Benelli TNT 600: Service Manual

Benelli TNT 600
Service Manual
BENELLI KEEWAY MOTORCYCLES SDN. BHD.

0
Contents
Preface ..................................................................................................................................................................... - 1 -
Preparing Documents ............................................................................................................................................... - 2 -
General Safety .................................................................................................................................................. - 2 -
Maintenance Rules .......................................................................................................................................... - 3 -
Specification .................................................................................................................................................. - 13 -
Failure Diagnosis............................................................................................................................................ - 15 -
Inspection/Adjustment ................................................................................................................................... - 21 -
Inspection and Maintenance of the Electrical System ........................................................................................... - 41 -
1. Battery/Charging System ................................................................................................................................... - 42 -
1.1 Preparing Documents............................................................................................................................... - 42 -
1.2 Failure Diagnosis...................................................................................................................................... - 43 -
1.3 Battery ..................................................................................................................................................... - 44 -
1.4 Charging System ...................................................................................................................................... - 45 -
1.5 Voltage/Current Regulator ........................................................................................................................ - 46 -
1.6 Magnetor Charging Coil............................................................................................................................ - 46 -
1.7 Magnetor Disassembly............................................................................................................................. - 47 -
2. Ignition System................................................................................................................................................... - 50 -
2.3 Ignition System Check ............................................................................................................................. - 52 -
2.4 ECU Unit ................................................................................................................................................... - 53 -
2.5 Ignition Coil .............................................................................................................................................. - 54 -
2.6 Sensor of the Crankshaft ......................................................................................................................... - 54 -
3. Starting System .................................................................................................................................................. - 56 -
3.3 Starter Motor ............................................................................................................................................ - 57 -
3.4 Starter Relay ............................................................................................................................................ - 59 -
4. Bulbs/ Switches / Meters ................................................................................................................................... - 61 -
4.3 Replacement of Headlamp Bulbs ............................................................................................................. - 62 -
4.4 Replacement of Front Position Lamp Bulbs ............................................................................................. - 63 -
4.5 Replacement of Tail Lamp ........................................................................................................................ - 64 -
4.6 Replacement of Rear Registration Plate Lamp Bulbs .............................................................................. - 65 -
4.7 Replacement of Front Steering Lamp Bulbs ............................................................................................ - 66 -
4.8 Replacement of Rear Steering Lamp Bulbs ............................................................................................. - 66 -
4.9 Meters ...................................................................................................................................................... - 66 -
4.10 Main Switch ........................................................................................................................................... - 67 -
4.11 Horn ....................................................................................................................................................... - 67 -
4.12 Handlebar Switch ................................................................................................................................... - 68 -
Inspection and Maintenance of the Motorcycle Body............................................................................................. - 69 -
1
5. Brake .................................................................................................................................................................. - 72 -
5.1 Maintenance Instruction .......................................................................................................................... - 72 -
5.3 Front Disc Brake....................................................................................................................................... - 75 -
5.4 Rear Disc Brake ....................................................................................................................................... - 79 -
6. Body ................................................................................................................................................................... - 83 -
6.1 Disassembly ............................................................................................................................................. - 83 -
6.2 Assembly .................................................................................................................................................. - 83 -
7. Front Wheel/Handlebar/Front Suspension.......................................................................................................... - 87 -
7.3 Front Wheel .............................................................................................................................................. - 89 -
7.4 Steering Handlebar .................................................................................................................................. - 94 -
7.5 Front Fork................................................................................................................................................. - 96 -
8. Rear Wheel/Rear Suspension ........................................................................................................................... - 100 -
8.1 Preparing Documents............................................................................................................................. - 100 -
8.2 Failure Diagnosis.................................................................................................................................... - 100 -
8.3 Rear Wheel ............................................................................................................................................. - 101 -
8.4 Rear Absorber ........................................................................................................................................ - 105 -
8.5 Drive Chain ............................................................................................................................................. - 106 -
8.6 Rear Swinging Arm ................................................................................................................................ - 108 -
9. Fuel Tank .......................................................................................................................................................... - 111 -
9.1 Preparing Documents............................................................................................................................. - 111 -
9.2 Failure Diagnosis.................................................................................................................................... - 111 -
9.3 Fuel Tank ................................................................................................................................................ - 112 -
10. Disassembly and Installation of Engine .......................................................................................................... - 114 -
10.1 Preparing Documents........................................................................................................................... - 114 -
10.2 Disassembly of Engine ......................................................................................................................... - 114 -
10.3 Installation of the Engine ..................................................................................................................... - 120 -
Inspection and Maintenance of Engine ................................................................................................................ - 121 -
11. Lubricating System......................................................................................................................................... - 122 -
11.2 Failure Diagnosis.................................................................................................................................. - 122 -
11.3 Oil Pump ............................................................................................................................................... - 123 -
12. Cylinder Head ................................................................................................................................................. - 128 -
12.3 Cylinder Head ....................................................................................................................................... - 130 -
13. Crankcase....................................................................................................................................................... - 138 -
13.3 Upper Case ........................................................................................................................................... - 141 -
13.4 Piston ................................................................................................................................................... - 142 -
13.5 Lower Case .......................................................................................................................................... - 147 -
13.6 Clutch ................................................................................................................................................... - 151 -
2
13.7 Gearshift Mechanism ........................................................................................................................... - 154 -
13.8 Crankshaft Connecting Rod Assembly Chamber and Variable Speed Chamber ................................... - 157 -
14. Cooling System............................................................................................................................................... - 163 -
14.3 Water Pump .......................................................................................................................................... - 164 -
Inspection and Maintenance of Exhaust Emission System .................................................................................. - 167 -
15. Exhaust Emission & Control System............................................................................................................... - 168 -
15.1 Warranty on the Exhaust Emission & Control System .......................................................................... - 168 -
15.2 Instructions on Periodic Maintenance .................................................................................................. - 169 -
15.3 Mechanical Function of the Exhaust Control System ........................................................................... - 169 -
15.4 Catalytic Transfer System .................................................................................................................... - 170 -
15.5 Measures When the Idle Speed Emission Value Exceeds the Standard ............................................... - 172 -
Inspection and Maintenance of Electronic Fuel Injection (EFI) System ................................................................ - 173 -
16. Electronic Fuel Injection System .................................................................................................................... - 174 -
16.1 Introduction of Electronic Fuel Injection System.................................................................................. - 174 -
16.2 Components of Electronic Fuel Injection System ................................................................................. - 174 -
16.3 Methods for Fault Diagnosis and Maintenance .................................................................................... - 187 -
16.4 Common Fault Removal Techniques .................................................................................................... - 197 -
TNT 600 Circuit Diagram ...................................................................................................................................... - 202 -
3
Preface
This service manual is used for operating and maintaining the TNT 600.
Preparing Documents include all necessary instructions and statements. Please read carefully
this manual before operation.
Inspection & Adjustment states how to check and adjust your motorcycle. All safety rules and
maintenance regulations shall be carried out from the beginning of periodic inspection.
Except for Chapter I, the rest chapters explain the disassembly/ assembly/ inspection of
Electronic Fuel Injection System, engine, entire motorcycle and electrical equipment.
Breakdown drawing, systematic drawing, failure analysis and statements are contained at the
first part of each chapter.
Please note that photos, pictures or instructions are for your reference only. The actual object
may differ from what is mentioned here. We will not make any notification for any discrepancy.
- 1 -
Preparing Documents
1. General Safety
2. Maintenance Rules
3. Specification Table
4. Inspection/Adjustment
1. General Safety
Carbon monoxide
Engine must be started up in a well-ventilated place, not in a closed area.
Note
Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human.
Start engine in an open place. The exhaust ventilating system shall be adopted if the engine is started up in a
closed area.
Petrol
Ventilation is required for working places. Naked fire is strictly forbidden in any working place or where petroleum
is stored.
Battery
Battery emits explosive gas. Therefore, it should be distance away from fire sources, naked flame or smoking. Make
sure good ventilation during charging.
Battery contains sulfuric acid (electrolyte). It will burn your skin or eyes when contacted. Therefore, wear protective
clothing and mask.
Clean with fresh water immediately if electrolyte splashes on the skin.
Clean with fresh water at least for 15 minutes immediately and then go to the doctor if electrolyte splashes
on eyes.
- 2 -
Electrolyte is poisonous. Drink a large quantity of fresh water, milk, milk of magnesia (laxative antacid) or mineral
oil if electrolyte is swollen accidentally. Seek doctor advice immediately.
Lubricating and Fuel
It may trigger cancer if repeatedly expose the hands in the air after contacting with oil. Although there is little
possibility for you to contact with oil in the daily life, wash hands thoroughly with water and soap if you have
contacted.
Thermal Energy
Parts of the engine and cooling system produce heat, which can last for some time before the engine gets started.
Wear protective when handling such heated items.
2. Maintenance Rules
Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage.
Clean up the surface of components or assembly parts before removing or opening the body cover for maintenance,
which can prevent dirt from falling into the engine, the chassis or the braking system.
Wash and dry parts with air compressor after disassembly and for
measurement.
Solvent or oil can easily damage rubber parts. Check rubber component
before reassembly and replace if necessary.
When removing assembly parts, please start form outside to inside. Small
assembly parts shall be loosened first.
Complex assembly parts, such as gearbox, shall be stored in proper order for
facilitating reinstallation.
Please specially note important steps before disassembly. Replacement parts

which will not be in use before disassembly.
- 3 -
Bolts and screws with different length shall be separately used for different
assembly parts and shields, and they shall be correctly mounted. Insert a bolt
into a hole to check whether it is of proper length.
Fill the groove with grease before mounting an oil seal. Check whether the oil
seal is smooth or damaged during assembly.
When installing a rubber hose (fuel, vacuum or cooling agent), insert its end
into the bottom of the connector so that the hose clip can properly fix the
connector. Rubber or plastic dirt-proof boot shall be mounted at the original
design position.
During dismantling ball bearings, one or two (inside & outside) bearing rollers
shall be supported by tools. Ball bearings may be damaged during
disassembly and have to be replaced if only one roller (either inside or outside)
is imposed with force.
- 4 -
Loose cables may affect proper electrical flow. Check each
cable after it is clamped to another for electrical safety;
Wire clamps are not allowed to bend towards welding point;
Bind cables at the designated place;
Do not deploy cables at the end of frame or at sharp point;
Do not deploy cables at the end of bolts or screws;
Cable deployment shall be far from heat source and where
cables may be clamped during moving;
Cables along the handlebar shall be neither too tight nor too
loose, and do not interface with any neighboring parts at
steering positions;
Cables shall be properly deployed without twist or knot;
Check whether the connector jacket is damaged and whether
the connector is over-stretched before mounting connectors;
Adopt adhesive tape or hose to protect cables if they are
positioned at sharp point or corner;
Bind cables with tape after repairing;
Control cables shall not be bent or twisted. Clumsy operation
may be caused in light of damaged control cables.
- 5 -
Identification
1The frame number, see figure
Frame Number
Frame
2Rivets of the frame sign and the frame, see figure
Frame Number Rivets
3The serial number of the engine, see figure

Engine Number
Significant Notes
1. Please insist genuine parts and accessories. Any part or accessory not in accordance with the design
specification may cause damage to engine.
2. Only metric tools are valid for maintenance and repair. Metric screws, bolts and nuts must always be used.
3. New gaskets, O-rings, cotter pins and locking pieces shall be used for re-assembly.
4. Bolts with large diameter or positioned inside shall be fastened first and then diagonally screw down until
reaching required torque.
5. Clean disassembled parts with cleanser. Lubricate all sliding surface before assembly.
6. Check whether all the parts and accessories are correctly mounted and operated after assembly.
7. Clean and remove oil before measurement. Add recommended lubricant to the lubricating areas during
assembly.
8. Apply lubricant to the surface of engine and driving system if they are dismantled for long-term storage,
which can prevent rust and dirt.
- 6 -
Special Tools
Special tools refer to tools which are specially designed for assembling or disassembling some motorcycle
parts on special positions. Applicable special tools are necessary for precise adjustment and installation. With them,
parts and accessories can be mounted safely, reliably and rapidly, which improves efficiency and saves energy.
1. Tools for repairing the engine
Special tools are required for properly disassembling/assembling some engine parts.
Table and drawing (1-1, 1-2) of special tools for disassembling/assembling engine parts are as follows:
Table 1-1
Name Remark
Special socket spanner Used for assembling/disassembling bolts for flywheels, Fig. 1-3
Clutch clamp holder Fig.1-4
Flywheel puller Fig. 1-4
Feeler gauge Fig. 1-5
Bearing disassembly tools Fig. 1-6
Bearing assembly tools Fig. 1-7
Oil seal remover Fig. 1-8
Handle for dismantling tools Fig. 1-9
Piston pin pulling device Fig. 1-10
Piston pin pliers Fig. 1-11
Socket spanner for spark plug Fig. 1-12
Clutch thickness measuring device Fig. 1-13
Cylinder diameter measuring device Fig. 1-14
Dial indicator Fig. 1-15
Dial indicator, V-block Measuring the inner diameter of the piston pin, Fig. 1-16
Dial indicator For measuring the bending of the valve rodFig. 1-17
Assembly/disassembly tool for valve catheter For measuring the external diameter of the valve rodFig. 1-18
Assembly tool for valve catheter Fig. 1-19
Adjustment tool for valve space Fig. 1-20
Assembly/disassembly tool for valve spring Fig. 1-21
Valve catheter reamer Fig. 1-22
Disassembly tool for crankcase Fig. 1-23
Fig. 1-24
Table 1-2 (continued)
Fig. 1-3 Fig. 1-4
- 7 -
Fig. 1-5 Fig. 1-6
Fig. 1-7 Fig. 1-8
Fig. 1-9 Fig. 1-10

handle
Fig. 1-11 Fig. 1-12 pliers piston
- 8 -
Fig.1-13 Fig.1-14
Fig. 1-15 Fig. 1-16
Fig. 1-17 Fig. 1-18
Fig. 1-19 Fig. 1-20
Fig. 1-21 Fig. 1-22
- 9 -
Fig. 1-23 Fig. 1-24
2. Tools for repairing the chassis
Table and drawing (1-25, 1-26) of ordinary tools and special tools for disassembling/assembling chassis
parts are as follows:
Fig. 1-25
Name Remark
Torque spanner Fig. 1-27
Inner hexagon spanner Fig. 1-28
Socket spanner Fig. 1-29
Micrometer Fig. 1-30
Magnetic rack, V-block Fig. 1-31
Dial indicator Fig. 1-32
Vernier calipers Fig. 1-33
Circlip pliers Fig. 1-34
Screwdriver with striking cap Fig. 1-35
Tool for assembling oil seal of front fork Fig. 1-36
Tool for hammering seal of front fork Fig. 1-37
Steering nut spanner Fig. 1-38
(1) Ordinary tools for repairing the chassis
Table 1-26 (continued)
Fig. 1-27 Fig. 1-28
Fig. 1-29 Fig. 1-30
- 10 -
Fig. 1-31 Fig. 1-32
Fig. 1-33 Fig. 1-34
Fig. 1-35 Fig. 1-36

(2) Special tools for repairing the chassis: tool for hammering seal of front fork
Fig. 1-37
(3) Steering nut spanner
Fig. 1-38
- 11 -
3. Tools for electric parts
Table and drawings (1-39, 1-40) of special tools for testing electric parts are as follows:
Fig. 1-39
Name Remark
Multimeter Fig. 1-41
Ignition tester Fig. 1-42
Fig. 1-40 (continued)
Fig. 1-41
Fig. 1-42
- 12 -
Specification
Motorcycle Model TNT 600 Engine Type BJ465MS-A
Length mm 2155 Fuel type Unleaded petrol95/97
Width mm 765 No. of cylinder 4
Height mm 1100 ID stroke 65.045.2
Wheelbase mm 1480 Engine Total displacement 600cc
Petrol tank capacity 15L Startup Electric
Forward 115 Cooling Liquid cooling

Weight kg
Back shaft 105 Lubrication Pressure splash lubrication
(Curb weight)
Total 220 Clutch type Wet multi-plate
Front tire 120/70 ZR Variable speed Six variable speed

Tire Size
Rear tire 180/55 ZR Transmission Chain
Primary
Battery capacity 12V-9AH 1.864
transmission ratio
Transmission ratio
Magnetor Flywheel permanent magnet 2.846
of gear 1
Electric Transmission ratio

Spark plug CR9E(NGK) 1.947
devices of gear 2
Transmissio Transmission ratio

Spark plug gap 0.6-0.7mm 1.556
n devices of gear 3
Transmission ratio
Ignition TLI 1.333
of gear 4
Transmission ratio
Max. Hp 60.0kW/11000rpm 1.190
of gear 5
Transmission ratio
Max. torque 52N.m/8000rpm 1.083
of gear 6
Final Transmission
Compression ratio 11.51 3.286
ratio
Performance
Dia. of front liquid
Max. speed 185km/h 320mm
brake discmm
Brake
Fuel consumption Dia. of rear liquid

5.2L/100km 240mm
limit brake discmm
- 13 -
TNT600
- 14 -
Failure Diagnosis
Diagnosis on difficulty or failure in starting up
Failure Diagnosis Adjustment & Inspection Causes of Failure
Check if petrol
pump is working No petrol in the tank
properly Oil tube of fuel injector blocked
Oil tube of petrol pump blocked
Tube of combustion chambers
Oil provided to fuel No petrol Evaporation Control System
injector is sufficient provided to blocked
and smooth fuel injector Petrol air filter blocked
Low oil pressure of petrol pump
Disassemble spark Abnormal spark plug
plug into its cap, Polluted spark plug
ground it with engine Abnormal CPU group
to check if it can spark Abnormal trigger
Open circuit or short circuit of
ignition coils wire
Spark-over Weak sparks
No Open circuit or short circuit of
ignition coil
Abnormal main switch
Test compression pressure Abnormal charging coil
Abnormal clutch for startup
Abnormal piston of cylinder and

Normal Too low piston ring
No
Leakage of cylinder gasket
Abnormal automatic choke

actuation
No ignition Ignition outbreak
outbreak of of the engine but
Intake manifold with air
the engine no sign of startup
Incorrect ignition time
Disassemble once agian the Abnormal adjustment to throttle

spark plug to check valve and bolt
Excessive oil injected to fuel

Dry spark plug Wet spark plug injector
Abnormal automatic choke
actuation
Throttle opens too large
- 15 -
Unsmooth gyration (No speed or weak speed)
Failure diagnosis Adjustment specification Causes of failure
Start engine with

soft refueling Air filter blocked
Abnormal petrol
accelerated Engine cannot Tube of combustion chambers
gyration speed fully speed up Evaporation Control System
of engine blocked
Exhaust pipe blocked
Adjust ignition timing and Abnormal automatic choke
use ignition timing light Abnormal throttle valve
Correct
Incorrect ignition Abnormal CPU group
ignition time
time
Abnormal trigger
Test compression pressure
Abnormal piston of cylinder and

piston ring
Normal Too low
Leakage of cylinder gasket
Blocking check to Carburetor
No Yes Contaminant removal
Disassemble the spark plug to

check
Contaminant removal
No pollution nor Polluted and
discoloration discolored Heat value of spark plug does
Check oil level in crankcase not conform
if it is high or polluted
Excessive oil
Normal High oil level Insufficient oil
No replacement of oil
Check the lubrication of
cylinder head
Normal Abnormal Abrasion in piston cylinder
Overheated engine Mixed gas too thin
Abnormal petrol
Too much carbon fouling in the
Yes No combustion chamber
Earlier ignition time
Accelerated driving or Too much carbon fouling in the
running combustion chamber
Abnormal petrol
Engine knock No engine knock Clutch slipping
Thin mixed gas
Earlier ignition time
- 16 -
Unsmooth gyrationespecially in low speed
Adjust ignition time
Abnormal CPU group
Normal Abnormal
Abnormal trigger
Adjustment to throttle valve and

bolt
Mixed gas too thin (loosen bolt)

Good Bad
Mixed gas too dense (tighten
bolt)
Spacer inhaled air or not
Abnormal spacer of heat

insulation piece
Throttle valve fixed, bolt
Yes No loosened
Heat insulation piece ruptured
Negative pressure pipe ruptured
Disassemble spark plug

into its cap and ground it
with engine to check if it
Spark plug abnormal or polluted
can spark
Abnormal CPU
Abnormal ignition coil
Good Bad spark-over
Open circuit or short circuit of
spark-over
spark plugs wire
Negative pressure pipe damaged

Good Bad
Air pass-hole blocked
- 17 -
Unsmooth gyration (high speed)
Adjust ignition time
Abnormal CUP group
Normal Abnormal
Abnormal trigger
Little oil in petrol tank

Petrol filter of the pipe blocked
Normal Abnormal
Tube of combustion chambers
Evaporation Control System
blocked
Blocked oil injector Abnormal automatic oil ring
No Blocked Remove
Good Spring broken

