Wolf SB 250 Ni

Wolf SB 250 Ni
SERVICE MANUAL
FOREWORD CONTENTS
HOW TO USE THIS MANUAL MECHANISM ILLUSTRATION
20120309
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Homepage Contents
Foreword
This service manual contains the technical data of each component inspection and
repair for the SANYANG PD25A series motorcycle. The manual is shown with
illustrations and focused on “Service Procedures”, “Operation Key Points”, and
“Inspection Adjustment” so that provides technician with service guidelines.
Copyright reserved.
If the style and construction of the motorcycle, PD25A series motorcycle, are
different from that of the photos, pictures shown in this manual, you should follow
the actual vehicle layout. Specifications may be changed without notice.
Service Department
SANYANG INDUSTRY CO., LTD.

How to use this manual
This service manual describes basic information of individual parts and system
inspection & service for SANYANG PD25A series motorcycle. In addition, please
refer to the manual contents for detailed information for the model year.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance information and special tools
manual.
The third to the 9th chapters cover engine and driving systems.
The 10th chapter covers cooling systems.
The 11th to the 13th chapters contain the parts of vehicle frame.
The 14th chapter is electrical appliances.
The 15th chapter is emission control system.
The 16th chapter is electrical diagram.
Please see index of content for brief information and quick guide.

Content
Page Content Index
1-1 ~ 1-19 General Information 1
2-1 ~ 2-16 Maintenance Information 2
3-1 ~ 3-45 Injection System 3
4-1 ~ 4-14 Lubrication / Clutch / Transmission 4
5-1 ~ 5-8 AC Generator / Starting Clutch 5
6-1 ~ 6-8 Engine Removal 6
7-1 ~ 7-16 Cylinder Head / Valve 7
8-1 ~ 8-10 Cylinder / Piston 8
9-1 ~ 9-14 Crankshaft / Crankcase / Shifting Gear 9
10-1 ~ 10-14 Cooling System 10
11-1 ~ 11-10 Brake System 11
12-1 ~ 12-14 Steering / Front Wheel / Front Fork 12
13-1 ~ 13-12 Rear Wheel / Rear Cushion 13
14-1 ~ 14-26 Electrical System 14
15-1 ~ 15-10 Emission Control System 15
16-1 ~ 16-2 Wiring Diagram 16

Mechanism Illustration
Start / RR brake
Engine stop pedal
switch
Starter relay
Main
Switch
Battery
Winker relay
Air cleaner
Headlight
dimmer / Fuel tank cap
Winker / Horn
switch
Ignition
il
ECU
Headlight
Fuse
Regulator/
Rectifier
Shifting
pedal
Meter
FR. Brake lever
Clutch lever Taillight
FR winker
RR. winker
Muffler

1. General Information
Symbols and Marks ·················· 1-1 Torque Values(Frame) ·············· 1-11

General Safety ··························· 1-2 Torque Values ··························· 1-11
Service Precautions·················· 1-3 Troubleshooting ························ 1-12
Specifications -·························· 1-9 Lubrication Points····················· 1-17
Torque Values(Engine) ············· 1-10
Symbols and Marks

Symbols and marks are used in this manual to indicate what and where the special service are
needed, in case supplemental information in procedures is needed for these symbols and marks,
explanations will be added to the text instead of using the symbols or marks.
Means that serious injury or even death may result if procedures are
Warning
not followed.
Means that equipment damages may result if procedures are not
Caution
followed.
Limits to use SAE 10W-30 API SG class oil. Warranty will not cover
Engine oil the damage that caused by not apply with the limited engine oil.
(Recommended oil: Bramax G-3 oil)
Grease King Mate G-3 is recommended.
King Mate gear oil serials are recommended. (Bramax HYPOID GEAR
Gear oil
OIL # 140)
Locking Apply sealant; medium strength sealant should be used unless
sealant otherwise specified.
Oil seal Apply with lubricant.
Renew Replace with a new part before installation.
Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid.
Special tools Special tools
Correct Meaning correct installation.
Wrong Meaning wrong installation.
Indication Indication of components.
Directions Indicates position and operation directions
Components assembly directions each other.

Indicates where the bolt installation direction, --- means that bolt goes
through the component (invisibility).
1-1
General Safety
Carbon monoxide Battery
If you must run your engine, ensure the place is
Caution
well ventilated. Never run your engine in a closed
‧ Battery emits explosive gases; flame is strictly
area. Run your engine in an open area, if you prohibited. Keeps the place well ventilated
have to run your engine in a closed area, be sure when charging the battery.
‧ Battery contains sulfuric acid (electrolyte),
to use a ventilator. which can cause serious burns, so be careful
not to get the sulfuric acid on your eyes or
Caution skin. If you get battery acid on your skin, flush
it off immediately with water. If you get battery
 Exhaust contains toxic gas, which may cause
acid in your eyes, flush it off immediately with
one to lose consciousness and even result in
plenty of water and then go to hospital to
death.
consult an ophthalmologist.
‧ If you swallow it by mistake, drink a lot of
water or milk, and take some laxative such as
Gasoline
vegetable oil and then go to see a doctor.
Gasoline is a low ignition point and explosive
‧ Keep electrolyte beyond reach of children.
material. Work in a well-ventilated place, no flame
or spark allowed in the work place or where
Brake shoe
gasoline is being stored. Do not use compressed air or a dry brush to clean
Caution components of the brake system; use a vacuum
 Gasoline is highly flammable, and may cleaner or the equivalent to avoid dust flying.
explode under some conditions, keep it away
from children. Caution
 Inhaling brake shoe or pad ash may cause
disorders and cancer of the breathing system
Used engine oil
Caution Brake fluid

Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer although Caution
it might not be verified. Spilling brake fluid on painted, plastic, or rubber
 We recommend you to wash your hands with parts may cause damage to the parts. Place a
soap and water right after contacting. Keep clean towel on the above-mentioned parts for
the used oil beyond reach of children. protection when servicing the brake system.
Keep the brake fluid beyond reach of children.
Hot components
Caution
 Components of the engine and exhaust
system can become extremely hot after
engine running. They remain very hot even
after the engine has been stopped for some
time. When performing service work on these
parts, wear insulated gloves and wait until the
vehicle is cooling down.
1-2
Service Precautions
 Always use with SANYANG genuine parts and  Never bend or twist a control cable to prevent
recommended oils. Using non-genuine parts for unsmooth control and premature worn out.
SANYANG vehicle may damage it.
 Rubber parts may become deteriorated when

 Special tools are designed for removal and old and easy to be damaged by solvent and oil.
installation of components without damaging the Check these parts before installation to make
part. Using wrong tools may result in damage. sure that they are in good condition, replace if
necessary.
 When loosening a component, which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
 Store complex components such as
 When servicing this bike, use only metric tools, transmission parts in the proper assemble order
metric bolts, and nuts. Using wrong tools and and tie them together with a wire for ease of
fasteners may damage this vehicle. installation later.
 Clean the outside of the parts or the cover
before removing it from the bike. Otherwise, dirt
and deposit accumulated on the part's surface
may fall into the engine, chassis, or brake
system, and cause damage.
 Wash and clean parts with high ignition point
solvent, and blow them dry with compressed air.
Pay special attention to O-rings or oil seals
because most cleaning agents have an adverse  Note the reassemble position of the important
effect on them. components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
 Components not to be reused should be
replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.
1-3
 The length of bolts and screws for assemblies,  Remove residues of the old gasket or sealant
cover plates or boxes is different from one before reinstallation, grind with a grindstone if
another; make sure they are correctly installed. the contact surface has any damage.
In case of confusion, Insert the bolt into the hole
to compare its length with other bolts, if its
length outside the hole is the same with other
bolts, it is a correct bolt. Bolts for the same
assembly should have the same length.
 The ends of rubber hoses (for fuel, vacuum, or

coolant) should be pushed as far as they can
go to their connections so that there is enough
room below the enlarged ends for tightening
the clamps.
Groove
 Tighten assemblies with different dimension Clamp

fasteners as follows: Tighten all the fasteners
with fingers, then tighten the big ones with Connector
special tool first diagonally from inside toward
outside, important components should be
tightened 2 to 3 times with appropriate
increments to avoid warp unless otherwise
indicated. Bolts and fasteners should be kept  Rubber and plastic boots should be properly
clean and dry. Do not apply oil to the threads. reinstalled to the original correct positions as
designed
Boots
 When installing oil seal, fill the groove with  The tool should be pressed against two (inner
grease, install the oil seal with the name of the and outer) bearing races when removing a ball
manufacturer facing outside, and check the bearing. Damage may result if the tool is
shaft on which the oil seal is to be installed for pressed against only one race (either inner race
smoothness and for burrs that may damage the or outer race). In this case, the bearing should
oil seal. be replaced. To avoid damaging the bearing,
use equal force on both races.
Manufacturer's name
Both of these examples can result in bearing damage.
1-4
 Lubricate the rotation face with specified  Before battery removal operation, you have to
lubricant on the lubrication points before remove the battery negative (-) cable first.
assembling.
Avoid using tools like open-end wrench, which
may contact with body or create spark.
● Check if positions and operation of installed

parts are correct and proper.  After service completed, make sure all
connection points is secured.
Battery positive (+) cable should be connected
firstly.
And the two posts of battery have to be
greased after connected the cables.
● Make sure service safety each other when

conducting by two persons.
● Make sure that the battery post caps are

located properly after the battery posts had
been serviced.
● Note that do not let parts fall down.
● If a fuse is burned, it has to find out the cause

and solved it. And then replace with specified
capacity fuse.
Capacity
verification
1-5
● When separating a connector, its locker has to ● Before connecting terminals, check if the boot
be unlocked first. Then, conduct the service is cracked or the terminal is loose.
operation.
● Insert the terminal completely.

● Check if the boot covers the terminal.
● Do not let boot open facing up.
● Do not pull the wires as removing a connector
or wires. Hold the connector body.
● Secure wires and wire harnesses to the frame

with respective wire bands at the designated
● Make sure if the connector pins are bent, locations. Tighten the bands so that only the
extruded or loosened. insulated surfaces contact the wires or wire
harnesses
● Insert the connector completely.

● If there are two lockers on two connector sides, ● Wire band and wire harness have to be
make sure the lockers are locked in properly. clamped secured properly.
● Check if any wire loose.
● Check if the connector is covered by the twin

connector boot completely and secured
● Do not squeeze wires against the weld or its
clamp.
properly.
1-6
● Do not let the wire harness contact with ● Protect wires or wire harnesses with electrical
rotating, moving or vibrating components tape or tube if they contact a sharp edge or
when routing the harness. corner. Thoroughly clean the surface where
tape is to be applied.
● Keep wire harnesses far away from the hot ● Secure the rubber boot firmly as applying it on
parts. wire harness.
Never Touch
● Never use wires or harnesses which insulation

● Avoid wire harnesses from sharp edges or has broken. Wrap electrical tape around the
corners, and also avoid the jutted-out ends of damaged parts or replace them.
bolts and screws.
● Never clamp or squeeze the wire harness

● Route harnesses so that they neither pull too when installing other components.
tight nor have excessive slack.
Never clamp or squeeze
the wire harness
Never too tight
1-7
● Do not let the wire harness be twisted when ● Use sand paper to clean connector
installation. pins/terminals if rust is found. And then
continue the connection operation.
Clean rust
● Wire harnesses routed along the handlebar

should not be pulled too tight or have
excessive slack, use rubber covering against
adjacent or surrounding parts in all steering
perimeters.
● Before operating a test instrument, the

operator should read the operation manual of
the instrument, and then conducts test in
accordance with the instruction.
Do you know how to set the

instrument to its measurement
position and the insert locations
of its two probes?
1-8
Specifications
Maker SYM Model PD25A1
Overall Length 2005 mm Suspension Front TELESCOPIC FORK
Overall Width 790 mm System Rear UNIT SWING
Dimension
Overall Height 1050 mm Tire Front 110/70-17 54H
Wheel Base 1320 mm Specifications Rear 140/70-17 66H
Front 82 kg
Curb Front DISK (ø 288 mm)
Rear 91 kg Brake System
Weight
Total 173 kg Rear DISK (ø 222 mm)
Passengers/Weight Two / 150 kg Max. Speed > 140 km/hr
Performance
Weight Front 112 kg Climb Ability < 28°
Rear 211 kg Primary

Total Reduction
2.826 (65/23T)
Weight
Total 323 kg Final
2.69 (35/13T)
Reduction
Water-cooled
Type/ Cooling Reduction
4-stroke Clutch Wet multi-plate
System gasoline engine
Vertical, below
Installation and Transmission 6 speed, circulated
center, incline
arrangement
15°
Above 92
Fuel Used Speedometer 0 ~ 199 km/hr
unleaded
Fuel supply injection Horn 1

Expansion & Pulse
C Bore Ø 71.0 mm Muffler
yl Type
in Exhaust Pipe Position and Right side and
Stroke 63.0 mm Direction Backward
d
Engine e Number/Arrangem Single Cylinder Lubrication System Forced / Wet sump
r ent
Displacement 249.4 cc Exh Solid Particulate -

aust
Compression Ratio 10.5 : 1 Con CO < 3.0 %
cent
25 ps / 7500 rati HC < 1600 PPM
Max. HP
rpm on
2.35 kg-m /
Max. Torque E.E.C. √
6000 rpm
Full transistor
Ignition P.C.V. √
Ignition
Electrical Catalytic reaction control
Starting System √
starter system
1-9
Torque Values (Engine)

Item Q’t Thread Dia. (mm) Torque Value(kgf-m) Remarks
Cylinder stud bolt 4 10 1.0~1.4
Cylinder head nut 4 10 3.6~4.0
Cylinder head right bolt 2 6 1.0~1.4
Cylinder head side cover bolt 3 6 1.0~1.4
Cylinder head cover bolt 4 6 0.8~1.2
Cylinder head stud bolt (inlet 2 6 1.0~1.4
i )
Cylinder head stud bolt (EX. 2 8 2.4~3.0
i )
Air inject pipe bolt 4 6 1.0~1.4
Tappet adjustment screw nut 4 5 0.7~1.1 Lubricate with oil
Spark plug 1 10 1.0~1.2
Camshaft gear fix bolt 2 6 1.0~1.4
Camshaft setting plate bolt 1 6 0.8~1.2
Cam chain tensioning bolt 2 6 1.0~1.4
Throttle fix nut 2 6 0.8~1.2
Engine oil draining bolt 1 12 3.5~4.5
Engine oil strainer cap 1 30 1.3~1.7
Flywheel nut 1 14 8.5~10.5
R. crankcase cover bolt 12 6 0.8~1.2
L. crankcase cover bolt 11 6 0.8~1.2
L. crankcase rear cover bolt 2 6 0.8~1.2
Oil pump screw 2 6 0.7~1.1
Oil pump cover bolt 2 6 0.8~1.2
Water pump impeller 1 7 1.0~1.4
Water pump cover bolt 4 6 0.8~1.2
Crankcase bolt 11 6 0.8~1.2
Oil strainer cover bolt 2 6 0.8~1.2
Balancing shaft drive gear bolt 4 6 0.8~1.2
Primary drive gear nut 1 16 8.5~10.5
Balancing shaft fix nut 1 14 8.5~10.5
Clutch lifter plate bolt 6 6 1.0~1.4
Clutch fix nut 1 16 8.5~10.5
ACG fix bolt 3 6 0.8~1.4
Drive gear bolt 2 6 0.8~1.2
The torque values listed are important tightening torque values. Please see standard values for
those not listed in the table.
1-10
Torque Values (Frame)

Q’t Thread Dia. Torque Value
Item Remarks
y (mm) (Kg-m)
Mounting bolt for steering handle post 4 8 1.0~1.4
Lock nut for steering stem 1 22 6.0~8.0

Steering top cone race 1 22 0.15~0.25
Front wheel axle nut 1 12 6.0~8.0
Rear wheel axle nut 1 14 10.0~12.0
Rear drive sprocket nut 4 8 2.7~3.0
Front cushion mounting bolt 4 8 3.0~3.5
Rear cushion upper connection bolt 1 10 3.5~4.5
Rear cushion lower connection bolt 1 10 3.5~4.5
Brake lever bolt 2 6 0.8~1.2
Brake hose bolt 4 10 3.0~4.0
Brake air-bleeding valve 2 6 0.8~1.0
Front brake disc mounting bolt 3 6 3.7~4.3
Rear brake disc mounting bolt 2 8 2.4~3.0
Gear change bolt 1 6 0.8~1.2
Brake clipper mounting bolt 2 6 1.5~2.0
Engine suspension nut 2 8 2.4~3.0 upper part of engine &
frame
Engine assembly nut 2 8 3.0~4.0 engine front part & engine
hanger
Engine assembly nut 1 10 4.5~5.5 engine rear part & frame
Special Bolt 8 8 1.5~2.5

Swing arm pivot nut 1 10 10.0~12.0
Muffler mounting nut 2 8 1.0~1.2
Muffler mounting bolt 2 8 3.2~3.8
The torque values listed in above table are for more important tightening torque values. Please refer to
standard values for those not listed in the table.
Torque Values
Type Tighten Torque Type Tighten Torque
5mm bolt, nut 0.45~0.60kgf-m 4mm screw 0.10~0.15kgf-m
6mm bolt, nut 0.80~1.20kgf-m 5mm screw 0.35~0.50kgf-m
8mm bolt, nut 1.80~2.50kgf-m 6mm screw, SH nut 0.70~1.10kgf-m
10mm bolt, nut 3.00~4.00kgf-m 6mm flange bolt, nut 1.00~1.40kgf-m
12mm bolt, nut 5.00~6.00kgf-m 8mm flange bolt, nut 2.40~3.00kgf-m
3mmscrew 0.05~0.08kgf-m 10mm flange bolt, nut 3.50~4.50kgf-m
1-11
Troubleshooting
A. Engine cannot be started or difficult to be started
Check and adjustment Fault condition Probable causes
Press the fuel injector feed

pipe and confirm whether
there is fuel in the feed pipe 1. Check the fuel amount in the fuel tank
2. Check if the fuel pipe and the vacuum
The fuel supply to the fuel The fuel injector is not tube are blocked or not
injector is sufficient supplied with sufficient fuel 3. Malfunction of fuel pump relay or wiring
4. Evaporative Emission Control System
clogged
5. Malfunction of fuel pump
6. The fuel strainer is blocked or not
Check the spark plug ignition
condition
1. Malfunction of spark plug

2. Spark plug contamination
Sparks
Week sparks or no spark 3. Malfunction of ECU
4. Malfunction of the AC Generator
5. Ignition coil is in open or short circuit
6. Ignition coil shorted or open circuit
7. Malfunction of main switch
Perform cylinder compression
pressure test
1. Piston ring seized

Normal cylinder Low or no compression 2. Malfunction of cylinder valves
compression pressure pressure 3. Worn cylinder and piston ring
4. Cylinder gasket leakage
5. Sand hole in the compression parts
Restart the engine
No ignition With signs of ignition but 1. Malfunction of throttle valve operation

the engine cannot be 2. Air sucked into intake manifold
started 3. Incorrect ignition timing
Remove and check the spark

plug
1. Contaminated or clogged fuel injector

Dry spark plug Wet spark plug 2. Malfunction of throttle valve operation
3. Malfunction of fuel pressure regulator
1-12
B. Engine runs sluggish (Speed does not go up, lack of power)

Accelerate gradually and check

1. Clogged air cleaner
engine RPM 2. Poor fuel supply
Engine RPM cannot be increased 3. Fuel tank emission control system clogged
Engine RPM can be increased
4. Clogged exhaust pipe
(Test on level road) 5. Clogged fuel injector
Check ignition timing Engine RPM cannot be 1. clutch slippage

increased 2. poor clutch contact surface
(Using ignition lamp)
3. clutch shoe damaged
Correct ignition timing Incorrect ignition timing
1. Malfunction of ECU
2. Malfunction of AC Generator
Check cylinder compression
pressure (using pressure gauge)

1. Worn out cylinder or piston ring
Normal compression pressure Abnormal compression pressure 2. Cylinder gasket leakage
3. and hole in compression parts
Check if the fuel injector is 4. Valve deterioration

clogged or not 5. Jammed piston ring
Not clogged 1. Replace the fuel injector

Clogged
Remove and check the spark

plug
1. Remove the dirt

2. Incorrect spark plug heat range
No contamination or discoloration Contaminated or discolored
3. Incorrect spark plug gap
Check if the engine is over

heated 1. Worn out piston or cylinder
2. Abnormal fuel injector
Normal Engine overheated 3. Poor fuel quality
4. Carbon deposit in the combustion chamber
Continually drive in acceleration 5. Abnormal ignition timing
or high speed
6. clutch slippage

No knocking Knocking 2. Malfunction of fuel injector
3. Poor fuel quality
4. Abnormal ignition timing
1-13
C. Engine runs sluggish (especially in low speed and idling)
Check ignition timing

(using ignition lamp)
Normal Abnormal Incorrect ignition timing (malfunction of
ECU or AC Generator)
Check for any air sucked in

through the throttle body insulator
1. Abnormal throttle body insulator gasket

No air sucked in Air sucked in 2. Abnormal throttle body installation
3. Abnormal inlet pipe gasket
Remove the spark plug and
check the spark condition
1. Contaminated spark plug

Good spark Poor spark 3. Malfunction of AC Generator
4. Malfunction of ignition coil
5. Open or short circuit in spark plug leads
6. Malfunction of main switch
D. Engine runs sluggish (High speed)

Check ignition timing
Normal Abnormal 1. Malfunction of ECU

2. Malfunction of AC
Check the fuel pump supply
1. insufficient fuel
Good Poor 2. fuel hose clogged, pressed
3. EEC clogged
Check if fuel injector clogged
Normal Clogged 1. Replace injector
1-14
E. Starter Motor Malfunction

1. Starter Motor doesn’t rotate
Check and adjustment Fault condition Possible causes
Pull the brake handle or step

on the braking pedal
1. Burnt Fuse
2. Insufficient Battery Voltage
Braking light activated Braking light not activated
3. Abnormal braking switch
4. Abnormal main switch
Check the battery circuit by
activating turning signal
Flashing normally Not flashing or dimmed Insufficient Battery capacity

(60~120 flashes per minute)
Push the staring button and check if

the starting relay is activated
1. Bad contact in the starter switch

Starting relay activated Starting relay not activated 2. Abnormal Starter relay
3. Loose coupler or terminals
Connect the starting motor to
the battery
1. Worn carbon brushes
Starter Motor rotates Starter Motor doesn’t rotate 2. Broken or shorted rotor windings
3. Broken Starter motor sub wire
4. Loose coupler
1. Abnormal wire harness
1-15
2. Starting Motor rotates slowly or spins without engagement with crankshaft

Check and adjustment Fault condition Possible causes
Check the battery circuit by

activating turning signal
Flashing normally Not flashing or dimmed Insufficient Battery capacity
Connect the starting motor to

the battery
Starting Motor Still rotating Rotates Normally 1. Loose coupler or terminals

slowly
2. Starting Relay bad contact
1. Engine Seized
2. Starting Motor shorted or damaged
3. Starter motor won’t stop rotating
Turn the main switch off
Motor keeps running Motor stops 1. Starting switch shorted/ stuck
1. Starting relay shorted
F. Abnormal Engine Noise

Fault condition Possible causes
Rocker arm noise 1. Excessive valve clearance

2. Worn rocker arm
3. Worn camshaft
Piston slapping 1. Worn piston and cylinder

3. Worn piston pin or connecting rod lower end
Cam chain noise 1. Worn camshaft bearings

2. Worn cam sprocket
3. Loose or worn cam chain
Clutch knocking Excessive clutch plate clearance

Transmission gear noise 1. Worn or deteriorated rear wheel damping rubber
2. Gear surface worn
3. Worn transmission gear set
1-16
Lubrication Points
Throttle cable / Front brake lever pivot / clutch lever
Steering stem
Front wheel bearing

Rear wheel bearing
Side stand bracket
Driven chain
1-17
NOTE:
1-18
2. Maintenance Information
Precautions in Operation ········· 2-1 Steering Mechanism ················· 2-8

Periodical Maintenance Schedule Suspension System ·················· 2-9
···················································· 2-2 Disk Brake System···················· 2-9
Lubrication System··················· 2-3 Tire·············································· 2-11
Cylinder Compression Test ····· 2-4 Battery········································ 2-12
Fuel System ······························· 2-5 Clutch Adjustment ···················· 2-12
Air Filter ····································· 2-5 Headlight Adjustment ··············· 2-13
Throttle Operation····················· 2-6 Brake Switch······························ 2-13
Spark Plug ································· 2-6 Nuts, Bolts Tightness ··············· 2-13 2
PCV System ······························· 2-7 Special Tools ····························· 2-14
Valve Clearance Adjustment ···· 2-7
Drive Chain Adjustment ··········· 2-8
Precautions in Operation
Specifications
Fuel tank Capacity 14000 c.c.
capacity Reserve 700 c.c.
Capacity 1700 c.c.
Engine Oil
Exchange 1500 c.c.
Throttle grip free play 2~6 mm
Spark plug NGK CR8E
Spark plug gap 0.7~0.8 mm
Ignition timing BTDC 13º / 1650 rpm
Idle speed 1650±100 rpm
Cylinder compression pressure 12±2 kgf/cm²
Valve In 0.10±0.02 mm
clearance Ex 0.15±0.02 mm
Front 110/70-17 54H
Tire size
Rear 140/70-17 66H
Single ride Front：2.0 kg/cm² / Rear：2.0 kg/cm²
Tire Pressure
Tandem ride Front：2.0 kg/cm² / Rear：2.25 kg/cm²
GT12A-BS
Battery Type
(12V 10Ah)
2-1
Periodical Maintenance Schedule

