Manual Taller Outlook Dierre 125 Efi Idioma Ingles PDF

OUTLOOK(DIERRE) 125 EFI
Service Manual
KEEWAY Motorcycle Co., Ltd.

Contents
Contents ................................................................................................................................................................. - 1 -
Preface ................................................................................................................................................................... - 5 -
Preparing documents ..................................................................................................................................... - 6 -
Inspection/Adjustment ................................................................................................................................. - 15 -
I. Battery/Charging System.................................................................................................................................. - 27 -
1.1 Preparing documents ............................................................................................................................. - 27 -
1.2 Failure diagnosis .................................................................................................................................... - 28 -
1.3 Battery ................................................................................................................................................... - 29 -
1.4 Charging system .................................................................................................................................... - 30 -
1.5 Voltage/current regulator ....................................................................................................................... - 31 -
1.6 Magnetor charging coil .......................................................................................................................... - 32 -
1.7 Magnetor disassembly ........................................................................................................................... - 32 -
II. Ignition System ............................................................................................................................................... - 35 -
2.3 Ignition system check ............................................................................................................................ - 37 -
2.4 CDI Group ............................................................................................................................................. - 40 -
2.5 Ignition coil (picture to be updated) ...................................................................................................... - 40 -
2.6 Trigger ................................................................................................................................................... - 41 -
III. Startup System ............................................................................................................................................... - 44 -
3.3 Startup motor ......................................................................................................................................... - 45 -
3.4 Starter relay............................................................................................................................................ - 47 -
IV. Bulbs/Switches/Meters .................................................................................................................................. - 49 -
4.3 Replacement of headlamp bulbs ............................................................................................................ - 49 -
4.4 Replacement of front steering lamp bulbs ............................................................................................. - 50 -
4.5 Replacement of tail lamp bulbs ............................................................................................................. - 50 -
4.6 Meter (picture to be updated)................................................................................................................. - 51 -
4.7 Main switch ........................................................................................................................................... - 51 -
4.8 Horn ....................................................................................................................................................... - 52 -
4.9 Handlebar switch ................................................................................................................................... - 52 -
V. Brake ............................................................................................................................................................... - 55 -
5.1 Maintenance instruction......................................................................................................................... - 55 -
5.3 Front disc brake ..................................................................................................................................... - 56 -
5.4 Rear disc brake ...................................................................................................................................... - 58 -
VI. Body .............................................................................................................................................................. - 61 -
- 1 -
VII. Front Wheel/Front Suspension ..................................................................................................................... - 63 -
7.3 Front wheel ............................................................................................................................................ - 64 -
7.4 Steering handle ...................................................................................................................................... - 66 -
7.5 Front fork ............................................................................................................................................... - 67 -
7.6 Radiator/expansion tank assembly......................................................................................................... - 68 -
VIII. Rear Wheel/Rear Suspension ...................................................................................................................... - 70 -
8.3 Rear wheel ............................................................................................................................................. - 71 -
8.4 Rear absorber/rear swing arm ................................................................................................................ - 72 -
IX. Lubricating System........................................................................................................................................ - 76 -
9.3 Fuel pump .............................................................................................................................................. - 77 -
X. Cylinder Head/Valve ....................................................................................................................................... - 81 -
10.1 Preparing documents ........................................................................................................................... - 81 -
10.2 Failure diagnosis .................................................................................................................................. - 82 -
10.3 Cylinder head ....................................................................................................................................... - 82 -
10.4 Cylinder head check ............................................................................................................................ - 84 -
10.5 Valve .................................................................................................................................................... - 85 -
10.6 Valve check .......................................................................................................................................... - 86 -
10.7 Replacement of valve guide................................................................................................................. - 87 -
10.8 Adjustment of the valve retainer .......................................................................................................... - 89 -
10.9 Installation ........................................................................................................................................... - 90 -
XI. Cylinder Block and Piston ............................................................................................................................. - 92 -
11.1 Preparing documents............................................................................................................................ - 92 -
11.2 Failure diagnosis .................................................................................................................................. - 93 -
11.3 Cylinder block...................................................................................................................................... - 93 -
11.4 Piston ................................................................................................................................................... - 94 -
11.5 Piston installation ................................................................................................................................. - 98 -
11.6 Cylinder installation ............................................................................................................................. - 98 -
XII. Drive Face/Clutch/Driven Wheel ............................................................................................................... - 101 -
12.1 Preparing documents ......................................................................................................................... - 101 -
12.2 Failure diagnosis ................................................................................................................................ - 101 -
12.3 Left crankcase cover .......................................................................................................................... - 102 -
12.4 Drive face .......................................................................................................................................... - 102 -
12.5 Clutch/driven wheel ........................................................................................................................... - 105 -
12.6 Breakdown of clutch and driven wheel ............................................................................................. - 106 -
12.7 Installation ......................................................................................................................................... - 110 -
XIII. Decelerator ................................................................................................................................................ - 112 -
- 2 -
13.3 Gearbox ............................................................................................................................................. - 112 -
13.4 Installation ......................................................................................................................................... - 114 -
XIV. Crankcase .................................................................................................................................................. - 115 -
14.1Preparing documents .......................................................................................................................... - 115 -
14.3 Crankcase........................................................................................................................................... - 116 -
14.4 Installation ......................................................................................................................................... - 118 -
XV. Cooling System .......................................................................................................................................... - 120 -
15.3 Thermostat ......................................................................................................................................... - 121 -
XVI. Exhaust Emission & Control System ....................................................................................................... - 125 -
16.1 Warranty on the exhaust emission & control system ......................................................................... - 125 -
16.2 Instructions on the periodic maintenance .......................................................................................... - 126 -
16.3 Mechanical function of the exhaust control system ........................................................................... - 127 -
16.4 Catalytic conversion system .............................................................................................................. - 127 -
XVII. EFI System .................................................................................................................................................. 129
17.1. Connection of the EFI system ............................................................................................................... 129
17.2. Engine controller (MC21)..................................................................................................................... 130
17.3. Power supply requirements ................................................................................................................... 135
17.4. Work temperature.................................................................................................................................. 135
17.5 Maintenance and repair.......................................................................................................................... 135
XVIII. M3 and M3.5 Fuel Injector ........................................................................................................................ 137
18.1. List of spare parts.................................................................................................................................. 137
18.2. General work principle ......................................................................................................................... 137
18.3. Appearance ........................................................................................................................................... 138
18.4. O-ring.................................................................................................................................................... 139
18.5. O-ring replacement ............................................................................................................................... 139
18.6. Suggested lubricant............................................................................................................................... 139
18.8. Temperature range ................................................................................................................................ 140
18.9. Fuel contaminants ................................................................................................................................. 141
18.10. Cable arrangement .............................................................................................................................. 141
18.11. Instructions.......................................................................................................................................... 141
18.13. Replacement ....................................................................................................................................... 143
18.14. Replaceability ..................................................................................................................................... 144
18.15. Fuel injector blocked .......................................................................................................................... 144
18.16. Cleaning .............................................................................................................................................. 145
XIX. Throttle Valve Assembly............................................................................................................................... 145
19.2General work principle ........................................................................................................................... 146
19.3. Appearance ........................................................................................................................................... 146
19.4. Technical parameters ............................................................................................................................ 146
- 3 -
19.5. Work environment ................................................................................................................................ 147
19.6. Disassembly of the throttle valve.......................................................................................................... 147
19.7. Cleaning ................................................................................................................................................ 147
19.8. Installation of the throttle valve ............................................................................................................ 148
19.9. Precautions............................................................................................................................................ 148
19.10. Instruction ........................................................................................................................................... 148
XX. Water Temperature Sensor for the Engine ..................................................................................................... 150
20.1 List of spare parts................................................................................................................................... 150
20.3. Appearance ........................................................................................................................................... 150
20.4. Installation requirements....................................................................................................................... 150
20.6. Storage environment ............................................................................................................................. 151
20.7. Electric environment ............................................................................................................................. 151
20.8. Cleaning samples .................................................................................................................................. 151
XXI. Intake Air Temperature Sensor ..................................................................................................................... 152
21.3. Appearance ........................................................................................................................................... 152
21.5. Installation requirements: ..................................................................................................................... 152
21.6. Cleaning samples .................................................................................................................................. 152
XXII. Oxygen Sensor ............................................................................................................................................ 153
22.3. Appearance ........................................................................................................................................... 153
22.5. Installation requirements....................................................................................................................... 154
22.6. Fuel quality requirements ..................................................................................................................... 154
XXIII. Fuel Pump Assembly ................................................................................................................................. 154
224. List of spare parts................................................................................................................................... 154
23.3. Appearance and structure ...................................................................................................................... 155
23.4. Dimension ............................................................................................................................................. 156
23.5. Label and mark ..................................................................................................................................... 156
23.8. Maintenance procedures ....................................................................................................................... 157
XXIV. Failure Diagnosis ....................................................................................................................................... 163
24.1. Diagnostic tools .................................................................................................................................... 163
24.2. Pin definition for the diagnosis interface: ............................................................................................. 163
24.3. Software instruction .............................................................................................................................. 164
24.4 Cross reference table for malfunction code ........................................................................................... 168
Circuit Diagram ................................................................................................................................................. 172
- 4 -
Preface
This maintenance manual is used for operating and maintaining EFI Motorcycle
OUTLOOK (DIERRE) 125.
Preparing Documents include all necessary instructions and statements. Please
carefully read this manual before operation.
Inspection & Adjustment states how to check and adjust your motorcycle. All
safety rules and maintenance regulations shall be carried out from the beginning of
periodic inspection.
Except for Chapter I, the rest chapters explain the disassembly/ assembly/
inspection of engine, entire motorcycle and electrical parts.
Breakdown drawing, systematic drawing, failure analysis and statements are
contained at the first part of each chapter.
Please note that photos, pictures or instructions are for your reference only. The
actual object may differ from this mentioned here. We will not make notification for
any discrepancy.
KEEWAY Motorcycle Co., Ltd.

- 5 -
Preparing documents
General safety Maintenance rules
Specification table Failure diagnosis
General Safety
Carbon monoxide
Engine must be started up in a well-ventilated place, not in a closed area.
Note
Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human.
Start up engine in an open place. The exhaust cleaning system shall be adopted if engine is started up in a closed
area.
Petrol
Ventilation is required for working places. Fire is strictly forbidden in any working place or where petroleum is
stored.
- 6 -
Maintenance Rules
Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage.
Clean up the surface of components or assembly parts before removing or opening the shield for maintenance,
which can prevent dirt from falling into the engine, chassis or braking system.
Wash and dry parts with air compressor after disassembly and
before measurement of attrition value.
Do not bend or twist it. Otherwise it will cause difficulty in

operation or early damage.
error
Solvent or oil can easily damage aging rubber articles. Check

rubber before reassembly and replace rubber if necessary.
boot
When loosening assembly parts, please start from outside to

inside. Small assembly parts shall be loosened first.
Complex assembly parts, such as gearbox, shall be stored in

proper order for facilitating installation in the future.
- 7 -
Please specially note important connections before disassembly.
Replace parts which will not be in use before disassembly.
Bolts and screws with different length shall be separately used for
different assembly parts and shields, and they shall be correctly
mounted. Insert a bolt into a hole to check whether it is proper if
you are confused.
Fill the groove with grease before mounting an oil seal. Check
whether the oil seal is smooth or damaged during assembly.
When installing a hose (fuel, vacuum or cooling agent), insert its end into the bottom of the connector so that the
hose clip can properly fix the connector. Rubber or plastic
dirt-proof boot shall be mounted at the original design position.
groove clip connector
During dismantling ball bearings, one or two (inside & outside)
bearing rollers shall be supported by tools. Ball bearings may be

damaged during disassembly and have to be replaced if only one
roller (either inside or outside) is imposed with force.
Bearings will be broken under either

occasion as mentioned.
- 8 -
Special Tools
Special tools refer to tools which are specially designed for assembling or disassembling some motorcycle
parts on special positions. Applicable special tools are necessary for precise adjustment and installation. With
them, parts and accessories can be mounted safely, reliably and rapidly, which improves efficiency and saves
energy.
1Tools for repairing the engine
Special tools are required for properly disassembling/assembling some engine parts.
Table and drawing (1-1, 1-2) of special tools for disassembling/assembling engine parts are as follows:
Table 1-1
Name Remark
Special socket spanner Used for assembling/disassembling bolts for flywheels, Fig. 1-3
Clutch clamp holder Fig. 1-4
Flywheel puller Fig. 1-5
Feeler gauge Fig. 1-6
Bearing disassembly tools Fig. 1-7
Bearing assembly tools Fig. 1-8
Oil seal remover Fig. 1-9
Handle for dismantling tools Fig. 1-10
Piston pin pulling device Fig. 1-11
Piston pin pliers Fig. 1-12
Socket spanner for spark plug Fig. 1-13
Clutch thickness measuring device Fig. 1-14
Cylinder diameter measuring device Fig. 1-15
Dial indicator Measuring the inner diameter of piston pin, Fig. 1-16
Table 1-2 (continued)
Fig. 1-3 Fig. 1-4
- 9 -
Fig. 1-5 Fig. 1-6
Fig. 1-7 Fig. 1-8
Fig. 1-9 Fig. 1-10

handle
- 10 -
Fig. 1-11 Fig. 1-12
pliers piston
Fig. 1-13 Fig. 1-14
Fig. 1-15 Fig. 1-16

2Tools for repairing the chassis
Table and drawing (1-17, 1-18) of ordinary tools and special tools for disassembling/assembling chassis parts
are as follows:
Table 1-17
Name Remark
Torque spanner Fig. 1-19
Inner hexagon spanner Fig. 1-20
Socket spanner Fig. 1-21
Micrometer Fig. 1-22
Magnetic rack, V-block Fig. 1-23
Dial indicator Fig. 1-24
Vernier calipers Fig. 1-25
Circlip pliers Fig. 1-26
Screwdriver with striking cap Fig. 1-27
Tool for assembling oil seal of front fork Fig. 1-28
Tool for hammering seal of front fork Fig. 1-29
Steering nut spanner Fig. 1-30
(1) Ordinary tools for repairing the chassis

- 11 -
Fig. 1-19 Fig. 1-20
1. socket head 2. crank handle 3. ratchet spanner

4. connecting rod
Fig. 1-21 Fig. 1-22
Fig. 1-23 Fig. 1-24
Fig. 1-25 Fig. 1-26
Fig. 1-27 Fig. 1-28
- 12 -
(2) Special tools for repairing the chassis: tool for hammering seal of front fork
Fig. 1-29
(3) Steering nut spanner
Fig. 1-30
3Tools for electric parts
Table and drawings (1-31, 1-32) of special tools for testing electric parts are as follows:
Table 1-31
Name Remark
Multimeter Fig. 1-33
Ignition tester Fig. 1-34
Fig. 1-33
Fig. 1-34
- 13 -
Specification (EFI Motorcycle QJ125T-30)
EFI
Model Motorcycle Engine type QJ153MI-2A
QJ125T-30
Length mm 2070 Fuel type Unleaded petrol
No. of
Width mm 715 1
cylinder
Height mm 1260 ID stroke 52.4*57.8
Total
Wheelbase mm 1360 Engine 125ml
displacement
Forward
50 Startup Electric
shaft
Weight kg
(Curb weight) Backshaft 80 Cooling Water cooling
Total 130
Force-feed and
Front wheel Lubrication
splash
Tyre 100/80-16
Size Rear wheel
Air filter Paper-made
120/80-16
Capacity of
gasoline 7.40.2L
tank
Clutch Automatic
Max. speed 90km/h

Transmission
gear Gradeability 20 degree
Transmission CVT
Idle speed
1500100rpm/min
-rpm
Drive Belt drive Performance Max. torque 12.5N.m/7500rpm
Battery 12V-6Ah/
Max. Hp 8.9kW/8250 rpm
capacity/type dry-charged
Electric Magnetor QJ153-212V Compression
10.41
devices type 200W/8500 rpm ratio
Cylinder
Spark plug CR8EH (NGK) 1.25MPa/1500rpm
pressure
- 14 -
Unit of front
Spark plug
0.6-0.7mm Braking fluid brake 240mm
gap
system disc (mm)
Electric spark Unit of rear
Ignition lighter fluid brake 240mm
DC capacitance disc (mm)
Inspection/Adjustment
Preparing information Cylinder pressure
Periodic Maintenance & Inspection Table Gear oil
Engine oil/ Oil filter Replacement of gear oil
Fixing steering stem bearing & handlebar Driving belt
Inspection & adjustment of throttle cable Free stroke of front/rear brake
Air filter Inspection of brake fluid level
Spark plug Headlamp
Battery Clutch
Ignition timing Front/rear suspension system
Rim/tyre Bolt/nut/fastener
Tyre specification
Preparing Principles
General
Warning!
Make sure that it is well ventilated before starting the engine. It is forbidden to start it in a closed area.
Exhaust gas, which contains monoxide, may cause unconsciousness or even death of human being.
Petrol is liable to volatile or explode under certain condition. Ventilation is required and no any fire exists in
working places. Fire is strictly forbidden in working areas or where oil is stored.
- 15 -
Specification
Engine
Idle speed 1500100rpm/min

