ZONGSHEN ZS125-86 User manual

ENGLISH
ZS125-86 Motorcycle Service Manual
First edition (April, 2017)
The copyright of this Motorcycle Service Manual is
owned by Zongshen Industrial Group. The content
and images in the Motorcycle Service Manual are
for reference only. Specifications are subject to the
physical product.

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The motorcycle service manual details the motorcycle’s basic structure, working principles,
disassembly and maintenance, fault diagnosis and exclusion, etc. At the same time, it has also introduced
the motorcycle’s technical specifications, performance parameters and maintenance and adjustment
data. The manual is informative, illustrated and practical. It is hoped that this manual can provide support
and guidance on the maintenance technology for the customers and aftersales staff.
The technical specifications, performance parameters and maintenance and adjustment data labeled in
the manual are based on the latest status. Our company’s subsequent improvements for the motorcycle
model will be done without notice. If there is any difference between the manual and the improved
product, please understand. We sincerely wish that you can tell us your ideas and suggestions about the
design, manufacture or quality of the motorcycle, so that we can make improvements in time. Thanks for
your support.
Althea information, figures, data and performance indexes shown in the manual were what they
were till the time the manual is printed. We have the authority to revise this manual without notice.
Please understand. Any part of this manual is copyrighted by Zongshen Industrial Group. No entities or
individuals shall be allowed to reproduce the manual without the permission of our company, otherwise,
investigations will be conducted for criminal liability according to law.
Taking the motorcycle model ZS125-86 as an example, the manual has detailed the disassembly,
assembly, maintenance, fault phenomena and maintenance methods of the motorcycle series. Due to the
limited level of the editor, there may be some faults or careless omissions in the manual. We are looking
forward to your criticism and corrections.
Chongqing Zongshen Automobile Industry Co., Ltd.
Address: Chaoyouchang, Ba’nan district, Chongqing
Customer Service Hotline: [phone]
For details, please click the website of our company: www.zongshenmotor.com
Foreword
Symbols given in this Motorcycle Service Manual have the following meanings:
Warning
Caution
Suggestion
It indicates a potential danger that may cause death or injury if any misoperation.
It indicates a potential danger that may cause damages to the motorcycle if any misoperation.
The most efficient service information is available for more simple maintenance and more
understandable instructions.

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Contents
Chapter 1 Overview ................................................................................................................... 1
Section 1 Overview of Complete Motorcycle .................................................................................... 1
Section 2 General Construction...................................................................................................... 2
Chapter 2 Knowledge about Maintenance..................................................................................... 4
Section 1 Cautions ....................................................................................................................... 4
Section 2 Common Sense of Maintenance ...................................................................................... 5
Chapter 3 Complete Motorcycle ................................................................................................ 11
Section 1 Fuel Supply System ..................................................................................................... 11
Section 2 Cooling System ........................................................................................................... 15
Section 3 EFI System.................................................................................................................. 17
Section 4 Air Intake and Exhaust System ...................................................................................... 19
Section 5 Evaporative System (EVAP) ........................................................................................... 23
Section 6 Rear Driveline.............................................................................................................. 25
Section 7 Frame and Accessory Mechanism .................................................................................. 29
Section 8 Steering Gear .............................................................................................................. 32
Section 9 Steel Wire Rope for Control .......................................................................................... 33
Section 10 Damper .................................................................................................................... 34
Section 11 Rear Fork.................................................................................................................. 38
Section 12 Wheels ......................................................................................................... 39
Section 13 Brake ....................................................................................................................... 44
Section 14 Instrument ................................................................................................................ 49
Chapter 4: Electrical Parts ....................................................................................................... 51
Section I Basic Knowledge .......................................................................................................... 51
Section 2 Power Supply .............................................................................................................. 52
Section 3 Control Part................................................................................................................. 56
Section 4 Power Consumption .................................................................................................... 60
Chapter 4 Motorcycle Fault Diagnostic Procedure ........................................................................ 63
Appendix: Electrical Schematic Diagram..................................................................................... 77

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[1] Front fender
[2] Front damper
[3] Steering mechanism
[4] Fuel tank
[5] Rear handrest
[6] Front wheel
[7] Front disc brake
[8] Gear shift pedal
[9] Side stand
[10] Rear wheel
[1] Tail lamp assembly
[2] Silencer
[3] Seat cushion
[4] Ignition lock
[5] Headlamp
[6] Rear disc brake
[7] Rear pedal
[8] Front pedal
[9] Rear brake pedal
Chapter 1 Overview
Section 1 Overview of Complete Motorcycle
Figure 1-1 LHS Elevation of ZS125-86 Complete Motorcycle
Figure 1-2 RHS Elevation of ZS125-86 Complete Motorcycle
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ZS125-86 motorcycles are a model applicable to run on highways developed by the Company. The
model is novel in appearance design and easy to operate. It applies a four-stroke ari-cooled engine with a
single cylinder, which renders an excellent cooling effect, strong power and good acceleration performance
and other advantages. The model has a tube-welded main frame, giving high strength and rigidity. The
brake system is configured with front and rear disc brakes, which enable stable, safe and reliable braking.
Nice and durable, wheels are made of aluminum alloy.