Weak elasticity Abnormal spring
- 18 -
Poor battery charging (over discharge or over charge)
Test the voltage of

batterys two ends, and
stat engine
Battery used up
No voltage rise Voltage rises to normal

value, and back to
original voltage value Poor battery
after flameout
Check the plug of voltage

regulator if it is loose
Poor connection of the plug

Normal Abnormal
Open circuit of the red wire of
the charging wire
Check if the red wire of voltage regulators

socket connects the multimeter, while
anode and cathode wire to the voltage
between parts of the body
Voltage regulator
Voltage No voltage
available Open circuit of the white wire of
the charging wire
Test the resistance value of

alternators coil
Abnormal coil
Normal Abnormal Poor connection of the joint
Open circuit of alternators
white wire
Poor battery
Poor battery charging
Overcharging Start the engine, connect the red wire of the
voltage regulators socket to the multimeter,
while anode and cathode wire to the voltage
between parts of the body
Voltage above Normal voltage

normal value
Check if charging wire of the voltage

regulator connects well
Loose
Normal Poor connection of the joint and
Bad connection
Use monomer of the voltage regulator
to test impedance charging wire to the ground
Abnormal voltage regulator
- 19 -
No spark-over of the spark plug
Replace on new spark

plug and check again
Weak spark-over or Strong spark Original spark plug abnormal

no spark-over
Check again after

checking spark plug
No sign of loose Loose

Spark plug cap loose
Check plugs of CDI group if they

are loose
Normal Abnormal
Bad connection of the plug
Check conduction between terminals
of CDI groups plugs, and test
resistance value
Abnormal charging coil
Normal Abnormal
Abnormal trigger
Check relevant parts
Normal Abnormal
Breakage of main wire
Bad connection of the plug and
socket
Use CDI tester to check CDI group
Normal Abnormal Abnormal CPU group
Use CDI tester to check ignition coil
Abnormal
- 20 -
Inspection/Adjustment
1. Preparing information
2. Periodic Maintenance & Inspection Table
3. Engine oil/ Oil filter
4. Liquid coolant
5. Assembly / Disassembly of the Clip of the Radiators Hose
6. Fuel Injector and Oil-route
7. Throttle Cable Adjustment
8. Air filter
9. Spark plug
10. Battery
11. Fuse replacement
12. Cylinder Compression
13. Drive Chain Free Play
14. Front Brake Free Play
15. Free play of rear brake
16. Headlamp
17. Clutch
18. Front/rear suspension system
19. Bolt/nut/fastener
20. Wheel/tire
21. Fixing steering stem bearing & handlebar
22. Throttle Body
23. Components to Lubricate
1. Preparing Information
General
Warning!
Make sure that it is well ventilated before starting the engine. Do not start the engine in a closed area Exhaust
gas, which contains monoxide, may cause unconsciousness or even death.
Petrol is liable to volatile or exploded under certain condition. Ventilation is required. Fire is strictly forbidden
in working areas or where oil is stored.
- 21 -
Specification
Engine
ID stroke 65.045.2
Total displacement 600cc
Ignition TLI
Spark plug gap 0.6-0.7mm
Spec. of spark plug CR9E(NGK)
Type of combustion chamber spherical
Frame
Free play of front brake lever 10-20mm

Free play of rear brake pedal 20-30mm
Specification Tire pressure
Tire pressure unitkpa Front tire 120/70 ZR 17 25010kpa
TNT 600
Rear tire 180/55 ZR 17 29010kpa
Fixing front wheel
100-140 Nm
Torque spindle
value Fixing nut of rear
130-150 Nm
wheel spindle
- 22 -
2. Periodic Maintenance & Inspection Table
Per Per Per

Per Per Per
Service cycle 1000K 3000 6000K
300 Km 12000 Km 14500 Km
and time m Km m Tools
One Three Six Twelve Fifteen

New
Inspection item month months months months months
* Air filter I C C R C Ordinary tools
* Petrol filter I I R Ordinary tools
* Fuel filter C C C Ordinary tools
Replacement of engine fuel R Replacement every 1000KM Ordinary tools
Tire pressure gauge,

Tire pressure I I I I I I
inflator
Battery inspection I I I I I I Densimeter, multimeter
Actuation gap inspection I I I I I I Ordinary tools
Inspection of steering handle

I I I Ordinary tools
fastening
Absorber working inspection I I I Ordinary tools
Screw fastening inspection I I I I I I Torque spanner
Oil leakage inspection for gearbox I I I I I I Ordinary tools
Inspection or replacement of spark

* I I R R I Ordinary tools
plug
* Replacement of gearbox oil I Replacement every 5000KM Ordinary tools
Lubrication of each part L L Lubricator
Muffler I I I I I I Ordinary tools
* Ignition timing I I I I I I Timing lamp
* Carburetor A I A A A A
Tachometer, CO HC
Exhaust gas inspection at idle
* A I A A A A analyzer
speed
* Throttle inspection I I I I I Ordinary tools
Fuel pipeline inspection I I I I I Ordinary tools
Lighting/metering/electric devices I I I I I I Visual multimeter
Main stand bracket I I I Ordinary tools
Absorber I I I I Ordinary tools
* Torque force of engine bolts I I I I I Torque spanner
Front/rear brake I I I I Ordinary
Drive chain I I I I A Ordinary
Clutch I I I I Ordinary
* Valve I I I I I Feeler
- 23 -
Anticipated Inspection
1 Ignition systemobviously continuous ignition abnormality, engine fire or overheating, which requires
inspection and maintenance.
2 Carbon fouling eliminationobviously insufficient horsepower, which requires carbon fouling removal from
cylinder head, piston head and exhaust system.
3 Piston & cylinderexcessive abrasion; replace cylinder if it is worn.
Please have your motorcycle inspected and adjusted periodically at Qianjiang distributors for being in best
condition.
The above table is established under the presupposition of 1000 km/month.
IInspection AAdjustment RReplacement CCleaning LLubrication
Note: 1. * Regulations on exhaust emission made by the State Environmental Protection Agency shall be complied
with. Maintenance must be carried out in accordance with the instruction manual supplied by the company. We are
not responsible for any loss rising from private adjustment or maintenance.
2. Increase frequency of washing air filter if your motorcycle runs on the sandy/gravel road or under heavily
polluted environment so as to extend its service life.
3. Motorcycles which often run at high speed or with high mileage shall be maintained frequently.
3. Engine Oil/Filter
Oil level
* Note
The motorcycle should be parked on a flat ground when
checking its oil level.
After the engine runs for 2-3 minutes or stops running for about
2-3 minutes, check the oil level.
Check the oil level.

Add oil to the upper limit when there is warning light from the oil
level sensor.
Check oil level

*Note
1. Do not tighten dipstick when check.
2. Check the oil level, when the motorcycle is vertical.
3. Oil level must be checked regularly when oil is constantly
being consumed, and refuel to a right level.
Oil capacity: 3.0L change oil 3.2L disassemble
The working of engine and clutch will be affected if the
oil level is too high.
- 24 -
And if it is too low, it will lead to overheated engine and earlier abrasion of the components. Always use high quality
oil to prolong engine life. Disassemble the dipstick after the engine stops, and dry it with a clean cloth. Put the
dipstick into the measurement hole with the engine on the flat ground, but do not tighten it up. Take out the dipstick
and check the oil level. If it is below or near the minimum level, refuel with the recommended oil to the maximum
level.
*Note
Check the O-ring.
Assemble the dipstick.
Oil Replacement
* Note
It will be easier to change oil when the engine is warming up.
1. Preheat the engine.

2. Place a drip pan under the engine, and disassemble the
drain bolt and the dipstick.
3. Repeatedly start the engine for several times until the oil
is discharged completed.
4. When the oil is discharged completely, install back the
drain bolt and the packing washer after cleaning.
5. Refuel recommended oil to the crankcase to a required
capacity.
6. Assemble the dipstick.
7. Start the engine to run in an idle speed for 2-3 minutes.
8. Stop the engine, and check if the dipstick is at the maximum level several minutes later.
9. The engine should be upright while checking.
10. Make sure that there is no leakage.
Replacement of the Oil Filter

*Note
It will be easier to change oil when the engine is warming up.
1. Turn off the engine.

2. Make the oil filter stuck with special removal tool, spin
Oil filter
anticlockwise and disassemble the oil filter that needs
replacement.
3. Replace on new oil filter and coat a layer of lubricant on
the O-ring.
Note:
Do not disassemble the O-ring, otherwise it will make the O-ring
- 25 -
out of position while installing, which can lead to oil leakage or the damage of the engine.
Install the new oil filter to the engine with hands, spin until it cannot be screwed any further, and then tighten it
with Torque spanner (torque: 12-20Nm).
Check oil leakage when the engine operates at its idle speed for minutes.
3. Liquid Coolant
Check the level of the coolant in the expansion chamber during

maintenance.
Recommended model of the cooling liquid: FD-2

Total liquid capacity of the cooling system: about 2.0L
Remove the front shield on the right side. The filler cap of radiator
is located.
Open the filler cap and fill a right amount of coolant.

Re-install the cap after filling up.
Check the coolant of the expansion chamber after the engine has
been turned off and cooled down.
While checking, make sure the motorcycle is on the flat ground
and its body upright.
Observe the capacity of the coolant in the expansion chamber
through the frame hole from the right side of the motorcycle.
Keep the capacity between the mark of H and L. If the liquid is below H, remove the cap of the expansion chamber
and then add coolant.
Warning:
Add the coolant after the engine is turned off and cooled down. In case of heat, do not open the filler cap
before the engine has cooled down. The cooling system is under pressure
- 26 -
4. Assembly / Disassembly of the Clip of the Radiators Hose
The clip of the radiators hose is disposable component, so the old

clamp cannot be reused when disassembled. And the clip can only be
assembled by special clamp pliers, or it may not in place, which will
lead to the breakdown of the vehicle.
5. Fuel Injector and Oil-route
The fuel pump has two connectors; oil passes through the
fuel filter from one of the two connector into the fuel
injector, and finally injects oil into the intake manifold of
the engine. When the fuel is under too high pressure, it will
pass through another connector back to the fuel pump.
Please connect the inlet and outlet fuel hose as shown in the
figure at right.
- 27 -
7. Throttle Cable Adjustment
*Note
Adjust the idle speed of the engine first before adjusting the
free play of the throttle cable.
The throttle cable free play should be 3-5mm.

Adjust if it does not conform to the specified value.
The motorcycle is fitted with 2pcs cable, among the two

cables, A for throttle forward
1. Remove the dustproof boot of the steel rope of
the throttle.
2. Loosen the locking nut.
3. Screw in completely the adjusting nut.
5. Rotate the adjusting nut to make the free
stroke of controlling handlebar of the throttle
to 1015.
6. Tighten up the locking nut.
7. Adjust nut to make the controlling handlebar of
the throttle flexible.
8. Tighten up the locking nut.
After adjusting the free stroke, the handle should be
twisted left and right to make sure that there is no
change of the idle speed of the engine.
8. Air Filter
Filter Replacement
1. Open the rear seat cushion with the key, and remove it.
2. Pull the seat cable, open the front seat and take it off.
- 28 -
3. Disassemble the cover of the fuel tank and its front
fixing bolt, and open the fuel tank.
4. Disassemble the cover of the air filter.

5. Take off its element.
6. Check whether the element is stained or damaged.
7. Replace it if necessary.
8. Clean thoroughly but gently the element with the
cleanser.
9. Do not use petrol, in case of fire.
10. Do not distort or wring the cartridge so as not to
damage the foam.
11. Then apply the engine oil to it, and squeeze out the
excess oil to make the element seem moist, but
make sure there is no oil dripping.
Air filter Element
Replacement Time
Replace it as early as possible if the motorcycle is always running on rainy days or on rugged road.
*Note
Do not start engine when disassemble the element of the air filter, otherwise, the engine will intake unfiltered air,
which may lead to rapid abrasion of other components, and the damage of the engine too.
In addition, rotation without element will cause sequential malfunctions of the carburetor, and it may lead to
overheat of the engine.
Install in reverse order.
- 29 -
9. Spark Plug
Remove the spark plug:

1. Lift up the fuel tank.
2. Disassemble the intake air temperature sensors on both
side of the air filter, and then remove the air filter.
3. Remove the stators of the spark plug caps on both sides.
4. Remove the spark plug cap, and you can see the spark plug.
5. Remove the spark plug with the spark plug wrench.
Check
Whether the insulator is cracked or damaged
Whether the electrodes are abrasive
The combustion condition and color
The condition is good in light grey
Combustion color of pale indicates that the ignition system gets
a breakdown or the mixed air is too thin.
The condition of wet or there is black carbon deposition
indicates that the mixed air is too thick.
If there occur any cases mentioned above, please remove with spark
plug cleaner or steel brush, and replace if necessary.
Check the spark plug visually.
Replace the cracked or abrasive insulator if necessary.
Replace the spark plug after 8000 kilometers of each driving.
Check the spark plug gap.
Gap: 0.6-0.7mm
Model: CR9E(NGK)
*Note
Re-install the spark plug to the cylinder head, and screw tight with a
specified torque.
Torque value: 20-25N.m
Manually install the spark plug first, and then tighten with the spark plug sleeve.
Do not tighter the spark plug too tight, so as to avoid damage the threads of the cylinder head.
When remove the spark plug, avoid impurities from entering into the engine.
- 30 -
10. Battery
Battery Disassembly
Disassemble the front seat.
Remove the mounting plate of the battery.
Remove the negative wire and then the positive wire.

Remove the battery from the battery box.
Take out the battery.
Warning!
When the positive wire is disassembled, do not make the tool
contact with the frame. Otherwise, it may cause short-circuit
spark, which may ignite gasoline and damage the battery. It is
dangerous.
Install it in reverse order.
Warning!
To prevent short circuit, connect the positive wire first and then the negative wire. Do not remove the battery when
the engine is running. Otherwise, it may cause damage to inner parts of the vehicle.
Check the Charging Condition (closed circuit voltage)

Open the front seat.
Remove the battery from the battery box.
Remove the negative wire and then the positive wire.
Take out the battery.
Test the voltage between battery terminals.

Fully charged: 13.1V
Insufficient charging: 12.3V1 hour off work
*Note
Use a voltmeter to check the charging condition.
Charging
Connection: Connect the positive pole of the charger to the positive pole of the battery.
Connect the negative pole of the charger to the negative pole of the battery.
- 31 -
Warning!
The battery should be far away from fire source.
Turn off the charger before or after charging to avoid
explosive danger caused by spark which may exist in any
connection.
Comply with the current and time requirements for charging
as stated on the battery.
* Note
Except emergencies, you should not use emergency charging.
Measure voltage in 30 minutes after the battery is charged.
Charging current: standard: 0.3A

quick: 3.0A
Charging time: standard: 10-15 hours
quick: 30 minutes
Charging accomplished: open-circuit voltage : above 12.8V
11. Fuse Replacement
The fuse is under the drivers seat, and near the battery.
The main fuse is set on the starter relay, and the fuse box is near
the fuse. As shown in the figure refers to the fuse, model: 40A,
refers to the spare fuse of the main fuse, model: 40A,
refers to the fuse box, the configuration of the fuse is shown in the
figure:
Frequent fuse blowout indicates that there is short circuit or
circuit overload.
Note:
Before check or replace the fuse, set the ignition switch to off
, in case of short circuit or damage to other electrical
components.
Use the specified fuse only, or it will cause serious effect to the
electric system, and it can even burn the lamps of the motorcycle
or cause a fire or loss of engine traction, which is very dangerous.
- 32 -
12. Cylinder Compression
1. Warm up the engine.

2. Insert the compression gauge.
3. Turn the choke lever to the fully open position.
4. Start up the engine repeatedly,
5. The pressure of the cylinder: 11.2mpa
*Note
Start the engine until the reading does not rise.
Reasons for low pressure:
Incorrect valve adjustment
Leakage of the valve
Abrasive piston ring or cylinder
Reasons for high compression:

Carbon deposition in the combustion chamber or piston
Turn off the engine, and remove the spark plug/spark plug cap
13. Drive Chain Free Play

The life of the drive chain depends on appropriate lubrication
and adjustment. Improper maintenance could lead to earlier
abrasion of the dive chain and the sprocket. It must be
maintained frequently if harshly used.
Free play: 10-20mm
Adjustment to the drive chain:

Adjust the drive chain to the sag of 10-20mm in every
1000 kilometers drive. Regular adjustment may need which
depends on your driving.
Warning:
It is the maximum interval for adjustment as
recommended; in fact, you should adjust the chain before
every drive. Over loosened chain may cause the accessory
chain off the drive chain or serious damages to the engine.
Adjust the chain according the following methods mentioned

1. Put up the motorcycle with the support frame.
2. Loosen the rear axle nut.
4. Turn right or left the adjustment bolt to adjust the looseness of the chain, and keep the centers of the
rear and back sprockets into a straight line. There are benchmarks on the swinging arm and each chain
adjuster to facilitate your adjustment, and they can be aligned with each other and the reference from one
- 33 -
side to the other. Align and adjust the looseness of the chain to 10 - 20mm, and then fix again the rear axle
nut for the final check.
Note:
The two sprockets of the newly replaced chain should be checked to make sure whether they are abrasive or
not, replace if necessary.
Inspect periodically the following condition of the chain:

1. Loose pin
2. Damaged idler wheel
3. Dry and rusty chain
4. Twisted or blocked chain link
5. Excessive damage
6. Adjust loose chain
If the chain has defects as mentioned above, then there is a high possibility that the sprocket will damage the chain.
So the following items should be check to the sprocket:
1. Excessively abraded gear tooth
2. Broken or damaged gear tooth
3. Loose fixing nut of the sprocket
Lubrication of the drive chain

Priority should be given to lubricate by the lubrication grease for the drive chain, and you may buy it or use engine
oil or other lubrication oil instead. Dip every chain joint to make the lubrication grease penetrate to the space
between the chain plates, pins, bushings and rollers.
*Note
Do not assemble new drive chain to worn out sprocket or vice versa.
The sprocket and the chain should be used as a set, or it will cause quick abrasion of the newly replaced chain or
sprocket.
14. Front Brake Free Play
Measure the free play of front brake at the tip of the brake
lever.
Free play: 10-20mm
Regulator of Lever Grip of the Front Brake

Depending on the operating needs for the comfort, the position
of the lever grip of the front brake can be adjusted by
adjusting the knob with the ring nut. There are four positions
for adjustment, and you can adjust to a desired position just by
moving gently forward the lever of the brake, and then rotating
the adjuster of the ring nut at the arrow
A . And position 1 of
the front brake lever is most remote to the controlling handlebar of the throttle, while the position 4 nearest to it.
- 34 -
15. Rear Brake Free Play
Measure the free stroke of the brake pedal.
Free play: 20-30mm
If specified value has not been met, it should be adjusted.

Adjust the free play of the brake pedal.
First loosen the nut 1.
Screw in or out nut 2 to adjust the free play of the brake pedal.
Screw in 2 to reduce the free play;
Screw out 2 to increase the free play.
Tighten the fixture 1 until the specified value is met.
After being adjusted, dragging should not occur to the brake.
16. Headlamp
Disassemble the fixing bolt of the headlamp support.
Disassemble the fixing bolt of the headlamp support.
- 35 -
Unplug the lamp holder connector of the headlamp,
remove the lamp holder, loosen the snap ring, and take out
the bulb.
*Note
During the installation, avoid direct touch with the glass of the bulb,
and avoid oil-stained or it will affect the transparency, life and
luminous flux of the bulb.
Once stained with oil, wipe thoroughly with a damp cloth with
alcohol or rubber solution of strong volatility.
17. Clutch
Check the free play of the clutch cable.
Free play: 10-15mm
Adjust the free play of the cable of the clutch.