Spark plug gap 0.6-0.7mm
Spec. of spark plug C5HSA(NGK)
Cylinder compression 1.25Mpa/1500rpm
pressure
Ignition time BTDC12 degree 1 degree, 1500100rpm
Frame
Free stroke of front brake 10-20mm

lever
Free stroke of rear brake 10-20mm
lever
Specification Tyre pressure
Front 100/80-16 225kpa
EFI
Tyre pressure unit: Kpa wheel
Motorcycle
Rear 120/80-16 225kpa
QJ125T-30
wheel
Locking nut for 55-62 Nm
Torque front wheel spindle
value Fixing nut for rear 100-113 Nm
wheel
- 16 -
Periodic Maintenance & Inspection Table
Service cycle and time Per Per Per Per Per Per
300 1000 3000 6000 12000 14500
KM KM KM KM KM KM Tools
Inspection item
One Three Six Twelve Fifteen
New month months months months months
* Air filter I C C R C Ordinary tools
* Petrol filter I I R Ordinary tools
* Fuel filter C C C Ordinary tools
Replacement of engine
R Replacement every 1000KM Ordinary tools
fuel
Tyre pressure
Tyre pressure I I I I I I
gauge, inflator
Densimeter,
Battery inspection I I I I I I
multimeter
Actuation gap inspection I I I I I I Ordinary tools
Inspection of steering
I I I Ordinary tools
handle fastening
Absorber working
I I I Ordinary tools
inspection
Screw fastening
I I I I I I Torque spanner
inspection
Oil leakage inspection for
I I I I I I Ordinary tools
gearbox
Inspection or replacement
* I I R R I Ordinary tools
of spark plug
Replacement of gearbox
* I Replacement every 5000KM Ordinary tools
oil
Lubrication of each part L L Lubricator
Exhaust pipe I I I I I I Ordinary tools
* Ignition timing I I I I I I Timing lamp
Exhaust gas inspection at Tachometer, CO
* A I A A A A
idle speed HC analyzer
* Throttle inspection I I I I I Ordinary tools
Fuel pipeline inspection I I I I I Ordinary tools
Lighting/metering/electric
I I I I I I Visual multimeter
devices
- 17 -
Main stand bracket I I I Ordinary tools
Absorber I I I I Ordinary tools
Torque force of engine
* I I I I I Torque spanner
bolts
Anticipated Inspection
1 Ignition systemobviously continuous ignition abnormality, engine fire or overheating, which requires
inspection and maintenance.
2 Carbon fouling eliminationobviously insufficient horsepower, which requires carbon fouling removal
from cylinder head, piston head and exhaust system.
3 Piston & cylinderexcessive abrasion; replace cylinder if it is blocked.
Please have your motorcycle inspected and adjusted periodically at KEEWAY distributors for being in best
condition.
The above table is established under the presupposition of 1000 km/month.
IInspection AAdjustment RReplacement CCleaning LLubrication
Note: 1. * Regulations on exhaust emission made by the State Environmental Protection Agency shall be
complied with. Maintenance must be carried out in accordance with the instruction manual supplied by the
company. We are not responsible for any loss rising from private adjustment or maintenance.
2. Increase frequency of washing air filter if your motorcycle runs on the sandy/gravel road or under heavily
polluted environment so as to extend its service life.
3. Motorcycles which often run at high speed or with high mileage shall be maintained frequently.
Engine oil/filter
Oil level
*Note
The motorcycle should be parked on a
flat ground when checking its oil level
After the engine runs for 2-3 minutes
or stops running for about 2-3 minutes,
check the oil level.
Check the oil level.
Add oil to the upper limit when it is below the lower limit.
dipstick upper limit lower limit
filter
- 18 -
Oil replacement
*Note*
It will be easier to change oil when the
engine is warming up.
Turn off the engine.
Remove the bolt at the bottom of the crankcase and discharge oil.
When oil is discharged completely, you can install the bolt and
packing washer after they are cleaned.
Add oil to the required level.
Check oil leakage when the engine operates at its idle speed for minutes.
Check the oil level again.
Throttle cable inspection/adjustment
Check whether the throttle cable works smoothly.

Check the free stroke of the throttle cable.
Free stroke: 5-10mm
Loosen the fixing nut and then rotate the adjusting nut for
adjustment.
fixing nut adjusting nut
Air filter (picture to be

updated)
Filter replacement.
Remove the fixing screws of air filter.
Remove the top cap of air filter.
Remove the cartridge from the filter.
clamp assembly
Check whether the cartridge is stained or damaged.
- 19 -
Replace it if necessary.
Remove the clamp assembly.
Remove the filter.
Check whether the filter is stained or damaged.
Replacement time
Replace it as early as possible if the motorcycle
is always running on rainy days or on rugged
road.
*Note*
Make sure the air filter cap is well
installed before installing the filter.
top cap of the air filter mounting screw resonance box body
cartridge
Spark plug
Remove the spark plug.

Check whether the spark plug is damaged or stained or has carbon
fouling.
If yes, please clean it with spark plug cleaner or steel brush.
Check spark plug gap.
Gap: 0.6-0.7mm
*Note
For the installation of spark plug, it
shall be installed with hand first and
then fastened with spark plug sleeve.
spark plug gap
- 20 -
Igition timing (picture to be updated)
*Note
Check the ignition system if ignition timing
is incorrect.
Remove the fastening bolt.

Remove the magneto end cap.
Check ignition timing with ignition timing lamp.
fastening bolt magnetor end

cap
Cylinder pressure
Operate it when the engine warms up.

Remove the seat and body guard.
Remove the spark plug.
Install the cylinder pressure gauge.
At full throttle, measure the cylinder pressure by starting
the engine.
Compression pressure: 1.25Mpa/1500rpm

Following items shall be checked in case of extra-low pressure: measure cylinder pressure
whether the spacer of cylinder head is damaged;
whether piston ring is damaged;
whether piston ring is worn;
whether the piston, cylinder or valve is worn.
When compression pressure is too high, please check whether there is too much carbon fouling inside the
combustion chamber and at piston head.
- 21 -
Gear oil
Inspection
*Note
Set the middle kickstand on the flat ground
and keep the motorcycle upright for
checking the oil level.
Remove the oil-check bolt after the engine is stopped.

It is good if the oil level is at the lower limit of the
oil-check bolt hole.
Add gear oil when the oil level is too low. drain bolt right cover
Install the oil-check bolt.
*Note
Make sure whether the bolt is well sealed,
slippery or damaged.
Gear oil replacement
Remove the oil-check bolt.

Remove the drain bolt and gear oil is drained.
Install the drain bolt.
*Note
Make sure whether the bolt is well sealed,
slippery or damaged.
Add gear oil. drain bolt right cover

Check whether there is oil leakage in any part.
Install the oil-check bolt.
Drive belt
Remove the cover of left crankcase.

Check whether the drive belt is ruptured or abraded.
Periodically maintenance shall be guaranteed, and replace
the drive belt if necessary.
drive belt
- 22 -
Free stroke of front/rear brake
Free stroke of front brake

Measure the free stroke of front brake at the tip of the brake
lever.
Free stroke: 10-20mm
Free stroke of rear brake

Measure the free stroke of rear brake at the tip of the rear brake
lever.
Free stroke: 10-20mm
Inspection of brake fluid level
Brake to the maximum and check the oil level through the oil
sight glass. In case the brake fluid level is at or below the arrow
in the picture, certain brake fluid shall be added until it reaches
the upper limit.
Note:
The fuel pump assembly shall be parallel with the ground
during inspection.
fuel pump body oil sight glass
- 23 -
Headlamp
Remove the front shield.

Disconnect the connector of the headlamp.
Remove the headlamp.
Clutch
Start the engine and increase its speed gradually to check the
work condition of the clutch. If the motorcycle fails to run or the
engine flames out, you should check the clutch block.
Front/rear suspension system Compress

upwards or
downwards
Front
Pull the front brake tight; compress the front absorber
upwards or downwards for check.
Check whether there is oil leakage in the front absorber
and whether any component is damaged or loosened.
compress upwards or downwards
Rear
Compress the rear absorber upwards or downwards for
check.
Check whether each part of the rear absorber is damaged or
loosened.
Suspend the rear wheel and check shimmy.
Check whether the suspension bushing of the engine is
loose or not.
compress upwards or downwards
- 24 -
Rim/tyre
Check whether tyres or rims have any crack, nail or any other damage.
Check tyre pressure.
*Note
Check tyre pressure when it is cold.
Required pressure Unit: Kpa

Specification Tyre pressure
Front 100/80-16 225
EFI
wheel
Motorcycle
Rear 120/80-16 225
QJ125T-30
wheel
Check whether the locking nut of the front wheel spindle is

loose.
Check whether the fixing nut of the rear wheel is loose.
Tighten it to the required torque value if it is loose.
measure tyre pressure
Torque value: locking nut of the front wheel spindle 55-62 Nm
fixing nut of the rear wheel 100-113 Nm
Fixing steering stem bearing and handlebar

(picture to be updated)
Move the handlebar to confirm there is no wire interference.

Rotate the front wheel and move the handlebar freely for check.
If the handlebar is not moved freely or loosened, check the steering
stem bearing.
move from side to side
- 25 -
FBT switch lock assembly stabilizer battery
startup motor
Charging System
- 26 -
I. Battery/Charging System
Preparing documents -------------1.1 Failure diagnosis --------------1.2
Battery -----------------------------1.3 Charging system ---------------1.4
Voltage/current regulator --------1.5 Charging coil of magnetor----1.6
Disassembly of magnetor--------1.7
1.1 Preparing documents
Work Instructions
*Note
1. Battery can be charged or discharged repeatedly. If it is placed after discharge, its service life will be shortened
and performance is undermined. Normally, the battery performance will be degraded after two or three years. For
battery with performance degradation (reduced capacity), voltage will recover temporarily after charging but
decrease sharply when loading.
2. Battery overcharge: normally, overcharge can be judged upon the battery. In the case of short circuit inside the
battery, its terminal is unable to detect voltage or the detected voltage is very low. Regulator failure: overvoltage
inside the battery will shorten its service life.
3. The battery will be self-discharged if being stored for a long time, which reduces its capacity. It shall be charged
about every three months.
4. Check the charging system following the sequence listed on the failure diagnosis table.
5. Do not remove the connector when there is current through electrical parts, otherwise it will cause overvoltage
and damage to electrical parts inside the voltage regulator. Please operate it after the main switch turns off.
6. It is unnecessary to check the maintenance-free battery and add electrolyte and distilled water.
7. Check all the electric load.
8. Emergency charging can only be used under emergency situation.
9. Remove the battery from the motorcycle for emergency charging.
10. Do not use electrolyte-added batteries when interchanging batteries.
11. Use a voltmeter to check charging condition of the battery.
Preparing principles
Item Specifications
Capacity/Type 12V-6AH/ dry-charged
Battery
Voltage Fully charged 13.1V
- 27 -
20 Necessary 12.3V (not working for 1h)
charging
Charging current Standard: 0.6A, quick: 6A
Charging time Standard: 10-15 hours, quick: 30 mins
Capacity 200W/8500rpm
Magnetor
Coil impedance (20) Between white-black 3.3-3.5
Voltage Type Three-phase full-wave
regulator Charging voltage 14.50.5V/5.000rpm
Tightening torque force Tools

Rectifier bolt 5.0 Nm Universal fixing spanner
High-voltage coil fixing bolt 9.0 Nm Flywheel remover
Flywheel fixing nut 5.0 Nm Test instrument
Body guard bolt 9.0 Nm Multimeter
1.2 Failure diagnosis
Power supply dead Interrupted current

Battery overdischarge Poor contact of the charging wire
Unconnected battery wiring Poor contact of the charging system
Fuse blow Poor contact or short circuit of the lighting system
Poor switch
Low voltage Poor charging system

Poor battery charging Poor contact, short circuit or open circuit of wire terminals
Poor contact Poor voltage/current regulator
Poor charging system Poor magnetor
Poor voltage/current regulator
- 28 -
1.3 Battery
1.3.1 Battery disassembly

Remove the battery cover.
Remove the fixing plate.
Remove the negative lead and then positive lead.
Remove the battery.
Warning!
During the removal of the positive

terminal, the tool should not be contacted
with the frame. It is dangerous that spark
caused by short circuit will ignite
petrol and destroy the battery.
battery cover fixing plate assembly
Install the battery in a reversal order. battery battery box pedal
*Note
First positive terminal and then negative
terminal to prevent short circuit.
Check the charging situation (open circuit voltage).

Open the battery cover and remove the fixing plate assembly of the battery.
Remove the lead of the battery connector.
Measure voltage between terminals.

Fully charged: 13.1V
Insufficiently charged: 12.3V (not working for 1h)
*Note
Use a voltmeter to check the charging
situation.
1.3.2 Charging
Connection method: connect the positive terminal of the
charger with the positive terminal of the battery;
connect the negative terminal of the
charger with the negative terminal of the battery.
- 29 -
Warning!
The battery should be far away from fire
source.
Turn off the charger before or after
charging to avoid explosive danger caused
by spark which may exist in any
connection.
Comply with the current and time
requirements for charging as stated on the
battery.
*Note
Except emergencies, you should not use
emergency charging.
Measure voltage in 30 minutes after the
battery is charged.
Charging current: standard: 0.6A

quick: 6.0A
Charging time: standard: 10-15 hours
quick: 30 minutes
Charging completed: open circuit voltage: above 12.8V
1.4 Charging system
1.4.1 Short-circuit test

Remove the earth lead from the battery. Install a
voltmeter between the negative terminal and the earth
lead. Turn off the switch. Check short-circuit.
*Note
Connect the positive terminal of the
multimeter with the negative terminal of
the battery.
Check whether there is short-circuit in the main switch or

in the main wire in the case of any abnormality.
- 30 -
1.4.2 Charging check
Use a multimeter to check the charging status of the battery
when it is being fully charged.
Install the fully charged battery after the engine warms up.
Connect a voltmeter between terminals.
Remove the main fuse and connect an ammeter between
terminals.
Start the engine and increase its speed gradually to measure
the limiting voltage and current.
Limiting voltage/speed: 14-15V (5.000rpm)
Check the voltage regulator if the limiting voltage is not
within its required range.
Check the limiting voltage of the lighting system.
*Note
Set the multimeter to the AC voltage
position.
multimeter
Limiting voltage: 13.10.5V/5.000rpm
Check the voltage/current regulator if the limiting voltage is not within its required range.
1.5 Voltage/current regulator
1.5.1 Main wiring check

Remove 4p plug of the voltage/current regulator.
Check conductivity between main wiring terminals.
Item (wire color) Judgment

Between With battery
Battery(red) and voltage
GND of the body
Between GND
wire (black) and With lead
GND of the body 3
2
Between charging
1
coil (white) and Resistance in the
the GND of the coil of the magnetor.
body
black red white
1.5.2 Voltage-current regulator check

- 31 -
1. Select diode in the multimeter;
2. The black probe connects the red terminal of the stabilizer, and the red probe respectively connects white
terminals of the stabilizer (white1, white 2 and white3). Pointers indicate values. If not, the stabilizer is damaged
and needs replacement.
3. The red probe connects the black terminal of the stabilizer and the black probe connects white terminals of the
stabilizer (white1, white2, white3). Pointers indicate values. If not, the stabilizer is damaged and needs
replacement.
*Note
Do not touch any metal part of the test
rod of the multimeter with your finger for
check.
Check with multimeter. Different
multimeters show different impedance
and different results.
Replace the voltage-current regulator when the impedance between terminals is abnormal.
1.6 Magnetor charging coil
*Note
Check the magnetor charging coil on the
engine.
Check
Remove the 6p connector of the magnetor.
Measure impedance between the white coil of the magnetor and the body with multimeter.
Standard: 0.6-120
Replace the magnetor coil when the measured value exceeds the standard value.
1.7 Magnetor disassembly
1.7.1 Disassembly
Remove the body guard.
Fix the flywheel using the universal spanner.

Remove fixing bolts of the flywheel.
Remove the flywheel using the flywheel remover.
Remove the solid key.
Remove the conductor joint. bolt
Remove the stator.
- 32 -
1.7.2 Installation
Install the stator on the body of the engine.
Connect the magnetor joint.
Clean up the crankshaft and the taper part of the flywheel.