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Section 2 General Construction
The motorcycle is mainly composed of running system, steering and braking system, transmission
system, oil supply system, electrical system and engine, and other portions, as shown in Figure 1-3.
Figure 1-3 General Construction Chart of a Complete Motorcycle
[1] Running system
[2] Steering and braking system
[3] Transmission system
[4] Oil supply system
[5] Electrical system
[6] Engine
1. Running System
Basic functions of the running system include:
[1.]To make the motorcycle as a whole, and support the whole mass;
[2.]To accept the output torque from driveline, and to produce the traction to drive the motorcycle
through the adhesive action between drive wheels and road surface;
[3.]To bear and pass various external forces and the resulting torque effected by road surface on
wheels;
[4.]To absorb or mitigate the impact and vibration of the running motorcycle. The running system
mainly consists of main frame assembly, front and rear dampers and front and rear wheels and other
accessories.
2. Steering and braking system
The steering and braking system mainly functions to exert direct control on running direction, driving
running speed, braking, lighting and signals, etc., to ensure the safe driving of the motorcycle.
The steering and braking system consists mainly of steering devices, brake devices, and accessories
such as operating handle, control switch and mechanic’s wire connected to some devices.
3. Transmission System
Based on road conditions and driving needs, the transmission system transmits the torque increased or
rotated speed reduced by a certain ratio to drive wheels, so as to drive the motorcycle.
The transmission system consists mainly of a starter, clutch, gearshift and rear transmission device and
other accessories.
[1.]Starter
A motorcycle start device activates the motionless engine and enables it in operation. Motorcycle start
devices can be divided into treadle-type starter and electric starter.
[2.]Clutch
The clutch ensures reliable, gentle transmission or cut-off of output power from the engine, thus
the motorcycle can start running and shift gears in a balanced way. The clutch ensures reliable, gentle
transmission or cut-off of output power from the engine, thus the motorcycle can start running and shift
gears in a balanced way. The model adopts an automatic wet-type multi-plate clutch.
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[3.]Gearshift
The gearshift changes the rotate speed and drive torque of the motorcycle transmission system and
ensures that the motorcycle has the appropriate traction and speed so as to adapt to regularly changing
driving conditions.
[4.]Rear Transmission Device
The rear transmission device transmits the power from the engine to rear whey further reducing the
rotate speed and increasing the torque, so as to drive the motorcycle. The rear transmission device of this
model adopts a chain drive.
4. Oil Supply System
The oil supply system regularly and quantitatively feeds a mixed gas prepared with clean gasoline
and air in proper proportion, according to different working conditions of the engine, into the combustion
chamber for combustion. The oil supply system mainly includes a fuel tank, fuel pump, fuel injector, fuel
filter and oil tube.
5. Electrical System
The electrical system provides electric energy to start and run the vehicle and emits a variety of
acoustic-optical signals to ensure safe and reliable driving. The electrical system generally includes a power
supply portion, an electricity consumption portion and a control portion.
[1.]Power Supply Portion
The power supply portion consists mainly of a generator (magneto) and a storage battery and other
components. When the engine drives the generator to reach a certain rotate speed, the generator outputs
electric energy. In addition that it supplies to electricity consumption equipment, it also charges the storage
battery. And the storage battery converts the stored chemical energy into electrical energy for consumption
by start devices, lamps and signal equipment.
[2.]Electricity Consumption Portion
The electricity consumption portion provides a variety of acoustic-optical signals to guarantee traffic
safety, while it also easily and rapidly starts the engine. The electricity consumption portion mainly
includes lamps, a signaler, and a electric starter.
[3.]Control Portion
The control portion guarantees and coordinates the normal operation of the power supply portion and
the electricity consumption portion. The control portion is mainly composed of a regulator, a rectifier, a
starting relay, a fuse protector (protective tube), a control switch and a main wire harness.
6. Engine
As the power source of the motorcycle, the engine is a power unit that makes the fuel burn in the
cylinder and converts the heat energy into mechanical energy. The overall structure of the engine consists
of a cylinder head, cylinder block, crankcase, piston group, crankshaft connecting rod group, valve train,
lubrication system, ignition system, cooling system and so on.

