ZONGSHEN ZS250GY-3(EFI) User manual

ENGLISH
ZS250GY-3 (EFI)MOTOCYCLE
SERVICE MANUAL
THEFIRSTEDITION(Aug,2013)
Zongshen industrial group reserves allrights of
this service manual.
The specifications and pictures in this manual
areonlyforreference.

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Editor Aug,2013
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INTRODUCTIONS
The manualintruducesthestructure,wokingprinciple,disassemblyandinspection, fault diagnosisandelimination.
Also,this includes technical specifications,performance parameter and maintenance data. Withboththedescriptionsand
pictures, youmay have acomprehensive understandingof theconfiguration as well as theserviceandrepairskill.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 manualare base uponthe
latest design features ofyourmotorcycle. Chongqing Zongshen AutomobileIndustryCo.Ltd.reserves therightto make
changes to the specifications of its vehicles withoutnotification. We sincerely hope you can give usyour suggestions
aboutthedesign,manufacture and qualityofthistype ofmotorcycle,so thatwecando theimprovement intime.Thank
you foryour supportand co-operation.
Allthespecifications,diagram, data and performance index in thismanual end intheprint ofthisbook. Our
companyreservestherightto change thebookwithoutany notification.All rights arereserved by Zongshen.Anypeople
orcompanieswon tcopy itif there is no permission.Otherwise,wewillgobehind the criminaland legal responsiblity.
In thisbook we take ZS250GY-3 for example to explain the detail of the disassembly,installation,inspection and
troubleshooting of thisseriesmodels.Due toourlimitedknowledge,it isverypossibletohave mistakesoromissions in
this book.And we welcomeyourcomments.
ChongqingZongshen Automobile Industry Co., Ltd.
Address: CHAOYOUCHANG,BANAN DISTRICT,CHONGQING,CHINA.
Servicehotline:4007003088
For more information, visitour website www:zongshenmotor.com
Zongshen IndustrialGroupareapplying this trademark.

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catalogue
INTRODUCTION
CATALOGUE
CHAPTER 1 GENERAL INFORMATION....................................................................................1
section 1 vehicle introduction.................................................................................................... 1
section 2structure.................................................................................................................... 2
CHAPTER 2MAINTENANCE KNOWLEDGE.............................................................................4
section 1 AttentionItems of Maintenance................................................................................... 4
section 2General knowledge of Maintenance ............................................................................................5
section3 AdjustingData of Maintenance.................................................................................... 8
CHAPTER 3VEHICLE...........................................................................................................10
section 1 Fuel Supply System................................................................................................. 10
section 2 EFI System.............................................................................................................. 13
section 3 Intake and Exhaust system....................................................................................... 20
section 4 Rear Transmission Device........................................................................................ 24
section 5 Frame and Accessories............................................................................................ 28
section 6 SteeringSystem...................................................................................................... 31
section 7 Control Steel Cable................................................................................................... 32
section 8 Shock Absorber....................................................................................................... 33
section 9 RearFork ....................................................................................................................................37
section 10 Wheel.................................................................................................................. 38
section 11 Brake................................................................................................................... 42
section 12 Meter................................................................................................................... 48
CHAPTER4 ELECTRICAL.....................................................................................................50
section 1 Basic Knowledge..................................................................................................... 50
section 2 Power Supply.......................................................................................................... 51
section 3 Control................................................................................................................... 54
section 4 Power Consumption ...................................................................................................................57
CHAPTER 5 TROUBLESHOOTING.........................................................................................60
APPENDIX CIRCUITDIAGRAM..........................................................................................74

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[1]Front fender
[2]Front shockabsorber
[3]Steering
[4]Fueltank
[5]Rear armrest
[6]Frontwheel
[7]Front brake
[8]Gearshiftpedal
[9]Side stand
[10]Rear wheel
[1]Taillight assembly
[2]Muffler
[3]Seat
[4]Ignitionlock
[5]Headlight
[6]Rear brake
[7]Rear pedal
[8]Frontpedal
[9]rear brakepedal
CHAPTER1GENERAL INFORMATION
section 1 vehicleintroduction
ZS250GY-3 is designed for use on road With futuramic appearance and easy operation. It adopt single
cylinder,4-stroke,aircooling engine.Thistype of enginehasthe advantagesofgood cooling,powerfuland
goodacceleration.The frameis pipejointwhichhas hightensityandgoodrigidity.Thebrakesystem
adoptsthecombinationof frontandreardisc sothatit could ensure thestabilization andsafety.Andrim
type wheel has good appearanceandfunctionofanti-abrasion.
FIGURE1-1Left view of motorcycle
FIGURE 1-2 Right view of motorcycle
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2
3
4
5
6
7
89
5
10
8
9
7
6
2
1
3
4

