yes Next step
Check the spark plug and its model and gap conformable
2 Adjustment or
to specifications. No
change
Remove the Idle governor and check the air throttle, the idle Yes Clean relevant parts.
3
governor, and the idle air bypass for any carbon deposition. No Next step
Press the engine temperature sensor connector and start the Correct circuits or
Yes
4 engine to check any instability of the idle speed during replace any sensor.
warm-up of the engine. No Next step
Disassemble the nozzle and check the nozzle leaking or Change the
Yes
5 blocked, or the flow out of tolerance with a nozzle cleaner defective nozzle.
& analyzer. No Next step
6
Eliminate any
Check pressure of the engine cylinder and find any Yes mechanical trouble
7 of the engine.
big difference in pressure.
No Next step
No
relevant circuits.
(8) Start-up normal but idle speed unstable when warm-up is finished
General trouble location: 1. Air Intake; 2. Spark Plug; 3. Idle Governor; 4. Temperature Sensor; 5. Nozzle; 6. Fuel Quality; 7.
Engine compression / valves; 8. Electrical.
Detection
Results
Repair the air
Yes
No Next step
Yes Next step
Check the spark plug and its model and gap conformable
2 Adjustment or
change
Remove the idle governor and check the air throttle, the idle Yes Clean relevant parts.
3
governor, and the idle air bypass for any carbon deposition. No Next step
Press the engine temperature sensor connector and start the Correct circuits or
Yes
4 engine to check any instability of the idle speed during warm-up replace any sensor.
of the engine. No Next step
Change the
Disassemble the nozzle and check the nozzle leaking or blocked, Yes
5 defective nozzle.
or the flow out of tolerance with a nozzle cleaner & analyzer.
No Next step
Yes Change fuel.
No Next step
Eliminate any
Check pressure of the engine cylinder and find any big Yes mechanical trouble
7 of the engine.
difference in pressure.
No Next step
8 voltages at Pins 5#, 10#, and 23#; check grounding at Pins 2# and
21#. Repair the
No
relevant circuits.
(9) Start-up normal but idle speed unstable or stalling with a load such as front lamp applied
General trouble location: 1. idle governor, air throttle and idle air bypass; 2. Load test; 3. Nozzle; 4. Electrical.
Detection
Results
Remove the idle governor and check the air throttle, the idle Yes Clean relevant parts.
1 governor, and the idle air bypass for any carbon deposition. No Next step
Yes Go to Step 4.
Check if the engine’s output power is increased with the
load applied; use the EMS diagnosis tester to check any
2 change in the ignition advance angle, duration of fuel No Next step
injection, and air input.
No Repair the air
regulating system.
Disassemble the nozzle and check the nozzle leaking or Change the
Yes defective nozzle.
3 blocked, or the flow out of tolerance with a nozzle cleaner
& analyzer. No Next step
No relevant circuits.
(10) Start-up normal but idle speed too high
General trouble location: 1. Air throttle and idle air bypass; 2. Vacuum tube; 3, Idle governor; 4. Engine temperature sensor;
5. Ignition timing.
Detection
Results
Yes Adjustment
1 Check the throttle cable for jammed or too tight.
No Next step
Repair the air
Check the air intake system and the connected vacuum Yes intake system.
2 tube for any leakage.
No Next step
Remove the idle governor to check the air throttle, the idle Yes Clean relevant parts.
3 governor and the idle air bypass for any carbon deposition. No Next step
Correct circuits or
Press the engine temperature sensor connector and start Yes
4 replace any sensor.
the engine; check if the engine’s the idle speed is too high.
No Next step
Yes Next step
Check if mechanical ignition timing of the engine is
5 conformable to specifications. Correct ignition
No timing.
No relevant circuits.
(11) RPM low or stalling during acceleration
General trouble location: 1. Water in fuel; 2. Inlet pressure sensor & air throttle sensor; 3, Spark plug; 4. Air throttle & idle
air bypass; 5. Air intake; 6. Idle governor; 7. Nozzle; 8. Ignition timing; 9. Exhauster.
Detection
Results
Check the air
Yes
1 Check the air filter for any jam. intake system.
No Next step
2 nozzle; start the engine to check the fuel pressure at 300kPa or
so during the idle status. Repair the fuel supply
No
system.
Yes Next step
3 Adjustment or
replacement
Remove the idle governor to check the air throttle, the idle Yes Clean relevant parts.
4
governor and the idle air bypass for any carbon deposition. No Next step
Yes Next step
5 Check the inlet pressure sensor, the air throttle and circuits. Correct circuits or
No
replace any sensor.
Replace the
6 defective nozzle.
No Next step
Yes Change fuel.
No Next step
Yes Next step
Check if ignition timing of the engine is conformable to
8
specifications. No Correct ignition timing.
Yes Next step
9 Check the exhauster for exhaust normally discharged. Repair or replace
No
the exhauster.
No
relevant circuits.
(12) Slow acceleration
General trouble location: 1. Water in fuel; 2. Inlet pressure sensor and air throttle sensor; 3. Spark plug; 4. Air throttle and
idle air bypass; 5. Air intake; 6. Idle governor; 7. Nozzle; 8. Ignition timing; 9. Exhauster.
Detection
Results
Check the air
Yes
1 Check the air filter for any jam. intake system.
No Next step
2 nozzle; start the engine to check the fuel pressure at
300kPa or so during the idle status. Repair the fuel
No
supply system.
Yes Next step
3 Adjustment or
replacement
Clean relevant
Remove the idle governor to check the air throttle, the idle Yes
4 parts.
governor and the idle air bypass for any carbon deposition.
No Next step
Yes Next step
Check the inlet pressure sensor, the air throttle sensor Correct circuits or
5
and circuits. No replace any
sensor.
Replace the
6 defective nozzle.
No Next step
7
Yes Next step
Check if the engine’s ignition timing is conformable to
8 Correct ignition
specifications. No
timing.
Yes Next step
9 Check the exhauster for exhaust normally discharged. Repair or replace
No
the exhaust.
10 check voltages at Pins 5#, 10#, and 23#; check grounding
at Pins 2# and 21#. Repair the
No
relevant circuits.
(13) Acceleration sluggish; poor performance
General trouble location: 1. Mechanical drag; 2. Air intake; 3. Fuel pump; 4. Ignition coil; 5. Spark Plug; 6. Air throttle and
idle air bypass; 7. Pressor sensors; 8. Nozzle; 9. Fuel Condition; 10. Ignition timing; 11. Exhaust; 12. Electronics.

Detection
Results
Check any troubles such as clutch slip, low tire pressure, brake drag, Yes Reparation
1
wrong tire size. No Next step
Repair the
Yes
2 Check the air filter for any obstructions. air intake system.
No Next step
Yes Next step

Connect a fuel pressure gauge prior to the fuel inlet of the nozzle; start
3
the engine; fuel pressure should be approximately 300kPa during idle. Repair the
No
fuel supply
system.
Yes Next step
Disconnect the ignition cable and connect a spark tester; start the
4
engine and check for high-voltage flash (blue/white). Repair the ignition
No
system.
Yes Next step
Inspect the spark plug and check the model, gap and condition conform
5 Adjustment or
replacement
Clean relevant
Remove the idle governor to check the air throttle, the idle governor Yes
6 parts.
and the idle air bypass for any carbon deposition.
No Next step
Yes Next step
7 Check the inlet pressure sensor, the air throttle sensor and circuits. Correct circuits or
No
replace any sensor.
Replace the
Disassemble the nozzle and check any leakage or jam in the nozzle with Yes
8 defective nozzle.
a nozzle cleaner & analyzer.
No Next step
Yes Change fuel.
No Next step
Yes Next step
10 Check if the engine’s ignition timing is conformable to specifications. Correct ignition
No
timing.
Yes Next step
11 Check the exhauster for exhaust normally discharged. Repair or
No
replace the
exhauster.
Yes Diagnosis assist
Connect an EMS adapter and press the power switch to check voltages
12
at Pins 5#, 10#, and 23#; check grounding at Pins 2# and 21#. Repair the
No
relevant circuits.
1) PCODE List
NO. function Description

1 P0107 Manifold Abs.Pressure or Bar.Pressure Low Input
2 P0108 Manifold Abs.Pressure or Bar.Pressure High Input
3 P0112 Intake Air Temp.Circ. Low Input
4 P0113 Intake Air Temp.Circ. High Input
5 P0117 Engine Coolant Temp.Circ. Low Input
6 P0118 Engine Coolant Temp.Circ. High Input
7 P0122 Throttle Pos.Sensor Circ. Low Input
8 P0123 Throttle Pos.Sensor Circ. High Input
9 P0130 O2 Sensor Circ. Malfunction
10 P0131 O2 Sensor Circ. Low Voltage
11 P0132 O2 Sensor Circ. High Voltage
12 P0134 O2 Sensor Circ. No Activity Detected
13 P0195 Engine Oil Temperature Sensor Abnormal
14 P0201 Cylinder 1- Injector Circuit
15 P0261 Cylinder 1- Injector Circuit Low
16 P0262 Cylinder 1- Injector Circuit High
17 P0321 Engine Speed Reference Mark
18 P0322 Eng.Speed Inp.Circ. No Signal
19 P0480 cooling fan control Circuit Open
20 P0501 Vehicle speed Malfunction
21 P0508 ISA control Circuit Low
22 P0509 ISA control Circuit High
23 P0511 ISA control Circuit/Open
24 P0560 System Voltage Malfunction
25 P0562 System Voltage Low Voltage
26 P0563 System Voltage High Voltage
27 P0571 Break switch Malfunction
28 P0650 Malfunction Indicator Lamp Control Circ.
29 P0691 cooling fan control Circuit Low
30 P0692 cooling fan control Circuit High
32 P1099 Malfunction wheelie Control Circ.
33 P1116 Engine Coolant Temp Hig
34 P1626 Wrong anti-thief resistor
35 P1136 K-LINE OPEN
2) Refer to the circuit diagrams for any troubleshooting or maintenance.

Installation & Removal of Exterior Components-2
2-0 Operating instructions
2-1 Removal of the exterior parts 2-0
Operating instructions
1. When removing exterior body panels, ensure that panels are not forcefully removed as this can make the panels
fracture.
2. Install exterior parts so they are not contacting the main wiring harness. If the mounting screw is too long and
penetrates the wiring, it will make the main wiring harness short circuit.
2-1 Removal of the exterior body parts

1) HANDLE BAR COVER UPPER / HEAD LIGHT COVER→SPEEDOMETER ASSY→HEAD LIGHT ASSY
1-1 HANDLE COVER UPPER / HEAD LIGHT COVER
Disassembly -
a. Remove screws (5/4), remove the speedometer
bezel (3).
b. Remove screws (2), remove the handlebar cover (1).
1-2 SPEEDOMETER ASSY
Disassembly -
a. Remove screws (3), remove the speedometer
cluster (2).
1-3 HEAD LIGHT ASSY

Disassembly -
a. Remove the Hex adjustment bolt, washer, and lock
washer (1、2、3).
b. Remove screws (4), remove the head light assy(5).
2. LOWER COVER (R/L)→MIDDLE COVER→STEP FLOOR→WIND SHIELD→FRONT PANEL,INNER
COVER→FRONT INNER PANEL (UPPPER、LOWER)
2-1 LOWER COVER (R/L)

Disassembly-
a. Remove screws (2, 6).
b. Remove screws and washers (3, 4, 7, 8), remove the
lower cover【L&R】 (1/5).
2-2 MIDDLE COVER→STEP FLOOR

Disassembly-
a. Remove screw (5), remove the step floor
b. Use a flathead screwdriver to remove the rubber plug*4
(4).
c. Remove screws (2), remove the step floor (1).
Disassembly-
2-3 WINDSHIELD→FRONT INNER PANEL COVER
a. Put your hand into the gap between the Wind
Shield and Front Fender, use your fingers to push
the circular cover (9) outward and remove the
circular cover
b. Remove
. the screw (8)
c. Remove the push rivets (7)

d. Remove self-tapping screws (6), remove the Wind
Shield (5).
e. Remove the push rivets (2), remove the front inner
panel cover (1).
f. Remove screw (4) ,remove the magnetic burglar
lock assy(3).
2-3.1 TURN SIGNAL COMP
Disassembly-
a. Remove the tapping screws (4), remove the turn
signal assemblies (2 & 3).
2-4 FRONT UNDER COVER

Disassembly -
a Remove screws (2), remove the under cover (1).
2-4.1 FRONT LOWER COVER/ FRONT

INNER COVER, UPPER Disassembly -
a. Remove tapping screws (4)
b. Remove the push rivets (5), remove the front
lower cover (3).
c. Remove the U-type spring nuts.
d. Remove the tapping screws (7), remove the
front under cover upper (6).
2-5 FRONT INNER COVER
Disassembly -
a. Remove the screw (5), remove the front hook (4).
b. Remove the washers & screws (2, 3)
c. Loosen hose clamp (6), pull out FUEL HOSE (8).
d. Remove the fuel tank cover cable.
e. Use needle nose pliers to remove the hose clamps (7)
and "THREE WAY ASSY "(9).
f. Remove the front inner cover assembly (10).
Note: Following removal of the fuel hose, seal the

fuel tank inlet with a cloth to prevent foreign objects
from falling into the fuel tank.
2-5.1 FRONT INNER COVER (UPPER, LOWER),

REFLECTORS
Disassembly -
a. Remove the tank inner cover (8).
b. Remove tapping screws (7), remove the fuel tank
cover and gas cap base assembly (6).
c. Remove nuts (3), remove the reflectors (2).
f. Remove tapping screws (5).
g. Separate front inner cover-upper (4) and
Front inner cover-lower (1).
Installation-
Follow the removal procedure in reverse for install.
3) HANDLE BAR ASSY.→HANDLE LOWER COVER
3-1 HANDLE BAR ASSY.→HANDLE LOWER COVER
Disassembly -
a. Remove tapping screws (17).
b. Remove washers, screws (18, 19).
c. Disassemble the handle switch (10-L/13-R) bolts and
cable terminal, remove the handle switch.
d. Remove the brake master cylinder (9 - left 12 right)
Socket Head Cap Screws。
e. Remove the screw/ nuts (2&3), remove the screw
washer (4).
g. The upward force separation of the handle bar (7)
and the fork (1).
h. Remove the handle lower cover (5).
Installation-
Follow the removal procedure in reverse can be install.
4-1 LUGGAGE COMP→REAR LUGGAGE BRACKET→BODY COVER (L、R) →FRONT BODY COVER
→LICENSE PLATE→REAR SIGNAL LAMP (L、R) →BATTERY BOX
4-1 LUGGAGE COMP→BATTERY COVER→SEAT
Disassembly -
a. Remove the screws (2), remove the luggage
compartment (1).
b. Remove the tapping screws (4), remove
the battery cover (3)
c. Demolition of the screw (6), remove the seat (5).
4-1.1 LUGGAGE COMPARTMENT

Disassembly -
a. Remove Diagnostic adaptor (2) fastening nut.
b. Remove the tapping screws (4), remove
the diagnostic connector plate (3).
c. Remove the RUBBER PLUG (5).
d. Loosen and remove the Power switch (6) fastening
nut.
e. Loosen & remove 12V charging port fastening nut (7)
f. Remove of the hinge bolt (10), and remove the bracket.
4-2 REAR LUGGAGE BRACKET
Disassembly -
Remove the screws (2), and remove the rear
luggage bracket (1).
4-3 BODY COVER ASSEMBLY (L、R)

Disassembly -
a. Remove the tapping screws (4).
b. Remove the tapping screws (5) and then remove the
body cover assembly (3).
4-3.1 FRONT BODY COVER

Disassembly -
a. Remove the tapping screws (3).
b. Separate the body cover assembly (1)
and front body cover (2).
4-3.2 LICENSE PLATE / REAR SIGNAL LAMP
Disassembly -
a. Remove the tapping screws (10 & 8), remove the
license plate (9-R, 7-L).
b. Remove the tapping screws (12), remove the rear
signal lamp (11).
c. Remove the tapping screws (6), remove the
license plate bracket(5).
4-3.3 REFLECTOR /LICENSE PLATE FIXED PLATE

Disassembly -
a. Remove the nut and washer (3/4), remove the
reflector (2).
b. Remove of the nuts and washers (6/7), remove the
license plate bracket (5).
c. Remove the “U TYPE SPRING NUTS”(8).
4-3.4 BODY COVER-R/ BODY COVER -L
Disassembly -
a. Remove of the tapping screw (4).
b. Separation of the right body cover (1) and left
body cover (2).
c. Remove the“U TYPE SPRING NUTS”(3).
4-4 BATTERY BOX

Disassembly –
a. Remove the tapping screws (4), remove
the battery box(5).
b. Remove of the tapping screws(1).

c. Remove the battery box pedestal(2).
d. Remove the “U TYPE SPRING NUTS”(3).
Installation-
Follow the removal procedure in reverse to install.
FRONT FENDER
5-1 FRONT WHEEL ASSY (10")
Disassembly –
a. Remove the tapping screws (14), remove the
brake caliper (13).
b. Remove the front axle (8) and the lock nut (12).
Torque value: 5.0~6.0kg-m
c. Remove the front Wheel (10), speedometer
gear assembly (11) and wheel spacer (9).
5-2 REAR SECTION FRONT FENDER }

Disassembly –
a. Remove the tapping screw (2) and screws (3).
b. Remove the rear section of the front fender (1).
5-2.1 FRONT FENDER
Disassembly –
a. Remove the screws (4).
b. Remove the tapping screw (7), remove
the front fender(2).
c. Remove the bolts (6).
d. Remove the front fender bracket (5).
Installation-
Follow the removal procedure in reverse to install.
Check & Adjustment-3
3-0 Operating instructions 3-15 Compression Pressure Measurement
3-1 Engine oil 3-16 Throttle Adjustment
3-2 Gear oil 3-17 Brake clearance
3-3 Air cleaner comp 3-18 Brakes-thin check
3-4 Main switch 3-19 Brake fluid check / adjustment
3-5 Seat lock / Fuel tank cover 3-20 Front lamp
3-6 Rear wheel disassembly instructions 3-21 Driving belt / clutch lining
3-7 Power transfer switch 3-22 Tire & wheel
3-8 Charging power switch 3-23 Ministries lubrication
3-9 Gearbox vent 3-24 Suspension system
3-10 speedometer 3-25 Steering checks
3-11 Spark plug 3-26 Battery Check
3-12 V-belt - air sponge cleaning 3-27 Fuse
3-13 Check / adjust timing 3-28 Side Stand
3-14 Valve clearance
3-0 Operating instructions

This chapter describes all regular maintenance inspections, adjustments and routine repairs. Follow these
maintenance procedures provided to reduce vehicle engine wear and extend the life of parts, so that the scooter will
run more smoothly and maintain proper operating condition.
Torque: (kg-M)
Oil drain screw: 20 lb-ft Spark Plug 8 lb-ft
Oil strainer cover: 13 lb-ft Gear oil drain screw: 16 lb-ft
Tools-
1. Spark plug gap gauge 4. Multimeter 7. Front fork - Bearing cage disassembly, tools
2. feeler gauge 5. Charging Machine 8. Dial indicator
3. Valve clearance adjustment tool 6. Brake fluid bleed unit
Inspection & Adjustment-3
PERIODIC MAINTENANCE SCHEDULE
First Mileages or Months
Item Content 500mi
1875mi 3750mi 5625mi 7500mi 9375mi 11,250mi
(1 Month) (3Months) (6Months) (9Months) (12 Months) (15 Months) (18 Months)
Replacement
Engine Oil* Replacement every 1875mi
Recommend 10w40 
Clean; replacement
Oil Screen Filter*
(as necessary)
 Clean every oil change (every 1875 miles) ; replacement (if necessary)
Filter (CVT) Cleaning or replacement

     
Gear Oil* Recommend SAE 80w90       
Front Brake; Rear Check brake linings for wear &
function and/or leakage of brake      
Brake Discs
fluid. Clean or repair as necessary.
Check the oil cooler and hoses for

Oil Cooling
leakage and/or ageing. (Replace as Check every 3750mi
System necessary).
Check for damage and/or wear;

V Belt * clean the belt prior to lubrication;  R - REPLACE 
replace the belt, if necessary.
Check function; clean the clutch, as

Clutch necessary.      
Check balance, damage and true;
Wheel * replace the tire/ wheel, if necessary.     
Wheel Bearing * Check torque of axle/ bearing play.      
Front Fork & Rear
Cushion *
Check functions and leakage.       
Steering Bearing Adjust tightness, if necessary.
*
  
Main(Side) Check functions; replace the
Stand * main (side) stand, if necessary.       
Check tightness of all components;
Tightness * adjust any component, if necessary       
Check if the battery voltage is greater
Battery * than 12.8V. Charge the battery,
if necessary; clean terminals.      
*: Service at a Genuine dealer only
R: Part changed every 7500 miles and thoroughly inspected every 3750 miles. To maintain maximum performance, a scooter driven in any harsh
environment such as dust shall be maintained according to a shorter service cycle.
○: Service mileage
PERIODIC MAINTENANCE SCHEDULE FOR MAXIMUM ENGINE PERFORMANCE / LONGEVITY
Mileages or Months
Item Content First 500mi 1875mi 3750mi 5625mi 7500mi 9375mi 12,500mi
(1 Month) (3 Months) (6 Months) (9 Months) (12 Months) (15 Months) (18 Months)
Check and adjust the valve
Valve Clearance* clearance with the engine
cooled down.
   