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Chapter 2 Knowledge about Maintenance
Section 1 Cautions
Subject to a breakdown, the motorcycle should be sent to an after-sales service station of the Company
or a professional motorcycle repair point. Besides, this Service Manual can be referred to for maintenance.
As the process of driving may cause components to be loosened and abraded to different degrees, without
proper maintenance, the motorcycle may be subject to decrease in power performance, economical
efficiency, reliability and security and also a shortened life. Therefore, proper maintenance can eliminate
breakdowns in a timely manner, extend the service life of motorcycle and reduce maintenance costs, for
purpose of driving safety.
[1.]For the maintenance of the motorcycle, please use original parts, accessories, lubricants and other
auxiliary materials manufactured or recommended by the Company. Use of parts that are not recognized
or recommended by the Company will affect the power performance, reliability, stability and comfort of the
motorcycle, and may further damage it.
[2.]For a reassembly after a disassembly, it is necessary to install a new washer, a sealing member and
a cotter pin, if applicable.
[3.]Bolts or nuts should be fastened in an order of diagonal cross, and gradually tightened 2 to 3 times
to reach a standard torque value as required.
[4.]To clean parts, the use of flammable cleaning solution is not allowed. Before assembly, the surface
of parts shall be wiped with lubricating oil or grease.
[5.]After assembly, check whether the parts are installed correctly by way of rotation, move, operation,
inspection, etc.
[6.]The dismantling of the motorcycle shall adopt special maintenance tools and commonly used
maintenance tools as provided.
[7.]The motorcycle shouldn’t be repaired until the flameout. In the case of maintenance with the
engine in operation, it must be conducted in a well ventilated site, as the waste gas exhausted from the
motorcycle contains toxic carbon monoxides (CO).
[8.]As gasoline is flammable and explosive, it is prohibited to smoke, ignite or shoot off fireworks in the
maintenance site.
[9.]The battery electrolyte contains sulfuric acid. Eyes, skins, and clothes, etc. accidentally splashed
with electrolyte can be rinsed by clean water thoroughly. In a severe case, please immediately seek
medical advice.
[10.]The storage battery will release hydrogen, which is flammable and explosive, so it is prohibited
to smoke, ignite or shoot off fireworks in the vicinity of the storage battery, especially when it is being
charged.

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Section 2 Common Sense of Maintenance
1. Maintenance Classification
According to the broadness of working range and the length of interval time, maintenance work can be
divided into overhaul (heavy repair), medium repair, minor repair and unit repair.
[1.]An overhaul is a thorough comprehensive repair towards the motorcycle, requiring a complete
disassembly, cleaning, inspection, repair or replacement of parts, and assembly and debugging. An
overhaul restores the original performance indicators such as motorcycle power performance, economical
efficiency, reliability and security.
[2.]A medium repair is to mend and adjust the position that affects the usability. A medium repair can
eliminate hidden dangers, to avoid the development of a failure and to maintain a good operating state.
[3.]A minor repair is maintenance of maneuverability, mainly to eliminate temporary faults and local
damages in the operation process.
[4.]A unit repair is adopted to take a separate repair to an assembly due to the damage, abrasion,
deformation, etc. of a certain assembly or a component that affects the usability of the complete motorcycle
2. Repair Process
1)Decomposing the Motorcycle
A decomposition can also be called a disintegration or a disassembly. It is an important link of repair
operations. The correctness of the decomposition method directly affects the quality and efficiency of repair
operations. An improper decomposition may cause parts to be damaged or stuck. It not only expands the
range of repair operations, but also delays the repair period, or even causes a pause to the decomposition.
The basic principle of a decomposition: to disassemble parts in an order and direction inverse to the
assembly, that is, firstly to disassemble those parts that have been assembled latter and then those parts
assembled earlier. In general, it can be conducted in the order from outside to inside, from upside to
downside, and from big to small. In particular, pay Caution to parts storage environment and ordering to
prevent from damages or confusion.
Decomposition order and method is not absolute. According to different models, decomposition
procedures and methods can be different. Refer to the subsequent methods given in respect of demolition,
installation and maintenance.
The engine assembly and other part assemblies are decomposed by the basic principles same to the
decomposition of a complete motorcycle. Due to differences of different part assemblies in structural style
and characteristics, the decomposition procedures and methods are also different. Meanwhile, as a part
assembly is decomposed into scattered parts, so it requires more in respect of storage environment and
ordering.
The following points should be noted in regard to the decomposition of a complete motorcycle and its
part assemblies:
[1.]For a part that expects much in locational fit, fit marks should be checked when the part is being
disassembled. If marks are not clear, it should be re-marked.
[2.]A part with a interference fit should be disassembled by use of special tools. Without special tools,
you can first cushion the part with a wooden or soft metal ware, and then ram it in the right direction and
position with a rubber hammer in the way that prevents the part from damages.
[3.]Front and rear dampers and wheels and other assemblies shall be decomposed when the main
frame is firmly supported, so as to prevent the main frame and parts from being overturned and damaged.
[4.]Decomposed parts should be placed in order of demolition. Painted parts, chromium-plated parts
and high-precision parts should not be directly put on the ground.
[5.]Removed nuts and bolts should be carefully stored, or be equipped to original positions without
being tightened.
[6.]Parts necessary to be removed by use of special tools should be carefully operated. Note the force
evenly exerted and proper direction.
[7.]Parts and components should be decomposed by use of proper tools and attaching importance to
the size and direction of force, so as to avoid damages to parts.
[8.]Removed brake shoes should be placed separately, and are strictly prohibited to contact with
lubricating oil, otherwise it will lead to a brake failure.
[9.]In case of any difficulty in decomposition due to the corrosion of screw elements, soaking the parts

