um CHILL 125 cc. User manual

1
CHILL 125 cc.
SERVICE MANUAL AND EFI SYSTEM DIAGNOSTIC

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
2
INDEX
Regular Service and Maintenance............................................................................................3
Precautions for the run-in period of a new motorcycle............................................................ 4
Level 1 Service and Maintenance.............................................................................................4
Level 2 Service and Maintenance.............................................................................................5
Level 3 Service and Maintenance.............................................................................................5
Check and Replacement of Lubricant.......................................................................................6
Service and Maintenance of the Spark Plug.............................................................................7
Service and Maintenance for the Air Filter ..............................................................................8
Adjustment of the accelerator handgrip..................................................................................9
Service and Maintenance for the Front Brake..........................................................................9
Service and Maintenance for the Rear Brake .........................................................................11
Adjustment of the rear braking light...................................................................................... 12
Service and Maintenance for Front and Rear Tires ................................................................13
Service and Maintenance for Battery..................................................................................... 15
Service and Maintenance for Fuse......................................................................................... 16
Service and Maintenance for the Horn..................................................................................16
Storage of the Motorcycle ..................................................................................................... 17
Service and Maintenance Interval Table ................................................................................18
Service and Maintenance Interval Table for Lubricated Parts................................................. 19
Common Failures and Troubleshooting………………………………………………………………………………20-22
Schematic Wiring Diagram……………………………………………………………………………………………………23
EFI maintenance and troubleshooting…………………….………………………………………………..….……24-48

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
3
Regular Service and Maintenance
During the operation of the motorcycle, different levels of loosening and
mechanical wear will occur to each part. Without regular service and
maintenance, the dynamic property, economy, reliability and security of the
motorcycle will be reduced, and the service life of the motorcycle will also be
shortened. Therefore, motorcycle drivers must check proper regular service
and maintenance for the motorcycle, so as to ensure best performance of the
motorcycle. Proper regular service and maintenance can remove faults at time,
prolong the service life of the motorcycle, reduce the maintenance costs and
achieve the goal of safe driving of the motorcycle.
Requirements on Service and Maintenance
There are requirements on the service and maintenance of the Motorcycle:
1. Keep the engine clean, and make sure there is no gas/oil leakage and the
engine is easy to start up and has good acceleration property and dynamic
property and has no abnormal noise.
2. Ensure that the automatic clutch separates thoroughly and squeezes
smoothly, and shows no slipping or abnormal noise, and the accelerator
handgrip operates flexibly.
3. Ensure handy and flexible operation of the braking handgrip, and ensure
that the braking results fulfilled relevant requirements. After the brake is
released, the brake should be able to be reset automatically, and show no
friction sound. Ensure good lubricating performance of the motorcycle.
4. The front and rear shock absorbers should work properly and reliably. The
air pressure of the tire should be normal, and the electrical components at
each part should be able to work properly.
5. There is no loose connection on the overall motorcycle. The appearance of
the overall motorcycle should be clean and tidy.
6. It is well lubricated and there is no oil leakage at each lubricated part.
7. The connection of the accumulator cell should not be loose. It should be
secure and reliable.
8. Tools delivered together with the motorcycle, as well as spare parts should
be complete, free from wear or corrosion.
Service and Maintenance in the Run-in Period
The run-in of a new Motorcycle directly affects the service life of the
motorcycle. Within the first 1000km of the new Motorcycle (the driving speed
should not exceed 45km/h, subject to the speedometer), overspeed should be
avoided. Run-in must be carefully performed, service and maintenance
should be conducted after the run-in, with a view of compensating the initial
light wear. In this way, we can prolong the service life of the engine, and ensure
best conditions and good performance of the motorcycle.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Precautions for the run-in period of a new Motorcycle
1. Within the run-in period, replace the oil after 1000 km, and clean the oil
filter screen.
2. Regularly check whether each connection is loose, and tighten it timely if
any loosening is found.