Check functions; adjust the gap
and clean the spark plug. Replace  
Spark Plug
spark plug if necessary.    
Crankcase Check the hose for cracks or
Ventilation System*
blockage. Replace the hose,   
if necessary.
Check the hose for crack or
Fuel System* blockage. Replace the hose,
if necessary.
 
Cleaning; replacement
Air Filter*
(if necessary)      
Evaporative Check the control system
Emission Control for damage. Replace the  
System* control system, if necessary.
Check for leakage. Fasten or
Exhaust System* replace the washer, if  
necessary.
ISC:1~10 When engine is hot
ISC Valve*       
Check all sensors’ functions (for
EMS* the motorcycle model with
EMS only).
      
Check and clean the throttle
Throttle Valve* every 3750mi; clean the throttle C C C
every 7500mi.
*: Service available only at Genuine dealers
C: Part checked (cleaned) every 3750mi
R: Part changed every 7500 miles or checked every 3750 miles for driving security. To maintain a scooter’s premium performance, a scooter regularly
driven in any harsh environment such as dust shall be maintained according to a shorter service cycle.
NON-PERIODIC MAINTENANCE SCHEDULE FOR EXHAUST CONTROL
Item Content
Removal of carbon It is necessary to maintain or check the ignition system in the event of ignition failure, engine fire, overheating, etc.
deposit in the ignition Remove carbon deposit on the cylinder head, the piston head, and the exhaust system in the event of the engine’s power
system has significantly dropped.
*: Service available in a Genuine dealer only

3-1 Engine oil

Volume:
Total oil volume: 1000c.c. Oil volume
replaced: 800c.c. Service cycle: 1875mi
Check the oil level
 Park the scooter on a horizontal surface for checks.

 Run the engine for 3-minute and stop it for 3-
minute; prior to making a measurement.
1. Turn oil fill plug counter-clockwise to open

2. Wipe the level indicator clean, and then re-tighten
into fill port, remove once again to measure the oil
3. The
level.oil level should be between the lower (a) and
upper limit (b) position, if the oil level is low, add oil
as required.
△Note: Sometimes engine damage and
performance deterioration may be attributed
to engine oil level exceeding the range.
Oil replacement
1. Remove and clean the drain plug bolt (3); check the gasket (2)
for any defects and replace defective gaskets with a new
ones. Retighten the bolt after the engine oil has been drained
Upper limit
completely.
Lower limit
2. Remove and clean the oil fill / level indicator. Add new engine
oil (approx. 800c.) and retighten the oil fill plug.
3. Start the engine and check to determine if there are any
engine oil leaks; remove the oil fill plug and check the oil level
indicator once again.
Torque: 2.5~3.5(kg-m)
△ Note: Engine oil replacement shall be approx. 1000c.c.
following engine disassembly.
Note:
If the amount of oil is not maintained within the standard
range, engine performance degradation or damage may
occur.
․Different types of oil cannot be mixed with each
other.
․Do not let foreign objects fall into the
crankcase.
․Do not start the engine with the oil fill removed
from the engine
ban.
★Recommended oil:
SAE15W-40 (800c.c) Engine oil
NOTE
After engine overhaul, please clean the oil screen filter, a
clogged oil screen will cause engine damage.
Oil strainer removal -

a. Remove the oil strainer cover (3), the spring (5), oil
strainer (6).
b. clean oil strainer and replace the O-ring(4).
c. Reinstall parts 5 → 6 → 3 in reverse order of
installation.
Torque -
. Oil drain screw: 25~30 N-m
. oil strainer cover: 15 ~ 20 N-m
3-2 Gear oil

Volume
Total oil volume: 110c.c.
Oil volume replaced: 90c.c.
Service cycle: Every 1500 miles
Checking Gear Oil Level
 Park the motorcycle on a horizontal surface for

oil level checks.
 Recommended oil: ○
3
SAE85W-140 (90c.c) Gear oil
○
2
1. Place a graduated cup under the drain plug bolt (3) prior to
removal of the bolt.
2. Check the oil volume after the gear oil has been drained.
Oil replacement
1. Place a vessel under the drain plug bolt; remove and clean the bolt.
2. Install the bolt with the gear oil drained.
3. Open the oil fill plug and pour in new gear oil; tighten fill plug.
Torque: 17~20(N-m)
△Note:
1. To avoid oil leakage, please check the aluminum gasket attached to the drain plug bolt (2) and the O-ring attached to the
filling orifice bolt (4) for any deformation.
2. Drain screw length is restricted to 40mm. Do not use different size screws, as this may make undesirable perforations
into the gear box cases.
3-3 Air Filter

Recommended service cycle:
Check: Every 1750 mi
Change: Every 3500 mi or less in the
event of dirty riding conditions.
Check / Change:
1. Remove 5 screws (1) on the air cleaner cover.
2. Remove fixed block (2).
3. Check gasket for dirt or damage; clean gasket with
high-pressure air gun.
4. Replace the air filter with a new one in the event the
old filter is too dirty.
Note:
Do not rinse with water or organic solvent.
NOTE
․Do not rinse gasket with water or organic solvent.
․Do not start the engine or drive with the air filter
removed. Direct intake of dust into the engine may
4
quickly cause internal damage to the engine parts.
․When re-installing air filter and cover, it is extremely
important to confirm both gaskets (9) are closely
aligned with the air cleaner body to prevent dust
inhalation into the airbox.
.
3-4. Main switch (for ignition & illumination)
3.4.1
The instructions for using the ignition switch to control
ignition and illumination are shown as follows:
1. Power disconnected; key removable.
2. Power connected; engine ready to be started; key not
removable.
3. Handlebar locked; power disconnected; key removable.
Please refer to “Steering Handlebar” (P-12) for correct
operations.
4. Under-seat Storage - “PUSH” & turn left to open the
Attention: Turn the key to “OFF” or “LOCK” and
seat with the key kept at “A”, “B”, or “C” positions.
remove it when the motorcycle is not driven. 5.“B”: Press and turn the key clockwise to open
the fuel cap .
Anti-theft status 6. Remove the key and press the “E” tab in to
protect the key hole from any intrusive foreign objects
and activate anti-theft status.
7. Plug the shutter magnetic lock on the key shank into
“F” and turn it clockwise to open the cover.
3.4.2 FUEL CAP
1. With the key remained at , press “PUSH” and turn
the key clockwise to open the fuel cap.
2.Press the fuel cap frontward and downward to close the
fuel cap.
3.4.3 LOCK FOR STEERING HANDLEBAR
Turn the steering handlebar far left prior to locking it. Turn the
key to “LOCK” from “OFF” and remove it. Turn the key
clockwise to unlock the steering handlebar.
3.4.4 SEAT LOCK
1. Push and turn the key counterclockwise, at any key
position, in order to lift and open the seat.
2. Use the seat lock to protect any personal objects inside
the luggage compartment and remember to activate the
anti-theft function prior to leaving your motorcycle.
3. Please close and press the seat downward gently in order
to activate the seat lock and extend its service life.
3-5 Seat lock / Fuel tank cover cables

Adjustment-
a
a- Seat lock lever cable
b- Tank cover lever cable
Adjustment screws (C):
Clockwise: loosen
Counterclockwise: Tighten
b c
3-6 Rear wheel disassembly instructions
※ When removing the rear wheels, remove the tire pressure

valve stem to remove all air from the tire, and then remove
the wheels.
3-7 Power transfer switch

Power switch is located under the seat and functions as a
secondary anti-theft system.
How to use: press the switch position

-: Turn off anti-theft
O: start anti-theft
When the switch is off-

1. The starting system and the main relay will not
function. The start motor won’t run, and the fuel
injection system does not work.
2. The ECU circuit symbol will appear on the dash
3-8 Charging port

1. Function: Supply 12V DC charging power.
2. Restrictions on Use: The charging current cannot be

higher than 1A.
3. Power Protection: 1A fuse.

4. Usage: Use a car charger style plug and insert it into the
port to charge your device.
Note:
The power supply cannot be used as a cigarette lighter. 圖表 3
3-9 Gearbox vent

Vent-
1. Gear box vent pipe cannot kink as that may result in too
much case pressure which can burst a seal or cause a
gasket leak.
2. Ventilation tube cannot be removed as it will allow
water or foreign material to enter into the gear box,
causing damage to the gears or roller bearings and gear
oil degradation.
3-10 SPEEDOMETER FUNCTIONS AND INDICATORS
Speed in miles per hour Function Indicator

and clock
Functional icon
Engine oil EMS indicator

indicator
High beam indicator Low beam indicator
Turn signal light (left) Turn signal light (right)
Fuel level
Mileage information
Function key
█ EMS Information • Injection diagnosis function is
automatically activated with power • Press the button to reset the

connected. mileage on the display panel
• Any error will be indicated on the in the “TRIP” mode.
display panel.
█ Millage Information
• The millage Information is
always indicated at the bottom
█ Time Information
for any mode. • Press the button on the display
• Press and hold the button to panel to indicate “Time”.
switch between “km” or “mile” • Refer to “Set-Up” for “Time”
in the odometer “ODO” mode. adjustments.
• Mileage indicator, select █ Voltage Information

• Press the button on the display
between ODO and TRIP:
panel for battery “Voltage”.
Continuously press the
• Voltage alarm: Battery voltage
button on the display panel
lower than 11.5V or greater
to switch to ODO or TRIP.
than 15.5V
█ Fuel Level
█ RPM • “Fuel Level” is always indicated at
the left-hand side of the display
• Press the button on the display panel for any mode.
panel to indicate engine “RPM”. • Low fuel level: “Fuel Level”
blinking and a symbol for low level
indicated on the upper right corner
█ Set-Up █ Reset of Oil Indicator in case of one scale only.

• Disconnect the power • The oil indicator “ON”
supply. implies the engine oil needs
• Press and hold the button to to be replaced.
enable power and enter the

• Reset the oil indicator
page for set-up.
following oil service
• Enter the page for time set- completion.
up; (1) Short press for • Press and hold the button
adjustment of time; (2) Long under ODO (total mileage)
press for switch between for 3 seconds until the oil
“HR” and “MIN”. indicator blinks.
• Adjustment of the display • When the oil indicator is

panel’s contrast: Continuous blinking, press and hold the
long press button for another 5 seconds in
order to eliminate blinking.
• Adjustment of the display
panel’s contrast.
Attention: Please drive your vehicle to a Genuine
dealer for inspection in the event any EMS error message is

shown on the display panel.
Attention: Do not change any speedometer function
while driving. Distracted driving can cause an accident.
Alert symbol:
Power switch symbol Diagnostic mode symbol Voltage warning symbol Low fuel symbol
On when power switch
under seat is off On when PC is connected On when voltage drops On when gasoline is
1. Starter motor fails to turn. to the diagnostic display below 11.5V or is higher less than 1/8 of
2. Injection system will than 15.5V.. capacity
not actuate.
3-11 Spark plug

1. Removal
› Remove the middle cover.
› Use a spark plug tool to remove the spark plug.
Torque value: 10 ~ 12 N-M
Check-
2. Check the spark plug for damage, corrosion, or carbon
deposition.
3. Use carbon remover or a steel brush to clean any
deposits or carbon build-up.
4. Porcelain insulator color:
Standard color → Sepia
Abnormal color → Replace
5. Electrode -
Wear / deformation → Replace
Adjustment –
Tools - Gauge (see section 1-6)
> Check the spark plug for carbon build-up, if dirty, use
carbon remover or a steel brush to remove build-up.
> Check spark plug gap with a spark plug gauge. If the gap is
too large or too small, use the spark plug gauge to adjust the gap.
Spark Plug Installation:

Install the plug by following the removal procedure in reverse.
Specific model: CR7E NGK or similar substitute
Spark plug gap: 0.6~0.7mm
Note
Prior to removing the spark plug, clean around the head, to prevent dirt from falling into spark plug port.
3-12 CVT - air filter cleaning
1. Removal -
> Loosen clamp bolt (1).
> Remove the breather pipe (2).
> Remove to remove the fixed plate (3).
> Remove the filter (4).
2. Checks -
> Replace sponge if it is excessively dirty.
3. Cleaning -
> Use compressed air to clean the filter.
2 1 4 3
Note:
Do not use flammable solvents to clean the filter.
4. Installation:
> Install in reverse order from the removal process.
3-13 Check / Adjust timing
1. Valve Cover Removal - Please refer to section 7 of the

cylinder head.
2. Check – timing
› Rotate the flywheel clockwise, align the flywheel mark
"T" with the arrow mark on the right crankcase cover.
› Check camshaft large opening, and the other two small
openings to ensure the cam sprocket marks (4) are
parallel to the cylinder head.
› If the camshaft sprocket marks are not parallel, adjust the
camshaft sprocket position accordingly
Junction surface
3. Camshaft sprocket position adjustment
› Remove the inner chain adjuster screws of the cam
chain tensioner.
› Using a slotted screwdriver in the port, turn the
adjustment screw within clockwise until the chain
becomes loose.
Junction surface › Remove the camshaft holder nut (3)

› Adjust the camshaft sprocket on the horizontal line
with the cylinder head of the cylinder head cover
parallel to the engagement surface.
4. Installation-
> Install in reverse order in accordance with the
removal instructions.
Adjustment fix
screws
3-14 Valve clearance
1. Valve Cover Removal
> Please refer to section 7 of the cylinder head.
Note
․Valve clearance adjustments are done when the engine
is cold.
․Rotate engine to top dead center for measurement and
adjustment.
2. Check valve clearance.

Tools: Feeler gauge; wrench for valve adjustment
Method: Adjust the piston to top dead center
(Flywheel “T” mark = Timing); use the feeler gauge to
check the valve clearance.
Adjustment: Loosen the lock nut and turn the adjusting
screw within the spec. in the event the valve clearance is
incorrect.
Valve clearance:
INTAKE: 0.10mm ~ 0.12mm
EXAUST: 0.12mm ~ 0.14mm
圖表 4
3. Adjustment -
> Tools: Valve adjustment tool
> Adjustment:
a: Loosen the lock nut.
b: Insert feeler gauge between the valve and the adjustment screw.
c: Rotation adjustment screw down onto feeler gauge to adjust to the predetermine clearance. Tighten lock nut.
d: Re-measure the valve clearance, if the valve clearance is beyond standard, re-adjust.
4. Installation-
> Reassemble components in reverse order from removal.
△Note: Check and adjust the valve clearance when the motorcycle engine temperature is low.
△Note: Torque the lock nut for the valve clearance, T = 7 N-m.
3-15 Compression pressure measurement
1. Remove -
> Spark Plugs
Note
Prior to removing spark plug, clean around the spark plug port
to prevent dirt and debris from dropping into the spark plug
port.
2. Measurement - cylinder pressure

Standard value: 10 ± 2Kg/cm ²-570rpm (142 psi standard)
Minimum - 125 psi, Maximum - 165 psi
Tools: compression pressure gauge
› Measurements -
a. Turn on ignition.
b. Open throttle fully, then turn over engine until the
compression pressure value is steady.
→ Analysis c. Test results:

1. If result is more than the maximum value
Pressure values Reason
→ Inspect the combustion chamber for
Result higher after adding carbon deposition.
Piston rings worn
oil to combustion chamber 2. If result is less than the minimum value
Valve, piston, piston → Add a few drops of oil to the cylinder via the
Result is the same after rings cracked, spark plug port, then re-measure.
adding oil to combustion cylinder head gasket 3. Installation -
chamber leak or other adverse > Install in reverse order from removal.
condition.
3-16 Throttle cable free play / adjustment
1. Check -
> Determine if the idle speed is too high.
> Rotate the throttle grip, check the throttle cable
clearance. If the clearance is abnormal, adjust cable so free
play does not exceeded the standard range.
2. Throttle cable free play measurement
Standard range: 2 ~ 6mm
3. Adjustments - throttle cable free play
a: Loosen cable adjustment lock nuts.
b: Rotate adjuster clockwise or counter-clockwise
until free play is within the standard range
clockwise (1) = loosen
counterclockwise (2) = Tighten
C: Tighten the cable adjusters
NOTE
Ensure the free play adjustments are completed with the
handlebar in the center of the turning range. Completing
adjustments while bars are turned to the left or right may
result in improper free play and could possibly lead to
engine speed changes when the bars are turned.
3-17 Check the brake clearance

Measurement - brake lever
> Check the back-play by pressing the brake lever
for any inconformity.
Standard clearance :10-20mm
Note:
Disk brake system can adjust the brake clearance, when
the clearance is not within the standard range, check
whether there is air in the brake system tubing.
How air exhaust brake system, please refer to the section
3-13.
3-18 Brakes-thin check
› Standard values:
Front brake pad thickness: 4.0mm
Rear brake pad thickness: 4.2mm
› Wear limits: front: 3.0mm
Rear: 3.5mm
Measurement –
> Measure pad thickness with a caliper
Out of range →
Replace
front brakes
NOTE
1. When either brake pad reaches the wear limit replace
both brake pads.
2. If the brake pad surface comes in contact with oil or
brake fluid, it will dramatically reduce braking
performance, and in severe cases may endanger life.
Rear brakes
3-19 Brake fluid check / adjustment

Check - brake master cylinder
> Brake fluid check (View Sight glass) determine whether the
amount of fluid is between the high oil level (2/3) and the low oil
level (1/3).
> Out of range > add or reduce the amount of oil.
Adjustment:
> Open brake master cylinder cover, add brake fluid if necessary.
NOTE:
1.Brake fluid is corrosive, if the master cylinder or bodywork
come in contact with Brake fluid, rinse with water.
2.Brake fluid can not be mixed with other types of oil.
3.DOT4 cannot be mixed with DOT5.
★Recommended brake fluid: FMVSS DOT4
Replacement -
Tools: pumping unit
1. Open the drain screw.
2. Remove old brake fluid using a brake bleeder pump. Open above the
top of the master cylinder, and add new oil.

A. Bleed the brakes
B. Ensure you continue to add brake fluid while bleeding to
prevent air from entering the brake line.
3.Tighten the drain screw and brake master cylinder cover.