Initial 1 month / 3 months / 6 months / 1year /
NO Items 300KM every1000 every3000 every6000 every12000K
KM KM KM M
1 ☆Air filter element I C C R
2 ☆Gasoline filter I I R
3 ☆Engine oil filter R R
4 ☆Engine oil strainer C C C
5 ☆Engine oil replacement R Change every 1000km
6 Tire pressure I I
7 Battery inspection I I
8 Brake lever free play check I I
9 Steering handle integrity check I I
10 Shock absorber performance check I I
11 Bolts tightening check I I
12 Check the engine for oil leakage I I
13 ☆Spark plug inspection or replacement I I R
14 ☆Change gear oil R Change every 5000km
15 Lubrication of the whole bike L
16 Exhaust pipe I I
17 ☆Ignition timing I I
18 ☆Idle emission check A I A
19 ☆Throttle operation I I
20 ☆Engine bolts torque I I
21 ☆Transmission / chain I I/L R
22 ☆Clutch free play inspection I I
23 Light/electrical system//instrument readings I I
24 Main stand/side stand spring I I
25 Fuel lines I I
26 Cam chain I I
27 ☆Valve clearance I A
28 ☆PCV I C
29 ☆Crankcase blow-by over-flow pipe I Drain every 2000km
30 ☆Evaporative control system I
31 ☆Throttle body A I A C
32 ECUimput voltage I
33 EFi sensor coupler I I
Note: I-Inspection A-Adjust R-Replace C-Clean L-Lubricate
Please have your periodical maintenance data recorded by your SYM Authorized Dealer to maintain the motorcycle in excellent
condition. The above maintenance schedule is established by taking the monthly 1,000 kilometers as a reference. Whichever
time or mileage comes first will be regarded as an index for maintenance.
Remark：These marks “☆ ” in the schedule are emission control items. According to EPA regulations, these item checks
must be performed periodically following the use r manual instructions. It’s prohibited to adjust or repair
these emission control items by unauthorized people. Otherwise, SYM is no responsible.
1. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the
heavily polluted environment.
2. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the
motorcycle has accumulated a higher mileage.
3. Preventive maintenance
a. Ignition system－Perform maintenance or check when continuous abnormal ignition, misfire, after-burn, overheating occur.
b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system when power is decreasing.
c. Replace worn out pistons, cylinder head.
2-2
Lubrication System
Engine Oil quantity
Caution
Upper limit
 Turn off the engine; park the motorcycle on
level surface with main stand.
 Run the engine for 3-5 minutes, check oil
capacity after engine off for3-5
Check oil quantity from inspection window, if oil Lower limit
level is near lower limit, fill in the recommended oil

to upper limit.
Exchange engine oil

Remove the oil drain bolt under the crankcase to
drain the engine oil. After completely drain the
engine oil, clean the drain bolt and the washer. If
the washer is deformed or cracked, please change
a new one.
Engine oil drain bolt torque：3.5~4.5kgf-m
Caution
 Warm up the engine before draining oil; that
will make engine oil easily and thoroughly Oil strainer cap Oil drain bolt
drained.
Fill in the engine oil to the standard quantity.
Oil viscosity :SAE10W -30
Engine oil exchange volume
Full disassembly：1700 c.c.
Regular exchange：1500 c.c.
Run the engine for several minutes, check for oil
leakage.
Engine oil strainer cleaning

Drain engine oil completely，remove oil strainer
cap, spring, and strainer from left side of
crankcase.
Clean oil strainer with solvent or compressed air.
Check if O-ring is deformed or damaged, replace if
necessary.
Install strainer, spring, and oil strainer cap.
Torque value：1.3~1.7kgf-m
2-3
Replace oil filter

Remove bolts of oil filter chamber.
Remove the filter and replace it with a new one.
Caution
boltx2
 Oil filter is paper type and cannot be cleaned
or reused.
Cylinder compression test Oil filter

Warm up engine and turn it off.
Remove left cylinder head cover
Remove spark plug cap and spark plug.
Install compression gauge into the spark plug hole,
full open the throttle, and rotate the engine.
Caution
Rotate the engine until the reading in the gauge
gains no more.
 Usually, the highest-pressure reading will Spark plug
appear in 4~7 seconds.
Compression pressure：12 ±2 Kgf/cm²

Check the following items if the pressure is too
Pressure
low:
gauge
 Incorrect valve clearance.
 Valve leakage
 Cylinder head leakage. Piston, piston ring,
cylinder damaged.
Over-high pressure means combustion chamber
or piston top deposit carbon.
2-4
Fuel System
Fuel lines Fuel filter
Check all fuel lines, and replace when they are

deteriorated, damaged or leaking.
Caution
 Gasoline is a highly flammable substance, so
any source of fire or spark is strictly
prohibited when operation.
Fuel filter
Warning Filter
 Any source of fire or spark is strictly
prohibited when operation.
 Fuel filter is sealed type, replace it if it is
clogged.
Remove seat, fuel tank, and fuel pump.
Check if fuel filter is clogged or broken; replace it
with a new one when necessary.
Check the fuel line for leakage.
Screw×4
Air filter
Air filter element
Remove the seat.
Remove the air filter cover (4 Screws)
Remove the air filter element
Check if the filter element is dirty or damaged.
If the air cleaner filter element is too dirty or
damaged, please replace with new parts.
Caution Air filter element
 The air filter element is paper type and
cannot be soaked or washed, or engine
performance will be affected.
 If the filter element is not installed correctly,
dust will be sucked into cylinder, which will
result in decreased power and shortened
engine life.
2-5
Throttle operation
Operate the throttle grip to see if the throttle cable 2~6 mm
is going smoothly.
If the throttle cable is deteriorated, twisted or
damaged, please exchange it.
If the cable does not go smoothly, lubricate the
cable.
Measure the free play of the throttle grip, through
the inner side flange of it.
Free play：2~6 mm
Adjustment can be done on both side of throttle

Adjusting nut
cable.
Conduct secondary adjustment on upper side.
Loose fix nut and rotate it to adjust free play.
Lock nut
Spark plug cap

Spark plug
Recommended spark plug：CR8E
Remove cylinder head left cover. (boltX3)

Remove spark plug cap.
Clean dirt around the spark-plug hole.
Remove spark plug.
Measure spark plug ignition gap.

Spark plug gap：0.7~0.8 mm
Carefully bend ground electrode of the plug to
Ground electrode
adjust the gap if necessary.
Center electrode
Hold spark plug and install the spark plug by
screwing it with hand, after tightening the plug by
hands, use plug socket to tighten it to the standard
torque value.
Standard torque：1.0~1.2kgf-m
Install the spark plug cap.
0.7~0.8mm
2-6
PCV System
Unplug the drain tube, and leak the deposit off.
Drain the tube every 2,000 km.
Caution
 Under rainy or full- throttle situation, the
maintenance period should be shortened.
You can check the deposit amount through
the transparent tube.
Valve clearance Adjustment
Caution Drain tube
 The valve clearance should be adjusted
when the engine is cold. (Under 35°C)
〝T〞mark
Remove fuel tank. Remove cylinder head.
Remove cylinder head side cover.
Remove the timing inspection cap and the AC.G
cap on the crankcase L cover.
Use a T socket wrench to rotate the crankshaft
counterclockwise. Align the “T” mark on the
AC.G flywheel with the crankcase sign, and
simultaneously, the cam- chain sprocket TDC
mark aligning with the cylinder head mark (That
means the piston is in the upper end of
compression stroke)
TDC mark
Valve clearance inspection & adjustment
Check the intake and exhaust valve clearance by
inserting the feeler gauge between the adjusting
screw and the lock nut.
Valve clearance： IN: 0.10±0.02 mm
EX: 0.15±0.02 mm
Adjust by loosening the lock nut first, and
turning the adjusting screw.
Caution
 When adjusting valve clearance, make sure
all clearance on standard volume; recheck
after tightening lock nuts.
Install cylinder head, cylinder head side cover,
timing inspection cap, and the AC.G cap
Caution
 Before installing cylinder head side cover,
timing inspection cap, and the AC.G cap,
check if the O-ring is damaged, and apply
some oil on it.
2-7
Drive chain adjustment
Drive chain inspection
Place the bike on its main-stand with its neutral
gear. Check the drive chain slack by moving the
chain up and down by fingers, and measure the
amount of chain slack.
Standard chain slack：10~20 mm
Caution
 Because the front and rear sprocket have
different wearing situations, so please rotate
the rear wheel to find the minimum chain
slack for the measurement.

If you need to adjust the chain slack, please
loosen the rear axle nut and sleeve nut first.
Turn the left and the right side adjusting nut evenly
to make the chain slack within the standard range.
Turn the nuts clockwise to tighten the chain, or
counterclockwise to loosen the chain.
Rear axle nut Adjusting nut
After tightening the rear axle nut, please check the
sleeve nuts to prevent them from loosening.
Recheck the chain slack, and make sure the rear
wheel rotates smoothly.
If the chain is too dirty, use high-flash point
solvents to clean the chain. (Kerosene or Diesel.)
Caution
 Don’t use gasoline when cleaning the chain.
The gasoline will damage the O-ring in the
chain.
After cleaning, lubricate the chain with chain
lubricant.
Steering mechanism
Caution
 Check all wires and cables if they are
interfered with the rotation of steering handle
bar.
Lift the front wheel off the ground.
Turn handle from right to left and check if turning
is smoothly.
If handle is uneven or bending, or the handle can
Lock nut
be lifted through vertical direction, adjust the
handle top bearing.
2-8
Suspension system
Caution
 Do not ride the motorcycle with poor cushion.
 Loosened, worn or damaged cushion will
make poor stability and maneuverability.
Front cushion
Press down the front cushion several times to
check its integrity.
Check if any oil leakage or damage.
Replace relative parts if damaged.
Tighten all nuts and bolts.
Rear cushion
Press down the rear cushion several times to
check its integrity.
Check if any oil leakage or damage.
Replace relative parts if damaged.
Start the engine and gradually rise R.P.M. to
rotate the rear wheel; check if any looseness,
vibration; replace bushing if damaged.
Tighten all nuts and bolts.
Disk brake system

Brake System Hose
Check the brake hoses for corrosion or brake fluid
leaking.
Brake Fluid
Check brake fluid level in the brake fluid reservoir.
If the level is lower than the LOWER limit, add
brake fluid to UPPER limit. Also check brake
system for leaking if low brake fluid level found.
Caution
 To keep the reservoir in horizontal position,
do not take off the brake fluid cap before
keeping the steering handle steady.
 Do not operate the brake lever after the cap
removed. Otherwise, the brake fluid will be
sprayed out.
 Do not mix non-compatible brake fluid.
Lower limit
2-9
Air bleeding operation

Master Cylinder Cap
Connect a transparent hose to air-bleeding valve.
Hold the brake lever and turn the air-bleeding
valve open. Perform this operation several times Diaphragm
until there is no air bubble inside the transparent
Upper limit
hose.
Caution Brake fluid
 Before closing the air bleed valve, do not
release the brake lever.
Add Brake Fluid
Add brake fluid to UPPER limit.
Recommended brake fluid: DOT3 or DOT4 WELL
RUN brake fluid.
Air Bubble Air-bleeding valve
Caution
 Never mix or use dirty brake fluid to prevent
braking system from deterioration or reducing
brake performance.
Brake Lining Wear

The indent mark on brake lining is the wear Transparent tube
limitation.
If the wear limit mark approximates the edge of Brake
brake disc, replace the brake lining. disc
Caution
 It is not necessary to remove brake hose
when replacing the brake lining.
Brake lining
wear limitation
2-10
Tire
Check the pressure of the tire to see if it is in the
specified pressure range.
Caution
 Tire pressure check should be done when the
tire is cold.
Specified tire pressure range
Tire pressure Front Rear
Tire pressure Single

2.0 2.0
when cold riding
(Kg/cm²) Dual riding 2.0 2.25
Specified tire:
Front：110/70-17 54H
Rear：130/70-17 62H
Check if tire surface is stuck with nails, stones or
other objects.
Check if tire surface and wall are damaged or
worn, replace when necessary.
Check tire tread depth with eye or tire depth
gauge.
Replace the tire if it is uneven worn or insufficient
tread depth.
If the wearing of the tire thread reaches triangle
TWI mark index, the tire have to be replaced.
Measure tire thread depth from tire central surface,
replace the tire, if the depth is not enough.
Minimum tread depth:
Front wheel: 1.5 mm
Rear wheel: 2.0 mm
“△ ”TWI mark
Caution
 The triangle TWI mark index is located along
the tire wall.
2-11
Battery Negative pole Positive pole

Battery removal
Remove the seat
Remove the〝─〞negative pole first, then remove
the〝＋〞positive pole.
Remove the battery holder and take out the
battery.
Caution
 If the rust on the posts is very serious, spray
some hot water on them. Then, you can
remove the rust by steel brush more easily.
 Apply some grease on the posts after
cleaning rust to prevent from happening
again.
If there is some rust on battery posts, clean it with

steel brush.
Install the battery in the reverse procedures of
removal.
Battery model : GT12A-BS 10~20 mm
Clutch adjustment
Clutch lever free play inspection
Slightly pull the clutch lever to check the free play
before clutch disengagement.
Free play：10~20 mm
Adjusting nut Lock nut

Clutch lever free play adjustment
Before adjusting the clutch lever free play, please
loosen the lock nut first. Then turn the adjusting
screw to achieve the recommended clutch free
play. If you want to decrease the free play of
clutch lever, turn it clockwise. If you want to
increase the free play, turn it counterclockwise.
After adjustment, tighten the adjusting nut with
lock nut.
Lubricate the clutch cable.
2-12
Headlight adjustment
Turn on main switch. Loosen the headlight
adjustment screw to adjust headlight beam height.
Caution
 The factory setting of the beam height is
consistent with government orders.
 Improper headlight beam setting will make
driver in the opposite lane dazzled and cause
danger. Headlight adjusting screw
Brake switch
Inspection on the brake switch
When brake lever is pulled, brake switch will light
up the brake lamp.
Make sure that electrical starter can be activated
only under braking condition.
Brake switch
Adjustment of rear brake switch
Turn on the main switch.
When the brake pedal is stepped down for
20mm，the brake lamp should be activated.
If the brake lamp is not activated or activated too
early, please adjust through the rear-brake-switch
adjusting nut.
Turning clockwise will decrease the free play, and
counterclockwise will increase the free play.
RR brake switch adjusting nut
Nuts, bolts tightness

Apply periodical maintenance in according with the
Periodical Maintenance Schedule.
Check if all the bolts and nuts on the frame are
tightened within standard torque.
Check all fixing pins, snap rings, hose (pipe)
clamps, and wire holders for security.
2-13
Special tools
Name Rocker arm shaft disassemble tool Name Flywheel puller Name Valve remove and assemble tool
SY No. SYM-1445100 SY No. SYM-3110000-HMA SY No. SYM-1471110/20
Name Valve spring compressor Name Tappet adjusting wrench Name Tappet adjusting tool
SY No. SYM-1471100 SY No. SYM-9001200 SY No. SYM-9001210
(6203/6004UZ) (20*34*7)
Name Steering Nut Wrench Name 6203/6004UZ bearing Driver Name 20*32*6 oil seal driver
(6204) (6301)
Name 6204 Bearing Driver Name 6301 Bearing Driver Name Digital clamp meter
SY No. SYM-9110400 SY No. SYM-9610000 SY No. SYM-HE07007-05
2-14
Name Inner bearing puller set Name Outer bearing puller Name Bearing driver
Name Crankcase bush puller Name Cylinder pressure gauge Name Vacuum pressure gauge
SY No. SYM-1120310 SY No. SYM-HT07008 SY No. SYM-HT07011
Name EFi System Diagnostic tool Name Fuel pressure gauge Name Multi-meter
SY No. SY No. SYM-HT07010 SY No. SYM-HE07007-01
Name Vehicle circuit test tool kit Name Vehicle circuit test harness Name Fuel hose clamp
SY No. SYM-HE170008 SY No. SYM-HE170008-01 SY No. SYM-1950500
2-15
Water pump mechanical

Name EFI fuel hose pliers Name EFI fuel hose removal pliers Name
seal driver
SY No. SYM-1768100 SY No. SYM-1768110 SY No. SYM-1721700-H9A
Name Water pump bearing driver Name Water pump oil seal driver
SY No. SYM-9100100 SY No. SYM-9120500-H9A
2-16
3. Fuel Injection System
EFi System Diagram·································· 3-1 Fuel Tank ····················································3-37

EFi System Operation ······························· 3-2 Fuel Pump···················································3-38
EFi System Introduction ··························· 3-3 Fuel Unit······················································3-39
Fuel System ··············································· 3-4 Air Cleaner ··················································3-39
Ignition System·········································· 3-5 EFi System Diagnosis Methods················3-40
Sensors / Drives ········································ 3-6 Check Light Fault Codes Differentiation··3-41
Precautions in Operation·························· 3-12 Fault Codes and Sensors Table················3-42
EFi System Components Description ····· 3-13 Fault Code and Check Light Flashing Light
Identification Table···································3-43
EFi System Circuit····································· 3-29
Troubleshooting Table ······························3-44
ECU Pin Configuration······························ 3-30
Comprehensive Maintenance List ············3-45
Troubleshooting ········································ 3-31
Intergrated Troubleshooting Procedure·· 3-35
EFi system diagram
Fuel pump Diagnostic tool

Ignition coil
AISV
TPS
EFi System
Check Lamp
Rollover
sensor
TA sensor
Injector O2
Sensor Relay
MAP ECT sensor

sensor Battery
ISC
(stepping motor) ECU
CPS
3-1
EFi system operation
Crankshaft
Position Sensor CPS
Manifold Absolute
Pressure Sensor MAP
INJECTOR Injector
Throttle Position
Sensor TPS
Ignition Coil
IGN COIL
Engine Coolant
TW ECU
Temperature
Sensor FUEL PUMP Fuel pump
Engine control
O2 sensor LAMBDA unit
CHECK LIGHT
Rollover K/S
sensor
AISV AISV
Intake Air
TA
Temperature Sensor
ISC Idle Speed Control
Valve
Battery VBATT (Stepping motor)
voltage
Tuning tools Diagnostic tool
3-2
EFi system introduction
Based on 4-stroke SOHC engine, displacement 250 c.c. electronically controlled fuel injection.
Fuel vapor will be absorbed by carbon canister; blow-by gas from crankcase will be introduced to
combustion chamber. The O2 sensor enhances the efficiency of the catalytic converter by
dynamically controlling the air / fuel ratio.
Electrical fuel injection system

Electrical fuel injection system is constructed by fuel supply device: fuel tank, fuel pump, fuel filter,
pressure regulator, and fuel control device: injector, ECU.
The fuel is pumped by electrical fuel pump in the fuel tank to the injector on the intake manifold
(inlet pipemanifold). The fuel pressure regulator keeps the pressure around 294±6kpa. The
signals from ECU enable the injector to spray fuel into the combustion chamber once each two
crankshaft-revolutions. The excessive fuel flows back to the fuel tank through the fuel pressure
regulator. Fuel pump is placed inside the fuel tank to reduce the working noise and simplify the
fuel system. Electrically controlled ignition and injection system effectively reduce fuel
consumption rate and pollution.
In traditional gasoline engine, carburetor supplies the fuel. The engine vacuum generates negative
pressure in the carburetor; then fuel mixed with air and together the mixed gas sent into
combustion chamber. Under this condition, air-fuel ratio is determined by air and fuel sucked in.
Thus, the three major processes are done simultaneously in the carburetor: air quantity
measurement, the determination of fuel quantity, the mix of fuel and air.
Electrical fuel injection system checks intake air quantity and temperature; on this basis, the
programmed air-fuel ratio in the ECU determines the amount of fuel to be injected; then the
injector sprays the fuel. The difference between carburetor and electrical fuel injection is that the
three mechanisms are independent which will lead to more precise fuel control and supply.
EFi engine uses computer-programmed fuel injection, the main features are:
1﹒ The quantity of fuel injected is determined according to the condition of the engine. The engine
RPM and throttle position determines the fuel quantity and injection time-length.
2﹒ The quantity of fuel injection, and the determination of injection time length, are all controlled by
16-bit microcomputer.
3﹒ The fuel pressure regulator maintains a 294±6kpa pressure difference between inlet pipe and
fuel pipe, raising the accuracy of fuel injection.
4﹒ By measuring the air pressure of inlet pipe, this system gives the vehicle better accommodation
to the environment.
5﹒ Idle speed control system supplies by-pass air to stabilize the idle running and cold starting.
6﹒ O2 sensor feeds back the signal to minimize the exhaust pollution.
3-3
Fuel system
Fuel pump
Injector
Fuel pump
relay
ECU
Power relay
Battery
System description
1. After Key-on, the sensors send signals to ECU. ECU controls the fuel pump relay to make the
fuel pump operate. If the engine is not started, the fuel pump will be shut down within 2 to 3
seconds in order to save electricity. Fuel pressure regulator maintains fuel pressure at 294 ±
6kPa (about 3 kg / cm ²). According to the operating conditions and environmental
compensation coefficient, appropriate fuel will be injected. After Key-off or engine stops
operating, the fuel pump stops running.
2. Fuel filter filtrates impurities in the fuel. Replace it periodically.
3. When the engine cannot be started, do not keep starting the motor, which may reduce battery
power (less than 10 V), and the fuel pump will not be able to operate. The correct way is to use
a new battery.
Injector
Ten-hole type injector provides fuel injection, enhances the effect of fuel atomization, and
reduces HC emission. Short-type injector cap can easily fix the injector, receive the fuel from the
fuel pump, and limit injector rotation sliding. The signals from ECU control the fuel pressure
regulator, using the diaphragm and spring to maintain the fuel pressure in 294 ± 6kPa (about 3 kg
/ cm ²), and determine the fuel injection quantity by adjusting injection time width under different
engine conditions.
Fuel pump
Electrical fuel pump is placed inside the fuel tank, powered by the battery and controlled by ECU.
Fuel pressure: 294 ± 6kPa (about 3 kg / cm ²)
3-4
Ignition system
Intake air temperature

Manifold absolute pressure
Engine coolant temperature
ECU
Throttle position Ignition coil
Oxygen content
Spark plug
ACG/ Flywheel Gear
(23+1 Long teeth)
Crankshaft
position
sensor Power
relay
Battery
REG. REC.
Principle
The computer programmed ignition system receives the signals from the crankshaft position
sensor, throttle position sensor, O2 Sensor, MAP sensor, intake air temperature sensor, engine
coolant temperature sensor. Calculating the engine RPM, the 16-bit microcomputer determines
the appropriate ignition timing, controls the ignition coil and triggers the spark plug This way can
not only make the engine achieve the maximum power output, but also help improve fuel
consumption rate.
Specification
1. Ignition timing: BTDC 10 ° / 1650RPM
2. Spark plug: NGK CR8E Clearance:0.7~0.8mm
3. ACG crankshaft position sensor coil resistance: 120Ω±20% (green/white-blue/yellow)
4. Ignition coil primary circuit resistance: 2.8 Ω ± 15% Secondary circuit：with cap9.0KΩ±20%
without cap14.0KΩ±20%
5. Battery Type / Capacity: GT12A-BS / 12V 10Ah
3-5
Sensors / drives
Crankshaft position sensor (CPS)
Function:
CPS identifies the teeth on the flywheel and sends voltage signal to ECU.
Crankshaft position
Long sensor
tooth
ECU
Flywheel
Description
Right after the engine is started; the crankshaft position sensor identifies the TDC position by
detecting the long tooth on the flywheel and ignites at the fixed angle. When the engine RPM
reaches the specified speed, the ignition timing will change to the software mode.
3-6
Manifold absolute pressure (MAP) / Engine water temperature (TW) / Intake air
temperature (TA) sensor
ECU
Map sensor
TA Sensor
TW Sensor
Engine water temperature / Intake air temperature sensor: Use the variable resistor of
negative temperature coefficient (thermistor) to identify the outside temperature. The electrical
resistance value goes down when the temperature rises. On the contrary, the electrical resistance
value becomes higher when the temperature falls. Sensors provide the temperature of the engine
coolant and intake air to ECU to determine the injection and ignition timing.
5V
ECU
Manifold absolute pressure sensor: uses the piezoresistive resistor composed of silicon
diaphragm, forming the Wheatstone bridge circuit to measure the atmospheric pressure and the
intake manifold pressure, which are both transmitted to ECU as reference of engine control.
Working voltage (5V)