First loosen the clamp nut1.
Then screw in or back to the adjusting device2.
Until the specified value of the free play is met.
Finally, tighten the clamp nut.
If adjusting the handle of the inhaul cable of the clutch to its

ultimate position cannot meet the requirement of the free play, and
A of the engine and the adjusting nut
then adjust the locking nut B
with the inhaul cable.
- 36 -
18. Front/Rear Suspension System
Front Absorber Compress upwards or downwards
Pull the front brake tight; compress the front absorber

upwards or downwards for check.
Check whether there is oil leakage in the front absorber and
whether any component is damaged or loosened
Rear Absorber
Compress upwards or downwards
Compress the rear absorber upwards or downwards for
check. Check whether each part of the rear absorber is
damaged or loosened. Suspend the rear wheel and check
shimmy. Check whether the suspension bushing of the
engine is loose or not.
19. Bolt/ Nut/Fastener
Check whether each bolt, nut and fastener is loose. If yes, tighten it to required torque.
- 37 -
20. Wheel/Tire
Check whether tires or wheel have any crack, nail or any

other damage.
Check tire pressure.
*Note
Check tire pressure when it is cold.
Specification Tire pressure

Front tire 120/70 ZR 17 25010kpa
TNT600
Rear tire 180/55 ZR 17 29010kpa
When the thread depth on the central thread of the tire

reaches to the figure in the table, the tire should be replaced.
Minimum thread depth

Front tire 1.6mm
Rear tire 2.0mm
Warning:
Improper tire inflation will lead to abnormal
abrasion of the tire and threat the safety. And insufficient
inflation will cause tire slip, or disengage the tire, or lead
to the deflation of tire which is out of control. It is
dangerous to drive with excessively abraded tires, and it
is adverse to the adhesion or driving.
Check whether the locking nut of the front wheel spindle is loose.
Check whether the fixing nut of the rear wheel is loose.
Tighten it to the required torque value if it is loose.
Torque value: Fixing the front wheel spindle 55-62 Nm

Fixing nut of the rear wheel spindle 85-108 Nm
- 38 -
21. Fixing Steering Stem Bearing and Handlebar
1. Move the handlebar to confirm there is no wire interference.

2. Rotate the front wheel and move the handlebar freely for check.
3. If the handlebar moves difficultly, release it and then check the bearing of the fixing steering stem.
22. Throttle Body
The idle speed of the motorcycle will be reduced to some

extent due to the pollution of the throttle body. It is better
to clean it after every 5000 kilometers run.
When cleaning, disconnect the negative pole of the battery,
connectors of the sensor installed on the throttle; and
remove the throttle cable, hose connected to the air filter
and the intake manifold, and the throttle body.
Open the lid on the bottom of the throttle body, spray
cleanser to its in-wall and brush the dust and carbon
deposition, etc.
After cleaning, operate in reverse order, install the throttle
and make sure that all parts are in place, and try to start
the engine successfully.
- 39 -
23. Components to Lubricate
Appropriate lubrication is of great importance to the normal operation of each part of the motorcycle, to an
extended life and to the safety drive. Lubricate the motorcycle after a long time running or exposure in the rain or
after cleaning. As for detailed points for lubrication and maintenance, see the following figure:
motorcycle lubrication grease

1. axis of the rear brake pedal

2. single bracket joint and spring hook

3. pin of the gearshift riding rod
4. throttle cable
5. pin of the front brake handle
6. clutch handlepin
- 40 -
Inspection and Maintenance of the Electrical System
- 41 -
1. Battery/Charging System
Preparing Documents-----------------------1.1
Failure Diagnosis----------------------------1.2
Battery-----------------------------------------1.3
Charging System-----------------------------1.4
Voltage/Current Regulator -------------------1.5
Charging Coil of Magnetor ------------------1.6
Disassembly of Magnetor -------------------1.7
1.1 Preparing Documents
Work Instructions
*Note
1. Battery can be charged or discharged repeatedly. If it is placed after discharge, its service life will be
shortened and performance is undermined. Normally, the battery performance will be degraded after two
or three years. As for battery of degraded performance (reduced capacity), whose voltage will recover
temporarily after charging but decrease sharply when loading.
2. Battery overcharge: normally, overcharge can be judged upon the battery. In the case of short circuit inside
the battery, its terminal is unable to detect voltage or the detected voltage is very low. Regulator failure:
over voltage inside the battery will shorten its service life.
3. The battery will be self-discharged if being stored for a long time, which reduces its capacity. It shall be
charged about every three months.
4. Check the charging system following the sequence listed on the failure diagnosis table.
5. Do not remove the connector when there is current through electrical parts, otherwise it will cause over
voltage and damage to electrical parts inside the voltage regulator. Please operate it after the main switch
turns off.
6. It is unnecessary to check the maintenance-free battery and add electrolyte and distilled water.
7. Check all electric loads.
8. Emergency charging can only be used under emergency situation.
9. Remove the battery from the motorcycle for emergency charging.
10. Do not use electrolyte-added batteries when interchanging batteries.
11. Use a voltmeter to check charging condition of the battery.
- 42 -
Preparing Principles
Item Specifications
Capacity/Type 12V-9AH/ dry-charged
Fully charged 13.1V
Battery Voltage
Necessary
20 12.3V(not working for 1h)
charging
Charging current Standard: 0.8A, quick:8A
Charging time Standard: 10-15 hours, quick: 30 mins
Impedance of the coil
Magnetor Between white-white 1.5-3.5
20
Type Three-phase full wave
Voltage
Charging voltage of the
regulator 14.50.5V/5.000rpm
battery
Tightening Torque Force Tools

Rectifier bolt 5.0 Nm Universal fixing spanner
High-voltage coil fixing bolt 9.0 Nm Flywheel remover
Flywheel fixing nut 5.0 Nm Test instrument
Body guard bolt 9.0 Nm Multimeter
1.2 Failure Diagnosis
Power Supply Dead Interrupted Current

Battery over-discharge Poor contact of the charging wire
Unconnected battery wiring Poor contact of the charging system
Fuse blow Poor contact or short circuit of the lighting system
Poor switch
Low Voltage Poor Charging System

Poor battery charging Poor contact, short circuit or open circuit of wire terminals
Poor contact Poor voltage/current regulator
Poor charging system Poor magnetor
Poor voltage/current regulator
- 43 -
1.3 Battery
1.3.1 Battery Disassembly

As for details, please see page 31.
Warning!
When the positive wire is disassembled, do not make

the tool contact with the frame. Otherwise, it may
cause short-circuit spark, which may ignite gasoline
and damage the battery. It is dangerous.
*Note
To prevent short circuit, connect the positive wire
first and then the negative wire.
Check the charging condition (closed circuit voltage).

Remove the seat.
Remove cables of the battery.
Test the voltage between battery terminals.
Fully charged: 13.1V
Insufficient charging: 12.3V (not working for 1 hour)
* Note
Use a voltmeter to check the charging condition.
1.3.2 Charging
Connection method: connect the positive pole of the charger with the positive pole of the battery; connect the
negative pole of the charger with the negative pole of the battery.
Warning!
The battery should be far away from fire source.
Turn off the charger before or after charging to avoid explosive danger caused by spark which may exist in
any connection.
Comply with the current and time requirements for charging as stated on the battery.
*Note
Except emergencies, you should not use emergency charging.
Measure voltage in 30 minutes after the battery is charged.
- 44 -
Charging current: standard: 0.8A
quick: 8.0A
Charging time: standard: 10-15 hours
quick: 30 mins
Charging completed: open circuit voltage: above 12.8V
1.4 Charging System
1.4.1 Short-circuit Test

Remove the earth lead from the battery. Install a voltmeter between the negative terminal and the earth lead. Turn
off the switch. Check the short-circuit.
*Note
Connect the positive terminal of the multimeter with
the negative terminal of the battery.
Check whether there is short-circuit in the main switch or in the main wire in the case of any abnormality.
1.4.2 Charging Check

Use a multimeter to check the charging status of the battery when it is being fully charged.
Install the fully charged battery after the engine warms up.
Connect a voltmeter between terminals.
Remove the main fuse and connect an ammeter between terminals.
Start the engine and increase its speed gradually to measure the limiting voltage and current.
Limiting voltage/speed: 14-15V 5.000rpm
Check the voltage regulator if the limiting voltage is not within its required range.
Check the limiting voltage of the lighting system.
Remove the seat.
*Note
Set the multimeter to the AC voltage position.
Limiting voltage: 13.1+/-0.5V/5.000rpm

Check the voltage/current regulator if the limiting voltage is not within its required range.
- 45 -
1.5 Voltage/Current Regulator
1.5.1 Main Wiring Check

Remove the shield of the body.
Remove 4p plug of the voltage/current regulator.
Check conductivity between main wiring terminals.
Item (wire color) Judgment
Between Battery(red) and GND With battery
of the body voltage
Between GND wire (black) and
With lead
GND of the body
Resistance in the
Between charging coil (white) coil of the
and the GND of the body magneto.
1.5.2 Voltage-current Regulator Check

1. Choose diode file with multimeter.
2. The black probe connects to the red wire terminal of the voltage regulator, and the red probe connects
respectively with the white wire terminal (white 1, white 2, white 3). The pointer gauge shows a certain value,
otherwise it indicates the damage of the voltage regulator and replacement is needed.
3. The red probe connects to the black wire terminal of the voltage regulator, and the black probe connects
respectively with the white wire terminal (white 1, white 2, white 3). The pointer gauge shows a certain value,
otherwise it indicates the damage of the voltage regulator and replacement is needed.
*Note
Do not touch any metal part of the test rod of the
multimeter with your finger for check.
Check with multimeter. Different multimeters show
different impedance and different results.
Replace the voltage-current regulator when the impedance between terminals is abnormal.
1.6 Magneto Charging Coil

*Note

Check the magneto charging coil on the engine.
Check
Remove the 6p connector of the magneto.
Measure the impedance between the three white terminals of the magneto with the multimeter.
Standard: 1.5-3.520
Replace the magneto coil when the measured value exceeds the standard value.
- 46 -
1.7 Magneto Disassembly
Left cover and
the magnetic coil
1.7.1 Disassembly
Loosen the fixing nuts on the left cover, and
remove the left cover and the magnetic coil.
Bolt
Fix the flywheel with the universal fixing spanner.

Remove fixing bolts of the flywheel.
Bolt
Remove the flywheel with the flywheel remover.
Remove the solid key.
Remove the conductor joint.
Remove the stator.
Loosen the four fixing bolts of the magnetic coil,

and remove the magnetic coil.
Bolt
- 47 -
Loosen the locking nuts of the flywheel with
electric, pneumatic tools or torque spanner. Locking nut of
Remove the flywheel assembly. the flywheel
1.7.2 Installation
Install the stator on the body of the engine.

Connect the magneto joint.
Clean up the crankshaft and the taper part of the flywheel.

Install the solid key into the groove above the upper crankshaft key and confirm it.
Aim the groove in the flywheel at the solid key on the shaft.
* Note
Ensure there is no any bolt in the inner magnetic
side of the flywheel.
Fix the flywheel with the universal spanner and tighten fixing nuts.
Torque force: 9.0 Nm
- 48 -
- 49 -
2. Ignition System
Preparing Documents -----------------2.1
Failure Diagnosis ---------------------2.2
Ignition System Check ---------------2.3
ECU Group----------------------------2.4
Ignition Coil ---------------------------2.5
Trigger ---------------------------------2.6
Work Instructions
1. Check the ignition system following the sequence listed in the table of failure diagnosis.
2. This ignition system is an electronically and automatically angling device. It is solidified in the ECU unit and
you dont have to adjust the ignition time.
3. Check the ignition system following the sequence listed in the table of failure diagnosis.
4. Do not make ECU of the ignition system fall down or hang down or hammer it with strong force (primary
causes for failure). Pay special attention during disassembly.
5. Failure of the ignition system is mostly caused by poor contact of the socket. Check whether each
connector is in good condition.
6. Check whether the heat value used for the spark plug is proper. If not, the engine may work abnormally or
the spark plug may be burnt.
7. Check in this chapter is based on the maximum voltage. It also refers to check on the impedance of the
ignition coil.
8. Check the main switch according to the conduction table.
9. Remove the magneto and the stator according to instructions.
Item Standard value
Spark plug
Standard CR9E(NGK)
recommended
Spark plug gap 0.6-0.7mm
Ignition coil impedance
Primary coil 65050m
20
Impedance of trigger20 100-300
Measure the maximum primary voltage of the ignition coil 14V
Trigger voltage Above 1.7V
Tools
Attachments to the Maximum Voltage Table
Multimeter
- 50 -
No spark-over of the spark plug

Abnormality Cause (confirm it sequentially as follows)
The inner resistance is too small and it should be
tested by required tester.
Low speed of the crankshaft.
Ignition Interfered tester (It is normal that voltage is always
coil Too low high-voltage beyond the required value upon several measurements.)
Poor wiring contact of the ignition system.
Poor ignition coil.
Poor charging coil (measured at the maximum
voltage).
Incorrect connection of the tester.
Poor main switch.
Poor contact of ECU terminal.
Short circuit or poor contact of the GND of ECU.
Poor contact of charging coil (measured at the
No or interrupted high voltage
maximum voltage).
Side voltage Poor trigger (measured at the maximum voltage).
Poor terminal of high-voltage wires.
Poor ECU group (when item - is checked to be
abnormal or there is no spark for spark plug.)
Poor spark plug or secondary leakage of the ignition
Normal high voltage, but no spark coil.
Poor ignition coil.
No high voltage Interfered tester (It is normal that voltage is always
Charging coil beyond the required value upon several measurements.)
Poor charging coil (Item - is checked to be
normal.)
Poor ignition coil.
Poor charging coil.
Too low high-voltage
Interfered tester (It is normal that voltage is always
Trigger
beyond the required value upon several measurements.)
Poor trigger (Item - is checked to be normal.)
Poor ignition coil.
Poor trigger.
- 51 -
2.3 Ignition System Check
*Note
When there is no spark, check whether there is
Multimeter
loose wiring
or poor contact, and make sure all voltage values
are normal.
There are kinds of multimeters with different
impedances and different test values.
Connect a high-pressure shunt or an ammeter with

input impedance above 10M10CV to the multimeter. High-pressure shunt
2.3.1 Primary Voltage of the Ignition Coil

If you replace the original spark plug with a better one, make ground connection with the engine.
*Note
Make sure all wiring is correct before test.
Cylinder compression pressure normally refers to the
test value when the spark plug is installed on the
cylinder head.
Connect the lead of the ignition coil and also the shunt
between the primary coil terminal (black/red) and the GND.
Press the startup motor or step the actuating lever to
measure the maximum primary voltage of the ignition coil.
Minimum voltage: above 95V
*Note
Never touch any metal part of the test rod with your
finger to avoid electric shock.
- 52 -
2.3.2 Sensor of the Crankshaft
*Note
Install the spark plug on the cylinder head and carry
out measurement when the compression pressure is
normal.
Remove 18 connectors of ECU group. Connect the

peak-voltage shunt between the charging coil
(blue/white terminal) with 18 connector and
the 18 connector (white/green terminal).
Press the startup motor or step the actuating lever to measure
the maximum voltage of the charging coil.
Connection: positive pole to blue/white; negative pole to white/green.

Minimum voltage: above 95V
*Note
Never touch any metal part of the test rod with your
finger to avoid electric shock.
When the maximum voltage measured at the terminal of ECU Group is abnormal; dismantle the shield of the body
and the magnetor terminal.
If the voltage of ECU is measured to be abnormal while the voltage at the magnetor terminal is normal, it is
caused by poor contact or disconnected wiring.
If the voltage at both ECU and magnetor terminal appears to be abnormal, it is caused by poor charging coil.
Please refer to charging coil check.
2.4 ECU Unit
2.4.1 System Check

Check the system.
Remove the ECU Unit, and check components
of the ignition system at the terminal.
- 53 -
2.5 Ignition Coil
2.5.1 Disassembly
Remove the body.
Remove the spark plug cap.
Remove the primary lead of the ignition coil.
Remove the fixing bolts and then the ignition coil.
Install the ignition coil in reverse order.
*Note
Install the primary coil with black/red
terminal.
2.5.2 Check the Primary Coil

Measure the impedance between terminals of the primary coil.
Standard: (40.2) (20)
It shows good if the impedance is within the range of standard values.
Replace the primary coil if the impedance shows which indicates that the coil breaks.
2.6 Sensor of the Crankshaft
*Note
Check the trigger on the engine.
Check
Remove the shield of the body.
Remove the trigger terminal.
Measure the impedance between the blue/white terminal of
the side wire of the engine and the body GND.
Standard: 100-30020
Replace the magnetor if the measured value exceeds the
standard value.
- 54 -
BATTERY
G/Y
G/Y M
Startup Schematic Diagram
- 55 -
3. Starting System
Preparing Documents ----------------3.1
Failure Diagnosis ---------------------3.2
Startup Motor -------------------------3.3
Starter Relay --------------------------3.4
Starter Clutch--------------------------3.5
Work Instructions
Disassemble the startup motor on the engine.
For the disassembly of the startup clutch, please comply with related regulations
Item Standard Limit for use
Length of the brush of the
12.5mm 8.5mm
startup motor
Bushing of the startup idler
8.3mm
shaft
Outer diameter of the startup
7.94mm
idler shaft
Tightening torque force

Bolts for the clutch cover of the startup motor 12 Nm
Retaining nut for the clutch of the startup motor 95 Nm
Tools
Spanner for retaining nuts
Universal fixing spanner
- 56 -
Weak in rotation of the No rotation of the engine of

Startup failure
starter motor the starter motor
Fuse blow Low battery Poor startup clutch
Low battery Poor wiring contact Reversal rotation of the
Poor main switch Gear seized starter motor
Poor startup clutch Low battery
Poor brake switch
Poor starter relay
Poor wiring contact
Poor startup motor
3.3 Starter Motor
3.3.1 Disassembly
Loosen the two fixing bolts of the startup motor, and
remove the motor.
Bolt
Starter motor
* Note
Before the starter motor is disassembled, turn off the
main switch, remove the GND wire of the battery, and
then power on to check whether the starter motor
works for ensuring safety.
- 57 -
Remove the wire clip of the startup motor.
Remove the fixing bolts of the startup motor, separate the
front cover and the back cover, and dismantle the startup
motor.
Roll the waterproof rubber case and dismantle the connector
of the startup motor.
3.3.2 Breakdown
Remove screws in the shell, front cover, motor housing and other parts.
3.3.3 Check
1. Check other components.

2. Replace any part with abraded, damaged or burnt
surface.
3. Clean the commutator surface if there is metal
power attached to it.
4. Check conduction between the surfaces of other
components.
5. Ensure non-conduction between armature shafts of
the commutator.
6. Check the conduction of the shell of the startup
motor.
7. Ensure non-conduction between the conduction terminal and the startup motor shell.
8. Check conduction between the conduction terminal and the brush.
9. Replace any abnormal part.
10. Check conduction of the brush bracket. Replace it when there is conduction.
11. Measure the length of the brush.
12. Limit for use: replace it if lower than 8.5mm
13. Check smooth rotation of the needle bearing inside the front cover and whether it is loose when press-in.
14. Replace it if there is any abnormality.
15. Check whether the oil seal is abraded or damaged.
- 58 -
3.3.4 Assembly
Lubricate the oil seal inside the front cover with grease.
Install the brush on the bracket.
Lubricate moving parts at two ends of the brush shaft
with grease.
Press each brush into the bracket,
* Note
Pay special attention that the contact surface between
the brush and the armature shall not be damaged.
Pay attention that the armature shaft shall not damage
lips of the oil seal.
and install the back cover of the electric machine.

Aim the screw hole of the motor shell at the screw hole of the front cover for installation.
Lock screws in the shell.
* Note
When the shell and the front cover are assembled, it is
easy to pull the front cover with magnet to attract the
armature. Press it gently for assembly.
3.3.5 Installation
Install the lead of the startup motor and the dustproof boot.
And then install the startup motor.
Install the wire clip for rear brake.
3.4 Starter Relay
3.4.1 Check
When the main switch is on, check there is click sound at
the time of pressing the startup motor.
With click sound, it is normal.
Without click sound: check voltage of the starter relay;
check the GND loop of the starter relay;
check the movement of the starter relay.
- 59 -
3.4.2 Check Voltage of the Starter Relay
Set up the main stand, and measure voltage between the
negative pole of the green/yellow wire of the starter relay
terminal and the body ground connection.
When the main switch is on, hold the brake lever. The
battery voltage shall comply with regulations.
When there is no voltage at the starter relay terminal,
check the conduction of the brake switch and leads.
3.4.3 Check GND Loop of the Starter Relay

Remove the starter relay connector.
Check conduction between the black wire of the lead terminal and the body ground connection.
When the startup button is pressed, it shall show good conduction between the black wire of the terminal and the
body ground connection.
Check conduction of the startup button and leads when it is not conducted.
3.4.4 Check
Connect the starter relay to the battery, and the terminal
of the startup motor to the multimeter.
Connect the fully charged battery between the black wire
and the green/yellow wire of the relay. The relay shall
sound click and the multimeter shall indicate
resistance of zero.