Actuate the brake several times to check the brake lever clearance. If
necessary, repeat the steps above to bleed the brake further.
Warning
Do not pull the brake lever when the master cylinder cover is removed, brake fluid can spray accidentally spray into
eyes and/or mouth. In the event you come into contact with brake fluid, flush with water repeatedly and contact
emergency personnel for further assistance.
3-20 Front lamp
1.Adjustment -
> Moves forward or backward to adjust the projection
angle of headlights.
3-21 Driving belt / clutch lining
1 Remove the following:

> Please refer to section- 9 CVT maintenance cycle
2 checks - V-belt
> Cracking, wear → Replace.
> Use limits: 19mm
1. Check the driving belt for any chaps or wear; replace

it if necessary.
2. Gradually increase RPM and check articulation of the 圖表 7

clutch lining. Please check the clutch lining and replace
it, if necessary, for any situation such as unsmooth
acceleration, no movement, stalling, etc.
Note:
V-belt and clutch can not come in contact with oil,
else engine performance will decline.
圖表 8
3-22 Tire & wheel

Check the tread / wall for any wear, break, or nail.
▽: Tread wear indicator
▽
Check tire pressure:
Front Wheel Rear Wheel
26 - 28 psi 26-28 psi

▽
▽
▽
Note
․Check the tire pressure at ambient temperature.
▽
․Gross vehicle weight must not exceed tire load,easy to make the tire burstor damage caused by a vehicle accident.
․The total weight does not include the Knight,passenger, accessories and cargo.
▽ ▽
2. Check-
› Tread/tire wall:
replacement tire→ wear, cracks
›Tread depth:
Minimum usage limit: 0.8mm
Tire model:
Front: 90/90-10 4PR
Rear: 90/90-10 4PR Depth (front and rear): According to the mark of tire”
▲” indicating the necessity to change a new tire.
1.Throttle cable inspection

a: check
> External Cables
Excessive bending, popping → Replace
> Cable actuation
a: If the cable has been overtightened, or the
cable has broken →replace
b: Lubrication
> Add oil to the cable.
2. Brake Master Cylinder

>Lubricate the Brake Master Cylinder piston and
under the pressure lever several times.
3. Side stand, Center stand

> Lubricate side stand and center stand, moving
back and forth several times to ensure the stand moves
freely.
Note:
Recommended lubricant: Lithium soap grease.
3-24 Suspension system

一. Front shock absorber
Check-
› Use the center stand to support the motorcycle; firmly
grip the front brake lever and press front shock
absorbers several times to check any noise, leakage,
screw loosened, or bushing worn.
› Make note of problem and fix or replace as necessary
Note:
Use centerstand and side stand on a flat area.
二. Rear shock absorber

1. Check-
› Use the center stand to support the motorcycle; firmly
grip the front brake lever and press front shock
absorbers several times to check any noise, leakage,
screw loosened, or bushing worn.
› Dysfunctional →Replacement
2. Lubrication -
> Lubricate suspension pivots.
Note:
Keep the motorcycles on a flat area.
3-25 Steering checks

1. Actuate the center stand so that the front wheel is
elevated.
2 checks -
> Grasp fork bottom half with hands, rock back
and forth to check for play.
> Grasp fork bottom half with hands holding turning left and
right.
Are there gaps? / Tighten / adjust as necessary
3 Adjustment -
> See chapter 12
Note:
Keep the motorcycles on a flat area.
3-26 Battery check

1. Demolition -
> Battery cable
By:
> First deremove battery cable (-) negative,
then split the battery lead (+) positive.
2 check - battery voltage

Tools: multimeter
Ways: (+) red probe is connected to the positive terminal
(-) black Probe is connected negative terminal 圖表 9
State voltage method
Fully Higher than 12.8V -
Charging 12.3V~12.7V charge
No electricity lower than 12.3V charge

(Minimum start-up voltage: 12.3V)
3. Charging current / time: 0.9A / 5 ~~ 10 hours
Note:
1) Do not rapid charge.
2) Sealed battery - Never open the battery cover as this will lead to battery internal imbalances which degrade performance.
3) In order to provide maximum battery performance, fully charge battery before initial use.
4) When adding electrolyte to a new battery, allow battery to stand for 30 minutes or more prior to sealing the cap,
this allows the electrolyte to completely soak pole portions of the battery.
5)When the vehicle is not used for long periods of time, please charge before the first drive, additionally, remove
the negative terminal when not in use for battery preservation.
3.Installation:
> Battery cable
By:
1)First install the battery lead (+) positive,and then install the battery cable (-) negative.
3-27 Fuse check

1. Demolition -
> Windshield / Luggage
> Fuse
Note:
Removable fuse, turn main switch to the OFF position
2 Check
> Tools: multimeter
Way: red probe(+) to one fuse end and the
black Probe(-) connected to the other end
> Multimeter stalls: Ω ∞ → replace fuse
Note:
. Turn the power to the OFF position.
. Please replace the fuse using the same amperage.
. If fuse blows again, check line for short.
Warning:
Do not replace with fuse greater than originally set specifications, as this may cause the vehicle fire.
1. Fuse-
1. 1A: 12V power switch
2. 10 A: headlight fuse
3. 15 A: Main fuse
3-28 Side stand switch comp (European specifications)

TURN OFF: TURN ON:
(Figure I) (Figure II)
Startup: will the side stand switch by the turn off position (Figure I) push to
the turn on position (Figure II), motocycle can be normal start.
TURN OFF: TURN ON:
(Figure III) (Figure IV)
When parking motocycle: will the side stand switch by the turn on position (Figure
III) push to the turn off position (Figure IV)，motocycle
automatically stops the engine immediately.
Electronic fuel injection system -4
Configuration and performance of parts in the MSE3.0 gasoline engine’s electronic control unit
Throttle Body(T- MAP)
1. Throttle Position Sensor Ignition coil/ Spark Plug

Ignition Coil/Spark Plug
2.Intake Pressure Sensor
Throttle Body Injector
進氣溫度感測器 Intake Temperature Sensor
Integrated Module Small Engine Injector Oxygen sensors
怠速執行器 Idle Speed Actuator
Oxygen Sensor
Speed Sensor/
ECU
Electronic Control Unit (ECU)

CDI Trigger Coil
故障燈 MIL coolant temperature sensor

Diagnosis Interface Idle/side shore
診斷介面
Engine Temperature Sensor
Immobilizer
ATV
Roll Over
翻車保護
Protection
Fuel Pump
Fuel Lever Sensor

調壓閥 Fuel Pressure Regulator
精濾器 Fine fuel filter
油泵支架 Fuel Pump Bracket

1.The basic principle of the electronic control system motorcycle MSE3.0
The basic composition of the gasoline electronic control system
Any electronic control systems, including gasoline engine electronic control systems are composed of the following
three components:
(1) sensor - the engine in a variety of non-electrical quantities converted into electrical quantity , whereby a variety
of information to the electronic control unit; sensors are the eyes and ears of the electronic control system.
Sensors for MSE3.0 electronic control system are:
• Intake manifold absolute pressure sensor (load information)
• Throttle position sensor (load information, load range information, acceleration and deceleration information)
• Inductive speed sensors (speed information and crankshaft position information)
• Intake air temperature sensor (air density information)
• Coolant temperature sensor (engine temperature information)
• Oxygen sensor (excess air ratio greater than 1 or less than information 1)
（2）The electronic control unit - is the brain of the entire electronic control system, initials as ECU. It provides a variety
of information to analyze sensors and processing, the conclusions in the form of instructions sent to the actuator, so
that the engine runs under optimized condition.
(3) Actuators - the electronic control unit to execute instructions. The actuator is the electronic control system for the
hands and feet. Electronic control for MSE3.0
Actuator-system are:
 Electric fuel pump
 Electromagnetic Injector
 Ignition Coil
 Idle speed control
2) Electronically controlled gasoline injection engine fuel system

Electronically controlled gasoline injection engine fuel system from the fuel tank, electric fuel pump, fuel filter, high
pressure tubing, injector cap, fuel pressure regulator, solenoid injectors and other components.
Injection system circuit diagram-
Electronic injection system parts configure-
FUSE
ECU
Crank speed sensor
Throttle assembly
1.Injector
2.T-MAP
3.TPS
4. Temperature sensor
Idle speed control (ISC) Oxygen sensors
FUSE
Fall down sensor

4-1 ECU(Electronic Control Unit)
Principle:
Electronic Control Unit (ECU) is the brain of the whole
electronic system. ECU is effective in analyzing and
processing information supplied by sensors and issuing
conclusion-induced commands to any actuator for
optimization of the running engine.
Function::
1.Receive signals from the engine’s RMP sensor.
2.Receive signals for the engine’s load.
ECU connector outline drawing 3.Control injection of fuel.
4.Control ignition.
Microcomputer system: 5.Control the idle speed.
Microcontroller:512k FLASH; program memory: 6.Supply power (5V/100mA) to any sensor.
36K RAM 7.RPM signal outputs (TN signal)
8.Vehicle speed signal inputs
9.Diagnose troubles of actuators and sensors
Case lvel: Ingress Protection, IP54K
Limit:
Battery voltage: Smallest operating voltage=9V
Temperature: Operating temperatures: -40〜+70 Storage
temperature: -40〜+90
Note:
1. When disassembling ECU, please be sure to turn off the
main switch (KEY OFF) status, to avoid destroying ECU
and sensors and other electronic components
2. In the event unrecognized problems occur, do not
Short-circuit protection:
disconnect the battery as this eliminate any stored
Under the normal status, the short-circuit protection is
fault codes which may help diagnose the problem.
applicable to all pins (for ECU’s inputs and outputs) to
battery’s voltages and GND except Pin# 2 & 21 (to GND)
and Pin# 5 & 23 (to power supply).
。
ECU PIN
ISA-TEV+canister purge(TEV)
ECU Pin
TEV
1 Ignition1
2 GND(Ignition,power)
3 Vehicle speed sensor or else input
4 MIL
5 KL15
6 intake air temp.(ADC)
7 Output
8 A/D input
9 Input
10 5V ex.supply
11 KL15
12 Engine speed sensor B
13 Engine speed sensor A
14 Injector
15 Lambda sensor heater
16 canister purge TEV/ Auxiliary start relay
17 ISA-TEV / TEV
18 coolant temp.(ADC )
19 Intake air pressure sensor
20 Throttle pos
21 GND(sensor)
22 Fuel pump Relay
23 UBD
24 lambda sensor
25 Engine speed output /
26 K line
Prompt-
1.Main switch operation 10 or more times and did not initiate or unable to start the engine, ECU will signal control
relay is not actuated.
2.Reinstall the battery or the ECU to restore normal conditions.
4-2 Electromagnetic fuel Injector
Injector
Throttle assembly
Function:
Subject to ECU, the fuel injects atomized fuel into the engine in the specific timing.
Constitution:
EV-Cup; clamp; EV
Injector
Principle:
Developed by the fuel Injector coils with electrical pulse supplied from ECU, the magnetic force will increases to
overcome a resultant force composed of the return spring’s pressure, the needle valve’s gravity, and friction and makes the
needle valve lifted and fuel injected. The needle valve’s lift range is not more than 0.1mm. With the pulse there of
interrupted, the needle valve is closed again by the return spring’s pressure.
Fault diagnosis:
The system does not diagnose any fault of the Injector itself but the Injector driving system. Any PCODE will be
displayed on the dashboard in the event of a short circuit (or overload) between the nozzle driving system and the battery
or a short (open) circuit between the Injector driving system and GND. In case of any situation thereof, the close loop
control of the Lambda sensor and prior self-learning control is terminated; the latest self-learning data is employed. Delete
the PCODE with any fault eliminated.
※ Injection system does not perform diagnostics on fuel Injector parts.

Detectability determination:
Check 1 -
Method: The main switch off, remove the injector
Terminal, connect a voltmeter to open main switch or start
the engine, check for voltage.
Measurement wire color probe stalls Judgment
red
1 (+)
Working voltage
injector DCV 12V
Brown / red
2 (-)
(Control Power)
※Red wire from the fuel relay provide 12V voltage Main switch turned on for about 4 seconds, motorcycle
,，Brown / red wire for the ECU to control the power engine is not started, ECU will control the fuel pump realy
power off.
Check 2- Single parts Measurement
Method:
(Remove the Terminals) using a multimeter will stalls go
ohms, two measuring rods were connected to injector
body two pins.
Resistance value: 12 ± 0.6Ω at20 °
Method:
Remove the fuel injectors, but not removed the plug, turn
Check 3: injector atomization on main switch, start the engine, check the atomizing
circumstances.
* Good atomization - injection angle and diffusion surface
good , injection strength strong.
* Poor atomization - injection strength good, but fuel ejected
as droplets or fuel is clearly insufficient or non existant.
Troubleshooting methods:
1. Poor atomization→Check the fuel pressure or injector
2. undesirable resistance values→ Replace the injector
3. No operating voltage or control source → Check wiring
or batteries
PC diagnostic checks -
Fault codes: Fault phenomenon:

P0201: Cylinder 1 - Injector Circuit 1. Cold difficult to start
P0261: Cylinder 1 - Injector Circuit Low 2. RPM is normal, but difficult to start
P0262: Cylinder 1 - Injector Circuit High 3. Idle instability
4. Accelerate the slow response
2 Check the injector tightness of after installation 5. Accelerated weakness, poor engine performance
6. Acceleration is not on or flameout
7. Part-load or idle instability flameout
4-2 Fuel pump
Fuel pump-
features: gasoline tank suction and controls the nozzle
fuel pressure 3kgf/cm2.
Pressure regulator Principle: pressure adjustment allows gas pressure to
pump maintain stability.
Low Pressure Filters ※ Injection system does not perform diagnostics on fuel
pump parts
Check1-
Measurement 1 - Turn main switch, do not start the engine,
measuring Terminal.
Yellow /
(+) 12V OK
Fuel pump White DCV
Black (-) OV NG
Main switch turned on for about 4 seconds, motorcycle

engine is not started, ECU will control the fuel pump
realy power off.
Check-2
Measurements 2 - Motor Test
> Use a 12V battery connected to fuel pump two pins,
positive then yellow / white pin ，negative then the
black pin
Check 3-
Measurements 3- Pressure test
›Tools: Gasoline pressure gauge、Hose clamp
removal tool
Tool installation -
1 Turn off the main switch
injector 2 Use Hose clamp removal tool and remove the

injector tubing
tubing
3. Injector connect one end of the gasoline pressure
gauges，Connect the other end pressure tubing.
圖表 1
Fault phenomenon: 4. Turn on main switch, check whether the pressure

1. Can not start the engine up to standard -3kgf/cm2
2. RPM to normal，difficult to start Insufficient pressure → Replace
3. cold difficult to start
4. hot car difficult to start
Fault reasons:
1.fuel pump is bad
2. filter clogged
3.pressure regulator is bad
4-3 Crank speed sensor
Function of Crank speed sensor:
function：induct the engine speed, tell ECU to control
fuel injection & igntion.
theory：calculate the interval time of each flange on the
outer portion of the flywheel.
Crank speed sensor gap: 0.6 ~ 1.2mm
Fault phenomenon: Fault reasons:

1.vehicle can not start. Crank speed sensor coil disconnection / short circuit.
2.The spark plug no ignition with the fuel injector fuel
injection.
Check 1 - coil resistance
Tools: Multimeter stalls: ΩX1
Method:
Resistance value: 120 ± 40Ω at20 ℃
out of range → Replace
Check 2 -
Coil disconnection, fall off, poor ,contact →
replace
PC diagnostic checks -
Fault codes:
P0321 Engine Speed Reference Mark
P0322 Eng.Speed Inp.Circ. No Signal
4-4 Ignition coil
Principle:
When the battery voltage is applied to the primary
winding, the primary winding is charged. Once the
primary winding circuit ECU off, the charge
termination，While in the secondary winding Induces a
high voltage.
Features:
Ignition coil primary winding of low voltage converted
into high voltage secondary winding, spark discharge
through the spark plug to ignite the air fuel mixture within
Detectability determination: the cylinder
Check 1-
Measurements 1 - coil impedance measurements
Primary resistance : 2.8Ω ± 10%
Primary Secondary resistance : 9.5kΩ ± 10% (excluding spark plug
cap)
Spark plug cap: 10.0kΩ ± 20%
Out of Range→ Replace
圖表 2
Check 2 -
Measurements 2 -
Coil disconnection, fall off, Popi,poor ,contact
→ replace
Secondary
Check 3-
Measurements3 - Check the spark gap
Tools: spark-over tester
Minimum spark gap: 6mm
Fault phenomenon:
1. Can not start the engine
2. Cold crank difficulties
3. Difficult to start when hot
4. Normal RPM, difficult to start
5.Acceleration weakness / poor performance
Fault reasons:
1. coil disconnection / short circuit
4-5 Intake air pressure sensor
Intake air pressure sensor Throttle assembly
Function：
Induct intake air pressure, ECU judges intake or compression stroke to decide injection & ignition.
Monitor absolute pressure (kPa) in the intake manifold; provide information about the engine load. Range of
pressures monitored: 10~115kPa
Principle:
Due to any change in the intake manifold’s pressure causing deformation of a pressure sensor’s diaphragm, the
piezo-resistance effect causes resistance to change and further developed to be signals (voltages) proportional to
pressure under a processor chip’s function.
Pressure Sensor characteristic curve

PC diagnostic checks :
Fault codes:
P0107 Manifold Abs. Pressure or Bar. Pressure Low Input
P0108 Manifold Abs.Pressure or Bar. Pressure High Input
Fault phenomenon:
1.Acceleration weakness / poor performance.
2.Acceleration reaction slow, RPM is not sustainable or engine stall.
Check1-
Measurement - main switch on but do not start the engine, measure terminals.

Pink (+) 5V
T-MAP
(Work voltage) (+) DCV

0.4~4.65V
Green / Black (-)
※ 4-pin Terminals , green / black is signal output, pink for

the ECU to provide 5V working voltage, gray is ground.
Check2-
Measurement 2 -
(Remove the terminal) Use a multimeter and turn to
ohm setting, Two probes are connected to the intake
pressure sensor two pins, at 20 ℃ rated resistance
1.5 ± 0.5KΩ at25 ℃
4-6 Intake temperature sensor
Function：
The core of the intake temperature sensor is a quick-
response thermistor with circuit as follows.
Principle:
Measuring the temperature of the atmosphere to adjust
the mix ratio. Air temperature is high (low resistance),
will reduce the amount of fuel injection, Air temperature
is low will contrarily increase the fuel injection quantity.
Intake temperature sensor circuit diagram
Check1- Measurement 1-
(Removing the terminal) Use the multimeter and
turn to ohm stalls, Two probes are connected to
the intake pressure sensor two pins at 20 ℃~30℃ ,
rated resistors 2,500Ω~1,200Ω ±10% .
Check2-
Measurement 2 - Turn on the main switch, but do not start
the engine, measure at the terminals

Blue
(+) 0~5V
(Work voltage)
T-MAP
Pink
(+) DCV
(Control Power)
5V
※4-pin Terminals , blue is signal output, pink for the Gray
(-)
ECU to provide 5V working voltage, gray is ground. (ground)
PC diagnostic checks-
Fault codes:
P0112 Intake Air Temp.Circ. Low Input
P0113 Intake Air Temp.Circ. High Input
4-7 Temperature sensor
Temperature sensor
Function:
The sensor is used to provide information about cylinder temperature.
Principle:
As one NTC (Negative Temperature Coefficient) thermistor, the temperature sensor has descending resistance with the
cylinder's ascending temperatures. The relationship is not linear.
Sectional view of a temperature

sensor:
1. Electric connector; 2. Bushing; 3.
NTC thermistor.
Fault diagnosis:
Any error signal for cylinder temperature higher than the upper limit will be indicated on the dashboard. However,
cylinder temperature below the lower limit may not be attributed to a defective temperature sensor but the engine just
started and has not yet warmed-up. In the event of any error signal indicated on the dashboard with the possible trouble
verified as inaccurate, please test the temperature sensor.
PC diagnostic checks –
Fault codes
P0118 EngineTemp.Circ. High Input

P0117 Engine Coolant Temp.Circ. Low Input
Fault phenomenon:
1.Idle speed too high
2.Start normal, warm-up idle unstable
3.Start normal, after warming-up idle instability
4.Cold start difficulties
5.Hot start difficulties
Method of measurement:
Dip the temperature sensor inside hot water at 80℃ first; take out the sensor and measure resistance. If normal, please
check other circuits of the engine temperature sensor.
Measured data:
Temperature Resistance
-10℃ 16.322~20.774k
+25℃ 9.4k~10.6k
+80℃ 1.3485~1.7163k
Range of temperatures -30℃~+170℃
Check 1-
（(Removing the terminal) Use the multimeter and turn to
ohm stalls, Two probes are connected to the intake pressure
sensor two pins at 20 ℃~30℃, rated resistors 2.5KΩ~1.2kΩ
±10%
※2-pin Terminals, yellow /green for the ECU to