Inlet pressure
Output voltage
sensor
Output voltage
Inlet pressure (kPa)
3-7
O2 Sensor
ECU
Power relay
O2 Sensor
Battery O2 Sensor
3
Output voltage
4
1. Ceramics tube
2. Electrode
3. Emissions
4. Atmosphere
1 2
Rich ← 14.7 → Lean
Function
O 2 Sensor measures the proportion of oxygen in the exhaust gas, sending signals to ECU which
adjusts the air-fuel ratio by changing the fuel injection time. If the proportion of oxygen is too low, it
means the air-fuel mixture is rich, the concentration of HC & CO in the exhaust gas will rise. If the
proportion of oxygen is too high, it means the air-fuel mixture is thin, thin air-fuel mixture will result
in higher combustion temperature and higher NOx concentration.
1. O 2 Sensor outputs feedback signal to ECU which keeps the air-fuel mixture near the
stoichometric ratio approximately 14.6 and forms the closed loop control system.
2. When the air-fuel mixture is near the stoichometic ratio, CO / HC / NOx are converted
most efficiently.
3. O 2 Sensor heater resistance: 6.7 ~ 10.5 Ω
4. O 2 Sensor amendment in the voltage value: between 100 ~ 900 mV
3-8
Throttle position sensor (TPS)
ECU
TPS
Battery
ECU
TPS 5V TPS output voltage
VC
6
VTA
Voltage
4
2
E
0
50 100 150
Throttle valve opening angle
Basic Principle:
TPS is a rotary variable electric resistor. When it is rotated, both electric resistance and voltage
value will change, determining the throttle position.
Function:
TPS identifies the throttle valve position and sends signal to ECU as reference of engine control.
3-9
Idle speed control valve (ISC stepping motor)
ISC
ECU
Battery
+Va
-Va N
+Vb
N
S S
-Vb N Vb
Step Va
Function:
ECU controls ISC stepping motor to adjust the bypass intake air quantity and stabilize the idle
speed.
3-10
Air injection solenoid valve (AISV)
Function: AISV introduces appropriate air quantity to reduce pollutant emission.
Basic principle: When the engine RPM and throttle opening are higher than the default value,
ECU controls AISV opening or closure.
Fresh air
ECU
Power relay
AISV
Reed valve Battery
Power relay
AISV
ECU
3-11
Precautions in operation
General information
Warning
● Gasoline is a low fire point and explosive material. Always work in a well-ventilated place and
flame is strictly prohibited when working with gasoline.
● Before dismantling fuel system parts, leak fuel out first, or grip the fuel pipe by using pliers to
prevent fuel from splashing.
Caution
● Do not bend or twist the throttle cable. Damaged cable will lead to unstable driving.
● When disassembling fuel system parts, pay attention to O-ring position, replace with new one
as re-assembly.
Method of releasing fuel pressure in fuel system:

After removing fuel pump relay, turn on the main switch, press start switch to start the engine till it
stops to drain fuel in the fuel system.
Specification
Item Specifications
Idle RPM 1650±100 rpm
Throttle handle free play 2~6 mm
Fuel pressure 294±6kpa (3.0kg/cm²)
Torque value
Engine temperature sensor: 0.74~0.88kgf-m
O2 Sensor: 3.6~4.6kgf-m
Special Tools
Vacuum Gauge
Fuel Pressure Gauge
EFi System Diagnostic Scanner
Fuel Pipe Pliers
3-12
EFi system components description
ECU(Electronic Control Unit)
Function Description:
● Powered by DC 8~16V, and has 36-pin socket on the unit.
● The hardware component consists of a 16-bit microcomputer that
is its control center. It contains the functional circuit interface of
engine condition sensing and the driving actuator for the fuel
injector, fuel pump, as well as ignition coil.
● Its major software is a monitor strategy operation program that
includes controlling strategy and self-diagnosis programs.
Testing Procedures:
1. Connect the diagnostic scanner to the diagnostic coupler on the
vehicle.
2. Key-on but do not start the engine, confirm the connection of ECU
and the diagnostic scanner.
3. Diagnostic scanner will automatically display Version
"certification" of the screen.
4. Confirm the application model, version is correct or not.
5. Check if the fault codes exist.
6. Remove the fault codes.
7. Start engine and check the parameters shown on the diagnostic
scanner.
Detection judge:
● Fault codes can be read and cleaned, and the fault codes will not
appear again after re-start.
Treatment of abnormal phenomena:

1. Can not connect→ First check whether the cartridge is correct
and ECU is normal or not. Replace with new parts and recheck.
2. Unable to start→ ECU or relevant parts abnormal. Replace with
new parts and recheck.
3. Fault codes appear→ ECU or relevant parts abnormal.
Troubleshoot and recheck.
3-13
Throttle body
Function description:
● Throttle body is an inlet air flow regulating device (similar to the
carburetor).
● Throttle valve pivot drives the throttle position sensor
synchronously and makes ECU detect the throttle opening
immediately.
● Throttle valve positioning screw has been adjusted and marked
on the production line. Readjustment is not suggested.
● The ISC on throttle body functions to supply air making cold
starting easier; after engine warmed up, the air channel will be
reduced according to engine conditions.

● If all fuel injection associated components identified no fault, and
other traditional engine components are also normal, the engine is
still not smooth, please confirm if too much carbon deposits in the
Throttle throttle body.
positioning ● If there is too much carbon deposit in the throttle body, please
screw clean throttle body, and then adjust the injection system.
3-14
MAP sensor
● Powered by 5V DC from ECU. It has 3-pin socket on the sensor. One
terminal is for power, and one terminal is for signal output. And, the
rest one is for grounding.
● The major component of the intake pressure sensor is a variable
transistor IC. Its reference voltage is DC 5V, and output voltage range
is DC 0~5V.
● It is a pressure-sensing sensor, and can measure the absolute pressure
in intake process. It also conducts fuel injection quantity correction
based on environmental position level.
Pin Wire color Function
Left Y/B 5V voltage input
Center B/R Signal output
Right G/P Ground
Testing Procedures
1. Connect inlet pressure sensor properly (using the probe tool).
2. Key-on but do not start the engine.
Y/B B/R G/P 3. Use "voltage meter" DC stalls (DCV) to check inlet pressure sensor
voltage.
4. Working voltage check:
● Voltage meter negative access to the inlet pressure sensor third pin
(Green/Pink)
● Voltage meter positive access to the inlet pressure sensor first pin
(Yellow / Black).
5. Confirm output voltage values:
● Voltage meter negative access to the inlet pressure sensor third pin
(Green/Pink)
● Voltage meter positive access to the inlet pressure sensor second pin
(Black/Red)
Caution
The probe tool should contact the inner terminals to measure
●
Working voltage measurement
the correct value.
Detection judge:
● Working voltage value: 5.0±0.1V
● Output voltage values:2.87±0.03V (Conditions: Measure on level ground
101.3 kPa)
Caution
● The higher the elevation, the lower voltage will be measured.
● Sea-level atmospheric pressure = 1Atm = 101.3kPa = 760mmHg =
1013mbar
● MAP sensor damaged, or poor contact couplers.
● Check if the wire harness abnormal.
Output voltage measurement ● If MAP sensor fails, replace with a new one and recheck output
voltage.
● If ECU fails, replace with a new one and recheck output voltage.
3-15
TA sensor
Function Description
● Powered by 5V DC from ECU. It has 2-pin socket on the sensor.
One terminal is for voltage output, the other is for grounding.
● The major component of TA sensor is a variable resistor of
negative temperature coefficient
● Installed in the air filter, the resistor in TA sensor varies with
temperature variation and sends voltage signals for ECU to
calculate the intake air temperature; then, ECU adjusts injection
time and ignition angle.
Testing Procedures:
Resistance value measurement:
● Dismantled TA sensor connector.
● Use the "Ohmmeter" Ohm stalls to inspect sensor resistance.
Detection judge:
Temperature(℃) Resistance value(KΩ)

-20 18.8 ± 2.4
40 1.136 ± 0.1
100 0.1553 ± 0.007

● Damaged TA sensor or poor connector contact.
● If TA sensor possibly failed, it is suggested to replace with a new
one.
Resistance value measurement
3-16
TPS
● Powered by 5V DC from ECU. It has 3-pin socket on the sensor.
One terminal is for power, and one terminal is for voltage output.
And, the rest one is for grounding.
● Its main component is a sophisticated variable resistor.
● Installed on the throttle body. While throttle is rotated, TPS senses
the throttle position (opening) and sends voltage signals for ECU
to judge the throttle position; then, ECU optimizes fuel injection
W/BR and ignition timing.
Y/B Pin Wire color Function
Up White/Brown Signal output
G/P Center Yellow/Black 5V voltage input
Low Green/Pink Ground
Testing Procedures:
1. Working voltage can be measured while sensor coupler is
connected (use probe tool) or removed (direct measurement).
2. Key-on but do not start the engine.
3. Use "voltage meter" DC stalls (DCV) to check voltage.
4. Working voltage check:
● Voltage meter negative access to TPS third pin.(green/pink)
● Voltage meter positive access to TPS second pin.(yellow/black)
Working voltage measurement 5. Throttle output signal check: (using the probe tool)
● Voltage meter negative access to TPS third pin.(green/pink)
● Voltage meter positive access to TPS first pin.(white/brown)
● Measure the output voltages of both full-throttle and
close-throttle.
Caution
● The probe tool should contact the inner terminals to measure
the correct value.
Throttle output signal
measurement - close
Detection judge:
● Working voltage value:5.0±0.1V
● Close-throttle voltage value:0.6±0.02V

● Full-throttle voltage value:3.77±0.1V

measurement - full
3-17
Diagnostic tool can be used to check throttle output signals.

1. Connect the Diagnostic tool, key-on but do not start the engine.
2. Switch screen to “data analysis.”
3. Rotate the throttle and check the voltage.
Throttle output signal Treatment of abnormal phenomena:

measurement -close ● TPS damaged or coupler poor contact.
● If TPS possibly failed, it is suggested to replace with a new one
and check again.
Warning
● It is prohibited to remove TPS from throttle body to conduct
any test.

measurement -full
3-18
TW sensor:
● Powered by 5V DC from ECU. It has the two-pin socket on the
sensor. One terminal is for voltage output, and the other terminal
is for ground.
● The major component of TA sensor is a variable resistor of
negative temperature coefficient
● Installed on the cylinder head, the resistor in TW sensor varies
with temperature variation and sends voltage signals for ECU to
calculate the intake air temperature; then, ECU adjusts injection
time and ignition angle.
Testing Procedures:
Resistance value measurement:
● Remove the TW sensor from the vehicle.
● Use the "Ohmmeter" Ohm stalls to inspect sensor resistance.
Detection judge:
Temperature (℃) Resistance value (KΩ)
-20 18.8 ± 2.4
40 1.136 ± 0.1
Resistance value measurement 100 0.1553 ± 0.007

● Damaged TW sensor or poor connector contact.
● If TA sensor possibly failed, it is suggested to replace with a new
one.
3-19
O2 Sensor
● Powered by 8-16V DC from ECU. It has the four-pin socket on the
sensor. One terminal is for heating power output, one for heating
control, one for signal grounding, and one for signal.
● O2 sensor sends signal to ECU, and ECU control air / fuel ratio
around 14.5 – 14.7 to form a close loop.
● When the air-fuel mixture is near the stoichometic ratio, CO / HC /
NOx are converted most efficiently.
G/P P/B
Testing Procedures:
1. Working voltage check
● Remove O2 sensor coupler from the wire harness.
● Key-on but do not start the engine.
P/W R/Y ● Use "voltage meter" DC stalls (DCV) to check the power supply of
wire harness to the heating circuit of the O2 sensor.
● Working voltage check
Voltage meter negative access to the second pin of wire harness coupler.
(pink/white)
Voltage meter positive access to the first pin of wire harness. (red/yellow)
2. Resistance value check

● Remove O2 sensor coupler from the wire harness.
● Use the "Ohmmeter" Ohm stalls to inspect the heater sensor
resistance.
● Resistance value check
Working voltage check Ohmmeter negative access to the second pin of O2 sensor. (white)
Ohmmeter positive access to the first pin of O2 sensor. (white)
B GR
W W
Resistance value check
3-20
3. Use of diagnosis tool to check O 2 sensor work situations
● Connect the Diagnostic tool, key-on and start the engine.
● Completely warm up the engine. (idle running for more than "5
minutes")
● Switch screen to "DATA STREAM 01/01", select "O 2 Sensor"
project, turn the throttle to achieve 4500 rpm. Observe O 2
Sensor acting.
voltage changing condition. ● Observe O 2 Sensor voltage changing condition.
Detection judge:
● Working voltage: above 10V
● Resistance value: 6.7~10.5Ω
● That Observe O 2 Sensor voltage between 100 ~ 900 mV means

pollution close loop control system is normal. However, it is
abnormal, if the value is a fixed one.

● Damaged O 2 Sensor, damaged heater, or coupler poor contact.
● If O 2 Sensor possibly failed, it is suggested to replace with a new
one and check again.
3-21
Rollover sensor
Normal Function description
● Rollover sensor controls power of the power relay coil and has
three-pin socket.
● When the vehicle tilt angle is greater than 65 degrees, rollover
sensor will be the implementation of ECU system power-off. At
this time, to restart the engine, the main switch has to be turn on
again.
● It is a safety device, when the vehicle rolls over, it will cut off
power supply to ECU.
Rollover
Testing procedures:
● Rollover sensor is an electronic control mechanism. It is unable to
test while the sensor removed from the vehicle.
● In normal situation, key on, measure the voltage of white/brown
and green/pink (ground) wire of ECU, then the condition of the
rollover sensor can be judged.
Detection judge:
Voltage: Normal: 0.4~1.4V
Rollover: 3.7~4.4V

Vehicle state vertical, no power supply to power relay or ECU.
● Rollover sensor internal short circuit or open circuit, or coupler
poor contact.
● If Rollover Sensor possibly failed, it is suggested to replace with a
new one.
3-22
ISC(stepping motor)：
● Powered by 8-16V DC from ECU. ISC has a four-pin socket.
● The 4-pin socket is composed of power supply and grounding
circuits of two motors, ECU controls the acting of stepping motor
by controlling the power supply and grounding circuit.
● Low-power-consuming DC motor drives the ISC. And the
movement of ISC controls the opening of idle speed air channel,
thus the idle speed of cold or warmed engine can be adjusted.
Testing Procedures
Resistance value check:
● Remove ISC coupler from throttle body. (It is okay to test while
ISC installed on throttle body.)
● Use the "Ohmmeter" Ohm stalls to inspect the resistance of the
two motor circuits.
A phase: ISCAP and ISCAN
ISCBP ISCBN B phase: ISCBP and ISCBN
Movement test (This test can only be conducted while ISC installed
on throttle body.)
● Key-off.
ISCAP ISCAN ● Touch ISC with hand.

● Key-on.
ISC pins ● Feel if the ISC moves.
Caution
● The movement test can only be conducted while ISC installed
on throttle body.
Detection judge:
1. Resistance value:
A phase: 80 ± 10Ω (Environmental conditions: 15 ~ 25 ℃)
B phase: 80 ± 10Ω (Environmental conditions: 15 ~ 25 ℃)
Resistance value measurement of 2. Movement test
A phase Test in accordance with the test procedure illustrated above, ISC
will vibrate slightly or sounds continuous “da…da…”

● Damaged ISC, or coupler poor contact.
● If ISC is abnormal, it is suggested to replace with a new one and
recheck its movement.
Resistance value measurement of

B phase
3-23
Fuel pump
● Powered by 8-16V DC from ECU. Fuel pump has a four-pin
socket.
● The two pins are power supply and grounding. ECU controls the
movement of fuel pump by controlling the power.
● Low-power-consuming DC motor (12V) drives the vane pump to
keeps the pressure around 294±6kpa(3kg/cm2)in the fuel supply
system.
● Fuel pump is placed inside the fuel tank. A fuel filter is installed
on the inlet front to prevent foreign material entering and
damaging the fuel pump and injector.
Testing Procedures 1
Fuel pump working voltage check:
● Connect fuel pump coupler (use probe tools), or remove it to
measure working voltage. (direct test)
● Key-on but do not start the engine.
● Use "voltage meter" DC stalls (DCV) to check fuel pump voltage.
● Working voltage check
Fuel pump working voltage Voltage meter negative access to the second pin of fuel pump. (green)
measurement Voltage meter positive access to the first pin of fuel pump.
(black/orange)
Caution
● While measuring fuel pump working voltage, if the engine is
not started, ECU will cut off power supply to fuel pump within
3 seconds.
Detection judge 1
1. Working voltage: above 10V
2. Resistance:1.5±0.5Ω
2
3. Fuel pressure:294±6kPa (3kg/cm )
Fuel pump resistance

measurement
Fuel unit resistance check
● Remove fuel unit coupler.
● Use the "Ohmmeter" Ohm stalls to inspect the resistance of the
fuel unit. (yellow/white & green)
3-24
Fuel pressure measurement
● Connect fuel gauge between fuel tank and injector.
Caution
● To measure fuel pressure, fuel hoses, injector side or fuel
pump side, will be removed. After the measurement, please
check if any fuel leaks.
Fuel system pressure
measurement
Detection judge 2
2
1. fuel pressure: 294±6kPa (3kg/cm )

1. Fuel pump internal circuit damaged, or coupler poor contact.
2. Clogged filter.
Pressure 3. If fuel pump is abnormal, it is suggested to replace with a new
measurement-injector side one.
4. If fuel gauge is abnormal, it is suggested to replace with a new
one.
Pressure measurement -fuel

pump side
3-25
Fuel injector
● Powered by 8-16V DC from ECU. Fuel pump has a two-pin
socket.
● Its major component is a high resistance voltage driven solenoid
valve.
● The two pins are power supply and grounding. Fuel injector is
controlled by ECU to decide the injection timing, and the injector
pulse width.
Testing Procedures:
1. Resistance test
Use the "Ohmmeter" Ohm stalls to inspect the injector resistance.
2. Injector injection state check

Remove injector fix bolts, but do not disconnect the coupler.
Hold injector and injector cap with hand, no leak should happen.
Key-on and start the engine; inspect the injecting state.
Injector resistance Detection judge:

measurement 1. Resistance between the two pins: 10.5±0.53Ω
2. Injection state
● Good fuel atomizing, with a clear scattering angle → judged as
normal.
● Injection-state resembles water drop, no obvious scattering
angle → judged as abnormal.

1. Resistance NG→ abnormal injector, it is recommended to replace
good injection
with a new one.
2. Abnormal injection state, reasons:
● Clogged injector→ abnormal injector, it is recommended to
replace with a new one.

● Insufficient fuel pressure→ check fuel pressure, it is
recommended to replace with a new one and recheck.
Warning
abnormal injection ● Fuel is highly flammable and explosive. Work in a
well-ventilated place, no flame or spark allowed.
● Properly store the fuel injected by injector while conducting
test.
3-26
Transistor ignition coil
● Powered by 8-16V DC from ECU. Fuel pump has a two-pin socket.
● The two pins are power supply and grounding. Its major component is a
high conversion ratio transformer.
● The computer programmed ignition system receives the signals from
the Crankshaft position sensor, Throttle position sensor, O2 Sensor,
MAP sensor, Intake air temperature sensor, Engine coolant temperature
sensor. Calculating the engine RPM, the 16-bit microcomputer
determines the appropriate ignition timing, controls the ignition coil and
triggers the spark plug This way can not only make the engine achieve
the maximum power output, but also help improve fuel consumption
rate.
Testing Procedures
Resistance measurement:
● Remove primary circuit coupler from ignition coil.(red/yellow &
black/yellow)
● Use the "Ohmmeter" Ohm stalls to inspect the ignition coil resistance.
Detection judge:
Primary circuit resistance
● Ignition coil primary circuit: 2.8Ω±15%
measurement
● Ignition coil secondary circuit: without cap9.0KΩ±20% with cap14.0KΩ±
20%
1. Ignition coil internal short circuit or open circuit, or coupler poor contact.
2. If ignition coil is abnormal or dose not ignite, it is recommended to
replace with a new one.
Crankshaft position / RPM sensor

Function Description
Long tooth ● It does not need power supply, and has a two-pin plug.
● Its major component is a reluctance induction coil.
● The spacing of flywheel and sensor should be 0.7 to 1.1 mm.
● Magnetic induction sensor is the use of flywheel on the Gear (23
+1 long tooth) rotary cutting induction coil changes in the
magnetic field sensor with the inductive voltage signal for ECU
judgment, calculated at the engine speed and crankshaft position,
and with a most appropriate time of fuel injection and ignition
control.
Testing Procedures
● Remove CPS coupler. (blue/yellow & green/white)
● Use the "Ohmmeter" Ohm stalls to inspect the CPS resistance.
Detection judge
● Resistance: 120Ω±20%
Treatment of abnormal phenomena
1. CPS internal circuit damaged, or coupler poor contact.
Resistance measurement 2. Check if the wire harness abnormal.
3. If CPS is abnormal, it is suggested to replace with a new one.
3-27
AISV
● AISV has two-pin socket, one is for power supply and the other is
for grounding.
● AISV acts while RPM under 3500.
● While idling, ECU controls AISV movements by controlling its
solenoid valve grounding circuit.
Testing Procedures
● Use the "Ohmmeter" Ohm stalls to inspect the AISV resistance.
Detection judge
Resistance: 22 ± 2Ω (20~30℃)
Treatment of abnormal phenomena

● AISV internal short circuit or open circuit, or coupler poor contact.
AISV working voltage ● If CPS is abnormal, it is suggested to replace with a new one.
measurement
Resistance measurement
3-28
EFi system circuit
R
switch
Battery
Main
B
G
G
EFi system
Y/G check light
Reg / Rec
Y G
ACG
Y R
B P
Y
Test
switch
G/W
W/G
CPS
Diagnostic
L/Y tool
coupler
R
B/Y
Rollover
sensor
L/O Silicon
controlled
Engine-off rectifier
Y/B relay
R/Y
W/BR
TPS
Engine-off
relay
G/P LG/R
Side stand
relay
sensor
B/R L/O
MAP
switch
Side stand
B/G
PU/R
G/BR G
sensor
G
TA
Side stand indicator
Neutral gear indicator

R/GR
sensor
TW
Silicon
controlled
G/R
rectifier
GR
O2 sensor
B P/B
Clutch
W switch
W P/W
B/L
L/B
Fan
W/B
ISC
Fan relay
BR/B
G/B PU
B/O
pump
AISV
Fuel
O/L
Fuel pump
relay
O/G
Injector
coil
IG.
B/Y
L/G
Water temp. injector

G/L
3-29
ECU pin configuration
(on ECU)
ECU Pin Note

Pin Wire Pin Pin Wire Pin
Note Note
NO. color code NO. color code
01 R/Y IGP Drive components Power + 19 R BAT ECU power +
02 B/W ROLL Rollover sensor signal input 20 P TEST Test switch signal (A/D)
03 L/Y CRK-P Crankshaft pos. Sensor+ 21 Y/G MIL Warning Lights O/P
04 LG/R NLSW Neutral gear switch signal 22 R/GR TW Eng. Water Temp. Sensor (A/D)
05 W/BR TH Throttle position [A/D] 23 - - No use
06 B/R PM Manifold Press. SNSR I/P [A/D] 24 G/P SG Sensor ground

HEGO O Sensor [A/D] Intake air temperature sensor
07 P/B
A/D
2 25 G/BR TA (A/D)
08 G LG ECU ground 26 No use
09 G/W CRK-M Crankshaft pos. Sensor- 27 PU FANR Cooling fan drive

10 W/G K-LINE Sequence transmission signal output 28 G/L TWL Water temp. drive
/ input
11 O/G FLPR Fuel pump relay O/P 29 - - No use
12 O/L SOL AISV O/P 30 - - No use
13 Y/B VCC Sensor power + (DC 5V) 31 BR/B ISCAN Step motor A phase power -
14 G/B ISCBP Step motor A phase power + 32 B/W ISCBN Step motor B phase power -
15 L/B ISCAP Step motor B phase power + 33 No use
16 L/G INJ Fuel injector O/P 34 G/R CLSW Clutch switch signal
HEGO
17 P/W
HT
O 2 Sensor heater ground 35 G PG1 Drive components ground
18 B/Y IG Ignition coil O/P 36 G PG Drive components ground
3-30
Troubleshooting
EFi Circuit inspection Main switch on
1. Bulbs blown?
2. Fuse blown?
3. Battery voltage too low?
NG 4. ECU Power line bad contact?
Warning lights extinguish after 2 seconds?
5. Poor contact the main power
switch?
OK 6. ECU fault？
NG 1. Charging line anomaly?

Battery voltage above 12.5V? 2. Battery unable to store
electricity?
OK 3. Short-circuit leakage?
Battery voltage & ECU voltage difference less
than 0.2 V?
1. Main switch OFF
2. Remove ECU coupler NG
3. Main switch ON 1. Lines anomaly?
4. Use voltage meter to measure the
power-pin voltage difference
5. Confirmed ECU and battery supply OK
voltage difference within 0.2 V
Battery voltage & actuator voltage difference

less than 0.2 V?
1. Main switch OFF NG
2. Remove injector, fuel pump, O2 sensor, 1. Lines anomaly?
rollover sensor, ig. coil couplers
3. Use voltage meter to measure the voltage OK
difference
4. Confirmed difference within 0.2 V
ECU 5V voltage - sensor voltage difference less than 0.1 V?

