Daytona DD125E-5C User manual

MOTORCYCLES
DAYTONA SERIES DD125E-5C DD350E-6C DD400E-6C

This manual including the following model
DD125E-5C DD350E-6C DD400E-6C
2
3
4-8
9
10
11-16
9
19
17-18
20-24
25
The engine of this motorcycle rotates at
high speed. In order to make sure that the
engine can run normally, prolong its service
life and safeguard your interests, please
operate the motorcycle according to the
following regulations:
Since this manual covers a few model and
specification, the pictures listed are not covering
all of the parts or spec, so please take the actual
Safety driving through
Position of parts mounting
Function of parts
1.Lubrication
2.Tire pressure
3.Operating instructions
4.Repair and maintenance
5.Fault maintenance
6.Maintenance period table
7.Motorcycle main specs
8.Motorcycle electrical schematics
products as the standard.
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CONTENTS

2
Motorcycle safety riding and &important notice
ACCESSORIES
Accessories produced by our company have
been under special design and test, and can render
the motorcycle safe. They are optional for users.
Users will take responsibility for their selection,
installation and use of accessories not produced
by our company. Please obey safe riding rules
and follow the next points: Carefully check your
accessories, make them out of sight line, reduce
ATTENTION
Proper use can extend the lifetime of the engine
Play a complete role of new bike function, please
ride bike according to following requirements.
1. During the first 1000km, avoid full throttle
and never labor the engine. The rotating speed of
the engine should be strictly restricted to less than
6000rpm.
2. After the first 300 km, 600km and 1000km,
please clean the engine and change. The engine oil
in accordance with the requirements of operation
and maintenance Manual.
EFI model has fuel injection system replying on
power.Please do not add extra equipment to cause
the problem like default or distroy the ECU.
A motorcycle rider ususally has his /her head
injured in an accident. In order to ensure personal
safety, the rider should wear a helmet, goggles,
boots, gloves etc.The passenger should wear the
The temperature of the muffler is very high when
the motorcycle is ridden. The passenger should wear
boots or shoes high enough to cover his/her angles to
prevent his/her feet from being scalded. The rider
should wear close-fitting clothes to prevent loose
clothing catching the handlebar, kick stand, footpegs
and tyres.
same gear.
PROTECTIVE APPAREL
distance between them and the ground and side up
angle, and keep suspension or steering device from
moving or affect handling. Avoid attaching any
electrical equipment.Otherwise it can bring trouble
to the electrical system.
Warning:

Motorcycle parts position
①REAR MIRROR
②CLUTCH CONTROLL GRIP
③LEFT SWITCH
④THROTTLE GRIP ⑤RIGHT SWITCH
⑥BRAKE LEVER ⑦ODOMETER
3
①
②
③④
⑤
⑦⑥

Headlock
headlock①is below the steering.
Please turn to the very left,take out
the key and turn at clockside, take
out the key
Attention:
When lock the bike, please don't move
orstart the bike
4
FUNCTION OF PARTS
②③
IGNITION SWITCH
Switch at ① right side of chasis, pls open the
switch cover first. Insert key,turn 90°at clockwise，
the ignition switch can turn both sides, start the
engine, the key can pull out any condition.
Ignition at position②：engine can not start with
all routing shut off。
Ignition at position③：engine can start with all
routing on Meanwhile all head light , tail light,etc
are on. Odometer dial is bright.
Ignition switch turn to position ④ ：engine can
start , but position light and meter dial light is off.
Kindly suggest you to switch the ignition to position
4 when start.
①④
①

Suit for water cooling model
EFI Bike valid
⑤ distance data resetting
anticlockwising the odometer handle, the
distance data changes to 0.
⑧short distance data
for short distance purpose, it can be changed to O.
⑥speed
showing the km/hr。
⑦odometer
it can grand total the number KM/miles, do not
delete the numbers.
⑨water temperature indicator (except DD400E-6C)
⑩EFI warning light
it shows the temperature of water cooling. When
it turns to the red,means the temperature is too high.
Warning:
When red light is on, please stop riding, check
the fun, coolant is enough or not. please check
the details until bike okay.
5
FUNCTION OF PARTS
ODOMETER
①Left idicator
switch to the left, it will flash when making a
left turn.
②high beam
high beam will be on by turning the switch to
high beam
③neutral light
when engine is in neutral, the N light will be
on, and others are off.
⑨
① ② ③ ④
⑤ ⑥ ⑦ ⑧
⑩
④right indicator
switch to the right, it will flash when making
a right turn.
⑨
①②
③④
⑥⑦
⑩
12 11

