Professional Documents
Culture Documents
Contents
Contents ................................................................................................................................................................. - 1 Preface ................................................................................................................................................................... - 5 Preparing documents ..................................................................................................................................... - 6 Inspection/Adjustment ................................................................................................................................. - 15 I. Battery/Charging System.................................................................................................................................. - 27 1.1 Preparing documents ............................................................................................................................. - 27 1.2 Failure diagnosis .................................................................................................................................... - 28 1.3 Battery ................................................................................................................................................... - 29 1.4 Charging system .................................................................................................................................... - 30 1.5 Voltage/current regulator ....................................................................................................................... - 31 1.6 Magnetor charging coil .......................................................................................................................... - 32 1.7 Magnetor disassembly ........................................................................................................................... - 32 II. Ignition System ............................................................................................................................................... - 35 2.1 Preparing documents ............................................................................................................................. - 35 2.2 Failure diagnosis .................................................................................................................................... - 36 2.3 Ignition system check ............................................................................................................................ - 37 2.4 CDI Group ............................................................................................................................................. - 40 2.5 Ignition coil (picture to be updated) ...................................................................................................... - 40 2.6 Trigger ................................................................................................................................................... - 41 III. Startup System ............................................................................................................................................... - 44 3.1 Preparing documents ............................................................................................................................. - 44 3.2 Failure diagnosis .................................................................................................................................... - 45 3.3 Startup motor ......................................................................................................................................... - 45 3.4 Starter relay............................................................................................................................................ - 47 IV. Bulbs/Switches/Meters .................................................................................................................................. - 49 4.1 Preparing documents ............................................................................................................................. - 49 4.2 Failure diagnosis .................................................................................................................................... - 49 4.3 Replacement of headlamp bulbs ............................................................................................................ - 49 4.4 Replacement of front steering lamp bulbs ............................................................................................. - 50 4.5 Replacement of tail lamp bulbs ............................................................................................................. - 50 4.6 Meter (picture to be updated)................................................................................................................. - 51 4.7 Main switch ........................................................................................................................................... - 51 4.8 Horn ....................................................................................................................................................... - 52 4.9 Handlebar switch ................................................................................................................................... - 52 V. Brake ............................................................................................................................................................... - 55 5.1 Maintenance instruction......................................................................................................................... - 55 5.2 Failure diagnosis .................................................................................................................................... - 55 5.3 Front disc brake ..................................................................................................................................... - 56 5.4 Rear disc brake ...................................................................................................................................... - 58 VI. Body .............................................................................................................................................................. - 61 - 1 -
VII. Front Wheel/Front Suspension ..................................................................................................................... - 63 7.1 Preparing documents ............................................................................................................................. - 63 7.2 Failure diagnosis .................................................................................................................................... - 63 7.3 Front wheel ............................................................................................................................................ - 64 7.4 Steering handle ...................................................................................................................................... - 66 7.5 Front fork ............................................................................................................................................... - 67 7.6 Radiator/expansion tank assembly......................................................................................................... - 68 VIII. Rear Wheel/Rear Suspension ...................................................................................................................... - 70 8.1 Preparing documents ............................................................................................................................. - 71 8.2 Failure diagnosis .................................................................................................................................... - 71 8.3 Rear wheel ............................................................................................................................................. - 71 8.4 Rear absorber/rear swing arm ................................................................................................................ - 72 IX. Lubricating System........................................................................................................................................ - 76 9.1 Preparing documents ............................................................................................................................. - 76 9.2 Failure diagnosis .................................................................................................................................... - 76 9.3 Fuel pump .............................................................................................................................................. - 77 X. Cylinder Head/Valve ....................................................................................................................................... - 81 10.1 Preparing documents ........................................................................................................................... - 81 10.2 Failure diagnosis .................................................................................................................................. - 82 10.3 Cylinder head ....................................................................................................................................... - 82 10.4 Cylinder head check ............................................................................................................................ - 84 10.5 Valve .................................................................................................................................................... - 85 10.6 Valve check .......................................................................................................................................... - 86 10.7 Replacement of valve guide................................................................................................................. - 87 10.8 Adjustment of the valve retainer .......................................................................................................... - 89 10.9 Installation ........................................................................................................................................... - 90 XI. Cylinder Block and Piston ............................................................................................................................. - 92 11.1 Preparing documents............................................................................................................................ - 92 11.2 Failure diagnosis .................................................................................................................................. - 93 11.3 Cylinder block...................................................................................................................................... - 93 11.4 Piston ................................................................................................................................................... - 94 11.5 Piston installation ................................................................................................................................. - 98 11.6 Cylinder installation ............................................................................................................................. - 98 XII. Drive Face/Clutch/Driven Wheel ............................................................................................................... - 101 12.1 Preparing documents ......................................................................................................................... - 101 12.2 Failure diagnosis ................................................................................................................................ - 101 12.3 Left crankcase cover .......................................................................................................................... - 102 12.4 Drive face .......................................................................................................................................... - 102 12.5 Clutch/driven wheel ........................................................................................................................... - 105 12.6 Breakdown of clutch and driven wheel ............................................................................................. - 106 12.7 Installation ......................................................................................................................................... - 110 XIII. Decelerator ................................................................................................................................................ - 112 13.1 Preparing documents ......................................................................................................................... - 112 - 2 -
13.2 Failure diagnosis ................................................................................................................................ - 112 13.3 Gearbox ............................................................................................................................................. - 112 13.4 Installation ......................................................................................................................................... - 114 XIV. Crankcase .................................................................................................................................................. - 115 14.1Preparing documents .......................................................................................................................... - 115 14.2 Failure diagnosis ................................................................................................................................ - 116 14.3 Crankcase........................................................................................................................................... - 116 14.4 Installation ......................................................................................................................................... - 118 XV. Cooling System .......................................................................................................................................... - 120 15.1 Preparing documents ......................................................................................................................... - 120 15.2 Failure diagnosis ................................................................................................................................ - 120 15.3 Thermostat ......................................................................................................................................... - 121 XVI. Exhaust Emission & Control System ....................................................................................................... - 125 16.1 Warranty on the exhaust emission & control system ......................................................................... - 125 16.2 Instructions on the periodic maintenance .......................................................................................... - 126 16.3 Mechanical function of the exhaust control system ........................................................................... - 127 16.4 Catalytic conversion system .............................................................................................................. - 127 XVII. EFI System .................................................................................................................................................. 129 17.1. Connection of the EFI system ............................................................................................................... 129 17.2. Engine controller (MC21)..................................................................................................................... 130 17.3. Power supply requirements ................................................................................................................... 135 17.4. Work temperature.................................................................................................................................. 135 17.5 Maintenance and repair.......................................................................................................................... 135 XVIII. M3 and M3.5 Fuel Injector ........................................................................................................................ 137 18.1. List of spare parts.................................................................................................................................. 137 18.2. General work principle ......................................................................................................................... 137 18.3. Appearance ........................................................................................................................................... 138 18.4. O-ring.................................................................................................................................................... 139 18.5. O-ring replacement ............................................................................................................................... 139 18.6. Suggested lubricant............................................................................................................................... 139 18.8. Temperature range ................................................................................................................................ 140 18.9. Fuel contaminants ................................................................................................................................. 141 18.10. Cable arrangement .............................................................................................................................. 141 18.11. Instructions.......................................................................................................................................... 141 18.13. Replacement ....................................................................................................................................... 143 18.14. Replaceability ..................................................................................................................................... 144 18.15. Fuel injector blocked .......................................................................................................................... 144 18.16. Cleaning .............................................................................................................................................. 145 XIX. Throttle Valve Assembly............................................................................................................................... 145 19.1. List of spare parts.................................................................................................................................. 145 19.2General work principle ........................................................................................................................... 146 19.3. Appearance ........................................................................................................................................... 146 19.4. Technical parameters ............................................................................................................................ 146
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19.5. Work environment ................................................................................................................................ 147 19.6. Disassembly of the throttle valve.......................................................................................................... 147 19.7. Cleaning ................................................................................................................................................ 147 19.8. Installation of the throttle valve ............................................................................................................ 148 19.9. Precautions............................................................................................................................................ 148 19.10. Instruction ........................................................................................................................................... 148 XX. Water Temperature Sensor for the Engine ..................................................................................................... 150 20.1 List of spare parts................................................................................................................................... 150 20.2. General work principle ......................................................................................................................... 150 20.3. Appearance ........................................................................................................................................... 150 20.4. Installation requirements....................................................................................................................... 150 20.5. Work environment ................................................................................................................................ 151 20.6. Storage environment ............................................................................................................................. 151 20.7. Electric environment ............................................................................................................................. 151 20.8. Cleaning samples .................................................................................................................................. 151 XXI. Intake Air Temperature Sensor ..................................................................................................................... 152 21.1. List of spare parts.................................................................................................................................. 152 21.2. General work principle ......................................................................................................................... 152 21.3. Appearance ........................................................................................................................................... 152 21.4. Technical parameters ............................................................................................................................ 152 21.5. Installation requirements: ..................................................................................................................... 152 21.6. Cleaning samples .................................................................................................................................. 152 XXII. Oxygen Sensor ............................................................................................................................................ 153 22.1. List of spare parts.................................................................................................................................. 153 22.2. General work principle ......................................................................................................................... 153 22.3. Appearance ........................................................................................................................................... 153 22.4. Technical parameters ............................................................................................................................ 153 22.5. Installation requirements....................................................................................................................... 154 22.6. Fuel quality requirements ..................................................................................................................... 154 XXIII. Fuel Pump Assembly ................................................................................................................................. 154 224. List of spare parts................................................................................................................................... 154 23.2. General work principle ......................................................................................................................... 155 23.3. Appearance and structure ...................................................................................................................... 155 23.4. Dimension ............................................................................................................................................. 156 23.5. Label and mark ..................................................................................................................................... 156 23.6. Work environment ................................................................................................................................ 156 23.8. Maintenance procedures ....................................................................................................................... 157 XXIV. Failure Diagnosis ....................................................................................................................................... 163 24.1. Diagnostic tools .................................................................................................................................... 163 24.2. Pin definition for the diagnosis interface: ............................................................................................. 163 24.3. Software instruction .............................................................................................................................. 164 24.4 Cross reference table for malfunction code ........................................................................................... 168 Circuit Diagram ................................................................................................................................................. 172
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Preface
This maintenance manual is used for operating and maintaining EFI Motorcycle OUTLOOK (DIERRE) 125. Preparing Documents include all necessary instructions and statements. Please carefully read 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 engine, entire motorcycle and electrical parts. 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 this mentioned here. We will not make notification for any discrepancy.