Install the solid key into the groove above the upper
crankshaft key and confirm it.
Aim the groove in the flywheel at the solid key on the shaft.
*Note

Ensure there is no any bolt in the inner
magnetic side of the flywheel.
Fix the flywheel with the universal spanner and tighten

fixing nuts.
Torque force: 9.0 Nm

bolt
Install the left body guard.
- 33 -
power lock assembly igniter electric horn battery
relay
MAIN SW
B/W B B/R
SPARK PLUG BL/W W/G
W/G W W W
BL/W
IGNITION COIL
MAGNETO
BATTERY

Ignition System
- 34 -
II. Ignition System
Preparing documents--------------2.1 CDI Group ----------------2.4
Failure diagnosis ------------------2.2 Ignition coil --------------2.5
Ignition system check-------------2.3 Trigger --------------------2.6
Work Instructions
1. Check the ignition system following the sequence listed in the table of failure diagnosis.
2. This ignition system is an electronically and automatically angling device. It is solidified in the CDI group and
you dont have to adjust the ignition time.
3. Check the ignition system following the sequence listed in the table of failure diagnosis.
4. Do not make CDI of the ignition system fall down or hang down or hammer it with strong force (primary
causes for failure). Pay special attention during disassembly.
5. Failure of the ignition system is mostly caused by poor contact of the socket. Check whether each connector is
in good condition.
6. Check whether the heat value used for the spark plug is proper. If not, the engine may work abnormally or the
spark plug may be burnt.
7. Check in this chapter is based on the maximum voltage. It also refers to check on the impedance of the ignition
coil.
8. Check the main switch according to the conduction table.
9. Remove the magnetor and the stator according to instructions.
Item Standard value
Standard C5HSA(NGK)
Spark plug
Hot type C6HSA(NGK)
recommended
Cold type C7HSA(NGK)
Spark plug gap 0.6-0.7mm
Ignition coil Primary coil 0.410
impedance With plug cap 8-11K
Secondary coil
(20) Without plug cap 4.5-5.5K
Impedance of trigger20 100-200
Measure the maximum primary voltage of the ignition
95-400V
coil
Trigger voltage Above 1.7V
- 35 -
Tools
Attachments to the Maximum Voltage Table
Multimeter
Non-sparking of spark plug
Abnormality Cause (confirm it sequentially as follows)

The inner resistance is too small and it should be
tested by required tester.
Low speed of the crankshaft.
Interfered tester (It is normal that voltage is
Ignition
always beyond the required value upon several
coil Too low high-voltage
measurements.)
Poor wiring contact of the ignition system.
Poor ignition coil.
Poor charging coil (measured at the maximum
voltage).
Incorrect connection of the tester.
Poor main switch.
Poor contact of CDI terminal.
Short circuit or poor contact of the GND of CDI.
Poor contact of charging coil (measured at the
No or interrupted high voltage
maximum voltage).
Side
Poor trigger (measured at the maximum voltage).
voltage
Poor terminal of high-voltage wires.
Poor CDI group (when item - is checked to
be abnormal or there is no spark for spark plug.)
Poor spark plug or secondary leakage of the
Normal high voltage, but no spark ignition coil.
Poor ignition coil.
Charging Interfered tester (It is normal that voltage is
No high voltage
coil always beyond the required value upon several
measurements.)
Poor charging coil (Item - is checked to be
normal.)
- 36 -
Poor ignition coil.
No or interrupted high voltage Poor charging coil.
Interfered tester (It is normal that voltage is
Too low high-voltage
always beyond the required value upon several
Trigger
measurements.)
Poor trigger (Item - is checked to be
normal.)
Poor ignition coil.
No or interrupted high voltage
Poor trigger.
2.3 Ignition system check

*Note
When there is no spark, check whether
there is loose wiring or poor contact, and
make sure all voltage values are normal.
There are kinds of multimeters with
different impedances and different test
values.
Connect a high-pressure shunt or an ammeter with

an input impedance above 10M10CV to the multimeter.
multimeter
19.1 Primary voltage of the ignition coil
If you replace the original spark plug with a better one,

make ground connection with the engine.
*Note
Make sure all wiring is correct before test.
Cylinder compression pressure normally
refers to the test value when the spark plug
is installed on the cylinder head.
Connect the lead of the ignition coil and also the shunt
- 37 -
between the primary coil terminal (black/white) and the GND.
Press the startup motor or step the actuating lever to
measure the maximum primary voltage of the ignition coil.
Minimum voltage: above 95V.
*Note
Never touch any metal part of the test
rod with your finger to avoid electric
shock.
19.2 Charging coil

*Note
/ /
Install the spark plug on the cylinder head
and carry out measurement when the /
compression pressure is normal.
Remove 4P connector and 2P connector from CDI group. /
Install a high-pressure shunt between the charging coil
with 2P connector (red/white terminal) and 4P connector
(black terminal). Press the startup motor or step the
actuating lever to measure the maximum voltage of the charging coil.
Connection: positive pole to red/white; negative pole to black.
black red white green blue
Minimum voltage: above 95V.
*Note
Never touch any metal part of the test rod
with your finger to avoid electric shock.
When the maximum voltage measured at the terminal of / /
CDI Group is abnormal, dismantle the body guard and the /

magnetor terminal.
Connect the charging coil (black/red) to the shunt. /
If the voltage of CDI is measured to be abnormal while
the voltage at the magnetor terminal is normal, it is caused
by poor contact or disconnected wiring.
If the voltage at both CDI and magnetor terminal appears
to be abnormal, it is caused by poor charging coil. Please
refer to charging coil check.
19.3 Trigger
- 38 -
*Note
Install the spark plug on the cylinder head
and carry out measurement when the
compression pressure is normal.
Remove 6P connector of CDI group. Connect the

peak-voltage shunt between the trigger with 6P connector
(blue/white terminal) and 6P connector (black terminal).
Press the startup motor or step the actuating lever to measure
the maximum voltage of the trigger.
/
Connection: positive pole to blue/white; negative pole to black.

Minimum voltage: above 1.7V.
*Note
Never touch any metal part of the test rod
with your finger to avoid electric shock.
white blue
When the maximum voltage measured at the terminal of

CDI Group is abnormal, dismantle the right body guard
and the magnetor connector. Connect the trigger (blue/white)
to the shunt.
If the voltage of CDI is measured to be abnormal while
the voltage at the magnetor terminal is normal, it is
caused by poor contact or disconnected wiring.
If the voltage at both CDI and magnetor terminal appears
to be abnormal, it is caused by poor trigger. Please refer to
the table of failure diagnosis.
- 39 -
2.4 CDI Group
/ / /
20.1 System check
/
Check the system.
Remove the CDI Group, and check components of the ignition
system at the terminal.
20.2 Check
Remove CDI Group and check whether the terminal is loose
or corrosive.
Item Test terminal Standard (20)

Main switch Red--red/white Conduction when the main switch is
OFF
Trigger Blue/white white/green 100-200
Primary coil of the ignition coil Black/white--black 0.410
Secondary coil of the ignition Black--spark plug capexcluding 4.5-5.5K10
coil the spark plug
2.5 Ignition coil (picture to be updated)
21.1 Disassembly
Remove the spark plug cap.
Remove the primary lead of the ignition coil.
Remove the fixing bolts and then the ignition coil.
Install the ignition coil in reverse order.
*Note
Install the primary coil with black/white
terminal.
(ignition coil)

21.2 Check the primary coil
- 40 -
Measure impedance between terminals of the primary coil.
Standard: 0.41020
It shows good if the impedance is within the range of standard values.
Replace the primary coil if the impedance shows which indicates that the coil breaks.
21.3 Secondary coil

Attached with spark plug. Measure the impedance between
the wiring side of the spark plug cap and the terminals.
Standard: 8-11K20
It shows good if the impedance is within the range of
standard values.
The impedance indicates that the coil breaks.
Remove the spark plug cap. Measure the impedance
between the primary side wire of the ignition coil and the
negative terminal.
Standard: 4.5-5.5K1020 (ignition coil)
2.6 Trigger
*Note
Check the trigger on the engine.
Check

Remove the trigger terminal. /
Measure the impedance between the blue/white terminal of

the side wire of the engine and the body GND.
Standard: 100-20020
Replace the magnetor if the measured value exceeds the
standard value.
white blue
- 41 -
/ /
DJ7061Y-2.3-21
DJ621-2.3A
MFD004-2
/ white/green / blue/white white

connector assembly copper
pieces waterproof bolt
- 42 -
FBT switch lock assembly stabilizer battery
startup motor
BRAKE SWITCH BRAKE SWITCH BATTERY RELAY STARTOR MOTOR

STARTER SWITCH

Startup Diagram
- 43 -
III. Startup System
Preparing documents---------------3.1
Failure diagnosis -------------------3.2
Startup motor------------------------3.3
Starter relay--------------------------3.4
Work Instructions
Disassemble the startup motor on the engine.
For the disassembly of the startup clutch, please comply with related regulations.
Item Standard Limit for use
Length of the brush of the startup 12.5mm 8.5mm
motor
Bushing of the startup idler shaft 8.3mm
Outer diameter of the startup idler 7.94mm
shaft
Tightening torque force

Bolts for the clutch cover of the startup motor 12 Nm
Fixing bolts for the clutch of the startup motor 95 Nm
Tools
Spanner for fixing nuts
Universal fixing spanner
- 44 -
Startup failure Weak in rotation No rotation of RE rotary engine
of the startup motor of the startup motor

Fuse blow Low battery Poor startup clutch
Low battery Poor wiring contact Reversal rotation of the startup motor
Poor main switch Gear seized Low battery
Poor startup clutch
Poor brake switch
Poor starter relay
Poor wiring contact
Poor startup motor
3.3 Startup motor
3.3.1 Disassembly
*Note
Before the startup motor is disassembled,
turn off the main switch, remove the
GND wire of the battery, and then power
on to check whether the startup motor
works for ensuring safety.
Remove the wire clip of the startup motor.

Remove the fixing bolts, separate the front and rear end
caps, and dismantle the startup motor.
Roll the waterproof rubber case and dismantle the terminal commutator
of the startup motor.
3.3.2 Breakdown
Remove screws in the shell, front cover, motor housing

and other parts.
3.3.3 Check
Check other components.
- 45 -
Replace any part with abraded, damaged or burnt surface. carbon brush
Clean the commutator surface if there is metal power attached to it.
Check conduction between the surface of other components.
Ensure non-conduction between armature shafts of the commutator.
Check the conduction of the shell of the startup motor.
Ensure non-conduction between the conduction terminal and the startup motor shell.
Check conduction between the conduction terminal and the brush.
Replace any abnormal part.
Check conduction of the brush bracket. Replace it when there is conduction.
Measure the length of the brush.
Limit for use: replace it if lower than 8.5mm
Check smooth rotation of the needle bearing inside the front cover and whether it is loose when press-in.
Replace it if there is any abnormality.
Check whether the oil seal is abraded or damaged.
3.3.4 Assembly
Lubricate the oil seal inside the front cover with grease.
Install the brush on the bracket.
Lubricate moving parts at two ends of the brush shaft
with grease.
Press each brush into the bracket.
*Note
Pay special attention that the surface of
the brush and the armature shall not be
damaged.
Pay attention that the armature shaft
shall not damage lips of the oil seal.
Install the rear cover of the motor.

Aim the screw hole of the motor shell at the screw hole of the front cover for installation.
Lock screws in the shell.
*Note
When the shell and the front cover are
assembled, it is easy to pull the front
cover with magnet to attract the armature.
Press it gently for assembly.
3.3.5 Installation
Install the lead of the startup motor and the dustproof boot.
- 46 -
Then install the startup motor.
Install the wire clip for rear brake.
3.4 Starter relay
3.4.1 Check
Remove the body guard
When the main switch is on, check there is click sound
at the time of pressing the startup motor.
With click sound, it is normal.
Without click sound: check voltage of the starter relay;
check the GND loop of the starter relay;
check the movement of the starter relay.

3.4.2 Check voltage of the starter relay
Set up the main stand, and measure voltage between the

negative pole of the green/yellow wire of the starter relay
terminal and the body ground connection.
When the main switch is on, hold the brake lever. The starter relay
battery voltage shall comply with regulations.
When there is no voltage at the starter relay terminal, check
the conduction of the brake switch and leads.
3.4.3 Check GND loop of the starter relay

Remove the starter relay connector.
Check conduction between the black wire of the lead
/
terminal and the body ground connection.
When the startup button is pressed, it shall show good

conduction between the black wire of the terminal and the

body ground connection.
Check conduction of the startup button and leads when it is
not conducted.
starter relay green yellow black
- 47 -
3.4.4 Check
Connect the starter relay to the battery, and the terminal of
the startup motor to the multimeter.
Connect fully charged battery between the black wire and
the green/yellow wire of the relay. The relay shall sound
click and the multimeter shall indicate resistance of zero.
- 48 -
IV. Bulbs/Switches/Meters
Preparing documents --------------4.1 Meters ----------------4.6
Failure diagnosis--------------4.2 Main switch --------------4.7
Replacement of headlamp bulbs --------4.3 Horn ----------------4.8
Replacement of front steering lamp bulbs------4.4 Handlebar switch -------4.9
Replacement of tail lamp bulbs-------4.5
Work Instructions
Remove the switch from the vehicle to measure its conduction.
When the main switch ON is not light, it is due to

Poor bulbs.
Poor switch.
Bad contact or broken wires.
4.3 Replacement of headlamp bulbs
4.3.1 Disassembly
Remove the front shield.
Remove fixing screws for dismantling the headlamp.
Disconnect the headlamp connector.
Remove the glass of the headlamp.
Fix the headlamp and rotate the socket clockwise to
remove the bulb.
headlamp
- 49 -
4.3.2 Installation
Install the bulb in reverse order.
4.4 Replacement of front steering lamp bulbs
4.4.1 Disassembly
Remove the handlebar shade.
Loosen fixing screws of steering lamps.
Remove the bulb socket from the lamps.
4.4.2 Installation
left/right steering lamp
4.5 Replacement of tail lamp bulbs
4.5.1 Disassembly
Remove fixing screws to dismantle the tail lamp shield.
Disconnect the tail lamp connector.
Remove the tail lamp.
(tail lamp)
4.5.2 Installation
Install the tail lamp in reverse order.
4.5.3 Replacement of tail lamp bulbs
4.5.3.1 Disassembly
Remove screws to dismantle the tail lamp shield.
Remove the bulb from the socket.
tail lamp bulb
- 50 -
4.5.3.2 Installation
4.6 Meter (picture to be updated)
Remove the rearview mirror.

Remove the handlebar shade and waterproof connector.
Remove screws.
Remove the odometer assembly to dismantle the odometer.
Install the odometer in reverse order.
odometer
4.7 Main switch
4.7.1 Check
Remove the front guard.
Remove the main switch lead terminal.
Check conduction of the terminal.

/ /
P
red /red/white yellow /orange/blue
power switch
4.7.2 Replacement of main switch

Remove the front guard.
Remove fixing bolts and the fixing seat for the main switch.
Remove fixing bolts and replace the main switch.
- 51 -
4.8 Horn
Check
Remove horn wires.
It shows good when the horn wire is connected to the battery.
4.9 Handlebar switch

1. Dipswitch PASSING
2. Steering lamp switch

3. Horn switch
4. Lamp switch

5. Startup switch
- 52 -
Front disc brake
1. front disc brake assembly 2. handle 3. handle screw 4. hexagon flange locking nut 5. hexagon flange
bolt 6. packing washer 7. fuel pump assembly 8. bolt 9. fixing cover 10. brake switch assembly 11.
screw 12. brake hose assembly 13. brake cylinder assembly 14. connecting bracket of the front disc brake
15. brake shoe assembly 16. bolt
- 53 -
Rear disc brake
1. rear disc brake assembly 2. fuel pump assembly 3. brake cylinder assembly 4. brake hose assembly 5.
handle 6. packing washer 7. hexagon flange locking nut 8. hexagon flange screw 9. fixing cover 10.
brake switch assembly 11. cross recessed countersunk screw 12. hexagon flange locking nut 13. handle
screw 14. connecting bracket of the rear disc brake 15. brake shoe assembly 16. mounting bolts for rear disc
brake 17. rear disc brake clamp
- 54 -
V. Brake
Maintenance instruction ------------------------5.1
Failure diagnosis---------------------------------5.2
Front disc brake ---------------------------------5.3
Rear disc brake ----------------------------------5.4
5.1 Maintenance instruction
Work Instructions
*Note
Do not stain the brake assembly with oil spots during installation or disassembly.
Clean it with required cleaning agent to maintain the brake performance.
*Check brake before riding.*
5.1.1 Specification
Item Standard (mm) Limit for use (mm)
Thickness of front brake disc 4.0 3.0
Thickness of front brake shoe 6.0 3.0
Thickness of rear brake disc 4.0 3.0
Thickness of rear brake shoe 6.0 3.0
EFI Motorcycle QJ125T-30 Diameter of front disc brake: 240mm Diameter of rear disc brake:
240mm
5.1.2 Torque force

Fixing bolts for front/rear brake disc 22-29 Nm
Mounting bolts for front brake cylinder assembly 22-29 Nm
Mounting bolts for rear brake cylinder assembly 22-29 Nm
Brake
- 55 -
Poor brake performance Slow reaction or tight lever
1. Improper adjustment of the brake 1. Improper adjustment of the brake
2. Abraded brake shoe 2. Abraded brake shoe
3. Improper installation of the brake shoe 3. Improper installation of the brake shoe
4. Stained brake shoe or brake disc
Abnormal noise
1. Abraded brake shoe
2. Stained brake shoe or brake disc
5.3 Front disc brake
5.3.1 Disassembly
*Note
Replace the brake shoe assembly.
If the brake shoe will be used again,
mark it before disassembly so as to
reinstall it at the original place.
Remove following assemblies from the front absorber.
Front brake:
1. brake cylinder assembly
2. front brake hose assembly
3. brake shoe assembly
4. connecting bracket of the front brake
fuel pump assembly brake cylinder assembly
*Note
Do not stain the brake assembly with oil spots during
installation or disassembly.
Clean it with required cleaning agent to maintain the
brake performance.
Loosen fixing bolts for the brake cylinder assembly.
Remove the brake cylinder assembly from the front absorber.
Remove the front wheel spindle.
Remove the front wheel.
Remove the brake disc from the front wheel.
5.3.2 Check
Check whether brake shoes are abraded. Replace it if
necessary.
Measure the brake shoe and the brake disc. Record maximum values.
- 56 -
Specification
Diameter of the front brake disc 240mm
Thickness of the front brake disc 4.0mm
*Note
Measurement with micrometer.
Measure the thickness of the brake shoe.
If the thickness of the brake disc or the brake shoe is below
the required value for maintenance or it is stained with
grease, please replace it.
Limit for use: brake shoe 3.0mm

brake disc 3.0mm
Note: replace brake shoes in pair.
brake shoe
5.3.3 Installation
Install the brake disc and the front wheel.
Install the front brake hose assembly and the brake cylinder assembly.
Do not stain the brake shoes and the brake disc with grease.
*Note
Any grease on brake shoes will reduce
the brake performance and even lead to
failure.
Tighten bolts and nuts to the required torque force.
Torque force:
Fixing bolts for the brake disc 22-29 Nm
Mounting bolts for the front brake shoe assembly
22-29 Nm
Do not stain brake shoes with oil spots.