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in gasoline for a few minutes can make the decomposition easier.
[10.]Washers and gaskets shall be decomposed meticulously in ways to prevent from damages.
2)Cleaning the Parts
Parts having been removed are mostly stained with greasy dirt or carbon deposits. Cleaning such
parts favors the maintenance and fitting. Gasoline, kerosene and cleaning fluid are optional. The cleaning
method is determined according to the characteristics of the part to be cleaned.
[1.]Cleaning greasy dirt
Metal parts can be cleaned by way of cold wash and hot wash. Put the parts are in gasoline or
kerosene as the cleaning agent and scrub with a brush. This is called the cold wash method. In respect
of hot wash method, put parts in alkaline solution as a cleaning agent, heat it to 79℃~ 90℃, and then
soak for 10min ~ 15min. After that, take out the parts and rinse.
Nonmetal parts should be cleaned in different methods based on the different materials. Rubber parts
should be cleaned by use of alcohol, and it is strictly prohibited to use kerosene or gasoline, lest the rubber
would swell and go bad. However, the clutch and brake shoes shall be scrubbed with gasoline, instead of
alkaline solution.
[2.]Removing carbon deposits
Carbon deposits on machine elements can be removed in the mechanical method or chemical method.
As for the mechanical method, a bamboo scraper or blade is first applied to remove carbon deposits, and
then purify the element with gasoline; as to the chemical method, a hairbrush is used to remove carbon
deposits after the element has been soaked in a cleaning solution and finally wash it with hot water.
3)Detecting the Parts
Cleaned parts should be rendered for appropriate detection operations. The purpose of detection is
to determine whether a part needs to be repaired or discarded. Parts detection methods include direct
inspection, measurement and probing.
[1.]Direct inspection
Instruments and other tools are not necessary in a direct inspection, which relies solely on the human
sensory organs to test and determine the technical status of parts. Simple and easy to practice, this
method is widely used in maintenance.
[2.]Measurement
The measurement method is to measure dimensions and geometrical shapes of parts with gauges and
instruments and compare the obtained data with the allowable limits to determine the technical condition
of parts. By this method, results are highly accurate, but the precision of measuring instruments and tools
must be carefully checked before the detection, and components to be measured should be reasonably
chosen.
[3.]Probing
Concealed defects on parts can be detection by way of probing. The simplest immersion-based
hammering method is generally applied in the maintenance. In this method, a part to be detected is
firstly immersed into kerosene or diesel for a few minutes. Take it out and dry the surface. Spread talcum
powder evenly on the surface of the part, and then tap gently the part on a non-working surface with a
small hammer. As the hammering will cause a vibration of the part, if the part has a crack, the oil left in
the crack when the part is immersed will be spilled out due to the vibration and make the talcum powder
yellow-colored on the surface, so that a yellow line emerges on the crack.
4)Maintenance Methods and Skills
In the maintenance process, it comes to main maintenance stage after decomposition, cleaning and
detection, etc. Mastering the basic maintenance skills is the key to ensure the quality of maintenance.
Machine elements are generally maintained in the following methods:
[1.]Chiseling, filing, and scraping
Chiseling is a method applied to process metal parts by means of knocking on a chisel with a hammer.
It functions to cut and split. Filing is a method applied to process metal parts by rasping off a layer of metal
on the surface of a machine element with a file. Filing includes coarse filing and fine filing.
The roughness of the surface of the filed machine element mainly depends on the thickness of file
teeth. The cross-sectional shape of the file and the filing movement are determined by the surface shape
required by the machine element. Scraping is a method applied to process metal parts by razing a layer of
metal on the surface of a machine element with a scraper.
As the scraping is a precision work, so scrapping allowance should not be too large, generally about
0.005 ~ 0.01 mm every time. Before scraping, the surface of the machine element should be coated with

