ZONGSHEN ZS250GY-3 User manual

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ZS250GY-3 (EFI)MOTOCYCLE
SERVICE MANUAL
The first edition(Dec.2017)
Zongshen industrial group reserves all rights of this
service manual.
The specifications and pictures in this manual are
only for reference.

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Statement in this manual preceded by the following words are of special significance:
WARNING
CAUTION
ADVICE
Indicates a potential hazardous situation, which if not avoid, may cause people hurt or death.
Indicates a potential hazardous situation, which if not avoid, may damage your bike.
Indicates special information to make maintenance easier or instructions clearer.
Editor Dec. 2017
INTRODUCTIONS
The manual intruduces the structure,woking principle, disassembly and inspection, fault diagnosis and
elimination. Also, this includes technical specifications,performance parameter and maintenance data.
With both the descriptions and pictures, you may have a comprehensive understanding of the configuration
as well as the service and repair skill.We hope it can bring technical support and guide to all the users and
after service staffs.
Technical specifications, performance parameter and maintenance data mentioned in manual are
base upon the latest design features of your motorcycle. Chongqing Zongshen Automobile Industry
Co.Ltd. reserves the right to make changes to the specifications of its vehicles without notification. We
sincerely hope you can give us your suggestions about the design,manufacture and quality of this type of
motorcycle,so that we can do the improvement in time.Thank you for your support and co-operation.
All the specifications,diagram, data and performance index in this manual end in the print of this
book. Our companyreserves the right to change the book without any notification.All rights are reserved by
Zongshen.Any people or companies won’t copy it if there is no permission.Otherwise,we will go behind the
criminal and legal responsiblity.
In this book we take ZS250GY-3 for example to explain the detail of the disassembly,installation,insp
ection and troubleshooting of this series models.Due to our limited knowledge, it is very possible to have
mistakes or omissions in this book.And we welcome your comments.
Chongqing zongshen automobile industry co., Ltd.
Address: chaoyouchang,banan district,chongqing,china.
Service hotline:[phone]
For more information, visit our website www:zongshenmotor.Com

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CATALOGUE
Introduction
Catalogue
Chapter 1 General Information .................................................................................................. 1
Section 1 Vehicle Introduction.................................................................................................... 1
Section 2 Structure ................................................................................................................... 2
Chapter 2 Maintenance Knowledge............................................................................................ 4
Section 1 Attention Items Of Maintenance .................................................................................. 4
Section 2 General Knowledge Of Maintenance ........................................................................... 4
Section 3 Adjusting Data Of Maintenance................................................................................... 8
Chapter 3 Vehicle .................................................................................................................. 10
Section 1 Fuel Supply System ................................................................................................. 10
Section 2 Efi System .............................................................................................................. 14
Section 3 Intake And Exhaust System ..................................................................................... 16
Section 4 Rear TransMission Device........................................................................................ 20
Section 5 Frame And Accessories .......................................................................................... 24
Section 6 Steering System .................................................................................................... 27
Section 7 Control Steel Cable .................................................................................................. 28
Section 8 Shock Absorber ...................................................................................................... 29
Section 9 Rear Fork ............................................................................................................ 33
Section 10 Wheel ................................................................................................................. 34
Section 11 Brake ................................................................................................................... 39
Section 12 Meter .................................................................................................................. 45
Chapter 4 Electrical .............................................................................................................. 47
Section 1 Basic Knowledge ..................................................................................................... 47
Section 2 Power Supply ......................................................................................................... 48
Section 3 Control Part .......................................................................................................... 51
Section 4 Power Consumption Part ......................................................................................... 54
Chapter 5 Troubleshooting ..................................................................................................... 57
Appendix：Circuit Diagram ..................................................................................................... 71

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1
[1]Front fender
[2]Front shock absorber
[3]Steering
[4]Fuel tank
[5]Rear armrest
[6]Front wheel
[7]Front brake
[8]Gearshift pedal
[9]Side stand
[10]Rear wheel
[1]Taillight assembly
[2]Muffler
[3]Seat
[4]Ignition lock
[5]Headlight
[6]Rear brake
[7]Rear pedal
[8]Front pedal
[9]rear brake pedal
Chapter 1 General Information
Section 1 Vehicle Introduction
ZS250GY-3 is designed for use on road With futuramic appearance and easy operation. It adopt single
cylinder,4-stroke,water cooling engine. This type of engine has the advantages of good cooling,powerful
and good acceleration.The frame is pipe joint which has high tensity and good rigidity.The brake system
adopts the combination of front and rear disc so that it could ensure the stabilization and safety.And rim
type wheel has good appearance and function of anti-abrasion.
1-1 left view of motorcycle
1-2 right view of motorcycle
10
10
5
5
9
9
8
8
4
4
3
3
1
1
2
2
7
7
6
6