- 60 -
4. Bulbs/ Switches / Meters
Preparing Documents ------------------------------------------------------------4.1
Failure Diagnosis -----------------------------------------------------------------4.2
Replacement of Headlamp Bulbs------------------------------------------------4.3
Replacement of Front Position Lamp Bulbs------------------------------------4.4
Replacement of Tail Lamp--------------------------------------------------------4.5
Replacement of Rear Registration Plate Lamp Bulbs-------------------------4.6
Replacement of Front Steering Lamp Bulbs -----------------------------------4.7
Replacement of Rear Steering Lamp Bulbs ------------------------------------4.8
Meters-----------------------------------------------------------------------------4.9
Main Switch ---------------------------------------------------------------------4.10
Horn -----------------------------------------------------------------------------4.11
Handlebar Switch ---------------------------------------------------------------4.12
Work Instructions
Remove the switch from the vehicle to measure its condition.
All plastic connectors have clamping jaws,
lift the clamping jaws and clamps before disassembly,
and make sure that the clamping holes aim at the clamping jaws when installing.
When looking up for electric faults,
check the continuity of the circuit passing through the electronic devices.
The state of the battery must be confirmed before carrying out any inspection,
including the voltage, to confirm that whether it is normal or not.
- 61 -
The ignition switch ON is not light, which due to

Poor bulbs.
Poor switch.
Bad contact or broken wires
Weak battery power or no voltage.
4.3 Replacement of Headlamp Bulbs
Remove the two fixing bolts of the headlamp at the

bottom left and bottom right of the meter.
Lower the headlamp forward, you can see the back of

the headlamp, and remove its dustproof cover.
- 62 -
The figure below shows the bulb of the dipped headlight
, and the bulb of the headlight on full beam,
remove the power cord socket, bulb snap, fixing bolts
and the bulb snap buckle of the dipped headlight and
the headlight on full beam that need to be replaced, and
finally remove the damaged bulb.
Aim the position of the light snap, and replace on a new

one of the same specification.
*Note
Keep combustible materials and your hands a distance
away from the bulb when it is light. Because the bulb is
very hot at that moment, you should let it cool down
before touching it.
Install the bulb in reverse order.
During the installation, avoid direct touch with the glass
of the bulb, an do not make it oil-stained. Or it will affect
the transparency, life and luminous flux of the bulb.
Once stained with oil, wipe thoroughly with a damp cloth of alcohol or rubber solution of strong volatility.
Install headlamp devices.
4.4 Replacement of Front Position Lamp Bulbs
The front position lamp and the headlamp are in one

lamp body, as shown in the figure, there is a front
position lamp bulb on the right and left sides.
(1) Operate according to the prompts of the above
chapterReplacement of the Headlamp Bulbs.
(2) Remove the damaged bulb, and replace on a new
one of the same specification.
(3) Install the bulb in reverse order.
- 63 -
4.5 Replacement of Tail Lamp
The illuminant of the tail lamp is LED, replace the whole

lamp if necessary.
(1) Remove the passengers seat and the drivers.
(2) Remove the tow fixing nuts of the tail-hood shield,
and then move it horizontally backward to take it
down.
(3) Remove the two fixing nuts of the rear lamp

combination.
(4) Remove the three fixing bolts of the rear lamp

combination.
(5) Remove the cable of the rear lamp combination, take
off the damaged lamp, and replace on a new one of
the same specification.
(6) Install the lamp in reverse order.
- 64 -
4.6 Replacement of Rear Registration Plate Lamp Bulbs
(1) Remove the fixing nuts of the rear registration plate

lamp to take down the tail-hood of it.
(2) Take off the damaged bulb, and replace on a new one
of the same specification.
- 65 -
4.7 Replacement of Front Steering Lamp Bulbs
The illuminant of the front steering lamp is LED, replace

the whole lamp if necessary.
(1) Operate according to the prompts of the above
chapterReplacement of the Headlamp Bulbs.
(2) Remove the fixing nuts of the right or left steering
lamp.
(3) Remove the cable of the front steering lamp, take off the damaged lamp, and replace on a new one of the same
specification.
4.8 Replacement of Rear Steering Lamp Bulbs
The illuminant of the rear steering lamp is LED, replace

the whole lamp if necessary.
(1) Remove the fixing nuts of the right or left steering
lamp from the back of bracket of the rear registration
plate.
(2) Remove the cable of the rear steering lamp, take off the damaged lamp, and replace on a new one of the same
specification.
4.9 Meters
Remove the rearview mirror;

Remove the handle cover, and unplug the connectors.
Remove the nuts the meter.
Install the meter in reverse order.
- 66 -
4.10 Main Switch
4.10.1 Check
Remove the front shield.
Remove the main switch lead terminal.
Check the conduction of the terminal.
POWER LOCK
ON
OFF
LOCK
R R/W
4.10.2 Replacement of Main Switch

Remove the front shield.
Remove the fixing bolts, and take off the fixing socket of the main switch.
Remove the fixing bolts, and replace the main switch.
4.11 Horn
Check
Remove horn wires.
It shows good when the horn wire is connected to the battery.
- 67 -
4.12 Handlebar Switch
Switch classification:
1. Light changing switch
2. Start switch
3. Steering switch
4. Horn switch
5. Turn off switch
6. Warning switch
B : blue
Y : yellow
R: red
LB: light blue
BK: black
GY: grey
W: white
G: green
- 68 -
Inspection and Maintenance of the Motorcycle Body
Tightening Torque of the Body

Name of fastening parts and fasteners Tightening torqueNm
Fixing bolt of the front absorber M6 5-10
Locking screw of the front wheel spindle M6 5-10
Front fixing bolt of the fuel tank M6 5-10
Fixing bolt of the front fuel pump assembly M6 5-10
Fixing bolt of the rear fuel pump assembly M6 5-10
Fixing bolt of the fixing seat on the handlebar M8 22-34
Fixing bolt of the upper connecting bracket M8 22-34
Rear fixing bolt of the fuel tank M6 5-10
Mounting bolt of the front brake cylinder assembly M10 37-55
Mounting bolt of the rear brake cylinder assembly M8 22-34
Fixing bolt of the sprocket M10 37-55
Fixing bolt of the rear frame M10 37-55
Fixing bolt of the pillar 50-70
Top bolt of the rear absorber M10 37-55
Bottom bolt of the rear absorber M10 37-55
Fixing bolt of the engine M10 37-55
Fixing bolt of the rear swinging arm axle M14 70-105
Front wheel spindle M16 100-140
Fixing nut of the rear wheel spindle M24 130-150
- 69 -
Front Disc Brake
Dia. of the front left/right brake
A
disc:320mm
Thickness of the front left/right brake
B disc:4.0mm
Limit for use: 3.6mm
Thickness of the brake shoes:7.8mm
C
Limit for use:3.8mm
Torque for mounting bolt 4 in the
D
figure:5-10Nm
E
figure:30-35Nm
F figure:
5-7Nm
G
figure:30-35Nm
H
figure:37-55Nm
I
figure:22-34Nm
1. handlebar assembly of the front brake disc 2.handlebar screw 3.fixing cover 4.bolt M623 5.hexagon
flange screw 6.brake switch 7.screw M412 8.nut M6 9.brake hose assembly 10.11. bleed nipple
12.mounting bolt of the oil tube 13.gasket 14.bolt M101.2555 15.front left brake cylinder assembly
16.brake shoes 17.bolt M816 18.D.320front brake disc 19.front right brake cylinder assembly
- 70 -
Rear Disc Brake
A Dia of the rear disc brake: 240mm
Thickness of the rear disc brake: 5.0mm
B
Thickness of the brake shoes: 7.0mm
C
D
figure:30-35Nm: 22-34 Nm
E
F
G
1.pin 2.joint M6 3.cotter 4.nut M6 5.pushrod 6.rear fuel pump assembly 7.gasket 8.rear brake
indicator 9.rear brake hose assembly 10.mounting bolt of the oil tube 11.rear brake cylinder assembly
12.brake shoes 13.rear disc brake 14.screw M620 15.bolt M81.2520
- 71 -
5. Brake
Maintenance Instruction ------------------------5.1
Failure Diagnosis --------------------------------5.2
Front Disc Brake ---------------------------------5.3
Rear Disc Drake ---------------------------------5.4
5.1 Maintenance Instruction
Work Instructions
*Note
A stained brake disc or protective gasket will reduce brake force, so discard
stained gasket and clean the brake disc with quality brake degreaser.
Check the brake system through the brake lever and pedals.
Spilled brake liquid is harmful to the focusing and paint of the equipment, and
the rubber parts too. So be careful whenever you remove the cap of the oil cup,
and the first thing you should do is to make sure that the liquid in the cup is
aclinic.
Never let the earth, water or other dirt into an open cup.
Use the DOT4 brake liquid taken out from a sealed container when doing
maintenance, and do not mix it with other type of liquid, since they can not
coexist.
* Check the brake before riding.*
5.1.1Specification
Item Standard Limit for use Item Standard Limit for use
Special brake liquid DOT4 - Special brake liquid DOT4 -
Thickness of the left/right brake
4.0mm 3.6mm Thickness of the brake disc 5.0mm 4.5mm
disc
Thickness of the left/right brake
7.8mm 3.8mm Thickness of the brake shoe 7.0mm 3.7mm
shoe
Dia. of the left/right brake disc 320mm - Dia. of the brake disc 240mm -
Front The jump of the brake surface Rear The jump of the brake
0.1mm - 0.1mm -
of the left/right brake disc surface of the brake disc
I.D. of the pump oil cylinder 16+0.043
0 mm - I.D. of the pump oil cylinder 11+0.027
0 mm -
O.D. of the oil-pumping
O.D. of the oil-pumping piston 16-0.032
-0.059 mm - 11-0.032
-0.059 mm -
piston
I.D. of the caliper cylinder 34+0.08
+0.03 mm - I.D. of the caliper cylinder 32+0.08
+0.03 mm -
O.D. of the caliper piston 32 -0.032
-0.065 mm - O.D. of the caliper piston 32 -0.032
-0.065 mm -
- 72 -
5.1.2 Torque Force
Fixing the front wheel spindle 100-140Nm
Mounting screw of the front left brake cylinder assembly 37-55Nm
Mounting screw of the front right brake cylinder assembly 37-55Nm
Fixing nut of the rear wheel spindle 130-150Nm
Mounting screw of the rear brake cylinder assembly 22-34Nm
5.2.1 Poor Brake Performance

1. Improper adjustment of the brake
2. Abraded brake shoes assembly or disc brake
3. Improper installation of the brake shoes assembly
4. Stained brake shoes assembly or disc brake
5.2.2 Slow Reaction or Tight Lever

1. Improper adjustment of the brake
2. Abraded brake shoes assembly or disc brake
3. Improper installation of the brake shoes assembly
5.2.3 Abnormal Noise

1 Abraded brake shoes assembly or disc brake
2 Stained brake shoes assembly or disc brake
5.2.4 Soft or Spongy Brake Lever/Pedal

1. Air in the hydraulic system
2. Leakage of the hydraulic system
3. Stained brake pedal/disc
4. Abraded seal of the caliper piston
5. Abraded brake pedal/disc
6. Stained caliper
7. Abnormal slip of the caliper
8. Insufficient brake liquid
9. Blocked brake liquid channel
10. Bended/fragmentary caliper piston
11. Bended/fragmentary piston of the main cylinder
- 73 -
12. Stained piston of the main cylinder
13. Bending braking lever/pedal
5.2.5 Brake Jam or Pulled to One Side

1 Stained brake pedal/disc
2 Wheel deviation
3 Blocked or limited joint of the brake hose
4 Bending/fragmentary brake disc
5 Abnormal slip of the caliper
5.2.6 Brake Resistance

1 Strained brake pedal/disc
2 Wheel deviation
3 Abraded brake pedal/disc
4 Bending/fragmentary brake pedal/disc
5.2.7 Stiff Brake Lever/Pedal

1 Blocked/limited brake system
2 Sticked/abraded caliper piston
4 Blocked/limited brake liquid channel
5 Abraded sealing gasket of the caliper piston
6 Sticked/abraded piston of the main cylinder
7 Bending brake lever/pedal
- 74 -
5.3 Front Disc Brake
5.3.1 Disassembly
*Note
Replace the brake shoes assembly.
If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place.
Remove following assemblies from the right grip and the front absorber.
Front brake:
Nut of the rearview
1. brake handle i
2. fuel pump assembly
3. brake hose assembly
4. left/right brake cylinder assembly Fixing screw of
5. left/right brake disc the fuel pump
*Note
Do not stain the brake assembly with oil spots during
installation or disassembly.
Clean it with required cleaning agent to maintain the brake
performance
Fixing screw of the handle
Fixing bolt of the brake hose
Brake hose
- 75 -
Bleed nipple
Right brake cylinder assembly
Fixing bolt of the brake cylinder
Loosen the fixing screws of the brake cylinder assembly.

Remove the brake cylinder assembly from the front absorber.
Bleed nipple
Left brake cylinder assembly
Fixing bolt of the brake

li d
1. Remove the front wheel

spindle.
2. Remove the front wheel.
3. Remove the disc brake off the
front rim.
- 76 -
5.3.2 Check
Check whether the brake shoes assembly and the brake disc
are abraded. Replace brake shoes if necessary.
Measure the brake shoes and the brake disc. Record
maximum values.
Specification
Diameter of the front brake disc 320mm
Thickness of the front brake disc 4.0mm
*Note
Measure them with micrometer.
Measure the thickness of the brake shoes.

If the thickness of the brake disc or the brake shoe is below
the required value for maintenance or it is stained with
grease, please replace it.
Limit for use

brake shoe 3.8mm
brake disc 3.6mm
Note:
Replace brake shoes in pair.
- 77 -
5.3.3 Installation
Install the brake disc and the front wheel.
Install the front brake hose assembly and the brake cylinder assembly.
Do not stain shoes and the brake disc with grease.
* Note
Any grease on brake shoes will reduce the brake performance and even lead to failure.
Tighten bolts and nuts to the required torque force.
Torque force
Fixing the front wheel spindle 120Nm
The bolt of the brake disc 28Nm
The fixing bolt of the fuel pump assembly 8Nm
Mounting bolt of the front brake cylinder assembly 50Nm
Do not stain the brake shoes with oil spots.

Use brake cleaning agent to clean brake shoes with oil spots.
*Note
Any grease on brake shoes will reduce the brake performance.
*Note
Do not stain the brake assembly with oil spots during installation or disassembly.
Clean it with required cleaning agent to maintain the brake performance.
- 78 -
5.4 Rear Disc Brake
5.4.1 Disassembly
*Note
Replace the brake shoes assembly.
If the brake shoes will be used again, mark it before disassembly so as to reinstall it at the original place.
Remove the following assembly off the frame and the rear swinging arm.
Rear disc brake:
(1) Fuel pump assembly
(2) Brake hose assembly
(3) Brake cylinder assembly
(4) Brake discs
Loosen the fixing screws of the right pedal cover plate
Right pedal cover
Fixing screws
Loosen the fixing screws of the oil pump assembly.

Remove the oil pump cylinder.
Fuel pump
Fixing screws
- 79 -
Remove the brake cylinder assembly off the rear
swinging arm.
Rear brake hose
Fixing bolt
Brake cylinder
Fixing screw
Remove the rear wheel spindle.

Then take off the rear wheel.
Remove the bake disc off the rear rim.
5.4.2 Check
Check whether the brake shoes assembly and the brake disc
are abraded. Replace brake shoes if necessary.
Measure the brake shoes and the brake disc. Record
maximum values.
Specification
Diameter of the rear brake disc 240mm
Thickness of the rear brake disc 5.0mm
*Note
Measure with micrometer.
- 80 -
Measure the thickness of the brake shoes.
If the thickness of the brake disc or the brake shoe is below
the required value for maintenance or it is stained with
grease, please replace it.
Limit for use

brake shoe 3.7mm
brake disc 4.5mm
Note:
Replace brake shoes in pair.
5.4.3 Installation
Install the rear brake disc.
Install the rear wheel.
Install the brake cylinder.
* Note
Any grease on brake shoes will reduce the brake performance and even lead to failure.
Tighten bolts and nuts to the required torque force.
Torque force
Fixing the rear wheel spindle 120Nm
The bolt of the brake disc 28Nm
The fixing bolt of the fuel pump assembly 8Nm
Mounting bolt of the rear brake cylinder assembly 50Nm
Do not stain the brake shoes with oil spots.

Use brake cleaning agent to clean brake shoes with oil spots.
*Note
Do not stain the brake assembly with oil spots during installation or disassembly.
Clean it with required cleaning agent to maintain the brake performance.
- 81 -
Body
*Note:
Do not damage any body part during disassembly.
Do not damage any hook or claw in the body during
disassembly.
Aim panels in the body at each corresponding
groove.
Ensure correct installation of each hook or claw
part during assembly.
Do not damage any part during assembly.
1. right air deflector mounting plate 2. windshield 3. left air deflector mounting plate 4. 5. right front shield 6.
right shield of the tank 7 bottom right shield 8. right shield 9. trim-cover of the right muffler 10. decorative cover of
the right muffler 11. back seat assembly 12. right rear handrail 13. left rear handrail 14. 16. left assembly of the
rear fender 17. right assembly of the rear fender 18. left shield 19. battery box 20. bottom left shield 21. front seat
assembly 22. middle shield of the tank 23. left shield of the tank 24. left front shield 25. front shield of the tank
26.connecting board of the left/right shield
- 82 -
6. Body
6.1 Disassembly
Disassemble in the following order:
back seat assembly front seat assembly front shield of the tank left shield of
the tank right shield of the tank left front shield right front shield middle
shield of the tank tank assembly
rear connecting board of the left/right shield left rear handrail right rear handrail
bottom left shield left shield bottom right shield right shield taillight
rear bottom fender decorative cover of the right muffler trim-cover of the right
muffler decorative cover of the left muffler trim-cover of the left muffler
barrel assembly of the muffler rear fender assembly battery box
mounting frame assembly of the headlamp windshield left air deflector
mounting plate right air deflector mounting plate headlamp

*Note
Do not damage any body part during disassembly.
Do not damage any hook or claw in the body during disassembly.
6.2 Assembly
Assembly in reverse order.

*Note
Aim panels in the body at each corresponding groove.
Ensure correct installation of each hook or claw part during assembly.
Do no damage any part during assembly.
- 83 -
Front Suspension
Torque for mounting the
fixing bolt 20 of the steering
A
column in the figure:
50-70Nm
fixing bolt 16 of the upper
B
base of the steering handlebar
in the figure: 22-34Nm
fixing bolt 13 of the upper
C
connecting board in the
figure: 22-34Nm
fixing bolt 5 of the front
D
absorber in the figure:
5-10Nm
Torque for mounting the front
E wheel spindle 1 in the figure:
100-140Nm
locking bolt 28 of the head of
F
the front wheel spindle in the
figure: 5-10Nm
1. front wheel spindle 2. bolt M50.814 3. screw M615.2 .4. front right absorber assembly 5. bolt M620
6. screw M50.812 7. bolt M6114 8. suspension bush 9. mounting base under the headlamp 10.
spacer bush 11. screw M6116 12. mounting base above the headlamp 13. bolt M81.2525 14. upper
connecting board 15. upper base of the steering handlebar 16. bolt M81.2525 17. locking screw of the
inner hexagon flat end M46 18. pin 19. column 20. fixing screw of the upper connecting board 21. nut 22.
locking nut of the upper connecting board 23. steering bearing 24. screw M68 25. fixing wire clip of the
front brake tube 26. bottom connecting board 27 front left absorber assembly 28. bolt M630 29. left
spacer bush of the front wheel
- 84 -
Handlebar
1. balance piece assembly 2. throttle lever 3. mounting base of the balance piece 4. front cover of the throttle
cable 5. screw 6. right switch group 7. handlebar 8. left switch group 9. cover of the left handlebar 10.
handle combination of the clutch 11. clutch cable assembly 12. throttle cable assembly I 13. throttle cable
assembly II
- 85 -
Front Wheel
Tyre size: front tyre: 120/70

A
ZR17
Pressure of the front tyre:
B
25010kpa
Minimum non-skid depth:
C
1.6mm
Rim run-out limit:
D Vertically: 2.0mm
Horizontally: 2.0mm
Torque for mounting the bolt 1
E
of the brake disc: 22-34Nm
1. bolt M816 2. front brake disc 3. bearing 6005-2RS/1-C3 4. middle spacer bush of the front wheel 5. front rim 6.
vacuum tyre 120/70 ZR17 7. front brake disc 8. valve
- 86 -
7. Front Wheel/Handlebar/Front Suspension
Preparing Documents--------------------------7.1
Failure Diagnosis-----------------------------7.2
Front Wheel-----------------------------------7.3
Handlebar--------------------------------------7.4
Front Suspension-----------------------------7.5
Work Instructions
Before removing the front wheel, you should use jack to support the body bottom and suspend the front wheel
which shall not be reversely rotated.
Pay attention that the brake shoes and the brake disc shall not be stained with grease during operation.
A stained brake disc or brake shoe will reduce brake force, so discard stained gasket and clean the brake disc with
quality brake degreaser.
Motorcycle Standards
Standard
Measurement points Item Limit for use (mm)
(mm)
Front wheel spindle Bending 0.2
Vertically 2.0
Front wheel Rim shimmy
Horizontally Within 1.0 2.0
Torque Force Tools

Fixing bolt of the upper connecting board assembly 22-34Nm Bearing puller
Fixing the front wheel spindle 100-140Nm Locking nut spanner
Locking screw of the head of the front wheel spindle 5-10Nm
Fixing screw of the front absorber 5-10Nm
Fixing bolt of the steering column 50-70Nm
Assembling bolt of the front brake cylinder 37-55Nm
- 87 -
7.2.1 Difficulty in Steering

Failure or damage of the steering handlebar.
Damaged bearing of the handlebar.
Too tight of the adjusting bolt of the faucet bearing.
Insufficient tire pressure.
7.2.2 Unsteady Steering

Damaged steering handlebar.
Insufficient tire pressure.
Bending of the front fork or the front wheel spindle.
Deformed or unbalanced front tire.
7.2.3 Front Tire Shimmy

Deformed rim.
Abraded front wheel bearing.
Flawed front tire.
Unbalanced tire or wheel.
7.2.4 Difficulty in Wheel Rolling

Failure in the front wheel spindle bearing.
Braking fault of the brake.
Failure in the front wheel spindle.
Bending of the front wheel.
7.2.5 Abnormal Noise of the Front Absorber

Insufficient liquid in the absorber.
Fricative sound of the absorber guard.
Loose bolts in the absorber.
7.2.6 Operation Only Available in One Side or Move in Curve

Unbalanced adjustment of the left and right forks
Bending absorber
Bending wheel
Incorrect installation of the wheel
Bending frame
Broken wheel bearing
Broken central axis of the swinging arm
7.2.7 Soft Front Absorber

Insufficient liquid in the absorber
The spring of the absorber is not firm.
Too low of the tyre pressure
- 88 -
7.2.8 Too Stiff of the Front Absorber
Improper weight of the liquid
Blocked pathway of the liquid in the absorber
7.3 Front Wheel
7.3.1 Disassembly
Note:
Support the motorcycle firmly.
Support the motorcycle with a safety frame or firm crane.