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a layer of red lead, and the machine element should be ground to match a plate, standard part or finished
part. The resulted high points are the objects to be scraped. After repeated grinding and scraping, high
points and sub-high points are gradually scraped, so that the scraped element has increased contact points
on the surface to form the required shape and achieve the fine fit.
[2.]Grinding
Grinding is to raze a thin metal layer from the surface of a machine element by use of grinding tools,
so that the surface has a precise size, accurate geometry and very low surface roughness. This is the most
finish machining method adopted to process the surface of a machine element. It can be divided into face
grinding, bore grinding and cylindrical grinding. The face grinding adopts a plate as grinding tool, while
the bore grinding adopts a grinding rod. In the maintenance process, grinding methods are often applied to
process crankcase planes and inner bores in connecting rod reducers.
[3.]Riveting and jointing
Riveting is to connect two or more machine elements together by use of rivets. The method of riveting
is widely used in the maintenance process, such as the riveting of the clutch sheet and the riveting of
various assembling units. According to its application, riveting can be divided into fixed riveting, movable
riveting and stitched riveting.
Jointing is to joint two metal faces firmly together by use of soldering tools and soldering flux. It is
widely used in the maintenance process.
Such as the recovery of cracks on solder joints of the main frame and other parts.
[4.]Drilling and reaming
Drilling is a method to process holes in a machine element or material with a drill bit.
The main drilling equipment and tools are radial drilling machines, bench drills, electric hand drills,
twist gimlets and fixtures. The purpose of reaming is to improve the accuracy of holes on a machine
element and reduce the surface roughness of holes, and reamers are used for hole finish machining.
Reaming can improve the accuracy of fit between a hole and a shaft up to Level 6 to Level 8. The main
reaming tools are reamers. Commonly used reamers include fixed hand reamers, adjustable reamers and
conical hand reamers, etc. A basic hole must be drilled before reaming. Drilling a basic hole is to leave a
proper processing allowance for the reaming process according to the accuracy requirements of a formed
hole required for a machine element.
[5.]Thread tapping and thread die cutting
Thread tapping is to process internal threads with screw taps, while thread die cutting is to ream
external threads with threading dies. Screw taps are the main tool for thread tapping. A set of hand screw
taps is usually composed of two pieces (head tap and second-tap). The two taps are different in the angle
of the cutting part: the head tap is smaller and the second-tap is bigger in angle. A chamfered basic hole
must be drilled before thread tapping. The diameter of the drill bit used for drilling the basic hole can be
referred to a specific table or calculated by the following formula:
Drilling diameter = thread external diameter -1.1mm ×pitch (applicable to pig iron, bronze, etc.).
Drilling diameter = thread external diameter -1.2mm ×pitch (applicable to steel, brass, etc.)
When tapping, the head tap is tapped along the chamfered basic hole, and retreats after the tapping.
Then tap with a second-tap to shape the thread.
Threading dies are the main tool for thread die cutting. Threading dies are classified into fixed,
adjustable and movable types. Fixed dies are commonly used, that is, circular dies. For the thread die
cutting, threading dies and bars in corresponding diameters should be selected based on the required
materials, thread diameters and pitches. Dimension relations can be found in a special table or calculated
by the following formula:
Bar diameter = thread external diameter -0.13mm ×pitch
Before the thread die cutting, an end of the bar need to be chamfered (15°~ 20°). The minimum
diameter at the cone angle should be less than the internal diameter of the thread so that the die and bar
is vertical, and facilitate aligned cutting.
[6.]Correction
Corrections intend to eliminate unevenness defects on plates, bars or cylindrical machine elements.
Corrections enable plastic deformation of machine elements. Therefore, only metal parts of high plasticity
(such as low carbon steel, red copper, etc.) can be directly corrected. Metal parts with higher carbon
content can be corrected after being annealed. Correction methods include twisting method, stretching
method, bending method and extending method.
[7.]Bonding