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2
[1]Riding system
[2]Operation and brake system
[3]Transmission system
[4]Fuel supply system
[5]Electrical system
[6]Engine
1 Riding System
The basic function of riding system:
[1]Make motorcycle in a whole and support whole motorcycle.
[2]Receive the torque from transmission setup.Provide traction for motorcycle running through the
contact of wheel and road.
[3]Endure and transmit road function and endure torque made by the outside force of wheel.
[4]Absorb and handle the strike and shake produced during motorcycle running.
Riding system mainly contains frame assembly,front/rear shock absorber,front/rear wheel and some
other accesories.
2 Operation and Brake System
The main function of operation system is to control running direction,running speed,brake,illumination
and signals,and to ensure motorcycle running safety.
The operation and brake system mainly consists of steering setup,brake setup and some relative
controlling handlebar,controlling switch,steel cable and accessories.
3 Transmission System
The basic function of transmission system is to augment torque or reduce transmission speed according
to the road condition and running need,After that,to transmit the result to drive wheel and to make
motorcycle run.
Transmission system mainly consists of starting device,clutch,gearshift and accessories of rear
transmission device.
[1]Starting Device
The function of starting device is to start engine and to make engine automatic running.The starting
device of motorcycle is divided into two modes.One is kick starting,and the other is electric starting.
[2]Clutch
The function of clutch is to transmit or cut off the power from engine reliably and softly,and to ensure
motorcycle抯stable start and gearshift.The clutch of this motorcycle adopts automatic,wet and multiple.
[3]Gearshift
The function of gearshift is to change the rev and drive torque of motorcycle transmission and to ensure
Section 2 Structure
This motorcycle mainly consists of riding system,operation system,brake system,transmission system,fuel
supply system,electrical system and engine.Refer to Diagram 1-3.
Diagram 1-3 structure
1
2
3
4
5
6

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3
proper pull and speed of motorcycle,so that it can adapt the changable running condition.The gearshift of
this motorcycle adopts gradational gearshift.
[4]Rear transmission device
The function of rear transmission device is to transmit the engine power to transmission device,so that
the rev is reduced and the torque is augmented.Then transmit the power to rear wheel to drive motorcycle
run.The transmission of this motorcycle is chain transmission.
[5]Intake and Exhaust System
The function of inlet system is to guide and filtrate air,to control the volume of mixed gas flowing into
cylinder according to the needs of working condition.It mainly consists of inlet pipe and air cleaner.
The function of exhaust system is to vent the exhaust gas in cylinder and to reduce the noise during
exhausting.It mainly consists of exhaust pipe and muffler.
4 Fuel Supply System
The function of fuel-supplying system is to confect clean gas and air into mixed gas with proper
proportion according to the working condition of engine,and to offer the mixed gas timely and
quantificationally to burning chamber to keep burning.
The fuel supply system mainly consists of fuel tank,fuel pump,fuel injector,fuel filter and fuel pipe.
5 Electrical System
The function of electrical system is to offer electric power to the starting and running of motorcycle,and
to send sound or light signals so that the running safety can be ensured.The electrical system mainly
contains the part of electric power supply,electric power consumption and electric power control.
[1]Electric Supply
The part of electric supply mainly consists of generator and battery.When generator reaches a certain
rev driven by engine,generator will export eletric power,which not only offers the power to electric
setup,but also to the battery so that it can be charged. The battery can transfer chemical power to electric
power,which can support starting,illumination and signal setup.
[2]Electric Consumption
The function of electric consumption part is to offer several kinds of sound or light signals to ensure
running safety,meanwhile it can start engine conveniently and fast.It mainly consists of illuminating signal
device and electric starter device.
[3]Control Part
The function of control part is to ensure and adjust electric supply and electric consumption.It mainly
consists of ECU,rectifier,starter relay,fuse，control switch and main wire.
6 Engine
Engine is a device,which is to make fuel burn in the cylinder and to transfer heat to mechanical power.
it is the power producer of motocycle.(The maintenance of engine please refer to the engine service
manual)