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1
2
3
4
5
6
1 Riding System
The basic function of riding system:
[1]Make motorcycle in a whole and support whole motorcycle.
[2]Receive thetorque from transmission setup.Providetractionfor motorcyclerunning through thecontact of wheel
androad.
[3]Endure and transmit road function andenduretorquemadebytheoutside force of wheel.
[4]Absorb and handle the strike and shake produced during motorcycle running.
Ridingsystem mainly contains frame assembly,front/rear shock absorber,front/rearwheel andsome other accesories.
2Operationand Brake System
Themainfunction ofoperation systemisto control running direction,running speed,brake,illumination and
signals,andtoensuremotorcycle runningsafety.
Theoperation andbrake systemmainlyconsistsofsteeringsetup,brakesetupandsomerelative controlling
handlebar,controlling switch,steel cable and accessories.
3 Transmission System
Thebasicfunctionof transmission systemis to augmenttorque orreduce transmission speed accordingto the road
conditionand runningneed,After that,to transmitthe resulttodrivewheel andtomake motorcyclerun.
Transmissionsystem mainlyconsistsofstartingdevice,clutch,gearshiftand accessories of reartransmission
device.
[1]Starting Device
Thefunction of starting device is to startengine and to make engineautomaticrunning.The starting device of
motorcycle is dividedinto two modes.One iskick starting,and the other is electric starting.
[2]Clutch
Thefunction of clutch istotransmit or cut off the power fromengine reliablyand softly,and toensuremotorcycle
stable start andgearshift.The clutchof thismotorcycle adoptsautomatic,wet and multiple.
[3]Gearshift
Thefunction of gearshift istochangetherev and drivetorque ofmotorcycle transmissionandtoensureproperpull
andspeed ofmotorcycle,sothat itcan adaptthechangablerunningcondition.The gearshiftof this motorcycle adopts
gradational gearshift.
Chapter 2Structure
Thismotorcycle mainly consists ofridingsystem,operationsystem,brakesystem,transmissionsystem,fuel
supplysystem,electrical system and engine.Refer to Diagram 1-3.
Diagram1-3 structure
[1]Riding system
[2]Electricalsystem
[3]Operationand brake system
[4]Fuel supplysystem
[5]Engine
[6]Transmissionsystem

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The functionofreartransmissiondeviceisto transmitthe enginepower to transmissiondevice,so that
therev is reducedand thetorqueisaugmented.Thentransmitthepowertorearwheeltodrivemotorcycle
run.The transmission of this motorcycle is chain transmission.
[5]Intake and Exhaust System
The function of inletsystem is to guideandfiltrate air,to controlthe volume ofmixedgasflowinginto
cylinderaccording to the needs of working condition.It mainly consists of inletpipeandair cleaner.
The functionof exhaust system is to vent the exhaust gas in cylinder andto reduce the noise during
exhausting.It mainly consistsof exhaust pipe and muffler.
[6]FuelSupplySystem
The functionof fuel-supplyingsystem isto confectclean gas andair intomixedgaswith proper
proportion accordingtotheworkingconditionofengine,andtoofferthe mixed gastimelyand
quantificationally toburning chamber tokeepburning.
The fuel supply system mainly consists of fuel tank,fuel pump,fuel injector,fuel filter and fuel pipe.
4 Electrical System
Thefunctionofelectricalsystemistoofferelectric power to the starting and runningofmotorcycle,and
to send soundor lightsignals so that the runningsafety can be ensured.The electrical system mainly
contains the part ofelectric power supply,electric power consumption andelectric powercontrol.
[1]ElectricSupply
The part ofelectric supply mainly consists of generator and battery.Whengenerator reaches acertain rev
driven by engine,generatorwill export eletric power,which not only offers thepower to electric setup,but also
to thebatteryso that it can becharged.The battery can transfer chemical power to electric power,whichcan
support starting,illumination and signal setup.
[2]ElectricConsumption
The function of electric consumption part is to offer severalkinds of sound or light signals to ensure
running safety,meanwhileitcanstartengineconveniently andfast.Itmainly consists of illuminating
signaldevice and electricstarter device.
[3]Control Part
Thefunctionofcontrolpart is toensureand adjust electric supplyand electricconsumption.It mainly
consistsof ECU,rectifier,starter relay,fuse，control switch andmain wire.
Engineisadevice,whichis tomakefuelburninthecylinderand totransfer heattomechanical power.
it isthe power producer of motocycle.(the maintenance of engineplease refer to theengine service
manual)
5Engine
[4]Rear transmissiondevice