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Bonding technology is a simple process and requires no special equipment and precious materials.
Bonded parts demand no high-precision machining. Due to these advantages, bonding technology is
widely used in the manufacture and maintenance process, such as the adhesion of the handlebar and the
steering bar, the plastic sign and painted metal parts, the brake pad and the brake shoe, etc. There are
many types of bonders, commonly used in epoxy resin and phenolic resin.
5)Assembling the Motorcycle
The last process of maintenance is assembly, which is the key to ensure that the vehicle achieves
various technical indicators.
[1.]Assembly is divided into minor assembly, sub-assembly and general assembly. In the assembly
processes, the minor assembly goes first, and then sub-assembly and lastly the general assembly. The
order of assembly is exactly opposite to the order of disassembly. That means to assemble those parts that
have been disassembled earlier, and then those parts disassembled earlier later.
[2.]The minor assembly is an early working procedure of the entire assembly process. In this
procedure, a number of related parts are connected to form a separate structural unit. Such as the brake
drum cover combination on the front wheel, brake shoe combination, and wheel rim combination, etc.
[3.]The sub-assembly is based on the minor assembly. In this procedure, all components and parts
belonging to a structural unit (an assembly) are assembled to form a separate integral structure. Such as
the front wheel assembly and rear wheel assembly, front fork assembly, and damper assembly, etc.
[4.]In a general assembly, all parts, components, units and structures are installed in proper order on
the main frame through a variety of connections so as to form a complete set.
[5.]Generally, order of operation of assembly is basically identical. The operation steps are as follows:
complete all minor assemblies firstly and then the sub-assemblies, and install the engine assembly and
gearbox assembly on the main frame; and then the following assemblies are installed in the following
order: front fork assembly, handlebar assembly, front and rear fender assembly, damper assembly, storage
rack assembly, front and rear wheel assemblies, fuel tank assembly, saddle assembly, etc; on this basis,
install the headlamp, tail lamp, sidelight, klaxon and storage battery assembly; connect all the electrical
circuits and control cables; install the transmission chains or toothed belts, various wind shields and chain
covers or belt covers, etc; finally, lubricate the entire vehicle assembled.
[6.]Because of different types and structures, the assembly sequences are also different. It may refer to
the demolition, installation and inspection procedures below.
[7.]The following points should be noted in assembly processes: choose a clean wide site; strictly
follow the assembly process requirement in the installation order; connections among parts shall meet the
requirements,
so as to prevent all kinds of washers, cotter pins and anti-loose lock plates from being mal-assembled
or missing.
3. Debugging After Maintenance
After maintenance, the interrelationship among the parts and components are affected to a certain
extent. In order to restore its performance indicators, adjustments must be made properly as provided in
this Service Manual, so that the interrelationship among the parts meets the working requirements. The
following items are to be adjusted:
1)Adjusting the duration of ignition
Improper engine ignition advance angle will cause difficulty in starting, power coastdown, fuel
consumption increase, engine overheating, incomplete combustion, excessive emission, lower service life
and so on. Therefore the ignition advance angle must be adjusted firstly.
If the ignition system is abnormal, check the electronic igniter, high voltage coil, the ignition coil on
magneto, trigger coil and other components.
2)Adjusting the Clutch
The clutch is a key component of transmission system to transmit power, must be adjusted based on
the maintenance requirements provided later. To adjust the clutch is mainly to adjust the free stroke of
control grip on the clutch (usually 10 mm ~ 20 mm), and for some vehicles, also to adjust the adjusting
screws on the detatching mechanism.
3)Adjusting the Brake
Braking performance is closely related to the driving safety, and thus the correct adjustment of the
brake is essential. To adjust the brake is mainly to adjust the free stroke of front braking grip (usually
10 mm ~ 20 mm) and the free stroke of rear brake pedal (usually 20 mm ~ 30 mm). The adjustment
methods are basically the same, and may be implemented according to the maintenance requirements