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4
Section 2 General knowledge of Maintenance
Section 1 Attention Items of Maintenance
1 Classification of Maintenance
Maintenance can be divided into 4 parts according to the range and interval period.4 parts contains
major repair,medium repair ,minor repair and assembly repair.
[1]Major repair is a thorough repair,which needs to make motorcycle completely disassembled,clea
ned,measured,inspected,adjusted and so on.After the major repair,motorcycle can reach the standard of
original motivity,economy,stability and safety performance.
[2]Medium repair is to repair and adjust some parts which influence the performance of motorcycle.
Medium repair can eliminate potentially hazardous,avoid deterioration of problems and keep a good
running condition.
[3]Minor repair is a running repair,which is mainly focus on elimination of some temporary problems or
partial hurts during running.
[4]Assembly repair is a separate repair for assembly,which is caused when the requirement of a certain
assembly or hurt,abrasion or distortion of a certain component influence the performance of motorcycle.
2 Repair Technics
Chapter 2 Maintenance Knowledge
When there are some problems with motorcycle,you can have it repaired at Zongshen after-service
station or professional maintenance station.Meanwhile you also can refer to this maintenance manual.
Parts on the motorcycle will be worn or loose during riding. Lack of regular maintenance can affect the
safety and reliability of your motorcycle and shorten the service life.So a regular maintenance will help to
keep your new motorcycle operating at peak performance.
[1]When motorcycle is being repaired,please use the components,accessories,luboil and other
accessorial materials which produced or recommended by our company or.If you use the components
which are not suitable for this motorcycle,it will influence the motivity,reliability,stability and comfort of
motorcycle.Seriously, the motorcycle will be destroyed.
[2]After disassembly and reinstallment,please replace new gasket,sealed components and open pin.
[3]When tightening bolts and nuts,you should do with the principle of diagonal crossover and
completely tighten to the standard torque value during 2 or 3 times.
[4]When cleaning the components,please adopt non-burning cleaning fluid. Paint some luboil on the
moving parts of components before installation.
[5]After installation,check whether components are installed correctly.Check methods are
circumrotate,movement,operation and inspection.
[6]When disassembling motorcycle,normally please use appropriative maintenance tools.
[7]Please repair motorcycle with flameout.If the motorcycle needs to be repaired while engine is
working,please do it at a well ventilated place,because the exhaust gas from motorcycle contains poisonous
CO.
[8]Gas is easy to burn or explode,so do not smoke or ignite at maintenance place.
[9]The electrolyte of battery consists of vitriol.If eyes,skin and clothes are spattered with
electrolyte,completely clean it with water.Seriously,please go to hospital.
[10]There is hydric gas from battery,which is flammable and explosive,so do not smoke,ignite fire near
battery.Especially when it is charging.

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（1）Disassembly of Motorcycle
Disassembly is a very important part during repair.The method of disassembly will directly influence the
quality and efficiency of repair.If components broken or blocked caused by unproper disassembly,it will not
only expand the repair range,but also will delay the repair period.Seriously,it will lead to the disassembly
stop.The basic principle of disassembly is the order and direction opposite to those of installation.
Normally,the order is from outside to inside,from up to down,from big to small.When disassembling,pay
attention to the store environment and order to avoid damnification and confusion.
The order and method of disassembly is not absolute.Different motorcycle has different order and
method of disassembly.You can refer to the following introduction of disassembly,installation and
maintenance.
The basic principle of disassembly of Engine and other components is the same as principle of
whole motorcycle.The order and method of disassembly is different because of different structure and
characteristic of different component.Pay more attention to the store environment and order for all
disassembled parts are components.
Pay attention to the following items when disassembling motorcycle and components:
[1]The components which have high requirement for position should check its position mark first when
disassembling.If the mark is not clear,please re-make a mark.
[2]When dismantling the components which are too tight,please use the special tools.If you have none
special tools,support the motorcycle with some wooden or soft metal,then hammer the right place with
gluey hammer to avoid component damage.
[3]When dismantling the assembly of front/rear shock absorber and front/rear wheel,support motorcycle
with main stand.Avoid motorcycle falling down to hurt people or damage the components.
[4]Put the components which are dismantled in order.Do not put those components directly on the
ground.Such as spray components,chromeplate components and high precision components.
[5]The nuts and bolts which are dismantled should be stored carefully,which also can be installed on
the original place,but don’t tighten them.
[6]The components which are only dismantled by special tools,please operate as regulation.Please
energize equally and pay attention to the direction.
[7]When dismantling components,please choose suitable tools,energize equally and pay attention to
direction to avoid component damage.
[8]The brake pads which are dismantled should be stored separately,which are also forbidden to
contact luboil,otherwise it will lead to brake failure.
[9]When there are some difficulties to dismantle because of the rust of screw thread components,you
can dip the components in gas for several minutes,then dismantle them.
[10]When dismantling gaskets,you should be much careful to avoid damage.
（2）Cleaning of Components
After the components are dismantled,they must be adhibited some oil or carbon deposit.Clean them to
help maintenance and installation.You can choose gas,coal oil and cleaning liquid to clean.The cleaning
method is adopted according to the speciality of components.
[1] Oil Stain Cleaning
Cool cleaning and heat cleaning are two methods for metal parts.Use gasoline or coal oil as
detergent,put the metal parts into detergent and scrub them by brush,which is called cool cleaning .Use
aqueous alkali as detergent,put metal parts into detergent ,heat up to 79℃～90℃and immerse for 10min
～15min,then take out the metal parts and clean,which is called heat cleaning.
[2] Carbon Deposit Removing
To remove the carbon deposit on component,we can use mechanical method or chemical method.
Mechanical method is that scrape deposit with bamboo-scraper or spade and clean them with gasoline.
Immerse the component,brush the carbon deposit off and clean them with hot water,which is called
chemical method.
（3）Parts Inspection
Inspect the parts after cleaning.The purpose for inspection is to check whether the parts need
to be repaired or replaced.There are three methods,i.e.direct inspection,instrument inspection and
troubleshooting.
[1] Direct Inspection
Direct inspection is to check and judge the condition of parts by individual sensation instead of
instrument.It is a simple and feasible method,which is widely used for maintenance.