Disassemble the front fender, and loosen the fixing screws.
Bleed nipple
Fixing bolt of the bake hose
Fixing bolt of the brake

li d
Disassemble the braking caliper of the front disc brake.
Remove the brake cylinder assembly off the front absorber.
- 89 -
Bleed nipple
Fixing bolt of the bake hose
Fixing bolt of the brake cylinder
Remove the clamping screw of the front wheel spindle

(right front absorber)
Disassemble the front wheel spindle
- 90 -
Disassemble the front wheel assembly
Remove the left spindle sleeve of the front wheel
Disassemble the bearing with the bearing remover.
Note:
Do not operate the brake controlling lever after the removal of the brake caliper.
- 91 -
7.3.2 Check
7.3.2.1 Check the Bending of the Wheel Spindle

Place the wheel spindle on the V-base and measure the
eccentricity ratio with a dial indicator.
Limit for use: replacement when beyond 0.2mm
7.3.2.2 Check the Rim Shimmy

Place the rim on a precision bracket and check the rim shimmy.
Rotate the wheel by manual and read indication.
Limit for use:

Vertically: replacement when beyond 2.0mm
Horizontally: replacement when beyond 2.0mm
Balance of the wheel

Warning
The balance of the wheel directly affects the stability, operation
and safety of the motorcycle. Check the stability of the wheel
when it is removed.
Note:
In order to keep balance, mark on the tire near the bleed nipple
by drawing a dot at the rim. Assemble the tire when necessary.
7.3.2.3 Balance of the Front Wheel

Note:
Paste marks of the rotating direction on wheels and tires.
Remove the dust-proof sealing ring off wheels;

Install the wheels, tires and brake disc assembly at the Checkpoints;
Stop the rotating wheels, and mark the lowest (highest) point with the chalk.
Verify the most important sector in this way for 2 or 3 times.
If the wheel is in balance, it will not stop at one point.
In order to keep the wheel in balance, put on weight to it at the higher side of the rim, and mark with the chalk at
the other side. Add enough weight to the wheel when it is on rotation until it does not stop at one point.
Do not add weight above 60g to the wheel.
- 92 -
7.3.2.4 Check the front wheel bearing
Remove the bearing, and the middle sleeve of the
front wheel.
Check the rolling of the bearings.

Replace it if the bearing does not roll, or the rolling is
unsmooth or unstable, or the it is abraded or loose.
7.3.3 Bearing Replacement

Remove the front wheel spindle, front wheel, left
spindle sleeve and the middle spindle sleeve. Then
remove the oil seal and the bearing respectively with
the oil seal remover and the bearing puller.
Note:
Replace dismantled bearings with new ones.
Lubricate the bearings with grease during
installation.
Then press the bearings in with bearing installation
tools.
*Note
Bearings must be pressed in horizontally.
7.3.4 Installation
Note:
Lubricate the front wheel spindle, left spindle sleeve of the front wheel, bearing 6005-2RS/1-C3, and the middle
spindle sleeve.
Albany grease is suggested.
When tighten the front wheel and the caliper assembly of the disc brake, make sure that the brake disc is between
the brake pads.
The free stroke of the front brake lever cannot be adjusted.
*Note
Torque of fixing the front wheel spindle: 100-140Nm
- 93 -
7.4 Steering Handlebar
7.4.1 Disassembly
Remove the left/right rearview mirror assembly.
Right rearview mirror
Left rearview mirror
Remove the oil pump assembly of the front brake.

Remove the right switch group.
Remove the mounting base assembly of the throttle
cable.
Oil pump assembly
Mounting base assembly of the throttle
Fixing screw
Right switch group
Fixing screw
- 94 -
Remove the left handle assembly.
Remove the left switch group.
Left handle
Fixing screw
Left switch group
Remove the balance block assembly.

Remove the right handle assembly.
Remove the balance block.
Remove the fixing bolts of the upper base of the

steering handlebar.
Turn the upper base of the steering handlebar.
Remove the tube of the handlebar.
7.4.2 Installation
Install in reverse order.
Note:
Fixing screw of the upper base of the steering handlebar
Torque: 22-34Nm
- 95 -
7.5 Front Fork
7.5.1 Disassembly
Support well the middle bracket of the motorcycle.
Disassemble the front wheel.
Disassemble the brake caliper and the brake pipe
clamp.
Remove the steering handlebar.
Remove the pillar bolt.
Remove the meter and the meter bracket.

Loosen the fixing bolts of the upper connecting
board.
Remove the upper connecting board.
Remove the headlamp and its bracket.

Loosen the clamping bolts of the upper connecting
board.
Remove the front absorber.
- 96 -
Tools:
Fixing nut spanner.
Special disassembly tool for bearing cup.
*Note:
The opening of the body guard shall be cleaned with cloth.
The upper/lower bearing cup shall be dismantled with a special disassembly tool for bearing cup.
7.5.3 Installation
Note:
Make sure that the hole of the front wheel spindle is concentric when installing the left and right absorber.
Steps are contrary to the process of disassembly.
Note:
Fixing screws for the bottom connecting board: 10N.m
Fixing screws for the upper connecting board: 28N.m
- 97 -
Rear Wheel/Rear Suspension
Tyre size: rear tyre: 180/55 ZR
A
17
Pressure of the rear tyre:
B
29010kpa
Minimum non-skid depth:
C
2.0mm
Rim run-out limit:
D Vertically: 2.0mm
Horizontally: 2.0mm
Torque for mounting the bolt 2 in
E
the figure: 5-10Nm
Torque for mounting nut 19 in the
F
figure: 37-55Nm
Torque for mounting nut 20 in the
G
figure: 130-150Nm
1. rear wheel spindle 2. screw M620 3. right spacer bush of the rear wheel 4. DIA.240 disc brake 5. bearing
6006-2RS1-3C 6. spacer bush of the rear wheel 7. valve 8. rear rim 9. vacuum tyre 180/55 ZR17 1. bearing
6006-2RS1-3C 11. buffer bushing 12. left spindle sleeve of the rear wheel 13. bearing 306223.8 14. spindle
sleeve of the sprocket wheel 15. fixing bolt of the sprocket wheel 16. sprocket wheel rim 17. sprocket wheel 18.
retaining ring 62 19. self-locking bolt M101.25 20. self-locking bolt M241.5
- 98 -
Rear Suspension/Rear Absorber
Torque for mounting bolt 1
A
in the figure: 70-105 Nm
Torque for mounting nut
T 10 in the figure: 37-55
Nm
Torque for mounting nut
C 10 in the figure: 37-55
Nm
1. screw 2. mounting sleeve of the rear swinging arm 3. rolling bearing 61905-2RS 4. straight pin 48 5. middle
spacer bush 6. mounting sleeve of the rear swinging arm 7. sleeve 8. rear absorber assembly 9. mounting gasket of
the rear absorber 10. fixing spindle of the rear absorber 11. nut M101.25 12. supporting board of the brake clamp
13. rear chain cover 14 bolt M68 15. bolt M6114 16. chain protecting block 17 bolt M6114 18 front chain
cover 19 bolt M6114 20 fixing spindle of the rear absorber
- 99 -
8. Rear Wheel/Rear Suspension
Preparing Documents --------------------8.1
Failure Diagnosis -------------------------8.2
Rear Wheel --------------------------------8.3
Rear Absorber -----------------------------8.4
Chain Drive--------------------------------8.5
Rear Swinging Arm----------------------8.6
Work Instructions
The surface of the disc brake and the brake shoes shall not be stained with oil spots.
Item Standard (mm) Limit for use (mm)
Rear wheel Vertically 2.0
shimmy Horizontally 2.0
Locking torque force

Fixing nuts for the rear wheel spindle 130-150Nm
Top bolts for the rear absorber 37-55Nm
Bottom bolts for the rear absorber 37-55Nm
Fixing bolts for the rear swinging arm 70-105Nm
Fixing nuts for the sprocket wheel 37-55Nm
Fixing bolts for the rear brake disc 5-10Nm
8.2.1 Rear Wheel Shimmy

Deformed rim
Abraded rear wheel spindle
Tire failure
- 100 -
Abraded or damaged bearings of the swinging arm spindle
Incorrect adjustment of the drive chain
Unbalanced tires and wheels
Too low of the tire pressure
Bending frame or the rear swinging arm
8.2.2 Inflexible Rolling of the Wheel

Bending rear disc brake
Abraded bearings of the rear wheel spindle
Too tight of the drive chain
8.2.3 Too Soft of the Suspension

Insecure or shaking damping spring
Incorrect front suspension regulator
Oil leakage of the absorber
Too low of the tire pressure
8.2.4 Too Stiff of the Suspension

Damaged assembly bearing of the absorber
Bending tube of the absorber
Damaged bearing of the rear swinging arm axis
Bending of the rear swinging axis
Fault in the suspension regulator
Too high of the tire pressure
8.2.5 Operation Only Available in One Side or Move in Curve

Bending rear wheel spindle
Incompetent of the axle arrangement/chain regulator on both sides
8.3 Rear Wheel
8.3.1 Disassembly
Support the motorcycle firmly with the rear wheel
above the group.
- 101 -
Caliper of the rear disc brake
Fixing screws of the caliper of

the rear disc brake
Adjusting screw of the rear wheel
Remove the caliper of the rear disc brake.

Loosen the adjusting screws of the rear wheel.
Remove the nuts of the rear wheel spindle and left adjusting block of the chain.
Nut of the rear wheel spindle
Left chain adjusting block
Adjusting screw of the rear wheel
Remove the rear wheel spindle and the right adjusting

block of the chain.
Take the chain off the big sprocket wheel.
Chain
Big sprocket
- 102 -
Remove the rear wheel assembly.
Remove the supporting board of the brake clamp.
Supporting board of the brake

l
Remove the sprocket wheel assembly.

Remove the fixing bolts of the sprocket wheel.
Fixing bolts of the sprocket
- 103 -
8.3.2 Check
8.3.2.1 Check the Rim Shimmy

Rotate the wheel by manual and measure the eccentricity
ratio with a dial indicator.
Limit for use:

Vertically: replacement when beyond 2.0mm
Horizontally: replacement when beyond 2.0mm
When the rear wheel indication goes beyond the limit for use,
the rear wheel bearing is loosened leading to the rear wheel
shimmy. Replace the rear wheel bearing after check.
8.3.3 Installation
Install the rear wheel in reverse order, and lock the nuts.
Fixing nuts for the rear wheel spindle

Torque force: 130-150 Nm
- 104 -
8.4 Rear Absorber
8.4.1 Disassemble the Rear Absorber
Remove the upper/lower fixing nut of the rear absorber.
Remove the rear absorber.
8.4.2 Check the Rear Absorber

Visually inspect of the absorber for damage.
Check the following items:

whether the absorber tube is bent or damaged
whether the absorber has signs of deformation or oil leakage
whether the rubber block is abraded or damaged.
whether the spring is damaged
Check all other parts for damage or abrasion

If necessary, replace the absorber
8.4.3 Install the Rear Absorber

Install the upper fixing nut and lower fixing bolt of the rear absorber.
Lock to the specified torque force.
Fixing bolts
- 105 -
8.5 Drive Chain
8.5.1. Disassembly
Put the motorcycle on level ground, and firmly support it.
Remove the left rear cover.
Fixing bolt of the left rear cover
Engine left rear cover
Disassemble the rear wheel, rear absorber, the drive

chain shade and drive chain.
8.5.2 Check
Measure the length of ten chain links ,

if the length doesnt meet the specified value, replace the
drive chain.
The limit value of the length of ten chain links is
1587.5mm.
- 106 -
* Note:
Measure after stretching the chain by hand.
Range from chain link roller (1) to the inside of roller (11).
Measure the length of ten chain links.
Measure the length of ten chain links of different parts 2-3 times.
Clean the drive chain, put it into the kerosene,

and wash off the dust as much as possible,
then take the chain out of kerosene and dry it.
Check the rotor and side panels ,

if damaged or frayed, replace the drive chain.
The lubricant for drive chain can be purchased from the
shop to lubricate the drive chain.
Check the hardness of drive chain,

clean, lubricate or replace it if hard.
- 107 -
Check the drive sprocket and driven sprocket.
If one-fourth of the teeth of a cogwheel is frayed,

replace the sprocket,
the bending of the teeth of a cogwheel also requires
the replacement of sprocket.
8.5.4. Installation
Fixing nuts
Note:
Adjust the laxation degree of the drive chain and the free stroke of the brake pedal.
If the laxation degree of the chain is too small, engine and other vital parts will be overloaded.
The laxation degree of the chain should be kept within the prescribed limit value.
8.6 Rear Swinging Arm
8.6.1 Disassemble the Rear Swinging Arm

Put the motorcycle on level ground, and firmly support it.
Disassemble the rear wheel.
Disassemble the lower fixing nut of the absorber.
Disassemble the bolt and drive chain shade.
Disassemble the fastening bolt of the swinging arm spindle

from the frame.
Disassemble the rear swinging arm spindle and rear swinging
arm assembly.
- 108 -
Disassemble the rear swinging arm spindle bearing and the
rear swinging arm spindle
8.6.2 Check the Rear Swinging Arm

Check the rear swinging arm mounting spindle, rotate the
spindle on a flat surface or measure with a dial indicator, if
bent, replace it.
*Note
Dont attempt to straighten the spindle already bent.
Clean the parts of the rear swinging arm mounting spindle in Rear swinging arm
the solvent.
Check the sleeve of the rear swinging arm and the middle
sleeve, if damaged, replace them.
Check the bearing for the damage
Use your finger to rotate in the inner bush of the right-pivot

bearing
The bearing shall rotate smoothly and steadily, and the
installment of the bearing's outer ring on the wheel hub
should be checked for security
If the ring cannot rotate smoothly and steadily, or it is flexible Bearing

in installation on the pivot, please disassemble and discard it
8.6.3 Install the Rear Swinging Arm

Spindle bush of the pivot should be greased,
Note:
Bolts for the rear swinging arm spindle
Torque force: 70-105Nm
- 109 -
Fuel Tank
Gasoline capacity of the
A gasoline tank:
150.2L
Torque force of bolt 3:
B
5-10Nm
D
5-10Nm
E
5-10Nm
F
5-10Nm
1.fuel tank body assembly 2.gasket 6.412.51.6 3.bolt M670 4.fuel pump seal gasket 5.fuel pump
assembly 6.petrol pump screw 7.fuel pipe assembly 8.filter assembly 9.bolt M6 10.gasket 5,3101
11.oil level sensor assembly 12.bolt M625 bolt M625 13. rubber gasket tube 14.fuel tank front mounting
pad 15.fuel tank front mounting board 16.bolt M81.2520 17.fuel tank cover support assembly 18.fuel
tank lock 19.socket head cap screw M530 20.socket head cap screw M514 21.fuel tank cover seal gasket
- 110 -
9. Fuel Tank
Preparing Documents -----------9.1
Failure Diagnosis -----------9.2
Fuel Tank -----------------9.3
Work Instructions:
It shall be dismantled far from fire sources.
Tighten all the bolts and screws to the required torque value for assembly.
After assembly, check whether all the parts are correctly installed and operated.
Gasoline tank capacity 150.2L /
Tightening torque force

Front fixing bolts for the gasoline tank 22-37Nm
Rear fixing bolts for the gasoline tank 5-10 Nm
Fixing bolts for the fuel tank front mounting pad 5-10 Nm
Fixing bolts for the fuel pump 5-10Nm
Fixing bolts for the oil level sensor 5-10Nm
9.2.1 Decreasing Gasoline

Natural consumption of gasoline
Leakage of gasoline
- 111 -
9.3 Fuel Tank
9.3.1 Disassembly
Remove the rear seat and the front seat
Remove the upper body of the fuel tank.
Remove the front fixing bolt of the fuel tank.
Remove the high-pressure oil pipe assembly.

Remove the fuel pump connector jacket.
Remove oil level sensor connector jacket Front fixing bolt of the fuel tank.
Oil level sensor
Fuel pump
High-pressure oil pipe assembly
Fuel pump connector jacket
Oil level sensor connector jacket
- 112 -
Remove the rear fixing bolt of the fuel tank.
Rear fixing bolt of the

fuel tank
Remove the fuel tank.
9.3.2 Installation
Torque force for mounting:

Front fixing bolts for the gasoline tank 22-37Nm
Rear fixing bolts for the gasoline tank 5-10 Nm
Fixing bolts for the fuel tank front mounting pad 5-10 Nm
Fixing bolts for the fuel pump 5-10Nm
Fixing bolts for the oil level sensor 5-10Nm
- 113 -
10. Disassembly and Installation of Engine
Preparing Documents -------------10.1
Disassembly and Installation of Engine ----------10.2
Work Instructions
It shall be dismantled far from fire sources.
Tighten all the bolts and screws to the required torque value for assembly.
After assembly, check whether all the parts are correctly installed and operated.
Locking torque force

Gearshift rod bolt: 10N.m
Engine fixing bolt: 50N.m
10.2 Disassembly of Engine
Support the motorcycle firmly to make its rear

wheel above the ground.
- 114 -
Unscrew the clamp of the engine water pump
inlet/outlet, remove the cooling water-pipe and
exhaust the coolant
Disassemble the front and rear seats
Disassembly of the rear seat

Insert the key into the guard lock, and open it
clockwise;
Slightly push the back of the rear seat with your
right hand, pull the rear seat upwards and
backwards
Remove the rear seat;
Disassembly of the front seat

Remove the rear seat;
Hold the front seat cable with hands;
Slightly push the back of the front seat with your
left hand, pull the front seat upwards and
backwards
Remove the front seat;
Note:
Confirm the left and right limits are set at
positions when installing the front seat.
- 115 -
Disassemble the fuel tank assembly
See 9.3.1 Disassembly of the fuel tank
Disassemble the air filter assembly
Disassemble the air filter fixing bolt

Disassemble the air filter hoop
Disassemble the connector jacket of the intake air
temperature sensor;
Disconnect the breather rubber pipe from the vent of
cylinder cover;
Remove the air filter
Note:
The stepper motor of the throttle body should be
set well to position when installing the air filter.
Disassemble the throttle body assembly