Preparing documents
General safety Maintenance rules
Failure diagnosis
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 up engine in an open place. The exhaust cleaning system shall be adopted if engine is started up in a closed area.
Petrol
Ventilation is required for working places. Fire is strictly forbidden in any working place or where petroleum is stored.
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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 shield for maintenance, which can prevent dirt from falling into the engine, chassis or braking system. Wash and dry parts with air compressor after disassembly and before measurement of attrition value.
Do not bend or twist it. Otherwise it will cause difficulty in operation or early damage.
error
Solvent or oil can easily damage aging rubber articles. Check rubber before reassembly and replace rubber if necessary.
boot
When loosening assembly parts, please start from outside to inside. Small assembly parts shall be loosened first.
Complex assembly parts, such as gearbox, shall be stored in proper order for facilitating installation in the future.
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Please specially note important connections before disassembly. Replace parts which will not be in use before disassembly.
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 proper if you are confused.
Fill the groove with grease before mounting an oil seal. Check whether the oil seal is smooth or damaged during assembly.
When installing a 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.
groove clip connector 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. Bearings will be broken under either occasion as mentioned.
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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.
Fig. 1-3
Fig. 1-4
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Fig. 1-5
Fig. 1-6
Fig. 1-7
Fig. 1-8
Fig. 1-9
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Fig. 1-11
Fig. 1-13
Fig. 1-14
Fig. 1-15
Fig. 1-16
(1) Ordinary tools for repairing the chassis Table 1-18 (continued)
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Fig. 1-19
Fig. 1-20
1. socket head 2. crank handle 3. ratchet spanner 4. connecting rod Fig. 1-21 Fig. 1-22
Fig. 1-23
Fig. 1-24
Fig. 1-25
Fig. 1-26
Fig. 1-27 - 12 -
Fig. 1-28
(2) Special tools for repairing the chassis: tool for hammering seal of front fork
Fig. 1-29
Fig. 1-30
Fig. 1-33
Fig. 1-34 - 13 -
Engine type Fuel type No. of cylinder ID stroke Total displacement Startup Cooling
QJ153MI-2A
Unleaded petrol 1 52.4*57.8 125ml Electric Water cooling Force-feed and splash Paper-made 7.4 0.2L
Automatic
CVT
Drive
Belt drive
Electric devices
Battery 12V-6Ah/ capacity/type dry-charged Magnetor QJ 153-2 12V type 200W/8500 rpm Spark plug CR8EH (NGK)
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Braking system
Unit of front fluid brake disc (mm) Unit of rear fluid brake disc (mm)
240mm
240mm
Inspection/Adjustment
Preparing information Periodic Maintenance & Inspection Table Engine oil/ Oil filter Fixing steering stem bearing & handlebar Inspection & adjustment of throttle cable Air filter Spark plug Battery Ignition timing Rim/tyre Tyre specification Cylinder pressure Gear oil Replacement of gear oil Driving belt Free stroke of front/rear brake
Inspection of brake fluid level Headlamp Clutch Front/rear suspension system Bolt/nut/fastener
Preparing Principles
General
Warning! Make sure that it is well ventilated before starting the engine. It is forbidden to start it in a closed area. Exhaust gas, which contains monoxide, may cause unconsciousness or even death of human being. Petrol is liable to volatile or explode under certain condition. Ventilation is required and no any fire exists in working places. Fire is strictly forbidden in working areas or where oil is stored.
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Specification
Engine
Idle speed Spark plug gap Spec. of spark plug Cylinder compression pressure Ignition time 1500 100rpm/min 0.6-0.7mm C5HSA(NGK) 1.25Mpa/1500rpm BTDC12 degree degree, 1500 1 100rpm
Frame
Free stroke of front brake lever Free stroke of rear brake lever Specification Tyre pressure unit: Kpa EFI Motorcycle QJ125T-30 Front wheel Rear wheel 10-20mm 10-20mm Tyre pressure
100/80-16 120/80-16
55-62 N m
225kpa 225kpa
Torque value
Locking nut for front wheel spindle Fixing nut for rear wheel
100-113 N m
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Tools
Inspection item New * * * Air filter Petrol filter Fuel filter Replacement of engine fuel Tyre pressure Battery inspection Actuation gap inspection Inspection of steering handle fastening Absorber working inspection Screw fastening inspection Oil leakage inspection for gearbox * * Inspection or replacement of spark plug Replacement of gearbox oil Lubrication of each part Exhaust pipe * * * Ignition timing Exhaust gas inspection at idle speed Throttle inspection Fuel pipeline inspection Lighting/metering/electric devices I I A I I I I I I I I I A I I I
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I I C R I I I I I I I I I I I I I I
I I I I
I I I
I I I I I
Anticipated Inspection
1 2 3 Ignition systemobviously continuous ignition abnormality, engine fire or overheating, which requires inspection and maintenance. Carbon fouling eliminationobviously insufficient horsepower, which requires carbon fouling removal from cylinder head, piston head and exhaust system. Piston & cylinderexcessive abrasion; replace cylinder if it is blocked.
Please have your motorcycle inspected and adjusted periodically at KEEWAY 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.
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 it is below the lower limit. dipstick upper limit lower limit filter
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Oil replacement
*Note* It will be easier to change oil when the engine is warming up. Turn off the engine. Remove the bolt at the bottom of the crankcase and discharge oil. When oil is discharged completely, you can install the bolt and packing washer after they are cleaned. Add oil to the required level. Check oil leakage when the engine operates at its idle speed for minutes. Check the oil level again.
Air
filter
(picture
to
be
updated)
Filter replacement. Remove the fixing screws of air filter. Remove the top cap of air filter. Remove the cartridge from the filter. clamp assembly Check whether the cartridge is stained or damaged.
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Replace it if necessary. Remove the clamp assembly. Remove the filter. Check whether the filter is stained or damaged. Replace it if necessary.
Replacement time
Replace it as early as possible if the motorcycle is always running on rainy days or on rugged road. *Note* Make sure the air filter cap is well installed before installing the filter. top cap of the air filter mounting screw resonance box body cartridge
Spark plug
Remove the spark plug. Check whether the spark plug is damaged or stained or has carbon fouling. If yes, please clean it with spark plug cleaner or steel brush. Check spark plug gap. Gap: 0.6-0.7mm *Note For the installation of spark plug, it shall be installed with hand first and then fastened with spark plug sleeve. spark plug gap
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Cylinder pressure
Operate it when the engine warms up. Remove the seat and body guard. Remove the spark plug. Install the cylinder pressure gauge. At full throttle, measure the cylinder pressure by starting the engine. Compression pressure: 1.25Mpa/1500rpm Following items shall be checked in case of extra-low pressure: measure cylinder pressure whether the spacer of cylinder head is damaged; whether piston ring is damaged; whether piston ring is worn; whether the piston, cylinder or valve is worn. When compression pressure is too high, please check whether there is too much carbon fouling inside the combustion chamber and at piston head.
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Gear oil
Inspection
*Note Set the middle kickstand on the flat ground and keep the motorcycle upright for checking the oil level. Remove the oil-check bolt after the engine is stopped. It is good if the oil level is at the lower limit of the oil-check bolt hole. Add gear oil when the oil level is too low. Install the oil-check bolt. *Note Make sure whether the bolt is well sealed, slippery or damaged.
Drive belt
Remove the cover of left crankcase. Check whether the drive belt is ruptured or abraded. Periodically maintenance shall be guaranteed, and replace the drive belt if necessary. drive belt
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Headlamp
Remove the front shield. Disconnect the connector of the headlamp. Remove the headlamp.
Clutch
Start the engine and increase its speed gradually to check the work condition of the clutch. If the motorcycle fails to run or the engine flames out, you should check the clutch block. Replace it if necessary.
Rear
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. compress upwards or downwards
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Rim/tyre
Check whether tyres or rims have any crack, nail or any other damage. Check tyre pressure.
Required pressure Specification EFI Motorcycle QJ125T-30 Front wheel Rear wheel
100/80-16 120/80-16
225 225
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: locking nut of the front wheel spindle fixing nut of the rear wheel measure tyre pressure 55-62 N m 100-113 N m
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stabilizer
battery
Charging System
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I. Battery/Charging System
Preparing documents -------------1.1 Battery -----------------------------1.3 Voltage/current regulator --------1.5 Disassembly of magnetor--------1.7 Failure diagnosis --------------1.2 Charging system ---------------1.4 Charging coil of magnetor----1.6
Preparing principles
Item Battery Capacity/Type Voltage Fully charged
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20
Necessary charging
12.3V (not working for 1h) Standard: 0.6A, quick: 6A Standard: 10-15 hours, quick: 30 mins 200W/8500rpm Between white-black 3.3-3.5 Three-phase full-wave 14.5 0.5V/5.000rpm
Charging current Charging time Magnetor Voltage regulator Capacity Coil impedance (20) Type Charging voltage
Tools
Universal fixing spanner Flywheel remover Test instrument Multimeter
Interrupted current
Poor contact of the charging wire Poor contact of the charging system Poor contact or short circuit of the lighting system
Low voltage
Poor battery charging Poor contact Poor charging system Poor voltage/current regulator
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*Note First positive terminal and then negative terminal to prevent short circuit. Check the charging situation (open circuit voltage). Open the battery cover and remove the fixing plate assembly of the battery. Remove the lead of the battery connector. Measure voltage between terminals. Fully charged: 13.1V Insufficiently charged: 12.3V (not working for 1h) *Note Use a voltmeter to check the charging situation.