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Chapter 2Maintenance Knowledge
Section1AttentionItems of Maintenance
When thereare some problemswithmotorcycle,you can haveit repairedatZongshen after-servicestationor
professionalmaintenance station.Meanwhileyoualso can refertothis maintenance manual.Parts on themotorcycle
willbe worn or loose duringriding. Lack of regularmaintenancecan affect the safety andreliability ofyour motorcycle
andshorten the service life.Soaregular maintenancewillhelp tokeepyournewmotorcycle operating at peak
performance.
[1]Whenmotorcycleis beingrepaired,pleaseusethecomponents,accessories,luboil
andotheraccessorialmaterialswhichproducedorrecommendedbyour companyor.Ifyou
use the components whichare not suitable for this motorcycle,it will influencethe
motivity,reliability,stabilityandcomfortofmotorcycle.Seriously,themotorcyclewill
bedestroyed.
[2]Afterdisassembly and reinstallment,please replace new gasket,sealed components
andopenpin.
[3]Whentighteningboltsandnuts,youshoulddowiththeprincipleofdiagonal
crossover and completely tighten to the standard torque value during 2or 3times.
[4]When cleaning the components,please adopt non-burning cleaning fluid. Paint some
luboil onthemovingparts ofcomponentsbeforeinstallation.
[5]After installation,check whether components are installedcorrectly.Checkmethods
are circumrotate,movement,operationand inspection.
[6]When disassemblingmotorcycle,normallypleaseuseappropriative maintenance tools.
[7]Pleaserepair motorcyclewith flameout.Ifthe motorcycle needs to be repaired while
engineis working,pleasedo it at awell ventilated place,because the exhaust gasfrom
motorcyclecontainspoisonousCO.
[8]Gas is easy to burn or explode,so donotsmoke origniteat maintenanceplace.
[9]The electrolyte of battery consists of vitriol.If eyes,skinand clothes are spatteredwith electrolyte,
completely clean it with water.Seriously,please go to hospital.
[10]There is hydric gas from battery,which isflammableandexplosive,so do not smoke,ignitefirenear
battery.Especially when it is charging.
Statement in this manual preceded by the following wordsare of special significance:
WARNING
CAUTION
ADVICE
Indicates apotential hazardoussituation, which ifnot avoid, maycausepeoplehurtor death.
Indicates apotential hazardous situation,which ifnot avoid, may damageyour bike.
Indicatesspecialinformationtomakemaintenance easieror instructions clearer.