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6
[2] Instrument Inspection
Instrument inspection is to measure the size and geometry shape of parts by gauge and apparatus;then
compare the measured value with limiting value to figure out the condition of parts.This method can get
an accurate judgement,but it needs careful inspection for the precision of instrument and reasonable
selection of parts.
[3] Troubleshooting
To find the latent fault of parts，we can apply troubleshooting.Usually we adopt the method of oil
immersion and knock during maintenance.The process of this method is as following.First,immerse
the parts into coal oil or diesel oil for several minutes.Second,take out and wipe the parts.Third,spread
talcum powder on the surface of parts. Finally, knock the non-working surface of parts gently with a small
hammer . In this way,the knock can produce vibration and oil that has remained in crack will splash for
vibration.The splashed oil will dye the talcum powder yellow,so we can easily find a yellow mark in crack
place.
Cleaning methods for non-metal parts differ in different materials.The best detergent for rubber parts
is alcohol.Do not use coal oil or gasoline to clean rubber parts,because they can cause inflation and
deformity of rubber parts.Gasoline is suitable for clutch disc and brake pads friction disc,while aqueous
alkali is forbidden.
（4）Repair methods and skills
After disassembly,cleaning and inspection,the following is the principal stage.Mastering the basic skill
well is the key to ensure a good quality of maintenance.The skills for maintenance are as following:
[1] Chiseling,filing and scraping
Chiseling is to process metal parts by hammer and chisel. The functions are cutting and parting.
Filing is to rasp off the surface of parts by a file.It includes rasp and delicate filing.Teeth of a file directly
decide the roughness degree when filing metal parts.The operation of file is different because of different
shape surface of parts.
Scraping is a process which scrapes off a thin layer from the surface of parts. It is a delicate work, so
we should scrape the parts bit by bit with great care.Usually,scraping off 0.005～0.01mm each time.
Before scraping,we need to spread red lead on the surface of parts.Then,match the parts with standard
one.The unmatched parts are the aim of scraping.After several match and scraping,the contact surface of
parts is bigger.So it reaches the requirement and achieves the purpose.
[2] Rubbing
Rubbing is to rub out a thin layer from the surface of parts by grinder and crocus.This is a fine finish
for the surface of parts,which can provide a precise size ,exact geometrical shape and the lowest degree of
roughness.It includes flat rubbing,internal rubbing and external rubbing.The rubbing tool for flat rubbing is
a plane plate,while internal rubbing tool is a pestle.During maintenance,rubbing methods are usually used
for rubbing the flat of crankcase and internal hole of connecting rod.
[3] Rivet joint and welding
Rivet joint is a process which can join two parts or more together with rivets.It is widely used in
maintenance,such as rivet joint of clutch disc and so on. Classified by its function,rivet joint can be divided
into fixed rivet joint,active rivet joint and seal rivet joint.
Welding is a process which can bring into close union of two metal parts with welding tool and solder.
It is also widely used in maintenance,such as repairing the crack of frame and other metal parts.
[4] Drilling and Reaming
Drilling is a process which drills holes on parts or materials with drill bit.The drilling tools mainly
include beam drill、bench drill、electric hand drill、rotary hand drill、drill bit and clamp.
Reaming is a fine finish by reamer,which can increase the precision degree of holes on parts and
decrease the roughness degree.It improves the match precision between hole and shaft and the precision
can reach grade 6 to grade 8. The basic tool for reaming is a reamer,such as fixed reamer,adjustable
reamer,conical reamer and so on.Before reaming,we need to drill a bottom hole in advance,which is for
the precision requirement of hole shaped and making room for reaming procedure.
[5]Tapping and thread die cutting
Tapping is to Process internal thread with screw tap and thread die cutting is to process external thread
with threading die. The essential tools for tapping is screw tap. Generally, screw tap consist of master tap
and plug tap. The difference between these Two kinds of tap is that master tap adopt a slight bevel angle
on cutting part,instead , plug tap adopt a steeply bevel angle. After tapping,we should drill a bottom hole
with chamfer.