1.3.2 Charging
Connection method: connect the positive terminal of the charger with the positive terminal of the battery; connect the negative terminal of the charger with the negative terminal of the battery.
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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: 0.6A quick: 6.0A Charging time: standard: 10-15 hours quick: 30 minutes Charging completed: open circuit voltage: above 12.8V
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With lead
3 2 1
1. Select diode in the multimeter; 2. The black probe connects the red terminal of the stabilizer, and the red probe respectively connects white terminals of the stabilizer (white1, white 2 and white3). Pointers indicate values. If not, the stabilizer is damaged and needs replacement. 3. The red probe connects the black terminal of the stabilizer and the black probe connects white terminals of the stabilizer (white1, white2, white3). Pointers indicate values. If not, the stabilizer is damaged and needs replacement. *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.
Check
Remove the 6p connector of the magnetor. Measure impedance between the white coil of the magnetor and the body with multimeter. Standard: 0.6-120 Replace the magnetor coil when the measured value exceeds the standard value.
bolt
1.7.2 Installation
Install the stator on the body of the engine. Connect the magnetor 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 N m bolt Install the left body guard.
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igniter
electric horn
battery
Ignition System
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BATTERY
Preparing principles
Item Spark plug recommended Standard Hot type Cold type Standard value
C5HSA(NGK) C6HSA(NGK) C7HSA(NGK) 0.6-0.7mm 0.4 10 8-11K 4.5-5.5K 100-200 95-400V Above 1.7V
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Impedance of trigger20 Measure the maximum primary voltage of the ignition coil Trigger voltage
Tools
Attachments to the Maximum Voltage Table Multimeter
Ignition coil
Charging coil
No high voltage
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Poor ignition coil. Poor charging coil. The inner resistance is too small and it should be tested by required tester. Low speed of the crankshaft. Interfered tester (It is normal that voltage is always beyond the required value upon several measurements.) Poor trigger (Item - is checked to be normal.) Poor ignition coil. Poor trigger.
multimeter
between the primary coil terminal (black/white) 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.
/ Remove 4P connector and 2P connector from CDI group. Install a high-pressure shunt between the charging coil with 2P connector (red/white terminal) and 4P connector (black terminal). Press the startup motor or step the actuating lever to measure the maximum voltage of the charging coil. Connection: positive pole to red/white; negative pole to black. black red white green blue 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 CDI Group is abnormal, dismantle the body guard and the magnetor terminal. Connect the charging coil (black/red) to the shunt. If the voltage of CDI 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 CDI and magnetor terminal appears to be abnormal, it is caused by poor charging coil. Please refer to charging coil check.
/ / / /
19.3 Trigger
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*Note Install the spark plug on the cylinder head and carry out measurement when the compression pressure is normal. Remove 6P connector of CDI group. Connect the peak-voltage shunt between the trigger with 6P connector (blue/white terminal) and 6P connector (black terminal). Press the startup motor or step the actuating lever to measure the maximum voltage of the trigger. Connection: positive pole to blue/white; negative pole to black. Minimum voltage: above 1.7V. *Note Never touch any metal part of the test rod with your finger to avoid electric shock. white blue When the maximum voltage measured at the terminal of CDI Group is abnormal, dismantle the right body guard and the magnetor connector. Connect the trigger (blue/white) to the shunt. If the voltage of CDI 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 CDI and magnetor terminal appears to be abnormal, it is caused by poor trigger. Please refer to the table of failure diagnosis.
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/ / /
20.2 Check
Remove CDI Group and check whether the terminal is loose or corrosive. black red white green blue Item Main switch Trigger Primary coil of the ignition coil Secondary coil of the ignition coil Test terminal Red--red/white
Blue/white white/green
Standard (20) Conduction when the main switch is OFF 100-200 0.4 10 4.5-5.5K 10
(ignition coil)
Measure impedance between terminals of the primary coil. Standard: 0.4 1020 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 Trigger
*Note Check the trigger on the engine.
Check
Remove the body guard. Remove the trigger terminal. Measure the impedance between the blue/white terminal of the side wire of the engine and the body GND. Standard: 100-20020 Replace the magnetor if the measured value exceeds the standard value.
white blue
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/ /
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stabilizer
battery
BATTERY
RELAY
STARTOR MOTOR
Startup Diagram
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Preparing principles
Item Length of the brush of the startup motor Bushing of the startup idler shaft Outer diameter of the startup idler shaft Standard 12.5mm Limit for use 8.5mm 8.3mm 7.94mm
Tools
Spanner for fixing nuts Universal fixing spanner
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3.3.2 Breakdown
Remove screws in the shell, front cover, motor housing and other parts.
3.3.3 Check
Check other components.
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Replace any part with abraded, damaged or burnt surface. carbon brush Clean the commutator surface if there is metal power attached to it. Check conduction between the surface of other components. Ensure non-conduction between armature shafts of the commutator. Check the conduction of the shell of the startup motor. Ensure non-conduction between the conduction terminal and the startup motor shell. Check conduction between the conduction terminal and the brush. Replace any abnormal part. Check conduction of the brush bracket. Replace it when there is conduction. Measure the length of the brush. Limit for use: replace it if lower than 8.5mm Check smooth rotation of the needle bearing inside the front cover and whether it is loose when press-in. Replace it if there is any abnormality. Check whether the oil seal is abraded or damaged.
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 surface of the brush and the armature shall not be damaged. Pay attention that the armature shaft shall not damage lips of the oil seal. Install the rear cover of the motor. 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.
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Then install the startup motor. Install the wire clip for rear brake.
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3.4.4 Check
Connect the starter relay to the battery, and the terminal of the startup motor to the multimeter. Connect 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.
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IV. Bulbs/Switches/Meters
Preparing documents --------------4.1 Failure diagnosis--------------4.2 Replacement of headlamp bulbs --------4.3 Meters ----------------4.6 Main switch --------------4.7 Horn ----------------4.8
Replacement of front steering lamp bulbs------4.4 Handlebar switch -------4.9 Replacement of tail lamp bulbs-------4.5
4.3.2 Installation
Install the bulb in reverse order.
4.4.2 Installation
Install the bulb in reverse order.
4.5.2 Installation
Install the tail lamp in reverse order.
4.5.3.2 Installation
Install the bulb in reverse order.
/ /
P
red /red/white yellow /orange/blue power switch
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4.8 Horn
Check
Remove horn wires. It shows good when the horn wire is connected to the battery.
1. Dipswitch 2. Steering lamp switch 3. Horn switch 4. Lamp switch 5. Startup switch
PASSING
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1. front disc brake assembly 2. handle 3. handle screw 4. hexagon flange locking nut 5. hexagon flange bolt 6. packing washer 7. fuel pump assembly 8. bolt 9. fixing cover 10. brake switch assembly 11. screw 12. brake hose assembly 13. brake cylinder assembly 14. connecting bracket of the front disc brake 15. brake shoe assembly 16. bolt
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1. rear disc brake assembly 2. fuel pump assembly 3. brake cylinder assembly 4. brake hose assembly 5. handle 6. packing washer 7. hexagon flange locking nut 8. hexagon flange screw 9. fixing cover 10. brake switch assembly 11. cross recessed countersunk screw 12. hexagon flange locking nut 13. handle screw 14. connecting bracket of the rear disc brake 15. brake shoe assembly 16. mounting bolts for rear disc brake 17. rear disc brake clamp
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V. Brake
Maintenance instruction ------------------------5.1 Failure diagnosis---------------------------------5.2 Front disc brake ---------------------------------5.3 Rear disc brake ----------------------------------5.4
5.1.1 Specification
Item Thickness of front brake disc Thickness of front brake shoe Thickness of rear brake disc Thickness of rear brake shoe EFI Motorcycle QJ125T-30 240mm Standard (mm) 4.0 6.0 4.0 6.0 Diameter of front disc brake: 240mm Limit for use (mm) 3.0 3.0 3.0 3.0 Diameter of rear disc brake:
Abnormal noise
1. Abraded brake shoe 2. Stained brake shoe or brake disc
5.3.2 Check
Check whether brake shoes are abraded. Replace it if necessary. Measure the brake shoe and the brake disc. Record maximum values.
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Specification Diameter of the front brake disc Thickness of the front brake disc *Note Measurement with micrometer.
240mm 4.0mm
Measure the thickness of the brake shoe. 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 3.0mm brake disc 3.0mm Note: replace brake shoes in pair.
brake shoe
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 the brake 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 bolts for the brake disc 22-29 N m Mounting bolts for the front brake shoe assembly 22-29 N m Do not stain brake shoes with oil spots. Use brake cleaning agent to clean brake shoes with oil spots. brake shoe brake cylinder *Note Any oil spot on brake shoes will reduce brake performance.