Use brake cleaning agent to clean brake shoes with oil spots. brake shoe brake cylinder
*Note
Any oil spot on brake shoes will reduce
brake performance.
- 57 -
5.4 Rear disc brake
5.4.1 Disassembly
Remove the rear brake cylinder assembly.
Remove the rear wheel.
Remove the brake disc from the rim of the rear wheel.
fuel pump assembly brake

cylinder assembly brake hose assembly
*Note
Replace the brake shoe assembly.
If the brake shoe will be used again,
mark it before disassembly so as to
reinstall it at the original place.
Remove following assemblies from the rear wheel.
Rear brake:
1. brake shoe assembly
2. rear brake hose assembly
3. brake cylinder
4. connecting bracket of the rear disc brake
5. rear disc brake clamp
fuel pump assembly brake cylinder assembly brake hose assembly
Note: for details, see P60
5.4.2 Check
Check whether the brake disc and the brake shoes are
abraded. Replace it if necessary.
Measure the brake shoe and the brake disc. Record
maximum values.
*Note
Scrub the rusty brake disc with
sandpaper #120.
Measurement with micrometer.
Measure the thickness of the brake disc and the brake

shoes.
If the thickness of the brake disc or the brake shoe is below
- 58 -
the required value for maintenance or it is stained with grease,
please replace it.
Note: replace brake shoes in pair.
Diameter of the rear brake disc 240mm
Thickness of the rear brake disc 4.0mm
Limit for use: brake shoes 3.0 mm
brake disc 3.0mm
5.4.3 Installation
Install the rear brake disc.
Install the rear wheel.
Install the rear brake cylinder assembly.
*Note
Any grease on brake shoes will reduce
the brake performance and even lead to
failure.
Tighten bolts and nuts to the required torque force.
brake shoe brake cylinder

Torque force:
Fixing bolts for rear brake shoe assembly: 22-29 Nm
Do not stain brake shoes and brake disc with oil spots.
Use brake cleaning agent to clean brake shoes and brake
disc with oil spots.
*Note
Any oil spot on brake shoes will
reduce the brake performance.
Note: for details, see P60.
fuel pump assembly brake cylinder assembly brake hose assembly
- 59 -
front shield lattic front shield front fender windshield
handlebar front shield decorating frame of the front shield front wind board
of the radiator rear wind board of the radiator front inner fender
rear handlebar shield battery cover frame number cover pedal
lower fender left/right lattice of the foot guard tail box cover
assembly battery front left guard left/right pedal guard front right
- 60 -
guard seat assembly front right guard right cover of the left pedal
left cover of the right pedal rear lower fender rear inner fender
rear inner fender rubber rear right guard rear left guard
left decorating board for the guard right decorating board for the guard rear
handrail rear fender rear reflector
VI. Body
Dismantle the body in following order.
Handlebar front shield windshield handlebar rear shield meter front
shield front inner fender foot guard
battery box cover left/right pedal cover left/right pedal rubber left/right
pedal guard rear handrail seat
helmet box left/right rear guard left/right front guard rear fender rear inner
fender
rear inner fender rubber rear lower fender pedal front fender
*Note
Do not damage any body part during disassembly.
Do not damage any hook or claw in the body during disassembly.
Aim panels in the body at each corresponding groove.
Ensure correct installation of each hook or claw part during assembly.
Do no damage any part during assembly.
- 61 -
Front wheel/front suspension
Front wheel
cotter pin gear housing assembly front rim oil seal brake disc
left bushing of the front wheel front wheel spindle slotted nut
rolling bearing front tyre middle spindle sleeve of the front wheel rolling
bearing mounting bolts for the brake disc
- 62 -
VII. Front Wheel/Front Suspension
Preparing documents-------------------------7.1
Failure diagnosis -----------------------------7.2
Front wheel -----------------------------------7.3
Steering handle -------------------------------7.4
Front fork -------------------------------------7.5
Work Instructions
Before removing the front wheel, you should use jack to support the body bottom and suspend the front wheel
which shall not be reversely rotated.
Pay attention that brake shoes and brake discs shall not be stained with grease during operation.
Motorcycle Standards
Standard
Measurement points Item Limit for use (mm)
(mm)
Front wheel spindle Bending 0.2
Rim Vertically 2.0
Front wheel
shimmy Horizontally Within 1.0 2.0
Torque force Tools
Fixing bolts for the steering handle 40-60 Nm Bearing puller

Locking nut for the front wheel spindle 55-62 Nm Locking nut spanner
7.2.1 Difficulty in steering

Failure of the steering handle bearing.
Damaged steering handle bearing.
Low tyre pressure.
- 63 -
Flat tyre.
7.2.2 Unsteady steering

Damaged steering handle bearing.
Low tyre pressure.
Bending of the front fork or the front wheel spindle.
Deformed or unbalanced front tyre.
7.2.3 Front tyre shimmy

Deformed rim.
Loose front wheel bearing.
Poor tyre.
7.2.4 Difficulty in wheel rolling

Failure of wheel bearing or gear housing.
7.2.5 Abnormal noise of the front absorber

Fricative sound of the absorber guard.
Loose bolts in the absorber.
7.3 Front wheel
7.3.1 Disassembly
Support the body bottom to suspend the front wheel.
Remove the cotter pin and locking nuts for the front wheel
spindle.
Remove the front wheel spindle, gear housing assembly
and front wheel.
Remove screws, front fender and odometer cable.
Remove the front brake hose. wheel spindle
Remove the oil seal and the bearings respectively with oil
seal remover and bearing puller.
7.3.2 Check
7.3.2.1 Check the bending of the wheel
spindle
- 64 -
Place the wheel spindle on the V-base and measure the
eccentricity ratio with a dial indicator.
Limit for use: replacement when beyond 0.2mm
7.3.2.2 Check the rim shimmy

Place the rim on a precision bracket and check
the rim shimmy.
Rotate the wheel by manual and read
indication.
Limit for use:
Vertically: replacement when beyond
2.0mm.
Horizontally: replacement when beyond
2.0mm.
7.3.2.3 Check the front wheel
bearing
Remove the left bushing and the oil seal of the
front wheel.
front rim rolling bearing brake disc left bushing of the front
wheel middle spindle sleeve of the front wheel oil seal mounting
bolts for the brake disc front wheel spindle
Check rolling of the bearings.

The bearings will not roll if abraded or loosened. Replace
it.
clearance axially radially
7.3.3 Bearing replacement

Remove the front wheel spindle, front wheel, middle
spindle sleeve and left spindle sleeve; then remove the oil
seal and the bearing respectively with oil seal remover and
bearing puller.
Note: replace dismantled bearings with new ones.
- 65 -
Lubricate the bearings with grease during installation.
Then press the bearings in with bearing installation tools.
*Note
Bearings must be pressed in
horizontally.
The oil seal side of the
bearings shall be pressed in
from outside.
7.3.4 Installation
Lubricate the oil seal of the front wheel with grease.
Lubricate gear engagement parts and moving parts with grease.
Install the middle spindle sleeve, bearings and oil seal.
Align the gear housing assembly and then install the front wheel.
Note
If the gear housing assembly of the odometer is not
aimed at and locked with the front wheel spindle, the
gear housing assembly will be deformed.
After the rim is installed, rotate the rim to ensure
that the drive shaft of the odometer works normally.
Install and tighten the front wheel spindle.

* Note: for the disassembly and assembly of the front suspension of EFI Motorcycle QJ125T-30, please see
P65.
Torque force
Locking nuts for the front wheel spindle 55-62 Nm
7.4 Steering handle
7.4.1 Disassembly
Remove the front and rear shield and the rearview
mirror assembly.
Remove the front brake handle and the rear brake
handle.
Remove the decorating cover of the grip, the
throttle cable assembly and the right grip assembly.
Remove the left steering handle sleeve.
Remove fixing bolts for the steering handle.
Remove the steering handle.
left steering handle sleeve rearview mirror assembly weld
- 66 -
assembly of the steering handle bolt locking nut fixing sleeve of the
steering stem throttle cable assembly decorating cover of the grip right
grip assembly screw right handle sleeve
7.4.2 Installation
Install it in reverse order.
Fixing bolts
Torque force: 40-60 Nm
7.5 Front fork
7.5.1 Disassembly
Remove the front wheel.
Remove the front shield, front inner fender and front
fender.
Remove the brake hose and the odometer cable.
Loosen the gland nut and the lock washer.
Remove the upper and the lower bearing cups.
Remove the front fork.
Tools:
Fixing bolt spanner for the steering handle.
Fixing nut spanner.
Special disassembly tool for bearing cups.
*Note:
The opening of the body guard shall be
cleaned with cloth.
7.5.3 Installation
Tools:
Fixing nut spanner.
Ensure the front fork is not loose by left and right movement.
Steps:
Install the steering handle.
Install the absorber.
Install the front wheel.
weld assembly of the lower connecting bracket front left absorber
assembly gland nut lock washer upper cup of the upper bearing
steel ball lower cup of the upper bearing bearing washer spring
washer bolt front right absorber assembly
- 67 -
7.6 Radiator/expansion tank assembly
7.6.1 Disassembly
Loosen four fixing bolts for the radiator assembly.
Loosen fixing bolts for inlet/outlet hoses of the radiator.
Remove the power cord of the cooling fan.
Remove the radiator assembly and the expansion tank
assembly.
heat sink
7.6.2 Check
Open the water tank cover and check the coolant level
inside.
Add coolant when it approaches the limit.
Broken or twisted heat sink will reduce the cooling heat sink
capability of the radiator.
Repair the radiator with a small club when over 1/3 of heat sink is damaged or twisted.
Check the liquid level of the radiator.

Remove the radiator cover after the liquid is
fully cooled;
Completely discharge the coolant;
Add the prepared coolant slowly through the
filling hole (mounting hole of the radiator) until
it reaches the edge of the hole;
Install the radiator cover.
Note: please use KEEWAY coolant;
The minimum temperature for using
KEEWAY coolant is -35.
edge heat sink coolant
- 68 -
Check the switch of the fan.
Replace it when the switch can not work normally.
cooling fan fan switch
Pressure test for the radiator.

Remove the radiator cover after coolant is fully cooled;
Apply required pressure to the cooling system with the
radiator cover tester (lower than pressure for opening the
valve of the cover) and ensure that it can keep for at least
6s under the required pressure;
In the case of pressure leakage, check the hose, all
connections, pump position and inspection hole.
7.6.3 Installation
radiator cover tester
- 69 -
Rear wheel/rear suspension (picture to be updated)
VIII. Rear Wheel/Rear Suspension
Preparing documents -----------------8.1
Failure diagnosis ----------------------8.2
Rear wheel -----------------------------8.3
Rear absorber/rear swing arm -------8.4
- 70 -
Work Instructions
The surface of brake discs and brake shoes shall not be stained with oil spots.
Item Standard (mm) Limit for use (mm)
Rear wheel Vertically 2.0
shimmy Horizontally 2.0
Locking torque force

Fixing nuts for the rear wheel 100-113 Nm
Top nuts for the rear absorber 37 - 44 Nm
Bottom nuts for the rear absorber 22 - 29 Nm
8.2.1 Rear wheel shimmy

Deformed rim.
Tyre failure.
Rear wheel not fixed.
Low tyre pressure.
8.2.2 Too soft absorber

Elastic fatigue of spring
8.3 Rear wheel
8.3.1 Disassembly
Remove the body guard and the muffler.
Remove the rear brake cylinder assembly.
Remove the nuts of the rear wheel spindle and the fixing
bolts of the rear right absorber.
Remove the rear absorber bracket assembly.
Remove the rear wheel.
rear wheel spindle nut
- 71 -
8.3.2 Check
8.3.2.1 Check the rim shimmy

Rotate the wheel by manual and measure the eccentricity
ratio with a dial indicator.
Limit for use:
Vertically: replacement when beyond 2.0mm.
Horizontally: replacement when beyond 2.0mm.
When the rear wheel shimmy exceeds the limit, the rear
wheel bearing is loose, which causes shimmy. Check and
replace the rear wheel bearings.
8.3.3 Installation
Install the rear wheel in reverse order and lock nuts.
Fixing nuts for the rear wheel

Torque force: 100-113 Nm
Rear wheel of EFI Motorcycle QJ125T-30
mounting bolts for brake discs brake disc tyre right

bushing of the rear wheel seal ring rear absorber bracket left bushing
of the rear wheel oil seal cotter pin retainer ring bearing retainer ring
slotted nut fixing sleeve assembly of the fixing bracket
stationary bushing assembly of the rear absorber rear rim rear absorber
bracket assembly
8.4 Rear absorber/rear swing arm
- 72 -
8.4.1 Disassembly of the rear absorber
Remove the seat and the left/right rear guard.
Remove the rear handrail and the rear fender.
Remove the muffler.
Remove the air cleaner assembly.
Remove the fixing bolts for the rear absorber.
Remove the rear absorber.
8.4.2 Installation
Install the rear absorber.
Torque force:
Upper fixing nut: 37-44 Nm
Lower fixing nut: 22-29 Nm
Install the rear absorber. bolt rear absorber assembly

Install the air cleaner.
Install the muffler.
Install the rear handrail and the rear fender.
Install the seat and the rear left/right guard.
- 73 -
Table of Torque Force of Engine Fasteners
Name of fastening parts and fasteners Tightening torqueNm
Cylinder cover bolts 2528

Drain bolts 2225
Spark plug 1015
Closing bolts 1012
Blots for the transmission chamber cover 1012
Fixing bolts for the motor 1012
Fixing bolts for the fuel pump 1012
Fixing bolts for the fuel pump sprocket 1012
Locking nuts for the flywheel 5060
Right cover stud 1012
Double-end stud 1822
Fixing bolts for the chain adjuster 1012
Fixing screws for the electrical cable clamp 47
- 74 -
Lubricating system diagram
camshaft
piston
crankshaft
Fuel pump
Fuel pump filter
- 75 -
IX. Lubricating System
Preparing documents -----------9.1
Failure diagnosis-----------9.2
Fuel pump-------------9.3
Work Instructions
After the fuel pump is disassembled, carefully clean each part and its surface with high-pressure gas.
When the fuel pump is disassembled, do not make any impurity fall into the crankcase.
Function of the lubricating system: the lubricating system of the engine is to provide lubricating oil to the
frictional surface of each part, which transforms dry friction into liquid friction between lubricating oil particles
and also reduces abrasion of parts. It also cools components with high thermal load, absorbs shock from bearings
and other parts, reduces noise, increases sealing between piston ring and cylinder wall, and cleans and removes
particles in the surface.
when replacing fuel 0.9L /
Fuel capacity
when disassembly 1L /
radial clearance between inner and
0.040.15 0.20
outer rotors
Fuel pump rotor clearance between outer rotor and
0.150.21 0.21
pump body
clearance between rotor surface 0.07-0.12 0.18
Decreasing fuel Burnt engine

Natural consumption of fuel No fuel or low fuel pressure
Fuel leakage Blocked fuel pipes
Abrasive or incorrectly installed piston ring No fuel used
- 76 -
9.3 Fuel pump
9.3.1 Disassembly
Remove the right cover and one-way clutch assembly.

Loosen the fixing bolts for the fuel pump chain cover and
then remove the chain cover.
chain cover screw
Remove the fixing nuts for the sprocket.