1. Main switch OFF
2. Use probe to insert TPS, engine temperature sensor, NG
1. Lines anomaly?
MAP sensor couplers
3. Main switch ON 2. ECU anomaly?
4. Use voltage meter to measure the sensor voltage OK
5. Voltage standard value: 5.0±0.1V
Battery voltage - fuel pump voltage difference

less than 0.2 V?
1. Main switch OFF NG 1. Lines anomaly?
2. Removed fuel pump power coupler 2. Relay fault?
3. Probe connects to two-pin connector of fuel 3. ECU anomaly?
pump
4. Main switch ON OK
5. Record voltage values in three seconds
6. Confirm voltage difference within 0.2 V
End
3-31
Difficult or unable to start engine
Difficult or unable to start engine
Warning lights extinguish NG 1. Inspection process in accordance with

after 2 seconds? circuit inspection
OK
1. Use diagnostic tool to view EMS fault

Warning lights displays Fault NG content
Code? 2. Troubleshoot in accordance with
procedures on troubleshooting
OK
1. Fuel tank inadequate?

2. Fuel injector pressure less than 294 ±
6kpr?
Fuel system anomaly? NG 3. Fuel system leaks?
4. Pressure Regulator anomaly?
5. Fuel pump hose leakage?
OK 6. Fuel pump anomaly?
7. Fuel injector anomaly?
1. Spark plug sparks?

2. Wet spark plug?
3. Spark plug cap loose?
4. Crankshaft position sensor Short
Circuit anomaly? NG Circuit
5. The high-voltage power wire loose?
6. ECU anomaly?
OK 7. O2 sensor connector corrosion, short
circuit?
1. Without valve clearance?

2. Incorrect valve timing?
Engine anomaly? NG 3. Valve seized?
4. Cylinder and piston ring worn?
OK 5. Improper adjustment of air adjusting
screw on throttle body?
END
3-32
Idle flameout diagnosis
Idle flameout Throttle line is jammed

and unable to revert to
full closure?
1. Link diagnostic tool to

view EFI fault content
2. Troubleshoot in
accordance with
Troubleshooting
procedures
Idle CO value beyond set

range (1.5% ~ 2.5%)?
Enough Gasoline?
Throttle body whether

Battery wires loose? coke seriously?
Idle Air Control Valve

Actuation whether or
failure?
If idle flameout cannot be

solved after checking the EFi
related mechanisms, it is
recommended to check
traditional engine
mechanisms.
3-33
CO value revised anomaly
In principle, system equipped with O2 Sensor, the CO value needs no adjustment. If CO value deviates from normal
range, please check if O2 Sensor or other mechanisms is abnormal.
Throttle line is jammed and

Idle flameout unable to revert to full
closure?
Link diagnostic tool to Connect with the

view if Idle CO value is diagnostic tool, enter
abnormal data steam screen.
Start engine and warm to 70

º C ~ 95 º C, check if engine
speed, idle control valve and
fuel injection timing, O2
sensor is abnormal?
Enough gasoline?
Battery wires loose?

Enough battery voltage?
Idle CO value beyond the
set range (1.5% ~ 2.5%)?
Idle running for 3 ~ 5

minutes, confirm the engine
is running normally then shut
off engine, eliminate fault
codes
If idle flameout cannot be

solved after checking the EFi
related mechanisms, it is
recommended to check
traditional engine
mechanisms.
3-34
Intergrated troubleshooting procedure
Checking, Detection items and Fault status Fault reasons Parts specifications
adjusting item procedures determination
Battery ● Use meter to ● Is battery ● Battery electricity ● Diagnostic tool

voltage measure battery voltage above ● Battery connector should show
voltage 10 V? NO loose voltage above
● Use diagnostic ● Is diagnostic tool ● Harness circuit 10 V.
tool to detect showing voltage opening
battery voltage above 10 V? ● ECU coupler
disconnect
YES t d l
Fault code ● Use diagnostic ● Is fault code ● TPS fault Please refer to
inspection tool to detect shown on ● ETS fault service manual for
with existing fault diagnostic tool? ● CPS fault detection method
diagnostic code ● Fault Code is YES ● MAP fault and specification of
tool ● Eliminating fault show again after ● O2 sensor fault each sensor.
codes, and fault code ● ROS fault
restart engine elimination? ● ECU fault
● Removed injector
from intake
NO
manifold, but do
Fuel not remove the ● Does injector ● Insufficient fuel in ● Fuel pressure
quantity and hose. (Injector and inject? fuel tank specifications:
fuel injector cap tightly ● Is injecting angle ● Injector fault Key-on three
by hands, fuel
pressure normal? ● Fuel pump relay seconds but no
spills should not
be the case)
● Fuel pressure fault start engine
Start the engine enough? ● Fuel pump fault →more than
● NO ● ECU fault 250 kPa
● Examine whether
injector injects ● Fuel pump filter Idle speed→
● Connect pressure clogged
gauge between
294±6kPa
the tank and ● Injector
injector resistance:
● Check fuel 11.7±0.6Ω
pressure
YES
Ignition ● Remove the ● Check if spark ● Spark plug fault ● Spark plug
situation spark plug from plug ignites? ● Rollover sensor fault specifications:
the cylinder ● Check if sparks NO ● ECU fault NGK-CR8E
head with of spark plug ● Ignition coil fault
ignition coil strength is ● Crankshaft position
connected normal? sensor fault
● Start the engine
● Check spark
plug sparks
YES
next page
3-35
Continued from previous page
YES
● Observe O2
sensor voltage ● Whether O2
Close-loop changes (Stand sensor voltage is ● O2 sensor fault
maintained ● O2 sensor
systems motorcycle and ● ECU fault voltage
mobility keep RPM abound within a certain NO
range in a long specifications:
4500 to 5500 100 ~ 900 mV
time
YES
Engine ● Use diagnostic Is the value shown ● Valve clearance ● Manifold

tool to detect the on diagnostic tool NG pressure
vacuum abnormal
manifold within set value? ● Intake system leak Specification:
pressure 32~38 kPa
YES
Normal starting Can not starting or starting

difficulties
Finish In traditional engine overhaul

way to maintenance
3-36
Fuel tank
Removal
Remove the rear seat.
Remove the front seat (bolt x2).
Release the fuel pipe band, fuel pump coupler, EEC Bolt ×2
tube.
Caution
● Make sure the fuel is not too much in the fuel
tank. Pump out the fuel if necessary. Fuel
pipe
Remove the fuel tank rear bolt.

Fuel pump coupler
Bolt ×1
Remove the fuel tank.
Caution
● If the fuel tank is damaged or leaking, replace
with new one.
Installation
Install in the reverse order of removal.
3-37
Fuel pump
Removal
Remove right and left turning signals and seat.
Drain fuel from fuel tank.
Remove EEC system and fuel hoses.
Remove power wire of fuel pump and fuel unit.
Remove fuel tank.
Remove fuel pump. (boltX8) 。
bolt×8
Fuel pump removal

Remove fuel pump power wire.
Loosen the clamp. Power Screw×
Clamp
Remove fuel hose by using fuel hose removal pliers.
Tool number: SYM-1768110
Fuel hose removal pliers
Remove the fuel pump.

Caution
● Check if the gasket worn or damaged.
Replace with new one if it is abnormal.
Check if the rubber hose fastened well.

Check if fuel filter contaminated or clogged. Replace
with new one if it is too dirty.
3-38
Fuel Unit Fuel unit
power wire
Remove fuel unit screw. (screw×4)
Remove fuel unit.
Installation
Caution
● Do not bend the fuel unit float arm. screw×4
● Do not fill out too much fuel in the tank.
● Apply glue to the screw before
installation.
● Replace the washer with new one.
Air cleaner
Remove the rear and front seat.
Remove the air cleaner cover (bolt x4).
Remove the air cleaner element.

bolt×4
Caution
● The air cleaner is paper-base; please
blow it clean with compressed air. Don’t
use water or other solvent
● Replace it with new one if the dirt cannot
be removed.
Installation
Element
3-39
EFi system diagnosis methods
When wrong signal occurs in motorcycle injection system, causing engine abnormal function or
unable starting, the check light at the meter will be lighting to inform drivers to carry out
maintenance.
While overhauling, diagnostic tool or meter flashing lighting identification can be applied to carry
out fault detection.
After troubleshooting maintenance, the check light will be off, but ECU will record the fault code.
Thus, fault code should be eliminated. There are two methods of fault elimination, one is using
diagnostic tool and the other is manual elimination.
Using diagnostic tool

Connect diagnostic tool and the test switch and check in accordance with diagnostic tool using
method. When EFi system or EFi parts malfunction is detected, replace or correct parts
according to information shown on the screen. After maintenance, fault code should be
eliminated, or the fault will exist in ECU.
Manual inspection
Use jumping wire (wire or paper clips, etc.) to ground test switch, check light on the meter will be
flashing, meaning that the injection system or parts is abnormal. When no diagnostic tool is
available, the long and short flashings can be used to tell the fault cause.
Test switch
coupler Diagnostic tool coupler
Diagnostic tool coupler and test switch coupler
3-40
Check light fault codes differentiation
Check light flashing mode
When there is no diagnostic tool for fault detection, wire jump the test switch and identify the
fault by check light flashing and then correct the fault.
1 1 0.5 1 0.5 Unit: second
1 1 3 1 6
Fault code 22 Fault code 12 Continuous repeated
Fault Code manual elimination procedure:

Fault code can be eliminated manually without using diagnostic tool, procedures as following:
1. Main switch OFF
2. Wire jump the test switch.
3. Full throttle and do not release.
4. Main switch ON
5. Continue step 3 and 4 for five seconds, five seconds later the check light will flash twice quickly. Then the fault
code will be eliminated.
6. Remove the jumping wire.
No wire-jump
Test switch
Wire-jump
No wire-jump
full
Throttle
close close
At least 5 seconds
ON
switch
Main
OFF OFF
Lighting
Lighting
Check light flashes twice

Not lit
Check
light
Not lit
3-41
Fault codes and sensors table
No. Fault Fault Description Parts Inspection

d
1 0120 Throttle position sensor fault TP Sensor and wire
2 0105 Manifold absolute pressure sensor fault MAP sensor and wire
3 0115 Engine temperature sensor fault (water) TW Sensor and wire
4 0110 Intake air temperature sensor fault TA Sensor and wire
5 1630 Roll over sensor fault Roll over sensor and wire
6 0130 O 2 sensor fault O 2 Sensor and wire
7 0201 ＩＮＪ #1 fault Injector and wire
8 0351 IG #1 fault Ignition coil and wire
9 0230 Fuel pump fault Fuel pump and wire
10 0135 O 2 sensor heater fault O 2 Sensor and wire
11 1505 ISC Idle speed control motor fault ISC stepping motor and wire
12 1410 Exhaust 2nd air control solenoid valve fault AISV and wire
13 0335 Crankshaft position sensor fault Crankshaft position sensor and
ire
14 1205 MAP wire fault MAP sensor and wire
15 0603 EEPROM fault EEPROM
16 0480 Fan relay fault Fan relay and wire
3-42
Fault code and check light flashing lighting identification table
Fault Check Check light flashing
No. Fault Description Parts Inspection
codes light state
Throttle position sensor fault Lighting long 0，short 6 Throttle position sensor and wire
1 0120 Fault detection procedures Please refer to the "EFI System components description" throttle position sensor
(TPS) chapter
Manifold Absolute Pressure sensor fault lighting long 0，short 9 MAP sensor and wire
2 0105 Fault detection procedures Please refer to the "EFI System components description" manifold Absolute
Pressure sensor (MAP) chapter
Engine temperature sensor fault (water) lighting long 1，short 2 Engine temperature sensor and wire
3 0115 Fault detection procedures Please refer to the "EFI System components description" engine temperature
sensor (WPS) chapter.
Intake temperature sensor fault lighting long 1，short 3 Intake temperature sensor and wire
4 0110 Fault detection procedures Please refer to the "EFI System components description" intake temperature
sensor (TAS) chapter.
Roll over sensor fault lighting long 1，short 5 Roll over sensor and wire
5 1630
Fault detection procedures Please refer to the "EFI System components description" Roll over sensor chapter.
O 2 sensor fault lighting long 1，short 7 O2 Sensor and wire

6 0130
Fault detection procedures Please refer to the "EFI System components description" O2 sensor chapter.
ＩＮＪ #1 fault lighting long 3，short 3 Injector and wire

7 0201
Fault detection procedures Please refer to the "EFI System components description" fuel injector chapter.
IG #1 fault lighting long 3，short 7 Ignition coil and wire

8 0351
Fault detection procedures to adhere to the traditional way
Fuel pump fault lighting long 4，short 1 Fuel pump and wire
9 0230
Fault detection procedures Please refer to the "EFI System components description" fuel pump chapter.
O2 sensor heater fault lighting long 4，short 5 O2 Sensor and wire

10 0135
Fault detection procedures Please refer to the "EFI System components description" O2 Sensor chapter.
ISC motor fault lighting long 4，short 9 Step motor and wire
11 1505 Fault detection procedures Please refer to the "EFI System components description" idle speed control valve
(ISC) chapter.
Exhaust 2nd air solenoid valve fault lighting long 5，short 4 2nd air control valve and wire
12 1410 Fault detection procedures Please refer to the "EFI System components description" 2nd air solenoid valve
chapter.
Crankshaft position sensor fault lighting long 6，short 6 Crankshaft position sensor and wire
13 0335 Fault detection procedures Please refer to the "EFI System components description" Crankshaft position
sensor chapter.
MAP sensor wire fault lighting long 6，short 8 MAP sensor wire
14 1205
Fault detection procedures Please refer to the "EFI System components description" MAP sensor chapter.
EEPROM fault Not lit long –，short – EEPROM

15 0603
This fault Please direct replacement ECU
Cooling fan relay fault lighting long 4，short 3 Cooling fan relay and wire
16 0480
Fault detection procedures Please refer to the "EFI System components description" cooling fan relay chapter.
3-43
Troubleshooting table
Test items Comprehensive testing program Parts
closed-
Fault Throttle Engine
Power Fuel Ignition Engine Injection loop
Abnormal Code ECU position temp.
voltage press. state vacuum state control Detection
phenomena sensor sensor
system
Can’t start       
Start
state
Difficult to
start      
Without
idle      
Idle not
smooth     ˇ
Idle
state
RPM NG  
CO NG     
Not smooth        
Acceler-
ation
Inability
and slow        
Idle
flameout  
Flameo-
ut
Acceleratio
n flameout  
Roll over Ignition

Related parts Fuel pump Inlet pipe Injector O2 sensor
sensor coil
Secondary
Fuel
air
Power pressure Cylinder
Spark plug Fuel pump injection
relay adjustment head
solenoid
valve
valve
Fuel Fuel
Main MAP pressure
switch pump adjustment
sensor
relay valve
Fuel
Battery
filter
Note: 1. Integrated test motorcycle, according to the "Comprehensive Maintenance list" implementation.
2. Spare parts, according to the "EFI System components description" implementation.
3-44
Comprehensive maintenance list
Maintenance
NO Project Testing Procedures Test items Determine benchmarks Fault reasons
1 Power and ● Use meter direct ● Battery voltage ● Battery voltage = 10V Above ● Battery electricity
voltage measurement battery voltage ● Battery connector loose
● Use diagnosis tool detection ● Harness circuit opening
of battery voltage  ECU coupler not
connected properly
2 Fuel ● Use fuel pressure gauge, ● Open the main ● Open main switch, but not ● Fuel not enough
pressure connected in series between switch, but not to start srart: ● Security switch not disarm
the injector and the Pressure the engine of pressure = 250kPa (Stable ● Ruel pump relay fault
Regulating Valve pressure value) ● Ruel pump fault
● Main switch ON, but not ● Pressure in idle ● Idle state: ● Injector fault
start engine ● Rotating throttle, pressure = 294±6kPa 1. ECU fault
● Check fuel pressure situation of pressure (Beating situation from top to
● Start engine (idle) changes bottom)
● Check change of the fuel ● rotation throttle moment:
pressure pressure = 294±6kPa (Slightly
● throttle several rotation beating)
● check to the change of fuel
pressure again
3 Ignition state ● The spark plug removed from ● Spark plug ● Specifications: NGK-CR8H ● Spark plug fault
the cylinder head, but the specifications ● Ignition conditions: ● Roll over sensor fault
power lines still ring ● Whether the spark With traditional engines found ● ECU No. 5 pin fault
● Start engines or use for the plug ignition ways ● Ignition coil fault
diagnosis tool of output View ● Spark plug sparks  Crankshaft position
spark plug ignition conditions whether it is normal sensor fault
strength
4 Engine ● Diagnosis tool to detect the ● Manifold pressure of ● Manifold pressure ● Valve clearance abnormal
vacuum use of diagnosis tool =32~38kPa  Intake system leak
5 Injection ● The injector removed from ● Open the main ● Not started, injector not ● Security unit is configured
state the throttle body, but not switch, but did not leaking fuel not disarm
dismantle pipeline start engine the ● In started, the injection state ● Fuel pump relay fault
● Main switch ON, but not injection situation must show fan shape ● Fuel pump fault
start engine ● Injector state when ● Injector fault
● Investigation the injector it’s start  ECU fault
leaking fuel?
● Once again start engines or
use for the diagnosis tool of
output function
● Check injector fuel injection
and the injection situation
6 Closed - ● Use of diagnostic tool ● Stable condition, ● Idle stable condition: O2 ● O2 Sensor fault
loop control observation O2 Sensor sensor voltage Sensor voltage = 50 ~ 200mV  ECU fault
system voltage changes variation (Idle (Show from top to bottom
continued 5 minutes beating phenomenon)
later to
measurement)
7 Fault Code ● Use of the diagnosis tool ● Diagnosis tool of the ● Without any residual Fault ● throttle position sensor fault
Detection existing fault-detection code fault code is it can be Code ● Engine temperature sensor
or historical Fault Code eliminated ● If residual Fault Code, fault
● Elimination of the ● Start again, the fault according to the "Fault Code ● Intake temperature sensor
implementation of fault is it will happen again Maintenance Form" fault
codes, check can be implementation of ● Manifold pressure sensor
eliminated troubleshooting fault
● Once again start engine ● O2 Sensor fault
● Check fault is it happen ● Crankshaft position sensor
again fault
● ECU fault
 Roll over sensor fault
Notes:
1. Fuel pressure gauge connected between the fuel tank and injector, open the main switch to
repeatedly shut down, fuel system makes pressure stability.
2. Injector and injector cap tightly by hands, fuel spills should not be the case.
3-45
4. Lubrication System / Clutch / Transmission
Mechanism Diagram ........................... 4-1 Clutch Disassembly............................. 4-5

Precautions in Operation.................... 4-2 Clutch Inspection................................. 4-6
Troubleshooting .................................. 4-3 Clutch Installation................................ 4-7
Engine Oil ............................................ 4-4 Oil Pump ............................................... 4-9
4
Engine Oil Strainer Cleaning .............. 4-4 Gear Shift Linkage Mechanism........... 4-11
Mechanism diagram
0.8~1.2kgf-m
0.8~1.2kgf-m
8.5~10.5kgf-m
0.8~1.2kgf-m
1.0~1.4kgf-m
0.8~1.2kgf-m
8.5~10.5kgf-m
0.8~1.2kgf-m
0.1~0.3kgf-m
4-1
Precautions in Operation
General information
 This chapter covers the engine oil pump and the oil exchange, also the disassembly and the
shifting linkage is covered. All these operations can be done while the engine is still on the
bike.
Specification
Engine Oil viscosity
Engine oil quantity：
Full disassembly：1700 c.c.
Regular maintenance：1500 c.c.
Recommended engine oil viscosity:
SAE 10W-30
(The Bramax series oil is recommended)
Measurement: mm
Item Standard Service Limit
Clearance between inner 0.15 0.20
rotor and outer rotor
Clearance between 0.15~0.20 0.25
Oil pump outer rotor and the
pump body
Rotor to pump cover 0.04~0.09 0.12
clearance
Lever free play 10~20 -
Spring free length 44.65~44.80 41.70
Clutch
Friction disk thickness 3.00 2.50
Clutch plate warp - 0.20
Torque value
Oil pump cover bolts: 0.8~1.2kgf-m R. Crank case bolts: 0.8~1.2kgf-m
Oil pump screw: 0.7~1.1kgf-m Clutch fix nut 8.5~10.5kgf-m
Primary drive gear nut 8.5~10.5kgf-m Clutch lifter plate bolt 1.0~1.4kgf-m
Special tools
4-2
Troubleshooting
Insufficient engine oil Clutch slips when accelerating
 Oil leaks  Insufficient clutch free play
 Valve guides or seals worn out  Worn clutch disks
 Worn piston rings  Weak clutch springs
Insufficient oil pressure Unable to disengage the clutch; or the

 Insufficient oil amount bike trembles while clutch disengaged
 Clogged oil strainer, oil route, oil tubes  Excessive clutch free play settings
 Abnormal oil pump  Warped clutch plates
Engine oil dirty Excessive clutch lever pulling force

 Engine oil is not exchanged periodically.  insufficiently lubricated clutch cable
 Cylinder head gasket damaged  Damaged clutch cable
 Worn piston rings  Clutch lifter mechanism damaged
Hard to shift gear

 Excessive clutch free play settings
 Twisted or bent shifting forks
Gearshift pedal won’t return

 Broken or weak return spring
 Bent shift spindle
Gear jumps out

 Broken stopper arm spring
 Bent shift spindle
4-3
Engine oil
Turn off the engine; park the motorcycle on level
surface with main stand. Check oil level Upper limit
3-5minutes later.
Check oil quantity from window, if oil level is near
lower limit, fill in the recommended oil to upper
limit.
Exchange engine oil Lower limit
Caution
 Drain oil when the engine is fully warmed
up, so the oil can be drained completely.
Place an oil basin under the bike, and remove
oil drain bolt.
Check if the washer damaged, replace when
necessary.
Fill in new engine oil after installing oil drain
bolt.
Engine oil strainer cleaning

Remove engine oil strainer cap. Engine oil strainer cap Oil drain bolt
Remove engine oil strainer and spring.
Clean oil strainer with compressed air.
Check if O-ring can be re-used. If it’s
damaged, please replace with a new one
Install engine oil strainer and spring.
Install engine oil strainer cap.
Fill in engine oil (oil viscosity SAE 10W-30)
Recommended using Bramax series oil.
Install dipstick, run the engine for several
minutes. Then turn off engine, and check oil
level again.
Engine oil strainer
Check if engine oil leaks.
4-4
Clutch disassembly Clutch cable

Drain all engine oil.
Remove clutch cable.
Remove right crankcase cover(bolt×12)。 bolt×12
Remove clutch lifter(boltX6)。 bolt×6
Remove clutch spring.
Remove clutch lock nut.

Remove clutch center, friction disks, clutch
plates, and pressing plate.
Clutch lock nut
4-5
Remove washer, clutch outer, and center

guide.
Washer
Disassemble the clutch center, clutch plates, Clutch center Pressing plate
clutch friction disks, and pressing plate.
Friction disk Clutch plate
Clutch inspection
Clutch spring inspection
Measure the free length of the 6 clutch
springs.
Service limit：41.70mm
Clutch friction disk inspection

Measure the thickness of each clutch friction
disk. If it’s under service limit or damaged,
please replace it with a new one.
4-6
Clutch plate inspection

Use a feeler gauge to measure the warp of
each clutch plate.
Clutch outer inspection

Check if the clutch outer is cracked or
damaged.
washer
Clutch installation
Install clutch washer, center guide.
Center guide
Install clutch outer and washer.
Washer
4-7
Install clutch center, clutch plate, friction disk, Clutch lock nut
and pressing plate.
Tighten clutch lock nut.
Clutch lifter
Install clutch spring, clutch lifter; tighten 6
bolts.
Install right crankcase cover. (bolt×12)。
Install clutch cable.
Fill in specified engine oil.
10~20mm
Turn the adjustment nut to optimize the clutch
free play.
Free play：10-20mm
Adjusting nut Lock nut

After achieving the correct free play, tighten
the adjusting nut and the lock nut. Decrease free play
Increase free play
4-8
Lock nut
Oil pump
Remove clutch cable.
Remove right crankcase cover.
Remove clutch assembly.
Remove initial driven gear lock nut.
Remove initial driven gear.
Initial driven gear
Remove oil pump cover. (boltX2)。
bolt×2
Remove oil pump drive gear fix circlip.

Remove oil pump gear and chain.
Circlip
Remove oil pump. (holding screwX2) 。
Caution
 It is recommended to remove the oil
pump holding screw with impact screw
driver.
Holding screw
4-9
Oil pump disassembly

Remove oil pump cover. (screw×1)
Disassemble oil pump.
Oil pump inspection

Check the clearance between oil pump body
and outer rotor.
Service limit: under 0.25 mm
Check clearance between inner and outer

rotors.
Service limit: under 0.20mm
Check the unevenness between rotor face

and pump body.
Service limit: under 0.12 mm
4-10
Gear shift linkage mechanism

Gear shift linkage disassembly
Remove shifting lever. (bolt×1)
bolt×1
Remove cultch cable.