⑥Choke handle
Please dial down the choke handle,open the choke
when starting the bike,
④
If you want to overtake the others. Please press
the high beam continuously for safety.
⑤headlight changing switch
If you need dipped headlight, please switch to
“ D ”position；if you need high beam, please
switch to“ D ”。
carburator version only.
Overtake
By starting the bike, please dial up the choke handle,
close the choke.
③clutch controll handle
when you want to shift the gear, please hold the
handle with grip hardly to seperate the clutch
If you wanna to start the engine, please pull the
handle as well, then the bike can start up.
6
×
Right handle switch(no AHO)
①cutoff preset switch
“ ” position：all circuit
shut off engine can not start or
cutoff the running engine.
Fuel gage
The EFI light is on when switched, it is off when
start the engine. If the light still on, it means that
the bike still have problem.
Please use the Diagnostic to check the failure code
and solve it.
For EFI bike
It shows the fuel in tank. If indicating below red
line, please fuel the bike a.s.a.p.
The EFI bike need enough fuel.otherwise few
fuel will cause the fuel pump idling and distroy
the fuel pump.
Warning:
Left switch
②turning light switch
If you need to turn left, then
move “ ”position，If you
need to turn right, then move to ”position.Move
the arrow to the middle, then it is 。
“
①horn
Press horn if you need to use it.
① ②
③④ ⑤
①②
③
④

×
①cutoff preset switch
“ ” position：all circuit
shut off engine can not start or
cutoff the running engine.
“ ”：means the bikecircuit on, you can start
the engine.Please set the swith to“ ”position.
②throttle grip
adjust the throttle full-size，controlling the bike
speed grip turning to rider yourself,it's accelerating.
otherwise it's slowing speed.
③power with electric press-button
1、Engine is in Neutral or in gears, grasp the
cluth handle to separate the clutch disc.
2、key to the ignition switch,turn to“ ”position.
3、cutoff switch to“ ”position, press power with
electric button“ ”turn throttle grip,the engine can start
warning：
Every ignition less than 5s and 10s between
twice.If failure,please check oil-way &system
7
Right handle switch(EURO Ⅳ）
NOTE:EURO 4 AHO.
P
“ ”：means the bikecircuit on, you can start
the engine.Please set the swith to“ ”position.
②throttle grip
adjust the throttle full-size，controlling the bike
speed grip turning to rider yourself,it's accelerating.
otherwise it's slowing speed.
③headlight switch
P
It has three swtiches“ ”“ ”and“ ".
“ ”：headlight, taillight, odometer light are on
“ ”：front position light, tail light,odometer
light are on.
“ ”：front light, tail light, front position light,
odometer light are closed.
④power with electric press-button
1、Engine is in Neutral or in gears, grasp the
cluth handle to separate the clutch disc.
2、key to the ignition switch,turn to“ ”position.
3、cutoff switch to“ ”position, press power with
electric button“ ”turn throttle grip,the engine can start
①②
③

It's not well locked to pull out the key.Please
do not extract it strongly forced.
please do not over fuel exceeding the neck of
it.Please lock it when fully fuele。d.
REAR SHOCK
Fuel tank & tank cover
Open the cover, insert the ignition
key turn right at 90 degree.Yo can
open the cover. Press it when you
want to close it and pull back&take
out the key.
Fuel tank switch
Suit for carburator models
The whole fuel is closed by this position。
Please close this fuel switch by long time riding.
Warning：
Please fuel the bike immediatley when you start
to use spares(only2.7L), please turn on the switch
after fueling it.
Turn on
please turn to this position, the fuel enters into
the carburator smoothly.
Spare
When normal fuel is
used up, please handle
this to use the spare.
Close
Fuel pump
Suit for EFI models
EFI fuel the bike using fuel
pump Open the ingition lock,
fuel pump runs 5 s.Stop working
after 2-3seconds.Pump always working afer engine
starts, It's destroyed by the pump idling.please pay
attention to the fuel always.
Fuel pump assy.
Fuel tank cover Turn on Spare Close
Attention：
8
①locknut
②Adjust
You can adjust the position
please loose the locknut ①，
loose or tighten the nut ②。
adjust the spring tention, to
tighten or loosen the rear
suspension。
please make sure the same
tension