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7
Please refer to the specialized list or the following formula for the bit diameter of bottom hole :
Diameter of drilling hole outside diameter of screw thread - 1.1mm×screw pitch(appropriate for iron
and copper)
Diameter of drilling hole outside diameter of screw thread-1.2mm×screw pitch(appropriate for steel
and brass)
When cutting inside threads,turn master tap into the chamfer-angle hole,then take out and use plug tap
to shape the threads.
The tool for outside screw threads cutting is screw plate.Screw plate includes fixed screw
plate,adjustable screw plate and active screw plate.Usually,we use fixed screw plate,i.e.round screw plate.
When cutting outside screw threads,choose screw plate and diameter of club-shaped material according
the required material,diameter of screw thread and screw pitch.To make proper choice,please refer to the
specialized list or the following formula:
Diameter of club shaped materialoutside diameter of screw thread-0.13mm×screw pitch
Bevel the end of club-shaped material in 15°～20°angle before cutting outside screw threads.
To ensure easy operation,the screw plate and club-shaped material should be in vertical,therefore,the
minimum diameter of cone angle should less than inside diameter of screw thread.
[6]Rectification
The operation that eliminates the unevenness of plane-shaped,bar-shaped and column-shaped parts is
called rectification.。Rectification can reshape the parts.
The rectification depends on the flexibility of metal parts.Therefore,metal parts with good flexibility can
be rectified directly,such as soft steel and red cooper’metal parts with less flexibility need to anneal before
rectification.
The ways for rectification are torsion,extension,bending and expansion.
[7]Bonding
Bonding is widely used in manufacture and repairs because it operates easily and can be done without
special equipment and expensive materials. In addition,the bonding parts don’t need to be processed by
high precision machine,such as the bonding of handlebar and steering head,bonding of plastic label and
spay-paint metal parts,bonding of brake disc and brake pads.There are various adhesive,such as epoxy
adhesive,phenol formaldehyde adhesive and so on.
（5）Motorcycle assembly
The last procedure in repair is assembly,which is a key to ensure the good quality of motorcycle.
[1]Assembly includes module assembly,parts assembly and overall assembly.In the process of
assembly,we should abide by the principle that assemble module first,then parts and the overall finally.
The sequence of assembly is opposite to disassembly,which is to first assemble the last disassembled
components,and to last assemble the first disassembled components.
[2]Module assembly is the first stage in whole process,which makes the parts into a single module,such
as the combination of front brake drum cover,the combination of brake pads ,the combination of wheel.
[3]Parts assembly is based upon module assembly,which assembles the parts and module as a
whole,such as front and rear wheel assembly,front fork assembly,shock absorber assembly and so on.
[4]Overall assembly is the last procedure to complete the whole working process,which connects parts
and modules with frame according to installation sequence by all means.
[5]The sequences of overall assembly are similar.The operation is as following：Firstly,finish all
modules assembly and parts assembly,then install engine assembly and gearbox assembly on frame.
Secondly,install front fork assembly,handlebar assembly,front and rear fender assembly,shock absorber
assembly,carrier assembly,front and rear wheel assembly,fuel tank assembly and seat assembly.
Thirdly,install headlight,taillight,steering indicator,horn and battery assembly.The fourth,connect all electric
circuit and control cables.The fifth,install driving chain, dentiform belt,wind shield and chain cover or belt
cover.Last,lubricate the whole motorcycle.
[6]Consult the following reference about disassembly,installation and inspection if there is any
assembly sequence difference which is caused by different type and structure.
[7]Pay attention to the following:：
Choose a clean and wide place ；strictly follow the assembly requirements；parts connecting should
accord with specification ;avoid misfitting and leaving out of any gaskets,cotter pin and fixing clip.
3 Adjustment after Repair
The interconnection of parts have been affected in some extent after repair.To recover the performance
of motorcycle,adjust them according to the specification of user’smanual.adjust as follows:

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limit Value (mm)
20～30
30～40
10～12
2.0
0.8
0.8
0.8
0.8
operation/ brake/ shock absorber/wheel
Table 2-1
items Standard Value (mm)
axial
radial
front
rear
10～20
20～30
2～6
4.0
130
425
45
235
Section 3 Adjusting Data of Maintenance
Free stroke of front brake lever
Free stroke of rear brake pedal
Free stroke of throttle control grip
Depth of flower pattern on tire surface
Stroke of front shock absorber
Free length of front shock absorber spring
Stroke of rear shock absorber
Free length of rear shock absorber spring
Wheel hub runout
Axle runout
（1）Ignition Time Adjustment
If there is a wrong ignition advance angle，it will cause a series of problems,such as hard engine
starting ,power decrease,high fuel consumption,engine overheating,uncomplete fuel burning,exhaust
value overrun,short service lifetime and so on.Therefore,adjust ingiton advance angle firstly.
If ignition system cannot work well,check electrical ignition device,high voltage coil,ignition coil and
triggering loop of magneto and so on.
（2）Clutch Adjustment
Clutch is used to transfer power,so it plays an important role in transmission system.Adjust the free
stroke of clutch operation grip within 10mm and 20mm.For some motorcycles,there is a need to adjust
adjusting bolts of disengagement parts.
（3）Brake Adjustment
The performance of brake directly affects the riding safety,so it is important to adjust brake in order.
Adjust the free stroke of front brake handle lever within 10mm and 20mm and the rear brake pedal
within 20mm and 30mm.The adjusting method is the same.
（4）Electrical Device Adjustment
The electrical device adjustment mainly includes headlight and electric horn adjustment.
[1]Adjust the position of headlight up or down to change the distance of light radiation.
[2]Adjust sound and tune of electric horn.The standard volume of motorcycle electric horn is (95～
105)dB(A).Adjust the adjusting bolt behind the electric horn if the volume and tune cannot operate well.
（5）Throttle Cable Adjustment
The free stroke of throttle control grip should be 2mm～6mm.Engine speed increase or decrease
should be prohibited in this process.Adjust free stroke according to specification.This adjustment is
usually accompanied with idle adjustment.