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Limit Value (mm)
20～30
30～40
10～12
2.0
0.8
0.8
0.8
0.8
Table 2-1: Steering/Brake/Damper/Wheel Maintenance and Adjustment
Items
Free stroke of front braking grip
Free stroke of rear brake pedal
Free stroke of fuel charging handle
Tire tread pattern depth
Front damper stroke
Free length of front damper spring
Rear damper stroke
Free length of rear damper spring
Wheel hub runouts
Wheel axle runouts
Standard Value (mm)
Axial runout
Radial runout
Front
Rear
10～20
20～30
2～6
4.0
120
375
40
210
Section 3 Data Adjusting for Maintenance
provided later.
4)Adjusting the Electrical Installations
The adjustment items of electrical equipment are mainly the headlamp and klaxon.
[1.]To adjust the headlamp is to adjust the light irradiation distance by moving up and down the
headlamp mounting position.
[2.]To adjust the klaxon is to adjust the volume and tone. Generally, the volume of a motorcycle klaxon
is set to (95 ~ 105) dB; the volume, whether big or small, and the tone, whether too thick or too thin,
can be adjusted through the adjusting screw on the back.
5)Adjusting the Throttle Line
The throttle twist grip should maintain a free stroke of 2mm ~ 6mm, in which process, the engine
should not be subject to speed increase and speed loss. The free stroke, whether too big or too small, shall
be adjusted. This adjustment item is generally coordinated with the idle-speed adjustment.

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Table 2-2: Maintenance Periodic Table
Motorcycles should be repaired as specified above. The symbols in the above table have the following
meanings:
R-Rinse, A- Adjustment, L-Lubrication, I- Inspection
●These maintenance items shall be serviced by our after-sales service personnel. Please refer to this
manual if any self-maintenance.
●●The Company suggests that these items be serviced by our after-sales service personnel, to ensure
driving safety.
Maintenance
frequency
Fuel system
Fuel filter
Control system
Choke cable
Air cleaner filter element
Spark plug gap
Valve lash
Transmission chain
Storage battery
Brake shoe abrasion
Braking system
Brake lamp switch
Headlamp dimming
Main side stand
Front and rear dampers
Nut/bolt/fastener
Front and rear tyre covers
Steering mechanism bearing
Odometer km
1000km 4000km 8000km 12000km
A
I
I
A/R
I
I
I/L
I
I
I
I
I
I
I
I
I
I
I
R/I
I
I
R
I
I
I/L
I
I
I
I
I
I
I
I
I
I
I
R/I
I
I
R
I
I
I/L
I
I
I
I
I
I
I
I
I
I
I
R/I
I
I
R
I
I
I/L
I
I
I
I
I
I
I
I
I
I
If a motorcycle is driven in dusty areas, it is appropriate to shorten the maintenance cycle.
Caution
67~75
8~12
85~95
85~95
28~32
85~95
28~32
65~75
85~95
85~95
Table 2-3: Tightening Torque Table
Motorcycle
M24×1
M6×20
M14×1.5
M14×1.5
M8×16
M12×1.25
M8
M10×1.25
M14×1.5
M14×1.5
Stand pipe lock nut
Handlebar tube fixed bolt
Front wheel axle nut
Rear wheel axle nut
Engine suspension bolt
Rear damper fixed nut
Chain wheel fitting nut
Rear rockshaft nut
Fork shaft nut
Fork shaft nut
Items Specifications Torque Value (N.m)
●
●
●
●
●●
●
●
●
●●
●●

11
ENGLISH
Chapter 3 Complete Motorcycle
Section 1 Fuel Supply System
The oil supply system includes a fuel tank, fuel pump, fuel injector, fuel filter and oil tube.
1. Structure and Working Principles of Fuel System
[1.]Fuel tank
The fuel tank is usually made of a 0.8mm ~ 1.0mm thick steel plate processed through stamping
and jointing. Some tanks have division plate with holes inside, which not only improves the tank
strength, but also prevents fuel from surging when the vehicle is driving. As the gasoline is strongly
corrosive, the internal tank surface should be galvanized or otherwise as an anti-corrosion treatment.
The top of the tank is equipped with a fuel filler and is covered with a fuel tank cap with a vent hole.
This prevents the fuel from overflowing when the motorcycle is driving and also maintains the balance
between the internal and external air pressure, so that the fuel can flow out naturally.
[2.]Fuel pump
The fuel pump assembly is composed of an oil pump, a bracket and an oil pressure regulator. The
elastic installation method can reduce the direct impact of vibration on the fuel pump. The fuel pump
installed in the fuel tank can make the oil supply system simple and hinder the fuel leakage.
The fuel pump is a turbine single-stage electric fuel pump, driven by a 12-volt DC motor and
controlled by ECU through the fuel pump relay. The pump outlet is designed with a one-way valve, so
that the stored oil in the tube will not retreat to the fuel tank when the engine does not work, to ensure
re-start performance.
[3.]Fuel injector
The fuel injector timely and exactly injects moderate atomized fuel into the engine intake pipe, and
then the atomized fuel is further sucked into the cylinder for combustion.
[4.]Fuel filter The fuel filter is connected in series on a
channel for oiling between the electric fuel pump
and the fuel guide rail. To ensure the filtering
effect and prevent the nozzle from being blocked
due to remains, it is necessary to adopt a fuel
filter specially used for electronic injection. The
enclosure of a filter must be of sufficient strength
to avoid breaking due to fuel pressure.
[5.]Fuel pipe
The fuel supply pressure of the system is
250kPa. For safety reasons, the selected fuel pipe
must have sufficient insurance factor.