Remove the throttle cable assembly and throttle cable
assembly II;
Disassemble four throttle body hoops in 1-2-4-3
order;
Remove the connector jacket of the intake air
pressure sensor.
Remove the ejector connector jacket;
Remove the connector jacket of the idle stepper
motor;
Remove the canister desorption rubber pipe;
Remove the intake oil pipe;
Remove the throttle body assembly
Note:
Confirm the throttle cable assembly and throttle cable
assembly are set at positions;
Confirm the oil pipe is connected well to place
without oil leakage after the correct installation of the
throttle body assembly.
Confirm the electric components are connected at
positions;
- 116 -
Disassemble the canister assembly
Canister assembly
Disassemble the clutch steel rope assembly
Clutch steel rope assembly
Disconnect the battery wire, disassemble the starter motor wire

and the ground wire
Disassemble the FBT connector jacket, rectifier and
outlet water temperature switch connector jacket
Battery wire
- 117 -
Disassemble the anterior segment of muffler exhaust
pipe
Disassemble the radiator filler, water tank, and

disconnect the fan switch connector jacket
Disconnect the crankshaft position sensor, neutral
switch connector jacket
Disconnect the single-kickstand flameout switch

connector jacket and disassemble the
single-kickstand flameout switch
Single kickstand flameout switch
- 118 -
Disassemble gearshift lever swing arm and the left cover of the
engine
Disassemble the small sprocket and detach the chain from the
sprocket
Release the engine fixing bolt and lift the engine
- 119 -
10.3 Installation of the Engine
Note:
Place an appropriate holder under the frame in case of rollover when disassembling the engine.
Engine fuel: 3.2L when assembling.
Start the engine and check it for abnormal vibration, noise and engine lubrication.
After the engine works properly at idle speed for a period of time, turn the throttle handle to maximum
level, then completely relax the throttle handle, at this time if the idle speed changes, it shows that the throttle
cable hasnt been regulated well. Therefore, attention should be given to the regulation in this regard prior to
the testing the engine.
Checking method of engine fuel

a. Pull out the fuel rod, wipe it off with a clean cloth.
b. Insert the rod into the oil and remove it to check the oil level, if the oil level is lower than the
lowest limit, increase the fuel.
c. Heating up for 5 minutes and cooling for 3 minutes, then check the oil level again, if the oil level is
lower than the lowest position, increase the fuel.
d. The oil level should always be kept between the lowest limit and the toppest limit.
- 120 -
Inspection and Maintenance of Engine
Table of Torque Force of Fasteners

Name of fastening parts and fasteners Tightening torque (Nm)
Magnetic bolt M14 20~25
Oil pan bolt M6 10~12
cylinder double-end bolt 60~62
Flywheel locking bolt 100~110
Gearshift positioner bolt M6 10~12
Crankcase bolt M6 10~12
Connecting rod bolt 23~27
Left/right crankcase cover bolt M6 10~12
Flywheel bolt M8 20~24
Fuel filter 18~22
Fuel filter connecting bolt 40~45
Fuel filter bolt M14 40~45
Round nut M20 95~105
Clutch release plate bolt M6 10~12
Cylinder cover shade bolt M6 10~12
Camshaft sprocket bolt M7 20~25
Fuel pump bolt M6 10~12
Gearshift positioning plate bolt M6 10~12
Spark plug 22~25
- 121 -
11. Lubricating System
Preparing Documents ------------11.1
Failure Diagnosis ------------11.2
Fuel Pump ---------------11.3
Function of the lubricating system:

The lubricating system of the engine is to provide lubricating oil to the frictional surface of each part, which
transforms dry friction into liquid friction between lubricating oil particles and also reduces abrasion of parts. It also
cools components with high thermal load, absorbs shock from bearings and other parts, reduces noise, increases
sealing between piston ring and cylinder wall, and cleans and removes particles in the surface.
Work Instructions:
Clean all parts carefully and blow the parts surface clean with high-pressure gas after disassembly of the fuel
pump.
Foreign matter shall not fall into the crankcase when the carburetor is disassembled
Standard of benchmark items and table of limit for use

When oil change 3.0L
Fuel capacity
When disassembling 3.2L
The radial clearance between
0.04-0.11mm 0.15mm
inner and outer rotors
Fuel pump rotor
The clearance between
0.04-0.11mm 0.15mm
outer rotor and pump body
Decreasing Oil Burnt engine

Natural consumption of oil No oil pressure or low fuel pressure
Oil leakage Blocked oil pipes
- 122 -
11.3 Oil Pump
11.3.1 Disassembly
Remove the clutch cover, loosen the oil pump fixing bolt, and take down the oil pump drive sprocket and the oil
pump drive chain.
Oil pump chain
Screw
Oil pump drive sprocket
Remove the screw.

Remove the oil pump body.
Screw
Oil pump body
Remove the screw, take down the oil pump cover, and decompose the
oil pump. Screw
Oil pump cover
- 123 -
Check the radial clearance between inner and outer rotors
Limit for use: 0.15mm.
Gauge
Check the clearance between outer rotor and oil pump cover
Limit for use: 0.15mm. Gauge
- 124 -
11.3.2 Assembly of Oil Pump
As shown below Oil pump
drive sprocket
Oil pump cover Outer rotor Pump body
Inner rotor
Pump shaft
Note: After the combination, the inner and outer rotors should rotate flexiblely without stagnation.
Installation
- 125 -
11.3.3 Lubricating Systematic Drawing
Piston cooler
- 126 -
- 127 -
12. Cylinder Head
Preparing Documents --------------------12.1
Failure Diagnosis -------------------------12.2
Cylinder Head / Valve--------------------12.3
Function of the cylinder head:

The cylinder head is used to seal the cylinder and form the combustion chamber with the piston. It bears HPHT gas,
and achieves air intake and exhaust through distribution mechanism.
Work Instructions:
The cylinder cover bears large bolt pretension to ensure sealing between the cylinder head and the upper cylinder
block. Pretension: 12 Nm, torque force: 60 Nm. All components must be cleaned and dried with high-pressure air
before check.
Standard of benchmark items and table of limit for use Unit: mm
Flatness of cylinder cover 0.03 0.05
Intake 013-0.19 __
Valve gap
Exhaust 0.19-0.25 __
Intake 3.97-3.98 3.96
Outer diameter of valve stem
Exhaust 3.97-3.98 3.96
Valve Intake 4.03-4.04 4.07
Inner diameter of valve catheter
Valve catheter Exhaust 4.03-4.04 4.07
Clearance between valve stem Intake 0.05-0.07 0.11
and valve catheter Exhaust 0.05-0.07 0.11
Intake 1.0-1.1 1.5
Width of valve seat
Exhaust 1.0-1.1 1.5
Intake 38.8 37.3
Valve spring Free length
Exhaust 41.6 40.1
Fitting clearance between camshaft and
Camshaft 0.041-0.054 0.08
cylinder head
- 128 -
Low compression pressure Noise in Cylinder head
Valve clearance maladjustment Valve clearance maladjustment
Burnt or bent valve Damaged valve spring
Poor air-tightness of valve seat Over high compression pressure
Too much carbon fouling in the combustion

Cylinder head gasket leaks gas
chamber.
Poor installation of spark plug
- 129 -
12.3 Cylinder Head
12.3.1 Disassembly
Remove the ignition coil.
Loosen six locating bolts, remove the gasket and cylinder cover shade.
Cylinder
Locating bolt
Loosen the fastening bolt, and remove the air-distributing chain

regulator.
Fastening bolt
Air-distributing chain regulator
Loosen the four sprocket bolts of the camshaft.
Sprocket bolt of the camshaft
Measure the fitting clearance between camshaft and cylinder

head.
Gauge
- 130 -
Loosen the camshaft holder.
Camshaft holder
Remove the camshaft, camshaft sprocket and chain.
Camshaft
Camshaft chain
Camshaft sprocket
Guide chain
plate
Cylinder
cover
Loosen the cylinder cover locking bolt.
Remove the cylinder cover.
Remove the top stem, compress the valve spring with valve spring
compression tools, and remove the valve block.
Remove the valve adjusting gasket, valve spring, valve spring
upper/lower seat and valve.
- 131 -
12.3.2 Cam Assembly Breakdown
Camshaft
Seal cover D13 Bolt
Camshaft sprocket
12.3.3 Valve Breakdown
Valve Valve spring Valve block Top

lower seat stem
Valve spring
Valve spring upper seat Valve adjusting
gasket
Ruler
Gauge
Check
Eliminate carbon deposit in the cylinder cover.
Measure the flatness of the joint surface of the cylinder cover.
When the flatness of the joint surface of cylinder cover exceeds
the limit for use, place the fine-sand paper on the flat plate, with
the joint surface of cylinder cover fitting the sand paper, and mill
it according to 8-shape.
- 132 -
Vernier calipers
Measure the free length of valve intake/ exhaust spring.

Limit for use: intake spring: 37.3mm.
exhaust spring: 40.1mm.
Measure the outer diameter of the valve stem.

Limit for use: intake valve 3.96mm
exhaust valve 3.96mm Micrometer
Check the valve catheter after eliminating the carbon deposit in

it with a reamer.
Note: The reamer should be rotated clockwise, and mustnt be
rotated anti-clockwise.
Tester
Measure the inner diameter of each valve catheter.

Limit for use: intake/ exhaust: 4.07mm.
Limit for use of the clearance between valve and valve catheter:
Intake valve: 0.11mm.
Exhaust valve: 0.11mm.
- 133 -
Screwdriver
12.3.4 Replace the Valve Catheter

Note: When the clearance between valve and valve catheter
exceeds the limit, replace the valve catheter. After the
replacement, trim the surface of the valve seating.
Put the valve catheter in the freezer of the refrigerator to cool
for one hour.
Heat the cylinder head to 100-150 with an electric furnace or
a hot oven.
Fix the cylinder head, disassemble the valve catheter from the
upper side of cylinder head with valve catheter disassembly
tools.
Put a new O-ring on the new valve catheter.

Install the valve catheter from the top of the cylinder head. Valve
Note: The cylinder head shall not be damaged when installing reamer
the valve catheter.
After inserting the valve catheter, trim with a valve catheter

reamer.
Note: Add proper amount of cutting oil when cutting with an
reamer. And the reamer should be rotated clockwise.
Eliminate the carbon deposit in the combustion chamber and

valve, clean thoroughly the intake/exhaust valve. Check the
width of the contact surface of the valve seat (width of the
valve seating).
Limit for use: intake/ exhaust: 1.5mm. Contact surface of the valve seat
- 134 -
12.3.5 Trim of Valve Seating
Remove the rugged or ragged parts of the valve seating surface Rugged part
with a milling cutter at 45angle.
Note: Coat a transparent or prussian-blue cladding on the valve
seating to get a better view.
Remove 1/4 of the outer end of valve seating with a milling

cutter at 25angle.
25
Remove 1/4 of the bottom of valve seating with a milling cutter

at 60angle. Take down the milling cutter and check the parts
treated.
60
Grind the valve seating with a refining milling cutter at 45angle

to achieve the proper width.
All dents and ragged parts must be removed. 1.0mm
Standard width of the valve seating: intake: 1.0mm

exhaust: 1.0mm
45
- 135 -
If the contact is the part where the valve is too high, please
lower the valve seating with a flat milling cutter at 25angle.
If the contact is the part where the valve is too low, raise the High contact surface
valve seating with a inner milling cutter at 60angle.
Refine the valve seating again with a refining milling cutter at 25
45angle to meet the specifications required. Low contact surface
After grinding the valve seating, please coat the polish on the
surface of valve to gently polish the valve.
60
12.3.6 Installation
Note:
When installing the valve spring, the end with smaller pitch of the spring shall be installed towards the
combustion chamber.
When installing the valve collet, install it by compressing the valve spring with valve spring compression tools
When installing the valve, the surface of the valve stem shall be coated with proper amount of fuel prior to
installing to the valve catheter.
- 136 -
- 137 -
13. Crankcase
Preparing Documents------------------------------------------------------13.1
Failure Diagnosis-----------------------------------------------------------13.2
Upper Box-------------------------------------------------------------------13.3
Piston------------------------------------------------------------------------13.4
Lower Box------------------------------------------------------------------13.5
Clutch-----------------------------------------------------------------------13.6
Variable Speed Gear Transmission---------------------------------------13.7
Camshaft Connecting Rod Assembly-------------------------------------13.8
Function of the upper box:
The cylinder block in the upper box provides space for gas compression, combustion and expansion, and also
guides piston movement.
It also transfers part of heat energy in the cylinder to cooling medium around.
Function of the piston:
1. It bears pressure arising from mixed gas combustion inside the cylinder and transfers such pressure to the
connecting rod for driving the crankshaft.
2. It forms combustion chamber along with the cylinder cover.
Function of the crankcase:
The crankcase is the load-bearing part of the engine. Its main function is to support the crankshaft, clutch, gearbox,
cylinder block and cylinder cover, sustain combustion shock and inertia force from the movement of the connecting
rod, and form part of closed space (oil sealing, gas sealing).
Suspension holes in the crankcase are linked with suspension holes in the body, which connects the engine to the
frame and other parts.
Work Instructions:
All components must be cleaned and blown with high-pressure gas before test.
The crankcase is thin-section casting thus shall not suffer impact during operation which may cause deformation or
fracture.
Lubricant in the crankcase should be drained out before operation.
- 138 -
Standard of benchmark items and table of limit for use
Limit for
Item Standard
use
Cylinder I 65 (0.025, 0.03) 65.100
Diameter of the cylinder
Cylinder II 65 (0.03, 0.035) 65.110
Cylindricity of the cylinder 0.008 0.050
Roundness of the cylinder 0.006 0.050
Flatness of the cylinder 0.03 0.05
Piston I 65 (-0.03, -0.025) 64.90
Outer diameter of piston (measured in piston skirt)
Piston II 65 (-0.025, -0.02) 64.91
Inner diameter of piston pin hole 16 (0.002, 0.008) 16.04
Outer diameter of piston pin 16-0.008, 0 15.96
Clearance between piston pin hole and piston pin 0.002-0.016 0.04
Upper box
Clearance between piston ring and Ring 1 0.05-0.09 0.11
ring groove Ring 2 0.04-0.08 0.11
Ring 1 0.15-0.30 0.5
Joint gap of the piston ring Ring 2 0.25-0.45 0.65
Fuel ring 0.20-0.70 1.0
Inner diameter of the smaller head of connecting rod. 16 (0.016, 0.034) 16.04
Clearance between connecting rod and piston pin 0.016-0.042
Thickness 1.5 (0-0.09) 1.48
Connecting-rod Clearance between the
bearing connecting-rod bearing and 0.025-0.05 0.065
crankshaft
Left-right clearance of the larger
0.1-0.25 0.5
end of the connecting rod
Connecting rod
Radial clearance of the larger end
0.008-0.016 0.05
of the connecting rod
Thickness 1.5 (0-0.012) 1.44
Main-shaft
Clearance between main shaft
bearing 0.03-0.05 0.07
and crankshaft
2.8 (-0.05, +0.05) 2.45
Thickness of friction disc
Lower box 3-0.1, 0 2.6
Clutch
24.3-0.15, +0.15 22.8
Length of pressure spring
23.5-0.2, +0.2 22.4
Outer diameter of fork shaft 11.973-11.984 11.96
Diameter of fork inner hole 12-12.018 12.03
Variable
Thickness of fork 5.80-5.90 5.75
speed gear
Outer diameter of gearshift drum 41.9-42.1 41.5
transmission
Width of gearshift drum lock
5.45-5.55 5.65
groove
- 139 -
Low compression pressure White smoke from the exhaust pipe

Abrasive, burnt or ruptured piston Abrasive or damaged piston ring
Abrasive or damaged cylinder or piston Abrasive or damaged cylinder or piston
Damaged spacer or crankcase leakage
Over-high compression pressure Abnormal noise of the piston

Too much carbon deposit in the combustion chamber Damaged cylinder, piston or piston ring
Abrasive piston pin hole and piston pin
Low compression pressure Abnormal noise in the crankcase

Crankcase leakage Loose or broken parts inside the crankcase
Engine overheating Engine automatic stopping
Clutch slipping Seized clutch
Poor lubricating
Not in gear Gear skip shift
Broken or deformed variable speed fork The clutch isnt completely released
Broken fork guide pin Abnormal transmission return spring
Abrasive gear convex claw Abrasive gearshift drum lock groove
Out of gear automatically

Abrasive joint claw, round edge
Decreasing elasticity of variable speed gear return spring
Abrasive spline gear of spline shaft and spline groove of sliding gear, leading to higher axial force when the gear
works
Abrasive gearshift drum and fork
- 140 -
13.3 Upper Case
BJ465MS/QJ465MS Engine cylinder block

Namely it is part of the upper case.
Upper case
Check
Check the abrasion of the inner wall of the cylinder.
If it is serious, replace it.
Spacer
Remove the spacer and locating pin.
Locating pin
- 141 -
13.4 Piston
13.4.1 Disassembly
Remove the retainer ring of the piston pin.
Note: during assembly, do not make the retainer ring fall into
the crankcase.
Remove the piston pin and the piston.
Retainer ring of the piston
Piston pin
Remove the piston ring.

Check the piston, piston pin and piston ring.
Note:
Do not rupture or damage the piston ring.
Eliminate carbon deposit in the groove of the piston ring.
Install the piston ring.

Measure the clearance between piston ring and piston ring
groove.
Limit for use: ring 1: 0.11mm.
ring 2: 0.11mm. Piston Push into
Piston ring
Gauge
- 142 -
Remove the piston ring, and install each piston ring on the
cylinder bottom.
Note:
Press the piston ring into the cylinder with piston head.
Measure the joint gap of the piston ring.
Limit for use: ring 1: 0.5mm.
ring 2: 0.65mm. Piston ring
Gauge
Measure the inner diameter of the piston pin hole.

Tester
Measure the outer diameter of the piston pin.

Clearance between piston pin hole and piston pin.
Limit for use: 0.04mm. 1
2
3
- 143 -
Measure the outer diameter of the piston I and piston II.
Note:
90
The measuring point shall be at 90with the piston pin, and at
the piston skirt.
Limit for use of the piston I: 64.90mm. 11mm
Limit for use of the piston II: 64.91mm.
Check whether cylinder I/II inner wall is scratched or abraded.

Note:
It is at 90 degree with the piston pin. Measure the inner
diameter of the cylinder at the top, middle and bottom points.
Limit for use of the cylinder I: 65.100mm.
Limit for use of the cylinder II: 64.110mm.
Tester
Measure the roundness of the inner wall of the cylinder (inner

diameter difference at X direction and Y direction). In Ex
Measure the cylindricity of the inner wall of the cylinder (inner Top
diameter difference at the top, middle and bottom points of X
direction and Y direction). Middle
Bottom
- 144 -
Check the flatness of the cylinder surface..
Limit for use: 0.05mm. Ruler
Gauge
Upper box
Measure the inner diameter of the smaller end of the

connecting rod.
Inner diameter of the

smaller end of the
connecting rod
Tester
Measure the clearance between connecting-rod bearing and crankshaft.

Connecting-rod bearing
- 145 -
Measure the clearance between main shaft bearing and crankshaft.
Main shaft bearing
Plastic gauge
13.4.2 Piston Installation Top ring

Install the locating pin.
Apply fuel to each piston ring and piston. Install the piston ring Ring 2
in place.
Fuel ring
Note:
Do not scratch the piston or break the piston ring.
After the piston ring is installed, it shall be able to rotate freely
in the piston ring groove.
- 146 -
Remove any residual spacer attached to the crankcase.
Note:
Do not make any object fall into the crankcase.
Install the piston, piston pin and retainer ring.
Note:
The dot mark on the top of the piston shall be installed towards
the intake valve.
Dot mark
- 147 -
13.5 Lower Case
13.5.1 Disassembly of the Crankcase Left Cover

Loosen the fixing bolt of starter motor, remove the starter motor.
Loosen the bolt of the crankcase left cover.
Remove the left cover.
Remove the electric starting bear, needle bearing and spacer.
Motor idle gear
Starter motor
Locating pin hole
Remove the starter motor idle gear.

Remove the spacer and locating pin hole.
Loosen the flywheel locking nut with the electric or pneumatic tool.
Pull the flywheel assembly (including the star wheel )
Flywheel assembly
- 148 -
13.5.2 Disassembly of the Clutch Cover
Loosen the fixing bolt, and remove the clutch cover.
Bolt
Clutch cover
Remove the clutch release stem from the right cover.
Right cover
Release stem assembly
Remove the fixing bolt, clutch, gearshift arm assembly and fuel pump sprocket.
Clutch assembly
Gearshift arm assembly
Fuel pump sprocket
Driven gear
- 149 -
Loosen the locking nut with the electric or pneumatic tool,
and remove the clutch.
Loosen the fuel pump screw, and remove the fuel pump
gear.
Gearshift drum assembly
Fuel pump chain
Fuel pump sprocket
- 150 -
13.6 Clutch
13.6.1 Disassembly
Unscrew the four bolts of the release plate in diagonally staggered sequence.
Loosen the clutch nut.
Remove the sleeve, bearing, release plate
and the clutch spring.
See the breakdown drawing for the disassembly of parts.
.
Release plate bolt
Clutch nut
Unscrew the clutch locking nut with the special tool, and remove the locking nut and gasket.
Remove the center holder of clutch.
Remove the clutch disc and friction disc.
Remove the clutch pressure plate.
See the breakdown drawing for the disassembly of
parts.
Remove the spline gasket.
Remove the shell assembly.
Four-claw socket spanner
Universal holder
Shell assembly
- 151 -
13.6.2 Clutch Breakdown
- 152 -
13.6.3 Check
Check the shell groove for burrs and brakeage, if trimmed
excessively by the file, replace it.
Check the pressure plate and the tooth profile of the center
holder for damage, if damaged, replace it.
Drive hub assembly
Driven hub
Measure the free length of the pressure spring.