Check 2 - Temperature Sensor Terminal provide 5V working voltage, gray is ground.
Tools: Multimeter
Draw: DCV 20
Way: Main switch turn on, remove the terminal - red probe (+) then yellow / green, black probe (-) connected to gray
whether there 5V (reference voltage).
4-8 Oxygen sensor (O2)
Oxygen sensor
圖表 3
Function:
Test the oxygen content in exhaust to make sure of the mixture of gasoline and air has completely burned and promote the
Air/Fuel Ratio precisely controlled by ECU.
Theoretical Air/Fuel Ratio: 14.7:1
Air-fuel ratio with the ratio between the theoretical equivalent called the excess air ratio, expressed by the Greek letter .
Excess air coefficient (): Ratio of a mixed gas’s actual air/fuel ratio to a theoretic equivalent air/fuel ratio.
=1: Mixed gas’s actual air/fuel ratio = theoretic equivalent air/fuel ratio;
1: Mixed gas’s actual air/fuel ratio > theoretic equivalent air/fuel ratio; thin mixed gas (lean); voltage output low (about
100mV)
1: Mixed gas’s actual air/fuel ratio < theoretic equivalent air/fuel ratio; thick mixed gas (rich); voltage output high
(about 800mV~1000mV)
Oxygen sensor characteristic curv

Principle:
When a ceramic tube’s temperature is up to 350℃, the solid ceramic electrolyte is conductive and the oxygen molecule
inside and outside ceramics is catalyzed to oxygen anion, which freely moves inside ceramics, by the sensor’s platinum
electrode so that oxygen molecule thereof diffuses via ceramics. Due to this characteristic, the difference in concentrations
of oxygen inside and outer ceramics could be transferred to the potential difference and further electrical signal outputs. In
virtue of the signals’ voltages changing at the theoretical equivalent air/fuel ratio (λ=1), it is necessary for a gasoline
engine to keep the excess air coefficient  in the range between 0.85 and 1.10, shown as follows.
O2 heating method:
Oxygen sensors can be divided into heating and non-heating type, this system uses a non-heated oxygen sensor, mainly
by using the engine exhaust temperature to reach operating temperature.
Fault diagnosis
A variety of signals from different sensors, actuators, power amplifiers and detection circuits are monitored by ECU. In the
event of each of the following situations detected by ECU, the corresponding PCODE for a Lambda sensor might be
indicated on the dashboard. (Refer to “Conditions of error information & records”.)
1. Error of a Lambda sensor’s signals
2. Error of a battery voltage
3. Signal error of the intake manifold’s absolute pressure
4. Signal error of the engine’s temperature
5. Error of the fuel injection nozzle’s function
For any PCODE with respect to a Lambda sensor indicated on the dashboard, the close loop control system is terminated
but the open loop control system is activated as per the fundamental injection MAP saved in ECU to dispense fuel.
◙ Acceptable fuel additives: unleaded gasoline; gasoline with the lead content of 0.15g/L.
Lead in Gasoline (g/L) Service Life (km)
0.6 30000
0.4 50000
0.15 80000
0.005 (Unleaded gasoline) 160000
Constitution:
1. Signal line
2. Dish washer
3. Lower isolating bush
4. Sheath
5. Wirework
6. Heater
7. Washer
8. Sensor support
Sectional view of a heated Lambda sensor 9. Ceramic probe
10. Protection tube
PC diagnostic checks-
Fault codes:
P0130: O2 Sensor Circ. Malfunction
P0131: O2 Sensor Circ. Low Voltage
P0132: O2 Sensor Circ. High Voltage
P0134: O2 Sensor Circ. No Activity Detected
Fault phenomenon:
1. Stalling when hot
2. Unstable idle
3. High fuel consumption
Check 1 - Open the main switch, but do not start the engine measuring terminals
※2-pin Terminals, Blue / Black for the ECU to provide

5V working voltage, gray is ground.
measuring terminals
Blue / Black
0.2~0.8V
(working (+) OK
jump
Oxygen
voltage)
DCV
Voltage is
gray (ground) (-) fixed or NG
Not beating
(Oxygen sensor when required to reach operating temperature starts to oscillate)
※ When measuring voltage has the following circumstances, can be judged as oxygen is bad:
(to be judged in a closed-loop state)
1. Voltage output continued at a fixed value, the voltage without oscillation.
2. Voltage sustained at high level (0.6 ~ 0.9V) oscillation.
3. Voltage sustained at a low level (0.5 ~ 0.1V) oscillation.
4 voltage sustained in (0.4 ~ 0.6V) oscillation.
4-9 Throttle position sensor(TPS)
圖表 4 Throttle assembly
Function:
The sensor can provide information about a throttle’s opening to ECU. According to the information thereof, ECU has
necessary data for engine load, operating status (start-up, idle speed, partial load, and full load), acceleration, deceleration,
etc.
Principle:
As one angle sensor for linear output, this sensor is composed of two curved slide resistors and two contact sliders. The
contact slider has its spindle connected to and aligned with the throttle’s axle. The voltage of 5V, U S, is applied to the slide
resistor’s both ends. With the throttle turning, the contact sliders also turn and move on contact sliders for output of UP at
any contact. Therefore, the sensor is also a potentiometer for output of angles.
Fault diagnosis:
For the throttle’s turning angle greater than the upper limit or less than the lower limit, any PCODE of the throttle sensor
will be indicated on the dashboard. Turn a multi-meter’s rotary switch to the “” function (“DCV” function) for
measurement of resistance (output voltage). In the event of any data beyond the spec., the sensor might be failed. For an
individual sensor with regular functions, please check other circuits for any short (open) circuit.
Fault codes
P0122: Throttle Pos.Sensor Circ. Low Input
P0123: Throttle Pos.Sensor Circ. High Input
※Throttle angle is larger than the upper limit of credible or less than the lower limit
of credible, throttle position sensor fault flag bits.。
TPS absolute position:

Full closure: 0% fully open: 60%
Measurement:
Input voltage: 5V
Check 1: Open the main switch, but do not start the engine,
measuring terminals
T D
Pink 5V OK
P (+) C
(working voltage)
S V 0V NG
Light Blue Fully closed:0.8±0.2V

T (+) OK
(working voltage) fully open:4.5±0.4V
P
Gray
S (-) OV NG
(Ground)
Check 2: Single product measurements - resistance
TPS Single product measurements - resistance
Fully closed 710~1380
fully open 1.6K~2.4K
※3-pin Terminals, Light Blue is signal

Output. Pink for the ECU to provide 5V working
voltage, gray is ground.
4-10 Fall down sensor
Function:
vehicles and dumping more than 65 degrees for
any reason,you can cut off the power turn off.
Principle:
The use of gravity to make the ball move position
touch sensor vehicle dumping
Check 1- Tools: Multimeter
Open the main switch, but do not start the engine
measuring terminals
Orange (+) 12V OK
Check1 DCV
(-) 0V NG
wire color probe stalls ＜65° ＞65°
Check 2 Blue /Black (+) DCV 0V 12V
Main relay Main relay
Black (-)
Conductive Conductive
Check 2-
※ invalidating: directly to the blue / black wire to ground.

Reset way: Re-opened the main switch.
4-11 Idle speed control
Function:
Based on ECU’s information for the engine load, the idle speed
actuator is used in controlling the bypass airflow by means of the
duration and the frequency (duty factor) of electrical pulse.
Idle speed control

Principle:
The idle sped actuator is composed of electromagnetic coils, armature iron, and valve. The airflow passing the idle speed
actuator is relevant to both the duty factor of pulse exported to the idle speed actuator by ECU and the pressure difference
between the inlet and the outlet of the idle speed actuator. The idle speed actuator is disabled during no supply of electrical
pulse.
In the case of a duty factor of 100% (full open), the airflow passing two types of idle speed actuators will be different. As
shown in figures below, the airflow is 3.0m3/h and 6.5 m3/h while detected in the idle speed actuator TEV2 (full open;
pressure difference: 200mbar) and TEV5 (full open; pressure difference: 700mbar).
Fig. 2-31, Airflows in idle speed actuators (Left: TEV2; right: TEV5)
Airflow direction
Fault diagnosis:
ECU is effective in diagnosing both the idle speed control and the driving system. In the event of a short circuit (or
overload) between the idle speed controller’s driving system and the battery or a short (open) circuit between the idle
speed controller’s driving system and GND, the close loop control for dispensing fuel and the idle air volume learning are
terminated but the latest self-learning data is employed.
Notices for maintenance:

Root causes of general troubles: Rustiness or airtight characteristic deteriorated due to any foreign object in the valve.
①Airflow direction conformable to spec. during installation;
②Check and replace the idle speed controller in case of failure of the controller due to some
black particles inside the valve;
③No liquid such as water and oil entering into the valve during maintenance;
○
4 In order to avoid any solid-borne noise, connect the idle speed controller to a hose without the controller
contacting any other supports.
Fault codes:
P0508: ISA control Circuit Low
P0509: ISA control Circuit High
P0511: ISA control Circuit/Open
Fault phenomenon:
1.any time idling unstable 7. Rotational speed not pull on when accelerating
2. warm-up idling unstable. 8. slow response when accelerating
3. After the warm-up idling unstable
4. idling too high
5. Vehicle stalled or instability at part load
6. Accelerate inability of poor performance
Method for measurement (simplified):
Disconnect the connector; turn a multi-meter’s rotary switch to the “Ω” function; connect two probes onto the idle speed
controller’s two pins and check if resistance is 26± 4 Ω within the spec. at 20℃.
Check 1:
Methods: open the main switch, remove the terminal
, connect a multimeter, red (+), black / red (-), start
the engine, measuring terminal.
red
I (working (+) 12V OK
S voltage) DCV
C black/red
(-) 0 NG
(ECU) Check 1
Check 2: Single piece measuring resistance

Measurement wire color probe stalls Temperature Standard values
I A (+)
S  20°c 26±4
B (+)
C
Check 2
一、IMSE (throttle body assembly) Height adjustment stopper screw
1. This screw height will affect the main air channel flow rate and initial throttle position (TPS) when it is in idle
mode.
2. The opening degree of idle speed control (ISC) will be automatically adjusted according to the flow rate of the
main air channel, and the inspection standards are:
3. During the engine warm-up process, the opening degree of ISC can be observed to decrease gradually along with
the temperature rise of the engine.
4. Wait for full warm-up of the vehicle, the engine temperature (the same of water temperature) at100℃ above：
J3-115:
New vehicle testing from 1 to 10 tooth
In - use Vehicle to 1-20 tooth

J3-125:
New vehicle testing from 5 to 10 tooth
In - use Vehicle to 1-20 tooth
When the Opening degree of ISC exceeds the scope, please follow the situation to adjust the height of the stop screw of the
throttle valve assembly:
 If it is larger than the standard, please turn in the stop screw to increase the flow rate in the main air channel
and to reduce the ISC opening degree;(Each turn-in of 1/2 cycle can reduce the opening of ISC by 10 step)
 If it is lower than the standard, please turn out the stop screw to reduce the flow rate of the main air channel
and to increase the opening degree of ISC;(Each turn-out of 1/2 cycle can increase the opening degree of ISC
by 10 step)
5. After the adjustment, the main power needs to be opened and closed repeatedly for about 2~3 times so that ECU
can learn again the zero position of the throttle (TPS); meanwhile, loose-proof agent should be applied on the
screw and main body of the stop screw (M5*0.8*15) to stop the screw to get loose.
Adjustment screw
 clockwise direction to screwed
 counterclockwise to unscrew
B. Ignition check
1. During the idle stage, the ignition angle will make compensation adjustment according to the rotational speed
of the engine. When it is lower than the target rotational speed, the ignition angle will be increased so as to
increase the rotational speed, on the contrary, when it is higher than the target rotational speed, the ignition
angle will be reduced so as to reduce the rotational speed, hence, some distinguished peak values can be
neglected first, and only the mean value needs to be observed.
2. Idle inspection range is: 0±10 degrees.
C. Zero point learning of the throttle
1. ECU, under the idle stage, will zero automatically the relative position of the throttle (0%), hence, if the
throttle is increased, ECU judged departing from an idling state control
2. After the height of the stop screw of the throttle valve assembly is adjusted, the power needs to be turned on
and off repeatedly for 2~3 times so as to zero the relative position of the throttle (0%), otherwise, it might lead
to too high or low in the rotational speed.
3. When battery, ECU, IMSE or cable throttle is disassembled and re-connection is needed for the start of the
engine, the power needs to be turned on and off repeatedly for 2~3 times so as to zero the relative position of
the throttle (0%).
D. Safety protection for engine start
1. When the engine is started, ECU will follow the relative position of the throttle to judge, if the Opening degree
is exceeded by more than half, the engine will not be started so as to ensure the safety of the user.
2. Such protection can also be called self-gas cleaning function, which can replace the simple effect of
disassembling the spark plug and clearing the mixing gas in the combustion room.
3. When the engine is started at low temperature or high elevation area, without starting this safety protection
mechanism, if the throttle is opened slightly, the engine starting function is going to be assisted.
Fault diagnosis
ECU is effective in diagnosing both the idle speed actuator and the driving system. In the event of a short circuit (or
overload) between the idle speed actuator’s driving system and the battery or a short (open) circuit between the idle speed
actuator’s driving system and GND, the close loop control for dispensing fuel and the idle air volume learning are
terminated but the latest self-learning data is employed.
Notices for maintenance:
Root causes of general troubles: Rustiness or airtight characteristic deteriorated due to any foreign object in the valve.
①Airflow direction conformable to spec. during installation;
②Check and replace the idle speed controller in case of failure of the controller due to some black particles inside
the valve;
③No liquid such as water and oil entering into the valve during maintenance;
③In order to avoid any solid-borne noise, connect the idle speed controller to a hose without the controller
contacting any other supports.
Method for measurement (simplified):

Disconnect the connector; turn a multi-meter’s rotary switch to the “Ω” function; connect two probes onto the idle speed
controller’s two pins and check if resistance is 26± 4 Ω within the spec. at 20℃.
Lubrication System-5
∮5-0 Operating Instructions / Troubleshooting: ∮ 5-1 Cleaning of filter screen
∮ 5-2 Oil pump disassembly / inspection
5-0 Operating Instructions

1. When disassembly of the lubrication system, maintenance work directly on the motorcycles.
2.Use oil viscosity: SAE15W-40 lubricating oil
3. Engine oil volume:
Exchange capacity: 800c.c total: 1000c.c
Torque: (kg-m)
oil filter screen cover 1.5~2.0
Measurement data
Standard Value Limit of use

item
( mm ) ( mm )
Clearance between the inner 0.12mm
0.045-0.1
gear And outer gear
Clearance between the outer 0.12mm
Oil pump gear And oil pump body 0.045-0.1
Clearance between gear end - 0.2mm

and Oil pump body
Troubleshooting:
Reduction in fuel oil volume
◆Natural consumption
◆Leakage of fuel
◆Piston loop seizes, or improperly installation
◆Worn out of valve’s oil seal
Engine burning-out
◆Zero or too low oil pressure
◆Blockage in oil route
◆Did not use the fuel oil recommended
Lubrication system diagram
5-1 Cleaning of filter screen
Demolition -
› Remove the oil filter screen cover(1)and O-ring (2).
› Remove the oil filter screen(4) and the spring(3).
clean-
› Clean the oil filter screen.
○
4
› Make sure of the O-ring (3)and the oil filter screen, or
○
3
replace any of broken part, if any.
○
2
○
1
Installation-
NOTE
Engine overhaul of situation, necessarily clean the oil
filter screen, in order to avoid impurities clog oil passages
caused engine damage.
5-2 Oil pump disassembly / inspection

Demolition –
› Removal: Refer to disassembly of the engine.
(Chapters -10)
Decomposition –
› Remove oil pump mounting screws.
› Remove the oil pump cover.
Check {1}
› Clearance between the inner gear And outer gear
Standard size: 0.045 ~ 0.10
Limit accepted: <0.12mm
Check {2}-
› Clearance between the outer gear and oil pump body.
Standard size:0.045~0.10
Limit accepted: <0.12mm
Check {3}-
› Clearance between gear end and Oil pump body.
Limit accepted:0.2mm
Assembly -
> The oil pump on the inner and outer gear shaft into
the oil pump body.
Note -
When installing the oil pump shaft into the corresponding
notch on the inner gear.
> Fitted with fixed pin

> Put on the oil pump cover (locating pins into the
mounting holes).
> Lock screw.
> Check the oil pump shaft rotation is smooth.
Installation
> The oil pump is installed into the crankcase.
Engine group disassembly (from frame)-6
∮6-0 Operating Information ∮6-1 Engine group disassembly (from frame)
6-0 Operating Information:

1.Please confirm before the job has the frame securely. Avoid injury to the operating personnel or vehicle.
2. Before disassembling the engine, move the engine oil drain dried and then dismantling operations.
3. before the frame and engine separation, make sure all the wiring is indeed separated,and then the job.
4. When assembling, please the set screw torque values in accordance with standard lock.
Torque:
ENGINE HANGER COMP -3.5~4.5Kg-m CUSHION- up:3.5~4.0Kg-m
Lower:2.0~3.0 Kg-m
REAR BRAKE CALIPER-2.5~2.8 Kg-m Oil Cooler-0.9~1.1 Kg-m
MUFFLER ASSY- Bolt:3.0~3.5 Kg-m

Nut:1.5~2.O Kg-m
6-1 Engine group disassembly (from frame)
Steps:
○
4
I. Remove the air cleaner.
a. Remove the hex flange bolts M6-35L (1).
○
2
flat washer (2), hex flange boltsM6-50L (3).
b. Remove the loosen tube clip screws M6-50 (4) .
○
3
○
2 ○
1
c. the secondary air introduction pipe (5) unplugging.