3. Regularly check periodically if the engine, drive system and braking system
is overheated, and whether there is enough lubricating oil on each
lubricated part. If any overheat occurs, the cause should be found at time
and be fix it.
4. Regularly check the tightness of the belt, and the free travel of the front
and rear brakes, accelerator handgrip and each maneuvering position.
Adjust them if necessary.
5. Within the run-in period, run the motorcycle after the engine is well
pre-heated. First run it at low speed for 1km~2km, and then run it at high
speed.
6. In order to reduce vibration and impact loads, the motorcycle should run
on a level road with good road conditions whenever possible.
7. Within the run-in period, overload run should be strictly forbidden.
Otherwise, the drive system will wear more faster. Heavy load should be
avoided.
8. Avoid suddenly and long-time braking.
9. Strictlycontrol the running speed of the motorcycle.
10. Within the run-in period, the load should not exceed 80% of the payload.
Level 1 Service and Maintenance
Level 1 Service and Maintenance should be performed every time after the
motorcycle runs approximately 1000km~3000km. Its main contents are as
follows:
1. Adjust the travel of the front braking handgrip to 10mm~20mm, and
adjust the rear brake pedal to 20mm~30mm.
2. Adjust the travel of the accelerator cable to 2mm~6mm, and lubricate the
accelerator handgrip and the accelerator cable.
3. Clean the fuel tank, oil filter screen and air filter.
4. Remove the carbon deposit of the spark plug, and adjust the electrode
gap of the spark plug to 0.6mm~0.7mm.
5. Remove the accumulator cell and charge it.
6. Check and tighten all bolts and nuts of all exposed parts.
7. Check the tightness of all connections of the electric system, and tighten
them properly.
8. Ajdust the engine valve lash: intake valve 0.03-0.05mm; exhaust valve
0.05-0.07mm.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Level 2 Service and Maintenance
Level 2 Service and Maintenance should be performed every time after the
motorcycle runs 3000km~6000km. Its main contents are as follows:
1. Remove the carbon deposit on the parts such as cylinder, piston, piston
ring, cylinder head and silencer, and clean them.
2. Check the wear of the cylinder, piston and piston wear. Check whether
the compression ratio of the cylinder falls within the range of standard
values.
3. Check the wear of the clutch friction lining and brake shoes. Replace them
in time if any serious wear is found.
4. Clean the air filter, fuel tank, fuel filter, etc.
5. Clean the upper and lower steel balls of the steering column, and fill
lubricating oil or grease.
6. Check whether the axial and radial runout wear of the front and rear
wheel, and adjust it if necessary.
7. Clean, lubricate, and check connections in the controller cables of the
whole motorcycle. Check the wear of controller cables, and replace them
if necessary.
8. Clean the rear transmission box and replace the lubricant in it if necessary.
Check the wear of the front clutch friction lining, rear clutch friction lining
and drive belt. Replace them if necessary.
9. Wipe off dust on the rearview mirror, and check whether the rearview
mirror is properly located.
10. Check whether the electrical components of the whole motorcycle can
work normally.
Level 3 Service and Maintenance
Level 3 Service and Maintenance should be performed every time after the
motorcycle runs 6000km~10000km. Its main contents are as follows:
1. Ensure normal oil supply for the lubricating system.
2. Ensure normal work of the air distribution mechanism.
3. Ensure normal work of the electric startup system.
4. Ensure normal operation, of front and rear automatic clutches and the
drive system.
5. Check whether there is any crack, erosion, spalling or serious stepped
wear on each gear tooth of the rear transmission box.
6. If case of disassembling the engine, the carbon deposit on the cylinder
head, piston top, piston ring and exhaust port should be removed. Check
the fit clearance between the piston and the cylinder wall, and the smaller
head of the crank connecting rod and the piston pin.
7. Ensure normal work of front and rear shock absorbers, the frame and
accessory mechanisms.