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Section2General knowledgeof Maintenance
1ClassificationofMaintenance
Maintenance canbedividedinto4partsaccordingtothe rangeand intervalperiod.4partscontains major
repair,mediumrepair,minorrepair and assemblyrepair.
[1]Majorrepair is athorough repair,which needs tomake motorcycle completelydisassembled,cleaned,
measured,inspected,adjusted and soon.Afterthe major repair,motorcycle can reachthestandardof origi-
nal motivity,economy,stabilityand safety performance.
[2]Medium repair is torepair and adjust some partswhich influence theperformance of motorcycle.
Medium repair can eliminate potentially hazardous,avoid deteriorationof problems and keepagood
running condition.
[3]Minorrepairisa runningrepair,which ismainly focus oneliminationofsome temporaryproblems
or partialhurtsduring running.
[4]Assemblyrepair is aseparate repair for assembly,which is caused when therequirement ofacertain
assembly or hurt,abrasionor distortion ofa certain componentinfluence the performanceof motorcycle.
2Repair Technics
1）Disassemblyof Motorcycle
Disassembly is avery importantpart duringrepair.The method of disassemblywill directlyinfluence
the quality and efficiency ofrepair.If components broken or blocked caused by unproper disassembly,it
willnot only expand therepairrange,butalsowilldelaythe repairperiod.Seriously,it will leadtothe
disassembly stop.The basic principleof disassemblyis the orderand directionopposite to those of
installation.Normally,theorder isfromoutsidetoinside,fromuptodown,frombig tosmall.When
disassembling,pay attention tothestoreenvironment andorder to avoiddamnification and confusion.
Theorderand method of disassembly isnotabsolute.Differentmotorcyclehasdifferent orderand
method ofdisassembly.Youcanreferto thefollowingintroduction ofdisassembly,installationand
maintenance.
Thebasic principleof disassemblyofEngine andothercomponents isthe same asprinciple ofwhole
motorcycle.The orderandmethodofdisassembly isdifferent becauseof different structureandcharacter-
istic of different component.Pay more attention to the store environment and order for all disassembled
partsare components.
Payattention to the followingitemswhendisassembling motorcycle and components:
[1]The componentswhich have high requirement for positionshould checkits positionmark first when
disassembling.If the markis notclear,pleasere-make amark.
[2]Whendismantlingthecomponentswhich are too tight,please use the special tools.Ifyouhavenone
special tools,support the motorcycle with some wooden or soft metal,then hammer the right place with
glueyhammerto avoid component damage.
[3]When dismantling the assembly of front/rear shock absorber and front/rear wheel,support motor-
cycle withmain stand.Avoid motorcycle falling down to hurtpeople or damage the components.
[4]Putthe components which are dismantled in order.Do not put those components directly onthe
ground.Such as spraycomponents,chromeplate components andhigh precision components.
[5]Thenutsand bolts whicharedismantledshould bestoredcarefully,whichalsocan beinstalledon
the originalplace,but don’ttighten them.
[6]The components which are only dismantled byspecial tools,pleaseoperate asregulation.Please
energize equally and pay attention to the direction.
[7]When dismantlingcomponents,please choose suitable tools,energizeequally and payattentionto
direction toavoidcomponentdamage.
[8]Thebrakepads whichare dismantled shouldbe storedseparately,whicharealso forbidden to
contact luboil,otherwise itwill lead to brake failure.
[9]When there aresomedifficultiesto dismantlebecause of the rust ofscrewthreadcomponents,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）CleaningofComponents
Afterthecomponentsaredismantled,theymustbeadhibitedsomeoilorcarbondeposit.Clean them to
helpmaintenanceandinstallation.Youcan choose gas,coaloil and cleaning liquid toclean.The cleaning
method is adopted according to the speciality of components.
[1]OilStain Cleaning
Coolcleaningand heatcleaningare twomethods formetalparts.Use gasoline or coaloil asdetergent,
put the metal parts into detergent and scrub them by brush,which is called cool cleaning .Use aqueous
alkalias detergent,put metalpartsintodetergent ,heatupto79℃～90℃and immerse for10min～
15min,then takeout the metal parts and clean,which is calledheat cleaning.