○
6 ○
8 d. the ISC air pipe (6) unplugging.
e. the EEC connecting pipe (7) unplugging .
○
5
f. Remove the air cleaner combination (8).
○
7
二. Remove each EMS Electrical wiring terminals

a. Unplug the temperature sensor terminals (1).
○
5
b. Unplug the injector terminals (2).
○
4 c. Unplug the oxygen sensor terminal (3).
d. Unplug the T-MAP terminal (4).
○
1
○
3 E. Unplug the throttle position sensor terminal (5).
○
2
三. Demolition throttle air pipe assembly.
a. unplugging negative pressure pipe(1) –EEC.
○
1 b. unplugging isc air introducing pipe(2).
○
3
○
2 c. unplugging spark plug cap(3).
d Remove the throttle assembly screws * 2, take out the
○
4 throttle assembly.
四.Remove the starter motor and the generator terminal

a. Remove the retaining nut, remove the starter motor
○
1 power lines(1).
b. Remove the generator terminal(2).
○
2
C.Remove ground wire (3).
○
3
五. Remove the muffler assy
a. Remove the hex flange nut (1).
Torque: 1.5 ~ 2.0kg-M
b. Remove the hex flange bolts (2), spring washers (3)
○
3
○
2 ○
4 ,flat washers (4).
○
1 ○
3 Torque: 3.0 ~ 3.5kg-M
○
3 ○
2 c. Remove the muffler assy (5).
○
2 ○
3
○
1 Note:
○
1 ○
2
○
3 When dismantling, oxygen sensor can not collide, avoid
○
1
○
3 ○ ○
1 2
internal ceramic rupture, causing damage.
○
3
○
3 ○
1
○
3
六. Remove the rear fork
a. Remove the hex flange bolts (1)M6-12L.
b. Remove the hex flange bolts (2) M8-35L .
○
3 Torque value: 2.5 ~ 2.8 kg-M
C. Remove the rear brake clamp.
○
2
d. Remove the hex flange bolts (3)M8-32L.
Torque: 3.0 ~ 4.0kg-m
○
1 e. introduction of the right outer tube.
f. Remove the hex flange bolts (4M8-32L)
Torque :3.0-4 .0 kg-M
g. launch of the left outer tube.
○
4
七. Remove the Oil Cooler
○
2
a. Remove the hex flange bolts (1) M8-15L.
○
1 b. Remove the pedal support bracket (2) left and right.
○
2
c. Remove the bolts with washers (3) M6-20L

d. Remove the Oil Cooler ..
○
3
e. The Oil Cooler pipe A.B (4.5) pulled out of frame.
○
5 ○
4
八. Separate engine hanger and engine assembly
a. Remove the hex flange nut (1) M10.
b. Remove the hex flange bolts (2) M10-290L.
○
1
○
2
C.Separate frame (3) and engine assembly (4).
○
3
○
4
Cylinder head -7
∮7-0 Operating Information ∮7-5 Check the valve / valve guide sleeve
∮7-1 Cylinder head removal steps ∮7-6 Check the valve spring
∮7-2 Disassemble the cylinder head ∮7-7 Check the Cylinder head flatness
∮7-3 Check the camshaft
∮7-4 Check the rocker arm / rocker arm shaft
7-0 Operating Information

1.Removable cylinder head, first separate the engine and frame.
2 .Remove the parts.Cleaned before re-checking.
3.Install the valve guide, valve, camshaft activity faces. Please coated with molybdenum disulfide or oil..
4.Check the oil passage should not be debris hindered.
Torque (kg-m)
Cylinder head cover 0.9~1.1 Cylinder head screws 2.0~2.4
Cylinder head nut 0.9~1.1 Exhaust pipe (front) 1.5~2.0
Valve clearance adjustment nut 0.7 Exhaust pipe (rear) 3.0~3.5
Camshaft sprocket 0.5~0.7
Tools: Valve compression tool (Chapters 1-6 of 13)
Measurements using the limits: J-BUBU 115/125

Item Standard value (mm) using limit (mm)
Intake 0.10 -
valve clearance
Exhaust 0.12 -
Compression pressure 10±2kg-cm -
Intake 31.05mm±0.03 30.65mm
camshaft height
Exhaust 30.999mm±0.03 30.599mm
Intake 10.0~10.015 10.05
Rocker arm inside diameter
Exhaust 10.0~10.015 10.05
Rocker arm shaft outside Intake 9.972~9.987 9.937
diameter Exhaust 9.972~9.987 9.937
Cylinder head flatness 0~0.03 0.05
Valve spring 37.91 37.9
Intake 4.475~4.490 4.465
Valve rod diameter
Exhaust 4.460~4.475 4.450
valve guide sleeve inside Intake 4.50~4.512 4.54

diameter Exhaust 4.50~4.512 4.54
Cylinder head -7
Troubleshooting / phenomena
Compression pressure is too low
1. cylinder valves 2. Cylinder head
◆Valve Seat bad leak tightness ◆Cylinder head gasket leak
◆valve timing is not correct ◆Cylinder head plane is skewed or crack
(bent valve leak)
◆valve clearance adjustment adverse
◆valve spring damage
◆Valve carbon deposition
3. abnormal noise
◆ valve spring damage
◆ camshaft wear
◆ camshaft chain wear
◆ rocker arm or rocker arm shaft wear
◆ valve clearance is too large
Cylinder head -7
Project Part name Quantity Project Part name Quantity Project Part name Quantity
1 CYLINDER HEAD 1 14 CAMSHAFT COMP 1 27 PLATE,BREATHER 1

CR TRUSS HD TAPPING
2 Valve Inlet 2 15 Retainer, Cam Shaft 1 28 4
SCREW(M4*8L)
PACKING,CYL HEAD
3 Valve Exhaust 2 16 HEXAGON BOLT 1 29 1
COVER
HEXAGON FLANGE
4 WASHER, Valve 4 17 1 30 HEXAGON FLANGE BLOT 4
BOLT(M6*1.0P*12L)
5 Seal Valve Stem 4 18 CAMSHAET SPROCKET 2 31 Spark Plug 1
6 VALVE SPRING 4 19 CAMSHAET SPROCKET 2 32 Insulator Carb. Gasket 1

RETAINER VALVE HEXAGON FLANGE BOLT INSULATOR COMP.,
7 4 20 2 33 1
SPRING (M5*12L) MANIFOLD
8 COTTER VALVE 8 21 STUD BOLT 1 34 O RING 1
In. Valve Rocker Arm
9 1 22 STUD BOLT 4 35 O-RING 1
Comp.
Ex. Valve Rocker Arm
10 1 23 Gasket, Cyl. Head 2 36 TUBE,CYL. 1
Comp.
TOPPED
11 ADJUSTABLE 4 24 HEXAGON FLANGE NUT 1
SCREW
HEXAGON NUT HEXAGON FLANGE BOLT
12 4 25 1
(M5*0.8P) (M6*100L)
SHAFT.ROCKER
13 2 26 Head Cover 1
ARM
Cylinder head -7
7-1 Cylinder head removal steps
一. fan cover
a. Remove the hexagon flange bolts (1) M6-22L * 2
○
3 b. Remove the self-tapping screws (2)*2.
C.Remove the fan cover (3).
○
2
○
1
○
1
○
2
○
1
二.cooling cowl(一、二)
○
1
a.Remove the self-tapping screws (1)*3.
○
2 b.Remove the cooling cowl 二 ((2).
c.Remove the hexagon flange bolts (3).
○
1 M6-22L
d.Remove the cooling cowl 一(4).
○
4
○
3
○
3
三. cylinder head
○
2
a Remove 4 set screws(1) on the cylinder head ， take
○
2
○
1
out the cylinder head cap(2).
○
1
○
2
Torque values:0.9~1.1kg-M
○
1
b.Remove the cylinder head cover gasket (3).
○
1
○
3
NOTE
Install the cylinder head cover gasket (3) is shown in
○
2
Figure surface marker at. Shall be coated with gasket
○
1
dispensing.
○
1
Cylinder head -7
四.chain adjuster
○
1
a.Remove the "CR ROUND HD MACHINE SCREW"
○
3 (1) M6-6L * 1 and O-ring (2)
b.Remove the hexagon flange bolts (3) M6-20L * 2
○
12 c. Remove the chain adjuster (4) and the chain adjuster
○
4 gasket (5).
○
1
○
1
○
5
NOTE
○
1 Make sure that the O-ring (2) normal installation to avoid
oil spills.
五. Camshaft sprocket
○
3
a.Remove the hexagon flange bolts(1) M5-12L*2
b. The camshaft sprocket (2) by a chain(3) Remove.
○
1
○
2
○
1
○
1
六. Cylinder head
a.Remove the hexagon flange bolts (1)M8*4 and .
○
3
Flat washers(2) * 4
○
1
Torque values:2.0~2.4kg-m
○
1
b.Remove the hexagon flange bolts(3) M6-100L*2
C.Remove the Cylinder head (4).
○
4
○
2
圖表 1 ○
3
○
1
○
1
Cylinder head -7
七. Cylinder head gasket
a. Remove the Cylinder head gasket(1).
NOTE
Cylinder head gasket can not be reused, replace with new.
Cylinder head installation steps:

○
1
Follow the removal procedure. Reverse installation.
2
Timing adjustment:
step:
a. Go to the top dead center of the piston
b. clockwise rotation of the flywheel to the flywheel of
the "T" mark on the prospective the crankcase on the
instructions ribs.
c. Confirm the large hole on the camshaft at the same
time appear in the vertex.
The camshaft sprocket (3) mark parallel to the cylinder
head (4).
Warning
1. Install the cylinder head. Timing adjustment can not
be wrong. Could damage the engine！
2. After installing the cylinder head. Valve clearance
adjustment is necessary。(Refer to chapter 3-8).
Cylinder head -7
7-2 Disassemble the cylinder head
一. Temperature Sensor / valve rocker arm
○
6 / Camshaft assembly
○
5 a. Using an open wrench (14mm), Remove the
○
1 temperature sensor (1).
○
7 b.Remove the hexagon flange bolts(2) M6-16L*1
c. Remove Camshaft Retainer (3).
○
4 ○
1 d. Take the 5mm screws lock into the rocker arm shaft
○
3 (4) on the screw holes and pull out the rocker arm
○
2 ○
1
Shaft.
○
1 e. Remove the intake and exhaust valve rocker arm
○
1
combinations (5.6).
○
7
○
4
○
1 f. Remove the camshaft assembly (7)
○
8
○
1
二. Intake and exhaust valves

○
1 ○
1
○
2
Tool:Valve compression tool
a.Using Valve compression tool, compress the valve.
○
1
b.Remove the cotter valve(1).
○
3 c.Remove the retainer valve spring (2).
○
4
d.Remove the valve spring (3)
○
1 ○
5
e.Using Needle Nose Pliers Clip valve seal (4) come out.
○
1
f.Remove the valve washer (5).
○
7
g.Remove the intake and exhaust valves (6.7).
○ 1
Cleaning - Combustor
○
7 ○
6
Note
․Clean the combustion chamber, do not use sharp tools
○
6 ○
1
cleared, will lead to the combustion chamber scratch it
․Suggested Use: in addition to carbon cleaner and
○
1
round head Spatulas
Cylinder head -7
7-3 Check the camshaft
Check the {1} -
> Cam surface and the height is worn.
Use limits:
IN: 30.05mm
EX: 29.999mm
Check the {2} -›

>Camshaft bearings
Abnormal noise or turn the ring true →Replace
7-4 Check the rocker arm / rocker arm shaft

Check -
› Rocker arm inside diameter -
Standard value:
Intake: 10.0 ~ 10.015 (mm)
Exhaust: 10.0 ~ 10.015 (mm)
Use limits:
Intake: 10.05 (mm)
Exhaust: 10.05 (mm)
Check -
> Rocker arm shaft -
Standard value:
Intake: 9.972 ~ 9.987 (mm)
Exhaust: 9.972 ~ 9.987 (mm)
Use limits:
Intake: 9.937 (mm)
Exhaust: 9.937 (mm)
Cylinder head -7
7-5 Check the valve / valve guide sleeve
Check -1
> Valves tightness
Methods: gasoline or cleaning agent into the intake
and exhaust ports.
valve leakage →Adverse airtight
Check the valves, valve seats, valve guide sleeve.
Check - 2
› Check the valve / valve guide sleeve
a. valve
bent or burned →Replace
b.valve / valve guide sleeve
sliding is not smooth →Replace
c. Valve rod diameter
Wear → Replace
Standard values -
Intake : 4.475 ~ 4.490 (mm)
Exhaust 4.460 ~ 4.475(mm)
Use limit -
Intake : 4.465 (mm)
Exhaust : 4.450 (mm)
d.valve guide sleeve inside diameter

Wear → Replace
Standard values -
Intake: 4.50 ~ 4.512 (mm)
Exhaust: 4.50 ~ 4.512 (mm)
Use limit -
Intake: 4.54 (mm)
Exhaust: 4.54 (mm)
Cylinder head -7
7-6 Check the valve spring
Check -
> Spring free length
Insufficient length → Replace
Standard value: 37.91 (mm)
Use limits: 37.9 (mm)
7-7 Check the Cylinder head flatness

Check -
> Cylinder head flatness
Over the limit → Replace
Standard value: 0 ~ 0.03 (mm)
Use limits: ≧ 0.05 (mm)
Cleaning -
> Use addition to carbon cleaner, cleaning the cylinder
head.
表 3
Cylinder combination -8
∮8-0 Operating Information ∮8-5 Check the Piston pin
∮8-1 Cylinder, pistons demolition ∮8-6 Check the Cylinder
∮8-2 Piston Ring demolition ∮8-7 Connecting rod small end diameter
∮8-3 Check the Piston ∮8-8 Check the Cam chain guide and Cam
∮8-4 The piston ring combination installation tension rods
8-0 Operating Information

1.Installation / removal C-clasp,set the crankcase opening with a clean cloth stuffed avoid small parts from falling
Crankcase.
2. Remove piston rings. Openings can not open too much, causing the piston ring fracture.
3.Before installation, please clean the carbon deposition on the cylinder piston, re-assemble.
Measurements using the limits: J-BUBU 115

Bore 51.5~51.515 51.6
Curve 0~0.05 0.05
Cylinder
Cylindrility - 0.05
Roundness - 0.05
Clearance b/w Piston 1st ring 0.015~0.055 0.09

and Piston Ring 2nd ring 0.015~0.055 0.09
1st ring 0.10~0.25 0.50
Piston Clearance of cutting
2nd ring 0.25~0.45 0.60
Piston Ring section
Side ring 0.2~0.7 0.9
Piston outer diameter 51.475~51.490 51.4
Piston pin hole inner diameter 13.002~13.013 13.04
Piston pin diameter 12.996~13.0 12.96
Connecting rod small end diameter 13.002~13.013 13.06
Measurements using the limits: J-BUBU 125
Bore 54.0~54.015 51.6
Curve 0~0.05 0.05
Cylinder
Cylindrility - 0.05
Roundness - 0.05
Clearance b/w Piston and 1st ring 0.015~0.055 0.09

Piston Ring 2nd ring 0.015~0.055 0.09
1st ring 0.10~0.25 0.50
Clearance of cutting
Piston 2nd ring 0.25~0.45 0.60
section
Piston Ring Side ring 0.2~0.7 0.9
Piston outer diameter 53.965~53.980 53.9
Piston pin hole inner diameter 15.004~15.010 15.04
Piston pin outer diameter 14.994~15.0 14.96
Compression pressure is too low Engine overheating
◆Cylinder or piston ring wear ◆Top of the piston too much coke
Compression pressure is too high Exhaust pipe exhaust white smoke

◆Pistons, combustion chamber ◆ Cylinder piston or piston ring wear deposits
◆Piston Ring poor installation
◆Cylinder or piston damage
Engine Knocking or abnormal noise
◆Cylinder and piston wear
◆ piston head too much coke
◆ Piston pin hole and piston pin wear
Cylinder
圖表 1
Project Part name Quantity Project Part name Quantity
HEXAGON FLANGE
1 CRANK SHAFT ASSY. 1 15 BOLT(M6*1.0P*12L) 1
2 WOODRUFF KEY 1 16 GASKET, CYLINDER 1
WOODRUFF KEY
3 (C1066502000 之附件) 1 17 LOCK PIN（10*14） 2
4 PISTON 1 18 CHAIN, CAMSHAFT 1
5 CLIP, PISTON PIN 1 19 TENSIONER, TIMING CHAIN 1
6 PISTON PIN 1 20 GUIDE COMP.,CAM CHAIN 1
7 Piston Ring (Top) 1 21 O RING 1
SCREW ASSY, TIMING CHAIN
8 Piston Ring Second 1 22 TENSIONER 1
9 OIL SCRAPER RING COMP. 1 23 DEEP GROOVE BALL BEARING 1
10 CYLINDER 1
11 Gasket, Chain Adjuster 1
12 CHAIN ADJUSTER COMP. 1
HEXAGON FLANGE BOLT
13 (M6*20L) 2
14 WASHER 1 1
8-1 Cylinder, piston removal
1. Cylinder
a.Remove the cam chain guide (1)
○
2 ○
3 ○
4 b.Remove the cylinder (2) and cylinder
gasket(3)
c.Remove the lock pins (4) * 2
二. Piston
a.using needle nose pliers to remove C-type retaining
ring (1)
○
1
b.Remove the piston pin (2)
c.Remove the piston (3)
Cylinder installation steps:

Follow the removal procedure. Reverse installation.
○
3
NOTE
1.Installation / removal C-clasp, set the crankcase
opening with a clean cloth stuffed avoid small parts
from falling crankcase.
○
2 2.Install the cylinder before,inner surface of the
○
1
cylinder, piston rings please painted oils.
3. piston rings can not be deformed or damaged.
4. Before installation, please clean the carbon
deposition on the cylinder piston, re-assemble.
5. top of the piston "IN" mark towards the intake
orientation .
8-2 Piston Ring demolition
Piston rings demolition:
Use the left and right hand thumb piston ring openings
distraction, the order to remove the piston rings.
NOTE
Carefully remove piston rings, Piston Ring openings
due to excessive distraction cause breakage or damage.
Check -
›Piston combination
Scratches →
8-3 Check the piston combination Replace the piston and Piston Ring combination
›Piston outer diameter measurement
Measurement position:
About ”6mm” starting the lower end of the piston skirt.
Standard value:
J-BUBU 115> 51.475 ~ 51.490 (mm)
J-BUBU 125> 53.965 ~ 53.980 (mm)
Use limits:
J-BUBU 115> 51.4 (mm)
J-BUBU 115> 51.4 (mm)
Check-
›The gap of piston ring slot
Over the limit→Replace a new piston and piston ring
set.
Standard value:
ring(Top): 0.015 ~ 0.055 (mm)
Second ring: 0.015 ~ 0.055 (mm)
Use limits: first ring: 0.09 (mm)
Second ring: 0.09 (mm)
Check -
›Clearance b/w Piston and Piston Ring
Standard value:
Ring(TOP): 0.10 ~ 0.25 (mm)
Second ring: 0.25 ~ 0.45 (mm)
Scraper ring: 0.2 ~ 0.7 (mm)
Use limits:
Ring(TOP): 0.50 (mm)
Second ring: 0.60 (mm)
Scraper ring: 0.9 (mm)
Over the limit→Replacing Piston Ring or cylinder
Check -
› Piston pin hole inner diameter
Standard value:
J-BUBU 115 ＞ 13.002~13.013(mm)
J-BUBU 125 ＞ 15.004~15.010(mm)
Use limits:
J-BUBU 115 ＞ 13.04(mm)
J-BUBU 125 ＞ 15.04(mm)
over the limit→Replace piston pin
8-4 The piston ring combination installation -

Installation -
›Install the spacer ring
› Install the ring 3 and ring 4
›" Side upward "install piston rings (2) - iron gray
›" Side upward "install piston rings (2) - Metallic
Silver
The piston ring arrangement method:

1.4th ring notch toward IN (inlet end)
5th ring notch toward top the right
side，With the 4th ring angle between
120∘.
3th ring notch toward top the left
side，With the 4th ring angle between
120∘.( Figure I)
(Figure I) 2. 2th ring notch towards top the right

side，With the inlet end (IN) angle
between 120∘.
2th ring "RN" mark facing up. (Figure
2)
3. 1th ring notch toward inlet end (IN)
1th ring "R" mark facing up. (Figure
3)
Note:
› Piston ring can rotate freely in the
piston groove.
(Figure 2) › When installing the piston can not be
Scratched. Piston ring shall not be
broken or damaged
(圖二) › Installing piston and piston rings
1.Lubricate the piston rings by motor oil.
(Figure 3)
8-5 Check the Piston pin
Check -
› Piston pin outer diameter
Standard value:
J-BUBU 115＞ 12.996~13.0(mm)
J-BUBU 115＞ 14.994~15.0(mm)
Use limits:
J-BUBU 115＞ 12.96(mm)
J-BUBU 125＞ 14.96(mm)
over the limit→Replacing Piston pin
8-6 Check the cylinder

Check -
› Inside the cylinder
Scratches, wear → Replace the cylinder
› Cylinder and piston pin into 90 ∘,
Perpendicular direction {X-Y direction} at the upper
, middle and lower three locations, Measuring bores。
Bores:
J-BUBU 115＞ 51.5~51.515(mm)
J-BUBU 125＞ 54.0~54.015
Use limits:
J-BUBU 115＞ 51.6(mm)
J-BUBU 125＞ 54.1(mm)
over the limit→ Replacement cylinder and piston
combination.
Check -
› The difference between the X and y is the roundness
The cylindrility is the max value of the difference
between the upper, middle and lower position of the
inner dia in X or Y direction.
Limit of use :
Roundness: change it when above 0.05mm
Cylindrility: change it when above 0.05m
Check -
› Cylinder surface flatness
Standard value:0~0.05(mm)
Use limits:≧0.05(mm)
over the limit→ Replacement cylinder
8-7 Connecting rod little end diameter

Check -
Standard value:13.002~13.013(mm)
Use limits:13.06(mm)
over the limit→Replace the crankshaft
8-8 Check the Cam chain guide and Cam

tension rods
Check -
>Cam chain guide and Cam tension rods
Wear, cracks → Replace
CVT(Continuously Variable Transmission) -9
∮9-0 Operating Information ∮ 9-4 Face movable drive disassembly / check
∮9-1 CVT disassembly ∮ 9-5 Driven face belt pulley disassembly /
∮ 9-2 Check the drive face check
∮9-3 Check the V-belt
9-0 Operating Information:

1. Maintenance CVT﹐Ministries parts can be implemented on a motorcycle check and replace.
2. Face movable drive, V type belt, driven face belt pulley comp, drive face, clutch outer body comp, can not have oil
, if attached to the, clean oil.
3. Weight roller installation, have coated side, toward the right side installation.
Torque:
CLUTCH OUTER BODY COMP 5.0~6.0kg-m DRIVE FACE 5.0~6.0kg-m SPECIAL NUT 5.0~6.0kg-m
Tool:
1. Clutch compression tool 2. Bearing puller tool

Belt width 20 19
The outer diameter of weight Roller set 17.90~18.10 17.4
The inner dia. Of slide driving plate 23.985~24.006 24.06
The outer dia. Of boss, movable Driving plate 23.960~23.980 23.94
Clutch lining thickness 112.0~112.2 112.5
Clutch lining thickness - 1.5mm

Driven plate spring, free length 105 95
The inner diameter of slide Driven plate 34.0~34.025 34.06
The outer diameter of driven Plate sets 33.965~33.980 33.94
Engine starts, but vehicle don’t move. the vehicle stops or tremble when running.
◆ driving belt worn out ◆ Clutch Facings and clutch outer cap bad junction surface
◆ driving plate worn out ◆ clutch lining spring cracked or broken
 clutch lining worn out ◆ Clutch Facings wear
 driving plate’s spring broken
Can’t reach high speed, no pick-up

 driving belt worn out. ◆ Weight roller worn out
 Driving plate spring distortion
 Driving plate dirty.
CVT SYSTEM
Project
圖表 1 Part name Quantity Project Part name Quantity
BELT PULLEY COMP., DRIVEN
1 FACE 1 27 WEIGHT ROLLER COMP (7.2g) 6
2 PLATE ASSY., DRIVE 1 28 SLIDE PIECE 3
3 NUT,SPECIAL 1 29 PAMP PLATE 1
11 SPRING,DRIVEN FACE 1 30 BOSS DRIVER FACE 1
13 OIL SEAL , G TYPE 2 31 DRIVE FACE 1
14 O-Ring (36.7D*1.92D) 2 32 WASHER 1
DEEP GROOVE BALL BEAR ONE
19 SEAL 1 33 HEXAGON FLANGE NUT 1
20 RETAINING RING C TYPE 1
21 NEEDLE BEARING 1
22 OUTER BODY COMP.CLUTCH 1
23 BEARING BUSH 1
24 HEXAGON FLANGE NUT 1
25 V BELT 1
26 FACE MOVABLE DRIVE 1
9-1 CVT demolition
Steps:
一. Sound off cover
○
2
b. Remove the left of the outer cap (2).
○
1
○
1
二. Left side cover

○
4
b. using a rubber mallet tapping off the left cover (2).
○
2 ○
1
c. Take out the left side cover gasket (3).
○
1
d. Take out the lock pin (4).
○
1 ○
3
○
1
三.CVT
○
3 ○
4 ○
5 ○
6
a.Remove the hex flange nut (1)
○
1 ○
1 ○
4 ○
4
Torque value: 5.0 ~ 6.0kg-m
○
1 66 b. Take out the flat washer (2)
○1 5
c. Take out the drive face (3)
○
1 d. Take out the V belt (4)
○
2
e.Take out the boss drive face(5)
○
1
f. Take out the face movable drive(6)
g. Remove the hex flange nut (7)
○
10 Torque value: 5.0 ~ 6.0kg-M
○
7 ○
8 ○
9
○6 h. Take out the bearing bushing (8)
○
6 ○
6 ○
6
1○ 4 i. Take out the outer body comp(9)
○
4 ○
4 ○
4
066 j. Take out the driven face belt pulley comp (10)
66 66 66
○1 5 ○1 5 ○1 5
○1 5
9-2 Drive face
Check - disk surface
> wear and tear (1) → Replace
Note:
Drive face with grease attached, will reduce the CVT
performance, please remove oil before installation.
9-3 V belt
Check -
> Peeling, cracking, cotton line is broken → Replace
Standard value: 20 (mm)
Use limit: 19 (mm)
Note
V-belt has too much fat attached, will reduce the
transmission performance, please remove oil before
installation.
9-4 Face movable drive combination

Demolition -
1 Remove the Pamp plate (1)
2 Remove the Weight roller (2)
3 Remove the Slide piece (3)
Face movable drive / Boss drive face
Check -
> Face movable drive inside diameter
Standard value: 23.985 ~ 24.006 (mm)
Over limit → Replace
>Boss drive face outside diameter

Use limit: 23.94 (mm)
Over limit → Replace
> disk surface:
Touch the disk surface from the inside out.
The height difference is too large → Replace
Note
Attached oil on Face movable drive, Performance
will drop, be sure to remove the oil, then installed.
Pamp plate / Slide piece

Check -
› Slide piece
Worn,broken →Replace
Check -
> Pamp plate
Wear, deformation → Replace
Note
When installing the slider (4) , triangular
side facing up, Quartet facing downwards in the
pressed into ramp plate(3).
Weight roller
Check -
> Weight roller
Wear → Replace
Exceed the limit → Replace
Installation-
Installation Notes:
Weight roller is not the same at both ends，Please coated
end is mounted on the the face movable drive trench right
side，To Weight roller life and prevent face movable drive
of abnormal wear.
9-5 Drive face belt pulley comp
一. Drive plate
○
4
a.Use the clutch spring compression(1) and fixed
○
3 ○
1
○
1
nut wrench(3)Remove clutch fixing nut(4)
○
1
b. The clutch spring compression (1) slowly relax.
c. Take off the drive plate (4).
○
2
二.Drive face spring /Collar spring/sealed socket

○
1 Take out the drive face spring (1), Collar spring (2),
sealed socket(3).
.
○
2
○3
1○
1
三.Sealed socket
a. Use two flathead screwdriver, take off the Sealed
socket (as shown)。
四. Bushing 、Guide roller pin
○
3 1 ○
1 a. Take off Bushing (1)、Guide roller pin (2)
b. Separation Movable driven face body comp (3)

and Driven face body comp (4)
○
2
○
4
五. Movable driven face body comp

a. using the seal screwdriver ，Remove the 'Movable
driven face body comp "on the G-Seal (1)
b. Remove the O-ring (2)
○
2 ○
1
六. Needle bearing / Single seal ball bearing

Demolition-
a. Use bearing puller tool，take out the needle bearing,
圖表 2
by the Driven face body comp.
b. Use snap ring plier, remove the C-type retaining ring.
C.Using a sleeve, would Single seal ball bearing
Qiaoxia by the Driven face body comp
Installation-
圖表 3
Note
1. Installation， would the Single seal ball bearing,
needle bearing, Movable driven face body comp,
groove, Guide pin, Bushing painted butter.
2.Please use the high-temperature butter (230 ° or
more).
圖表 4
Drive plate assy
Check clutch lining wearing condition and
Measure the lining thickness:
Wear, spring break → Replace
limit of use : change it below 1.5mm.
Driven face spring

Check driving spring free length.
Standard: 105mm
Limit of usage:
Change it below 95 mm
Outer body comp.cluth

Check -
> Clutch the outer cover inner surface
Scratch (uneven), rust or rust → Replace
Check clutch driving face.

Check clutch cover about its wearing condition and
innerdiameter measurement.
limit of use: change it above 112.5mm
Note:
. Minor scratches can be polished using emery cloth
. Clutch outer cover can not be attached to the inner
surface of the oil, not accidentally touch, use cleaner to
remove grease. When the clutch inner surface of outer
cover has oil, check oil seals, O-rings are not damaged
Movable driven face body comp
Check-
Use limits:34.06(mm)
› G-type seal
Oil spills, damage → Replace
> O-ring
Oil spills, damage → Replace
Driven face body comp

Check-
› Single seal deep groove ball bearing

needle bearing
Different sound, cracked →replace
表 5
Guide roller pin、Bushing 、Driven face

body groove Check -
> groove
Wear, deformation, reaming → Replace
the Driven face belt pulley .
Check -
> Guide pin、Bushing
Wear→Replace
Installation-
Follow the removal procedure in reverse can be
install。
Note:
1 Note that when you install V-belt, drive face, clutch
cover, can not have grease adhesions.
2. When the locking CVT fix screw , please tighten the
screws by hand, make sure there is alignment of the
crankshaft and drive surface groove, and then lock it.
Crankcase, crankshaft -10
∮10-0 Operating Instructions / Troubleshooting ∮10-1 Removing the crankcase
∮10-2 Check the crank shaft ∮10-3 Check the camshaft chain
∮10-4 Timing chain tensioner ∮10-5 Disassembly Quakeproof bush-(engine)
∮10-6 crankcase inspection and cleaning

1. Crankshaft decomposition must complete the following tasks,Before decomposition.
◎ cylinder head
◎ cylinders, pistons
◎ CVT system
2. After decomposition, please clean the crankcase.
3. When assembled, the gasket can not be reused ，Please all the updates.
Torque: kg-m
fan-0.9~1.1 Fly wheel-4.0~4.5 STATOR COMP- Pulse -0.7~0.9
STATOR COMP -0.9~1.1 OIL PUMP COMP -0.9~1.1 ONE WAY CLUTCH -9.0~10.0
CRANKCASE -0.9~1.1 CRANKCASE COVER-M6-30L:0.9~1.1 M6-95/110L:0.9~1.25
Tool:
1. flywheel puller 2. Bearing Striking Tools 3. Bearing puller tool

Item Standard value (mm) Limit
Connecting rod small end inner diameter 15.01~15.028 15.06

Clearance of connecting rod big end 0.05
Crank shaft 0.006~0.014
axle direction
Clearance of connecting rod big end 0.8
0.15~0.40
vertical direction.
Troubleshooting:
Engine noise
◆ crankshaft bearing wear
◆ crank pin bearing wear
◆ crankshaft fracture
CRANKCASE
NO. Part No. Q'TY NO. Part No. Q'TY

1 CRANKCASE,RIGHT 1 15 BOLT. SPECIAL 1
2 BUSH, QUAKEPROOF 1 16 WASHER 1
HEXAGON FLANGE BOLT
3 Bush, Mainstand 2 17 (M12*15L) 1
4 OIL PLUG 2 18 STUD BOLT 2
DEEP GROOVE BALL
5 BEARING 1 19 LOCK PIN （10*14） 4
6 PLUG OIL 1 20 HEXAGON FLANGE BOLT 1
7 STUD BOLT 2
8 LOCK PIN 2
9 CRANKCASE LEFT 1
10 BUSH, QUAKEPROOF 1
DEEP GROOVE BALL
11 BEARING 1
12 BALL BEARING 1
13 BALL BEARING 1
14 HTCL Oil Seal 2
Start System

1 OIL PUMP COMP 1 15 MOTOR ASSY STARTER 1
2 C-R RECESS PAN HD. TAPPING 2 16 HEXANGON FLANGE BOLT 2
3 Oil Pump ,Driving Gear 1 17 One Way Clutch comp. 1
4 COVER CLUTCH OUTER 1 18
5 BODY, ONE WAY CLUTCH 1 19
6 ROLLER ONE WAY CLUTCH 3 20
7 COP，ROLLER SPRING 3
8 COMPRESS S PRING 3
9 HEXAGON SOCKET BOLT 3
10 NEEDLE BEARING 1
11 GEAR COMP.STARTING CLUTCH 1
SHAFT,STARTET REDUCTION
12 GEAR 1
13 GEAR, STARTER REDUCTION 1
14 O RING 1
RIGHT CRANKCASE COVER

1 COVER, R. CRANKCASE 1 11 OIL STRAINER 1
2 Gasket Rh. CrankCase Cover 1 12 COMPRESSION SPRING 1
3 OIL SEAL TC TYPE 1 13 O RING 1
4 PIN 2 14 OIL STRAINER COVER 1
5 GAUGE, OIL LEVEL ASSY 1
6 GAUGE. OIL LEVEL 1
7 O-RING 1
HEXAGON FLANGE BOLT
8 (M6*30L) 2
9 HEXANGON FLANGE BOLT 4
10 HEXANGON FLANGE BOLT 4
GENERATOR / FAN COVER

1 A.C.G COMP 1 15 DAMPER 4 , COOLING SHROUD 1
2 FLYWHEEL COMP 1 16 DAMPER 2 , COOLING SHROUD 1
3 STATOR COMP 1 17 DAMPER 3 ,COOLING SHROUD 1
4 HEXAGON FLANGE BOLT 2 18 DAMPER 1 , COOLING SHROUD 1
5 HEXAGON FLANGE BOLT (M5*12L) 2 19 RUBBER PLUG 1
6 HEXAGON FLANGE NUT (M10*P1.25) 1 20 PLASTICS LOCK 1
7 FAN 1
8 HEXAGON FLANGE BLOT 4
9 FAN SHROUD 1
HEXAGON FLANGE BOLT (M6*20L) 2
11 C-R RECESS PAN HD. TAPPING 7
12 HEATPROOF SHIELD 1
13 COOLING SHROUD 2 1
14 COOLING SHROUD 1 1
10
10-1 Removing the crankcase
1. Fan
a. Remove the screws (1) .
○
2
b. Remove the fan(3).
○
1
2.
a. Remove the screws(1) Remove the flywheel (3) .
3.. flywheel
a. flywheel puller to remove the flywheel.
Note
flywheel puller is left-hand thread ,tighten counterclockwise.
4.. Stator comp
a.Remove the hex flange bolts (1) M6-22L.
b. Remove the hex flange bolts (2) M6-12L.
Torque values:0.7~0.9M
○
2 C.Take out the Stator comp (3).
○
1
○
3
5. Starter motor
a. hex flange bolts (1). M6-22L.
b. Remove the Starter motor (2).
○
1
定螺絲。
○
2
6. Right crankcase cover

○
1
a. Remove the hex flange bolts (1).
M6-30L: Torque value: 0.9 ~ 1.1 kg-M
○
2
M6-95/110L: Torque: 0.9 ~ 1.125kg-M
b. Remove the right crankcase cover (2).
c. Remove the right crankcase cover gasket (3).
d. Remove the lock pin (4).
○
3
○
4
d. Right crankcase cover screw length configuration
diagram.
○
3
7. one-way clutch
○
4
Tools: one-way clutch removal tool
○
5
a. Remove the Starter reduction gear (1) and Starter
reduction gear shaft (2).
○
6 b .using the tool one-way clutch removal tool (a)
○
1
counter-clockwise, remove the lock nut (L) (3).
○
2 Torque: 9.0 ~ 10.0kg-M
c. Remove the flat washers (4).
d. removing the one-way clutch combination (5).
e. Remove Oil Pump driving gear (4).
Note
Lock nuts "left-hand thread," Remove the nut
counterclockwise.
a
\ ○
1
9. Oil pump assembly
a. Remove the "CR ROUND HD MACHINE SCREW"
○
2 ○
3
(1). M6-25L
b. Remove the oil pump assembly (2)
c. hex flange bolts (3). M6-55L
Decomposition crankcase
○
1
a. Remove the right crankcase (1)
b. Remove the crankshaft (2)
c. Remove camshaft chain (3)
○
2 d. Remove the lock pin (4)
e. Remove the left crankcase (5)
f. Remove the Cam chain guide comp (6).,
○
4
○
3
○
6
○
5
10-2 Check the crank shaft
Measurement -
› swing ness of the crankshaft journal.
Over the limit→ replace a new crankshaft
Standard value:0~0.04(mm)
Limit of use:≧0.08(mm)
Note: please rotate the crankshaft slowly during inspection
Measurement -
›Clearance of connecting rod big end vertical direction.
Over the limit→ replace a new crankshaft.
Limit of use: ≧0.8(mm)
Measurement -
› Measure the difference of the connecting rod big end
between the X and Y.
Over the limit→ replace with new crankshaft
Limit of use:≧0.05(mm)
Check -
> Ball Bearings
Breaking bad, abnormal sound, wear → Replace the
Crankshaft.
> Big end bearing
Different sound, the gap is too large →Replace the
crankshaft .
Item Standard value (mm) Limit Item

Connecting rod small end inner
15.01~15.028 ≧15.06
diameter
Clearance of connecting rod big end
0.006~0.014 0.05
Crank shaft axle direction
Clearance of connecting rod big end 0.15~0.40 0.8
vertical direction.
Swingness of the crank shaft journal. 0~0.04 0.08
10-3 Check the camshaft chain
Check -
> Camshaft chain
wear → Replace the Camshaft chain
10-4 Timing chain tensioner

Check -
> Timing chain tensioner
Wear, cracks → Replace
10-5 Disassembly Quakeproof bush-(engine)
Removal -
a. use the Shockproof bush dismantling tool.
(As shown)
b. Removing Shockproof bush.
Installation -
a. Use hands to flatten the Shockproof bush.
b. Installation Shockproof bush dismantling tool.

c. The Shockproof bush pressed into the
crankcase.
Note
There are four places to install rubber
cushion (Left crankcase * 2, right crankcase *
1, Rear swingarm * 1).
10-6 crankcase inspection and cleaning
1. Pre-installation tasks:
a: Use cleaning materials to clean the crankcase.
b: Use a scraper to remove all the gaskets and sealants.
Check -
> Crankcase
Uneven mating surface→Use sandpaper to
adjust.
Rupture, deformation →Replace the crankcase.
> Oil Galley

Obstruction →Use Compressed air to
clean Note: See section 5 - lubrication
system
2. The evenly coated with sealant to the
right crankcase.
Note
Recommended to use: LOCTITE # 5060G sealant.
3. Installation follows the removal

procedure in reverse.
Note
Before installation, sealant needs to be applied evenly.
Do not touch the sealant at the time of installation.
․ When installed, In case of excessive force, check the
parts, whether placed uneven situation, do not force
the installation.
․ After installation, check the crank shaft rotation
Gearbox system -11
∮11-0 Operating instructions/ Troubleshooting ∮11-1 Gearbox disassembly

∮11-2 Bearing Removal ∮11-3 Drive shaft check
∮11-4 Idler gear check ∮11-5 Rear axle / final gear check
∮11-6 Check the gearbox
11-0 Operating instructions/ Troubleshooting:

Oil Model: SAE85W-140 The total amount of gear oil:110C.C
Recommended gear oil: PGO special gear oil Exchange capacity:90C.C
Torque:
1. Gear cover 0.9~1.1 kg-m 2. Oil drain screw 1.7~2.0 kg-m
Tool:
1. Snap ring pliers 2. Bearing puller tool 3. Bearing Striking Tools
Troubleshooting
Engine can be started, but the vehicle doesn’t move.
1. Gear worn-out or cracked.
2. Gear burnt out.
Noise occur when running.
1. Gear worn out, burnt or gear surface.
2. Bearing worn out of loosen.
Oil leakage
1. Too much oil
2. Seal worn out or damaged.
Gearbox system -11
Gear system

1 TRANSMISSION COVER 1 15 Tube, Tranmission Vent. 1
2 Trans Cover Gasket 1 16 CLIP 2
HEXAGON FLANGE
3 LOCK PIN 2 17 BOLT(M6*60L) 2
DEEP GROOVE BALL HEXAGON FLANGE BOLT
4 BEARING 1 18 (M6*40L) 5
5 BALL BEARING 1 19 WASHER (8*1.6T) 1
BALL BEARING, DOUBLE HEXAGON FLANGE BOLT
6 SEALED 1 20 (M8*40L) 1
7 Oil Sealtc TC Type 1 21 O RING 1
8 DRIVING SHAFT 1 22 OIL BOLT 1
9 IDLE GEAR COMP 1
10 AXLE DRIVE 1
11 C TYPE RETAINING RING 1
12 DISC SPRING WASHER 1
13 FINAL GEAR 1
14 TUBE,CYL.HEAD COVER 1
Gearbox system -11
11-1 Gearbox disassembly 1. Transmission cover

a. Remove the hex flange bolts (1), the gear oil leaked.
○
2 ○
1
b. Remove the hex flange bolts (2).
c. Take out the transmission cover (3).
○
1 ○
1
○
3
2. Transmission gear set
a. Remove the axle drive (1).
○
1 b. Remove the flat washer (2).
c. Remove the idler gear (3).
○
1
d. Remove the final gear (4).
○
3 e. Remove the gearbox gasket (5).
○
1
○
2 f. Remove the lock pin (6).
○
2 ○
4
○
1
○
6 ○5
○1 ○
2
○
5 ○4
○
1
3. Drive shaft removal
○
4 ○
2
1. Using the removal tool, remove the drive shaft .
2. The original the fixed nuts (17mm), the lock to the drive
○
2 ○
1 shaft, lock into the depth of cut Qi drive shaft leading
edge, take 17mm pneumatic sleeve mounted on the nut
○
1 Qiaoxia.
Installation -
The drive shaft into the bearing, drive shaft tail put 14mm
pneumatic tool sleeve knock.
Gearbox system -11
11-2 Bearing Removal
Bearing installation –
11-3Drive shaft check
Check -
> Gear Ministry
Discoloration, wear and tear, rupture → replacement
Measurement -
Tools: dial gauge
> Roundness
Maximum out-of-roundness: 0.04mm
→ replace the drive shaft exceed the limits
11-4Idler gear check
Check -
> Gear Ministry
Measurement -
Tools: dial gauge
> Roundness
Maximum out-of-roundness: 0.04mm
Exceed the limits → Replace the idler gear
Gearbox system -11
11-5 Rear axle / final gear check Check -