Remove the sprocket and the chain.
chain sprocket nut
Remove screws and fuel pump assembly.
fuel pump screw
- 77 -
Remove screws and fuel pump cover.
fuel pump cover
Check the radial clearance between inner and outer

rotors.
Limit for use: 0.20mm
Check the clearance between the outer rotor and the

fuel pump housing.
gauge
Check clearance between rotor surface.

gauge panel
- 78 -
9.3.2 Breakdown
Break down the fuel pump according to the following picture.
inner rotor fuel pump fuel pump shaft fuel pump chain
cotter pin outer rotor fuel pump cover screw
Note:
After assembly, the inner and outer rotors shall rotate flexibly without being seized.
9.3.3 Installation
- 79 -
- 80 -
X. Cylinder Head/Valve
Preparing documents---------------11.1 Valve check---------------11.6
Failure diagnosis---------------11.2 Replacement of valve guide-----------11.7
Cylinder head-----------------11.3 Adjustment of valve retainer ---------11.8
Cylinder head check-------------11.4 Installation-------------------11.9
Valve-------------------11.5
Work Instructions
To ensure sealing between the cylinder head and the cylinder block, the cylinder head shall sustain the bolt
pretension of 50Nm.
All parts shall be cleaned and blown with high-pressure gas before check.
Function of cylinder head: The cylinder head is used for sealing the cylinder and constitutes the combustion
chamber with the piston to sustain high-temperature and high-pressure gas. It achieves gas intake and exhaust
with the valve actuating mechanism.
Preparing Principles Unit: mm

Cylinder pressure 1.25MPa /
Flatness of cylinder cover 0.03 0.03
Intake 0.10 0.12
Valve clearance
Exhaust 0.13 0.14
Inner diameter of valve Intake 5.00-5.012 5.03
Valve guide Exhaust 5.00-5.012 5.03
Valve Clearance between the Intake 0.010-0.035 0.08
guide valve stem and the valve
Exhaust 0.030-0.05 0.10
guide
Intake 1.2 1.7
Width of valve seat
Exhaust 1.2 1.7
Valve Intake/exhaust 35.4 34.9
Free length
spring
Diameter of swing arm Intake/exhaust
Swing arm 10.00-10.015 10.10
hole
- 81 -
Diameter of swing arm Intake/exhaust
9.982-9.988 9.90
shaft
Clearance between the Intake/exhaust
swing arm hole and the 0.012-0.033 0.033
swing arm shaft
Intake 29.78 29.83
Cam height
Exhaust 29.54 29.59
Low compression pressure Abnormal noise in the cylinder head

Poor adjustment of the valve clearance Poor adjustment of the valve clearance
Burnt or bent valve Damaged valve spring
Poor sealing of the valve seat Abrasive or damaged camshaft
Leakage of the cylinder head spacer Abrasive camshaft or valve swing arm
Poor installation of spark plug
High compression pressure

Too much carbon deposit in the combustion chamber
10.3 Cylinder head
11.3.1 Disassembly
Remove fixing bolts.
fixing bolt
- 82 -
Remove bolts, chain tensioner and spacer.
chain tensioner spacer

Remove the washer and the cotter pin.
Loosen bolts and remove the camshaft bracket assembly.
Note: when the bolts of the camshaft bracket are removed,
apply staggered steps. Otherwise, the bracket will be
broken.
washer cotter pin camshaft bracket
Remove the chain from the timing driven sprocket.

Remove the camshaft.
Remove the cotter pin.
Remove the cylinder head.
Note: hang the chain with a section of metal wire to
prevent it from falling into the crankcase.
camshaft cotter pin
- 83 -
Fasten M5 screw into the swing arm shaft and pull the shaft
out. Remove the swing arm and the decompressor.
M5 M5 screw
10.4 Cylinder head check
Check the outer ring of the bearing. Replace it if it can not

rotate steadily and flexibly.
Check the inner ring of the bearing. Replace it if it is not
fastened on the camshaft.
Check the raised part of the camshaft. Replace it if it has
abrasive, scratched or blue spots.
Measure the cam height and meanwhile check whether it is
abraded or damaged.
Replace it if it can not meet requirements.
Limit for use: Cam height: intake: 29.83mm
exhaust: 29.59mm
Measure the outer diameter of the swing arm shaft.
micrometer
- 84 -
Measure the inner diameter of the swing arm hole.
Clearance between the swing arm hole and the swing arm
shaft.
tester
Compress the valve spring with the valve spring

compression tool and remove the valve cotter.
Remove the spring plate, valve spring, spring washer for
the outer valve and valve in sequence.
valve cotter
10.5 Valve
Valve breakdown
- 85 -
valve spacer spring plate valve oil seal spring
valve cotter
10.6 Valve check
Eliminate carbon deposit on the cylinder cover.

Measure the flatness of the connection surface of the
cylinder cover.

When the flatness of the connection surface of the cylinder
cover exceeds the limit, place the emery paper on the plate
and contact the connection surface of the cylinder cover
with the emery paper. Scrub the surface in the shape of 8.
ruler gauge
Measure the free length of the valve spring.

Limit for use: spring: 34.9 mm
vernier caliper
Measure the outer diameter of the valve stem.

- 86 -
Check the valve guide and eliminate carbon deposit in the
valve guide with reamer before check.
Note: rotate the reamer clockwise, but not
counterclockwise.
valve reamer
Measure the inner diameter of each valve guide.

Limit for use: intake/exhaust: 5.03mm
Limit for use for the clearance between the valve and the
valve guide:
Intake valve: 0.08mm
Exhaust valve: 0.10mm
tester
10.7 Replacement of valve guide
Note: when the clearance between the valve and the valve
guide exceeds the limit, replace the valve guide. After
replacement, adjust the surface of the valve retainer.
Place the valve guide in the freezer for cooling for 1 hour.
Heat the cylinder head in the stove or oven to 100-150.
valve guide screwdriver
- 87 -
Fix the cylinder head. Remove the valve guide from the
cylinder head with the valve guide disassembly tool.
Place a new O-ring on the new valve guide.
Install the valve guide over the cylinder head.
Note: do not damage the cylinder head when the valve
guide is installed.
valve guide screwdriver
Insert the valve guide. Adjust it with the valve guide

reamer.
Note: add some cutting oil when cutting with the reamer
which shall rotate clockwise.
valve reamer
Eliminate carbon deposit inside the combustion chamber

and the valve. Thoroughly clean the intake valve and the
exhaust valve.
Check the width of the contact surface of the valve seat
(width of the valve retainer).
Limit for use: intake/exhaust: 1.7mm
contact surface of the valve seat
- 88 -
10.8 Adjustment of the valve retainer
Remove any hackly or uneven part in the surface of the

valve retainer with a milling cutter of 45.
Note: add a layer of transparent or Prussian blue coating on

the valve retainer so as to see it clearly.
hackly part
Eliminate 1/4 of the outer edge of the valve retainer with a

milling cutter of 20.
Eliminate 1/4 of the bottom end of the valve retainer with a

milling cutter of 60. Remove the milling cutter and check
any milled part.
- 89 -
Mill the valve retainer with a refined milling cutter of 45
to make it have proper width.
Any dent or hackly part must be removed.
Standard width of the valve retainer: intake: 1.2m

exhaust: 1.2m
If the higher part of the valve is contacted, reduce the

height of the valve retainer with end mills of 20.
If the lower part of the valve is contacted, increase the
height of the valve retainer with an inner milling cutter of
60.
Mill the valve retainer with a refined milling cutter of 45
again to make it meet requirements.
After milling, coat the valve surface with brightener and
slightly polish the valve.
high contact surface low contact surface
10.9 Installation

Note:
When the valve spring is installed, point the spring end with smaller pitch to the combustion chamber.
When the valve cotter is installed, apply a valve spring compression tool.
When the valve is installed, apply some fuel to the surface of the valve stem and then install it into the valve
guide.
- 90 -
- 91 -
XI. Cylinder Block and Piston
Preparing documents -----------------12.1 Piston-------------------12.4
Failure diagnosis -----------------12.2 Piston installation-------------12.5
Cylinder block -------------------12.3 Cylinder installation-------------12.6
Work Instructions
All parts shall be cleaned and blown with high-pressure gas before check.
Function of the cylinder block: The cylinder block provides space for gas compression, combustion and
expansion, and also guides the piston movement.
It transfers part of heat inside the cylinder to cooling medium around.
Function of the piston:
1It is able to sustain pressure caused by combustion of mixed combustible gas in the cylinder and transfer such
pressure to the connecting rod which drives the crankshaft to rotate.
2It forms a combustion chamber with the cylinder cover.

Inner diameter 52.40-52.413 52.413
Cylindricity 0.004 0.004
Cylinder
Roundness 0.005 0.005
Flatness 0.05 0.05
Marked direction IN opposite the intake
/
valve
52.3652.37 (7mm
Outer diameter measuring point below the bottom of the 52.37
Piston piston skirt
Piston ring Inner diameter of the piston pin
14.00214.008 14.04
Piston pin hole
Outer diameter of the piston pin 13.994-13.999 13.97
Clearance between the cylinder and
0.03-0.053 0.053
the piston
Clearance Ring 1 0.030.07 0.10
- 92 -
between the
piston ring and Ring 2 0.030.07 0.10
the ring slot
Ring 1 0.10-0.25 0.50
Joint gap of the
Ring 2 0.20-0.35 0.60
piston ring
Oil ring 0.10.6
Clearance between the piston and
0.003-0.014 0.03
the piston pin
Inner diameter of the smaller end
14.01014.018 14.04
of the connecting rod
Clearance between the connecting
0.0110.024 0.05
rod and the piston pin
Low compression pressure White smoke from the exhaust pipe

Abrasive, burnt or ruptured piston Abrasive or damaged piston ring
Abrasive or damaged cylinder or piston Abrasive or damaged cylinder or piston
Damaged spacer or crankcase leakage
Over-high compression pressure Abnormal noise of the piston

Too much carbon deposit in the combustion chamber Damaged cylinder, piston or piston ring
Abrasive piston pin hole and piston pin
11.3 Cylinder block
119.1 Disassembly of the cylinder block

Remove the cylinder head, spacer for the cylinder cover
and locating pin.
Remove the main chain plate.
Remove the cylinder.
cylinder locating pin spacer main chain plate
- 93 -
119.2 Cylinder block check
Check the abrasion of the inner wall of the cylinder.
If it is serious, replace it.
Remove the spacer and the locating pin.

Remove any residual spacer attached to the cylinder.
locating pin spacer
11.4 Piston
120.1 Disassembly
Remove the retainer ring of the piston.
Note: during assembly, do not make the retainer ring fall
into the crankcase.
Remove the piston pin and the piston.
piston pin retainer ring
Check the piston, piston pin and piston ring.

Remove the piston ring.
Note:
Do not rupture or damage the piston ring.
Eliminate carbon deposit in the groove of the piston ring.
- 94 -
Install the piston ring.
Measure the clearance between the piston ring and the
piston ring groove.
Limit for use: top ring: 0.10mm.
Ring 2: 0.10mm.
piston gauge push in piston ring
Remove the piston ring and install each piston ring at the
cylinder bottom.
Note: Press the piston ring into the cylinder with the piston
head.
Measure the joint gap of the piston ring.
Limit for use: 0.5mm.
gauge piston ring
Measure the inner diameter of the piston pin hole.

- 95 -
Measure the outer diameter of the piston pin.
Clearance between the piston pin hole and the piston pin.
Measure the outer diameter of the piston.

Note:
The measuring point shall be at 90 degree with the piston
pin, and at 7mm below the piston skirt.
Limit for use52.37mm
90
7mm
Check whether the inner wall of the cylinder is scratched or

abraded.
Note:
It is at 90 degree with the piston pin. Measure the inner
diameter of the cylinder at the top, middle and bottom
points.
Measure the clearance between the cylinder and the piston.
Record the maximum value.
tester
- 96 -
Measure the roundness of the inner wall of the cylinder
(inner diameter difference at X direction and Y direction).
Measure the cylindricity of the inner wall of the cylinder
(inner diameter difference at the top, middle and bottom
points of X direction or Y direction).
Check the flatness of the cylinder surface.

ruler gauge
Measure the inner diameter of the smaller end of the

connecting rod.
smaller end of the connecting rod
- 97 -
11.5 Piston installation
Install the locating pin.

Apply fuel to each piston ring and piston. Install the piston
ring with marked side upward.
Note:
Do not scratch the piston or break the piston ring.
After the piston ring is installed, it shall be able to rotate
freely in the piston ring groove.
top ring ring 2 oil ring
Open the right cover and remove the starting lever

assembly.
Remove any residual spacer attached to the crankcase.
Note:
Do not make any object fall into the crankcase.
Install the piston, piston pin and retainer ring.
Note:
Install the piston with its top mark IN towards the intake
valve.
IN IN mark
11.6 Cylinder installation
Install the spacer and the locating pin on the crankcase.
locating pin spacer
- 98 -
Evenly apply fuel to the inner wall of the cylinder, piston
and piston ring.
Carefully install the piston ring into the cylinder.
Note:
Do not damage the piston ring.
- 99 -
- 100 -
XII. Drive Face/Clutch/Driven Wheel
Preparing documents -------------------13.1 Clutch/driven wheel ---------13.5
Failure diagnosis -------13.2 Breakdown of clutch and driven wheel----13.6
Left crankcase cover--------------------13.3 Installation --------------------13.7
Drive face -------------------------------13.4
Work Instructions
During operation, the surface of the triangle belt can not be stained with any grease which must be
removed. It helps avoid slipping between the triangle belt and the belt pulley as much as possible.
Function: Drive face, clutch and driven wheel constitute stepless transmission. The triangle belt transfers torque
between the drive face and the driven wheel.

Inner diameter of right half-driven wheel 28-28.02 28.04
Outer diameter of the sliding sleeve 23.967-23.98 23.98
Width of the triangle belt 21.222.8 22.8
Thickness of the clutch facing 1.5 1.5
Inner diameter of the clutch sleeve 125125.2 125.5
Free length of the clutch spring 691 70
Outer diameter of the bushing on the right half driven wheel 42.92-42.98 42.90
Outer diameter of the sliding sleeve on the left half driven
33.9533.975 34.00
wheel
Outer diameter of the ball 20-20.2 19.5
No run after engine startup Insufficient horsepower Vibration during run

Abrasive triangle belt Abrasive triangle belt Ruptured or damaged clutch facing
- 101 -
Damaged driven wheel Deformed clutch spring
Broken or damaged clutch facing Abrasive ball
Ruptured clutch spring Stained surface of the driving pulley
12.3 Left crankcase cover
Disassembly
Remove fixing bolts, spacer and locating pin.
left cover fixing bolt
Note:
Fixing bolts shall be removed in staggered sequence.
Remove the spacer and locating pin.
spacer locating pin
12.4 Drive face
Disassembly
Remove fixing nuts for the drive face and the left half-drive
face.
Remove the triangle belt from the drive face.
fixer triangle belt : left half drive face spanner
- 102 -
Check whether the triangle belt is cracked and whether
rubber or cotton yarn falls down or is abnormally abrasive.
Measure the width of the triangle belt.
Note: apply original parts from our company for
replacement.
Width
Remove the right half drive wheel assembly.
right half drive wheel assembly
Breakdown of right half drive wheel assembly
- 103 -
Check abrasion of the ball.
Measure the outer diameter of the ball.
Measure the inner diameter of the right half drive wheel.

Measure the outer diameter of the sliding sleeve.
- 104 -
sliding sleeve right half drive wheel
12.5 Clutch/driven wheel
13.5.1 Disassembly
Fix the clutch sleeve with the fixer and remove fixing nuts.
Remove the clutch sleeve, clutch and driven wheel.
driven wheel clutch sleeve fixer socket spanner
13.5.2 Breakdown of clutch

Remove the retainer ring and break down the clutch.
Note: do not stain the clutch facing with any grease during breakdown.
retainer ring clutch facing
- 105 -
Check abrasion of the clutch sleeve.
Measure the outer diameter of the clutch sleeve.
Check abrasion of the clutch facing.

Measure the thickness of the clutch facing.

clutch facing
12.6 Breakdown of clutch and driven wheel
Clutch spring compressor must be used for disassembling

the clutch spring.
Note: spring compressor must be used for disassembly to
avoid damage to spring.
Fix the spring compressor to remove fixing nuts of the
clutch.
Loosen the compressor, and disassemble the clutch and the
driven wheel.
spanner clutch spring compressor
- 106 -
Remove the spring guard.
spring guard
Remove the guide pin.

Remove the weldment on the left half driven wheel.
Remove the oil seal on the left half driven wheel.
weldment on the left half driven wheel guide pin oil seal
Check the free length of the clutch spring.

Limit for use: 70mm.
free length
- 107 -
Check abrasion of the driven wheel.
Measure the outer diameter of the bushing on the right half
driven wheel.
Measure the inner diameter of the sliding sleeve on the left

half driven wheel.
right half driven wheel left half driven wheel
13.6.1 Replacement of the bearing on the
right half driven wheel

Remove the needle bearing from the right half driven
wheel.
Remove the elastic retainer ring and the outer rolling
bearing.
needle bearing elastic retainer ring rolling bearing
Note:
Removed bearings can not be used any more.
Apply grease evenly to the outer rolling bearing and then

place it into the sleeve.
Note: place the outer rolling bearing into the sleeve with its
marked side outwards. Then fill the sleeve with 8-9g grease.
Install the elastic retainer ring.
bearing screwdriver elastic retainer ring rolling bearing
- 108 -
Install the needle bearing.
Press the needle bearing in as shown in the picture.
bearing screwdriver
13.6.2 Combination of clutch and driven wheel

Eliminate any grease on the surface of the driven wheel.
Install the oil seal in the sliding sleeve of the left half
driven wheel.
Apply grease evenly on the O-ring and install it on the
sliding sleeve of the left half driven wheel.
lubricating grease oil seal O o-ring
Combine the left half and the right half driven wheel.
Apply grease evenly to the guide pin and then install it into
the guide groove.
guide pin guide groove
- 109 -
Install the spring guard.
Eliminate leaked grease.
spring guard
Install the clutch spring and the clutch on the driven wheel.
Use the clutch spring compression combination. Install
locking nuts after compression.
Note: properly compress the spring to avoid damage to the

spring.
spanner (locking nut) clutch spring compressor
12.7 Installation
Install the drive face/ clutch/ driven wheel in reverse order.
- 110 -
input shaft intermediate shaft output shaft
- 111 -
XIII. Decelerator
Failure diagnosis ---------------------14.2
Gearbox --------------------------------14.3
Installation ----------------------------14.4
Function: transfer torque and decide final output torque and rotational speed.
No run after engine startup

Broken driving gear
Burnt driving gear
Leaked gear oil

Too much gear oil
Damaged oil seal
13.3 Gearbox
14.3.1 Disassembly
Remove bolts and the gearbox cover.
gearbox cover bolt
- 112 -
locating pin spacer
Remove the output shaft assembly.