Shifter
N
① ② ③ ④ ⑤
This engine has 5 gears internationally,The
relationship chart please refer
to following：
Lubrication fuction
lubrication oil is very important for engine
lifetime,please forbid to use bad quality oil.
We suggest to use SAE15W / 40 API SJ oil.If you
want to use others, the level need to reach above SG,
the viscosity shows a rather pronounced variation
with temperature. Please exhaust all lubrication in
the crankcase and fuel the new lubrication oil。
Attention:：
Please send the used
lubrication to the recycle
bin.to avoid polluting the
environment.
Tyre pressure
Correct tyre pressure can hold the best stable ride
and comfort ride,make the tyre long time use.
It's dangerous to use over worn tyre,and effect
stability,steering and operation improper pressure
can cause the extra worn and cause accident, Less
pressure can cause the damage or get out of rim
and lead to accident.
Please check the tyre pressure. Check its scratch ,
nail or others sharps when bike is not started.Check
the tyre sunk or out of shape. If problem, please
repare it or replace it immediately.
Please change tyre of following limits pattern
min.limit Deep pattern（mm）
Front tyre：1.5 Rear tyre：2.0
Dangerous
Load
Rider
rider and passengers
Pressur（e Kpa）
Pressur（e Kpa）
F.tyre:225 rear tyre:225
front tyre:250
rear tyre:250
9

New bike grinding in is 1000km
Please use only≤3/4 thorrtle to avoid over grinding in
Change gears oftenly to avoid contineously
running at one RPM.
Control the engine RPM max.less than6000r/min
Max. speed shall less than 55km/h during 500km；
during 500-1000km max speed shall less than 70km/h.
Keep fit after first grind.tighten all screwsws，
adjust all parts,replace all polluted oil, examine the
first 1000km to ensure the best status of your
motorcycles,extend the life time of your engine.
Engine grinding-in
Operation Guide
Take your few minutes to check your bike before
usage, it can save the failure rate and guarantee the
safety riding.
check level of engine lubrication if need,add oil,
and check if it is oil leakage.
Check front,rear brake…Check &adjust the free
route of brake, check braking function (locking or
no braking)
Examination before ride
Adjust it if necessary.
Check drive chain…check its tension or lubrication,
If seriously worn or damaged, please change it.
Check steering control mechanism…check its
flexibility and stablity，adjust it when necessaty.
Check engine…check its noise or not
Check the coolant engough or not.
Warning：
Please don't start engine at narrow space to
escape the pollution. Please forbid to start
engine when engine is in gear. It can damage
the engine parts or cause accident.
Check throttle control…check free route of grip
to handle, cable connect, adjust it or change it if
necessary.
Check lighting and signal…check front light,tail
light, turning light and function of horn.
Check tyre…check both tyre pressure and wear
damage,please filling or fixing it
10