Limit for use I: replace it if lower than 22.8mm.
Limit for use II: replace it if lower than 22.4mm.
Free length
Measure the thickness of the friction disc with vernier

Thickness
calipers.
Limit for use I: replace it if lower than 2.45mm.
Limit for use II: replace it if lower than 2.6mm.
- 153 -
13.7 Gearshift Mechanism
13.7.1 Disassembly
Remove the gearshift shaft assembly.
Remove the bolt and gearshift locating plate.
Remove the bolt, stop arm and spring.
Remove the locating pin.
See the breakdown drawing for the disassembly of
parts.
Gearshift shaft assembly
13.7.2 Gearshift Shaft Mechanism Breakage

Fork shaft spring Fork Fork shaft
Pressure plate
Gearshift drum Gearshift drum bearing Ratchet
Gearshift arm assembly
13.7.2.1 Check
Before the breakage, the gearshift plate should flexibly return without being seized.
Check the gearshift plate and gearshift shaft assembly for abrasion. If heavily abrasive, replace the assembly.
Check the gearshift locating plate for abrasion, If heavily abrasive, replace the assembly.
Check whether the gearshift shaft is bent, if excessively bent, replace it.
Check the return spring for decreasing elasticity, if necessary, replace it.
- 154 -
Loosen the crankcase bolt.
Separate the crankcase. Upper case
Note: Do not damage the spacer and crankcase surface. Remove
the upper case.
Crankcase bolt
Lower case
Main shaft assembly
Countershaft assembly
Remove the main-/ countershaft.
Loosen the pressure plate bolt, and remove the pressure plate.
Pull the fork shaft.
Remove the gearshift drum.
Remove the gearshift fork.
Gearshift drum
Fork
Fork shaft
- 155 -
13.7.2.2 Check
Measure the outer diameter of the fork shaft. Fork shaft
Micrometer
Measure the inner diameter of the fork hole.

Tester
Vernier calipers
Measure the thickness of the fork.

Width of the lock groove

Measure the outer diameter of the gearshift drum.
Measure the width of the gearshift drum locking groove.
- 156 -
13.8 Crankshaft Connecting Rod Assembly Chamber and Variable Speed
Chamber
Depository for
the main shaft
Depository for the
crankshaft connecting rod Depository for
the countershaft
Gearshift chamber
- 157 -
Main shaft
assembly
Gearshift drum
assembly
Gearshift arm
Fork shaft
assembly
- 158 -
13.8.1 Crankshaft Connecting Rod Assembly
13.8.1.1 Disassembly
Remove the upper box.
Remove the crankshaft connecting rod assembly from the lower box.
Countershaft Main shaft Drive gear

assembly assembly
Note: Do not damage the spacer and crankcase surface.
- 159 -
13.8.1.2 Check
Measure the left-right clearance of the larger end of the connecting rod.
Measuring point at the

clearance between the larger
Measuring point at the larger

Measure the clearance of the larger end of the connecting rod (X-Y
direction).
- 160 -
13.8.1.3 Assembly
Assemble in reverse order of breakdown and disassembly.
Remove the main shaft assembly
Remove the countershaft assembly.
13.8.2 Main-/Counter Shaft Breakdown

13.8.2.1 Main-/Counter Shaft Breakdown
Main shaft assembly
- 161 -
13.8.2.2 Check
Check the abrasion of gear surface and driving-claw point of the gear respectively.
If it is seriously abraded or damaged, replace it.
Gear surface
Check whether the bearing and oil seal are damaged, If yes,
replace it.
Driving claw
Note:
Removed bearing cannot be used any more. It shall be replaced.
Use special tools to dismantle the bearing and the oil seal.
13.8.2.3 Main-/Counter Shaft Assembly
Note:
Lubricate all gears and shafts with grease when assembling.
Ensure all gears without being seized after assembling.
Note:
Install the crankcase in reverse order.
- 162 -
14. Cooling System
Preparing Documents -------------------------14.1
Failure Diagnosis ------------------------------14.2
Water Pump ------------------------------------14.3
Function of the cooling system:

The cooling method of the engine is water cooling. Water cooling, in which the water is used as the heat
conductor, is a method of cooling high-temperature components and then transferring heat to the outside air, thus
keeping the engine working under the optimum temperature.
Specific cooling circuit:
The cooling water entering from the crankcase goes to the cylinder water jacket through the water channel of
crankcase, then goes upward through the cylinder cover, finally enters into the radiator through the pipe to dissipate
heat, and transfers heat to the outside air with the help of radiators fin.
- 163 -
Water leakage
Damaged seal ring
Broken pump assembly
Broken water pipe
Over high temperature in cylinder block
Damaged blade of the water pump
Blocked water pipe
Damaged cooling fan
Damaged water temperature switch
14.3 Water Pump
Disassembly
Loosen the bolt, and remove the water pump sub assembly.
Bolt
- 164 -
Water pump sub assembly
Bolt
Loosen the bolt, and remove the water pump cover.
Water pump cover
Remove the blade.

Blade
Check
Check the abrasion of the blade assembly.
If it is serious, replace it.
Note: Dont damage the spacer and the joint surface of box during
operation.
Installation
- 165 -
Cooling Systematic Drawing
- 166 -
Inspection and Maintenance of Exhaust Emission System
1 exhaust pipe gasket assembly 2 screw M830 3 gasket 8 4 spring gasket 8 5 muffler assembly 6 muffler
buffer rubber 7 muffler decorating panel 8 heat-insulating spacer 9 combined screw M610
- 167 -
15. Exhaust Emission & Control System
Warranty on the Exhaust Emission & Control System 15.1
Instructions on the Periodic Maintenance / Compliance with Standards 15.2
Mechanical Function of the Exhaust Control System 15.3
Catalytic Conversion System 15.4
Measures When the Idle Speed Emission Value Exceeds the Standard 15.5
15.1 Warranties on the Exhaust Emission & Control System
15.1.1 The exhaust emission & control system of this motorcycle is in conformity with the GB 14621-2011, GB
14622-2007, GB 19758-2005 and GB 20998-2007 standards prescribed by the state. We warrant that the exhaust
emission & control system works normally during its effective period provided that users completely comply with
all operation and maintenance requirements.
15.1.2 Warranty Range
Function warranty of the exhaust emission & control system

We warrant that it satisfies all periodic or non-periodic inspection by the related government authorities within
riding of (30000 kilometers).
15.1.3 This provision is not applicable under any following condition. However, our distributor or service store would
like to provide maintenance or repair services at reasonable prices.
1. Users fail in periodic maintenance within the required period or kilometers.

2. Periodic maintenance, adjustment or repair is not carried out at our distributor or service center, or there is
no evidence of maintenance record.
3. Overload or improper operation.
4. Refit the motorcycle, remove original parts or replace with other devices in private.
5. Ride the motorcycle on race tracks or on any non-motorized vehicle lane frequently.
6. Damage to the motorcycle due to extreme weather such as typhoon or flood, or damage or failure due to
negligence, crash or impact.
7. Users fail in periodic maintenance since it is out of service for a long time.
8. The odometer is not repaired immediately after being damaged, or it is refit, stopped, or replaced in
private.
All new motorcycles delivered by our company have passed the noise test and comply with the GB 4569-2005 and
GB 16169-2005 standards prescribed by the state.
- 168 -
15.2 Instructions on Periodic Maintenance
It is the national requirement that all motorcycles produced domestically shall comply with exhaust emission
standards to lessen environmental pollution. We strictly accord with these exhaust emission standards and
also make great effort in purifying air and reducing pollution.
This motorcycle has been strictly examined before delivery and is in conformity with all exhaust emission
standards. We provide the following periodic inspection table for exhaust emission in consideration of different
use by customers. Users shall carry out periodic inspection, adjustment or maintenance according to the
schedule to ensure normal emission.
For any problem, please contact BENELLI KEEWAY MOTORCYCLES distributors or BENELLI KEEWAY
MOTORCYCLES service center.
Relevant emission provisions are shown as follows:
Emission regulation CO HC NOX
Emission standard 2.0g/km 0.3g/km 0.15g/km
The latest national regulation shall prevail if there is any change.
We are not responsible for any problem due to failure in periodic maintenance at our distributor or service
center. Please carry out necessary inspection to ensure its best condition.
Note: Clean the air filter frequently if the motorcycle runs in sandy road or under seriously polluted condition to
extend the service life of the engine.
Increase maintenance if the motorcycle often runs at high speed or frequently.
Pay attention to following items to ensure meeting emission standards:

1. Please use lead-free gasoline #95 or #97.
2. Please use fuel with stipulated specification.
3. Please comply with periodic maintenance requirements.
4. For the exhaust control system, it is forbidden to make any adjustment or replacement at random
(including use of spark plug, adjustment of idle speed, ignition timing, throttle adjustment, etc.)
5. Notes:
Since any problem in the ignition system, the charging system or the fuel system has significant
effect on the muffler device, please go to our designated distributor or service center for
inspection, adjustment or repair immediately when there is any problem found in the engine.
Please use lead-free gasoline #95 or #97. Otherwise, the muffler device (four-stroke system) will
be affected.
6. The exhaust control system of this motorcycle is in accordance with the national regulation. For
replacement of any component, please use our original parts and have our designated distributor or
service center carry out such replacement.
15.3 Mechanical Function of the Exhaust Control System
General
This system adopts four-stroke single-cylinder engine, EFI and air conduction device to maintain qualified
exhaust gas. Meanwhile, active carbon canister is used for exhaust gas evaporated from fuel.
- 169 -
Engine improvement
As the spark plug, spherical combustion chamber, compression ratio, ignition time, exhaust system and other
engine components are improved, as well as the intake/exhaust efficiency is enhanced, the combustion efficiency
is raised.
15.4 Catalytic Transfer System
15.4.1 Structure:
15.4.2 Instruction:
1. Function of transfer catalyst is to transfer completely burnt HC, CO and NOX to harmless gas such as H2O,
CO2andN2 for discharge.
2. Transfer catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used.
Note that lead gasoline may invalidate catalyst.

- 170 -
Notes in maintaining motorcycles (gas discharge tube) with catalytic transfer:
a) For motorcycles with transfer catalyst, when the motor is running or just shut, it shall not be touched because
of high temperature.
b) Motorcycle with transfer catalyst shall not be near flammable material.
c) There is CO inside gas discharge tire, which is harmful to health. So do not run the motor in closed space.
d) Motorcycle with transfer catalyst shall not use lead gasoline. (Prevention for catalytic poison.
e) Do not push motorcycle to run motor. If it is necessary, you must stop for temperature of motor and catalyst to
lower down.
f) Do not shut the motor with gear up when running downward.
g) Do not drive motorcycle with bad ignition.
h) Do not remove spark plug and run motor to see whether there is spark in maintain motor ignition system. If
necessary, the time shall be short.
- 171 -
15.5 Measures When the Idle Speed Emission Value Exceeds the Standard
Qualified
Periodic inspection (maintenance plan)
Measure idle emission (note 1) Qualified
Adjust Carburetor (note2) Qualified
Qualified for
Remove and clean the Qualified delivery
carburetor
Replace the carburetor Qualified
Dismantle and repair