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fuel pump assembly brake cylinder assembly brake hose assembly *Note Replace the brake shoe assembly. If the brake shoe will be used again, mark it before disassembly so as to reinstall it at the original place. Remove following assemblies from the rear wheel. Rear brake: 1. brake shoe assembly 2. rear brake hose assembly 3. brake cylinder 4. connecting bracket of the rear disc brake 5. rear disc brake clamp pump assembly fuel brake cylinder assembly brake hose assembly Note: for details, see P60
5.4.2 Check
Check whether the brake disc and the brake shoes are abraded. Replace it if necessary. Measure the brake shoe and the brake disc. Record maximum values. *Note Scrub the rusty brake disc with sandpaper #120. Measurement with micrometer. Measure the thickness of the brake disc and the brake shoes. If the thickness of the brake disc or the brake shoe is below
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the required value for maintenance or it is stained with grease, please replace it. Note: replace brake shoes in pair. Diameter of the rear brake disc 240mm Thickness of the rear brake disc 4.0mm Limit for use: brake shoes 3.0 mm brake disc 3.0mm
5.4.3 Installation
Install the rear brake disc. Install the rear wheel. Install the rear brake cylinder assembly. *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.
brake shoe brake cylinder Torque force: Fixing bolts for rear brake shoe assembly: 22-29 N m Do not stain brake shoes and brake disc with oil spots. Use brake cleaning agent to clean brake shoes and brake disc with oil spots. *Note Any oil spot on brake shoes will reduce the brake performance. Note: for details, see P60.
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front shield lattic front shield front fender windshield handlebar front shield decorating frame of the front shield front wind board of the radiator rear wind board of the radiator front inner fender rear handlebar shield battery cover frame number cover pedal lower fender left/right lattice of the foot guard tail box cover assembly battery front left guard left/right pedal guard front right
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guard seat assembly front right guard right cover of the left pedal left cover of the right pedal rear lower fender rear inner fender rear inner fender rubber rear right guard rear left guard left decorating board for the guard right decorating board for the guard rear handrail rear fender rear reflector
VI. Body
Dismantle the body in following order.
Handlebar front shield windshield handlebar rear shield meter front shield front inner fender foot guard battery box cover left/right pedal cover left/right pedal rubber left/right pedal guard rear handrail seat helmet box left/right rear guard left/right front guard rear fender rear inner fender rear inner fender rubber rear lower fender pedal front fender
*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 no damage any part during assembly.
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Front wheel
cotter pin gear housing assembly front rim oil seal brake disc left bushing of the front wheel front wheel spindle slotted nut rolling bearing front tyre middle spindle sleeve of the front wheel rolling bearing mounting bolts for the brake disc
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Motorcycle Standards
Measurement points Front wheel spindle Front wheel Rim shimmy Item Bending Vertically Horizontally Within 1.0 Standard (mm) Limit for use (mm) 0.2 2.0 2.0
Torque force
Fixing bolts for the steering handle Locking nut for the front wheel spindle 40-60 55-62 N m N m
Flat tyre.
wheel spindle
7.3.2 Check
7.3.2.1 Check the bending of the wheel spindle
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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
Check rolling of the bearings. The bearings will not roll if abraded or loosened. Replace it.
clearance
axially
radially
Lubricate the bearings with grease during installation. Then press the bearings in with bearing installation tools. *Note Bearings must be pressed in horizontally. The oil seal side of the bearings shall be pressed in from outside.
7.3.4 Installation
Lubricate the oil seal of the front wheel with grease. Lubricate gear engagement parts and moving parts with grease. Install the middle spindle sleeve, bearings and oil seal. Align the gear housing assembly and then install the front wheel. Note If the gear housing assembly of the odometer is not aimed at and locked with the front wheel spindle, the gear housing assembly will be deformed. After the rim is installed, rotate the rim to ensure that the drive shaft of the odometer works normally. Install and tighten the front wheel spindle. * Note: for the disassembly and assembly of the front suspension of EFI Motorcycle QJ125T-30, please see P65. Torque force Locking nuts for the front wheel spindle 55-62 N m
weld
assembly of the steering handle bolt locking nut fixing sleeve of the steering stem throttle cable assembly decorating cover of the grip right grip assembly screw right handle sleeve
7.4.2 Installation
Install it in reverse order. Fixing bolts Torque force: 40-60 N m
7.5.3 Installation
Tools: Fixing nut spanner. Ensure the front fork is not loose by left and right movement. Steps: Install the steering handle. Install the absorber. Install the front wheel. weld assembly of the lower connecting bracket front left absorber assembly gland nut lock washer upper cup of the upper bearing steel ball lower cup of the upper bearing bearing washer spring washer bolt front right absorber assembly
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7.6.2 Check
Open the water tank cover and check the coolant level inside. Add coolant when it approaches the limit. Broken or twisted heat sink will reduce the cooling heat sink capability of the radiator. Repair the radiator with a small club when over 1/3 of heat sink is damaged or twisted. Check the liquid level of the radiator. Remove the radiator cover after the liquid is fully cooled; Completely discharge the coolant; Add the prepared coolant slowly through the filling hole (mounting hole of the radiator) until it reaches the edge of the hole; Install the radiator cover. Note: please use KEEWAY coolant; The minimum temperature for using KEEWAY coolant is -35.
edge
heat sink
coolant
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Check the switch of the fan. Replace it when the switch can not work normally.
cooling fan
fan switch
Pressure test for the radiator. Remove the radiator cover after coolant is fully cooled; Apply required pressure to the cooling system with the radiator cover tester (lower than pressure for opening the valve of the cover) and ensure that it can keep for at least 6s under the required pressure; In the case of pressure leakage, check the hose, all connections, pump position and inspection hole.
7.6.3 Installation
Install it in reverse order. radiator cover tester
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Preparing Principles
Item Rear wheel shimmy Vertically Horizontally Standard (mm) Limit for use (mm) 2.0 2.0
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 shimmy exceeds the limit, the rear wheel bearing is loose, which causes shimmy. Check and replace the rear wheel bearings.
8.3.3 Installation
Install the rear wheel in reverse order and lock nuts. Fixing nuts for the rear wheel Torque force: 100-113 N m
mounting bolts for brake discs brake disc tyre right bushing of the rear wheel seal ring rear absorber bracket left bushing of the rear wheel oil seal cotter pin retainer ring bearing retainer ring slotted nut fixing sleeve assembly of the fixing bracket stationary bushing assembly of the rear absorber rear rim rear absorber bracket assembly
8.4.2 Installation
Install the rear absorber. Torque force: Upper fixing nut: 37-44 N m Lower fixing nut: 22-29 N m Install the rear absorber. Install the air cleaner. Install the muffler. Install the rear handrail and the rear fender. Install the seat and the rear left/right guard. bolt rear absorber assembly
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Tightening torqueN m
Cylinder cover bolts Drain bolts Spark plug Closing bolts Blots for the transmission chamber cover Fixing bolts for the motor Fixing bolts for the fuel pump Fixing bolts for the fuel pump sprocket Locking nuts for the flywheel Right cover stud Double-end stud Fixing bolts for the chain adjuster Fixing screws for the electrical cable clamp
2528 2225 1015 1012 1012 1012 1012 1012 5060 1012 1822 1012 47
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camshaft
piston
crankshaft
Fuel pump
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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.
Preparing Principles
Item Fuel capacity when replacing fuel when disassembly radial clearance between inner and outer rotors Fuel pump rotor clearance between outer rotor and pump body clearance between rotor surface Standard 0.9L 1L 0.040.15 0.150.21 0.07-0.12 Limit for use / / 0.20 0.21 0.18
Burnt engine
No fuel or low fuel pressure Blocked fuel pipes No fuel used
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chain cover
screw
Remove the fixing nuts for the sprocket. Remove the sprocket and the chain.
chain
sprocket
nut
Check the radial clearance between inner and outer rotors. Limit for use: 0.20mm
Check the clearance between the outer rotor and the fuel pump housing. Limit for use: 0.21mm gauge
gauge
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panel
9.3.2 Breakdown
Break down the fuel pump according to the following picture.
inner rotor fuel pump fuel pump shaft fuel pump chain cotter pin outer rotor fuel pump cover screw Note: After assembly, the inner and outer rotors shall rotate flexibly without being seized.
9.3.3 Installation
Install it in reverse order.
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X. Cylinder Head/Valve
Preparing documents---------------11.1 Failure diagnosis---------------11.2 Cylinder head-----------------11.3 Cylinder head check-------------11.4 Valve-------------------11.5 10.1 Preparing documents Work Instructions
To ensure sealing between the cylinder head and the cylinder block, the cylinder head shall sustain the bolt pretension of 50Nm. All parts shall be cleaned and blown with high-pressure gas before check.
Valve check---------------11.6
Function of cylinder head: The cylinder head is used for sealing the cylinder and constitutes the combustion
chamber with the piston to sustain high-temperature and high-pressure gas. It achieves gas intake and exhaust with the valve actuating mechanism.
Preparing Principles
Item Cylinder pressure Flatness of cylinder cover Valve clearance Inner diameter of valve guide Clearance between the valve stem and the valve guide Width of valve seat Valve spring Swing arm Free length Diameter of swing arm hole Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake/exhaust Intake/exhaust
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Unit: mm Standard 1.25MPa 0.03 0.10 0.13 5.00-5.012 5.00-5.012 0.010-0.035 0.030-0.05 1.2 1.2 35.4 Limit for use / 0.03 0.12 0.14 5.03 5.03 0.08 0.10 1.7 1.7 34.9
10.00-10.015
10.10
Diameter of swing arm shaft Clearance between the swing arm hole and the swing arm shaft Cam height
Intake/exhaust Intake/exhaust
9.982-9.988
9.90
fixing bolt
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chain tensioner spacer Remove the washer and the cotter pin. Loosen bolts and remove the camshaft bracket assembly. Note: when the bolts of the camshaft bracket are removed, apply staggered steps. Otherwise, the bracket will be broken.
washer
cotter pin
camshaft bracket
Remove the chain from the timing driven sprocket. Remove the camshaft. Remove the cotter pin. Remove the cylinder head. Note: hang the chain with a section of metal wire to prevent it from falling into the crankcase.
camshaft
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cotter pin
Fasten M5 screw into the swing arm shaft and pull the shaft out. Remove the swing arm and the decompressor.