Remove right crankcase cover.
Remove cultch assembly.
Take out the gear shifting spindle.
Gear shifting spindle
Remove the shifting drum stopper arm and the Retainer

return spring. (bolt×1)
Remove shifting drum retainer. (boltx2)
Shifting drum stopper
4-11
Remove shifting cam. (bolt×1)
Remove alignment pin.
Shifting cam
Inspection
Check if shifting spindle and the fork assembly
damaged or worn.
Check if shifting drum stopper arm and the

return spring damaged or worn.
Check if gear shifting cam damaged or worn.
4-12
Gear shift linkage mechanism installation

Install alignment pin.
Install the gear shifting cam by matching the
alignment pin.
Tighten gear shifting cam lock bolt. (bolt×1)。
Gear shifting cam
Retainer
Install shifting drum stopper and the return

spring. (bolt X 1)
Install shifting drum retainer. (boltx2)
Caution
 Check if the stopper is working smoothly
after assembly.
Shifting drum stopper
Install the gear shifting spindle and the fork

assembly. Then install the shifting pedal (bolt
X1)
Caution
 The return spring on the shifting spindle
should contact the salient on the
crankcase.
Install cultch assembly.
Install alignment pin and another new right
crankcase gasket, then the right crankcase
cover.
Connect clutch cable, and adjust the clutch
free play.
Fill in specified engine oil.
4-13
NOTE:
4-14
5. AC Generator / Starting Clutch
Mechanism Diagram ···················5-1 ACG Stator Disassambly ············5-3

Precautions in Operation ···········5-2 ACG Flywheel/ Starter Clutch ····5-5
Mechanism diagram
2.8~3.2kgf-m
0.8~1.2kgf-m
8.5~10.5kgf-m
0.3~0.4kgf-m
0.7~1.1kgf-m
0.3~0.5kgf-m
0.15~0.25kgf-m
0.8~1.2kgf-m
5-1
General information
 For engine troubleshooting and inspection, please refer to the first chapter.
th
 Starting Motor repairing process and cautions please refer to Chapter 14 .
Specifications measurement：mm
Item Standard Service limit
Start Driven Gear exterior diameter 42.192~42.208 42.100
Starting Clutch interior diameter 25.026~25.045 25.050
Torque value
Flywheel nut 8.5~10.5kgf-m
Left crankcase cover bolt 0.8~1.2kgf-m
Starting clutch inner-hexagon bolt 2.8~3.2kgf-m with screw adhesive
Special tool
Flywheel puller SYM-3111000-HMA
5-2
ACG stator disassembly CPS coupler

ACG stator disassembly
Remove ACG coupler and CPS coupler.
ACG coupler
Remove left crankcase chain cover. (bolt×2)
bolt×2
Remove left crankcase cover. (bolt×11)。
bolt×11
Remove foreign objects and gasket on the

interface of crankcase and cover.
5-3
screw×3
Remove ACG stator holding screw.
(screwX3)
ACG stator inspection

Remove ACG coupler and check its resistance
and grounding condition with ohmmeter.
Y1
Replace ACG if any abnormal situation found.
Ω
V Ω
Y2 Ω
Y1 70~80 0.42Ω±20%
Ω
Y2 70~80 0.42Ω±20%
Y3
Y3 70~80 0.42Ω±20%
Ω
Without removing coupler, voltage generated
can be measured by voltage meter while the
engine is running.
Y1
V
Y2 V
V
Y3
5-4
ACG stator assembly screwX3 Rubber seal

Install ACG stator. (screw×3)。
Assemble the stator wire correctly onto the
L-crankcase cover with the rubber seal.
Install dowel pin and new L crankcase cover

gasket.
Dowel pin
Install left crankcase cover. (bolt×11)。 bolt×11
start reduction gear A

ACG flywheel / starter clutch
ACG flywheel / starter clutch disassembly
Remove start reduction gear A / B and shaft.
start reduction gear B
5-5
Remove flywheel, starting clutch, and start

driven gear with flywheel puller and shaft
protector.
Special tool:
ACG flywheel puller SYM-3111000
Shaft protector
Start reduction gear ACG flywheel puller
Starting clutch inspection

Assemble the start driven gear onto the
starting clutch.
Hold the starting clutch and turn the start
driven gear.
Start driven gear should only be able to turn
counterclockwise.
Check if the start driven gear damaged or

worn.
Measure the exterior diameter of the start
driven gear.
Service limit:
Interior diameter: over 25.050 mm
Exterior diameter：over 42.100 mm
Check if the roller of starting clutch damaged

or worn.
5-6
ACG flywheel / starting clutch assembly

Install ACG flywheel, starting clutch, and
starting gear.
Tighten ACG flywheel. (bolt×1)。
Torque value: 8.5~10.5kgf-m
Install start reduction gear A / B and shafts..
Install dowel pin and new gasket.

bolt×11
Install left crankcase cover. (bolt×11)。
Install left crankcase chain cover. (bolt×2)
bolt×2
5-7
NOTE:
5-8
6. Engine Removal
Precautions in Operation ···········6-1 Engine Installation ······················6-7

Engine Removal ··························6-2 6
General information
● During the maintenance of a removed engine, you need to use an adjustable rack or cart to
support the engine.
● The following parts can be repaired with the engine installed on the frame:
1. AC generator
2. Starting cultch
3. Clutch
4. Transmission mechanism
● You must remove the engine for repairing the following parts:
1. Piston
2. Cylinder
3. Cylinder head
4. crank shaft / balancing shaft
5. Transmission mechanism
Specification
Model Specification
Regular
1500 c.c.
exchange
Engine oil capacity
Fully
1800 c.c.
disassembly
Torque value
Engine suspension nut (the upper part of engine and frame) 2.4~3.0kgf-m
Engine assembly nut (the front part of engine and engine hanger) 3.0~4.0kgf-m
Engine assembly nut (the back part of the engine and frame) 4.5~5.5kgf-m
L crankcase chain cover bolt 0.8~1.2kgf-m
Driven sprocket bolt 0.8~1.2kgf-m
6-1
6. Engine Removal
Engine removal
Engine oil drain bolt
Drain all coolant.
Coolant drain bolt
Disconnect CPS and ACG couplers. CPS coupler
ACG coupler
Disconnect starter motor coupler.
Starter motor coupler
6-2
6. Engine Removal
Loosen clutch cable lock nut and adjusting nut,

remove clutch cable.
Clutch cable
Loosen throttle wire lock nut, remove throttle Map sensor ISC
cable.
Disconnect MAP sensor and ISC couplers.
Throttle wire lock nut
Loosen coolant hose band, remove coolant

hose.
Coolant tube
Remove PCV tube.

Disconnect TW sensor coupler.
TW sensor PCV tube
6-3
6. Engine Removal
Disconnect ignition coil coupler and AISV AISV tube

tube.
Ignition coil
Disconnect fuel hose. Fuel hose

TPS
Disconnect injector and TPS couplers.
Remove injector. (lock nutX2)
Injector Lock nut
Loosen rear wheel axle lock nut. Rear wheel lock nut
Loosen drive chain adjusting nut and push the
rear wheel forward.
Adjusting nut
Remove left crankcase chain cover.

Remove the drive sprocket bolts (bolt×2),
sprocket fixing plate, drive sprocket, and
chain.
Fixing plate
bolt×2
6-4
6. Engine Removal
Disconnect O2 sensor coupler.
O2 sensor coupler
Remove exhaust pipe front lock nut. (nut×2)。
nut×2
Remove the exhaust pipe center bolt.
bolt×1
bolt×1
Remove the exhaust pipe rear bolt.
Remove the exhaust pipe.
6-5
6. Engine Removal
Settle the engine on a rack.

Remove engine front hanger. (nut×4, bolt×4)
nut×4
Remove engine rear holding bolts. (nut×2,

bolt×2)。
Remove the engine.
nut×2
6-6
6. Engine Removal
Engine installation
Install the engine in the reverse order of
removal.
Caution
 When assembling, always pay attention
to possible injuries.
 Wires, cables, tubes, and hoses cannot
be bent or pressed.
 Please align the wires and cables in
accordance with the setting diagram.
Torque value:
Engine suspension nut (the upper part of
engine and frame) 2.4~3.0kgf-m
Engine assembly nut (the front part of engine
and engine hanger) 3.0~4.0kgf-m
Engine assembly nut (the back part of the
engine and frame) 4.5~5.5kgf-m
L crankcase chain cover bolt 0.8~1.2kgf-m
Driven sprocket bolt 0.8~1.2kgf-m
After installation, fill in specified engine oil and

coolant, adjust clutch lever free play, drive
chain free slack, and idle speed.
6-7
6. Engine Removal
NOTE:
6-8
7. Cylinder Head / Valve
Mechanism Diagram ···················7-1 Valve Guide Replacement ··········7-10

Precautions in Operation ···········7-2 Valve Seat Inspection & Refacing
Troubleshooting··························7-3 ······················································7-11
Cylinder Head Removal ··············7-4 Cylinder Head Assembly ············7-13
Cylinder Head Disassembly ·······7-6 Cylinder Head Installation ··········7-14
Cylinder Head Inspection ···········7-8 Valve Clearance Adjustment ······7-16 7
Mechanism diagram
0.8~1.2kgf-m
0.8~1.2kgf-m
0.8~1.2kgf-m
1.0~1.4kgf-m
1.0~1.4kgf-m
3.6~4.0kgf-m
1.0~1.4kgf-m
0.8~1.2kgf-m
0.7~1.1kgf-m
0.8~1.2kgf-m
7-1
General information
This chapter includes the repair information of cylinder head, valve, camshaft, and rocker arm.
The engine must be removed before the repairing of cylinder head.
Specification measurement: mm
Item Standard Service Limit
Valve Clearance (when In 0.10 ± 0.02 ─

engine is cold) Ex 0.15± 0.02
Compression Pressure 12 ± 2 kg/cm² ─
In 34.880 34.860
Camshaft Cam Lift
Ex 34.740 34.725
Rocker Inner Diameter 11.982~12.000 12.080

Arm Outer Diameter 11.966~11.984 11.936
Valve stem outer In 4.975~4.990 4.900

diameter Ex 4.950~4.975 4.900
Valve guide 5.000~5.012 5.030
Clearance between In 0.010~0.037 0.080

Valve Valve stem and guide
Ex 0.025~0.062 0.100
Valve spring free Inner spring 38.700 35.200

length Outer spring 40.400 36.900
Valve seat width 1.600 ─
Warpage/clearance between cylinder head and
─ 0.050
cylinder
Torque value
Cylinder head bolt 0.8~1.2kgf-m Rocker arm shaft setting plate bolt
Cylinder head right bolt 1.0~1.4kgf-m 0.8~1.2kgf-m
Cylinder head side cover bolt 1.0~1.4kgf-m Valve adjusting holding nut
Cylinder head nut 3.6~4.0kgf-m 0.7~1.1kgf-m (Apply engine oil
Cam chain sprocket bolt 1.0~1.4kgf-m on threads and seats)
Spark plug 1.0~1.2kgf-m
Special tools
Valve Guide reamer 5.0mm Valve Spring Assemble/Disassemble Tool
Valve Guide driver 5.0mm SYM-1471110/20
Rocker arm shaft/ Camshaft Disassemble tool Valve Clearance Adjustment Wrench
SYM-1445100 SYM-9001200
Valve Spring Compressor SYM-1471100
7-2
Troubleshooting
Engine performance will be affected by troubles on cylinder-head perimeter parts. The trouble
usually can be determined by performing cylinder compression test or judging the abnormal
noise.
Poor idling
The compression pressure is too low.
Low compression pressure
1. Valve
 Improper valve clearance adjustment
 Burnt or bent valve
 Improper valve timing
 Valve spring damaged
 Valve carbon deposit

 Valve seat warpage
 Improper spark plug installation
2. Cylinder head
 Cylinder head gasket leaking or damaged
 Tilted or cracked cylinder
3. Piston
 Piston rings worn
High compression pressure

Too much carbon deposit on combustion chamber or piston head
Abnormal noise
 Improper valve clearance adjustment
 Burnt valve or damaged valve spring
 Camshaft worn out or damaged
 Chain worn out or loosened
 Auto-tensioner worn out or damaged
 Camshaft sprocket worn not or damaged
 Rocker arm or rocker arm shaft worn out
Smoke from exhaust pipe

 Valve guide or stem worn
 Valve guide oil seal worn
7-3
Cylinder head removal

Remove engine. (Refer to chapter 6)
Remove auto-tensioner adjusting bolt.

Remove auto-tensioner. (bolt×2)。
boltX2
Remove thermostat. (bolt×2)。
boltX2
Remove AI pipe. (bolt×4)。

Remove spark plug.
bolt×4
Remove cylinder head cover. (bolt×4)。
bolt×4
7-4
Remove cylinder head side cover. (bolt×3)。 bolt×3
Remove timing-inspecting hole cap.

Remove ACG cap, turn ACG flywheel
counterclockwise, align “T” mark with the mark Timing marks
on L crankcase; align the timing marks on cam
gear and cylinder head.
bolt×2
Remove cam gear lock nut. (bolt×2)。
Remove cam gear.
Remove bolts on right side of cylinder head

first (bolt×2)，then the cylinder head nuts.
(nut×4)
Remove cylinder head.
Remove cylinder head gasket and dowel pins.

Remove cam chain guide. nut×4
Clean up the matching surfaces between
cylinder and cylinder head.
Cylinder head gasket
Caution
 Do not damage the matching surfaces of
cylinder and cylinder head
 Avoid residues of gasket or foreign Cam chain guide
materials falling into crankcase when
cleaning.
7-5
Cylinder head disassembly bolt×1 Holding plate
Remove rocker arm shaft holding plate.

(bolt×1)
Use Rocker arm / camshaft puller to pull out

the rocker arm shafts. Rocker arm shaft
Special tool:
Rocker arm / camshaft puller SYM-1445100
Use Rocker arm / camshaft puller to pull out

the camshaft. camshaft
Special tool:
Rocker arm / camshaft puller SYM-1445100
Use Valve removal / assembly tool to

compress the spring, remove the valve cotter.
Special tool:
Valve removal / assembly tool Rocker arm /
SYM-1471110-SY125 camshaft puller
Caution
 Do not over compress the valve spring.
Valve removal / assembly tool
 When removing springs, place cloth in
combustion chamber to hold the valves
avoiding bending the valve.
7-6
Remove cotters, springs, and the spring Intake valve Inner valve Spring retainer
retainers.
Outer spring
Exhaust valve Cotter
Remove valve guide oil seals.
Oil seal
Clean up carbon deposit in combustion

chamber.
Clean up cylinder head matching surface.
Caution
● Do not damage cylinder head matching
surface.
7-7
Cylinder head inspection

Cylinder head surface / hole
Check if spark plug hole and valve hole
cracked or damaged.
Measure the cylinder head surface for
warpage.
Service limit: 0.05mm
Camshaft
Measure the camshaft.
Service limit:
Intake: 34.860mm
Exhaust: 34.725mm
Check if the camshaft bearing loosened or
worn, replace the camshaft assembly if
necessary.
Rocker arm
Measure rocker arm inner diameter.
Service limit: 12.080 mm
Check if the oil hole clogged and the surface
worn.
Rocker arm shaft

Measure the active outer diameter of the cam
rocker arm shaft and cam rocker arm.
Calculate the clearance between rocker arm

shaft and rocker arm.
7-8
Valve spring
Measure the free length of intake and exhaust
valve springs.
Service limit:
Inner valve spring: 35.20mm
Outer valve spring: 36.90mm
Valve stem
Check if valve stem bent, burnt, or worn.
Check the operation condition of valve stem in
valve guide, and measure the valve stem
outer diameter.
Valve guide
Caution
 Clear all the carbon deposit with reamer
before measuring the valve guides.
Special tool: valve guide reamer 5.0mm
Measure and record each valve guide inner
diameter.
The clearance value is valve guide inner
diameter deducts valve stem outer diameter.
Service limit:
Intake valve 0.080 mm
Exhaust valve 0.100 mm Valve guide reamer 5.0mm
Caution
● If clearance is over service limit, check if
only replacing a new valve guide will fix the
clearance into service limit or not. If yes,
replace valve guide only.
Fix the guides with reamer after replacement.
If clearance still exceeds service limit after
replacing valve guides, please also replace
valve stem.
Caution
● Fix the valve seat when replacing valve
guides.
7-9
Valve guide replacement

Heat cylinder head with heating plate or Valve guide driver 5mm
toaster till the temperature reaches 100~150
℃.
Caution
●Do not use flame to heat cylinder head
directly. Otherwise, cylinder head will be
deformed.
● Wear heat insulation gloves to protect your
hands when operating.
Hold the cylinder head, and then press out old
valve guide from combustion chamber side.
Tool: valve guide driver 5mm
Caution Valve guide
driver 5mm
● Check if new valve guide deformed after
installation.
● When installing new valve guide, keep
cylinder head on 100~150℃.
Adjust the valve guide driver and let valve

guide height be 13 mm.
Install new valve guide from rocker arm side.
Tool: valve guide driver 5mm
Valve guide reamer 5.0mm
After cylinder head cooling down to room

temperature, fix the new valve guide with
reamer.
Caution
●Use cutting oil when fixing valve guide with
a reamer.
● When inserting or rotating the reamer, turn
it in same direction.
Correct the valve seat, and clean up all metal
residues from cylinder head.
Special tool: valve guide reamer 5mm
7-10
Valve seat inspection and refacing

Clean up all carbon deposits around intake
and exhaust valves.
Apply emery slightly onto valve contact
surface. Grind valve seat with grinding tool.
Caution
●Prevent emery from getting into valve stem
and guide.
● After grinding, clean up emery, and apply
red lead slightly onto the surface.
Remove valves and check if the contact
surface even or not.
Caution
● The valve cannot be ground and reused. If
the valve is burned, worn, or contact
surface is uneven, replace it.
● If the valve contacts the valve seat Valve seat width
unevenly after grinding, replace it.
Valve seat inspection

If the valve seat is too wide, too narrow, or
worn, re-grind it.
Valve seat width
Check the contact condition of the valve seat. roughness
Valve seat grinding
Grind the worn surface with specified valve
seat cutter.
Use the 45 degree valve seat cutter to remove
any roughness on the valve seat. 45°
Caution
● Use the 45 degree valve seat cutter to
grind the seat after changing the valve
guide.
Use the 32 degree cutter to remove the upper

1/4 part of the valve seat. Old valve
seat width
32°
7-11
Use the 60 degree cutter to remove the

bottom 1/4 part of the seat and check the new
valve seat. Old valve
seat width
60°
Use the 45 degree cutter to cut the seat to the

proper width.
1.0mm
Caution
● Confirm that all roughness is removed.
Re-grind if necessary.
45°
Coat the valve seat surface with Prussian blue
or red lead.
Install the valve through valve guide until the
valve contacting with valve seat, slightly press Contact surface
down the valve but do not rotate it so that a too high
Old valve
seal track will be created on contact surface. seat width
Caution
● The contact surfaces of valve and valve
32°
seat are very important to the valve sealing
capacity.
If the contact surface on the valve is too high,
cut the valve seat with the 32 degree cutter.
Then cut the valve seat to the proper width
with the 45 degree cutter.
Contact surface
If the contact surface on the valve is too low, too low Old valve
cut the valve seat with the 60 degree cutter. seat width
Then cut the valve seat to the proper width
with the 45 degree cutter.
60°
7-12
After grinding, apply emery slightly onto valve

contact surface. Grind valve seat with grinding
tool.
Clean up emery covered on the cylinder head
and valve.
Cylinder head assembly

Lubricate valve stem with engine oil, then
Valve spring retainer Valve guide oil seal
insert it to valve guide.
Install new valve stem oil seal.
Install valve spring and valve spring retainer. Valve cotter Intake valve
Caution
 The dense end of valve spring should face
down to combustion chamber.
Valve spring
Exhaust valve
Install valve by valve spring assemble /
disassemble tool.
Special Tool: valve spring assemble / disassemble tool
Valve Spring Assemble/Disassemble Tool
SYM-1471110
Caution
● When installing springs, place cloth in
combustion chamber to hold the valves
avoiding bending the valve.
Slightly tap the valve stem with a plastic

hammer to secure the valve cotter.
Caution
● Hold cylinder head on a working table to
avoid damaging the valve.
7-13
Install camshaft into cylinder head. Install
valve rocker arm, rocker arm shaft and rocker bolt×1 Holding
arm shaft holding plate. plate
Cylinder head installation
Clean up foreign materials on the matching
surfaces of cylinder and cylinder head.
Install cam chain guide.
Install new dowel pins and gasket on the
cylinder.
Caution
●Do not damage matching surfaces.
● Prevent foreign material from falling into
the crankcase.
Install cylinder head. Dowel pin
Tighten the 4 cylinder head nuts, then the 2
bolts on right side of cylinder head.
Torque value:
Cylinder head nut 3.6~4.0kgf-m
Bolt on right side of cylinder head
1.0~1.4kgf-m Cam chain guide
Caution
● Lubricate with engine oil and tighten the
cylinder head nuts in diagonally opposite gasket
sequence.
● Do not exceed the specified torque value
to prevent damaged cylinder head,
abnormal noise, leakage or poor engine
performance.
Rotate the crankshaft counterclockwise and
align the “T” mark on the flywheel with the
index mark on the left crankcase cover. (The
piston is on the top dead center.)
Install the cam chain sprocket and sprocket,
align the timing mark with the index mark on
the cylinder head.
Tighten sprocket bolt. (bolt×2) nut×4
Install spark plug.
Torque value:1.0~1.2kgf-m Timing
mark
Caution
● Make sure aligning the timing mark.
bolt×2
7-14
Install cylinder head side cover. (bolt×3)。 bolt×3
Install thermostat. (bolt×2)。

Loosen cam chain auto-tensioner adjusting boltX2
bolt, remove the spring.
Install auto-tensioner (bolt×2), then install the Adjusting
bolt
spring and adjusting bolt.
Install cylinder head cover. (bolt×4)
bolt×4
Install AI pipe (bolt×4)

Install spark plug.
Install the engine onto the frame. (refer to 6th

chapter) bolt×4
7-15
Valve clearance adjustment
bolt×4
Remove AI pipe. (bolt×4)。
Remove cylinder head cover. (bolt×4)。
bolt×4
bolt×3
Remove cylinder head side cover. (bolt×3)。
Remove timing-inspecting hole cap.

Remove ACG cap, rotate the crankshaft
counterclockwise and align the “T” mark on
the flywheel with the index mark on the left
crankcase cover. Align the cam sprocket
timing mark with the index mark on the
cylinder head.
Loosen the fixing nut and rotate the adjusting Timing

bolt to adjust valve clearance. mark
Fasten the adjusting bolt and tighten the fixing
nut when the standard value is reached.
Valve clearance: In 0.10±0.02 mm
Ex 0.15±0.02 mm bolt×2
Install cylinder head side cover. (bolt×3)

Start the engine, make sure engine oil
pumped up to cylinder head, then shut off the
engine immediately.
Install cylinder head cover. (bolt×4)
Install AI pipe. (bolt×4)
Caution
● Cylinder head parts will be seriously
damaged, if engine oil does not lubricate
properly.
● Check the lubrication condition while
idling, do not rise R.P.M.
7-16
8. Cylinder / Piston
Mechanism Diagram ···················8-1 Piston Removal / Inspection ······8-5

Precautions in Operation ···········8-2 Piston Rings Installation ············8-8
Troubleshooting··························8-2 Piston Installation ·······················8-9 8
Cylinder Removal / Inspection ···8-3 Cylinder Installation ····················8-10
Mechanism diagram
0.8~1.2kgf-m
1.0~1.4kgf-m
1.0~1.4kgf-m
8-1
General information
 The engine must be removed from the frame before repairing cylinder and piston.
Specification Measurement: mm
Inside Diameter 70.995~71.015 71.100
Cylinder
Warpage － 0.050
Taper － 0.050
Out of round － 0.050
Piston Ring / Top Ring 0.015~0.050 0.130
Groove Clearance Second Ring 0.015~0.050 0.120
Top Ring 0.150~0.300 0.500
Piston Ring End
Second Ring 0.300~0.450 0.650
Gap
Piston / Oil Ring 0.200~0.700 －
Piston Ring Piston Ring Top Ring 1.475~1.490 1.460
Thickness Second Ring 1.475~1.490 1.460
Piston Outside Diameter 70.430~70.480 70.380
Piston/ Cylinder Clearance 0.010~0.040 0.100
Piston Pin Hole Inside Diameter 17.002~17.008 17.020
Piston Pin Outside Diameter 16.994~17.000 16.960
Piston/ Piston Pin Clearance 0.002~0.014 0.020
Connecting Rod Small End Inside 17.016~17.034 17.064
Troubleshooting
Low Compression or Instability Excessive Smoke
Worn cylinder or piston rings Worn cylinder, piston, or piston rings
Improper piston rings installation
Worn cylinder or piston rings
Over High Compression
Excessive carbon built-up on the piston or Overheating
combustion chamber Excessive carbon built-up on the top of the
piston
Knocking or Abnormal Noise

Worn piston or cylinder
Excessive carbon built-up on the top of the
piston
Worn Piston Pin and Piston Pin Hole
8-2
Cylinder removal / inspection Dowel pin

Remove the cylinder head. (refer to chapter 7)
Remove cylinder head gasket and dowel pins.
Remove cam chain guide.
Cam chain guide
Remove cylinder.
Caution
 Prevent cam chain from falling into
crankcase when removing cylinder.
Cam chain
Remove cylinder gasket and dowel pins.
Dowel pin
Clean all the gasket material from the contact

surface.
Caution
 Use solvent to wet the gasket material in
order to remove it more easily.
 Do not damage the contact surface
during operation.
8-3
Cylinder inspection
Check if the inner diameter of cylinder is worn
out or damaged. Exhaust side Inlet side
Measure the cylinder inner diameter in X and
Y axis at three levels. Top
Calculate the taper and out of round at three Center
levels in X and Y axis. Take the maximum
value to determine. Bottom
Service limit:
Out of round：correct or replace if over 0.05
mm
Taper：correct or replace if over 0.05 mm
Measure the cylinder upper surface for
warpage.
Service limit: correct or replace if over
0.05mm
8-4
Piston removal / inspection

Block the crankcase and camshaft chain hole
with a clean cloth to prevent the piston pin clip
from falling into the crankcase.
Piston pin
Remove the piston pin circlip and remove the

piston pin and piston.
Remove piston rings.