8. Ensure normal fuel supply for the fuel system.
9. Ensure normal work of instruments and the electric system.
10. In case of disassembling the whole motorcycle, check if there is any
damaged part for the steering column, front and rear wheels, the air filter,
front and rear brakes, the maneuvering system, and the drive system.
Clean each part and fill in lubricating grease and lubricating oil. Adjust the
fit clearance after reassembly .

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Check and Replacement of Lubricating Oil
Caution
Replace the lubricating oil when the engine is in the hot state.
When the lubricating oil is basically drained off, turn the engine for
several times to completely discharge residual lubricating oil.
Before filling new lubricating oil, remove the residual dirt from the
crankcase with 0.5L gasoline, and then drain the gasoline.
The specification and grade of lubricating recommended is 10W40
engine oil is recommended.
Check whether the filter screen, sealing gasket, spring, O-ring and oil
drain plug are in good conditions. If not, replace them.
After replacing the lubricating oil, tighten the oil drain plug and oil fill
plug, and check periodically if there is any oil leakage.
After replacing the lubricating oil, the idle speed of the engine must be
re-adjusted to be within the range of standard values.
First, twist off the oil
gauge and check
whether the lubricating
oil becomes black or
deteriorated.
If the lubricating oil
becomes black or
deteriorated, remove the
drain plug of the engine
to drain the lubricating
oil and replace it.
Level the motorcycle and
fill in oil until the oil level
is between the upper
and lower markings.
Upper oil level marking
Lower oil level marking

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Service and Maintenance of the Spark Plug
Type of spark plug: Connecting screw, flat seating, with nut
Service of the spark plug:
Take off the spark plug. When the color of the insulator skirt of the spark plug is
offwhite, it indicates overheat of the engine. Generally, the engine overheat
may be caused by the following reasons:
The heat value of the spark plug is too small, and it should be replaced
with a spark plug with appropriate heat value.
The spark plug thread is too large, then the insulator excessively
extrudes into the combustion chamber. It is necessary to adjust the
thread area of the spark plug.
The overheat of the engine is caused by the friction in transmission
parts of the engine.
Take off the spark plug. If it is found that the color in the insulator of the spark
plug is dark-black, or there is serious oil stain or dark black carbon deposit on
the surface.
Take off the spark plug. If it is found that the color of the insulator skirt of the
spark plug is brown, it indicates that the engine works properly, and there is
nothing wrong with the spark plug.
Cleaning the Spark Plug
Caution
In cleaning the spark plug, make sure not to damage the insulator. It is
forbidden to remove the carbon deposit or filth by burning with fire or
scrubbing with metal wires.
Side
electrode
The normal skirt of
the insulator of the
spark plug is brown.
First, soak it with spark plug
detergent or gasoline for about
half an hour and then use a
non-metal blade to remove the
carbon deposit surrounding the
spark plug, and finally clean the
spark plug with gasoline.
First, mount the sealing washer
onto the spark plug, and then
tighten the spark plug to place
with hands, and finally tighten
the spark plug with a socket
spanner.
Check the electrode gap of
the spark plug with a plug
gauge, and adjust the gap
to 0.6mm -0.7mm.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Service and Maintenance for the Air Filter
When the filter element of the air filter is blocked by dust, it may result in
increased resistance of the air intake system, too rich mixture, reduced power
and greater fuel consumption. Therefore, the filter element of the air filter
should be cleaned on a regular basis.
Caution
* It is forbidden to use the following cleaning agents to clean paper filter
elements, such as gasoline, low ignition-point solvent, acid, alkaline or organic
volatile oil.
Take off the fastening screws
of the air filter cover, and
remove the air filter cover.
Check whether there is too
much dust on the sponge
foam of the filter element.
Take off the sponge foam.
Wipe off the dust inside the air
filter with a clean and dry rug.
Clean the foam filter element: Take off the foam filter element.