Remove the intermediate shaft assembly.
Remove the input shaft.
output shaft assembly intermediate shaft assembly input shaft
Check abrasion of the input shaft, output shaft and each

gear.
It shall be replaced if being abraded seriously.
Remove the oil seal from the gearbox cover and hammer
out the bearing.
Note:
Removed bearing can not be used any more. It shall be
replaced.
Use special tools to dismantle the bearing and the oil seal.
bearing oil seal
- 113 -
13.4 Installation

Note:
Use special tools to install the bearing and the oil seal to avoid any damage.
- 114 -
XIV. Crankcase
Preparing documents-----------------15.1
Failure diagnosis ---------------------15.2
Crankcase -----------------------------15.3
Installation ----------------------------15.4
14.1Preparing documents
Work Instructions
The crankcase is thin-section casting thus shall not suffer impact during operation which may cause deformation
or fracture.
All components must be cleaned and blown with high-pressure gas before test.
Lubricant in the crankcase should be drained out before operation.
Function of the crankcase The crankcase is the load-bearing part of the engine. Its main function is to
support the crankshaft, clutch, gearbox, cylinder block and cylinder head, sustain combustion shock and inertia
force from the movement of the connecting rod, and form part of closed space (oil sealing, gas sealing).
Suspension holes in the crankcase are linked with suspension holes in the body, which connects the engine to the
frame and other parts.

Left-right clearance of the larger end of the
0.1-0.35 0.55
connecting rod
Crankshaft
Radial clearance of the larger end of the
0.008-0.016 0.05
connecting rod
Tools
Universal holder Clutch spring compressor
Screwdriver lever Socket spanner
Guide rod Bearing screwdriver
- 115 -
Noise in the crankcase

Loose or broken parts inside the crankcase Loose crankshaft bearing
Loose crankpin bearing Seized clutch
14.3 Crankcase
15.3.1 Crankcase disassembly

Loosen bolts and remove the right crankcase cover.
right crankcase cover bolt
Remove the spacer.

Loosen locking nuts with a special tool and remove the
magneto.
Remove the starter idler gear and the shaft.
electric starter idler gear locking nut magneto spacer
Remove bolts and the end cap of the fuel pump sprocket.
Remove the fuel pump.
sprocket cap bolt
- 116 -
Remove the bolts of the right crankcase.
Put down the left crankcase and remove the right
crankcase.
right crankcase

Remove the connecting rod combination.
Remove the timing chain.
locating pin spacer connecting rod combination
15.3.2 Check
Measure the left-right clearance of the larger end of the
connecting rod.
measuring point at the larger end of the connecting rod
- 117 -
Measure the clearance of the larger end of the connecting
rod (X-Y direction).
Check whether there is noise when the crankshaft bearing

rotates or whether it is loose.
If yes, replace the crankshaft assembly.
crankshaft bearing
Remove the oil seal from the left crankcase.

Note:
Removed oil seal can not be used any more.
Remove the oil seal with a special tool.
oil seal
14.4 Installation
Install the crankcase in reverse order.

Note:
Install the oil seal with special tools to avoid any damage to it.
- 118 -
Cooling System Diagram (picture to be updated)
Filler
Water outlet
pipe
Water inlet
pipe
Thermostat
Pump
- 119 -
XV. Cooling System
Failure diagnosis----------------------16.2
Thermostat-----------------------------16.3
Function of the cooling system: Use water as heat absorption medium to take heat outside through the
cylinder block and the cylinder cover in the engine. Then dissipate heat into air with the radiator to ensure the
engine works under the best temperature condition.
Work Instructions:
1. Check and maintain the cooling system after the engine is cooled.
2. Do not remove the radiator cover except that the radiator liquid is filled up again or drained out after the
cooling system is dismantled.
3. It is feasible to maintain the cooling system on the motorcycle.
Insufficient cooling water Overheated engine

Evaporation or leakage Poor cooling cycle
Cracked or aged hose Leakage of cooling water which causes little working medium
Loose joint Too much impurity inside the radiator pipe
Poor sealing of the cylinder gasket Wrinkled water pipe
Deformed iron pipe at the outlet of the hose Pump in bad condition
Dirty radiator lattice
- 120 -
15.3 Thermostat
Disassembly
Drain out the coolant and remove the
thermostat.
Put the thermostat into the water vessel.
Raise water temperature and check the
temperature when the valve of the
thermostat opens.
Initial temperature 7284C

for opening
Full-open 9396C
temperature
Lift at the time of Above 4.27mm
Hydrostatic test at 392KPa shall be carried out on the thermostat for
fully opening
3 minutes. There shall be no leakage.
sensor assembly thermostat assembly bolt thermostat

chamber upper lid of the thermostat chamber seal ring of the thermostat o
o-ring
Radiator
Repair the radiator with a small club when over 1/3 of heat
sink is damaged or twisted.
heat sink
- 121 -
Water outlet temperature switch
assembly
Conductivity temperature: 93C2C
Reset temperature: 88C2C
water outlet temperature switch assembly
Coolant replacement
Confirm the coolant is cooled. Remove drain bolts, tilt the
body to the right, completely drain out coolant and then
install drain bolts.
drain bolt
Fill the prepared coolant into the filling hole.
filler cap assembly water inlet pipe water outlet pipe
- 122 -
Pump check
Check whether the mechanical seal is damaged through the
leakage inspection hole. If the coolant is leaked through the
hole, it shows there is damage to the mechanical seal.
Replace the whole pump. For any pump which can be
disassembled, replace the mechanical seal.
pump leakage inspection hole
- 123 -
Muffler (picture to be updated)
- 124 -
XVI. Exhaust Emission & Control System
Warranty on the exhaust emission & control system ---------------------------17.1
Instructions on the periodic maintenance/ compliance with standards-------17.2
Mechanical function of the exhaust control system ----------------------------17.3
Catalytic conversion system -------------------------------------------------------17.4
Measures when the idle speed emission value exceeds the standard---------17.5
16.1 Warranty on the exhaust emission & control system
1. The exhaust emission & control system of this motorcycle is in conformity with the revision of EC/97/24/5/I
and 2002/81/EC B issued by the EU. We warrant that the exhaust emission & control system works normally
during its effective period provided that users completely comply with all operation and maintenance
requirements.
2. Warranty range
1Function warranty of the exhaust emission & control system
We warrant that it satisfies all periodic or non-periodic inspection by the related government authorities
within riding of (15000 kilometers).
3. This provision is not applicable under any following condition. However, our distributor or service store would
like to provide maintenance or repair services at reasonable prices.
1Users fail in periodic maintenance within the required period or kilometers.
2Periodic maintenance, adjustment or repair is not carried out at our distributor or service center, or there is no
evidence of maintenance record.
3Overload or improper operation.
4Refit the motorcycle, remove original parts or replace with other devices in private.
5Ride the motorcycle on race tracks or on any non-motorized vehicle lane frequently.
6Damage to the motorcycle due to extreme weather such as typhoon or flood, or damage or failure due to
negligence, crash or impact.
7Users fail in periodic maintenance since it is out of service for a long time.
8The odometer is not repaired immediately after being damaged, or it is refit, stopped, or replaced in private.
9Users fail in periodic exhaust inspection at the station every three months.
All new motorcycles delivered by our company have satisfied the noise test and comply with EC 97/24/9
implemented by the EU.
- 125 -
16.2 Instructions on periodic maintenance
It is the national requirement that all motorcycles produced domestically shall comply with exhaust emission
standards to lessen environmental pollution. We strictly accord with these exhaust emission standards and also
make great effort in purifying air and reducing pollution.
This motorcycle has been strictly examined before delivery and is in conformity with all exhaust emission
standards. We provide the following periodic inspection table for exhaust emission in consideration of different
use by customers. Users shall carry out periodic inspection, adjustment or maintenance according to the schedule
to ensure normal emission.
For any problem, please contact KEEWAY distributors or KEEWAY service center.
Relevant emission provisions are shown as follows:
Emission regulation CO HC NOX

Emission standard 2.0g/km 0.3g/km 0.5 g/km
The latest national regulation shall prevail if there is any change.

We are not responsible for any problem due to failure in periodic maintenance at our distributor or service center.
Please carry out necessary inspection to ensure its best condition.
Note: Clean the air filter frequently if the motorcycle runs in sandy road or under seriously polluted condition to
extend the service life of the engine.
Increase maintenance if the motorcycle often runs at high speed or frequently.
Pay attention to following items to ensure compliance with emission standards:

1Please use lead-free gasoline.
2Please use fuel with stipulated specification.
3Please comply with periodic maintenance requirements.
4> For the exhaust control system, it is forbidden to make any adjustment or replacement at random (including
use of spark plug, adjustment of idle speed, ignition timing, etc.)
5Notes:
Since any problem in the ignition system, the charging system or the fuel system has significant effect on the
catalytic device, please go to our designated distributor or service center for inspection, adjustment or repair
immediately when there is any problem found in the engine.
6The exhaust control system of this motorcycle is in accordance with the national regulation. For replacement of
any component, please use our original parts and have our designated distributor or service center carry out such
replacement.
- 126 -
16.3 Mechanical function of the exhaust control system
General
This system adopts four-stroke single-cylinder engine and air conduction device to maintain qualified exhaust gas.
Meanwhile, active carbon canister is used for exhaust gas evaporated from fuel.
Engine improvement
As the spark plug, combustion chamber, compression ratio, ignition time, exhaust system and other engine
components are improved, as well as the intake/exhaust efficiency is enhanced, the combustion efficiency is
raised.
Air induction device

Induce air into the exhaust pipe, which enables incompletely combusted CO and HC to be reacted again and
become harmless gas.
Division Device Constitution Function
Canned oxidized catalyst installed in the
Exhaust
Catalytic device Catalytic converter center of the exhaust pipe is able to oxidize
system
CO, HC and NOX.
Adjustable parameters and suggested value setting

Adjustment of idle speed rotating speed of engine 1500100rpm/min
CO concentration 0.5-1.2
16.4 Catalytic conversion system
17.4.1 Structure:
- 127 -
where catalyst is placed
17.4.2 Instruction
1. The function of convertible catalyst is to converse exhaust gas HC, CO and NOX after complete combustion
to harmless gas such as H2O, CO2andN2 before emission.
2. Convertible catalyst includes rare metal such as platinum and rhodium. Only lead-free gasoline can be used.
Note that lead gasoline may invalidate catalyst.
General instructions for maintaining motorcycles (exhaust pipe) with catalytic converter:
1For motorcycles with catalytic converter, when the engine is running or just closes down, it shall not be
touched for a while because of high temperature.
2Motorcycles with catalytic converter shall not be near flammable material.
3There is CO inside the exhaust pipe, which is harmful to health. So do not run the engine in closed space.
4Lead gasoline can not be used for motorcycles with catalytic converter (to prevent catalytic poison).
5Do not push the motorcycle to run the engine. If it is necessary, you must wait until the temperature of the
engine and the catalytic converter lowers down.
6Do not make gear up or flame out when descending.
7Do not drive the motorcycle with bad ignition.
8Do not remove spark plug and run the engine to see whether there is spark when maintaining the ignition
system of the engine. If necessary, it shall be finished in a short time.
- 128 -
XVII. EFI System
17.1. Connection of the EFI system
The following figure 1 shows the connection diagram of a typical double-cylinder engine
EFI system. Full lines in this figure represent input signals of the engine controller, while dotted
lines represent input signals obtained from sensors and switches by the engine.
Figure 1
Crankshaft position target wheel Crankshaft position
sensor Heated oxygen sensor Magneto
temperature sensor / Air intake temperature/pressure combined
sensor Neutral gear switch Dump switch
Ignition switch Battery Burglar alarm Selective
Engine control module Serial
communication interface for the failure diagnosis switch Failure indicator
Engine rotating speed signal Throttle position
sensor Idle speed control valve Throttle valve body
Ignition coil Nozzle Fuel pressure regulator
Fuel pump Metal carrier catalytic converter
- 129 -
17.2. Engine controller (MC21)
17.1.1 Work principle
MC21 controller is the last generation of 16-bit digital control device used for some
small engines.
This controller is able to monitor data related to engine temperature, air intake
pressure, crankshaft angle and exhaust oxygen sensing signal for accurate fuel
injection and ignition control. Thus, the engine fuel can be used economically and
dynamically.
The shell of MC21 controller is made of plastic and glass fiber. It is encapsulated
and sealed. It is shockproof and waterproof.
17.1.2. Label and mark

The following figure 7 is the label on MC21 controller. Information includes ECU type,
component code, customer code, hardware code, production code, software revision and bar
code. Any erasion from or stain in this label will affect product warranty.
Figure 7
17.1.3. Pin definition for the controller interface
The following figure 8 shows the pin definition diagram for the controller interface. It shall be
ensured that input/output load is within the range of the table 9.
- 130 -
Figure 8
Figure 9
- 131 -
Figure 10
- 132 -
17.20. Instructions
MC21 controller instructions Table: 4
Instruction Cause
Forbidden: Place ECU beside the engine or The service life of ECU is affected by high
the exhaust pipe during transfer. temperature which also easily damages the
plastic shell of ECU.
Forbidden: Place ECU in water, oil or ECU is sensitive to liquid.
liquid environment.
Forbidden: ECU is covered with mud or Unfavorable for heat dissipation of ECU
water drops. surface.
Forbidden: Power connection to ECU It seriously affects ECU work and definitely
randomly. damages ECU.
Forbidden: Water drops or too much vapor Short-circuit of ECU connector or damaged
on the connector. ECU.
Forbidden: Clean ECU with agent or Damage ECU shell.
corrosive liquid.
Should: Clean ECU with wet cloth and Prevent ECU from damage.
keep it dry.
Should: When ECU is reinstalled, check Keep vehicle performance.
whether the air intake pipe is blocked. If
yes, clean it.
Should: When ECU is reinstalled, fix the Keep vehicle performance.
air intake pressure pipe and ensure no
leakage. Clamps and air intake pressure
hoses shall match with the vehicle type.
Should: Keep the air intake hose always Prevent dust from entering into the engine
connect ECU and intake manifold. to ensure safety.
Should: When the air intake hose is pulled Prevent joints inside ECU from being loose
out from ECU, loosen the clamp at the joint and coating from being damaged.
and then pull the hose carefully from ECU.
- 133 -
17.21. Installation requirements
The installation requirements for MC21 controller are shown in figure 11
(the tightening torque force for fixing bolts (M6) is 5Nm).
11
- 134 -
17.3. Power supply requirements
Power on
Under normal condition, the input voltage from battery keeps stable.
When the ignition switch closes and the battery voltage exceeds 6.5V,
ECU starts normal work.
Operation:
When the EFI system works, the battery voltage shall keep between
9-16V to ensure normal operation of the system.
Power down:
When the ignition switch turns off, the ignition voltage is below 6.2V,
ECU enters into power down condition. ECU records values in EEPROM,
such as fault code, frozen fault code, closed-loop value, revised air flow
value and throttle value. Based on these values, it enables precision
calculation on each parameter for next startup.
Reset mode:
When ECU receives reset command or faces serious problem, the
system enters into the reset mode. All I/O interface is reset to the
predefined state and enters into normal work condition after reset is
finished.
Overvoltage/counter-voltage
ECU, which works under overvoltage of 24V for no more than 1
minute, will not be damaged.
ECU, which works under counter-voltage of 14V for no more than 1
minute, will not be damaged.
17.4. Work temperature
Normal work temperature range: -30 to 70
Maximum work temperature: 80 (continuous work for no more than
30 minutes)
Storage temperature range: -40 to 85
17.5 Maintenance and repair

The controller can not be maintained after sale. When there is any
problem, make sure whether it is cause by calibration or software first. If
- 135 -
yes, update the calibration software. If any controller hardware fails or is
damaged during the warranty period, the controller must be sent back to
the factory, attached with detailed controller component number, serial
number, vehicle type, date of production, accumulated kilometers, where
be used, and date of return.
The following table shall be filled up by the distributor and sent to
the factory with the controller for finding reasons. Some actions are only
valid for products within the warranty period. Otherwise, users shall be
responsible for expenses resulting from the replacement of damaged
controllers.
DELPHI Request on the Repair of Workshop
Damaged Controller
Distributor: Vehicle type: Date of failure:
Address:
Engine displacement:
Date of vehicle production:
Accumulated kilometers:
Details on controller:
Telephone: Part number:
Mobile telephone: Serial number:
Contact: Date of controller production:
Detailed description of failure:
Failure under what condition:
- 136 -
Any measures taken by users and the distributor after failure:
Other information and inferred causes:
XVIII. M3 and M3.5 Fuel Injector