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[3]Rivetjointand welding
Rivet jointisaprocess whichcanjointwo partsormoretogetherwith rivets.Itis widelyused in
maintenance,suchasrivet jointofclutch discandsoon.Classifiedby itsfunction,rivet jointcanbe
divided intofixed rivet joint,active rivet joint and seal rivet joint.
Welding is aprocesswhich can bringinto close union of twometal parts with welding tooland solder.
Itisalso widely used in maintenance,such as repairing the crack of frame and other metal parts.
[4]DrillingandReaming
Drilling is aprocess which drills holes onpartsor materialswith drill bit.The drilling tools mainly
include beamdrill、benchdrill、electrichanddrill、rotaryhand drill、drillbitandclamp.
[2]Rubbing
Rubbing is torub out a thin layerfrom the surface of parts bygrinder and crocus.This is a fine finish
forthesurfaceofparts,whichcanprovideaprecise size,exact geometrical shapeandthelowestdegree of
roughness.Itincludes flat rubbing,internal rubbingandexternalrubbing.The rubbingtool for flat rubbing
is aplane plate,while internal rubbingtool is a pestle.Duringmaintenance,rubbing methods are usually
usedforrubbing theflat ofcrankcase andinternal holeof connecting rod.
[2] Carbon DepositRemoving
To remove the carbon deposit oncomponent,we can use mechanical method orchemical method.
Mechanical methodis that scrape depositwithbamboo-scraperorspade andclean them with gasoline.
Immersethe component,brushthe carbon deposit offandcleanthemwithhotwater,which iscalled
chemical method.
3）Parts Inspection
Inspect theparts after cleaning.Thepurposefor inspection is to check whethertheparts need to berepairedor
replaced.Therearethree methods,i.e.direct inspection,instrument inspection and troubleshooting.
[1]DirectInspection
Directinspection is tocheckand judgethe conditionof partsby individual sensationinsteadof instrument.Itisa
simple and feasiblemethod,whichis widely used for maintenance.
[2] Instrument Inspection
Instrumentinspection is tomeasure thesizeandgeometry shape of partsbygaugeandapparatus;then compare
themeasuredvaluewithlimitingvaluetofigureouttheconditionof parts.Thismethod cangetanaccurate
judgement,but it needscareful inspection for theprecision of instrument and reasonableselection of parts.
[3]Troubleshooting
To find thelatentfault of parts，we can applytroubleshooting.Usuallyweadopt themethod of oil
immersion and knock during maintenance.Theprocess of thismethod is as following.First,immerse the
partsinto coaloilordiesel oil forseveral minutes.Second,takeoutand wipetheparts.Third,spreadtalcum
powder on the surface of parts. Finally, knock the non-working surface of parts gently with asmall hammer
. Inthis way,theknock canproducevibrationandoil thathasremained incrack willsplashfor vibration.
Thesplashed oil will dye the talcum powderyellow,so we can easily finda yellow mark in crack place.
Cleaningmethodsfor non-metal partsdifferin differentmaterials.The bestdetergentforrubber partsis alcohol.Donot
use coal oilor gasoline toclean rubber parts,because they can cause inflationand deformity of rubberparts.Gasoline is
suitable for clutchdisc and brake pads friction disc,while aqueous alkali is forbidden.
4）Repairmethods andskills
After disassembly,cleaning andinspection,the following isthe principal stage.Masteringthebasicskill
well is the key to ensure a good qualityofmaintenance.The skills formaintenance are as following:
[1]Chiseling,filing andscraping
Chiselingis toprocess metal parts by hammerand chisel.The functions arecutting andparting.
Filing is to raspoff the surface ofpartsby afile.Itincludes rasp anddelicate filing.Teeth ofafiledirectly
decide theroughness degreewhenfiling metalparts.Theoperationoffile isdifferent becauseof different
shape surface ofparts.
Scraping is aprocess whichscrapes off athin layer from the surface of parts. Itis adelicate work, so we
should scrapethepartsbit bybitwithgreat care.Usually,scrapingoff0.005～0.01mmeach time.Before
scraping,weneedto spread redlead onthe surfaceof parts.Then,matchthepartswith standardone.The
unmatchedparts are theaimofscraping.After several match and scraping,thecontact surface of parts is
bigger.So itreachesthe requirementandachieves the purpose.