First, soak the foam filter element of the air filter in the detergent,
and then pinch and wash it. After the foam filter element is cleaned
and dried, soak the foam filter element in SAE lubricating oil until it
is saturated. Extrude excessive lubricating oil and mount it.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Adjustment of the accelerator handgrip
Check whether the free travel of the accelerator handgrip is within the
specified range, and then adjust it. Please follow the following steps in
adjusting the free travel of the accelerator handgrip:
1. First, loosen the locking nut.
2. Then adjust the regulating solenoid.
3. After adjustment, tighten the locking nut.
Service and Maintenance for the Front Brake
This model uses the front disc brake, which is featured by secure and reliable
braking, labour-saving and good heat dissipation.
Adjustment of the front disc brake
1. First, use the main support to prop up the Motorcycle, and then it is
possible to adjust the free travel of the front brake.
2. Adjust the regulating nut of the front brake to adjust the free travel of the
front braking handgrip to 10mm~20mm.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Check the wear in the front brake. If the travel of the front braking
handgrip is too large, it indicates that the wear of the front brake shoe
is already beyond the limit.
Check the wear of the front disc brake. If the surface of friction is
abnormal or deformed, please replace it with a new disc brake.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Service and Maintenance for the Rear Brake
Adjustment of the rear disc brake
First, use the support to prop up the rear wheel of the motorcycle and
then adjust the free travel fo the rear brake.
Grip the rear braking handgrip for several times, and then loosen it.
Rotate the rear wheel assembly to check whether the rear wheel
rotates freely.
First check the wear of the rear brake shoes. If the travel of the rear braking
pedal is too large to be adjusted, it indicates that the wear of the rear brake shoe
is already beyond the limit.
Use the support to prop up the motorcycle, and adjust the free
travel of the rear braking handgrip to 10mm-20mm.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Adjustment of the rear braking light
Due the braking light of the Motorcycle directly relates to the driving
safety, the conditions of the braking light should be checked from time
to time.
When the braking light can not work properly, the braking light switch
and the braking light bulb should be checked and replaced.
Check the air pressure of the tire and check whether the
rim deforms. If any abnormality is found, it should be
handled properly.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Service and Maintenance for Front and Rear Tires
Only when the proper air pressure is set for the tire is possible to ensure the
comfort and stability of the driving and prolong the service life of the tires and
tire casings of the motorcycle.
Removal and Replacement of Front Wheel
Use the main support to prop up the motorcycle.
Remove the nut of the front wheel shaft, and take off the front wheel
shaft. Take off the front wheel.
Caution:
After taking off the front wheel, make sure not to grip the front braking
handgrip.
In remounting, the tightening torque to the wheel shaft nut must be
50N.m~70N.m.
Adjust the front brake, and make several braking tests. After loosening
it, check the front wheel rotate flexibly.
Check the air pressure of the tire and check periodically for rim
deforms. If any abnormality is found, it should be handled properly.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Removal and Replacement the Rear Wheel
Turn off the ignition lock switch.
Use the main support to prop up the motorcycle, and take off the
silencer.
Take off the nut of the rear wheel shaft, and remove the rear wheel.
Assembly Precautions
In reassembly, torque to the rear wheel shaft nut: 70N.m~90N.m.
Re-adjust the free travel of the rear braking handgrip to 10mm~20mm.
If the tread wear depth in the middle area of the tire of the motorcycle reaches
the following limit, the tire should be replaced immediately.
Minimum limit of tread
depth
Front wheel
2.0mm
Rear wheel
2.0mm
Caution
Too low tire pressure will increase the rolling resistance of the tire of
the motorcycle and increase fuel consumption. In worse cases, it may
cause local delaminating of the tire body and cause tire burst.
Too high tire pressure will reduce the comfort of riding and fasten the
wear of each part.