engine
Valveleakage Qualified
Pistonabrasive
Combustorcleaning
Notes:
1. Measure it with the idle speed measurement program.
2. Adjust the engine speed with stop screws to live up to requirements and measure CO/HC at the idle speed.
- 172 -
Inspection and Maintenance of Electronic Fuel
Injection (EFI) System
- 173 -
16. Electronic Fuel Injection System
Electronic Fuel Injection System 16.1
Components of Electronic Fuel Injection System 16.2
Failure Diagnosis 16.3
Common Troubleshooting Methods 16.4
16.1 Introduction of Electronic Fuel Injection System
TNT600 adopts the small-scale engine electronic fuel injection system manufactured by Delphi Company, which is
controlled with four oxygen sensors within a closed loop. Besides, it is equipped with four-cylinder independent fuel
injection and ignition control functions. The three-way catalytic converter would go through treatment with the gas
after combustion in the engine, turn it into harmless gas and discharge it into the air. This system adopts the
closed-loop independent function that can efficiently eliminate the manufacturing differences within the system
and the other corresponding components, highly improving the integrity of the motorcycle, which can also reduce
the deviations of the motorcycle after sometime of actual using.
16.2 Components of Electronic Fuel Injection System
16.2.1 Engine Controller (MT05.2 ECU)
The engine controller can test the operation conditions of the engine with various sensors at any time and
guarantee the emission and economy of fuel by proper computing and self-study control output mechanism with
the driving performance optimized. Once failures are found within the engine, the control would go through
automatic diagnosis. The normal working of the system requires two ECU.
- 174 -
16.2.1.1 ECU Appearance
ECU 12 is located on the left of battery and ECU 34 is behind the battery.
16.2.1.2 Definition of ECU Connector Pin
1) ECU 12
J1-1 J2-1 Pin for activating 1-cylinder ignition coil
J1-2 Headlight control pin J2-2 Pin for system grounding
J1-3 Pin for trouble light J2-3 Pin for K line communication
J1-4 Pin for heating 2-cylinder oxygen sensor J2-4 Pin for crank signal high potential
J1-5 Pin for signal 2-cylinder oxygen sensor J2-5 Pin for activating 1-cylinder fuel injector
J1-6 Connector pin for tachometer J2-6 Pin for activating 2-cylinder fuel injector
J1-7 CAN line low signal 1 pin J2-7 Pin for heating 1-cylinder oxygen sensor
J1-8 CAN line high signal 1 pin J2-8 Pin for intake temperature sensor signal
J1-9 Pin for system grounding J2-9
J1-10 Pin for activating 2-cylinder ignition coil J2-10 Pin for 5V system reference voltage grounding
J1-11 J2-11 Pin for intake pressure sensor signal
J1-12 J2-12 Pin for throttle position sensor signal
J1-13 J2-13 Pin for crank signal low potential
J1-14 Dump switch (efficient at low) J2-14 Signal pin for water temperature sensor
J1-15 J2-15 Ignition power (12V positive voltage after key)
J1-16 J2-16
J1-17 J2-17 Pin for signal 1-cylinder oxygen sensor
J1-18 Pin for neutral gear switch J2-18 Battery power supply (battery 12V positive voltage)
Remarks:
J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey connector.
- 175 -
2) ECU34
J1-1 Idle speed stepper motor high A pin J2-1 Pin for activating 4-cylinder ignition coil
J1-2 Canister solenoid valve pin J2-2 Pin for system grounding
J1-3 Pin for trouble light J2-3 Pin for K line communication
J1-4 Pin for heating 3-cylinder oxygen sensor J2-4 Pin for crank signal high potential
J1-5 Pin for signal 3-cylinder oxygen sensor J2-5 Pin for activating 4-cylinder fuel injector
J1-6 J2-6 Pin for activating 3-cylinder fuel injector
J1-7 CAN line low signal 2 pin J2-7 Pin for heating 4- cylinder oxygen sensor
J1-8 CAN line high signal 2 pin J2-8 Pin for intake temperature sensor signal
J1-9 Pin for system grounding J2-9 Pin for oil pump control signal
J1-10 Pin for activating 3-cylinder ignition coil J2-10 Pin for 5V system reference voltage grounding
J1-11 Idle speed stepper motor low A pin J2-11 Pin for intake pressure sensor signal
J1-12 Idle speed stepper motor high B pin J2-12 Pin for throttle position sensor signal
J1-13 Idle speed stepper motor low B pin J2-13 Pin for crank signal low potential
J1-14 Dump switch (efficient at low) J2-14 Signal pin for water temperature sensor
J1-15 Pin for vehicle speed sensor J2-15 Ignition power (12V positive voltage after key)
J1-16 J2-16 5V reference voltage
J1-17 J2-17 Pin for signal 4-cylinder oxygen sensor
J1-18 Pin for neutral gear switch J2-18 Battery power supply (battery 12V positive voltage)
Remarks:
J1 indicates grey connectors on ECU, and J2 indicates black connectors on ECU. J1-1 means No. 1 pin on ECU grey connector.
- 176 -
16.2.1.3 Circuit Diagram of Electronic Injection System
Notes:
a) Keep ECU away from places of high temperature, like muffler or engine;
a) Keep ECU away from water, engine oil or any places of liquid;
b) Keep ECU away from mud or other dirt that would affect the heat dissipation function of ECU;
c) Connect with M8 bolts and make sure the tightening torque is around 3.9Nm, keep the surface neat to prevent
outside force to ECU in case of circuit board bending;
d) The DC power supply voltage of ECU of normal working is between 9V and 16V. When it's working under a
voltage not over 26V for one minute, permanent damage would not happen to ECU, neither when the backward
voltage is not over 13V.
- 177 -
16.2.2 Fuel Injector
16.2.2.1 Working Principle of Fuel Injector:
The fuel injector is designed with magnet coil surrounding iron core inside. Two electrodes from magnet coil
are input control connectors of the fuel injector. When magnet coil is energizing, electromagnetic attraction
generated by magnet coil will conquer spring force and fuel oil pressure of ball valve to uplift the ball valve. Then
high pressured fuel oil (250Kpa) in fuel pipes can inject cone-shaped fuel oil to the air inlet through value seat hole
and orifice plate. After power of the fuel injector, magnetic force of the magnet coil will automatically disappear. The
ball valve closes by the action of return spring and fuel injection stops.
16.2.2.2 Appearance:
Fuel injector is designed with a filter which is not a repairable component because it is designed for only
filtering impurities between fuel filter to fuel injector. The impurities may cause failures such as injector
bonding, flow deviation and leakage. Thus, fuel filter system is very important.
Replace the fuel injector with parts of the same models.
- 178 -
16.2.3 Throttle Body
16.2.3.1 Working Principle:
The throttle body assembly is comprised of the main casting valve body, return spring, throttle position sensor
system and idle adjusting screws.
Throttle position sensor system offers accelerograph opening for ECU; idle adjusting screws controls and idle
speed and the stability by clockwise reducing the ventilation to lower the idle speed and anticlockwise increasing
the ventilation to higher the idle speed, which is normally required around 2 circles.
16.2.3.2 Appearance:
- 179 -
16.2.3.3 Cleaning
Clean the throttle body assembly with carburetor cleanser by spraying it on the inner wall of the throttle body
and brush the dusts and carbons away gently.
Notice:
Make sure the side channel is not blocked by the dirty.
16.2.4 Engine Cylinder Head Temperature Sensor
16.2.4.1 Working Principle:
This sensor is used on the air cooled engine for measuring the engine cylinder head temperature. Within the
temperature scope of the sensor, the electric resistance would vary with different temperature of the engine, which
is a negative temperature coefficient resister. It is a not a repairable part.
- 180 -
16.2.4.2 Appearance
16.2.5 Intake Air Temperature Sensor
16.2.5.1 Working Principle
It is used for measuring the temperature of the intake air. Within the temperature scope of the sensor, the
electric resistance would vary with different temperatures of the engine, which is a negative temperature
coefficient resister. The intake air temperature sensor is not a repairable part.
16.2.5.2 Appearance
- 181 -
16.2.6 Intake Pressure Sensor
This sensor is mainly used for measuring the absolute pressure of the intake bend tube, which, in compliance
with the change between the resistance value and the intake pressure, can measure the air input of the engine's
combustion chamber indirectly.
16.2.6.1 Appearance
16.2.7 Oxygen Sensor
Oxygen sensor is mainly used for measuring the oxygen content within the exhaust pipe of combustion engine
and for the fuel closed loop controlling in the engines, which can make sure the combustion of the engine is
maintained at a reasonable air-gasoline ratio (14.7).
- 182 -
16.2.7.2 Appearance
16.2.8 Ignition Coil
The ignition coil can provide energy to the spark plug. The high voltage wire is used to connect the ignition coil
and the spark plug.
- 183 -
16.2.8.1 Appearance
16.2.9 Idle Speed Stepper Engine
The idle speed control valve is used to control the ventilation circulation area aside the throttle body so as to
adjust the intake air to the engine, realizing controlling of the idle speed of the engine.
- 184 -
16.2.9.1 Appearance
16.2.10 Fuel Pump Assembly
The electric pump would work together with the pressure regulator to provide 250Kpa fuel pressure for the
engine. It is installed under the gasoline tank.
16.2.10.2 Appearance
- 185 -
Back side:
Front side:
16.2.10.3 Failure Diagnosis of Fuel Pump Assembly
a) Turn on the key and run the fuel pump for about 3 seconds. If the fuel pump starts to run, refer to step d).
b) Cut off the connector of the fuel pump and check whether the power supply voltage is 12V or so.
c) If there is nothing wrong with the second step, supply 12V DC to the fuel pump with an external storage
battery. Check whether the fuel pump runs or not.
d) If the fuel pump runs normally, check the oil pressure gauge to see whether the front supply pressure of
- 186 -
the nozzle is about 250Kpa when the engine is idling.
e) If the pipe pressure is lower than 220Kpa, check if there is a leakage in the oil pipe, if the fuel pump runs
backwards, or if the filter is blocked.
16.2.10.4 Common Problems
a) The reverse connection of the connector of the fuel pump assembly causes the fuel pump run
backwards, thus leading to inadequate fuel pressure for the engine. As a result, the engine cannot
work normally.
b) The fuel pump is damaged and cannot run.
Note:
1. Since a new motorcycle has no gasoline in its fuel tank at the very beginning, much air remains in the fuel
line after the tank is fueled up. Therefore, it is necessary to turn the motor over for several times to discharge all
the air in the fuel line so that the engine can operate normally. This is a normal process, which will avoid the
engine from taking a long time to start but still in failure in the later startup.
2. The gasoline can cool down the fuel pump, so do no run the pump with little or no fuel, or the fuel pump will
be overheated and damaged.
16.3 Methods for Fault Diagnosis and Maintenance
The trouble light is on the instrument panel, with a sign of FI down blew. In a normal circumstance, when
turning on the key, the trouble light will turn on to indicate the electronic control injection system is power-on and is
ready to work. If the trouble light is off, it indicates that there is no power supply in the electronic control injection
circuit and thus it cannot work. In this case, check the fuse and the connection of both positive and negative
electrodes of the storage battery. After the engine has been started, if the trouble light turns off, it indicates that
there is no fault; otherwise, if the trouble light is still on, it indicates that the electronic control injection system is
abnormal and it is necessary to remove the faults.
There are three methods for fault detection:
16.3.1 Direct Diagnosis through the Flickering Trouble Light (FI) on the
Instrument Panel
When any fault is confirmed, by switching the key for three times, i.e., turning the key on-off-on-off-on, the
trouble light will flash in corresponding fault code. Then check the fault code list for the breakdown in
correspondence.
In case of reading faults with the trouble light, the rules of flash codes are illustrated as below. Take the open
circuit of intake pressure sensor or short circuit of signal end pin to the negative electrode of the battery as an
example, after the key has been switched for three times, the trouble light will flash 10 times standing for 0, flash
once after 1.2 seconds standing for 1, flash 10 times after another 1.2 seconds standing for 0 and flash 7 times
- 187 -
after another 1.2 seconds standing for 7, that is P0107. It shows that, except the number 0 is represented by
flashing for 10 times, other numbers from 1 to 9 will flash as the number itself shows. If there are other fault codes,
such as fault P0201, a fault in the fuel injector of front cylinder, the light of fault code P0201 will flash in 3.2
seconds after the flashing of P0107. The trouble lights of P0107 and P0201 will flash circularly in case of no other
fault. Then faults can be checked according to the fault code list.
Decimal number will be adopted to show the fault code in PCHUD software. The decimal number in the fault code
list is corresponded to the previous hexadecimal, thus faults can be found out in correspondence. If MULFCURR
(current fault) =263, the corresponding fault code in the fault code list is P0107, i.e., a fault of intake pressure
sensor.
- 188 -
MT05 Fault Code List
Corresponding decimal
Fault code Description number
open circuit of intake pressure sensor or short circuit of signal end pin to the
P0107 negative electrode of the battery 263
short circuit of signal end pin of the intake pressure sensor to the positive
P0108 electrode of the battery 264
short circuit of signal end pin of the intake temperature sensor to the negative
open circuit of intake temperature sensor or short circuit of signal end pin to the
P0113 positive electrode of the battery 275
short circuit of signal end pin of the cylinder end temperature sensor to the
open circuit of cylinder end temperature sensor or short circuit of signal end pin
P0118 to the positive electrode of the battery 280
open circuit of throttle position sensor or short circuit of signal end pin to the
short circuit of signal end pin of the throttle position sensor to the positive
short circuit of signal end pin of the front cylinder oxygen sensor to the negative
short circuit of signal end pin of the front cylinder oxygen sensor to the positive
short circuit of heating end pin of the front cylinder oxygen sensor to the
short circuit of heating end pin of the front cylinder oxygen sensor to the positive
P0201 fault of for fuel injector front cylinder 513
fault of for fuel injector rear cylinder (plug-in device of the fuel injector is not
P0202 plugged) 514
P0230 open circuit of oil pump or short circuit to the negative electrode of the battery 560
P0232 short circuit of oil pump to the positive electrode of the battery 562
P0336 signal interference of crank shaft position sensor 822
P0337 no signal of crank shaft position sensor 823
P0351 fault of ignition coil for front cylinder 849
P0352 fault of ignition coil for rear cylinder 850
P0562 voltage below level of electronic control injection system 1378
P0563 over tension of electronic control injection system 1379
P0560 fault of trouble light (damage of filament or plug-in device) 1616
P1693 short circuit of tachometer line to the negative electrode of the battery 5779
P1694 short circuit of tachometer line to the positive electrode of the battery 5780
P0137 short circuit of signal end pin of the rear cylinder oxygen sensor to the negative 311
- 189 -
electrode of the battery
short circuit of signal end pin of the rear cylinder oxygen sensor to the positive
short circuit of heating end pin of the rear cylinder oxygen sensor to the positive
short circuit of heating end pin of the rear cylinder oxygen sensor to the negative
- 190 -
16.3.2 Fault Diagnosis by Diagnostic Apparatus
Operation steps
a) Find the 6-hole diagnostic port on the motorcycle.
b) Connect the connecting line to the port on the diagnostic apparatus.
c) Turn on the key to diagnose the faults.
16.3.3 Fault Diagnosis with the Diagnostic Software PCHUD
PCHUD software is used to inspect and record the operating data of the engine. Before using the software,
connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line. The notebook
computer needs to install the K line driver software before using.
- 191 -
Instructions of PCHUD Software:
1Connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line and turn on the
key.
2Click the icon "HUD.EXE" to start PCHUD software
3Select "File" on the software interface, click "Open", choose "PCHUD.HAD" and select OK.
4Select "Parameter File" within "Setup", click the file MT05COMMON.par, choose "Comm protocol" within
"Setup", then select "Keywork2000" and click OK, meanwhile, choose 17 in Device Code.
- 192 -
5If the real-time communication data fail to display on the soft ware interface when the power is on, check
whether the connection setting of COM port in "Setup". Under the normal circumstance, set COM Port: 4 and Baud
Rate: 10400, instead of DTR High at startup.
Normal communication is ready to make then. Current fault code is displayed in the position of MALFCURR and
historical fault code displayed on MALFHIST.
- 193 -
Then check the corresponding fault according to the fault code list
- 194 -
Interpretation of PCHUD Software Parameter
VRPM engine speed
VTHROT throttle position
VBARO BARO
VMAP manifold air pressure
VMAPEXP expect manifold air pressure
VIGN ignition key voltage
VCLTS cylinder temperature or coolant temperature
VIAT intake air temperature
STATUSBYTE5 STATUSBYTE5
VAFCMET airflow correction met
VBAROCMET Baro update met
VCSINSYNSPRK sequential spark enable
SATITRIG tip-in Spark Advance retard trigger
CATLOENB catalyst light-off logic enable
IF ENGSTATE=3 engine work in run state
NISTBLIDLE stable warm idle
FO2REDY2 O2 ready
FCNO block learn memory cell
FBLMCOR1 cylinder 1 block learn memory
FCLCINT1 integral of close loop correction
FCLCMUL1 close loop correction
IARDRPM desired idle rpm
IARPMERR idle rpm error
FPWVC1 base pulse width of cylinder 1
VO2 Oxygen sensor signal
FO2STAT1 cylinder 1 oxygen sensor signal rich lean state
FCLREST1 cylinder 1 close loop correction reset
FOSHTREN Oxygen sensor heater enable
FO2REDY1 cylinder 1 Oxygen sensor ready
IF IACV MODE=0 idle airflow control valve close loop correction enable
IAMTRLOST IACV lost
IACMVIHB IACV move disable
VIGNS ignition state
FVE1 cylinder 1 Volumetric efficiency
VMAPRANG MAP read angle
AFFNLAFR target air fuel ratio
SAESTA cylinder 1 Spark Advance
SAIDLDYN idle dynamic Spark Advance
SPDWELL dwell time
IAINTEGOFST airflow integral of idle air control valve
IACVDSMP desired position of idle air control valve
- 195 -
FCLCEN1 cylinder 1 close loop correction enable
PPDSEBL prime pulse disable
FPENABL fuel pump enable
FTRNSAES acceleration enrich enter
FTRNSDES deceleration enlean enter
FTRNSAEDCLOAD acceleration enrich exit
FTRNSDEINLOAD deceleration enlean exit
FCLCEN2 cylinder 2 close loop correction enable
- 196 -
16.4 Common Fault Removal Techniques
16.4.1 Repair Tools
a) Disassembling the parts of the electronic control system- common disassembly tools for auto machinery parts
b) Circuit of the electronic control system and its electrical signal- digital multimeter (with beep)
c) Diagnosing the faults in the electronic control system and checking the engine's operation
Fault diagnostic apparatus for electronic control system(recommended)
Fault diagnosis software(PCHUD) and port wire( if available)
d) Fault code list of the electronic control system( for emergency)
e) Fuel pressure gauge, range: 0 ~ 300kPa
16.4.2 The Operation Data Flow of the Engine Shown on the Diagnostic
Apparatus
Analyze and check the faults in engine through the operation data flow of the engine shown on the diagnostic
apparatus.
16.4.2.1 Step One
a) Engine wire harness and vacuum line- may influence the system in controlling air flow and oil supply.
b) Assembly of Oxygen sensor- may influence the system in judging the air-fuel ratio.
- 197 -
c) Engine trouble light- influences the system in fault warning.
d) Storage battery voltage- judges whether the battery power is adequate.
e) According to the experience, judge whether the readings of coolant temperature sensor, air intake temperature
sensor, manifold absolute pressure sensor and oxygen sensor are normal.
f) Working range of throttle position sensor- Failure in completely turning on or off the sensor may influence the
power performance of the engine and part of system function.
16.4.2.2 Step Two
Check whether the power supply of ECU is cut off- the communication between the diagnostic apparatus and
the system halts after turning off the key switch.
16.4.2.3 Step Three
a) Coolant temperature and its cycling- indicate whether the thermostat operates normally.
b) Storage battery voltage- shows whether the generator works normally.
Too high: maybe a fault in the generator regulator.
Too lowmaybe the inappropriate connection of generator wires or a fault in the generator
c) Manifold air pressure- may indicate whether there is an intake air leak or an air valve clearance
The air valve clearance is too small: the over high figure may influence the power performance of the engine.
Meanwhile, because the exhaust valve opens too early, the increased temperature of the exhausted air will
significantly reduce the service lives of oxygen sensor and ternary catalytic converter.
The air valve clearance is too large: may cause the manifold air pressure become low, thus influencing the
system in judging the engine's operation and leading to abnormal idling in the engine's warming-up.
Besides, the clogged exhaust system, e.g., foreign materials in the exhaust passage, or the blocked ternary
catalytic converter caused by the over-consumption of the engine oil, or damaged pieces inside of the ternary
catalytic converter, will lead to an over high figure.
d) Cycle number of the oxygen sensor reading- a small cycle number indicates the failure of the oxygen sensor.
16.4.3 Concise Fault Removal Techniques
Please take the following steps to repair the electronic control injection system. If the fault is removed in a
certain step, the following steps can be suspended. Then check and remove the fault code by diagnostic apparatus
in compliance with the term 14.4.2.
When using the diagnostic apparatus, the storage battery voltage cannot be lower than 8.5V.
16.4.3.1 Daily Use and Maintenance
Unleaded gasoline #92 or #95 is strongly recommended.

Though ECU is damp-proof, do not wash the cover with a high-pressure water gun.
- 198 -
The fuel filter should be replaced every 7,000-10,000km
In common circumstances, the throttle valve should be washed every 10,000km or every 1 year.
16.4.3.2 Fault Description- Startup Failure
a) Turn the ignition lock to "ON" to check whether the trouble light turns on.
If no Check the fuse and the ground wire.
Check whether ECU's plug is tightly connected.
Check whether the light and circuit are normal through the inspection function of the diagnostic
apparatus's actuator.
Check and repair the light and its circuit.
Make the judgment with another ECU.
If yes Connect the diagnostic apparatus to the system's diagnostic port.
b) Whether the diagnostic apparatus can be connected to the system for communication
If no: Check the fuse and the ground wire
Check whether ECU's plug is tightly connected
Check whether the diagnostic apparatus works normally on another normal motorcycle.
If yes: Remove the fault shown by the diagnostic apparatus.
c) Check the faults in the ignition system- whether the spark plug can ignite normally
If no: Check whether the high-tension cable and spark plug are connected tightly or are damaged.
Make the judgment with another ignition coil assembly
If yes: Check whether the high-tension cable is connected with the ignition coil and spark plug in a
correct way
d) Check the faults in the oil supply system
Whether the fuel pump is working- the working noise of the fuel pump can be heard in its nearby when
starting the engine.
If no: Check whether the fuel pump relay works normally.
Check whether the connection of crankshaft position sensor and its operation are normal.
Check the fuel pump circuit
If yes: 1) Whether the supplied oil pressure is above 220Kpa
2) Inadequate Check whether there is enough gasoline in the fuel tank
pressure Check whether it is necessary to replace the fuel filter (note: the special
fuel filter for the electronic control injector should be replaced every
7,000-10,000km)
Whether the oil supply line and oil return line are damaged
3) Normal Check whether the nozzle control line is abnormal
pressure Whether it is necessary to clean the oil nozzle
e) Check whether the cylinder is flooded with oil
If yes Press the accelerator pedal to the limit and turn on the starter. After several seconds, there will
be a sign showing the engine running.
f) Whether the clearance of crankshaft position sensor is too large
- 199 -
16.4.3.3 Fault Description- Startup Failure Accompanied with Backfire
a) Check whether the high-tension cable of ignition coil is loose

b) Whether the timing gear is loose.
16.4.3.4 Fault Description- Unstable Idle Speed
Idle speed control Check whether the idle speed by-pass bolt is too loose or tight. Usually it is necessary to
system: screw 2 turns.
Oil supply system Whether there is an oil pipeline leak
16.4.3.5 Fault Description- Too High/Low Idle Speed (Apparent Non-conformity to
Target Idle Speed)
Idle speed is When the water temperature is lower than 68, the system will increase the idle speed to
too high: accelerate the warming up. Besides this normal process, check according to the following
steps.
Check whether the idle air bypass hole is too large.
Check whether the air valve clearance, especially the exhaust valve clearance, is too large.
Idle speed is Check the oil amount in the fuel tank, the fuel filter, the oil line pressure and the oil nozzle.
too low: Check whether the idle air bypass hole is too tiny.
Check whether the air valve clearance is too small.
16.4.3.6 Fault Description- Unstable Idle Speed Slowing Down with Flameout
a) Check the valve clearance

b) Check whether the idle air bypass hole and throttle body are too dirty
16.4.3.7 Fault Description-Poor Acceleration
a) Whether the parameters at idle speed and high idle speed are normal
b) Check the oil amount in the fuel tank, and fuel filter.
c) Check whether the exhaust system is blocked, e.g., whether the ternary catalytic converter is clogged because
of burning engine oil or damages.
d) Check the oil line pressure and the oil nozzle.
e) Check whether the trouble light turns on and whether it is because only one cylinder can work normally to
ignite.
- 200 -
16.4.3.8 Fault Description- Little Misfire
Check whether the spark plug gap meets the standard between 0.7-1mm.
16.4.3.9 Fault Description- Non-conformity between Fault Code and Fault When
Trouble Light is On
The ground wire of the system may be not connected well. Reconnect the ground wire, turn off the storage
battery power line for 3 minutes and turn it on, then start the engine.
16.4.3.10 Fault Description- Abnormally High Oil Consumption
a) Check the assembly of the oxygen sensor of two cylinders. If it is in a loose state, the oxygen sensor will make
a wrong judgment of the slight lean burn in the cylinders, and thus add more fuel, leading to abnormally high
oil consumption.
b) When the engine's mechanical parts and the oxygen sensor are confirmed to be normal, start the engine to
check the reading of the oxygen sensor. If the reading is always above 500 mV in a normal water temperature,
check whether there is a leakage in the oil nozzle.
Note
Most parts of electronic control injection system are non-repairable. Once a part is damaged, usually it needs
to be replaced.
When starting the engine, do not run any other organs of the engine (including the throttle, do not push the
throttle in the startup).
If the engine trouble light turns on when the engine is operating, it is necessary to check the reason and
remove the fault as early as possible.
Do not use leaded gasoline for lead will do harm to the oxygen sensor and ternary catalytic converter.
When there is an abnormal consumption of the engine oil, the fault should be removed as soon as possible, or
some substances in the engine oil will also do harm to the oxygen sensor and ternary catalytic converter.
The air valve clearance should not be too small. If the air valve does not tightly shut off in the exhaust process,
the exhaust temperature will be too high so that the service life of ternary catalytic converter will be reduced.
When the temperature is lower than 10, if the motorcycle and the engine run at a low speed for a long time,
the exhaust pipe may have carbon deposits and appear to be black. This is a normal phenomenon. It will
disappear after the engine operates at a high speed for some time or by adopting appropriate methods to keep
the engine coolant temperature in a specified range
- 201 -
TNT600 Circuit Diagram

/ /
/ /

ECU1
ECU2
IN5408 2# Gr ECU J1 2#BLACK ECU J2
10A 10A 15A 15A 10A 15A

30A /
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 /
/

/

// / / /

1 / 1 / / / / / / / / / / /
/ / / / 1

/ / / / / 11
/
/
/ /

/2
/ / / /1 / / / / / / / / /2
/ / /
/ /1 / / / / / / / 3
/ / / / / / /2
/
/

/
/
/

/ /1 / /
/ /1 /1 / /
/2

/
/
/
/
/ /

/
/
/

/
/

/
/2
/2
4
/2
/
/
/2
/
/
/
/
/
/2
/
/2
/
/

/
/ /2
/2
/2
/
/
/2
2

/ /2
/2

/2
1

/2
/
/1
/
/2
1 /
/ /
/1
/1
/
/1
/1

/
/ /1 / / / / / / / /
/ / / / / /1 / /
/ / / / / / /

/ / / / / / / / / / /
/ / / / / / / / / / / / / / / / / / / / / 1 1 11 1 1
1 1 1 1 1 1 1 1 1 1
3 2 1
12 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

/
/ / 1#Gr ECU J1 1#BLACK ECU J2

1
2

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Benelli TNT 600

BENELLI KEEWAY MOTORCYCLES SDN. BHD.

Engine must be started up in a well-ventilated place, not in a closed area.

Lubricating and Fuel

Please specially note important steps before disassembly. Replacement parts

1The frame number, see figure

Frame Number Rivets

3The serial number of the engine, see figure

Fig. 1-3 Fig. 1-4

Fig. 1-7 Fig. 1-8

Fig. 1-9 Fig. 1-10

Fig. 1-11 Fig. 1-12 pliers piston

Fig. 1-15 Fig. 1-16

Fig. 1-17 Fig. 1-18

Fig. 1-19 Fig. 1-20

Fig. 1-21 Fig. 1-22

Fig. 1-27 Fig. 1-28

Fig. 1-29 Fig. 1-30

Fig. 1-33 Fig. 1-34

Fig. 1-35 Fig. 1-36

Motorcycle Model TNT 600 Engine Type BJ465MS-A

Length mm 2155 Fuel type Unleaded petrol95/97

Width mm 765 No. of cylinder 4

Height mm 1100 ID stroke 65.045.2

Wheelbase mm 1480 Engine Total displacement 600cc

Petrol tank capacity 15L Startup Electric

Forward 115 Cooling Liquid cooling

Front tire 120/70 ZR Variable speed Six variable speed

Electric Transmission ratio

Transmissio Transmission ratio

Fuel consumption Dia. of rear liquid

Abnormal piston of cylinder and

Abnormal automatic choke

Incorrect ignition time

Disassemble once agian the Abnormal adjustment to throttle

Excessive oil injected to fuel

Start engine with

Abnormal piston of cylinder and

Blocking check to Carburetor

No Yes Contaminant removal

Disassemble the spark plug to

Adjust ignition time

Abnormal CPU group

Adjustment to throttle valve and

Mixed gas too thin (loosen bolt)

Abnormal spacer of heat

Disassemble spark plug

Negative pressure pipe damaged

Adjust ignition time

Abnormal CUP group

Little oil in petrol tank

Good Spring broken

Test the voltage of

No voltage rise Voltage rises to normal

Check the plug of voltage

Poor connection of the plug

Check if the red wire of voltage regulators

Test the resistance value of

Voltage above Normal voltage

Check if charging wire of the voltage

Replace on new spark

Weak spark-over or Strong spark Original spark plug abnormal

Check again after