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Reamingisafinefinish byreamer,whichcan increasethe precision degreeof holesonpartsanddecrease
theroughness degree.Itimproves the matchprecision between holeandshaft and the precisioncanreach
grade 6 tograde8.Thebasictool for reaming isareamer,suchasfixed reamer,adjustablereamer,conical reamer
and so on.Beforereaming,weneedto drill a bottom holein advance,which is for theprecision requirement of hole
shapedandmaking room forreaming procedure.
[5]Tapping and threaddie cutting
Tapping istoProcess internalthreadwithscrewtapandthread diecuttingis to processexternalthread with
threading die.Theessential tools fortapping is screw tap. Generally, screwtap consist of mastertap and plug tap.
Thedifferencebetween theseTwokindsoftapisthatmaster tapadoptaslightbevel angleon cuttingpart,instead,
plugtap adopt a steeply bevel angle.Aftertapping,weshould drilla bottom hole with chamfer.
Pleaserefer tothespecialized list orthefollowingformulaforthebit diameter ofbottom hole :
Diameterof drilling hole outsidediameterof screwthread -1.1mm × screw pitch(appropriate for ironand
copper)
Diameter ofdrillinghole outside diameter ofscrew thread-1.2mm × screw pitch(appropriate for steel and brass)
When cuttinginsidethreads,turnmastertapintothe chamfer-angle hole,thentake outand use plugtap to shape
thethreads.
Thetool foroutsidescrew threads cutting is screw plate.Screw plateincludes fixed screw plate,adjustable screw
plate andactivescrew plate.Usually,weusefixed screwplate,i.e.roundscrewplate.When cuttingoutside screw
threads,choose screw plate and diameterof club-shaped material accordingtherequired material,diameter of screw
thread and screw pitch.To makeproperchoice,pleaserefertothespecializedlistor thefollowing formula:
Diameter of clubshaped materialoutsidediameterof screw thread-0.13mm × screwpitch
Beveltheendof club-shaped material in 15 °～ 20 ° angle beforecutting outsidescrew threads.To ensureeasy
operation,thescrewplateand club-shaped material should be in vertical,therefore,theminimum diameter of cone
angleshould less than insidediameter of screw thread.
[6]Rectification
Theoperation thateliminatestheunevenness of plane-shaped,bar-shaped andcolumn-shaped parts is called
rectification. 。 Rectificationcanreshapethe parts.
Therectification depends on theflexibility of metal parts.Therefore,metal parts with good flexibility can be
rectified directly,suchassoft steel and red cooper ’ metalpartswith less flexibility need toanneal before rectification.
Theways for rectification aretorsion,extension,bending and expansion.
[7]Bonding
Bonding is widelyused inmanufacture and repairs because it operateseasily and canbedone without special
equipment andexpensivematerials. In addition,thebondingparts don ’ tneedto beprocessedbyhighprecision
machine,such as thebonding of handlebar and steering head,bonding of plastic label and spay-paint metal parts,
bondingofbrakedisc andbrakepads.Therearevariousadhesive,such as epoxyadhesive,phenolformaldehyde
adhesive andso on.
5 ） Motorcycle assembly
Thelast procedurein repair is assembly,which is a keyto ensurethegood quality of motorcycle.
[1]Assemblyincludes module assembly,partsassemblyandoverallassembly.Intheprocessofassembly,we
should abide by theprinciple that assemble modulefirst,then parts and theoverallfinally.The sequence ofassembly
isoppositetodisassembly,which istofirstassemblethe lastdisassembled components,and tolast assemble thefirst
disassembledcomponents.
[2]Moduleassemblyis thefirst stagein wholeprocess,which makes theparts into a singlemodule,suchas the
combination of front brakedrum cover,thecombination of brakepads ,thecombination of wheel.
[3]Parts assembly is based upon moduleassembly,which assembles theparts andmoduleas a whole,such as
front and rear wheelassembly,front fork assembly,shockabsorberassembly and so on.
[4]Overall assembly is thelast procedureto completethewholeworkingprocess,whichconnectsparts and
moduleswith frameaccording to installation sequenceby all means.
[5]Thesequencesofoverall assembly are similar.Theoperation is as following ： Firstly,finishallmodules
assemblyandpartsassembly,theninstallengineassemblyandgearboxassembly onframe.Secondly,install front fork
assembly,handlebar assembly,front and rear fenderassembly,shock absorber assembly,carrierassembly,front and
rear wheel assembly,fueltank assembly and seat assembly.Thirdly,install headlight,taillight,steering indicator,horn
and battery assembly.The fourth,connectall electriccircuitandcontrol cables.The fifth,install drivingchain, dentiform
belt,wind shield and chain cover orbelt cover.Last,lubricatethewholemotorcycle.
[6]Consultthefollowingreferenceaboutdisassembly,installation andinspection if there isany assemblyse-
quencedifferencewhich is causedby different typeand structure.
[7]Pay attention to thefollowing: ：
Choose a clean andwide place ； strictly followtheassemblyrequirements ； partsconnecting shouldaccord
with specification ;avoid misfitting and leavingout of any gaskets,cotter pin and fixing clip.
3Adjustmentafter Repair
Theinterconnectionof parts havebeenaffected in someextent afterrepair.To recovertheperformanceof
motorcycle,adjust them accordingto thespecification of user ’ smanual.adjust as follows:

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limitValue(mm)
20～30
30～40
10～12
2.0
0.8
0.8
0.8
0.8
operation/brake/shockabsorber/wheel
Table2-1
items StandardValue (mm)
axial
radial
front
rear
10～20
20～30
2～6
4.0
130
425
45
235
Section 3Adjusting Data ofMaintenance
1 ） IgnitionTimeAdjustment
If thereis a wrong ignition advance angle，it willcause a series of problems,such as hard engine starting ,
power decrease,high fuel consumption,engine overheating,uncomplete fuel burning,exhaust value overrun,
short servicelifetime and so on.Therefore,adjust ingitonadvance angle firstly.
If ignition system cannotwork well,check electricalignitiondevice,high voltage coil,ignition coil and
triggeringloop ofmagnetoandso on.
2 ） Carburetor Adjustment
Carburetor adjustment isveryimportant,whichdirectly decidesthe performanceofengine,so maintain
it asthe following:
Before carburetor adjustment,make sure the operation temperature of engine is in order,open choke
valve,check whetherthevalveclearanceand ignition timingare right,and ensureno leakage or blockof
engine andcarburetor.Carburetoradjustment includesidleadjustment andfluidleveladjustmentof float
chamber.The adjustmentcanmaketheoperationof engineidle stablerandavoidpoor orrichoilin
carburetor.
3）Clutch Adjustment
Clutchis usedto transferpower,so itplaysan importantrole intransmission system.Adjust the free stroke
ofclutchoperationgrip within 10mmand 20mm.For some motorcycles,there isa need to adjustadjust-
ing boltsof disengagement parts.
Freestroke of frontbrakelever
Freestrokeof rear brake pedal
Freestrokeofthrottlecontrol grip
Depthof flowerpatternon tire surface
Strokeoffrontshockabsorber
Freelengthoffrontshockabsorber spring
Strokeof rear shock absorber
Freelength ofrearshock absorberspring
Wheel hub runout
Axle runout

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MaintenanceCycle
Table2-2
Maintain themotorcycle according to the period thatislistedabove.Each capital letteron thelist stands
foras follows:
R-clean、A-inspect、L-lubricate、I-inspect、clean、adjust、lubricateorreplace
●indicates thatmaintainingthisitem byservice centerof ourcompany.If maintainitbyyourself,please
consult thismaintenance manual.
●● indicates thatmaintaining this itemonly byservice centerof ourcompany.To ensure riding safety,
please follow our advice.
Times
Items
Items
Period
Fuel system
Fuelfilter
Control system
Choke valve cable
Aircleaner 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
Shortenthe maintenanceperiodif motorcycleusuallyruns in dustyregion.
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 mainpipe
Fixed bolt of handlebar
Front axle nut
Rear axle nut
Engine suspension bolt
Fixed nutof rearshockabsorber
Locknut of chain wheel
Nut of rear rocker arm
fork shaft nut
fork shaft nut
Items Specification TorqueValue(N.m)
●
●
●
●
●
●
●
●●
●●
●●
sparkplug gap
CAUTION
Valveclearance
Driving chain
Battery
Abrasion ofbrakepads
Brake system
Brake lightswitch
Headlightadjusting
Main/sidestand
Front/Rear shock absorber
nut/bolt/fixingcomponents
Outter tire of front and rear wheel
steeringsystembearing

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Section1Fuel SupplySystem
1TheStructure andWorking PrincipleofFuelSystem
[1]FuelTank
Fuel tankisjointedbythe armorplatewhichis normally 0.8mm 1.0mm.Somefuel tankisjointed
apertured clapboard inside,which not onlystrengthens the fuel tank,butalsoavoids the fuel gurgitation
duringriding.Becauseofthestrongerosion ofoil,itmust begalvanized onthe surfaceof fueltank.There
isa fuel-addingholeonthe topoffueltankand closethefuelcap whichhas airhole,sothatitcan avoid
fuelleakage duringriding andensurethebalancedpressureofinner and outerfueltank.So thatfuelcan
flow out naturally.
[2]FuelPump
The fuel pump consists of pump, support and oil pressure adjuster. Flexible installationcan decrease
the vibrationonthefuel pump.The pump installed in the fuel tank is toget asimple construction and
non-leakage.
Thepumpadopts turbo, singlestageand electrictype. It is drivenby aDCmotor with 12V and
controlled by ECU through the pumprelay. Thereisa one-wayvalveatthe exit of thepump which can
prevent theoil from flowing back to the bank when engine stops and ensures agood starting performence.
[3]Fuel Injector
Fuel supply system consistsof fueltank,fuelpump,injector,fuel filterandoilpipe.
Fuel injectorinjectsthe proper amount ofatomized fuelintotheintake pipeofengineby ECU,thusthe
atomized fuel can participate in the combustionprocess in thecylinder.
[4]Fuel Filter
Fuel filter connects withtheoil way between the electric fuel pump and fuelrail. This system adopts the
dedicatedfilterfor EFIto makeimpuritiesnot block thenozzle. The housingoffilter has enoughintensityand
it neverbreak due tothefuel pressure.
[5]FuelPipe
Thepressure of thefuel supply systemis 250kPa. Itsselection must have enough safetyfactor for security.