Check the tread wear depth
of the tire and whether there
is any crack. If any
abnormality is founded, the
tire should be replaced
immediately.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
15
Service and Maintenance for the Battery
In this model, the battery is mounted below the seat cushion. DC power supply
is used for the electric system of the model. For the first 1000km~3000km of
the motorcycle, the battery should be checked and maintained as follows:
1. Check whether that the battery can work properly.
2. Check whether the positive and negative electrode connection is loose.
3. When the motorcycle is not used for a long time, the battery must be
charged once a month.
4. Check whether the electrolyte level of the accumulator cell is between the
upper and lower markings. When the level is below the lower marking,
add some distilled water.
Check whether the connection of the accumulator
cell is loose. It is loose, tighten it.
Check whether the battery voltage is within the range of
“12V”. When the voltage of the battery is not enough, charge
it.
When battery of the motorcycle is not used for a long
time, it will self-discharge, must be charged once a
month.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Service and Maintenance for the Fuse
The fuse is connected in series to the charging and discharging of the battery.
When the charging current or the discharging current exceeds the specified value,
the fuse will automatically will break itself to protect the battery and the electrical
components. For this model, the fusing current of the fuse is 15A.
Caution
After the fuse burns out, we should first find out the reason of causing
too high current, and at the same time, replace it with a fuse with
appropriate specification.
Horn Service and Maintenance
After the motorcycle has run for a certain period of time, the horn fixing could
be loose, and its housing may collide with other parts, thus affecting the sound
of the horn. In this case, the sound volume of the horn should be re-adjusted.
When the electric system of the motorcycle outputs no current,
first we should check whether the fuse is broken. If yes, replace the
fuse.
If the horn gives a weaker or no sound, remove the front panel. Use a
multi-meter to measure the output voltage of the horn circuit. If the input
voltage is normal, use the horn regulating screw to adjust the sound volume
of the horn to the normal level.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Storage of the Motorcycle
Long-time storage:
If the motorcycle needs to be parked for a long-time (more than one month), it
should be done in the following steps:
Drain off all the residual fuel in the fuel tank. Spray the fuel tank with
spray-type antirust oil. Mount the fuel tank cover.
Take off the spark plug. Pour 5mL clean lubricating oil into the cylinder.
Tread the starting arm for several times to enable the poured-in
lubricating oil to be evenly distributed in the combustion chamber.
Install the spark plug.
Take off the battery, and store it in a dry, dark and indoor environment.
Perform slow charging for the battery once per month.
Wash the motorcycle, and wipe it dry with soft rugs. Wax the painted
surfaces, and apply a film of anti-rust oil to the chromium-plated
surface.
Increase the tire pressure to the specified standard value. Place tie
plugs below the tires of the motorcycle to lift the wheels from the
ground.
Protect and cover the motorcycle, park it in a well-ventilated, dry,
clean, rainproof and sun proof place, far away from any hazardous
substance such as inflammable material or chemical corrosive.
To Re-use after Storage
Clean the Motorcycle. Replace the engine oil if the motorcycle has
been stored for more than 4 months.
Check the battery. If is necessary, use it after it be charged.
Clean up the antirust oil in the fuel tank, and fill in new fuel /
Perform overall checkup necessary to be done before driving.

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
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Service and Maintenance Interval Table
Regular Service and Maintenance is generally based on the reading of the odometer. When the motorcycle is working under bad conditions or under load
operation for a long time, the service and maintenance interval should be appropriately shortened.
Times to service
Items
Item
Odometer
Interval
1000km
3000km
6000km
9000km
Remarks
Fuel system
C
C
C
C
Item ※※ can only be
serviced and
maintained by
designated after-sales
service personnel.
When driving in an
extremely moisture or
highly dusty place, the
service and
maintenance interval
should be appropriately
shortened.