18.1. List of spare parts
List of spare parts of the fuel injector Table: 5
Name of spare parts Remark
M3 fuel injector
M3.5 fuel injector
18.2. General work principle

M3 fuel injector boasts high performance and excellent durability. It
is designed by DELPHI and used for engines. Electromagnetic coil is
around the iron core inside. Two electrode from the electromagnetic coil
are input control interface of the oil injector. When the coil is connected
to power, the electromagnetic attraction suppresses spring force and fuel
pressure of the ball valve, and raises the valve. Thus, high-pressure fuel
in the fuel pipe (250400kPa) runs through the valve seat hole and the
orifice plate, forms cone-shaped fog and injects to the air intake valve.
After the injector is disconnected, the magnetic force of the
electromagnetic coil vanishes automatically, and the ball valve of the
fuel injector closes automatically under the action of return spring,
which stops fuel injection.
The work principle of M3.5 fuel injector is similar to that of M3
fuel injector. The difference is that its electromagnetic coil is more
- 137 -
efficient and it has better durability and speed of response.
18.3. Appearance
The following figure 12 shows the appearance of M3 fuel injector.
O-ring for connecting

the fuel rail
or the fuel injector cap.
O-ring for connecting

the end of the air intake pipe.
Figure 12
There are two types of M3.5 fuel injector: long-type and mini-type.
M3.5 fuel injector is able to provide better integrated function.
Long-type fuel injector Mini-type fuel injector
Figure 13
- 138 -
18.4. O-ring
O-ring shown in figure 12 is able to ensure that there will no
leakage in the fuel injector when working at between -40 and 150
(-40 and 302). It also resists corrosion from kinds of fuel additives
(such as ethanol). The current o-ring design is shown below. If any
DELPHI fuel injector is not consistent with following data, please
contact DELPHI.
O-ring for connecting the fuel rail or the fuel injector cap
Dimension:
Inner diameter: 6.35mm
Outer diameter: 14.85mm
Section thickness: 4.25mm
Material:
Viton GLT(blue): application under low temperature
Viton A(black): application except for low temperature
O-ring for connecting the end of the air intake pipe
Dimension:
Inner diameter: 9.61mm
Outer diameter:14.49 mm
Section thickness: 2.44 mm
Material:
Viton A (blue or brown)
18.5. O-ring replacement
Use the suggested lubricating oil to lubricate O-ring. Do not contact the
orifice plate with lubricating oil, otherwise it affects fuel injection.
We suggest that o-ring can be used only once. If replacement is
impossible, please check whether it is damaged before repeated use. Any

minor damage will cause fuel leakage. To avoid any danger, please
strictly comply with requirements to install the oil injector.
When o-ring is installed into the fuel injector, please be careful and do
not damage the o-ring.

18.6. Suggested lubricant
- 139 -
For the convenience of fuel injector installation, lubricant shall be
applied to o-ring. Table 4 lists applicable and proved lubricant.
According to test, following lubricant will not affect the performance of
fuel injector.
Suggested lubricant Table: 6

Name of lubricant Manufacturer Viscosity (cSt)
@40
Spindura 10 Equilon 10
Spindura 22 Equilon 21
DTE-24 Mobil 32
DTE-25 Mobil 46
DTE-26 Mobil 68
Norpar15 Exxon/Mobil <1
Drawsol 60 DA Stewart 1-2
NocoLube AW 46 NOCO Energy 46
NocoLube AW 32 NOCO Energy 32
Advantage Spindle Oil Advantage Lubrication Specialties 10
18.7. Over-voltage effect

M3 fuel injector and M3.5 fuel injector can work under the voltage
of 26V and pulse width of 100ms (200ms for a cycle) for 1 minute (with
fuel). It will not affect flow or cause permanent damage to the
electromagnetic coil or reduce the electromagnetic performance.
18.8. Temperature range
The standard temperature range of fuel injector is as follows. Under
normal temperature rang and normal flow tolerance, M3 and M3.5 fuel
injector will not be invalidated. Meanwhile, under normal work
environment, fuel injectors will not cause any leakage, aging or
shortened service life.
Work temperature range: -30125
Work limits (leading to some performance degradation): 40
150
Storage temperature: -6060
- 140 -
18.9. Fuel contaminants
Filter is designed inside the fuel injector, but it can not be
maintained. It is only used for filtering accumulated impurities in the
fuel pipe between the fuel filter and the fuel injector. Impurities will
cause failure such as bonding, flow deviation and leakage.
18.10. Cable arrangement
Cables of the fuel injector shall be deployed far away from heat
source and protected from any outside abrasion or damage.
Do not insert/pull the fuel injector connector it is not necessary.
18.11. Instructions
Fuel injector instructions Table: 7
Instruction Cause
Forbidden: use o-ring repeatedly. If it Void leakage.
has to be used repeatedly, please check
whether it is damaged before use.
Forbidden: immerse the injector Block the injection hole.
mouth in lubricant.
Forbidden: dry run under no fuel Damage inner mechanical parts.
pressure.
Forbidden: operate the fuel injector Eliminate contaminants and analyze
whose leakage rate maybe exceed causes for injector interference.
standards (leakage rate >50sccm air).
Forbidden: water enters into the fuel Cause damage to the fuel injector.
pipe during leakage rate inspection.
Forbidden: Impose force on the fuel During installation on the nylon intake
injector head during installation. pipe, it is allowed to impose force at the
angle of 45 degree.
Forbidden: strike the fuel injector Damage the fuel injector and o-ring.
when it is installed on the intake pipe.
Forbidden: impose tensile force on the Cause interrupted power supply.
connector.
Forbidden: use the fuel injector which Possible damage.
- 141 -
has been thrown.
Forbidden: store fuel injector, fuel rail Possible damage to electronic and
or engine with fuel injector installed mechanical components of the fuel
under non-protective environment. injector by the external environment.
Forbidden: pick up the fuel injector Damage the fuel injector.
when lifting the assembly.
Forbidden: components contact each Damage the fuel injector.
other during storage.
Forbidden: components contact each Possible impact, which may cause damage
other during transportation. to the fuel injector.
Forbidden: hammer the oil injector for Damage the fuel injector.
troubleshooting in the case of an error.
Forbidden: use non-suggested fuel Significantly affects the performance of
injector instead of original fuel the fuel injector.
injectors.
Should: note that the o-ring shall not Protect the o-ring.
be cut by the installation seat during
the installation of the fuel injector.
Should: install it into the hole after Protect the o-ring and reduce pollution.
being applied with correct lubricant.
Should: test the fuel injector adhered Confirm the invalidation of the fuel
to the needle valve or whose needle injector.
valve fails in seating. (pulse to the fuel
injector with the voltage between
9-15V for less than 5 seconds)
Should: before the fuel injector is The needle valve of the fuel injector may
assembled, carry out no fuel leakage fail in seating during transportation or
test to confirm seating of the needle transfer, which causes fuel leakage.
valve.
Should: avoid liquid pollution to the Cause short-circuit of the electromagnetic
fuel injector. coil.
Should: carefully dismantle the cables. Cause damage to terminals.
Should: use suggested lubricant during Cause corrosion to terminals.
the installation of the connector.
- 142 -
Should: do not use fallen, damaged or Find causes to problems as soon as
unqualified components, and label possible.
them to indicate problems.

Please strictly comply with following instructions for installation and
disassembly to avoid damage to fuel injectors and electronic
components.
Lubrication: apply a little lubricant to the lower part of the o-ring.
Do not use ISO 10 light mineral oil or equivalent product.
If it is possible, it is better to apply lubricant to the fuel injector
seat other than o-ring. Thus, it can minimize pollution by the fuel
injector.
Do not make the orifice plate contact with lubricant, which
affects the volume of fuel injection. Do not pick up lubricant with
the top of the fuel injector.
All M3 and M3.5 oil injector o-rings are assembled before
delivery. In principle, o-rings are not allowed to be used
repeatedly. Please check whether there is any damage to o-rings.
Any minor damage will cause leakage. Install the o-ring into the
holder carefully.
Do not damage the connector when it is installed. The fuel
injector connector is properly installed when there is a click
sound.
Do not install or disassemble unnecessary connectors.
Do not tighten cables too much, otherwise it may lead to short
circuit.
Do not rotate the fuel injector during the installation of the
connector, which will lead to deviation from fuel injection
targets.
18.13. Replacement
The disassembly and replacement of M3 and M3.5 fuel injectors are as
follows.
- 143 -
Note: high temperature in the fuel injector and its surrounding
parts.
The motorcycle flames out.
Disconnect the negative pole of the battery to avoid any
accidental startup of the engine.

Remove the fuel injector connector.
Discharge fuel pressure.
Remove the fuel pipe from the fuel injector.
Remove the fuel injector from the air intake pipe.
Remove the fuel injector retention clamp and the fuel injector
from the seating carefully.

Carefully clean impurities on the contact surface of the fuel
injector. Do not damage the contact surface.

Apply lubricant to o-rings on two ends of the new fuel injector.
Install the new fuel injector into the air intake pipe carefully and
make sure it is towards the same direction as the original one is.
Install the fuel injector seating and the retention clip.
Tighten mounting bolts with required torque according to
installation manual.
Install the fuel pipe.
Insert the fuel injector connector.
Insert the key for power on. Check fuel leakage from the fuel
injector without engine startup.

Start up the engine to check its work.
18.14. Replaceability
Replace the fuel injector with the one of the same part number. Part
number may change. Please check the vehicle maintenance manual and
the list of spare parts to select correct fuel injector.
18.15. Fuel injector blocked
Accumulated impurities in fuel will cause flow deviation and
reduction of service life. When the engine stops working, deposits may
be generated in fuel as heat from the engine runs through the fuel
injector head. Deposits accumulated around the fuel injection hole will
- 144 -
lead to flow deviation.
If the fuel injector is blocked, reduced flow, increased friction
and accumulated impurities will take place, which finally affects
emission and durability.
Fuel and environment factors will cause fuel crystallization or
corrosion to the fuel injector, which also leads to flow deviation.
Unsteady fuel oxidation will generate deposits. Please use
high-quality gasoline.
Add a certain amount of fuel injection cleaner to avoid deposits.
When the fuel injector is blocked, please clean the fuel injector
with following methods.
18.16. Cleaning
Disconnect the fuel pump first.
Discharge fuel pressure and then remove the fuel pipe. After the
fuel pipe is removed, stuff it up with some material to avoid fuel

drainage.
Add fuel injection cleaner and gasoline at certain proportion to the
fuel injector cleaner tank.

Connect the fuel injector cleaner tank to the fuel injector.
Adjust the cleaner fuel pressure to the vehicle system pressure of
2.5bar.
Start up the engine, and keep it at the idle speed for 15-20 minutes.
Remove the cleaner tank, and re-install the fuel pipe to the fuel
injector.
Start up the engine and keep it at the idle speed for 2 minutes.
Ensure cleaner is completely discharged.
XIX. Throttle Valve Assembly

List of spare part of the fuel injector Table: 8
Name of spare part Remark
- 145 -
Throttle valve
Throttle position sensor
Idle adjustment screw
19.2 General work principle

The throttle valve assembly mainly consists of following parts: main
cast valve body, bearing, shaft and valve block, return spring,
throttle cable and throttle position sensor system. All above
subsystems work together to achieve following functions:
control air intake flow
control air flow at the idle speed
check the throttle positionprovide throttle feedback signals to
the engine control system

provide the throttle with return force
19.3. Appearance
Figure 16
19.4. Technical parameters
Throttle valve (inner diameter: 26mm):
- 146 -
Maximum flow: 19.291.0g/s@0.75kPa vacuum degree
Torque for opening the throttle valve:
At idle speed: 0.190.05Nm

When fully open: 0.370.10Nm
Throttle position sensor
Reference voltage: 50.1VDC
Resistance between T1 and T2: 3k12k
Figure 17
19.5. Work environment
Normal work environment: -40125
19.6. Disassembly of the throttle valve
Disconnect the negative pole of the battery
Disconnect the throttle position sensor
Remove the throttle cable
Remove the hose between the air cleaner and the intake manifold
19.7. Cleaning
Remove the cover at the bottom of the throttle valve and clean the
body with carburetor cleaner (3M product suggested). Spray cleaner on
the inner wall of the throttle valve and remove dust and carbon deposit
slightly with brush. Do not block the bypass with impurities.
If idle screws are removed and cleaned, assemble idle screws in
- 147 -
following order:
Install o-ring 1 on the idle bypass screws
Install spring, washer, o-ring 2 on the idle bypass screws
Install above idle bypass screws on the throttle valve.
After idle screws are cleaned and assembled, use diagnosis tools and
adjust idle speed.
Note: new o-rings shall be used every time of installation.
19.8. Installation of the throttle valve
Install the throttle valve in reverse order and pay attention to
followings:
Adjust the throttle cable.
Ensure all removed components are installed in place.
Re-install all necessary parts.
19.9. Precautions
Do not spray any cleaner into TPS throttle position sensor.
Use the throttle cable to open the throttle valve block.
Do not insert any tool or stick into the throttle valve hole to keep
the valve block open. It will cause deformation of the valve block and
damage to the inner wall of the throttle valve.
Keep carbon deposit around the valve block to maintain air flow
required by idle speed setting.

Do not adjust the position of idle screws.
Replace o-rings once disassembled.
19.10. Instruction
Instructions of the throttle valve assembly Table: 10
Instruction Cause
Should: be careful when the throttle Avoid damage to the connector.
valve connector is used.
Should: avoid any liquid pollution to Ensure normal work.
the throttle valve.
Should: take and install only one piece Possible damage to components.
of throttle valve from the component
- 148 -
tray.
Should: use a label to describe any Accurately analyze causes as soon as
problem related to any fallen, possible.
damaged or unqualified throttle valve
(within warranty range).
Should: remove and discard protective Protect the system from pollution and
cap before installing components. keep it work normally.
Should: clean bypass when the seating Ensure stable idle speed.
is removed.
Should: if idle screws are removed, Ensure no air leakage from o-ring.
replace o-rings.
Forbidden: use any fallen or defective Possible inner damage.
component.
Forbidden: no protective cap for Possible impact on normal work due to
storage parts. pollution.
Forbidden: no protection during Possible impact on normal work due to
transportation or transfer around salt corrosion.
spray.
Forbidden: completely exposed to the Possible impact on normal work due to
environment (humid) before assembly. corrosion.
Forbidden: tested voltage exceeds the Possible damage.
system voltage.
Forbidden: use excessively tightening Possible damage.
torque.
Forbidden: hammer the fuel injector Damage to the fuel injector.
for troubleshooting when there is an
error.
Forbidden: components bump into Possible impact on the minimum air
each other when being unpacked. leakage or other damage.
Forbidden: completely release the Possible damage.
throttle at any position.
Forbidden: block the bypass hole with Possible impact on the stability of idle
dirt or sand. speed.
Forbidden: take, store or hold Possible damage.
- 149 -
components in a way of possibly
touching other parts.
XX. Water Temperature Sensor for the

Engine
20.1 List of spare parts
List of spare parts of the water temperature sensor Table: 11
Name of spare part Remark
Water temperature sensor for the Used for all water-cooled engines.
engine

This water temperature sensor is used for water-cooled engines.
Within the temperature range of this sensor, its resistance will vary upon
the engine temperature. Its character refers to negative temperature
coefficient resistance property. It is not maintainable.
20.3. Appearance
Figure 18
Dynamic torque requirement: install it by manual and guide into
threads correctly. Then tighten it to the required torque with electric
- 150 -
spanner at the speed of beyond 400 rounds/minute or with the manual
spanner. Suggested assembly torque is as follows:
Maximum: 20N m
Minimum: 25N m
Static torque requirement: torque used for dismantling the sensor
from the engine shall be no more than 200% of the assembly torque.
This sensor is mainly used for water-cooled engine.
Temperature range under normal work: -40135 (continuous
work)
Relative humidity under work environment: 0100%
Typical work pressure: under the minimum assembly torque, the
sensor can achieve coolant sealing for the engine under the actual
pressure of 206.8kPa (30psi) and the temperature of 135.
Extreme work environment: only for 1 hour under the maximum
temperature of 150
20.6. Storage environment
Storagetemperature: -40 to 120
Transportation without time limit below the altitude of 13700m.
20.7. Electric environment

Typical work pressure: reference voltage is 50.1VDC
Maximum exciting current: When the properties of the sensor are
tested under any temperature, its performance shall not be affected by

current of less than 1mA.
20.8. Cleaning samples
If necessary, clean the sensor with isopropanol and then dry it. Sink it
in isopropanl for no more than 1 minute. Install sealed connections
during cleaning to prevent cleaning agent from entering into the sensor.
- 151 -
XXI. Intake Air Temperature Sensor
List of spare parts of the intake air temperature sensor Table: 12
Name of spare parts Remark
Intake air temperature sensor Used for all engines