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Maintenance Cycle
Table 2-2
Maintain the motorcycle according to the period that is listed above.Each capital letter on the list stands
for as follows:
R-clean、A-inspect、L-lubricate、I-inspect、clean、adjust、lubricate or replace
●indicates that maintaining this item by service center of our company.If maintain it by yourself,please
consult this maintenance manual.
●●indicates that maintaining this item only by service center of our company.To ensure riding
safety,please follow our advice.
Times
Items
Items
Period
Fuel system
Fuel filter
Control system
Choke valve cable
Air cleaner element
Mileage 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
Shorten the maintenance period if motorcycle usually runs in dusty region.
25~35
50~60
70~80
70~80
45~55
45~55
28~32
50~60
55~65
45~5
Torque tighteningCAUTION
table 2-3
Motorcycle
M24×1
M10×1.25
M14×1.5
M14×1.5
M10×1.25
M10
M8
M12×1.25
M12×1.25
M10×1.25
Locknut of main pipe
Fixed bolt of handlebar
Front axle nut
Rear axle nut
Engine suspension bolt
Fixed nut of rear shock absorber
Locknut of chain wheel
Nut of rear rocker arm
fork shaft nut
fork shaft nut
Items Specification Torque Value(N.m)
●
●
●
●
●
●
●
●●
●●
●●
spark plug gap
CAUTION
Valve clearance
Driving chain
Battery
Abrasion of brake pads
Brake system
Brake light switch
Headlight adjusting
Main/side stand
Front/Rear shock absorber
nut/bolt/fixing components
Outter tire of front and rear wheel
steering system bearing

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Section 1 Fuel Supply System
1 The Structure and Working Principle of Fuel System
[1] Fuel Tank
Fuel tank is jointed by the armor plate which is normally 0.8mm～1.0mm.Some fuel tank is jointed
apertured clapboard inside,which not only strengthens the fuel tank,but also avoids the fuel gurgitation
during riding.Because of the strong erosion of oil,it must be galvanized on the surface of fuel tank.There is
a fuel-adding hole on the top of fuel tank and close the fuel cap which has air hole,so that it can avoid fuel
leakage during riding and ensure the balanced pressure of inner and outer fuel tank.So that fuel can flow
out naturally.
[2]Fuel Pump
The fuel pump consists of pump, support and oil pressure adjuster. Flexible installation can decrease
the vibration on the fuel pump. The pump installed in the fuel tank is to get a simple construction and
non-leakage.
The pump adopts turbo, single stage and electric type. It is driven by a DC motor with 12V and
controlled by ECU through the pump relay. There is a one-way valve at the exit of the pump which can
prevent the oil from flowing back to the bank when engine stops and ensures a good starting performence.
[3] Fuel Injector
Fuel supply system consists of fuel tank,fuel pump,injector,fuel filter and oil pipe.
Fuel injector injects the proper amount of atomized fuel into the intake pipe of engine by ECU,thus
the atomized fuel can participate in the combustion process in the cylinder.
[4]Fuel Filter
Fuel filter connects with the oil way between the electric fuel pump and fuel rail. This system adopts
the dedicated filter for EFI to make impurities not block the nozzle. The housing of filter has enough
intensity and it never break due to the fuel pressure.
[5]Fuel Pipe
The pressure of the fuel supply system is 250kPa. Its selection must have enough safety factor for
security.
Chapter 3 Vehicle

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11
[1]The capacity of the fuel tank is 16L。
When refueling, please keep air circulation and
keep away from sparks and flame.
Fuel is highly combustible.Smoking and getting
close to the fire are strictly forbidden
Switch off the motorcycle and operate in an airy
place.
WARNING fuel tank cap
2 Disassembly and Maintenance of Fuel System
The brand of oil allowed is 93#. Do not using
other type of oil.
[2]Check the fuel tank cap for fuel leakage.Replace
the sealing ring of cap if necessary.
[4]Check the fuel pipe for fuel leakage or aging.
Check filter for block, repair or replace it if blocked.
[3]Check the fuel tank for fuel leakage.Replace or
repair it if necassery.
If the fuel tank is deformed by the collision of
external force,repair it to original condition with
wooden hammer.If the fuel tank has cracks,replace
the fuel tank without repair.
If the fuel pipe has fuel leakage or aging,replace it.
Before replacing the fuel pipe or filter, Shut up
ignition switch to stop the fuel pump and avoid the
fuel flow out of the fuel tank.
WARNING
CAUTION
check the filter
CAUTION
open fuel tank
check fuel tank