M5 M5 screw
micrometer
- 84 -
Measure the inner diameter of the swing arm hole. Limit for use: 10.10mm Clearance between the swing arm hole and the swing arm shaft. Limit for use: 0.033mm
tester
Compress the valve spring with the valve spring compression tool and remove the valve cotter. Remove the spring plate, valve spring, spring washer for the outer valve and valve in sequence.
valve cotter
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spring plate
spring
ruler
gauge
Measure the free length of the valve spring. Limit for use: spring: 34.9 mm
vernier caliper Measure the outer diameter of the valve stem. Limit for use: 4.95mm
- 86 -
Check the valve guide and eliminate carbon deposit in the valve guide with reamer before check. Note: rotate the reamer clockwise, but not counterclockwise.
valve reamer
Measure the inner diameter of each valve guide. Limit for use: intake/exhaust: 5.03mm Limit for use for the clearance between the valve and the valve guide: Intake valve: 0.08mm Exhaust valve: 0.10mm
tester
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Fix the cylinder head. Remove the valve guide from the cylinder head with the valve guide disassembly tool. Place a new O-ring on the new valve guide. Install the valve guide over the cylinder head. Note: do not damage the cylinder head when the valve guide is installed.
Insert the valve guide. Adjust it with the valve guide reamer. Note: add some cutting oil when cutting with the reamer which shall rotate clockwise.
valve reamer Eliminate carbon deposit inside the combustion chamber and the valve. Thoroughly clean the intake valve and the exhaust valve. Check the width of the contact surface of the valve seat (width of the valve retainer). Limit for use: intake/exhaust: 1.7mm
- 88 -
Remove any hackly or uneven part in the surface of the valve retainer with a milling cutter of 45 . Note: add a layer of transparent or Prussian blue coating on the valve retainer so as to see it clearly.
hackly part Eliminate 1/4 of the outer edge of the valve retainer with a milling cutter of 20 .
Eliminate 1/4 of the bottom end of the valve retainer with a milling cutter of 60 Remove the milling cutter and check . any milled part.
- 89 -
Mill the valve retainer with a refined milling cutter of 45 to make it have proper width. Any dent or hackly part must be removed. Standard width of the valve retainer: intake: 1.2m exhaust: 1.2m
If the higher part of the valve is contacted, reduce the height of the valve retainer with end mills of 20 . If the lower part of the valve is contacted, increase the height of the valve retainer with an inner milling cutter of 60 . Mill the valve retainer with a refined milling cutter of 45 again to make it meet requirements. After milling, coat the valve surface with brightener and slightly polish the valve. high contact surface low contact surface
10.9 Installation
Install it in reverse order. Note: When the valve spring is installed, point the spring end with smaller pitch to the combustion chamber. When the valve cotter is installed, apply a valve spring compression tool. When the valve is installed, apply some fuel to the surface of the valve stem and then install it into the valve guide.
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- 91 -
Function of the cylinder block: The cylinder block provides space for gas compression, combustion and
expansion, and also guides the piston movement. It transfers part of heat inside the cylinder to cooling medium around.
Preparing Principles
Item Inner diameter Cylinder Cylindricity Roundness Flatness Marked direction Standard 52.40-52.413 0.004 0.005 0.05
IN opposite the intake valve 52.3652.37 (7mm below the bottom of the piston skirt 14.00214.008 13.994-13.999 0.03-0.053 0.030.07
Outer diameter measuring point Piston Piston ring Piston pin Inner diameter of the piston pin hole Outer diameter of the piston pin Clearance between the cylinder and the piston Clearance Ring 1
52.37
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between the piston ring and the ring slot Joint gap of the piston ring
Clearance between the piston and the piston pin Inner diameter of the smaller end of the connecting rod Clearance between the connecting rod and the piston pin
cylinder
locating pin
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spacer
Remove the spacer and the locating pin. Remove any residual spacer attached to the cylinder. locating pin spacer
Check the piston, piston pin and piston ring. Remove the piston ring. Note: Do not rupture or damage the piston ring. Eliminate carbon deposit in the groove of the piston ring.
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Install the piston ring. Measure the clearance between the piston ring and the piston ring groove. Limit for use: top ring: 0.10mm. Ring 2: 0.10mm.
Remove the piston ring and install each piston ring at the cylinder bottom. Note: Press the piston ring into the cylinder with the piston head. Measure the joint gap of the piston ring. Limit for use: 0.5mm.
gauge Measure the inner diameter of the piston pin hole. Limit for use: 14.04mm.
piston ring
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Measure the outer diameter of the piston pin. Limit for use: 13.97mm. Clearance between the piston pin hole and the piston pin. Limit for use: 0.03mm.
Measure the outer diameter of the piston. Note: The measuring point shall be at 90 degree with the piston pin, and at 7mm below the piston skirt. Limit for use52.37mm
90
7mm
Check whether the inner wall of the cylinder 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: 52.413mm Measure the clearance between the cylinder and the piston. Record the maximum value. Limit for use: 0.053mm
tester
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Measure the roundness of the inner wall of the cylinder (inner diameter difference at X direction and Y direction). Limit for use: 0.005mm Measure the cylindricity of the inner wall of the cylinder (inner diameter difference at the top, middle and bottom points of X direction or Y direction). Limit for use: 0.004mm
Check the flatness of the cylinder surface. Limit for use: 0.05mm
ruler
gauge
Measure the inner diameter of the smaller end of the connecting rod. Limit for use: 14.04mm
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Open the right cover and remove the starting lever assembly. 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: Install the piston with its top mark IN towards the intake valve.
IN IN mark
Evenly apply fuel to the inner wall of the cylinder, piston and piston ring. Carefully install the piston ring into the cylinder. Note: Do not damage the piston ring.
- 99 -
- 100 -
Left crankcase cover--------------------13.3 Drive face -------------------------------13.4 12.1 Preparing documents Work Instructions
During operation, the surface of the triangle belt can not be stained with any grease which must be removed. It helps avoid slipping between the triangle belt and the belt pulley as much as possible. Function: Drive face, clutch and driven wheel constitute stepless transmission. The triangle belt transfers torque
between the drive face and the driven wheel.
Preparing Principles
Item Inner diameter of right half-driven wheel Outer diameter of the sliding sleeve Width of the triangle belt Thickness of the clutch facing Inner diameter of the clutch sleeve Free length of the clutch spring Outer diameter of the bushing on the right half driven wheel Outer diameter of the sliding sleeve on the left half driven wheel Outer diameter of the ball Standard 28-28.02 23.967-23.98 21.222.8 1.5 125125.2 69 1 42.92-42.98 33.9533.975 20-20.2
Unit: mm Limit for use 28.04 23.98 22.8 1.5 125.5 70 42.90 34.00 19.5
Damaged driven wheel Broken or damaged clutch facing Ruptured clutch spring
Deformed clutch spring Abrasive ball Stained surface of the driving pulley
fixing bolt
spacer
locating pin
- 102 -
Check whether the triangle belt is cracked and whether rubber or cotton yarn falls down or is abnormally abrasive. Measure the width of the triangle belt. Limit for use: 22.8mm Note: apply original parts from our company for replacement.
Width
- 103 -
Check abrasion of the ball. Measure the outer diameter of the ball. Limit for use: 19.5mm
Measure the inner diameter of the right half drive wheel. Limit for use: 28.04mm Measure the outer diameter of the sliding sleeve. Limit for use: 23.98mm
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sliding sleeve
socket spanner
retainer ring
clutch facing
- 105 -
Check abrasion of the clutch sleeve. Measure the outer diameter of the clutch sleeve. Limit for use: 125.5mm.
Check abrasion of the clutch facing. Measure the thickness of the clutch facing. Limit for use: 1.5mm
clutch facing
spanner
- 106 -
spring guard Remove the guide pin. Remove the weldment on the left half driven wheel. Remove the oil seal on the left half driven wheel.
oil seal
Check the free length of the clutch spring. Limit for use: 70mm.
free length
- 107 -
Check abrasion of the driven wheel. Measure the outer diameter of the bushing on the right half driven wheel. Limit for use: 42.90mm. Measure the inner diameter of the sliding sleeve on the left half driven wheel. Limit for use: 34.00mm. right half driven wheel left half driven wheel
needle bearing elastic retainer ring rolling bearing Note: Removed bearings can not be used any more.
Apply grease evenly to the outer rolling bearing and then place it into the sleeve. Note: place the outer rolling bearing into the sleeve with its marked side outwards. Then fill the sleeve with 8-9g grease. Install the elastic retainer ring.
Install the needle bearing. Press the needle bearing in as shown in the picture.
bearing screwdriver
O o-ring
Combine the left half and the right half driven wheel. Apply grease evenly to the guide pin and then install it into the guide groove.
guide pin
guide groove
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spring guard
Install the clutch spring and the clutch on the driven wheel. Use the clutch spring compression combination. Install locking nuts after compression. Note: properly compress the spring to avoid damage to the spring.
12.7 Installation
Install the drive face/ clutch/ driven wheel in reverse order.
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input shaft
intermediate shaft
output shaft
- 111 -
XIII. Decelerator
Preparing documents -----------------14.1 Failure diagnosis ---------------------14.2 Gearbox --------------------------------14.3 Installation ----------------------------14.4 13.1 Preparing documents
Function: transfer torque and decide final output torque and rotational speed.
locating pin Remove the output shaft assembly. Remove the intermediate shaft assembly. Remove the input shaft.
spacer
Check abrasion of the input shaft, output shaft and each gear. It shall be replaced if being abraded seriously. Remove the oil seal from the gearbox cover and hammer out the bearing. Note: Removed bearing can not be used any more. It shall be replaced. Use special tools to dismantle the bearing and the oil seal.
bearing
- 113 -
oil seal
13.4 Installation
Install it in reverse order. Note: Use special tools to install the bearing and the oil seal to avoid any damage.