Fuel filter
C
C
C
C
Controller cable
A
A/C
A/C
A/C
Air filter element
C
C
C
C
Spark plug gap
A/C
A/C
A/C
A/C
※※
valve lash
A
A
A
A
Lubricating oil of engine
R
R
R
R
Lubricating oil filtering screen
C
C
C
C
※※
Timing chain
I
A
A
A
※※
Drive belt
-
A
R
R
Battery
B
B
B
B
Brake shoe
I
A
A
R
※※
Braking system
A
A
A
R
Braking light switch
A
A
A
A
Lighting system
I
I
I
I
※※
Clutch
I
I
I
I
※※
Shock absorber
I
I
A
A
Nuts and bolts
G
G
G
G
Tire casings for front and rear
wheels
I
I
I
I
Steering handgrip bearings
I
A
A
R
A-Adjustment C-Cleaning I-Inspection R-Replacement G-Tightening B-Battery Charging

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
19
Service and Maintenance Interval Table for Lubricated Parts
Name
Model
Odometer reading
Kilometers
1000
3000
6000
9000
12000
15000
18000
lubricating oil of engine
SAE 10W 40
-
R
R
R
R
R
R
R
Braking pull-rod
OKS-400(Multipurpose
lithium-based lubricating
grease)
-
-
R
R
R
R
R
R
Disc brake braking liquid
DOT3 or DOT4
-
R
-
Lubricating oil for front
shock absorber
Lubricating grease for
shock absorber
-
I
I
I
T
I
I
I
Tachometer gear
OKS-400(Multipurpose
lithium-based lubricating
grease)
-
I
R
I
R
I
Steering gear
OKS-400(Multipurpose
lithium-based lubricating
grease)
-
I
-
R
-
Bearings for front and rear
wheels
OKS-400(Multipurpose
lithium-based lubricating
grease)
-
I
R
I
R
R
Rear braking swing arm
OKS-400(Multipurpose
lithium-based lubricating
grease)
-
I
-
I
-
I-Inspection R-Replacement T-Addition

CHILL 125 cc. SERVICE MANUAL AND EFI DIAGNOSTIC
20
Common Failures and Troubleshooting
Fault system
Fault
Causes
Troubleshooting
Air intake/exhaust
system
The motorcycle is difficult to
be started or is short of
power.
The Air filter element is blocked;
Clean the air filter element
The air filter leaks;
Replace the air filter
The air filter has too much dust;
Clean the air filter element.
The air filter housing leaks;
Repair or change the air filter housing.
Too much carbon is built up at the exhaust port;
Clean the carbon buildup at the exhaust port.
The exhaust port leaks;
The exhaust port leaks.
The silencer is blocked.
The silencer is blocked.
Environmental
protection device
Emitted pollutants exceed
applicable standards
Too much carbon is built up at the secondary air intake
port.
Clean the carbon buildup at the secondary air intake port.
The air pump is blocked or damaged.
Replace the air pump.
The air pump filter is blocked or damaged.
Replace the air pump filter.
The intake rubber hose is aged or leaks.
Replace the intake rubber hose.
The clamp is loose or damaged.
Replace the clamp.
Ignition system
Weak spark or no spark
There is carbon buildup or dirt on the spark plug.
Clean the carbon buildup and dirt on the spark plug .
The spark plug gap is improper.
Adjust the gap to 0.6mm~0.7mm
The insulation part of the spark plug is damaged,
resulting in Short-circuit of electrodes.
Replace the spark plug
Short-circuit of the ignition coil
Replace the ignition coil
C.D.I igniter is faulty.
Replace C.D.I igniter.
The impulse generator is faulty.
Replace the impulse generator.
The connection of the ignition system is loose.
Check each connection.
Air distribution system
The engine is difficult to be
started up or the idling is not
stable
The sealing washer of the cylinder head leaks.
Replace the sealing washer or apply some sealant.
The adjustment of the valve lash is incorrect .
Adjust the valve lash to 0.10mm~0.14mm
The air valve stem bends.
Replace the air valve.
Th elasticity of the air valve spring is reduced.
Replace the air valve spring.