12
ENGLISH
[1] The motorcycle fuel tank capacity: 20L.
The fuel must be filled in well ventilated and
circulated venues away from the sparks and
flames.
As the fuel is flammable, smoking and open fire
are strictly prohibited.
The motorcycle should be shut down and fueled
in a ventilated area.
Warning
Warning
Fuel cap
2. Demolition and Maintenance of Fuel System
The fuel should be ≥ 90 # gasoline, and other
fuels are prohibited.
[2] If the fuel tank cap is subject to fuel
penetration, install a new gasket on the fuel tank
cap.
[4] Check if the fuel pipe is subject to fuel
penetration or aging phenomenon, and check if the
fuel filter is blocked. A blocked fuel filter must be
cleaned or replaced.
[3] Check if the fuel tank is subject to fuel
penetration. if the oil leakage occurs, the fuel tank
must be restored or replaced.
If the fuel tank is deformed due to an external
force, for example a pit occurs, a wooden hammer
may be used to knock the pit. If the fuel tank
cracks, it is best not to repair, but to replace the
fuel tank.
A penetrated or aged fuel tube must be replaced.
To replace the fuel tube or fuel filter, the ignition switch
must be turned off to stop the fuel pump and prevent the
fuel from flowing out of the tank.
Caution
Caution
Check the fuel filter
Open the fuel tank
Check the fuel tan

13
ENGLISH
[5] Firstly, remove the LHS and RHS side covers
and seat cushion. Then loosen fixed bolts on the
fuel tank and take out the fuel tank.
To let out the fuel, the location must be kept away
from fire sources.
Warning
[8] Check the fuel pump gasket for aging or crack
as well as for fuel penetration. In case of any of
these found, install a new fuel pump gasket.
[7] Take out the fuel pump. Wash away the oil
residues and moisture in the fuel tank with a
cleaning agent.
[6] Apply an allen wrench to release six M4×12
fixed bolts on the fuel pump.
Let out the fuel firstly before detaching the fuel
pump, and the location must be kept away from
fire sources.
Place and dry the cleaned fuel tank in a well
ventilated place before you can use it.
Caution
Check gasket
Detach the fuel tank
Remove fuel pump
Warning
Take the fuel pump

14
ENGLISH
[9] Check if the fuel pump motor rotates and clean
or replace the fuel filter screen.
For a motorcycle that has driven for 8000 ~
10000 Km, a new fuel filter should be installed.
Suggestion
3. Refer to Table 4-1 in respect of damage forms, fault phenomena and common
maintenance methods of the fuel system:
Table 4-1: Maintenance of Fuel Supply System
Component Name Damage Form Component Fault
Phenomenon
Motorcycle Fault
Phenomenon
Maintenance
Method
Fuel tank
The tank is rusted
with broken holes. The fuel tank leaks. -------------- Repair or place the tank.
The vent hole is
blocked.
Fuel is supplied
improperly.
The motorcycle fails
to start.
Unclog the vent
hole.
The fuel tank is
deformed.
The fuel tank
becomes uneven.
The motorcycle
looks not good.
Repair or place the
tank.
Fuel pump
The oil-filter screen
is too dirty or
clogged.
Fuel is supplied
improperly.
The motorcycle
has difficult in
starting or fails to
start, the engine is
under powered, the
engine idling is of
instability
Clean the fuel filter
screen
The chamber of fuel
pump is clogged.
Fuel is supplied
improperly.
The motorcycle fails
to start.
Clean or replace the
fuel pump.
The fuel pump
motor does not
rotate.
Oil supply fails. The motorcycle fails
to start.
Replace the fuel
pump motor.
The oil pressure
regulator is clogged.
The fuel fails to
retreat.
The oil conduit
blows out.
Clean or replace the
fuel pump.
The oil pressure
regulator is always
open.
The fuel is supplied
at low pressure.
The motorcycle
has difficult in
starting or fails to
start, the engine is
under powered, the
engine idling is of
instability.
Check fuel pump