Caution
 Piston rings are easy to break, please be
careful during operation
Check if the piston rings are damaged or the
grooves are worn. Clean the carbon deposit.
Measure the clearance between piston rings

and ring grooves
Service limit：
Top groove: replace if over 0.13 mm Piston ring
Second groove: replace if over 0.12 mm Insert
Piston
Thickness gauge
8-5
Install piston rings respectively into cylinder 20 Piston ring

mm below cylinder top.
Measure the piston ring end gap.
Caution
 Use the piston head to push the piston
rings squarely into the cylinder. Thickness gauge
Service limit：
Top ring：replace if over 0.5 mm
Second ring：replace if over 0.65 mm
Measure the piston pin outer diameter.

Measure the conrod small end inner diameter.

Measure the inner diameter of piston pin hole.

Calculate the clearance between the piston

pin and its hole.
8-6
Measure the outer diameter of piston pin.

Caution
 Measure the piston outer diameter in the
direction perpendicular to the piston pin
axis.

Compare the measured value with service
limit to calculate the clearance between the
piston and cylinder.
Measure piston ring thickness.

8-7
Piston rings installation

Clean up the piston top, ring groove, and piston surface.
Install the piston ring onto piston carefully.
Place the openings of piston rings as diagram shown below.
Caution
 Do not damage the piston and piston rings as installation.
 All marks on the piston rings must be forwarded to up side.
 Make sure that all piston rings can be rotated freely after installation.
120°
Top ring
Second ring
Side rail
Spacer Oil ring

Side rail
Over 20 mm
Top groove
Second groove
Oil groove
8-8
Piston installation
Place a piece of clean rag under the piston.
Clean all the gasket material from the contact
surface.
Caution
order to remove it more easily.
IN mark
Install piston and piston pin and make the IN
mark facing the inlet side.
Install the new piston pin circlip.

Caution
 Do not make the piston pin circlip
opening coincide with the slit of the piston
pin hole.
 Place a clean cloth between the piston
and the crankcase to prevent the piston
pin circlip from falling into the crankcase.
8-9
Cylinder installation
Install dowel pins and new cylinder gasket.
Dowel pin
Apply clean engine oil to the cylinder bore,

piston and piston rings.
Install the cylinder carefully. Press the piston
rings respectively when installing.
Caution
 Do not force the piston into the cylinder
because the piston and piston rings will
be damaged.
Dowel pin
Install the cam chain guide, dowel pins and
cylinder head gasket.
Install the cylinder head. (refer to chapter 7)
Cam chain guide
8-10
9. Crank / Crankcase / Shifting gear
Mechanism Diagram ··························· 9-1 Transmission Disassembly··············· 9-8

Precautions in Operation···················· 9-3 Transmission Inspection··················· 9-9
Troubleshooting ·································· 9-4 Crankcase Inspection························ 9-10
Crankcase Disassembly ····················· 9-5 Crankcase Assembly························· 9-11 9
Crankshaft Inspection························· 9-7
Mechanism diagram
Crankcase / crankshaft
1.0~1.4kgf-m
0.8~1.2kgf-m
3.5~4.5kgf-m
1.0~2.0kgf-m
8.5~10.5kgf-m
9-1
Transmission
Gear shift cam

Shift fork shaft
Right gear shift fork
0.8~1.2kgf-m
Gear shift spindle comp
Left gear shift fork
Central gear shift fork
Shift drum Shift

stopper comp drum
Six-speed gear
Counter shaft
1.0~1.4kgf-m
1 gear 6 gear 3 gear 4 gear 5 gear 2 gear Drive

sprocket
Main shaft
9-2
General information
 This chapter concerns disassembly of the crankcase, transmission system, and balancing
shaft for repair purpose.
 The following components need to be removed before disassembling the crankcase.
Engine Chapter 6
Cylinder head Chapter 7
Cylinder / piston Chapter 8
Clutch / Oil Pump / Gear Shift Spindle Chapter 4
ACG / Starter Clutch / Starter Motor Chapter 5
 The crankshaft should be replaced as a unit if the timing sprocket or the crankshaft bearing
needs to be replaced.
Specification measurement：mm
Conrod big end side clearance 0.050~0.300 0.600
Conrod big end vertical clearance 0.004~0.012 0.050
Crankshaft
Run-out ─ 0.100
Conrod small end inner diameter 17.016~17.034 17.064
Inner diameter 12.000~12.018 12.050
Gear shift fork
Claw thickness 4.930~5.000 4.700
Shift fork shaft Outer diameter 11.976~11.994 11.960
Torque value
Crankcase bolt 0.8~1.2kgf-m
Cylinder / cylinder head bolt 1.0~1.4kgf-m
Engine oil drain bolt 3.5~4.5kgf-m
Oil strainer cover 1.0~2.0kgf-m
Gear switch bolt 0.7~1.1kgf-m
Special tools
Inner bearing puller SYM-6204025
Bearing driver 6204 SYM-6204024
Bearing driver 6203/6004 SYM-6204024
9-3
Troubleshooting
Excessive engine noise
 Worn conrod big end
 Worn crankshaft bearing
 Worn piston pin or piston pin hole
Hard to shift gear

 Bent shift fork
 Bent shift fork shaft
Gear jumps out

 Worn gear teeth
 Bent or damaged shift fork
 Bent shift fork shaft
Excessive gear noise

 Worn gear teeth
 Worn gear shaft
9-4
Crankcase disassembly bolt×2

Remove the 6mm bolt from right crankcase.
(boltX2)
Remove the cam chain tensioner arm from

right crankcase. (bolt×1)
Remove cam chain.
bolt×1
Lock nut Balancing shaft gear

Remove balancing shaft lock nut and fix circlip
from left crankcase.
Remove balancing shaft gear.
Balancing shaft
Fix circlip
drive gear
bolt×4
Remove balancing shaft drive gear bolt.
(boltX4)
Remove balancing shaft drive gear.
9-5
Remove the 6mm bolt from left crankcase. bolt×11

(boltX11)
Balancing
shaft
Remove the left crankcase from the right
crankcase.
Remove balancing shaft.
Crankshaft
Shake the crankshaft gently and pull out the

crankshaft.
9-6
Crankshaft inspection
Use a feeler gauge to measure left and right
clearance of conrod big end.
Service limit: replace if over 0.6mm
Place the crankshaft on a V-block, measure

the clearance of the big end at the vertical
direction.
Place the crankshaft on a V-block, measure

the crankshaft run-out.
Crankshaft bearing inspection Clearance

Rotate the bearings to check if the bearings
rotate smoothly and silently. Clearance
Check if the inner ring of the bearing fixes
firmly on the crankshaft.
Replace the bearing if there is excessive
noise or roughness.
9-7
Transmission disassembly
Remove the gear shift fork shaft. Shift fork shaft
Left
Central
Right
Remove shift drum, then remove left, central,

and right shift fork.
Left Central Right
Remove the transmission mechanism.
Disassemble the gears and washers on the

main shaft and counter shaft, and arrange
them in order. Main shaft gears Counter shaft gears
Check if the teeth and grooves of each gear
worn and damaged.
Assemble the gears and washers onto the

main shaft and counter shaft in order after the
inspection.
Caution
 Apply clean engine oil to the gears before
assembly.
 Make sure circlips are securely seated in
the shaft grooves.
9-8
Transmission inspection
Check if the gear shift fork worn, bent or
damaged.
Measure the inner diameter of the gear shift
fork.
Measure the thickness of the gear shift fork

claws.
Measure the outer diameter of the gear shift

fork shaft.
Check if the gear shift drum worn or damaged.
9-9
Crankcase inspection
Check if the oil path on the crankcase clogged,
blow the oil path with compressed air if
necessary.
Clearance
Crankcase bearing / oil seal inspection
Rotate the bearings to check if the bearings Clearance
rotate smoothly and silently.
Check if the outer ring of the bearing fixes
firmly on the crankcase.
noise, roughness, or looseness.
Check if counter shaft oil seal damaged,
replace if necessary.
Crankcase bearing removal

Remove the damaged bearing by using the
inner bearing puller.
Special tool:
Crankcase bearing installation

Install new bearings onto the crankcase by
using bearing driver.
Special tools:
Bearing driver 6203/6305 SYM-6204024
9-10
Crankcase assembly
Remove the crankcase gasket and dowel
pins.
Clean the gasket residues off the crankcase
contact surface.
Caution
 Do not damage the contact surface of the
crankcase.
order to remove it more easily. Dowel pin
Install main shaft and counter shaft to the right

crankcase.
Caution
 Make sure the right washer in the
position.
Main shaft gears Counter shaft gears
Install the gear shift drum.
Caution
 When installing shift forks, make sure the
letters facing upward.
Right
Central
Left
9-11
Install shift forks (left, right) on counter shaft, and
install the shift fork pin into shifting drum groove.
Install shift fork (center) on main shaft, and install
the shift fork pin into shifting drum groove. Align Guide shaft
the holes of shift forks, then insert gear fork guide
shaft.
Caution
Left
 Make sure all parts move smoothly; rotate the
gear shift drum to neutral gear. (rotate the
main shaft, and the counter shaft will not Center
rotate simultaneously)
Right
Install crankshaft and balancing shaft to the right

crankcase.
Install the new crankcase gasket and dowel pins.
Install left crankcase.
Tighten crankcase left side screws.

Coat grease to the new counter shaft oil seal and
install it to crankcase.
Tighten crankcase right side bolts.
boltX2
9-12
Install balancing shaft drive gear, and align mark

woodruff key and the mark on the gear.
Tighten balancing shaft drive gear bolts.
Caution
 Make sure aligning woodruff key and the
mark on the gear; incorrect installation
will result in knocking of crankshaft and
balancing shaft and cause serious
damage. Woodruff key
mark mark
Install balancing shaft gear, align marks on

balancing shaft gear and balancing shaft drive
gear.
Torque value:0.8~1.2kgf-m
Caution
 Make sure aligning marks on balancing
shaft gear and balancing shaft drive gear; Woodruff key
incorrect installation will result in knocking
of crankshaft and balancing shaft and
cause serious damage. Lock nut
Install the fix circlip on the balancing shaft

gear.
Tighten balancing shaft lock nut.
Fix circlip
Install cam chain.

Install the cam chain tensioner arm. (bolt×1)。
bolt×1
9-13
NOTE:
9-14
10. Cooling System
Mechanism Diagram ··············· 10-1 Coolant Change ······················· 10-5

Precautions in Operation········ 10-2 Radiator ···································· 10-6
Troubleshooting ······················ 10-2 Water Pump······························ 10-8 10
Diagnosis of Cooling System· 10-3 Thermostat ······························· 10-12
Mechanism diagram
Radiator filler cap
Engine coolant
outlet pipe
Cooling fan
Reserve
tank Radiator
Reserve tank
pipe
Engine coolant
inlet pipe
TW sensor
Thermostat
Water pump
10-1

10. Cooling System
General information
Caution
● While the engine is running, never attempt to open the radiator filler cap, the pressurized hot
coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to
perform unless the engine is completely cooled down.
● Refill the radiator with distilled water or specified additives.
● Add coolant to the reservoir.
● The cooling system can be serviced on the motorcycle.
● Never spill the coolant to the painted surface.
● Test the cooling system for any leakage after the repair.
● Please refer to Ch3 for inspection of TW sensor.
Specification
Item Specification
Pressure to open filler cap 0.75~1.05 Kgf/cm²
Capacity of coolant: Engine + radiator 1200c.c.
Reservoir 400c.c.
Begins to activate at: 82~95ºC
Thermostat
Stroke : 0.05~3.00mm
Not-pressure :107.7ºC
Boiling point
Pressurized: 125.6ºC
Torque Value
Water pump rotor 1.0~1.4kgf-m
Special tools
Water pump bearing driver (6901) SYM-9100100
Water pump oil seal driver (Inner) SYM-9120500-H9A
Water pump mechanical seal driver SYM-1721700-H9A
Troubleshooting
Engine temperature too high Engine temperature too low
● TW sensor malfunction. ● TW sensor malfunction.
● Thermostat seized. ● Thermostat seized.
● Insufficient coolant.
● Water hoses clogged. Coolant leakage
● Water pump malfunction.
● water pump mechanical seal malfunction
● Fan motor malfunction.
● Thermostat O ring deterioration.
● The filler cap of the radiator malfunction.
● Water hose deteriorated or damaged
10-2

10. Cooling System
Diagnosis of cooling system
The water temperature

signal flashes
A. Stop and waiting for

the engine is completely
N A-1. Refill the radiator with Y
coolant and check for any Water leaking
cooled down, open cap problem
leakage?
to check the capacity of
coolant in radiator. N
Y
B. Turn on main switch N B-1. Inspect the circuits of Y

and check the water water temperature have Short or earth
temperature indicator short or earth? problem
back to zero?
N
Meter problem
Y
C-1. Eng. stop and remove

C. C. Open radiator water pump cover, start the
N motor to inspect pump N
cap and gently rotate Water pump repair
throttle, inspect if rotation?
coolant circulating?
Y
Y Water hose clogged
D. Close radiator cap,

measure thermo unit to N
confirm voltage reduction Replace thermo unit
comply with temperature
rise.
Next page
10-3

10. Cooling System
Preceding page
E. Keep eng. 3000~4000

rpm and inspect cooling N
fan operating.
E-2. Connect cooling fan

E-1. Confirm the rotating N
terminals with battery (12V) Replace cooling fan
direction of cooling fan. directly to inspect its
Y operation
Y
Meter unusual
E-3. Remove thermostat N
and heat it by water directly Replace thermostat
to check its operation.
If circuit connects
reversely cooling fan
will forward, correct Y
and check again. Refill with coolant
and recheck.
To bleed the air bubbles

completely, open radiator cap and
start engine while engine is cool
then press water hose softly by Notice if water hose is
hand to bleed. bend or twisted
Turn the throttle repeatedly until the improperly and bleeding
coolant surface becomes stable. of air bubbles
completely.
10-4

10. Cooling System
Coolant change
Warning
● Never attempt to carry out service work on the
cooling system unless the engine is
completely cooled down, otherwise, you may
get scalded.
Remove right-front body cover. (screwX2)
Remove radiator tank cap.
Radiator tank cap
Remove under spoiler. (boltX4)

Place a water pan under the water pump;
loosen the drain bolt to drain out the coolant.
Reinstall the drain bolt.
Refill system with coolant and bleed the air

bubbles.
● Remove radiator tank cap.
● Start the engine and confirm no bubbles from
the radiator and the coolant level is stable.
● Shut down engine, refill coolant if necessary. drain bolt
Caution
● To avoid the water tank rusting, please do
not use an unknown trademark refrigerant.
Coolant recommended: SYM Bramax radiator
agent.
Concentration: 50%
Reserve tank check

● Remove left-front body cover. Reserve tank cap
● Check reserve tank coolant level, refill coolant to
standard level. (between upper and lower)
● Install reserve tank cap.
Caution
● Do not fill too much coolant, or the collant
will backflow after the water temperature
rises.
10-5

10. Cooling System
Radiator
Removal / Check
Remove radiator air duct. (boltX3)
Check for any leakage from weld seam.
Blow radiator with compressed air. If the
radiator is blocked by dirt, use low pressure bolt×3
water jet to clean it.
Care shall be taken when straightening the
sink fan.
Place a water pan under the water pump;

loosen the drain bolt to drain out the coolant.
Install drain bolt.
Drain bolt
Remove radiator bolt. (bolt×2)
bolt×2
10-6

10. Cooling System
Disconnect the fan motor coupler. coolant inlet pipe

Remove engine coolant inlet pipe, reserve
tank inlet pipe and radiator inlet pipe.
Remove the radiator and the cooling fan.
fan motor coupler
bolt×3
Disassembly
Remove the cooling fan mounting bolt and the
fan. (bolt×3)
Remove thermo switch.
Assembly
Install cooling fan onto the radiator. (bolt×3)
Install thermo switch.
Cooling fan
Installation
Install the removed parts in the reverse order
of removal.
Upon completion, check for any leakage.
10-7

10. Cooling System
Water pump
Water pump seal / cooling
system leakage inspection
● Remove drain bolt to drain some coolant to
check if there is greasiness in it.
● Remove engine oil gauge rule to check if
the oil is emulsified.
If the two phenomena appear, oil seals of
water pump, cooling system, cylinder head, or
cylinder gasket could be damaged. Please
remove right crankcase to check (replace) Drain bolt
water pump oil seals, then inspect cylinder
head and cooling system.
Water pump removal

Remove drain bolt and drain out coolant.
Remove the water hose.
Remove four water pump bolts and cover.
Remove gasket and dowel pin.
Remove 12 right crankcase bolts and the
crankcase.
Remove gasket and dowel pin.
rotor
Hold water pump drive shaft and remove

water pump rotor clockwise.
Caution
● The rotor is provided with left turn
thread.
Remove circlip from right crankcase.

Remove water pump shaft and inner bearing.
Remove the outside bearing by inner bearing
puller.
Rotate the inner ring of bearing, the bearing
shall move smoothly and quietly.
If the bearing does not rotate smoothly or
produces a noise, replace it with new one.
Water pump shaft
10-8

10. Cooling System
Check if mechanical seal and inside seal Mechanical seal

damaged or worn.
Caution
● The mechanical seal and inside seal must
be replaced as a unit.
Bearing driver
Replacement of Mechanical Seal
Remove the inside bearing from inner side of
right crankcase by inner bearing puller.
Drive the seal by bearing driver.
Special tool
Bearing driver(6901) SYM-9100100
Caution
● Replace with a new mechanical seal after
removing it.
Apply sealant to the mating surfaces of the Mechanical seal

right crankcase before installing the new
mechanical seal.
Install the new mechanical seal onto the right

crankcase.
Special tool
Water pump mechanical seal driver
SYM-1721700-H9A
10-9

10. Cooling System
Install the new inner seal (12×20×5) onto the Water pump oil seal driver
right crankcase.
Special tool
Water pump oil seal driver (inner)
SYM-9120500-H9A
Bearing driver
Install a new outside bearing to the right
crankcase cover.
Special tool
Bearing driver (6901) SYM-9100100
Caution
● Do not reuse old bearing. It must be
replaced with a new one once it has
been removed.
Inner bearing
Mount the water pump shaft and the inner

bearing to the right crankcase cover.
Water pump shaft
Install the inner bearing circlip.
10-10

10. Cooling System
Rotor installation
Install the seal washer onto the water pump
shaft.
Caution
● Washer must be replaced together with
the mechanical seal.
Rotor
Install the rotor onto the water pump shaft.

Torque Value:1.0~1.4kgf-m
Caution
● The rotor is left thread.
Install the dowel pin and right cover gasket.

Rotate the rotor to align it with water pump
drive shaft. Install right crankcase. (bolt×10)
Install the dowel pin and new gasket.

Install the water pump cover. (bolt×4)
10-11

10. Cooling System
Thermostat
Removal
Remove thermostat cover. (boltX2)
bolt×2
Remove thermostat
Inspection thermostat
Check if thermostat damaged.
Place the thermostat into heated water to

check its operation.
Caution
● If the thermostat or thermometer contact
with the container, the value displayed
will be incorrect. If the valve of the
thermostat remains open at room
temperature or the valve operation is
not corresponding to the temperature
change, then it must be replaced.
Technical Data
Valve begins to
82~95ºC
open
Valve stroke 0.05~3.00mm
10-12

10. Cooling System
Installation
Install the thermostat.
Install the thermostat cover. (bolt×2) TW sensor

Install hose, refill coolant and bleed out air
bubble.
bolt×2
10-13

10. Cooling System
NOTE:
10-14

11. Brake System
Mechanism Diagram - Front Disk Brake Brake Fluid Replacement / Air Bleed
·························································11-1 ························································11-6
Mechanism Diagram - Rear Disk Brake Front Brake Caliper ······················11-7
·························································11-2 Rear Brake Caliper ·······················11-8
Precautions in Operation ··············11-3 Brake Disk ·····································11-9
Troubleshooting·····························11-4 Brake Master Cylinder··················11-10
Disk Brake System Inspection······11-5
Mechanism diagram – front disk brake

0.8~1.2kgf-m
3.0~4.0kgf-m
0.8~1.0kgf-m
3.0~4.0kgf-m
3.5~4.5kgf-m
11-1
11. Brake System
Mechanism diagram – rear disk brake
1.5~2.5kgf-m
0.8~1.2kgf-m
2.4~3.0kgf-m
2.4~3.0kgf-m
11-2
11. Brake System
Caution
 Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use
compressed air or dry brush to clean brake system. Use vacuum cleaner or other authorized
tool instead.
 The brake caliper can be removed without removing the hydraulic system.
 After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the
hydraulic system.
 While refilling brake fluid, care should be taken not to let the foreign material entering the brake
system.
 Do not spill brake fluid on the painted surfaces, plastic, or rubber parts to avoid damage.
 Check the operation of the brake system before riding.
Front brake disk thickness 5.00 4.50
Rear brake disk thickness 4.00 3.00
Front brake disk outer diameter 288.00 ─
Rear brake disk outer diameter 222.00 ─
Brake disk eccentricity 0.1 0.30
Bake pad thickness ─ Mark on brake pad
Torque value Special tool

Brake hose bolt 3.0~4.0kgf-m Inner bearing puller SYM-6204020
Front brake caliper bolt 3.5~4.5kgf-m
Brake disk bolt 3.7~4.3kgf-m
Air bleed valve 0.8~1.0kgf-m
Front wheel axle nut 6.0~8.0kgf-m
Rear wheel axle nut 10.0~12.0kgf-m
11-3
11. Brake System
Troubleshooting
Disk brake
Soft brake lever Uneven brake
1. Air inside the hydraulic system 1. Dirty brake pad / disk
2. Hydraulic system leakage 2. Poor wheel alignment
3. Worn master cylinder piston 3. Blocked brake hose
4. Poor brake caliper 4. Warped / bent brake disk
5. Worn brake pad 5. Blocked brake hose / joint
6. Low brake fluid
7. Blocked brake hose Tight brake
8. Warped / bent brake disk 1. Dirty brake pad / disk
9. Bent brake lever 2. unbalanced brake disk / wheel
3. Warped / bent brake disk
Hard brake lever operation
1. Blocked brake system Brake noise
2. Poor brake caliper 1. Dirty brake pad / disk
3. Blocked brake hose 2. Deformed brake disk
4. Seized / worn master cylinder piston 3. Poor brake caliper installation
5. Bent brake lever 4. Imbalanced brake disk / wheel
11-4
11. Brake System
Disk brake system inspection

Inspection Brake hose joint
Visually examine for leakage or damage.
Inspect the brake hose joint for looseness.
Turn the handle bar to right and left; press the
cushion to see if there is any interference with
the brake system.
Check if the brake pads worn. Replace the

Brake disk
brake pads if either pad is worn to the bottom
of wear limit groove.
Park the vehicle on the level ground. Check

the brake fluid level.
Recommended Brake Fluid: WELL RUN Wear limit groove
BRAKE OIL (DOT 3).
Caution
Lower limit
 When the vehicle is inclined or just
stopped, the brake fluid level could not be
accurate.
 Do not mix different types of brake fluid
which are not compatible with each other.
 Use the same brand brake fluid to ensure
the brake efficiency.
Adding brake fluid

Turn the handlebar to make the reservoir level
before opening the reservoir cap.
Cover the painted, plastic or rubber surface
Reservoir cap
with a rag before performing brake system
maintenance.
Diaphragm
Caution
 Do not fill brake fluid over upper limit. Fluid level upper limit
Brake
fluid
11-5
11. Brake System
Remove the reservoir cap and diaphragm.
Fill the clean brake fluid. Reservoir cap
Clean the dirty brake disk.
Caution Diaphragm
 Contaminated brake disk or pad Fluid level upper limit
decreases braking performance.
 Foreign material will clog brake system Brake
and lead to decline or malfunction of fluid
braking capability.
Brake fluid replacement / air bleed
Connect a drain hose to air-bleed valve. Open
the air-bleed valve. Pump the brake lever until
the old brake fluid is entirely drained out. Air-bleed valve
Close the air-bleed valve and add specified
brake fluid into the brake fluid reservoir.
Caution
 Reuse of old brake fluid will affect brake
efficiency.
Connect a drain hose to the air-bleed valve,
and put the other end into a container.
Open the air-bleed valve around 1/4 turns,
and at the same time pump the brake lever
until there is no air bubble in the drain hose
and also feeling resistance on the brake lever. Air-bleed valve
Close the air-bleed valve when the brake Transparent drain hose
system fluid filling procedure is finished.
Pump the brake lever to check whether air
bubble is in brake system or not.
If brake is still soft, please bleed the system
as described below:
1. Tightly hold the brake lever and open the
drain valve around 1/4 turns, and then close
the valve.
Air bubble
Caution
 Do not release the brake lever before the
air-bleed valve is closed. Air-bleed valve
 When bleeding air, frequently check fluid level to
avoid air entering the brake system.
2. Release the brake lever slowly.
3. Repeat step 1 and 2 until there is no air
bubble at the end of the hose. Tighten
air-bleed valve.
4. Confirm the brake fluid level, add fluid if
necessary.
5. Cover the reservoir cap.
11-6
11. Brake System
Front brake caliper

Removal
Place a container under the brake caliper, and
loosen the brake hose bolt, drain brake fluid.
Caution bolt×2
 Do not spill brake fluid on painted

surfaces.
Remove caliper bolts, (bolt×2) remove the
caliper.
Check the brake pad wear condition, replace

with new brake pad if wear limit is reached.
Installation
Install the caliper and tighten the bolts.
Brake pad replacement Wear limit groove

Remove pin clips.
Remove pad pins and spring.
Pin clip
Remove brake pads.