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XIV. Crankcase
Preparing documents-----------------15.1 Failure diagnosis ---------------------15.2 Crankcase -----------------------------15.3 Installation ----------------------------15.4 14.1Preparing documents Work Instructions
The crankcase is thin-section casting thus shall not suffer impact during operation which may cause deformation or fracture. All components must be cleaned and blown with high-pressure gas before test. Lubricant in the crankcase should be drained out before operation.
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 head, 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.
Preparing Principles
Item Left-right clearance of the larger end of the connecting rod Radial clearance of the larger end of the connecting rod Standard 0.1-0.35 0.008-0.016
Crankshaft
Tools
Universal holder Screwdriver lever Guide rod Clutch spring compressor Socket spanner Bearing screwdriver
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right crankcase cover Remove the spacer. Loosen locking nuts with a special tool and remove the magneto. Remove the starter idler gear and the shaft.
bolt
electric starter idler gear locking nut Remove bolts and the end cap of the fuel pump sprocket. Remove the fuel pump.
magneto spacer
- 116 -
Remove the bolts of the right crankcase. Put down the left crankcase and remove the right crankcase.
right crankcase
Remove the spacer and the locating pin. Remove the connecting rod combination. Remove the timing chain.
locating pin
spacer
15.3.2 Check
Measure the left-right clearance of the larger end of the connecting rod. Limit for use: 0.55mm.
- 117 -
Measure the clearance of the larger end of the connecting rod (X-Y direction). Limit for use: 0.05mm.
Check whether there is noise when the crankshaft bearing rotates or whether it is loose. If yes, replace the crankshaft assembly.
crankshaft bearing Remove the oil seal from the left crankcase. Note: Removed oil seal can not be used any more. Remove the oil seal with a special tool.
oil seal
14.4 Installation
Install the crankcase in reverse order. Note: Install the oil seal with special tools to avoid any damage to it.
- 118 -
Thermostat
Pump
- 119 -
Work Instructions:
1. Check and maintain the cooling system after the engine is cooled. 2. Do not remove the radiator cover except that the radiator liquid is filled up again or drained out after the cooling system is dismantled. 3. It is feasible to maintain the cooling system on the motorcycle.
Overheated engine
Poor cooling cycle Leakage of cooling water which causes little working medium Too much impurity inside the radiator pipe Wrinkled water pipe Pump in bad condition Dirty radiator lattice
- 120 -
15.3 Thermostat
Disassembly
Drain out the coolant and remove the thermostat. Put the thermostat into the water vessel. Raise water temperature and check the temperature when the valve of the thermostat opens. Initial temperature for opening Full-open temperature Lift at the time of fully opening 7284 C 9396 C Above 4.27mm Hydrostatic test at 392KPa shall be carried out on the thermostat for 3 minutes. There shall be no leakage.
sensor assembly thermostat assembly bolt thermostat chamber upper lid of the thermostat chamber ring of the thermostat seal o o-ring
Radiator
Repair the radiator with a small club when over 1/3 of heat sink is damaged or twisted.
heat sink
- 121 -
Water assembly
outlet
temperature
switch
Coolant replacement
Confirm the coolant is cooled. Remove drain bolts, tilt the body to the right, completely drain out coolant and then install drain bolts.
drain bolt
- 122 -
Pump check
Check whether the mechanical seal is damaged through the leakage inspection hole. If the coolant is leaked through the hole, it shows there is damage to the mechanical seal. Replace the whole pump. For any pump which can be disassembled, replace the mechanical seal.
pump
- 123 -
- 124 -
- 125 -
The latest national regulation shall prevail if there is any change. are not responsible for any problem due to failure in periodic maintenance at our distributor or service center. We 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.
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Engine improvement
As the spark plug, 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.
Adjustable parameters and suggested value setting Adjustment of idle speed rotating speed of engine 1500 100rpm/min CO concentration 0.5-1.2
- 127 -
17.4.2 Instruction
1. The function of convertible catalyst is to converse exhaust gas HC, CO and NOX after complete combustion to harmless gas such as H2O, CO2andN2 before emission. 2. Convertible catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used. Note that lead gasoline may invalidate catalyst. General instructions for maintaining motorcycles (exhaust pipe) with catalytic converter: 1For motorcycles with catalytic converter, when the engine is running or just closes down, it shall not be touched for a while because of high temperature. 2Motorcycles with catalytic converter shall not be near flammable material. 3There is CO inside the exhaust pipe, which is harmful to health. So do not run the engine in closed space. 4Lead gasoline can not be used for motorcycles with catalytic converter (to prevent catalytic poison). 5Do not push the motorcycle to run the engine. If it is necessary, you must wait until the temperature of the engine and the catalytic converter lowers down. 6Do not make gear up or flame out when descending. 7Do not drive the motorcycle with bad ignition. 8Do not remove spark plug and run the engine to see whether there is spark when maintaining the ignition system of the engine. If necessary, it shall be finished in a short time.
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Figure 1
Crankshaft position target wheel Crankshaft position sensor Heated oxygen sensor Magneto temperature sensor / Air intake temperature/pressure combined sensor Neutral gear switch Dump switch Ignition switch Battery Burglar alarm Selective Engine control module Serial communication interface for the failure diagnosis switch Failure indicator Engine rotating speed signal Throttle position sensor Idle speed control valve Throttle valve body Ignition coil Nozzle Fuel pressure regulator Fuel pump Metal carrier catalytic converter
- 129 -
Figure 7
Figure 8
Figure 9
- 131 -
Figure 10
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17.20. Instructions
MC21 controller instructions Instruction the exhaust pipe during transfer. Cause temperature which also easily damages the plastic shell of ECU. Forbidden: Place ECU in water, oil or ECU is sensitive to liquid. liquid environment. Forbidden: ECU is covered with mud or Unfavorable for heat dissipation of ECU water drops. randomly. on the connector. corrosive liquid. Should: Clean ECU with wet cloth and Prevent ECU from damage. keep it dry. Should: When ECU is reinstalled, check Keep vehicle performance. whether the air intake pipe is blocked. If yes, clean it. Should: When ECU is reinstalled, fix the Keep vehicle performance. air intake pressure pipe and ensure no leakage. Clamps and air intake pressure hoses shall match with the vehicle type. Should: Keep the air intake hose always Prevent dust from entering into the engine connect ECU and intake manifold. to ensure safety. Should: When the air intake hose is pulled Prevent joints inside ECU from being loose out from ECU, loosen the clamp at the joint and coating from being damaged. and then pull the hose carefully from ECU. surface. damages ECU. ECU. Forbidden: Power connection to ECU It seriously affects ECU work and definitely Forbidden: Water drops or too much vapor Short-circuit of ECU connector or damaged Forbidden: Clean ECU with agent or Damage ECU shell. Table: 4
Forbidden: Place ECU beside the engine or The service life of ECU is affected by high
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11
- 134 -
work temperature range: -30 to 70 Maximum work temperature: 80 (continuous work for no more than 30 minutes) Storage temperature range: -40 to 85
yes, update the calibration software. If any controller hardware fails or is damaged during the warranty period, the controller must be sent back to the factory, attached with detailed controller component number, serial number, vehicle type, date of production, accumulated kilometers, where be used, and date of return. The following table shall be filled up by the distributor and sent to the factory with the controller for finding reasons. Some actions are only valid for products within the warranty period. Otherwise, users shall be responsible for expenses resulting from the replacement of damaged controllers. DELPHI Request on the Repair of Workshop
Damaged Controller
Distributor: Address: Engine displacement: Date of vehicle production: Accumulated kilometers: Details on controller: Telephone: Mobile telephone: Contact: Detailed description of failure: Part number: Serial number: Date of controller production: Vehicle type: Date of failure:
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18.3. Appearance
The following figure 12 shows the appearance of M3 fuel injector. O-ring for connecting the fuel rail or the fuel injector cap.
Figure 12 There are two types of M3.5 fuel injector: long-type and mini-type. M3.5 fuel injector is able to provide better integrated function.
Figure 13
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18.4. O-ring
O-ring shown in figure 12 is able to ensure that there will no leakage in the fuel injector when working at between -40 and 150 (-40 and 302). It also resists corrosion from kinds of fuel additives (such as ethanol). The current o-ring design is shown below. If any DELPHI fuel injector is not consistent with following data, please contact DELPHI. O-ring for connecting the fuel rail or the fuel injector cap Dimension: Inner diameter: 6.35mm Outer diameter: 14.85mm Section thickness: 4.25mm Material: Viton GLT(blue): application under low temperature Viton A(black): application except for low temperature O-ring for connecting the end of the air intake pipe Dimension: Inner diameter: 9.61mm Outer diameter:14.49 mm Section thickness: 2.44 mm Material: Viton A (blue or brown)
the suggested lubricating oil to lubricate O-ring. Do not contact the orifice plate with lubricating oil, otherwise it affects fuel injection. We suggest that o-ring can be used only once. If replacement is impossible, please check whether it is damaged before repeated use. Any minor damage will cause fuel leakage. To avoid any danger, please strictly comply with requirements to install the oil injector. When o-ring is installed into the fuel injector, please be careful and do not damage the o-ring.
For the convenience of fuel injector installation, lubricant shall be applied to o-ring. Table 4 lists applicable and proved lubricant. According to test, following lubricant will not affect the performance of fuel injector.