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12
[5]First of all, dismantle the left and right side
cover and seat.Then remove fixed bolt and take
out the fuel tank.
Keep the oil away from fire when dumping
the oil.
[8]Check the pump seal ring for aging, breaking
or oil leakage. Replace it if necessary.
[7]Take out the pump, and then clean the oil
sludge and water in the tank with oil sludge.
[6]Remove the six fixed bolt(M5×16) of fuel
pump by hexagon wrench.
Please dump oil first and keep away from the
fire when dismantling the pump.
WARNING
After cleaning, the fuel tank could be used
when drying out.
CAUTION
WARNING
dismantle the fuel pump
dismantle the fuel tank
remove the fuel pump
check seal ring

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13
[9]Check the motor of fuel pump for running.And
clean or replace the fuel strainer.
Replace the fuel filter when the motorcycle
drives about 8000~10000Km.
ADVICE
check the fuel pump
Table 4-1 Maintenance of Fuel Supply System
3 The cause,trouble description and repair method of fuel supply system
component
description cause trouble description of component
trouble description of motorcy
cle repair method
fuel tank
Fuel tank body is
broken. leakage of fuel tank Repair or replace fuel tank.
The venthole of fuel
tank cap is blocked.
Fuel supply is not
good. Motorcycle cannot start.
Unblock the
venthole of fuel
tank cap.
Fuel tank is
deformed.
Fuel tank is
accidented.
The appearance of motorcycle
is bad.
Repair or replace
fuel tank.
fuel pump
oil-filter screen is
dirty or small holes
are blocked.
Fuel supply is not
good.
Motorcycle is hard to be
started or cannot be started.
The engine power is not
enough and the idle speed is
not stable.
Clean oil-filter
screen.
The fuel pump body
is blocked.
Fuel supply is not
good. Motorcycle cannot be started. Clean or replace fuel pump.
The motor of fuel
pump does not run
Fuel can not be
supplied. Motorcycle cannot be started. Replace the motor.
Fuel pressure
regulator is blocked. Fuel can not be
back. Oil duct is cracked
Clean or replace
the pump
assembly.
Fuel pressure
regulator is normally
open.
The pressure of oil
supply is low.
Motorcycle is hard to be
started or cannot be started.
The engine power is not
enough and the idle speed is
not stable.

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14
Section 2 EFI system
The main effect of EFI system is to convert the fuel which is supplied from fuel tank into a mist, then
mixture of the mist and air import into the combustion chamber.
1 The Structure and Working Principle of EFI system
EFI system consists of ECU,nozzle,throttle valve,intake air temperature,integrated pressure
sensor,engine temperature sensor,ignition coil,CKP,fuel pump,oxygen sensor.
EFI system could control the ratio of fuel-air mixture which import into the engine cylinder, combustion
process and exhaust gas conversion accurately .So as to optimize engine performance and driveability ,and
control the exhaust emission strictly.
ECU is a microprocessor as a core of SCM. By sensor and working request switch installed in the
engine and body of motorcycle, ECM could analyse mode of operation and estimate operating conditions.
Finally,controlling engine and relevant mechanisms accurately through actuator in the engine and body of
motorcycle.
The type of engine speed and crankshaft angle sensor is magnetoelectricity. The function of this sensor
is to determine the position of the rotating and revolving speed for crankshaft.
Crankshaft angle sensor is installed on the clutch housing and it works with 24x gear ring from
flywheel.
MAP sensor is installed in the intake manifold to measure the pressure,so ECU could judge air enter
into the engine from this signal.
MAP sensor consists of an elastic diaphragm seal and a magneticcore. Diaphragm seal and
magneticcore is placed in the coil accurately.When they sense pressure, they could produce a 0～5v
output signal in direct proportion to input pressure.
Throttle position sensor is installed on the throttle body and has a same axle with throttle lever and
throttle valve. The structure is a linear variable resistor and its sliding terminal is drived by throttle axle.
Resistance signal,which is passed to the ECU through this sensor, depends on the opening of throttle.
EFI could judge the real-time load of engine and dynamic variation according to the signal and its rate of
changes which output from the sensor.
Sensor of intake air temperature is installed on the pipe of intake system. The function of it is to test air
temperature enter into the engine. It also use thermistor of NTC coefficient as a sensing element.
The change of gas temperature directly affects its density fluctuation, therefore, intake air temperature is
one of the importance parameters for computing actual amount of air,which enters into the cylinder.
Nozzle is an electromagnetic switch device.Two poles elicite from coil connect with ECU through
engine wires. Voltage is applied to coil under the control of ECU, and the coil produces magnetic force to
overcome spring force, fuel pressures and a vacuum suction of intake manifold, suck up iron core, that
could enables fuel to traverse the seal surface of ball valve which is the one with the iron core ,then the
fuel sprays from nozzle and forms a mist spray; After interruption of power supply, magnetic disappears
and nozzle shuts.
The top of fuel injector adopts rubber sealing for forming a reliable leakproofness of fuel pressure with
the port of fuel channel;The bottom of it adopts rubber sealing for forming a aeroseal with engine intake
manifold. Nozzle spray the fuel as mist into the inlet valve.
Throttle body is installed in the front of the intake manifold. It consists of valve body,throttle position
sensor and ISCV. The main function is to control air inflow when engine is working.
Oxygen sensor is installed on the exhaust pipe of engine.It is a important part of closed-loop fuel control
system.
The main sensitive materials of oxygen sensor is zirconia. Zirconia is heated to 300℃by exhaust
and is activated, then oxygen ion traverses the zirconia part and gets to its external electrode. Ultimately,
zirconia part induct content of oxygen from engine exhaust emission and change the output voltage value.
Oxygen sensor adopts Teflon insulated wires and stainless steel materials of component.Air for reference
is imported through wire,so it is non-blocking.
When AFR becomes thin，oxygen content of exhaust increases and the output voltage of oxygen
sensor reduces;Otherwise, the output voltage valve rises, it provide feedback of the real-time condition of
AFR to ECU.