Install new brake pads, pad pins, and spring. Wear limit groove
Install pin clip.
11-7
11. Brake System
guide bolt
Rear brake caliper
Removal
Place a container under the brake caliper, and
loosen the brake hose bolt, drain brake fluid.
Caution
 Do not spill brake fluid on painted
surfaces.
Remove caliper bolts, (bolt×2) remove the
caliper. bolt×2
Check the brake pad wear condition, replace

with new brake pad if wear limit is reached.
Installation
Install the caliper and tighten the bolts.
Wear limit groove

Brake pad replacement
Remove guide bolts.
Remove brake pads.
Remove pad support.
Pad
support
Install pad support.

Install new brake pads.
Install guide bolts. Wear limit groove
Install brake caliper, tighten caliper bolts.
11-8
11. Brake System
Brake disk Brake

disk
Inspection
Visually check if the brake disk worn or
damaged.
Measure the thickness of the disk at several
places. Replace the disk if it has exceeded the
service limit.
Micrometer
Remove the brake disk from wheel.
Check if the disk for deformed or bent.
Caution
 The dirty brake pad or disk will reduce the
brake performance.
 Brake pad includes the asbestos
ingredient. Do not use compressed air to
clean the brake system. The operator
should put on gauze mask and glove, use
vacuum cleaner to clean it.
Front brake disk service limit: 4.5 mm
Rear brake disk service limit: 3.0 mm
11-9
11. Brake System
Brake master cylinder

Removal
Caution
 Do not let foreign materials entering the
cylinder.
Remove back mirror.
bolt×2
Disconnect brake light coupler.
Drain brake fluid.
Remove the brake lever from brake master
cylinder.
Remove brake hose.
Remove brake master cylinder from handlebar. (bolt×2)。
Clean the master cylinder with recommended
brake fluid.
Installation
Install brake master cylinder on handle bar,
tighten bolts. (bolt×2)。
Install brake lever, connect brake light coupler.
Brake hose bolt

Apply 2 new seal washers, install brake hose.
Tighten the brake hose bolt to the specified
torque value.
Make sure the hose is installed correctly.
Caution
 Improper routing may damage the hose
and wire.
 Twisted brake hose and wire may reduce
brake performance.
Add specified brake fluid and bleed the system.
11-10
12. Steering / Front wheel / Front fork
Mechanism Diagram ················· 12-1 Front Wheel ······························· 12-6

Precautions in Operation ········· 12-2 Front Fork ·································· 12-9
Troubleshooting························ 12-3 Steering Stem ···························· 12-12 12
Steering Handlebar ··················· 12-4
Mechanism diagram
6.0~8.0kgf-m
1.0~1.4kgf-m
3.0~3.5kgf-m
0.15~0.25kgf-m
3.0~3.5kgf-m
6.0~8.0kgf-m
3.7~4.3kgf-m
12-1
General information
 While removing the front wheel, hold the engine bottom with a hanger to lift the front wheel.
 During maintaining, do not stain brake pads with any oil or grease.
 The brake caliper can be removed without removing the hydraulic system.
 After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the
hydraulic system.
 While refilling brake fluid, care should be taken not to let the foreign material entering the brake
system.
 Do not spill brake fluid on the painted surfaces, plastic, or rubber parts to avoid damage.
 Check the operation of the brake system before riding.
Caution
 Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use
compressed air or dry brush to clean brake system. Use vacuum cleaner or other authorized
tool instead.
Wheel axle runout ― 0.2
Axial ― 2.0
Wheel rim runout
Radial ― 2.0
Torque value
Front wheel axle locknut 6.0~8.0kgf-m Front brake hose bolt 3.0~4.0kgf-m
Steering handlebar bolt 1.0~1.4kgf-m Air bleed valve 0.8~1.0kgf-m
Steering head thread comp 0.15~0.25kgf-m Brake disk fix bolt 3.7~4.3kgf-m
Steering stem locknut 6.0~8.0kgf-m Front brake caliper bolt 3.5~4.5kgf-m
Front fork bolt 3.0~3.5kgf-m
Special tool
Cone race puller
Steel ball race driver 32×35mm
Steel ball race driver 42×47mm
Steering stem locknut socket wrench SYM-5320000, SYM-5320010
12-2
Troubleshooting
Steering mechanism / front fork
Hard steering Soft suspension
 Steering stem nut too tight  Worn fork spring
 Worn or damaged steering ball bearing /  Fork seal leakage
seat
 Insufficient tire pressure Hard suspension
 Bent fork pipes
Steering handlebar tilted  Excessive fork fluid
 Incorrect fork adjustment
 Bent forks Front suspension noise
 Bent wheel axle  Bent fork pipes
 Damaged tire  Insufficient fork fluid
 Loosened suspension
Front wheel runout
 Bent wheel rim
 wheel axle locknut loosened
 Worn tire
 Worn or damaged front wheel bearing
12-3
Steering handlebar throttle cable locknut

Removal
Loosen the throttle cable locknut. Remove the
right handle switch screws. (screw×2)。
screw×2
Remove the throttle cable. Remove the Throttle cable

throttle grip and right handle switch.
Remove the front brake master cylinder. (bolt

x2)
bolt×2
12-4
Remove the left handle switch. (screw x2)
screw×2
Loosen the clutch cable locknut and adjusting

locknut
nut.
Adjusting nut
Remove the clutch lever pivot bolt. Remove

the clutch lever and clutch cable.
Remove the clutch lever socket. (bolt×2)
Remove the handlebar bolts and holders. (bolt
x4) Remove the handlebar.
Installation
Torque value:
Steering handlebar bolt 3.0~3.5kgf-m
Lubricate switches, throttle grip, and throttle bolt×2

cable when installing.
Align the salient on the switch and the intaglio
on the handlebar holder.
After the handlebar is installed, confirm and
adjust：
 throttle grip operation and free play
 meter, electrical parts operation
bolt×4
12-5
Front wheel
Removal axle locknut
Use a bracket to hold the bottom of engine
and let the front wheel away from the ground.
Remove the front wheel axle locknut.
Pull out the front wheel axle.
Remove the front wheel and side collar.
Caution
 Do not pull the front brake lever when the
front wheel is removed to prevent the
brake pads from being pushed out.
Inspection
Wheel axle
Put the axle on a V-block and measure the run
out.
Bearing
Rotate the bearings to check if the bearings clearance
rotate smoothly and silently.
firmly on the wheel hub. clearance
Caution
 The bearings should be replaced in pair.
Wheel rim
Place the rim in a rotating stand.
Spin the rim by hand and measure the runout
by using a dial indicator.
Service limit: radial 2.0mm
axial 2.0mm
12-6
Disassembly bolt×5
Remove the brake disk. (bolt×5)。
Pull out the left side bearing and oil seal by

using the inner bearing puller.
Remove the distance collar.
Pull out the right side bearing and oil seal by
using the inner bearing puller.
Special tool
Assembly
Install in the reverse order of removal. Bearing will be damaged
Apply grease to the wheel hub / bearing in these two examples of
contact surface. assembly.
Install the left side bearing.
Install the distance collar and the right side
bearing.
Caution
 Do not use a used bearing; replace the
bearings in pair when removed from wheel
hub.
 The bearing cannot lean to one side during
installation.
Tool：
Bearing driver
12-7
Installation
Oil seal
Apply grease to the inner and outer side of oil
seal and install oil seal into the wheel hub.
bolt×5
Install brake disk. (bolt×5)。

Install side collar.
Caution
 Contaminated brake pad will decrease
braking efficiency; therefore grease cannot
be applied to brake pad and brake disk.
Axle locknut
Install the front wheel axle from the right
cushion.
Install the axle locknut and tighten the locknut
to the specified torque.
12-8
Front fork
Disassembly
Speed sensor
Remove the front wheel, speed sensor and
front brake caliper.
3 bolts for both sides

Remove the front fender. (bolt×6)。
Loosen the front fork bolt on the top bridge.

(bolt×2)。
bolt×2
bolt×2
Loosen the front fork bolt on the steering stem.

(bolt×2) Remove the front fork.
12-9
Front fork inspection / oil seal
replacement
Push the fork pipe for several times to check if
there is any oil leakage or excessive noise. scratch
Check if there is any scratch on the fork pipe if
oil leakage happens.
Replace the front fork if there is a scratch on
the fork pipe.
Stopper ring
If there is oil leakage but without scratch on

the fork pipe, replace the oil seal.
Pour out the fork fluid.
Remove the oil seal stopper ring and then
remove the old oil seal.
Caution
 Do not damage the fork pipe when
removing the oil seal.
Stopper ring
Coat the inner side of the new oil seal with
cushion oil and then put in the fork pipe. Oil seal
Install the oil seal to the right position by using
an oil seal driver.
Clip the stopper ring.
Adjust the fork fluid capacity if the front fork is

too hard or too soft.
Cushion oil : BRAMAX CUSHION OIL
Capacity: 160~180c.c.
12-10
Installation Fork pipe cap
Caution
 The installing will be easier by rotating the
fork pipe.
Install the fork pipe from the bottom of the
front fork. Align the fork pipe cap with the top
bridge.
Top bridge
Fork pipe
Hold the fork pipe by hand and tighten the bolt

front fork upper bolt. (bolt×2)。
Tighten the fork bolt on the steering stem.

(bolt×2)
bolt
bolt
Tighten the front fork upper bolt. (bolt×2)
12-11
Steering stem
Removal
Remove the meter, headlight, steering
handlebar, front wheel, front brake and front
fork.
Remove top bridge locknut. (nut×1)
Remove the steering stem locknut and

steering upper cone race by using stem
locknut socket wrench. Top bridge locknut
Special tool:
Stem locknut socket wrench SYM-5320000
Remove the steering stem.
Caution
 Keep the steering steel balls in a
container to avoid missing them.
Remove the steering upper ball race by

rubber hammer. steering stem locknut
Remove the steering bottom ball race by
driver.
Remove the steering bottom cone race from
the steering stem.
Caution
 Do not damage the frame and steering
stem.
Installation
Install a new steering bottom cone race onto
the steering stem and lubricate with grease.
Install the steering upper / bottom ball race to steering stem locknut
the right position. Bottom ball race
Upper cone race
Caution
 Do not let the ball race lean on one side Upper ball race
during installation.
Coat the upper / bottom ball race with grease
and install the steering balls.
Bottom ball race
12-12
Install the steering stem into the frame.

Lubricate the steering upper cone race. steering stem
Tighten the upper cone race and steering stem locknut
locknut to the steering stem till the steering balls Counterclockwise
1/2 circle
touch the upper cone race closely.
Turn the upper cone race counterclockwise 1/2
circle and then tighten it with specific torque value.
(1/4~3/8 circle)
Special tool:
Clockwise
Stem locknut socket wrench SYM-5320000 1/4~3/8
Top bridge locknut socket SYM-5320010 Steering
Torque value: 0.15~0.25kgf-m stem
Caution
● Do not over tighten upper cone race or
the steering ball race may be damaged.
Install the top bridge and tighten the nut.

Caution
● After installation, check if the steering
stem rotate freely without vertical
clearance.
Install other parts in the reverse order of removal.
Top bridge locknut
12-13
NOTE:
12-14
13. Rear wheel / Rear cushion
Mechanism Diagram ······················13-1 Drive Chain / Sprocket / Flange ··13-6

Precautions in Operation ··············13-2 Rear Cushion ································13-9
Troubleshooting·····························13-2 Swingarm ······································13-10 13
Rear Wheel ·····································13-3
Mechanism diagram
3.5~4.5kgf-m
3.5~4.5kgf-m
10.0~12.0kgf-m
10.0~12.0kgf-m
13-1
General information
Refer to the service manual of tire for the information of tire removal, repair and installation.
Specification measurement: mm
Axle runout ― 0.2
Radial ― 2.0
Wheel rim runout
Axial ― 2.0
Drive chain slack ― 10~20
Torque value
Rear drive sprocket bolt 2.7~3.0kgf-m
Rear wheel axle nut 10.0~12.0kgf-m
Rear cushion upper bolt 3.5~4.5kgf-m
Rear cushion lower bolt 3.5~4.5kgf-m
Special tool
Stem locknut socket wrench SYM-5320000
Rubber bush puller / driver SYM-1120310
Troubleshooting
Rear wheel wobbling Rear suspension noise
 Bent rim  Incorrect cushion nut tightening
 Faulty rear tire  Damaged rubber bush
 Incorrect wheel axle tightening  Cushion fluid leakage
 Bent rear cushion / spring
Too soft suspension
 Weak cushion spring Poor brake efficiency
 Faulty rear cushion  Poor brake adjustment
 contaminated brake pad
Too hard suspension  Worn brake pad
 Damaged rubber bush
 Bent rear cushion
13-2
Rear wheel
Removal
Remove the rear brake caliper. (boltX2)
boltX2
Loosen the drive chain adjusting nuts on both

sides.
adjusting nut
Remove the rear axle locknut.
After removing rear axle, remove the rear wheel,

right / left side collar, chain adjuster, and brake
disk. nut×1
13-3
Inspection
Wheel axle
Put the axle on a V-block and measure the run
out.
Bearing
Rotate the bearings to check if the bearings
rotate smoothly and silently. clearance
firmly on the wheel hub.
clearance
Caution
 The bearings should be replaced in pair.
Wheel rim
Place the rim in a rotating stand.
Spin the rim by hand and measure the runout
by using a dial indicator.
Service limit: radial 2.0mm
axial 2.0mm
13-4
Rear wheel installation

Adjust drive chain slack. (refer to ch 2)
Tighten rear wheel washer nut.
Adjusting nut
Tighten axle locknut. (nut×1、PIN×1)
locknut×1
Install the caliper.
13-5
Drive chain / sprocket / flange

Drive chain / sprocket removal
Remove the left crankcase rear cover. (bolt×2)
bolt×2
Remove the drive sprocket bolts (bolt×2),

sprocket fixing plate, and drive sprocket.
bolt×2
Remove the drive chain cover. (boltX2)。

bolt×2
Remove the drive chain fixing clip and drive

chain.
Fixing clip
13-6
Drive chain / sprocket inspection

Sprocket
Check the condition of sprocket teeth.
Replace the sprocket if the teeth are worn out.
Caution
 Sprocket and drive chain condition should
be checked at the same time.
Drive chain
Clean and check the drive chain links
condition. Replace the drive chain if it is worn
out.
Fixing washer
Sprocket / flange removal

Remove rear wheel / drive chain.
Flat the sprocket bolt fixing washer.
Remove sprocket nuts and fixing washer.
Remove the sprocket.
nutX4
Remove the flange.
13-7
Damper rubber inspection Damper rubber×4

Check if the damper rubbers worn or
damaged, replace if necessary.

Turn the left and the right side adjusting nut evenly
to make the chain slack within the standard range.
Fixing nut
Turn the nuts clockwise to tighten the chain, or

counterclockwise to loosen the chain.
Chain slack: 10~20mm
Adjusting nut
Tighten axle nut.

After tightening the rear axle nut, please check the
adjusting nuts to prevent them from loosening.
Recheck the chain slack, and make sure the rear
wheel rotates smoothly.
Lubricate the chain with chain lubricant.
Rear axle nut
13-8
Rear cushion
Removal
Remove the left body cover.
Remove the fuse / relay bracket. (bolt x2)
bolt×2
Remove the rear cushion upper bolt. (bolt×1)。
bolt×1
Remove the rear cushion lower bolt.

Remove the rear cushion.
Installation
Torque value: cushion locknut 3.5~4.5kgf-m
bolt×1
Caution
 The rear cushion should be replaced as a
complete set. Do not disassemble it, or
the structure and rubber bush will be
damaged.
Press the rear cushion to check if the rear
cushions move freely.
Special tool:
Steering stem locknut socket wrench
SYM-5320000
13-9
Swingarm
Removal
Remove rear wheel, drive chain, sprocket,
and rear cushion lower bolt.
bolt×1
Remove the swingarm pivot locknut. (nut×1)。
nut×1
Pull out the swingarm pivot bolt.
pivot bolt
Remove the swingarm pivot sleeve and dust
seal. Swingarm pivot sleeve
Remove the swingarm.
Inspection
Check if the swingarm worn or damaged.
Dust seal
13-10
Check if swingarm collars, sleeves and dust

seals cracked or worn. collar
Sleeve Dust seal
Installation
Torque value: swingarm pivot locknut
10.0~12.0kgf-m
Caution
 The rear cushion should be replaced as a
complete set. Do not disassemble it, or
the structure and rubber bush will be
damaged.
pivot bolt
13-11
NOTE:
13-12
14. Electrical system
Mechanism Diagram .............................. 14-1 Starting System ..................................... 14-13

Precautions in Operation ...................... 14-2 Light system........................................... 14-15
Technical Specification ......................... 14-3 Meter ....................................................... 14-16
Troubleshooting..................................... 14-4 Light / Bulb ............................................. 14-17
Fuse......................................................... 14-5 Switch / Horn.......................................... 14-22 14
Charging System ................................... 14-6 Fuel Unit ................................................. 14-26
Mechanism diagram
TA sensor
MAP sensor Starter relay
TW sensor Rollover
sensor
Battery
Sidestand
ISC switch
ECU
TPS Turn light relay

Low beam relay
Injector High beam relay
Cooling fan relay
Fuel pump
Engine stop relay
Fuel pump relay
Ignition coil
Fuse box
Horn
Speed sensor
O2 sensor
ACG / CP Sensor Reg. Rec.
AISV
14-1
Charging system
 When removing battery, first disconnect the negative cable terminal, then the positive cable terminal.
 The maintenance free battery requires no inspection of electrolyte level and refilling of distilled water.
 When charging, the battery has to be removed from the vehicle, but do not remove the sealing cap.
 Do not apply rapid recharge, unless it is an urgent situation.
 Use a digital voltmeter to check the charging voltage.
 The battery can repeatedly discharge and be recharged. After discharging, if the battery is not in use for
a long time, deterioration, lowered efficiency, or shortened service life may occur to the battery. The
battery efficiency will be lowered after 1~2 years in usual case. After recharging, the voltage of battery
can be restored; If it connects to an additional load, the voltage will plunge then rise,
 Normal overcharging conditions can be observed from battery appearance. If battery inner circuit
shorted, voltage cannot be measured at the battery terminals. If voltage regulator does not operate,
the voltage will be too high and that may reduce battery’s life.
 When not in use for a long time, the battery will self-discharge and the capacity decrease. Please
recharge the battery around 2 months.
 After filling electrolyte, a new battery will generate a voltage of 12.5V or more after 10 minutes.
If the voltage is still low, keep charging the battery. After fully charging a new battery, the
service life of it will be prolonged.
 Please check electrical device according to the procedure of diagnosis chart.
 Do not disconnect and connect the connector of electrical devices when current is passing
these devices because this will generate high voltage and the electrical components in the
voltage-current regulator will be damaged. The ignition switch must be turned OFF before
performing any work.
 Please do not replace with a traditional type battery as replacement.
 Please refer to the removal instruction when removing ACG and CPS.
Ignition System
 Please follow the procedure of trouble diagnosis chart to check ignition system.
 As E.C.U. transistor ignition assembly does not require an ignition timing check. In case ignition timing
is incorrect, check E.C.U. and AC generator. Verify with an ignition timing light after replacement if
necessary.
 E.C.U. failure reasons are most resulted from E.C.U. looseness or impact. Take special care when
removing.
 Most of ignition system problems were resulted from poor connecting connector. Please
check the connectors first when servicing.
 Make sure that the heat range of spark plug is suitable. Improper spark plug is the main cause
of poor engine operation or combustion.
 Inspection procedures in this manual are based on Max. voltage. This manual also contains
methods of how to check ignition coil resistance and component operation.
 Please follow the continuity chart to check ignition switch.
Starting system
 Please follow the inspection procedures of troubleshooting to check ignition system.
 Starting motor can be removed directly from engine.
 Please refer to chapter 5 for starting clutch removal procedures.
14-2
Techinical specification
Charging system
Item Specification
12V 10Ah
Capacity / Model
GT12A-BS
Standard:1.2A / 5~10hr
Battery Charging rate Rapid:5A / 1hr
Fully charged 13.0~13.2V
voltage(20ºC)
Need to be charged 12.6V
Output 14.5~28A
ACG
Charging circuit resistance (20ºС) 0.42Ω±20% (Y/Y)
Leaking current Under 10mA
Start charging R.P.M. Under 2100 rpm
Voltage controlled by regulator 14.5±0.5 V
Others 15A
Battery 20A
Fuse
Main switch 15A
Injection system 10A
Ignition system
Item Specification
Model NGK CR8E
Spark plug
Gap 0.7~0.8 mm
Ignition coil Primary 2.8Ω±15%
resistance Secondary Without plug cap: 9.0KΩ±20% With plug cap :14.0KΩ±20%
CPS resistance 120Ω±20%
Starting system
Item Specification
Model DC type
Starting motor
Output 0.6 KW
14-3
Troubleshooting
Charging system Ignition system
No power supply No spark
 Disconnected battery cable  Poor spark plug
 Battery over discharging  The cable is poorly connected, open or
 The fuse is blown short-circuited
 Improper operation of the main switch - Between ACG and ECU
- Between ignition coil and ECU
Low voltage - Between main switch and ECU
 The battery is not fully charged  Poor main switch and relay
 Poor contact  Faulty ECU
 Poor charging system  Faulty ACG
 Poor regulator rectifier
Engine does not crank smoothly
Intermittent power supply  Primary coil circuit
 Loosened charging system connector - Poor ignition coil
 Poor battery cable connection - Cables, wire, ,connector poor contact
 Poor connection or short-circuit of the - Main switch poor contact
charging system  Ignition circuit
 Poor connection or short-circuit of the power - Poor ignition coil
generation system - Poor spark plug
- Faulty ignition coil wire
Faulty charging system - Current leakage in the spark plug cap
 The fuse is blown  Incorrect ignition timing
 Connector poor contact, short, or open - Faulty ACG
 Poor regulator rectifier - Improper installation of CPS
 Poor ACG - Faulty ECU
Starting system
Starter motor does not work Weak starter motor
 The fuse is blown  Poor charging system
 The battery is not fully charged  The battery is not fully charged
 Poor main switch  Poor connection in the windings
 Poor starter switch  The motor gear is jammed by foreign
 The front or rear brake switches do not material
operate correctly
 Starter relay is out of work Starter motor is working, but engine does
 The ignition coil is poorly connected, open not crank
or short-circuited  Poor starter motor pinion
 The starter motor is out of work  Poor starter clutch
 The starter motor run in reverse direction
 Poor battery
14-4
Fuse
Fuse circuit
O2 sensor
Engine-off relay
Fuel pump relay
Ignition coil
Diagnostic tool
coupler
AISV
Main switch Others
Reg. Rec.
Light
Battery
14-5
Charging system
Battery removal
Remove the rear seat.
注意
 Electrolyte (diluted sulfuric acid) is very
toxic. Once it spread on clothes, skin, or
eyes, it will cause burn. In case of being
spread, flush with great quantity of water
immediately, and then send to hospital.
 Once clothes are spread by electrolyte, it
will contact with skin. Immediately take off bolt×2
the clothes and flush with great quantity
of water.
Negative Positive
Disconnect the negative terminal wire first and terminal terminal
then the positive terminal.
Remove the battery.
Battery installation
注意
 To prevent short circuit, the positive
terminal wire should be connected before
the negative terminal being connected.
Current leakage inspection
Key off and disconnect the ground cable
(negative) from the battery.
Connect the ammeter (+) probe to the ground
cable and the ammeter (-) probe to the Negative terminal
negative terminal of the battery.
Caution
 When measuring the current, set the
ammeter to a higher range and then set
the range down to the appropriate level.
Current flow higher than the selected
range may blow out the fuse in the Ground
cable
ammeter.
 While measuring the current, do not key
on or a sudden surge of current may blow
out the fuse in the ammeter.
If the current leakage exceeds the specified
value, a shorted circuit may occur.
Current leakage：below 10mA
Locate the shorted circuit by disconnecting the
connections one by one and measuring the
current.
14-6
Voltage inspection
Measure the battery voltage by using a digital
multimeter.
Voltage
Fully charged: 14.0~15.0V (20°C)
Insufficiently charged: 12.3V (20°C)
Charging
Remove the battery cell caps.
Connect the charger positive (+) cable to the
battery positive (+) terminal.
Connect the charger negative (-) cable to the
battery negative (-) terminal.
Warning
 Avoid any fire near the battery during
charging.
 Control the charging from ON/OFF on the
charger, do not disconnect the cables.
 Before or after charging, always turn off
the charging machine to avoid explosion
caused by sparks.
 Follow the regulated charging current and
time shown on the battery.
Caution
 Do not charge the battery quickly except
for emergency situation.
 Confirm the charging current and time
before charging the battery.
 Excessive charging current or time will
damage the battery.
 After charging the battery, wait for 30
minutes and then measure the battery
voltage.
After installing the battery, coat the terminal

with grease to avoid oxidation.
14-7
Inspection on Charging Voltage / Current
Connect a tachometer.
Voltmeter Turn on the headlight to high beam and start the
Ammeter engine.
Accelerate the engine to the specified revolution
per minute and measure the charging voltage.
Charging Current: 0.6A / 2100rpm (headlight off)
1.2A / 6000rpm
Control Charging Voltage: 14.5±0.5V/2100rpm
Fuse Caution
 To replace the old battery, use a new battery
Caution with the same current and voltage.
 Before conducting the inspection, be sure
that the battery is fully charged with a voltage The following problems are related to the charging
larger than 13.0 V. If undercharged, the system; follow the instructions provided in the
current changes dramatically. checking list to correct it if any of the problems
 While starting the engine, the starter motor takes place.
draws large amount of current from the . The charging voltage can not exceed the
battery. voltage between two battery terminals and the
After the engine is warmed up, replace original charging current is in the discharging direction.
battery with a fully charged battery. . The charging voltage and current are much
higher than the standard values.
Connect a digital voltmeter to the battery terminals.
The following problems are not related to the
Connect an ammeter between both ends of the
charging system; correct it if any by following
main fuse.
steps indicate in the checking list.
Caution . The standard charging voltage and current
 When the probe is reversibly connected, use can only reach when the revolution of the
a voltmeter having an indication that the engine exceeds the specified rpm.
current flows from the positive or the negative  Bulbs used exceed their rate and consume
direction and the measurement should be at too much power.