Suggested lubricant Name of lubricant Spindura 10 Spindura 22 DTE-24 DTE-25 DTE-26 Norpar15 Drawsol 60 NocoLube AW 46 NocoLube AW 32 Advantage Spindle Oil Manufacturer Equilon Equilon Mobil Mobil Mobil Exxon/Mobil DA Stewart NOCO Energy NOCO Energy Advantage Lubrication Specialties Table: 6 Viscosity (cSt) @40 10 21 32 46 68 <1 1-2 46 32 10
18.11. Instructions
Fuel injector instructions Instruction Forbidden: use o-ring repeatedly. If it Void leakage. has to be used repeatedly, please check whether it is damaged before use. Forbidden: immerse the injector Block the injection hole. mouth in lubricant. Forbidden: dry run under no fuel Damage inner mechanical parts. pressure. Forbidden: operate the fuel injector Eliminate standards (leakage rate >50sccm air). Forbidden: water enters into the fuel Cause damage to the fuel injector. pipe during leakage rate inspection. Forbidden: Impose force on the fuel During installation on the nylon intake injector head during installation. pipe, it is allowed to impose force at the angle of 45 degree. Forbidden: strike the fuel injector Damage the fuel injector and o-ring. when it is installed on the intake pipe. Forbidden: impose tensile force on the Cause interrupted power supply. connector. Forbidden: use the fuel injector which Possible damage.
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Table: 7 Cause
contaminants
and
analyze
has been thrown. Forbidden: store fuel injector, fuel rail Possible under non-protective environment. when lifting the assembly. Forbidden: components contact each Damage the fuel injector. other during storage. Forbidden: components contact each Possible impact, which may cause damage other during transportation. troubleshooting in the case of an error. Forbidden: use non-suggested fuel Significantly affects the performance of injector injectors. Should: note that the o-ring shall not Protect the o-ring. be cut by the installation seat during the installation of the fuel injector. Should: install it into the hole after Protect the o-ring and reduce pollution. being applied with correct lubricant. Should: test the fuel injector adhered Confirm the invalidation of the fuel to the needle valve or whose needle injector. valve fails in seating. (pulse to the fuel injector with the voltage between 9-15V for less than 5 seconds) Should: before the fuel injector is The needle valve of the fuel injector may assembled, carry out no fuel leakage fail in seating during transportation or test to confirm seating of the needle transfer, which causes fuel leakage. valve. Should: avoid liquid pollution to the Cause short-circuit of the electromagnetic fuel injector. coil. Should: carefully dismantle the cables. Cause damage to terminals. Should: use suggested lubricant during Cause corrosion to terminals. the installation of the connector.
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damage
to
electronic of the
and fuel
components
Forbidden: hammer the oil injector for Damage the fuel injector.
instead
of
original
Should: do not use fallen, damaged or Find causes to problems as soon as unqualified components, and label possible. them to indicate problems.
Lubrication: apply a little lubricant to the lower part of the o-ring. Do not use ISO 10 light mineral oil or equivalent product. If it is possible, it is better to apply lubricant to the fuel injector seat other than o-ring. Thus, it can minimize pollution by the fuel injector. Do not make the orifice plate contact with lubricant, which affects the volume of fuel injection. Do not pick up lubricant with the top of the fuel injector. All M3 and M3.5 oil injector o-rings are assembled before delivery. In principle, o-rings are not allowed to be used repeatedly. Please check whether there is any damage to o-rings. Any minor damage will cause leakage. Install the o-ring into the holder carefully. Do not damage the connector when it is installed. The fuel injector connector is properly installed when there is a click sound. Do not install or disassemble unnecessary connectors. Do not tighten cables too much, otherwise it may lead to short circuit. Do not rotate the fuel injector during the installation of the connector, which will lead to deviation from fuel injection targets.
18.13. Replacement
The disassembly and replacement of M3 and M3.5 fuel injectors are as follows.
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Note: high temperature in the fuel injector and its surrounding parts. The motorcycle flames out. Disconnect the negative pole of the battery to avoid any accidental startup of the engine. Remove the fuel injector connector. Discharge fuel pressure. Remove the fuel pipe from the fuel injector. Remove the fuel injector from the air intake pipe. Remove the fuel injector retention clamp and the fuel injector from the seating carefully. Carefully clean impurities on the contact surface of the fuel injector. Do not damage the contact surface. Apply lubricant to o-rings on two ends of the new fuel injector. Install the new fuel injector into the air intake pipe carefully and make sure it is towards the same direction as the original one is. Install the fuel injector seating and the retention clip. Tighten mounting bolts with required torque according to installation manual. Install the fuel pipe. Insert the fuel injector connector. Insert the key for power on. Check fuel leakage from the fuel injector without engine startup. Start up the engine to check its work.
18.14. Replaceability
Replace the fuel injector with the one of the same part number. Part number may change. Please check the vehicle maintenance manual and the list of spare parts to select correct fuel injector.
If the fuel injector is blocked, reduced flow, increased friction and accumulated impurities will take place, which finally affects emission and durability. Fuel and environment factors will cause fuel crystallization or corrosion to the fuel injector, which also leads to flow deviation. Unsteady fuel oxidation will generate deposits. Please use high-quality gasoline. Add a certain amount of fuel injection cleaner to avoid deposits. When the fuel injector is blocked, please clean the fuel injector with following methods.
18.16. Cleaning
Disconnect
the fuel pump first. Discharge fuel pressure and then remove the fuel pipe. After the fuel pipe is removed, stuff it up with some material to avoid fuel drainage. Add fuel injection cleaner and gasoline at certain proportion to the fuel injector cleaner tank. Connect the fuel injector cleaner tank to the fuel injector. Adjust the cleaner fuel pressure to the vehicle system pressure of 2.5bar. Start up the engine, and keep it at the idle speed for 15-20 minutes. Remove the cleaner tank, and re-install the fuel pipe to the fuel injector. Start up the engine and keep it at the idle speed for 2 minutes. Ensure cleaner is completely discharged.
Table: 8
19.3. Appearance
Figure 16
Maximum flow: 19.29 1.0g/s@0.75kPa vacuum degree Torque for opening the throttle valve: At idle speed: 0.19 0.05Nm When fully open: 0.37 0.10Nm Throttle position sensor Reference voltage: 5 0.1VDC Resistance between T1 and T2: 3k12k
Figure 17
the negative pole of the battery Disconnect the throttle position sensor Remove the throttle cable Remove the hose between the air cleaner and the intake manifold
19.7. Cleaning
Remove the cover at the bottom of the throttle valve and clean the body with carburetor cleaner (3M product suggested). Spray cleaner on the inner wall of the throttle valve and remove dust and carbon deposit slightly with brush. Do not block the bypass with impurities. If idle screws are removed and cleaned, assemble idle screws in
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following order: Install o-ring 1 on the idle bypass screws Install spring, washer, o-ring 2 on the idle bypass screws Install above idle bypass screws on the throttle valve. After idle screws are cleaned and assembled, use diagnosis tools and adjust idle speed. Note: new o-rings shall be used every time of installation.
19.9. Precautions
not spray any cleaner into TPS throttle position sensor. Use the throttle cable to open the throttle valve block. Do not insert any tool or stick into the throttle valve hole to keep the valve block open. It will cause deformation of the valve block and damage to the inner wall of the throttle valve. Keep carbon deposit around the valve block to maintain air flow required by idle speed setting. Do not adjust the position of idle screws. Replace o-rings once disassembled.
Do
19.10. Instruction
Instructions of the throttle valve assembly Instruction valve connector is used. Should: avoid any liquid pollution to Ensure normal work. the throttle valve. Should: take and install only one piece Possible damage to components. of throttle valve from the component
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Table: 10 Cause
tray. Should: use a label to describe any Accurately analyze causes as soon as problem related to any fallen, possible. damaged or unqualified throttle valve (within warranty range). Should: remove and discard protective Protect the system from pollution and cap before installing components. is removed. Should: if idle screws are removed, Ensure no air leakage from o-ring. replace o-rings. Forbidden: use any fallen or defective Possible inner damage. component. Forbidden: no protective cap for Possible impact on normal work due to storage parts. Forbidden: spray. Forbidden: completely exposed to the Possible impact on normal work due to environment (humid) before assembly. system voltage. Forbidden: use excessively tightening Possible damage. torque. Forbidden: hammer the fuel injector Damage to the fuel injector. for troubleshooting when there is an error. Forbidden: components bump into Possible impact on the minimum air each other when being unpacked. throttle at any position. Forbidden: block the bypass hole with Possible impact on the stability of idle dirt or sand. Forbidden: take, store or speed. hold Possible damage.
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Should: clean bypass when the seating Ensure stable idle speed.
corrosion.
Water temperature sensor for the Used for all water-cooled engines. engine
20.3. Appearance
Figure 18
spanner at the speed of beyond 400 rounds/minute or with the manual spanner. Suggested assembly torque is as follows: Maximum: 20N m Minimum: 25N m Static torque requirement: torque used for dismantling the sensor from the engine shall be no more than 200% of the assembly torque.
temperature: -40 to 120 Transportation without time limit below the altitude of 13700m.
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The appearance of the intake air temperature sensor is shown as in figure 20 above.
voltage: 5DVC Response time: 15S Work temperature: -40150 Relative humidity: 0 to 100% RH
diameter of mounting hole: 12mm Suggested depth of mounting hole: 12mm to 16mm Mounting angle with the horizontal plane: 50
If necessary, clean the sensor with isopropanol and then dry it. Sink it in isopropanl for no more than 1 minute. Install sealed connections during cleaning to prevent cleaning agent from entering into the sensor.
22.2. General work principle Oxygen sensor is used for monitoring the content of waste oxygen inside the exhaust pipe of the combustion engine, including wideband oxygen sensor and switch-type oxygen sensor. Normally, we use switch-type oxygen sensors for small engines. It is mainly used for controlling the fuel closed loop of the engine.
22.3. Appearance
The appearance of the oxygen sensor is shown as in figure 22 below.