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15
3 The trouble description of EFI system
Check the EFI system by the test instrument.If it has fault，replace homologous
component of EFI. If not, please check the system as following:
1.Check the line connection;
2.Check whether or not the voltage reaches 9V.
3.Check the vehicle and EFI safe system
4.Check whether the oil-ways are blocked,extruded or broken.
2 Disassembly and Maintenance of EFI system
The EFI of motorcycle has been calibrated before leaving the factory. When EFI system has failure, adjust
idle screw of throttle voluntarily and replace or adjust parts of EFI are strictly prohibited.Please go to our
service station to maintain for any queries.
EFI failure indicator is equipped in the meter.When ignition system is opened, the indicater lights up. when
the indicator does not light up, that means there is failure. When engine starts, the indicator puts out. When
the indicator keeps the light on or flashing ,that means there is failure.
Structural drawing of EFI system
crankshaftposition sensor
LSH
engine
temperature
sensor
Inlet temperature/
pressure sensor
neutral switch
ignition switch
battery
fault diagnosis
switch SCI
dumping switch
burglar alarm
optional
idle air control valve
optional
throttle body
igniton coil
throttle position sensor
M3.5 nozzle
WCPRfuel
pressure
regulator
fuel pump
catalytic
converter for
metal carrier
engine
control
module
fault
indicating
lamp
high
Temperature
indicator of
engine
rev signal
of engine
optional
24X aiming
wheel of
crankshaft
position

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16
Section 3 Inlet and Exhaust System
The inlet system of engine mainly consists of air cleaner and inlet pipe.The main function of which is
to guide and filtrate air,reduce inlet noise and control the volume of mixed gas which is going to engine.
The exhaust system mainly consists of exhaust pipe and muffler.The main function of which is to
transfer the exhaust gas to atmosphere,reduce the noise when exhausting and the temperature of exhaust
gas and eliminate the spark in exhaust gas.A good exhaust system can advance the inlet and exhaust
system,increase engine power and reduce the fuel consumption,so it is also called exhaust muffler.
1 The Structure of Inlet System
[1]The Structure and Working Principle of Air Cleaner
Air cleaner is the important component of inlet system.The function of which is to filtrate,purify
the air entering into cylinder,avoid dust,sand entering into cylinder so that it will reduce the abrasion of
cylinder,piston and piston ring.Its performance has a big effect on the motivity of engine,noise of inlet and
service lifetime.Experiences indicate the abrasion of cylinder will increase 8 times ,the abrasion of piston
will increase 3 times and the abrasion of piston ring will increase 9 times if air cleaner is not installed.In
this way,the reliability of engine will reduce and the service lifetime will be shortened.Therefore,motorcycle
must be installed with air cleaner. The requirement of air cleaner is not only to filtrate the air,but also the
resistance of air flowing must be small so that the volume of engine inlet will enhance.More requirements
are reliable working performance,simple structure,small dimension of appearance,light body and easy to
maintain.The air cleaner mainly consists of element and sealed box.When engine runs,air will enter into
the front cavity of air cleaner through air pipe,then flow into the rear cavity after filtration.and finally enter
the throttle.
[2]The Structure and Working Principle of Inlet Pipe
Inlet pipe is the important component to
connect throttle and engine inlet.Meanwhile,it
has a function of supporting throttle and has a
simple structure.Its bending shape depends on the
position which the throttle should be corresponding
to the engine inlet,but you should think about the
influence of inlet resistance.If the pipe is long,it has
an advantage of fuel pulverization,but air resistance
is big.If the pipe is short,which is not good for fuel
pulverization,but air resistance is small.
The mixed gas after pulverization of throttle
flows into cylinder through inlet pipe and engine
inlet.The inlet pipe reduces the heat which engine
has transferred to throttle and separates the shake
of engine from throttle.
2 The Structure and Working Principle of Exhaust
System
The exhaust pipe in exhaust muffler is made
of bending steel pipe.It locates between exhaust
vent of engine and muffler.Its funtion is to guide
the exhaust gas from engine to the muffler.