Ride
Heating up the engine gradually
1.To release clutch when engine idling,change
gears to first gear position.
2.throttling engine speed,releasing clucth handle，
coordinate these two steps for better starting.
3.when you ride the bike steady, disconnecting
clutch, shifting to 2nd gear;please use the same way
shifting to other speed.
Please do not shift gears without holding hard
clutch hand shank, otherwise it can cause the
transmimission chain damaged.
please do not shift to neutral when down hilling,
you need to hold the bike by engine power.
Dangerous：
Brake and park
Please reduce throttle until close for low speed
Lowing speed by front&rear brake,hold clutch handle,
shift to neutral, hold the bike and kick the stand up.
Before cornering please close the throttle&low it
by brakes. Otherwise, you could not control it by
sudden braking and cause the slide and turnover.
please pay attention to control bike evenly on
wet road,If you accelerate it too much, the bike can
be out of control
Check and keep in good repair
Oil level check
Please check the oil lever before
running the bike.There is engine oil
dipstick①backward the right crankcase
to measure the lubrication level.
Please measure it after 5 minutes
by stopping the engine.Please laythe
bike vertical with the ground.Clen the
dipstick,insert the dipstick into the oil,
unlock screw, check the level.
Level is between②and③two means
it is full of lubrication.
Level is under③,please add SAE
15W/40 API Sj engine oil to this top
level.
Fit on the dipstick&check whether
it is leakage
①Oil gauge
②upper calibration line ③lower line
warning：
It leads to parts damage due to
less oil. It effects the max.speed
due to over oil.
11

Change lubrication oil
Oil by machinery running can be
poured out thoroughly.
Set a suitable vessel for used oil
under the engine, then open refueling
cover and piston①,release oil and lock
the secrew,Leaning the engine for 2-3
hours until used oil is all out, then add
1.8L new oil.
DD150E-2 add 0.9L new oil
Please strike the strainer ③then
clean it.
Please reverse spring, take out the
strainer by holding the pot head.
Please ensure the oil pump seal
ring is well before fitting on the drain
plug.Otherwise please change the seal
ring to avoid leakage.
②
①drain plug
③strainer
②oil pump
seal ring
Spark plug
Take out plug cap,clean it,strike
the spark plug by special spanner，
Please clean its dirts by wire brush，
check it damaged or not, fired by
electrodes,if damaged, please change
the spark plug.
check the clearance between side
electrode① ,and adjust to 0.6-0.7mm.
①low speed or winter time, electrode show
black please choose type CR5HSA
②Hig speed or hot summer time, electrode
shos white,please choose type CR7HSA
③standard type is CR6HSA （original is
CR6HSA）。
①side electrode
Attention：
Please mount the spark plug by hand, then
tighten it by the special spanner.
Pay attention to the dirt inside the engine
during having the spark plug out.
How to choose spark plug
The core is made by filter,
please always check it to avoid
blocking up by dirt and reduce
the output power.
Disasemble the outer cover,
loose every bolt②，
take out the air filter cover①。
take out the locater，strike
the core③，install new core.
please use new air filter core.
Install air filter with different step
as above.
Air filter
Check the spark plug seal gasket is ok.
12
①②
③
④

AB
①locknut
②plate bracket
a d j u s t i n g s c r e w r o d
③
BATTERY
UPPER LOWER
Attention：
Check outtake and air drain of battery well connected.
Pls take off battery if you do not use bike long time
Please take out the negative first, store at ventilated
place after charing..
Please clean the wiring terminal of battery oftenly,
andensure it no loose.
Please use same battery spec as 12V9Ah
Red sheath wire to connect positive, black to
negative.Please do not mix them
Adjust of clutch lever
Loosen the locknut at crankcase
clutch control plate bracket
②①,adjust screw rod .turn
according to(A)，reduce
travel of left handle；
turn according to (B)side，
increase free travel。Lock
the top and below nuts
after finishing adjustment.
Adjust screw rod at left
switch④can adjust the free
travel. Loose locknut ⑤，
adjust the adjusting rod,
locknut it when handle has
enough free travel.
Adjust of throttle cable
①locknut
②upprt adjust coil
10-20mm
The free clearance is 10-20
mm by holding clutch hanle and
feeling the resistance.If you ind
the free clearance wrong,please
adjust it as following steps:
check throttle grip flexible from
open to close side.
Check if cable from throttle
grip to carburator well connected.
If cable is wrenched,cut or improper
routing,you should replace cable.
Check the grip idling free travel
is between 2～6mm 。
Please loose locknut① if it is adjusted，
Please check its electroyte
always keep it between:"UPPER"
and"LOWER".If below "LOWER"
please add distilled water to Upper
Forbid to add other liquid.
Check voltage of battery either
end,charging it below 12.3V.
If you start the engine hard or meet the electricity
failure due to lack of electroyte,please examine it
by local repair station.
13
④adjust pole ⑤locknut