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ENGLISH
[1]The capacity of the fuel tank is 16L。
When refueling, pleasekeep aircirculationandkeep
away from sparksand flame.
Fuelishighly combustible.Smokingand getting
close to the fire are strictly forbidden
Switch offthe motorcycleand operate inanairyplace.
Warning fuel tank cap
2Disassembly andMaintenanceof FuelSystem
The brandofoilallowed is93#.Do notusing
other type of oil.
[2]Check the fuel tank cap for fuel leakage.Replacethe
sealing ring ofcapifnecessary.
[4]Checkthefuelpipeforfuelleakageoraging.Check
filter for block,repairorreplaceit ifblocked.
[3]Checkthe fuel tank for fuel leakage.Replace or repair it
if necassery.
If the fuel tank is deformed by the collisionof
external force,repair it tooriginal conditionwith
wooden hammer.Ifthefueltankhascracks,
replace the fuel tank without repair.
If the fuel pipehas fuel leakageor aging,replace it.
Before replacingthe fuel pipe or filter, Shut up
ignition switch to stop thefuelpump andavoid the
fuel flow out of the fueltank.
WARNING
CAUTION
openfuel tank
CAUTION
checkfuel tank
checkthe filter

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ENGLISH
[5]First of all, dismantletheleftand right side cover and
seat.Thenremovefixedboltandtakeout thefuel tank.
Keep the oil away from fire when dumping the oil.
[8]Check the pump seal ring for aging, breakingor oil
leakage. Replaceit ifnecessary.
[7]Takeoutthe pump,andthen cleanthe oil sludge and
water in thetankwith oil sludge.
remove the
fuelpump
[6]Removethesix fixedbolt(M5×16) of fuelpump
byhexagon wrench.
Please dump oil firstand keep away from
the fire when dismantling thepump.
WARNING
After cleaning, the fuel tank could beused
when drying out.
CAUTION
dismantlethe
fueltank
dismantlethe
fuelpump
WARNING
check seal ring

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ENGLISH
[9]Checkthemotor of fuel pumpfor running.And clean
orreplacethe fuel strainer.
Replacethefuelfilterwhenthemotorcycle
drivesabout 8000~10000Km.
ADVICE
check the
fuelpump
3The cause,troubledescription and repair methodof fuel supplysystem
Maintenance ofFuelSupplySystem
Fueltankbody isbroken. leakageoffueltank Repair orreplacefueltank.
Fuelsupplyisnotgood.Motorcycle cannot start. Unblock the ventholeof
fuel tank cap.
fueltank
fuel pump
The venthole of fuel
tank cap is blocked.
Table4-1
component
description cause troubledescription
of component troubledescriptionof
motorcycle repair method
Fueltank isdeformed. Theappearance ofmo-
torcycleis bad. Repairor replacefuel
tank.
Fueltank isaccidented.
Motorcycle is hard to be
startedorcannotbe
started.Theenginepower
is not enough andthe
idle speed is not stable.
Cleanoil-filter screen.
Fuel supplyisnotgood.
Cleanorreplacefuel pump.
Fuelsupply is not good. Motorcyclecannot be
started.
Thefuel pumpbodyis
blocked.
Themotor offuelpump
does not run Fuelcan not be supplied. Motorcyclecannot be
started. Replace themotor.
Fuel pressureregula-
tor is blocked. Fuel cannotbeback. Oil duct is cracked
Fuel pressureregulator is
normallyopen. The pressure of oil
supply is low.
Clean orreplace the
pump assembly.
Motorcycleis hardtobe
startedorcannotbe
started.The enginepower
is not enoughand the
idle speed is not stable.
oil-filter screen is dirty
orsmallholesare
blocked.