zero, ammeter at one direction only.  The replacement battery is aged and does
not have enough capacity.
. The charging voltage is normal, but the current
Caution is not.
 The replacement battery is aged and does
 Do not use a short-circuit cable.
not have enough capacity.
 It is possible to measure the current by
 Battery used does not have enough electricity
connecting an ammeter between the battery
or is over charged.
positive terminal and the cable position
 The fuse of the ammeter is blown.
terminal, however, while the starter motor is
 The ammeter is improperly connected.
activated, the surge current the motor draws
from the battery may damage the ammeter. . The charging current is normal, but the voltage
Use the kick starter to start the engine. is not.
 The fuse of the voltmeter is blown.
 The main switch shall be turned to OFF
position during the process of inspection.
Never tamper with the ammeter and the
cable while there is current flowing through. It
may damage the ammeter.
14-8
Charging circuit
Reg. Rec.
R Y ACG
Fuse 15A
Fuse 10A
B Y
Fuse 20A
G Y
Main
Starter relay switch
R G
Starter
motor
Battery
Regulator/ rectifier inspection (KΩ)

+ Y1 Y2 Y3 R B G
-
Y1 ∞ ∞ ∞ ∞ ∞
Y2 ∞ ∞ ∞ ∞ ∞
Y3 ∞ ∞ ∞ ∞ ∞
R ∞ ∞ ∞ ∞ ∞
B 5~30 5~30 5~30 ∞ 1~10
G 2~20 2~20 2~20 ∞ 1~10
14-9
AC Generator Wire coupler
Remove wire strap right-up side cover.

Disconnect the ACG coupler 3P coupler.
Disconnect the regulator rectifier 6 pin coupler

and inspect the wire circuit.
Item Wire color Judgment
Main switch R─ B Battery voltage (ON)
Battery R─ G Battery voltage
Charge coil Y─ Y 0.42Ω±20%
If the readings measured are not normal,
check parts in the circuit.
If the parts are normal, then trouble is in the
wiring.
If there is nothing wrong with parts and wiring,
replace the regulator rectifier.
ACG coil inspection Y1

Disconnect 3 pin couplers of the generator coil.
Connect an ohmmeter to the each terminal Ω
end. Y2 Ω
Check the continuity of the each terminal end,
and engine ground with short circuit? Ω
If there is no continuity or short circuit, replace Y3
the AC. Generator.
V Ω
Y1 70~80 0.42Ω±20% Ω
Y2 70~80 0.42Ω±20%
Y3 70~80 0.42Ω±20%
Y1
Without disconnecting the coupler, voltage
generated can also be checked by voltmeter V
while the engine is running.
Y2 V
V
Y3
14-10
Ignition coil Ignition coil

Removal
Remove side cover and seat.
Remove spark plug cap.
Remove ignition coil wire.
Remove bolts and ignition coil.
boltX2
Spark plug confirmation
Remove the spark plug and install a good plug
into plug cap, and then ground it to engine
ground. Check its spark condition. If it is in not
good or burnt spark plug, replace the spark
plug with a new one.
注意
 Make sure each wire connection is
correct, and test as required. Even the
wire connection is correct; sometimes the
test may not be carried out successfully. Spark plug
Connect the high voltage shunt with a

multi-meter or input a resistor in the 10M
10CV of voltage meter.
Measure voltage and resistance.

Voltage: battery voltage
注意
 Do not touch metal parts on the test
probe with fingers to avoid electric shock.
14-11
Ignition circuit
O2 sensor
TW sensor
MAP sensor
TA sensor
RPM
Ignition coil
G/W
B/Y
L/Y R/Y
ACG
Spark plug
CPS
Ignition coil inspection
Remove ignition coil connector.

Measure the resistance of ignition coil.
Standard value:
Primary: 2.8Ω±15%
Secondary: Without plug cap: 9.0KΩ±20%
With plug cap: 14.0KΩ±20%
CP Sensor inspection
Remove wire strap.
Disconnect CP Sensor 2P coupler, measure
the resistance between the terminals of
green/white and blue/yellow.
Standard value: 120Ω±20%
Caution
● No need to remove circuit from the engine
to carry out this test.
Please refer to ch. 5 if the circuit needs to be
replaced.
14-12
Starting system
Starting circuit diagram
R
ECU R/Y EFi system actuators

Side stand
Eng. Stop Relay light Side stand
R Switch
PU/R
Side stand
Main Switch Eng. Stop
R L/O
Switch Relay B/G Switch
W/R
Silicon
Controlled LG/R
Fuse
10A Rectifier B
Fuse 15A
Neutral Light
Starter
Silicon Controlled Rectifier Switch
Fuse
20A B Y/R
Gear change
G/R Starter
switch
Relay
Clutch R
Switch
Starter
G G G/R
Motor
Battery
Starter relay inspection

Key on and pull the brake lever and press the Starter
starter switch. relay
If a sound of “Looh Looh” is heard, it indicates
the relay function normally.
Disconnect the negative terminal wire.

Disconnect the starter relay coupler.
Connect an ohmmeter to the starter relay
terminal.
Connect the green / yellow wire to the battery
positive terminal and the yellow / red wire to
the battery negative terminal.
Check the continuity of the starter relay
terminal.
If there is no continuity, replace the relay.
14-13
Starter motor removal nut×1

Remove the starter motor wire. (nut×1)
Remove the starter motor. (bolt×2)
bolt×2
Starter motor inspection

Connect the battery positive terminal and
starter motor power terminal.
Put up iron between the battery negative
terminal and starter motor case.
Check the starter motor rotating condition.
Replace the starter motor if the rotating speed
is too slow.
Starter motor installation
注意
 Make sure the O ring is ok and coat it
with motor oil before installation.
14-14
Light system
Light circuit
Brake light
switch
Tail light /
brake light
G/Y
B
BR
BR
Position light
BR G
B
Light switch Meter light High beam indicator

BR BR G L
BR High / low / passing W

beam switch Headlight
Main switch L
W
B
G
Tuurn light SB
B
relay
Turn light Right turn light indicator
switch
SB SB
GR
Right turn light
SB
O
O
Left turn light indicator

O
Left turn light
Battery
O
14-15
Meter bolt×2
Removal
Remove the headlight / meter (bolt x2).
Disconnect the headlight / meter coupler. Meter coupler
Headlight coupler
Remove the headlight locknuts. (nut×4)
nut×4
Remove the meter locknuts. (nut×3) nut×3

Remove the meter.
Installation
14-16
Light / Bulb Headlight coupler

Headlight bulb replacement
Remove the headlight / meter. (boltX2)
Disconnect the headlight coupler. Headlight wire×1 Rubber protector

Remove the rubber protector.
Push down the bulb fixing spring and remove
the bulb.
Replace with a new bulb if necessary (12V
55W/60W)。
Caution
 Never touch the bulb with bare fingers,
which may create a heat point and lead to
premature bulb failure. Wear gloves or
cover with cloth.
 Clean the fingerprint left on the bulb with
alcohol. Bulb fixing spring

After installation, make sure the headlight
work properly.
Adjust the headlight beam.
Headlight beam adjustment

Key on and turn on the headlight.
Turn the headlight beam adjuster to adjust
headlight beam height.
Caution
 Do not adjust the headlight beam except
for necessity.
 Improper headlight beam adjustment
dazzles the coming driver / rider or results
in insufficient illumination.
Headlight beam adjuster
14-17
Front turn light bulb replacement

Remove the front turn light lens screw.
(screw×1)
screw×1
Remove the front turn light bulb socket

screws. screw×2
Replace the bulb. (12V 10W)

Replace turn light socket if necessary.
Caution
Make sure turn light lens, case, and
gasket properly sealed up during
assembly.
Installation
14-18
Rear turn light bulb replacement

Remove the rear turn light lens (screw x1).
Caution
 Do not damage the lens when removing.
screw×1
Rotate the turn light bulb socket

counterclockwise and pull it out from the lens.
Replace the bulb. (12V 10W)

Replace turn light socket if necessary.
Caution
 Make sure turn light lens, case, and
gasket properly sealed up during
assembly.
Installation
Taillight / Brake light
14-19
Remove the front / rear seat and right / left
body cover. bolt×1
Remove the rear carrier bolts (boltX4) and
rear body cover upper bolt. (boltX1)
bolt×4
Remove the rear body cover bolts. (4 bolts for

both sides) 4 bolts for both sides
Remove the rear body cover lower bolts and boltX4

screws.
screwX2
Remove the rear fender bolt.
boltX1
14-20
Disconnect the taillight / brake light coupler.
Taillight / brake light coupler
Remove the rear fender fixing screws.

(screwX4)。
screwX4
Remove the taillight screw.
screwX1
Remove the taillight assembly.

Replace the taillight as an assembly if the led
is burned out.
Specification: taillight / brake light LED
Installation
14-21
Switch / horn
Main switch
Inspection
Remove the headlight. (bolt×2)
Disconnect the main switch coupler.
Check the continuity between two points as Main switch coupler

indicted below
pin
BAT1 BAT2 IG
position
LOCK
G R
OFF
ON
color B R G
B
Replacement
Remove the headlight assembly (bolt ×2).
Disconnect the main switch coupler.
Remove the main switch. (bolt x 2)
Installation
Install in the reverse order of removal. bolt×2
14-22
Right handle switch
Remove the right handlebar switch coupler. Engine stop switch
Check the following switch circuit.

Headlight switch
pin
BAT TL HL
position
Start switch Headlight switch
color B BR L/W
Cable locknut
Start switch
pin
BAT ST
position
FREE
color B Y/R
screw×2
Engine stop switch

pin
ST BAT
position
color B/G B
Removal
Loosen the throttle cable locknut and remove
the right handle switch screws. (screw×2)
Remove the throttle cable.
Remove the throttle grip and right handle
switch.
Installation
Check if switch operation is normal after
installation.
14-23
Left handle switch
Disconnect the left handle switch wire coupler. Pass switch Dimmer
switch
Check the following coupler circuit.
Dimmer switch
pin Turn light
position HI LO HL BAT switch
PASS Horn
switch
color L W L/W B
Turn light switch

pin
position L W R
color O GR SB
Horn switch
pin
position HO BAT
screw×2
FREE
color LG B
Removal
Remove the left handle switch screws,
(screw×2) remove the left handle switch.
Installation
Check if switch operation is normal after
installation.
14-24
Brake light switch
While pulling the brake lever or stepping the
rear brake pedal, the terminals of black and
green/yellow of the brake should have
continuity.
Replace the switch if damaged.
Front brake switch
Rear brake switch
Horn
Disconnect the horn coupler and remove the
horn. (bolt x 1)
bolt×1
Apply 12 V power source to two terminals of

the horn, the horn should sound.
Replace the horn if necessary.
14-25
十三、電器裝置
Fuel unit
Remove the fuel tank. (Please refer to ch.3)
bolt×4
Disconnect the fuel unit wire coupler.
Remove the fuel unit. (bolt×4)
注意
 Do not bend or damage the float arm.
Connect the fuel unit coupler to the wire

harness.
Turn on the main switch.
Move the float arm to verify the proper
position the fuel gauge needle indicates.
Arm position Needle position
Up (full) F (full)
Down (empty) E (empty)
注意
 While conducting the test, turn on the turn
light to make sure that the battery is in
serviceable condition.
When the float arm shifts to the F position or

the E position, the resistance measured shall Up
(full)
be as follows:
Arm position Resistance
Up (full) 100±5Ω
Down (empty) 600±15Ω Down

(empty)
14-26
15. Emission Control
Emission Control Syetem Mechanism····· 15-1 Positive crankcase ventalition system (P.C.V.)
·····································································15-4
Function of mechanism in the emission control
system ························································· 15-1 Air injection solenoid valve (AISV)···········15-5
Fuel Evaporative Emission Control system Ignition system···········································15-6
(E.E.C.) ························································ 15-2
Inspection Items·········································15-7 15
E.E.C. inspection········································ 15-3
Countermeasure for Abnormal Emission
Catalytic Converting System (C.A.T.A) ·· 15-3 Pollutants ····················································15-8
Emission control system mechanism

Four-stroke engine model
1. Catalyst Converter (C.A.T.A.)
2. Evaporative Emission Control System (E.E.C.)
3. Air Injection System (A.I.)
4. Positive Crankcase Ventilation System (P.C.V.)
Function of mechanism in the emission control system
General
The emission control strategy of this model was formulated basing on a four-stroke single
cylinder engine. It adopts secondary air introducing device to purify the exhaust, in addition, it
also adopts a charcoal canister to absorb the fuel vapor generated through evaporation in the fuel
system.
Engine refinements
Optimum compression ratio, ignition timing, intake and exhaust timing have all contributed to
maximize the intake/exhaust efficiency and combustion efficiency.
Secondary air introducing system

It is used to introduce secondary air into exhaust manifold so that incomplete burned exhausts,
CO & HC, may be burned again and to be harmless gases.
System Device Components Purpose & function

Combustion Combustion Four valves combustion chamber is designed
4-valve combustion chamber
system chamber to achieve the combustion stability.
Installed a three-way catalytic converter in
Exhaust Post-treatment
Catalytic converter the middle of exhaust pipe to oxidize the CO,
system device
HC in the exhaust gas.
Evaporative A canister is used to absorb vapor and to
Activated carbon canister
EEC system emission control introduce it into combustion chamber at an
Purge control valve
system opportune timing.
Secondary To introduce flesh air into exhaust manifold
Air injection solenoid valve
A.I. system air-injection controlled by an air cut-valve to burn the
system Secondary air filter exhaust again.
Crankcase
To introduce blow-by into combustion
PCV blow-by
Vapor separator chamber via a vapor separator for burning
system introducing
then discharging.
device
15-1
Fuel evaporative emission control system (E.E.C.)

1. Construction:
1. Reduce air-polluting HC.
2. To absorb fuel vapor and saving fuel consumption.
injector
Throttle
valve
Fuel tank
Vapor hose
ECU
Evaporative gas pipe

Active carbon canister
Purge control valve
2. Principle of operation
1. Vapor generated from the fuel tank and fuel system through evaporation is contained in
the confined system to prevent it from escaping into the atmosphere, at the same time,
the vapor will be introduced into an activated carbon canister where the hydrocarbon in
the vapor will be absorbed by active carbon.
2. When the engine is running, the negative pressure of the intake manifold opens the purge
line, release HC from the activated carbon and then sucks it into the engine together with
air from the bottom of the canister.
3. The canister can be used repeatedly without reducing its performance because of the
system's purge function.
3. Troubleshooting:
Fuel can not flow to the fuel injector
- No fuel in the fuel tank
- Manifold vacuum hose loosened.
- Clogged fuel system
4. Cautions:
1. Do not exceed the reed valve of the fuel filler when filling fuel.
2. Do not accelerate forcefully or ride on high speed when applying the spare fuel.
15-2
Evaporative Emission Control System (E.E.C.) Inspection

1. Visual check
Check all hoses for breakage.
2. Purge Control Valve (P.C.V.) function test:
Disconnect the hose of connection to the active carbon canister, and then connect a T-type
hose connector to pressure source as shown below:
Engine vacuum Pressure

gauge
To air filter Pressure source
P.C.V.
Apply 100mmAq into pressure source inlet as engine stopped then plug it. The pressure at
the gauge should not drop to below 10mmAq within 10 seconds.
Catalytic converter (C.A.T.A.)：

1. Construction:
Catalytic converter
Engine muffler
2. Description:
1. The function of the catalytic converter is to transfer unburned CO, HC, and NOx to
harmless CO 2 , H 2 O, N 2 gases.
2. Catalytic converter contains rare metals such as Pt, Pd, Rh. Use only unleaded gasoline
to prevent the catalytic converter from malfunction.
15-3
Positive Crankcase Ventilation System (P.C.V.)

1. Construction
→ blow-by gas
engin
Drain hose
Air cleaner
ECU
2. Principle of operation
1. Install a separated chamber on cylinder head, and suck the blow-by gas to the fuel vapor
separator by engine vacuum.
2. Drill a hole in the air cleaner and install a vapor separator, so that blow-by from
crankcase will flow through a cylinder check valve and then separated by the separator.
3. The separated vapor will be sucked into combustion chamber by engine negative
pressure to be burned again instead of discharging into atmosphere. Drain liquidized fuel
in the drain pipe periodically.
3. Service method
Visual check
- Drain the fuel when the level reaches 80% in the drain pipe.
- Check if hose damaged or loosened.
15-4
Air injection solenoid valve(AISV)

Description
To promote stable combustion and idle speed, an open loop is applied to maintain air / fuel ratio
on 13 : 1, AISV is used to neutralize pollutants like CO and HC.
ECU can accurately control AISV according to RPM and engine vacuum to avoid the backfiring
situation of traditional carburetor-type bikes.
AISV consumes higher current; to save power in idle speed, AISV is designed normal open, which
means that air inlet and outlet holes are unobstructed while no power supply, and can introduce
secondary air into exhaust gas.
Act condition
1.AISV act: in idle speed and low speed (under 15km/h), ECU do not let AISV earth, thus valve is
open and secondary air can be introduced into exhaust gas. Generally speaking, AISV can
neutralize 50% CO. (Ex: The original CO is 4%, after secondary air introduced, CO could be
lowered to 2%).To prevent backfiring, secondary air will be introduced while RPM is under
3000.
Battery
voltage
Battery
voltage
AISV ECU
1.AISV no act: While speed is over15km/h, ECU will let AISV earth, after AISV is off, secondary
air introduced to exhaust gas will be cut off.
Battery
voltage
Close to
AISV 0V ECU
15-5
Ignition system
Ignition circuit
O2 sensor
TW sensor
MAP sensor
TA sensor
RPM
Ignition coil
G/W
B/Y
L/Y R/Y
ACG
Spark plug
CPS
Principle
The computer programmed ignition system receives the signals from the Crankshaft position
sensor, Throttle position sensor, O2 Sensor, MAP sensor, Intake air temperature sensor, Engine
coolant temperature sensor. Calculating the engine RPM, the 16-bit microcomputer determines
the appropriate ignition timing, controls the ignition coil and triggers the spark plug This way can
not only make the engine achieve the maximum power output, but also help improve fuel
consumption rate.
15-6
Inspection items
Evaporative emission control system:
 Visual check if charcoal canister and hose damaged.
 Check if any leakage.
 Check purge control valve.
Catalytic converter:
 Remove and shake exhaust pipe to check if any abnormal noise.
 Check if emission within standard.
Fuel system
 Clean air filter.
 Check fuel filter.
 Clean injector and fuel hose by compressed air or specified solvent.
 Adjust idle speed CO/HC value. (RPM within standard)
Ignition System:
 Check or replace spark plug.
 Check or replace ignition coil.
15-7
Countermeasure for abnormal emission pollutants

Conduct periodical
inspection (1500 km/6
months)
Idle speed exhaust

emissions test (note 1)
Adjust injection system (note

2)
Keep CO value in 0.5~2.5%

Clean fuel injector by adjusting fuel injection
(note 3)
Replace fuel injector Clean the carbon deposit in

combustion chamber and
cylinder.
Check if piston rings leaking

or seized
Clean or replace the muffler
Inspect other related

mechanism on the engine
Note 1. Test in accordance with the idling test procedure.

Note 2. Adjust CO with diagnostic tool, set idle speed within standard, measure CO and HC on
idle speed, and adjust CO set value in injection system，adjust CO emission value around
0.5~2.5 %.
Note 3. If CO value can not be adjusted to the default value by adjusting ECU, follow the procedures to
check or replace components.
15-8
NOTE:
15-9
NOTE:
15-10
16. Wiring diagram
T2 電路圖
16
16-1

16. Wiring diagram
NOTE:
16-2

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HOW TO USE THIS MANUAL MECHANISM ILLUSTRATION

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Page Content Index

1-1 ~ 1-19 General Information 1

2-1 ~ 2-16 Maintenance Information 2

3-1 ~ 3-45 Injection System 3

4-1 ~ 4-14 Lubrication / Clutch / Transmission 4

5-1 ~ 5-8 AC Generator / Starting Clutch 5

6-1 ~ 6-8 Engine Removal 6

7-1 ~ 7-16 Cylinder Head / Valve 7

8-1 ~ 8-10 Cylinder / Piston 8

9-1 ~ 9-14 Crankshaft / Crankcase / Shifting Gear 9

10-1 ~ 10-14 Cooling System 10

11-1 ~ 11-10 Brake System 11

12-1 ~ 12-14 Steering / Front Wheel / Front Fork 12

13-1 ~ 13-12 Rear Wheel / Rear Cushion 13

14-1 ~ 14-26 Electrical System 14

15-1 ~ 15-10 Emission Control System 15

16-1 ~ 16-2 Wiring Diagram 16

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Symbols and Marks ·················· 1-1 Torque Values(Frame) ·············· 1-11

Symbols and Marks

Renew Replace with a new part before installation.

Special tools Special tools

Correct Meaning correct installation.

Wrong Meaning wrong installation.

Indication Indication of components.

Directions Indicates position and operation directions

Components assembly directions each other.

Caution components of the brake system; use a vacuum

Caution Brake fluid

 Rubber parts may become deteriorated when

 The ends of rubber hoses (for fuel, vacuum, or

 Tighten assemblies with different dimension Clamp

Both of these examples can result in bearing damage.

● Check if positions and operation of installed

● Make sure service safety each other when

● Make sure that the battery post caps are

● Note that do not let parts fall down.

● If a fuse is burned, it has to find out the cause

● Insert the terminal completely.

● Secure wires and wire harnesses to the frame

● Insert the connector completely.

● Check if the connector is covered by the twin

● Never use wires or harnesses which insulation

● Never clamp or squeeze the wire harness

Never too tight

● Wire harnesses routed along the handlebar

● Before operating a test instrument, the

Do you know how to set the

Rear 211 kg Primary

Fuel supply injection Horn 1

Displacement 249.4 cc Exh Solid Particulate -