Adjust idle of carburator
Adjust nut a Adjust nut b
Then turn top adjust coil②、
still need adjust,loose nut a b
adjust pole to 2～6mm free
travel, lock adjust nut a、b。
、
Suit for carburator models
Check ,adjust &lubricate drive chain
Check the sprocket,chain
Lubrication on chain
Lock clip
Disc Max worn limit
attention：
ensure the open side of clip is
opposite as normal running way.
Dirty chain will wear the sprocket
and chain more.Please check regular
date according to "check list"
Clean chain by detergent oil，
after dry,please add proper engine
oil or chain oil.
14
Check the pin of chain loose or not、damaged on
pin roller
Check rusty or dry up on chain，
Check chain moving flexible，
Check it over worn on chain and sprocket
Check teeth of sprocket damage
Check the loose of fixing bolt loose or not
Heat the engine, operate it
after high temperature.
WARNING:
you can not adjust EFI model since it is softwared
②
③
④

Adjustment on brake
Rear brake disc suitable
Suit for water cooling bike
Fuse replacement
Coolant
⑥adjust nut
⑧bolts
⑦nut
Fuse box
Holding motorcycle,test the
pedal from update to free travel,
it is 20-30mm.
If adjustment,loose the nuts
⑦,adjust the doble bolts⑧,increase
or reduce pedal route and brake it
several times,release brake,turn
rear wheel checking its running,
lock it.
If you happens often burnout fuse,
short circuit or overload. Please check
with the local repair station.
Coolant is made by coolant and distilled water.
freeze-proofing function.It can reduce
the engine temperature by circularly
radiation of coolant.
The new bike is with coolant.
Pleae pay attention to volume of
coolant when maintaining.You need
to add if needed open water bottle
cover②，add coolant into water
bottle until 80%
If coolant become muddy or time
for maintain,please change coolant.
Please follow the below steps.：
Stand the motorcycle at smooth ground.
15
Water bottle cover②
20-30mm
please check fuse first when
bike incoperation or cutoff.
Loose the cross screw on right
cover when replacing.disassemble
the right cover,open the fuse box
you can replace it.
The rated fuse is 15A。
Radiator cover①

Brake friction plate
Attention：
Attention：
Danger：
Liquid has strong corrosive. Please
disgorge it if you drink it.please wash
it if it is in eye or on skin. And see
doctor immediately.
5-10mm
hole of observation
lower limit
Checklist on braking system：
A:check the level of brake liquidcup
B:check leakage
C:check the cable leakage or crack
D:check worn of disc &friction plate
E:front brake lever free travel
5-10mm,rear brake foot bar free
travel is 20-30mm
Liquid disc brake pump is working under high
pressure to ensure its safe,please do not change
it exceeding.
Please maintain the braking system or disc
brake to special appointed repair station.
Check if the friction plate is max.worn.Please
change it if exceeding
Please do not ride it just after changing. Please
run the front brake lever several time or rear
foot bar,let the disc brake and caliper well cotact,
function of braking sytem return to normal
Brake liquid
Check the liquid level of right
handle switch and brake liquid cup.
If it is few, please add the
appointed brake liquid inside.
If the brake disc is worn, then
the liquid will be auto matically flow
into oil-pressure pipe.Check and fill
in liquid is the most important item.
16
20-30mm