Figure 22
value for air-fuel ratio (dense): 750VDC Threshold value for air-fuel ratio (dilute): 120Mvdc Heater power for the oxygen sensor: 7.0W (above parameters are measured at the engine test bench under the exhaust temperature of 450, duty cycle of 70%, 10Hz and voltage of 13.5V. ) Heater resistance: 9.61.5 (measured below 21) Work temperature range: 260-850
Threshold
Figure 22
List of spare parts of the fuel pump Name Fuel pump assembly Fuel pump device Fuel pressure regulator Sealing device for the fuel pump assembly Remark
Table: 19
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pressure fuel
pipe clamp
fuel pipe
23.4. Dimension
Dimension of the bottom panel: 115mm 70mm. Mounting height: 135mm (reference dimension)
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Figure 28
1. Check the loop 1. Check the from the fuel throttle cable; pump to ECU; 2. Check the fuel 2. Check ECU. pump. The fuel assembly normally. pump Go to step 5. works
1. Check whether 1. The fuel filter is there is leakage blocked; in the fuel pipe; 2. The fuel pipe is 2. Check fuel bent and pump device; twisted; 3. Check pressure 3. Check pressure regulator. regulator.
Please make reference to fuel pressure in the fuel drain pipe in fuel pressure release procedures. Disconnect the negative pole of the battery. Disconnect the connector of the fuel pump assembly cable. Pump the residual fuel in the fuel tank out and store it in a proper vessel to ensure safety and reduce pollution. Disassemble the fuel pipe connecting to the fuel pump assembly with standard tools. Remove the fuel tank from the vehicle. Place the fuel tank upside down. Protect it from any scratch or
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Replace the sealing washer of the fuel pump assembly (an used washer may lead to fuel leakage). Fold the filter carefully and asymmetrically arrange mounting bolts for the fuel pump assembly which only can be installed towards required direction. The pressure regulator shall face the back of the fuel tank to ensure the surface of the fuel tank is clean and neat. Install screws in the cover plate of the fuel pump assembly and evenly tighten screws in sequence as shown in figure 33. Torque for mounting screws: 34Nm. The fuel pump assembly shall be fixed with special screws. Apply required tightening sequence and torque to fix. Over-torque or incorrect tightening sequence will lead to deformation of the washer, which causes leakage. Install the fuel tank in the vehicle. Connect the fuel pipe and clamp it properly. Connect the connector of the fuel pump cables. Check leakage according to fuel leakage inspection procedures before the engine works.
Remove the seating of the pressure regulator. Remove the snap spring from the pressure regulator with the snap
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spring tool. Avoid any damage caused by popup of the spring. Remove the pressure regulator. Carefully avoid damage to the outer edge of the pressure regulator. Apply lubricant around o-ring of the new pressure regulator to facilitate installation. Make sure two o-rings are installed on the pressure regulator (one with larger diameter, one with smaller diameter). Install the pressure regulator in the bracket of the fuel pump frame. Do not hammer the pressure regulator (damage to the pressure device). Install the snap spring of the fuel pressure regulator. Replace o-rings of the fuel pump.
Check whether there is leakage in any component of the fuel system (fuel tank, fuel pipe, joint, etc.).
Table: 18 Cause Damage to the inside of the fuel pump.
Instructions for the fuel pump assembly Instruction Forbidden: crash the fuel pump. (no fuel from the filter at the entry of the fuel pump); make sure enough fuel in the fuel tank.
Forbidden: dry run by the fuel pump Damage to the inside of the fuel pump.
Forbidden: damage the filter during Impurities enter into the damaged filter maintenance. and then the fuel pump, which destroy the fuel pump. Forbidden: disassemble inner parts of No warranty. the pump body and the pressure regulator. Forbidden: regulate the fuel pump and the pressure regulator. Forbidden: pick up the fuel pump Damage the cables and disconnect the fuel assembly cables to lift the fuel pump pump. assembly. Forbidden: lift the fuel pump assembly cables vertically along the fuel pump cover plate. Forbidden: use damaged fuel pipe Pressure leakage/ fuel leakage. clamp. Forbidden: use seriously damaged or Impurities enter into the fuel pump broken filter in the fuel pump through the damaged filter, and damage the pump body. purpose. assembly. tank with the fuel pump.
Forbidden: draw fuel from the fuel Fuel pump is not designed for such Forbidden: use mounting screws of the Affect the installation of the fuel pump fuel pump assembly to fix other assembly. components.
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terminals
will
cause
bad
cables when the fuel pump assembly contact/ disconnected power supply. Forbidden: the manual pump contacts Avoid damage to the fuel pump assembly. the fuel pump assembly when drawing fuel from the fuel tank. Should: ensure no damage to the fuel Avoid fuel leakage. pipe during maintenance. Should: only use original sealing Faked ones may lead to fuel leakage. washers for the fuel pump assembly. Should: use designated hose clamps. Ensure no fuel leakage on joints of the fuel pipe. Should: the fuel pump cables are fixed Reduce vibration. on the vehicle. Should: use standard fuel. Unqualified fuel will lead to early damage to the fuel pump. Should: replace the fuel filter within Blocked filter will reduce fuel supply. the stipulated period. Should: use stipulated and qualified Unqualified filter will damage the injector fuel filter. mouth, fuel pressure regulator and fuel pump. Should: ensure the correct direction of Incorrect direction or interference will the fuel pipe deployment and no damage the fuel pipe. interference with other parts. Should: ensure enough fuel in the fuel Avoid dry run of the fuel pump. tank (over the fuel pump filter). Should: replace two o-rings when the Ensure the correct pressure regulation pressure regulator is maintained. Should: cables. Should: return any fallen, damaged or Find causes as soon as possible. unqualified parts and describe related problem.
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carefully
connect
- 163 -
Connect the computer serial port to the motorcycle diagnosis interface with the diagnostic cable.
- 164 -
- 165 -
Click Engine Data for displaying and monitoring engine status. Set the sampling frequency as 0.1 second and establish document name and path for data saving.
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ECU version
- 167 -
Click Malf Code to show current malfunction code. 24.4 Cross reference table for malfunction code Malfunction Description Description of code malfunction code P0106 Map Rationality Rationality of air intake pressure P0107 Map Open/GND Open circuit or short circuit grounding of the built-in air intake pressure sensor P0108 Map Short V Short circuit power supply of the built-in air intake pressure sensor P0112 IAT Short GND Short circuit grounding of the air intake temperature sensor P0113 IAT Short V/Open Short circuit power supply or open circuit of the air intake temperature sensor P0117 Toil Short GND Short circuit grounding of the engine temperature sensor P0118 Toil Short V/Open Short circuit power supply or open circuit of the engine temperature sensor P0563 Battery voltage high Overhigh voltage of the battery P0122 TPS Open/GND Short circuit power
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Flash code 35 34
33
69
71
15
14
49 22
P0123
P0131
P0132
P0231
P0232
P0601 P0261
P0262
P1351
P0351
supply or open circuit of the throttle position sensor TPS Short V Short circuit grounding of the throttle position sensor O2 Short GND Short circuit grounding of the oxygen sensor O2 Short V Short circuit power supply of the oxygen sensor Pump Open/GND Short circuit grounding or power supply of the fuel pump Pump Short V Short circuit power supply of the fuel pump EEPROM Error EEPROM error Cylinder 1 Inj Short circuit Open/GND grounding or open circuit of the injector of cylinder 1 Cylinder 1 Inj Short V Short circuit power supply of the injector of cylinder 1 Cylinder 1 Ign Short circuit Open/GND grounding of the ignition coil of cylinder 1 Cylinder 1 Ign Short V Short circuit power supply of the ignition
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21
45
44
29
31
51 16
17
64
42
P1650
P0650
P1654
P0654
P0335 P1352
P0352
P0321
P1321
P0264
coil of cylinder 1 MIL Open /GND Short circuit grounding or open circuit of the fault light MIL Short V Short circuit power supply of the fault light TACO Open/GND Short circuit grounding or open circuit of the engine speed output TACO Short V Short circuit power supply of the engine speed output Crank Sensor Crankshaft position Malfunction sensor malfunction Cyl2 Ign Short GND Short circuit grounding of the ignition coil of cylinder 2 Cyl2 Ign Short V Short circuit power supply of the ignition coil of cylinder 2 Cyl1 IGBT over Overcurrent of the current ignition module of cylinder 1 Cyl2 IGBT over Overcurrent of the current ignition module of cylinder 2 Inj_2 Open/GND Short circuit grounding or open circuit of the injector of cylinder 2
- 170 -
12
11
19 95
96
79
23
P0265
Inj_2 Short V
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Circuit Diagram
QJ125T-30 ELECTROJETELECTRICITY PRINCIPLE DIAGRAM
CLOCK FAN LIGHT WATER TEMPERATURE LIGHT
B N/G
FUELMETER SPEEDOMETER LIGHT CONTROL SWITCH START SWITCH POWER LOCK BRAKE SWITCH
ON OFF
LOCK
R Y B
BL/W1 R/W B
W/Y W/BL B
BATTERY
RELAY
RECTIFIER
DIAGNOSE
SKID SENSOR
PUMP RELAY
BLACK
R R/W Y O/BL
W/BL
B W/Y
B R/W BL/B
B Dg
R B/R
Y/G ORANGE/WHITE
N/B
R/W
BL
R/W
O/BL
LR B Gr
G/Y B
R W W W B
B G/W
HEAD LIGHT
BL B Y
Y B P
TAIL/BRAKE LIGHT
HEAD LIGHT
Y B LBL B G/B
B G/B
B G/B
HORN
B N
G/B B G/W
G/R R/P
N/W N/B
Gr
B/W W/P
BL/W W/G
B/BL B/R B/O B/BL Y/G B/BL B/BL B/G W/N G/R R/G W/Gr B/R W/O
B/R
N/G B
W/G BL/W
R/W N/G
N R/W
BL Y/R LBL
G/B O G/W
B N/G
FAN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
ALARM SYSTEM OXYGEN SENSOR INTAKE AIR FUEL LIFT PUMP IGNITION COIL OIL RTOMIZER SOLAR TERM POSITION TEMPERTURE SENSOR ENGINE COOLANT SPARK PLUG SENSOR TEMPERATURE SENSOR
>98