> Gear Ministry
Measurement -
Tools: dial gauge
> Roundness
Maximum out-of-roundness: 0.04mm→
replace the rear axle exceeds limits
Note:
1. Install rear axle C-rings, no R angle side upward.
2.The spring washer raised face up
3. C-type retaining ring deformation or loose→replace
11-6 Check the gearbox Check -

> gearbox
Turn the wheel - the gear gap is too large, abnormal sound
→ Replace gears or bearings.
Installation-
Shock absorber / brake system/wheel -12
∮ 12-0 Operating instructions/ Troubleshooting ∮ 12-5 Rear suspension
∮ 12-1 Front wheel ∮ 12-6 Rear swingarm
∮ 12-2 Rear wheel ∮ 12-7 Brake fluid replacement
∮ 12-3 Check the steering handle bar assy ∮ 12-8 ABS (Anti-Lock Brake System)
∮ 12-4 The front fork assembly installation

1.When replacing the brake system parts can not be stained oil, If there are oil stains, use degreaser cleaner.
2. can not be mixed other oil or brake fluid , can not have debris in the brake fluid tank..
3. There is leakage of brake fluid , cause poor braking performance and rupture of plastic parts or rubber.
4. When plastic parts and rubber stains brake oil，use the water to clean.
5. When replacing brake fluid , use cloth cover the plastic or rubber parts.
Torque - Kg-m
disc: 2.0~3.0 Brake hose joint bolt:3.5±0.2
Rear suspension(up):3.5-4.0 Front axle:5.0~6.0
Rear suspension(low):2.0~3.0 Brake calipers:2.0~3.0
Tool-
1. Front fork - Bearing cage disassembly tools 2. Bearing Striking Tools
3. Reatining Ring Pliers 4. Bearing puller tool
Use limits: (mm)
Item Standard Limit

Front 4.0 3.0(≦1.0)
Brake pad thickness
Rear 4..2 3.5(≦0.7)
thickness (F)-3.6 (R)-4.0 (F)-3.1 (R)-3.5
Brake disc roundness - ≧0.3
Front axle curvature - ≧0.25

Vertical direction - ≧1.0
Front and rear wheel curvature
Horizontal direction - ≧1.0
Troubleshooting
1.steering handlebar is abnormal, too tight. 2.steering handlebar is aslant.
a. steering mechanism; washer of conical a.left and right damper is not even.
bush locked too tightly. b.Front fork is crooked.
b. steering mechanism; steel ball is cracked. c.The axle of front fork is crooked, wheel is aslant.
c. steering mechanism; steel ball base and
washer of conical base is damaged. 4.front damper is too soft, spring fatigue.
d. wheel pressure is too low.
3.front wheel swings. 5.noise in front damper.

a.wheel rim is distorted. a.noise comes from damper box.
b.bearing of front axle too free. b.locking screw of damper is slackness.
c.wheel rib is distorted.
d.Wheel is not good.
e.Front wheel axle locked improperly.
12-1 Front wheel Steps:
1. Remove the front brake bolts(14).
2. Remove the front axle nut (12).
3.Remove the front axle(8)" spacer ring(9) code table
gear(11) and wheels(10).
12-1.1 Front wheel measure

Measuring -
›Horizontal direction:≧2.0mm
Vertical direction:≧2.0mm
Beyond the limits - replace
12-1.2 Front wheel -One sealed ball bearing

>Demolition -
Tool: Bearing Removal Tool
Demolition of oil seal tool
Specification: Sealed ball bearing 6201
1) Use Oil seal tool demolition oil seal demolition.
2) Use of the bearing removal tool will hammer out the
single sealed ball bearings.
圖表 1
Front wheel demolition

Rotating ring true and different sound
→ Replace the ball bearings.
2.Oil seal
Specification:22-35-7
Wear, damage→replace
>Installation -
Tools - Bearing removal tool.
1.A first bearing does not cover the surface with butter.
2 Bearing stamped facing the use of tools bearing knock .
3 Oil seal is loaded, installed at the sealing lip painted
yellow Oil.
12-1.3 Front wheels - Brake disc

Measurement –
1.Thickness:
Standard values:3.6mm
Use limits:≦3.1mm
2.lost roundness: ≧ 0.3mm

Disassembly steps -
1.Remove the windshield plate (see chapter 2)
2.Remove the handle cover uper, the wheel speed

sensor plug out.
Disc fetch:
4. Remove the bolts (10/11), remove the front fender rear

section (9).
5. The wheel speed sensor launched by the retaining ring.
6.Remove the bolt (5)

(4).
3. Remove the bolts (27), remove the wire clips (26).

Disassembly steps –
1.Remove the bolts (21), remove the Brake fluid hose
clip A (19), Brake fluid hose clip B (20).
12-1.4 Front wheel – Meter gear assy Check -
›Speed meter gear”1”
Pinion speed meter”2”
Wear, damage → Replace the code table gear
12-1.5 Front wheel - brake pads (disc)

Disassembly brake pads :
step-
1. Remove the brake caliper mounting bolts.
2. Use a slotted screwdriver to push the piston back.
step1 step 2 3.using needle nose pliers remove the Spring pin.
2 4. Remove the yoke spring and brake pad.

圖表 3 圖表 2
Measurement - brake pads

Use limits: ≦1.0mm
step3 step 4 Lower than those limits - Replacement
3 4
圖表 4
Installation-
12-1.6 Front wheel–Front axle

Measurement –
Limit of use: Change it when above 0.25mm.
12-2 Rear wheel Removing the rear wheels -
> Step
1 Remove the oxygen sensor(4)
2 Remove the muffler(3) and gasket(2)
3 Remove the rear swing arm
4. The tire pressure to vent out
5 Remove collar and wheels
Measuring -
› Horizontal direction:≧1.0mm
Vertical direction:≧1.0mm
Out of limits → Replace
Installation-
12-2.1 Change the rear brake pad

Demolition -
1. Remove the brake caliper mounting bolts.
2. Use a slotted screwdriver to push the piston back.
3. Use the long nose pliers to remove the R-type
retaining ring.
4. Remove the brake pad.
圖表 6 圖表 5
Check -
Use limit : ≦0.7mm
Out the limit → Replace
Installation-
圖表 8 圖表 7
Demolition -
12-2.2 Rear disc > Step
1 Remove the rear wheels follow the steps
2 Remove the disc screws * 3
Torque value: 2.0 ~ 3.0 kg-m
Checking the rear brake-disk.

Standard values: 4±0.2mm
Use limits:≦3.5mm
Roundness:±0.1mm
lost roundness: ≧ ±0.3mm
1.Remove the rear wheels on the right side screws (3)

12-3 Check the steering Handle bar assy

Demolition -
See Section 2 (3-1)
Check –
> Handle bar
Distortion, skew → Replace
Remove Helmet case assy (1).
2.
12-4 The front fork assembly installation

Disassembly -
> Step
1.Remove the handle bar(1).
2.Remove the front wheels (see section 14-1).
3.Remove the front fender (see Chapters 2-5).
4.Remove the brake hose clip and speedmeter cable
Clip.
5.Using the front fork disassembly tool，Remove the
steering shaft lock nut(4) and Upper ring-shape nut(3).
6 Remove the front fork assembly (1) and (upper / lower)
cage ball bearing (2).
Check -
›Ball bearing cage
Rupture, deformation → replacement
›Upper ring-shape nut、Upper bearing cage、Lower bearing
cage、Inner bearing cage .
Wear, deformation → replacement
Note:
Ball bearing cage and Bearing Rupture depression
deformation will cause handle tube rotating flow, and
body shaking unstable.
12-4.1Ball bearing disassembly
Tools –
Fork bearing disassembly tool
Demolition -
The use of impact rod will “upper bearing cage ”and”
lower bearing cage” Qiaoxia.
1. First “upper
bearing cage”and”lower bearing cage” Parallel pressed
into
2. Use Fork bearing disassembly tool Will be “upper
bearing cage”and”lower bearing cage”slowly turn Into the
vehicle inside the station.
3.Check“upper bearing cage”and”lower bearing cage”
whether there is smooth
12-4.2 The front fork assembly installation

Installation –
1. Ball bearing cage (up / down) Smear the butter
Note: Ball bearing cage direction, the installation can not
be wrong Loaded.
2.front fork assembly installation.
Installation:
一. Hand " steering shaft lock nut " lock，Use the fork
disassembly tool left about 1/4 to 1/2 turn and then
locking.
二. Hand attendance“Upperring-shape nut” locking，Use
Fork bearing disassembly tool，Fixed “Steering
shaft lock nut”and "Upperring-the shape the nut right
locking.
三. Check the front fork can not be too loose or too tight.
This side up This side up
3. Install the front fender and front wheels.

4. Installation on the handle bar.
此面朝 Note:
下 a.When the fork is too tight will cause the
motocycle instability or steering difficult.
step1 step2 b.Fork too loose will cause the motocycle brakes
or driving have different voice to produce.
圖表 9
step3
12-4.3 New ball bearing gage (bakelite)
Concave Convex
Installation –
Note:
The new ball bearing gage (bakelite), when installed,
must be used in conjunction with the upper bearing
12-4.4 Front suspension assembly
Demolition -
步步 1. Remove the front wheels (see the chapter 12-1 ).
驟:3 驟:4 2. Remove the front fender.
3. Remove the front suspension Inner cylinder
a b screws(a).
4. Remove the front suspension fixing screws
(b), take out the suspension.
Decomposition
○
2 1. Remove RUBBER SLEEVE SET (1).
○
5 2.Remove the large coil spring (2).
3. using a desktop fixed clamp fixed outer cylinder
○
4
Remove the hex bolts (3) and gasket.
○
1 Note: Please use a cloth protective outer cylinder
fixed outer cylinder.
4 .Remove the the inner tube (4).
○
6
5.Remove the inner tubing set (5) "dampers 、 buffer
○
3○8 ○
7 spring.".
○
3 6. Remove the outer tube buckles (6).
7. Using Oil seal removal tool, remove the oil seal (7).
Check -
> Inner cylinder group, inner tubing set
Bent, deformed → Replace
> Big Spring
Bending, fatigue → Replace
> O-rin
圖表 12 Damage, wear → Replace
Fork oil - > Seal Specifications
Oil Specification: 10W Damage, wear → Replace
Total oil: 65C.C Note:
1 Whn installing fork seals, lubricating grease painted lip
Installation- portion.
Follow the removal procedure in reverse can be install. 2 Remove the seal can not be reused after.
3 Use the fork seal assembly installation tool is
unavailable knock way, will cause deformation of seal
leakage.
12-5 Rear suspension

Demolition -
> Right Suspension
1 Remove the muffler (see Chapters 6-1).
2 Remove the hex flange bolts (1). M10-32L.
> Left suspension

12-6 Rear swingarm

Removing the way -
Tools: Oil seal removal tool - Large,
Bearing puller tool (See Chapter 1-6).
> Steps:
1 Remove the seal (3.4)
2 Remove the ball bearing (2)
> Specifications -
1. Seal:
Inner :25 -35-7(3)
Outer :26 -40-5 (4)
2. ball bearings: double seal 6203

12-7 Brake fluid replacement Tools: pumping unit
1.Relax the drain screw.
2.Vacuum pumping unit, taking the dirty oil.
3.Open above the brake master cylinder, pour new oil.
4.Use vacuum pumping unit, out of the air brake tubing
Please add brake fluid at the same time, do not let the
oil cup is taking the time to suck Into the air.
5.Tighten the drain screw and brake master cylinder cover.
The following strut several times to check the brake
lever clearance whether Normal, in the absence of a
repeat of the action four five.
Warning:
Brake master cylinder cover is not installed, do not pull the brake lever, brake fluid will spray accidentally sprayed into the
eye and mouth and other important parts, after a large number of rinse with water, and immediately taken to hospital.
12-8 Side stand switch comp

Removal steps:
1. Remove the bolts with washers (41).
2. Remove the side stand switch comp (40).
3. Remove the nut (30), and then remove the side
stand bolt (29) .
4. Remove the side stand comp (28) and spring (31).
Installation:
Follow the removal procedure in reverse can be
install.
Electronic Parts and Components-13
∮13-0 Operating Instructions ∮13-6 Fuel guage
∮13-1 Starter syster ∮13-7 Ignition /Fuel supply system
∮13-2 Charging System ∮13-8 Fuse Description
∮13-3 Leakage current testing ∮13-9 Ignition /Fuel supply system
∮13-4 Power transfer switch ∮13-10Engine stop switch
∮13-5 Horn
∮13-0 Operating Instructions

1. Use a multimeter measurements when Electrical Parts.
2. bulbs, fuses, follow the original specifications changed to prevent Electrical
Parts burned.
3.When the battery charge, according to the battery marked Implementation of the
charging operations.
4. When dismantling Electrical Parts, turn off the main switch.
Item specification values

Control Voltage 14.5±0.5V at2000rpm
Charging System
Charging coil 1.3±0.5Ω
Leakage current testing - 1mA low
main switch Anti - theft resistance - 51kΩ
Oil level-F 100Ω
Fuel guage
Oil level-E Flashing- 600Ω/700Ω
Troubleshooting
Start System
◆ fuse is blown ◆ line connection is bad or open circuit, short circuit
◆ battery voltage is low ◆ One way clutch is bad
◆ main switch is bad
◆ stop light switch is bad
◆ start switch is bad
◆ Start the motor is bad
Charging System
◆ fuse is blown ◆ line connection is bad
◆ battery is bad ◆ ACG is bad
◆ regulator rectifier
13-1 start system
Inspection process:
a. fuse → b. batteries → c. Power transfer switch d. stop light switch → e. starter motor → f. starter relay → g. starting
system wiring
a.fuse
Measurement - 15A fuse broken wire
> Tools: multimeter stalls: Ω
Use a multimeter probe connected to the fuse pin
Open circuit (∞) → replacement
b. Battery
Check -
> terminal and cable
Loose, poor contact → fixed, Clean (positive
/ negative) terminal
Measurement - battery voltage
> Tool: multimeter stalls: DCV
Use a multimeter probe connected to the battery (+, -)
terminal.
Below 12.3V →Recharge or replace
c. Power transfer switch

Check -
› Tool: multimeter stalls:Ωx1
Cut to switch ON: ─
Method: The multimeter probes connected to two pin
power transfer Switch
∞→replace
d. stop light switch
Measurement - switch actuation, continuity
> Tools: multimeter
use multimeter probe is connected to the
switch pin
wire
Measurement probe stalls Judgment
color
O (+) conduction normal
switch Ω
LB (-) ∞ replace
e.starter motor
Check - start the motor rotation is normal

─
> Tools: 12V battery
Method: directly connection the 12V voltage to the motor
+
Not rotate / rotate too slowly → replace
圖表 1
f. starter relay
Check - starter relay actuation is normal

> Tools: multimeter (Stalls: Ωx1,), 12V battery
Ways: using the battery to the relay coil is energized, the
measurement relay is turned on
Not conducting → replace relay
Electronic Parts and -13
g. starting system wiring
Check -
Tools: Multimeter
> connections are correct, the line is open circuit
Measurement -
R/W (+)
12V OK
1.main switch
O (+) V
(turn on)
0V NG
Ground (-)
O
12v OK
2. Power transfer
V
switch (ON) O/B
0V NG
O/B (+)
Check the starting 12V OK
system wiring 3. stop light switch
LB (+) V
(turn on)
OV NG
Ground (-)
4.start switch B (+) conduction OK
Ω
(turn on) G/W (-) ∞ NG
LB (+) 12V OK
V
G/W (-) 0V NG
5.starter relay
(Wire harness) (+) conduction OK
G/W1
Ω
Ground (-) ∞ NG
13-2 Charging system
Check the process:

a:battery → b:A.C.G → c: charging line check
a. battery
Check - Battery
` > Tools: multimeter
Measurement: Voltage: at20 ℃ when 12.8V or more
Insufficient voltage → recharged or replaced
Measurement the A.C.G, connect a voltmeter (hook table

or pointer).
> Tools: multimeter
Control voltage: 14.2V ± 0.5 at: 2000r/min
★ charging voltage = battery voltage or voltage rose
slightly.
→ replace the regulate rectifier or A.C.G
圖表 2
b: Check A.C.G
Check-
Tools: multimeter
The measurement-A.C.G rechargeable coil impedance
Measurement line color probe stalls Judgment

Y(1) (+) 1.3±0.5Ω
1 Ωx1
Y(2) (-) at20°
A (+)
Y(1) 1.3±0.5Ω
C 2 (-) Ωx1
Y(3) at20°
G
(+)
Y(2) 1.3±0.5Ω
3 (-) Ωx1
Y(3) at20°
c: Charging line inspection

Check -
> Each connection line
Open / short circuit, fall off, too loose →Adjustments
13-3 Leakage current testing

Tools: ammeter (A)
1.Method:Turn off the main switch
2. Negative (-) battery removed
Connect ammeter → probe (+) connection wire harness-
battery negative line
→ Probe (-) connected to the battery (-)
Testing -
> Current
Short circuit leakage 1mA more →
Excluded: electrical equipment connected to the main
wiring contact， demolished one by one until you find
the short-circuit location.
NOTE:
․Measurement can not be turned on main switch
․Ammeter stalls, from large to small sequence
adjustment,avoid excessive current, causing the ammeter
or fuse burned.
13-4 Lamps lighting system
a- Bulb check
Check - filament whether disconnection
Measurement:
> Tools: Three multimeter stalls: Ωx1
Method: Three multimeter measuring rod connected to the
bulb three-pin
∞ → replace
Measurement: (Figure 13-2)
> Tools: 12V battery stalls: DC 20V
Way: using the battery connection bulbs pin
Bulb does not light → Replace
◎ Measurement Method: (check for all lamps)
Note:
1. Remove the bulb, high temperatures are not
directly hand pick.
2. Bulb surface can not be contaminated with oil or touch,
will lead lamp life and brightness. When dirty, wipe clean
with alcohol.
b- Light switches and line checks

› Stop light switch
Measurement:
Tools: multimeter stalls: DC 20V
Check the order:
1.Check bulb filament burns out.
2.Measured starting safety switch orange 12V.
3.ON: measured starting safety switch light blue
whether.
.
13-4.1Headlight / license lamp line loop (Electronic injection version)
Measurement - 8.measurements dimmer switch (HI) -

> Tools: Multimeter stalls: DC 20V Brown / white if there is 12V
Check the order: 9.measurements dimmer switch (LO) -
1. fuse (10A) is blown. Blue if there is 12V
2. filament bulbs are blown. 10.measurements dimmer switch (PASS) -
3. Check the fuel pump relay - red line if there is 12V Orange if there is 12V
4.Measurement headlight switch -. Orange line Is there 12V 11. Check whether the line open circuit，Contacts are
5. Measurement headlight switch - Yellow line if there is corrosion
12V
6. Measurement head light switch (rear lights) -. Green line
if there is 12V
7. measurements dimmer switch - gray line if there is
12V.
13-4.2 Signal lamp
Check the order:

1. Check whether each bulb filament burns out. 6. Measurement direction light switch (left) -. Pink if there
2. Measurement flasher relay - orange line if there is is 12V .
12V. 7.Check the each signal lamp Are there 12V。
3. measurements flasher relay -. Green line blue / white 8. Check the grounding Are there open circuit。
line if there is 12V.
4 Measurement flasher relay - Black line with the frame
is turned on.
5 measurement signal switch (right) -. Brown line if
there is 12V .
13-5 Main switch
Tools: multimeter
Stalls: DC 20V
Key Red / Orange Orange Green
position White
off 12V OV OV OV
12V 12V 12V
on ○ ○
○ ○
○ ○
Anti-theft voltage: main switch install a resistor (51KΩ) in the Orange wire with the middle of the green wire, a
signal voltage is connected to the E CU, ECU without receiving this voltage or voltage at the same time, the
vehicle will not start
13-6 Horn
Tool:Battery、multimeter
›Check-
Items wire Probe Stalls Measurement
color
Horn G/Y (+) 12V Horn
DCV
B (-) 0V
Single product inspection

Way: The speaker two pins connected tothe battery
Adverse → no sound or the sound is too small
13-7 Fuel guage

Tool:multimeter
›Check-
Line Probe Stalls Measurement

Items
color
F:100Ω
Fuel Gr (+) OK
Ω E:600~700Ω
guage
B (-) ∞ NG
13- 8 Control of relays
＊ (Relay) 15A
＊theory： use small current to
control big current
＊Usage：
fuel pump & injector
EMS whole system
headlamp
＊ Relay measurement
＊use the pocket tester
＊使用三用電表
1.find the control coil
1.繼電器卡損位於上方 4.再將12V電源接在右側兩接腳
2.fit 12V to the control coil
2.使用電阻歐姆檔位
3.the relay sounds “ka” 5.繼電器發出作動聲“喀”
3.量測右側兩接腳
4.measure the resistance 6.量測左側兩接腳
<disconnect-->NG connected-->OK>
<未導通-->NG 導通-->OK> <未導通-->NG 導通-->OK>
Ω Ω DC
12V
13-9 Ignition /Fuel supply system system
13-9.1 Ignition system checks:
1. Check the spark plug is normal (color brown)? Gap is normal (0.6~0.7mm)?
2. Spark gap tester to check the spark gap is more than 6mm?
3. Check the ignition coil:
1) Measurement primary circuit: Primary side: 2.8Ω ± 10%，Secondary side: 9.5kΩ ± 10%
2) Measurement line
multimeter Stalls Red probe Black probe Normal Not Normal
ignition coi DCV Red line Green Line 12V 0V
1. Check that the relay is normal?
NOTE:
Turn the main switch within 4 seconds
measurement，more than four seconds,
the ECU controlled fuel pump relay to
turn the power off。
2.Check the battery?
Ω Green Line ECU turn on ∞
(GreenLine) 1. Check the line for open
circuit?
2.Check the ECU is normal?
Ω Red line Fuel pump turn on ∞
relay 1. Check the line for open
- Red circuit?
4. Check the fuel pump relay:

Relay measurements: (see 7-6) Relay System Description
1) Measurement line:
fuel pump DCV 1.white/red Ground 12V 0V
relay 2. Orange 1. White / red - Check the main
Relay?
Check the line for open circuit?
2.Orange -
a. check the proper functioning of other
electrical appliances? If normal, open
circuit,
b. Check 15A fuse or power lock failure
Ω Dark blue ECU(Dark turn on ∞
blue line) 1.Check the line for open circuit?
2. check the ECU is normal?
Ω Red line Ground 12V 0V
1.Check that the relay is bad?
5. Check the main relay:
Relay measurements: (see 7-6) Relay System Description
1) Measurement line:
main relay DCV 1. red / white Ground 12V 0V
2. Orange 1. red / white - Check the main Relay?
Check the line for open circuit?
2.Orange -
a.check the proper functioning of other
electrical appliances? If normal, open
circuit,
b.Check 15A fuse or power lock failure。
Ω 1.Blue/black 1.topple switch turn on ∞

(Blue/black) 1.Check the line for open circuit?
2. Check topple switch line is normal?
2 .Topple switch 2.frame or battery Or single piece of bad。
(black) ground Note: blue / black wire grounding, can
determine whether the to topple switch
adverse。
Ω red / white ground 12V 0V

1. Check the main relay
6. Check 15A fuse - Use a multimeter measurement is burned?

7.Check the main switch: see 7-5main switch measurement。
13-9.2 Fuel supply system system
Check the fuel pump:
1. Check whether the fuel pump action?
1) Turn on main switch, check if there is the sound of relays and fuel pump action?
 Relay does not actuate voice: check whether the relay is bad or line anomalies?
 Fuel pump does not actuate voice:
Measurement:
Fuel pump DCV Red line Black line 12V 0V
1. Check that the relay is normal?
NOTE:
Turn the main switch within 4 seconds
measurement，
more than four seconds, the ECU
controlled fuel pump relay to turn the
power off。
2.Check the line for open circuit?
Ω Black line ECU(Green Line) turn on ∞
1.Check the line for open circuit?
1.Line is normal and 12V
Voltage!
Check the ECU is normal?
2) The battery is connected directly across to the fuel pump, check for rotation?
 No Action: Replace the fuel pump
3) Use the Fuel pressure gauges,check whether the gasoline pump 3kgf/cm2
2. The rest of the circuit system check with the same ignition system。
13-10 Fuse Description

1A:12V supply switch fuse
10A:Headlight fuse
15A: Main fuse
Note:
1.Fuse replacement in accordance with the original specifications.
2.Consecutive blown fuse, check the main wiring or electrical components
short circuit caused by undesirable phenomena.
13-11 Engine stop switch
Check the process:

Project Handle
1. Battery (check the voltage)
12V- Please replace or recharge
2.Fuse:(check 15A)
∞-Replace
3.main switch (KEY ON): Check the line color: Red / White (12V)→ orange (12V)
Red / white, orange = 0V to replace the ingition
switch Or line barrier.
4. Engine stop switch: ON＞orange (12V)，Orange / Black (out)12V
orange：0V- line barrier。
ON＞Orange / Black：0V- Replace righ haft switch.
Start relay non-functioning
ECU 11PIN(O/B) ＞OV ，ECU no signal (KEY ON) Input
Injection system does not work, the motorcycle would
not start。
( Repeat check)
Injection system diagnosis-14
PGO EMS Diagnostic Software Operation Manual
Vehicle Type :
● A1
● F7
● J3
● PAH
SENTEC E&E Co., Ltd.
Diagnostic Software
Operation Manual V01
Hardware Connection
Use USB cable to connect your PC with Diagnostic Tool.

Use K-Line to connect Diagnostic Tool with Diagnostic Connector on the vehicle.
PC Diagnostic Tool Vehicle Diagnostic Connector
K-Line
USB cable Wire Harness
Software Installation
Step1: Install USB driver, in folder English\CP2102 Driver

Execute the installation file“ CP210x_VCP_Win_XP_S2K3_Vista_7.exe ”
please refer to “CP210x USB Driver Installation.pdf”.
Step2: Copy “PGO EMS DIAG Software” folder (in English folder) in the CD
to your PC hard disc (eg. C:\ or D:\)
This folder should contain following files:

PGO EMS DIAG Software.exe
Set_Limits.exe
Default_Sales_Limits.ini
Sales_Limits.ini
(after executed the software it will create Config.ini and Records folder)
Step3: Right click the file “PGO EMS DIAG Software.exe”,

and choose “Send To” “Desktop As Shortcut”.
You can get a software shortcut on your computer desktop.
Execute Software
Double click the file “PGO EMS DIAG Software.exe” or it’s shortcut on the desktop.
Click the square icon in the upper right corner to maximize the window.
The program screen shows as below:
Connect to ECU
Please turn key on, select correct Vehicle Type and Com Port,
then click “Start Connection”
1. Press “Vehicle Type”,there are 4 vehicle type options (A1,F7,J3,PAH)
Please select the vehicle type name connecting with the diagnostic tool.
Please don’t change vehicle name under diagnostic process.
2. Press “Select Com Port” it will list available Com Ports of your PC.
Select the Com Port number connected with diagnostic tool.
The Com Port is the COM number of computer connected with diagnostic tool.
You can open the computer’s Device Manager to check the COM Port (Note).
You can also select a number in the list, then click “Start Connection” to test
If the number selected is correct.
(Note): Please check Start →Control Panel →System →Hardware →
Device Manager →Ports(COM and LPT)
Click (+) to expand. Find Silicon Labs CP210x USB to UART Bridge
(COMx) where x is the COM number.
3. Click “Start Connection”. If the connection is successful, then the rectangle

at left side of button will show green color. Please repeat steps 1~3 if click several
times “Start Connection” but can not get connection.
“Connect”page
If connection is successful, the“Connect”page will show ECU Identification,
Including ECU Software No, System Name and Part No.
“Troubles”page
Press “Troubles” it will show “Current Trouble Codes” (the malfunctions existing
now detected by ECU) and “History Trouble Codes” (the malfunctions which have
occurred and saved in ECU memory).
Trouble codes include: the number with P as head, malfunction name and status.
Format = P-Code + Name + (Status)
Status description:
No fault: No malfunction detected by ECU
Above maximum threshold: Open circuit or short to battery voltage
Below minimum threshold: Short to ground
No signal: No signal detected by ECU
Invalid signal: With signal, but abnormal
These codes help you to indicate problems of the system.

After you have repaired these problems, you can click “Clear History” and reply
“Yes” to erase all the “History Trouble Codes” in the ECU memory.
List of “Trouble Codes” (A1,F7,J3 Vehicle type)
Trouble
No. Malfunction name
codes
1 P0107 Manifold Absolute Pressure 1
2 P0108 Circuit abnormal
3 P0112 Intake Air Temperature Sensor

5 P0117 Engine Temperature Sensor

7 P0122 Throttle Position Sensor A

9 P0130
10 P0131 Oxygen Sensor Circuit
11 P0132 abnormal
12 P0134
13 P0201 Injector 1 abnormal
14 P0261
Injector 1 Circuit abnormal
15 P0262
16 P0321 Engine Speed Input Circuit
17 P0322 abnormal
18 P0508 Idle Speed Control System

19 P0509 abnormal
Idle Speed Control Circuit

20 P0511
abnormal
21 P0560
22 P0562 Battery Voltage abnormal
23 P0563
Warning Light (Malfunction
24 P0650 Indicator Lamp) Control Circuit
abnormal
List of “Trouble Codes” (PAH Vehicle type)

Trouble Malfunction name
codes
P0105 Manifold Absolute Pressure 1 Circuit abnormal
P0110 Intake Air Temperature Sensor Circuit abnormal
P0115 Engine Temperature Sensor Circuit abnormal
P0120 Accelerator Handle Position Sensor A Circuit
abnormal
P0130 Oxygen Sensor Circuit abnormal
P0135 Oxygen Sensor Heater Circuit abnormal
P0201 Injector 1 abnormal
P0217 Engine Over Temperature
P0219 Engine Over Speed
P0220 ETC Throttle Position Sensor B Circuit abnormal
P0225 ETC Throttle Position Sensor C Circuit abnormal
P0230 Fuel Pump Circuit abnormal
P0335 Crankshaft Position Sensor Circuit abnormal
P0351 Ignition Coil 1 Circuit abnormal
P0505 Idle Speed Control System abnormal
P0560 Battery Voltage abnormal
P0615 Start Motor Relay Circuit abnormal
P0650 Warning Light (Malfunction Indicator Lamp) Control
Circuit abnormal
P0654 Engine RPM Output Circuit abnormal
P1110 Kill Switch On
P1550 Main Relay Abnormal
P1560 System Voltage(5V) abnormal
P1571 Key Switch Signal abnormal
P1654 Signal Frame Error
P1A17 Wheel Motor abnormal
P2100 Electronic Throttle Control Circuit abnormal
“Data”page
Column width can be adjusted by mouse
Adjust Row height: Select any item, then press “+” key to increase row height
Or press “-” key to decrease row height.
Press “Data”,it will show data items from ECU, and show each data’s lower limit
and upper limit. If the value of data is lower than lower limit or higher than upper
limit, then the value’s color will turn red.
(If you need to change lower or upper limit, you can first execute Set_Limits.exe
program to modify, then execute the diagnostic software.)
Record function
Check “Record Data”, it will record all data items on Data Analysis table
in the “Record” page every 0.5 Sec.
It will record data only at “Data” or “Chart1” or “Chart2” or “Record” pages.
“Chart1”page
Press“Chart1”to show 4 common data’s change with time.
“Chart2”page
“Chart2”also shows 4 common data’s change with time.
Record page
Press “Record” the “ECU Identification and Trouble Codes” window will record
“Connect” page’s ECU identification information and “Troubles” page’s all
malfunction information.
※Note: You need to select “Connect” and “Troubles” pages first.
The “Data Analysis” table will record “Data” page’s all the data items’ values.
※Note: You need to check “Record data”, and it will record data only at “Data”
or “Chart1” or “Chart2” or “Record” pages.
Record page
Press “Save” it will save data to “Records” folder using present date time as file name.
Save as type (extension name) is “csv” file, which can be opened by Excel program.
If you want to diagnose another vehicle or to have new records,

Please press “Clear Data”, reply “Yes”, it will clear all information
On Record page.
Calibration page (PAH vehicle type)

Note:
1.A1,F7,J3 vehicle type does not need calibration on this page.
2.When you start one calibration function (eg. TPS Calibration), You need to
complete this calibration (Save or Abort it), then to start another calibration
(eg. Idle CO adjustment).
Throttle Position Sensor (TPS) Calibration

On “Calibration” page select “TPS” page
1. Make sure engine is stopped, and turn on the key.
2. Press “Start”.
3. Open throttle fully (turn accelerator handle to the end) , then close throttle completely.
4. Press “Save” to save the TPS calibration data in ECU memory. The message box
below will show “TPS calibration completed” ,i.e. TPS calibration has completed.
5.If you do not want to save this calibration result, press “Abort” to quit calibration.
The message box below will show “Abort TPS calibration”. ECU still use last time
calibration value.

Idle CO Adjustment
On “Calibration”page select “Idle CO” page

1.Warm up engine in idle condition.
2.Press “Start”.The Idle CO adjustment (uSec) block will show current Idle CO
adjustment amount stored in ECU.
Press big to increase idle injection pulsewidth by 16 uSec.
Press small to increase idle injection pulsewidth by 4 uSec.
Press big ⊳ to decrease idle injection pulsewidth by 16 uSec.
Press small ⊳ to decrease idle injection pulsewidth by 4 uSec.
3.After you have adjusted idle injection pulsewidth to reach desired CO emission,
then press “Save” to save the adjustment in memory of ECU
4.If you do not want to save this calibration result, press “Abort” to quit calibration.
-16 -4 +4 +16 uSec


ETC Reset
On “Calibration” page select “ETC” page
1. Make sure engine is stopped, and turn on the key.
2. Press “Start”.
3.ECU will perform ETC throttle position sensor calibration automatically.
4.Press “Confirm”, then ETC reset is completed.
“Messages” page shows the “Diagnostic Software” version.
Quit Software
Click “Quit” and reply “Yes” to quit the Diagnostic Software.
Note: Before quit, if there is record data, please save file
On “Record” page.
Diagnostic Software
Operation Manual V01
DIGITAL METER
INSTRUCTION PANEL
FUEL INDICATOR
RH TURN SIGNAL LAMP
LH TURN SIGNAL LAMP
HI LAMP INDICATOR
12V-5W 12V-55W/60W
SIGNAL LAMP SWITCH RH STARTING SWITCH HEAD LAMP SWITCH
FRAGILE STICKER
HEAD LAMP
DIMMER SW START SWITCH HAZARD SWITCH

HORN SWITCH O Dg Y
O LH STARTING SWITCH B G/W B P Bl/W Br
O B Lb O/B
Br B O
B P
Gr/B Br/W W
G/Y Dg
O/B Lb O B
Dg Bl
O O P Br O Dg Y
Y Bl Br/W
Bl/W G/W
Br/W
Bl/W R/W
W/Bl R Y/B
G/Y
ECU Pin26 SENSOR Y
DC12V
HORN
B
12V-2W
Br RH FR SIGNAL LAMP
B
O
FLASHER RELAY
12V-2W P Bl/W
B
LH FR SIGNAL LAMP
B
MAIN SWITCH
DC12 Lb
G/W
STARTER RELAY
O
Bl/B BALANCE SWITCH
Y
W/R W/R R/W
GENERATOR
B PUMP & SENSOR FUEL PUMP RELAY
Y
Y O
ANTITHEFT
O/B
ECU Pin11
Y STARTER
Y
Y
57 R/W
R BATTERY
VOL REGULATOR R/W
54
B B
Gr/B
FUEL GAUGE B
P Lb Dg Br
B
B
R/W FUSE
12V POWER
B
LH REAR LAMP RH REAR LAMP
12V-2W 12V-2W 12V-2W
TAIL LAMP
12V-5W

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Bu

WIDTH 710 mm 28 in 1ST REDUCTION 0.75~2.6

HEIGHT 1060 mm 41.75 in 2ND REDUCTION 47/17*47/15=8.66

WHEEL BASE 1215 mm 47.8 in CLUTCH CENTRIFUGAL

FRONT 41 kg 90.40 lbs GEARBOX C.V.T.

REAR 62 kg 136.70 lbs FRONT 90/90-10

RIDERS 2 up to 150kg / 330 lbs FRONT DISK

FRONT 83 kg 183 lbs REAR DISK

REAR 170 kg 375 lbs SPEEDOMETER 140 km/hr 87 mi/hr

TOTAL 253 kg 558 lbs HEADLAMP 12V-35W/35W

FUEL CONSUMPTION 42 km/L 98.8 mpg BRAKE LIGHT 12V-2W

HILL CLIMB 25°↑ SIGNAL LIGHT 12V- 2W/12V-2W

TYPE J1 HORN DC 12V

FUEL 92 UNLEADED MUFFLER C-D ABSORPTION

CYCLE/COOLING 4T / FORCE D AIR&OILCOOL EXHAUST DIRECTION RIGHT & BACKWARD

BORE 54 mm LUBRICATION COMPRESS & SPLASH

NUMBER SINGLE P. C. V. YES

DISPLACEMENT 124.8 cc CATALYST YES

COMPRESSION RATIO 10.1：1 S. A. I. YES

MAX POWER 8.0kW / 10.73hp @ 8250rpm STARTER ELECTRIC

MAX TORQUE 9.5N-m / 7 ft-lbf @ 6750rpm IGNITION TRANSISTOR

ARRANGEMENT HORIZONTAL FUEL TANK 5.5L 1.45 gal

NOTE FUEL SUPPLY：INJECTION

Classification Item Page

Installation or Removal of External Components 2 28~40

Engine disassembly 6 111~116

Cylinder combination 8 127~135

HEAD LIGHT COVER

REAR TURN SIGNAL (R/L)

FRONT BRAKE CALIPER SIDE STAND

BODY COVER WINDSHIELD

MUFFLER OUTER FORK TUBE ASSY

REAR BRAKE CALIPER

Number Type Number Type

3 ECU 4 MAIN / FUEL RELAY

7 HORN 8 TOPPLE SWITCH

9 MAIN SWITCH 10 FUSE

11 RECTIFIER 12 FUEL GUAGE

13 FUEL PUMP 14 THROTTLE BODY

J1F00000 125 C.C

1-4-1 Directions for maintenance of the Engine Management System (EMS)

1) Directions for General Maintenance

1-6 Service tools

4. Clutch compression tool 5. Clutch Fixator 6. feeler gauge

7. Bearing Striking Tools 8.Cylinder pressure gauge 9. Test line group

25. Oil seal removal tool - Large

Make sure the engine trouble indicator light is functioning normally;

(1) Check for any fuel hose leakage.

(2) Engine running but stalling during start-up

Procedure for general diagnoses:

(3) Difficulty starting when hot

Yes Next step

2 Yes Next step

Yes Replace fuel.

Yes Next step

Procedure for general diagnoses:

Yes Next step

NO. function Description

2) Refer to the circuit diagrams for any troubleshooting or maintenance.

2-1 Removal of the exterior body parts