Warning：
Fault repair
Fault repair
Suit for carburator model
Suit for EFI model
Warning：
Please check the leakage every 400km
water pump or circulating tube is leakaged.
Press the tube to find if it has flaw and replace it.
Please contact maintainance people if leakage,Please
do not open it by yourself.
Screw up the radiator cap①，put fully coolant
Screw tightenly after fitting on radiator cover.
Start the bike and idle it at 2-3seconds,open it cap
again①,continuously add coolant.Add tripe coolant,
tighten it ①open water bottle cap②,put approx.400
ml coolant,total volume is 1600ml
Attention：
When engine temperature reaches 125℃，
odometer sense light on,means the engine need
to have a rest,otherwise it will effect lifetime of
engine.
Please use 3500 anti-rusty antifreeze fluid
coolant is harmful and corrosive. please do
not drink it or infect with skin. Please recycle
it to avoid pollution.
Please do not open the radiator cover,to
avoid expulsion out and hurt people.
Please exhaust coolant by disassembly cylinder
body when repairing engine,this can avoid it into
crankcase.
Please check out the reason if engine can not start:
1.Check if the fuel tank switch at open position.
2.Check if fuel is enough
3.Pull out the oil tube below fuel tank,and check
if fuel is outflowing
4.disassemble spark plug and connect ignition
coil please put spark plug on unpainted hardware,
press electric botton.If it has blue spark,ignition
system is fine.If no spark,please go to the repair
station and fix it.
Please check as following if engine can not start
EFI fault light no on)：
1.check the fuel indicator and ensure if you have
enough fuel
2.Check if the battery connect is correct.
3.Check if the fuse is okay
Start 3-5 minutes after replacing ECU,close
ignition switch and re start
please shut down ignition switch when you
want to pull out the EFI connector otherwise it will
leave the historic record,you need to get rid of it
by special diagnostic.please press the plug
connector and pull out.
17

Clean
Motorcycle storage
Use it
.
Daily maintain
Maintain chart
You should clean the motorcycle,and check its
damagement,wear and oil leakage or not.
Please do not clean the bike by high-pressure water
to cause the damage.：
Ignition swtich,electric switch,odometer,exhaust ex.
fuel tank。
please avoid wet the exhaust,spark plug and battery
please use clean water to wash
Dry motorcycle,start engine by running few minutes.
lubricate the drive chain.
please test your brakes for good function before you
ride out.
You should do special check before your longtime storage.
1.clean and dry the motorcycle
2.exhaust the fuel in fuel tank and carburator
and have some antirust.
3.Take out the spark plug,put some（15-20ml）
lubrication in cylinder body. Close ignition switch,
press it several time again for more oil inside cyclinder,
please install spark plug again.
4.disassemble the battery and store it into well
ventilate, dry shady place.
Attention: please close ignition switch, please
disassemble negative wire first,then positive electrode;
please fix positive first then negative ,close ignition
Please maintain the bike according to following
symbols：
*you can fix it by your self if you can
**you need to go the maintain shop to fix it
Please clean it by cloth oftenly, dry the wet.
Put some antirust oil on chrome, put some wax on
paint.
air the tyre accoring to pressue.
check every bolt and nuts to avoid falling
down and cause accident.
Check the tyre and brakes flexibility ,if it
is over worn or damagement, please change it.
1.Take off the cover, clean it.
2.check the voltage of battery, if it is below
12.3V，charge the bike then install battery.
3.get rid of antirust agents, add new fuel
4.test the bike carefully.
switch when installation.
5.air the tyre to regular air pressure, stand it
until front &rear wheel out of ground.
6.Please cover the motorcycle by cloth or
breathability,save in the dry with ood ventilation place.
18

Remark：
Period
Milage（km）
2000
1000 4000 8000
1
Times
adjust adjust adjust adjust
adjust adjust adjust adjust
check check check check
check check check check
drive chain
rear brake
project period times maintance KM
1000 4000 8000 12000
times
every 4
years
brake wear
pipe
fluid cup
fluid
front brake
rear brake
clutch
hanger
bracket
nut bolt
wheel/ tyre
bearing
coolant
fuel injector
once every 2 years
clean every 30000km
per
month
one
month
3months
3months
**
**
**
*
**
**
**
**
**
*
**
**
**
*
*
*
Replace
adjust
adjust
4000km
change
friction disc
Remark：valid for all EFI modles.
①Often clean it driving in dusty area
②if data is over max speed of odometer，please
check details according to below details.
③to adjust timing chain and valve clearanc, must
be adjusted by authorized service shop for safety.
Fuel route check check check check
throttle system
carburator
core
spark plug
lubricate first 500km, them 1000 km
filter net clean it by placing the oil
tention
valve clearance
period
check check check check
check check check check
check check check check
check check check check
check check check check
check check check check
check check check check
check check check check
check check check check
check check check check
check check check check
check check check check
check check check check
check check check
check check check
check check check
check check check
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