Within the temperature range of this sensor, its resistance will vary
upon the engine temperature. Its character refers to negative temperature
coefficient resistance property. It is not maintainable.
21.3. Appearance
The appearance of the intake air temperature sensor is shown as in

figure 20 above.
Work voltage: 5DVC
Response time: 15S
Work temperature: -40150
Relative humidity: 0 to 100% RH
21.5. Installation requirements:

Suggested diameter of mounting hole: 12mm
Suggested depth of mounting hole: 12mm to 16mm
Mounting angle with the horizontal plane: 50
21.6. Cleaning samples
- 152 -
If necessary, clean the sensor with isopropanol and then dry it. Sink
it in isopropanl for no more than 1 minute. Install sealed connections
during cleaning to prevent cleaning agent from entering into the sensor.
XXII. Oxygen Sensor

List of spare parts of the oxygen sensor Table: 15
List of spare part Remark
Oxygen sensor

Oxygen sensor is used for monitoring the content of waste oxygen
inside the exhaust pipe of the combustion engine, including wideband
oxygen sensor and switch-type oxygen sensor. Normally, we use
switch-type oxygen sensors for small engines. It is mainly used for
controlling the fuel closed loop of the engine.
22.3. Appearance
The appearance of the oxygen sensor is shown as in figure 22
below.
Figure 22
- 153 -
Threshold value for air-fuel ratio (dense): 750VDC
Threshold value for air-fuel ratio (dilute): 120Mvdc
Heater power for the oxygen sensor: 7.0W
(above parameters are measured at the engine test bench under the
exhaust temperature of 450, duty cycle of 70%, 10Hz and voltage of
13.5V. )
Heater resistance: 9.61.5 (measured below 21)
Work temperature range: 260-850

Installation angle (angled with the horizontal plane) 10 degree
Figure 22
Tightening torque force: 40-60Nm

22.6. Fuel quality requirements
Pb0.005g/L
P0.0002g/L
S0.04%(
Si4ppm
XXIII. Fuel Pump Assembly

224. List of spare parts
- 154 -
List of spare parts of the fuel pump Table: 19
Name Remark
Fuel pump assembly
Fuel pump device
Fuel pressure regulator
Sealing device for the fuel pump
assembly

Fuel pump assembly: provide the engine with fuel which satisfies
the requirements of the pressure system. It is installed at the bottom of
the fuel pump and supplies fuel to the engine through connected fuel
pipes.
Fuel pump: this electric pump obtains pressure fuel from the fuel
tank by the motor impeller.
Pressure regulator: mechanical diaphragm type; it regulates
pressure for fuel provided by the fuel pump to make it meet constant fuel
pressure requirements.
23.3. Appearance and structure
- 155 -
fuel pipe pressure regulator clamp pressure
regulator fuel pump cable pump body frame fuel
pump filter washer fuel pump assembly pipe clamp
fuel pipe fuel pump bracket
23.4. Dimension
Dimension of the bottom panel: 115mm70mm.
Mounting height: 135mm (reference dimension)
23.5. Label and mark
Fuel pump assembly, fuel pump device and pressure regulator are
marked with production batch and date.
Fuel pump assembly: labeled on the mounting plate of the fuel
pump assembly.
Fuel pump: engraved on the pump body.
Fuel pressure regulator: engraved on the shell.
The fuel pump shall be installed at the bottom of the fuel tank
according to installation requirements.
The general design of the fuel tank is only for gasoline. If it
contains ethanol, please contact the fuel pump factory to ensure whether
it can be used.
During the first operation of the fuel pump, please ensure there is
enough fuel in the tank. Do not operate it under no fuel condition.

For the connection of fuel pipes, please see the reference diagram
28.
Overall Fuel Pipe Arrangement
- 156 -
Figure 28
23.8. Maintenance procedures
Safety precautions:
Please be careful and keep your safety when maintaining the fuel
system.
Disconnect the negative pole of the battery.
Smoking is forbidden. Place a sign of No Smoking near the
operation area.
Ensure there is fire extinguishing devices.
Ensure good ventilation and keep away from fire sources.
Wear protective goggles.
To release fuel vapour inside the fuel tank, open the fuel tank and
then re-install it.

When the engine stops working, there is still high pressure inside
the fuel pipe and fuel shoots up if the fuel pipe is disassembled or
loosened. Please make reference to fuel pressure release
procedures in this chapter.
A small amount of fuel flows out after the fuel pipe is
disassembled. To avoid any danger, please apply proper and clean

material to block the pipe.
After maintenance, please make sure the fuel pipe and the clamp
are installed according to the installation manual.

After maintenance, please check fuel leakage according to the
fuel leakage inspection procedures.

After maintenance, make sure there is enough fuel in the fuel
- 157 -
tank when the fuel pump works.
Failure diagnosis of the fuel pump assembly:
Step Operation Yes No
1 After startup by the ignition key, If you can hear fuel If you cannot hear
the fuel pump works for 3 pump working, fuel pump working,
seconds. please go to step 4. please go to step 2.
2 Disconnect the fuel pump Go to step 3. Check the power
connector, and check whether the supply circuit of
voltage of the fuel pump is the fuel pump.
within 10-14V.
3 Supply DC of 12V to the fuel 1. Check the loop 1. Check the
pump; from the fuel throttle cable;
ensure there is enough fuel in the pump to ECU; 2. Check the fuel
fuel tank to avoid dry run; 2. Check ECU. pump.
whether the fuel pump works?
4 When the engine works at idle The fuel pump Go to step 5.
speed, check whether the fuel assembly works
supply pressure at the front end normally.
of the injector mouth is within
220-270kPa.
5 Whether pressure is lower than 1. Check whether 1. The fuel filter is
220kPa. there is leakage blocked;
in the fuel pipe; 2. The fuel pipe is
2. Check fuel bent and
pump device; twisted;
3. Check pressure 3. Check pressure
regulator. regulator.
Disassembly of the fuel pump assembly:

Please make reference to fuel pressure in the fuel drain pipe in
fuel pressure release procedures.
Disconnect the negative pole of the battery.
Disconnect the connector of the fuel pump assembly cable.
Pump the residual fuel in the fuel tank out and store it in a proper
vessel to ensure safety and reduce pollution.
Disassemble the fuel pipe connecting to the fuel pump assembly
with standard tools.
Remove the fuel tank from the vehicle.
Place the fuel tank upside down. Protect it from any scratch or
- 158 -
crash.
Do not damage the filter during removal.
Installation of the fuel pump assembly:
Replace the sealing washer of the fuel pump assembly (an used
washer may lead to fuel leakage).
Fold the filter carefully and asymmetrically arrange mounting
bolts for the fuel pump assembly which only can be installed
towards required direction. The pressure regulator shall face the
back of the fuel tank to ensure the surface of the fuel tank is clean
and neat.
Install screws in the cover plate of the fuel pump assembly and
evenly tighten screws in sequence as shown in figure 33. Torque
for mounting screws: 34Nm. The fuel pump assembly shall be
fixed with special screws. Apply required tightening sequence
and torque to fix. Over-torque or incorrect tightening sequence
will lead to deformation of the washer, which causes leakage.
Install the fuel tank in the vehicle.
Connect the fuel pipe and clamp it properly.
Connect the connector of the fuel pump cables.
Check leakage according to fuel leakage inspection procedures
before the engine works.
Tightening sequence for mounting screws

Figure 33
Replacement of the pressure regulator
Remove the seating of the pressure regulator.
Remove the snap spring from the pressure regulator with the snap
- 159 -
spring tool. Avoid any damage caused by popup of the spring.
Remove the pressure regulator.
Carefully avoid damage to the outer edge of the pressure
regulator.
Apply lubricant around o-ring of the new pressure regulator to
facilitate installation.
Make sure two o-rings are installed on the pressure regulator (one
with larger diameter, one with smaller diameter).
Install the pressure regulator in the bracket of the fuel pump
frame.
Do not hammer the pressure regulator (damage to the pressure
device).
Install the snap spring of the fuel pressure regulator.
Replace o-rings of the fuel pump.
Fuel pressure release procedures:
Note: do not operate when the engine is hot.
Make sure the engine is cooled and then carry out following fuel
pressure release procedures:
The transmission is at the status of neutral.
Disconnect the connector connecting fuel pump assembly cables
and vehicle cables.

Start up the engine until it automatically flames out. Open and
close the ignition key two or three times at an interval of 3

seconds.
After above operation, connect the connector of the fuel pump
assembly cables.
Fuel leakage inspection procedures:
After maintenance on any fuel system, please confirm following fuel
leakage inspection test is carried out.
Add enough fuel into the fuel tank.
Start the ignition key for 3 seconds and then closes it for 15
seconds; repeat it three or four times to set up fuel pressure in the

fuel pipe.
- 160 -
Check whether there is leakage in any component of the fuel
system (fuel tank, fuel pipe, joint, etc.).
Instructions for the fuel pump assembly Table: 18

Instruction Cause
Forbidden: crash the fuel pump. Damage to the inside of the fuel pump.
Forbidden: dry run by the fuel pump Damage to the inside of the fuel pump.
(no fuel from the filter at the entry of
the fuel pump); make sure enough fuel
in the fuel tank.
Forbidden: damage the filter during Impurities enter into the damaged filter
maintenance. and then the fuel pump, which destroy the
fuel pump.
Forbidden: disassemble inner parts of No warranty.
the pump body and the pressure
regulator.
Forbidden: regulate the fuel pump and
the pressure regulator.
Forbidden: pick up the fuel pump Damage the cables and disconnect the fuel
assembly cables to lift the fuel pump pump.
assembly.
Forbidden: lift the fuel pump assembly
cables vertically along the fuel pump
cover plate.
Forbidden: use damaged fuel pipe Pressure leakage/ fuel leakage.
clamp.
Forbidden: use seriously damaged or Impurities enter into the fuel pump
broken filter in the fuel pump through the damaged filter, and damage
assembly. the pump body.
Forbidden: draw fuel from the fuel Fuel pump is not designed for such
tank with the fuel pump. purpose.
Forbidden: use mounting screws of the Affect the installation of the fuel pump
fuel pump assembly to fix other assembly.
components.
- 161 -
Forbidden: damage the fuel pump Damaged terminals will cause bad
cables when the fuel pump assembly contact/ disconnected power supply.
is maintained.
Forbidden: the manual pump contacts Avoid damage to the fuel pump assembly.
the fuel pump assembly when drawing
fuel from the fuel tank.
Should: ensure no damage to the fuel Avoid fuel leakage.
pipe during maintenance.
Should: only use original sealing Faked ones may lead to fuel leakage.
washers for the fuel pump assembly.
Should: use designated hose clamps. Ensure no fuel leakage on joints of the
fuel pipe.
Should: the fuel pump cables are fixed Reduce vibration.
on the vehicle.
Should: use standard fuel. Unqualified fuel will lead to early damage
to the fuel pump.
Should: replace the fuel filter within Blocked filter will reduce fuel supply.
the stipulated period.
Should: use stipulated and qualified Unqualified filter will damage the injector
fuel filter. mouth, fuel pressure regulator and fuel
pump.
Should: ensure the correct direction of Incorrect direction or interference will
the fuel pipe deployment and no damage the fuel pipe.
interference with other parts.
Should: ensure enough fuel in the fuel Avoid dry run of the fuel pump.
tank (over the fuel pump filter).
Should: replace two o-rings when the Ensure the correct pressure regulation
pressure regulator is maintained. curve.
Should: carefully connect the Avoid damage to the connector terminals.
connector of the fuel pump assembly
cables.
Should: return any fallen, damaged or Find causes as soon as possible.
unqualified parts and describe related
problem.
- 162 -
XXIV. Failure Diagnosis
Failure diagnosis for the EFI system is carried out as follows:
I. Connect a special diagnostic apparatus to the failure diagnosis interface in the

motorcycle cables to effectively and accurately read failure.
II. Connect a computer installed with diagnostic software to the failure diagnosis interface
with a special communication cable, and then read failure in the computer.
In addition, the fault light in the meter (as shown in 4-1) also provides failure warning.
Under normal condition, Keyon, the fault light turns on and it turns off after startup. In the case
of failure, it is always light.
24.1. Diagnostic tools

Diag Tool software of PC version (for MC21 system) is used for
monitoring and recording operation data of the motorcycle. Connect the
computer serial port to the diagnosis interface of the motorcycle with K
line before use.
24.2. Pin definition for the diagnosis interface:
Pin 6 of the diagnosis interface is defined as follows: the pin
combination can achieve different diagnostic service functions. The
diagnostic tool uses three pins which are 12V, ground and K line.
- 163 -
Pin2ground
Pin4: K line
Pin6: 12V
24.3. Software instruction

Initial setting:
Connect the computer serial port to the motorcycle diagnosis interface with the
diagnostic cable.
Start Diag Tool software.
- 164 -
Click connect for connection.
Click Engine Data for displaying and monitoring engine status.
- 165 -
Click Engine Data for displaying and monitoring engine status.
Set the sampling frequency as 0.1 second and establish document
name and path for data saving.
- 166 -
ECU version
- 167 -
Click Malf Code to show current malfunction code.
24.4 Cross reference table for malfunction code

Malfunction Description Description of Flash
code malfunction code code
P0106 Map Rationality Rationality of air 35
intake pressure
P0107 Map Open/GND Open circuit or short 34
circuit grounding of
the built-in air intake
pressure sensor
P0108 Map Short V Short circuit power 33
supply of the built-in
air intake pressure
sensor
P0112 IAT Short GND Short circuit 69
grounding of the air
intake temperature
sensor
P0113 IAT Short V/Open Short circuit power 71
supply or open circuit
of the air intake
temperature sensor
P0117 Toil Short GND Short circuit 15
grounding of the
engine temperature
sensor
P0118 Toil Short V/Open Short circuit power 14
of the engine
temperature sensor
P0563 Battery voltage high Overhigh voltage of 49
the battery
P0122 TPS Open/GND Short circuit power 22
- 168 -
of the throttle position
sensor
P0123 TPS Short V Short circuit 21
grounding of the
throttle position
sensor
P0131 O2 Short GND Short circuit 45
grounding of the
oxygen sensor
P0132 O2 Short V Short circuit power 44
supply of the oxygen
sensor
P0231 Pump Open/GND Short circuit 29
grounding or power
supply of the fuel
pump
P0232 Pump Short V Short circuit power 31
supply of the fuel
pump
P0601 EEPROM Error EEPROM error 51
P0261 Cylinder 1 Inj Short circuit 16
Open/GND grounding or open
circuit of the injector
of cylinder 1
P0262 Cylinder 1 Inj Short V Short circuit power 17
supply of the injector
of cylinder 1
P1351 Cylinder 1 Ign Short circuit 64
Open/GND grounding of the
ignition coil of
cylinder 1
P0351 Cylinder 1 Ign Short V Short circuit power 42
supply of the ignition
- 169 -
coil of cylinder 1
P1650 MIL Open /GND Short circuit 0
grounding or open
circuit of the fault
light
P0650 MIL Short V Short circuit power 0
supply of the fault
light
P1654 TACO Open/GND Short circuit 12
grounding or open
circuit of the engine
speed output
P0654 TACO Short V Short circuit power 11
supply of the engine
speed output
P0335 Crank Sensor Crankshaft position 19
Malfunction sensor malfunction
P1352 Cyl2 Ign Short GND Short circuit 95
grounding of the
ignition coil of
cylinder 2
P0352 Cyl2 Ign Short V Short circuit power 96
supply of the ignition
coil of cylinder 2
P0321 Cyl1 IGBT over Overcurrent of the 79
current ignition module of
cylinder 1
P1321 Cyl2 IGBT over Overcurrent of the 23
current ignition module of
cylinder 2
P0264 Inj_2 Open/GND Short circuit 4
grounding or open
circuit of the injector
of cylinder 2
- 170 -
P0265 Inj_2 Short V Short circuit power 5
supply of the injector
of cylinder 2
- 171 -
Circuit Diagram
QJ125T-30 ELECTROJETELECTRICITY PRINCIPLE DIAGRAM
FUELMETER SPEEDOMETER
CLOCK
B
FAN LIGHT N/G LIGHT CONTROL SWITCH
START SWITCH
R
Y
B
POWER LOCK
R/W
B
BL/W1
W/BL
W/Y
B BATTERY RELAY RECTIFIER DIAGNOSE SKID SENSOR PUMP RELAY
WATER TEMPERATURE LIGHT BRAKE SWITCH
ON
B/G
OFF
LOCK BLACK B DARK GREEN Dg
Y
INSTRUMENT LIGHT
O/BL
R R/W Y O/BL
Y/R
R/W
B BLUE BL BLACK/RED B/R
M LIGHT BLUE LBL ORANGE/YELLOW N/Y
W/BL
G/W
W/Y
TURN SIGNAL INDICATOR LIGHT 15A
B
G/B G/Y
FUSE BROWN N RED/GREEN R/G
R/W
30A
BL RED/WHITE R/W PURPLE P
BEAM INDICATOR LIGHT B
P R/W G/Y B R W W W B R/W B B R YELLOW/RED Y/R GREEN/BLUE G/BL
R/W BL/B Dg B/R
FAILURE LIGHT ORANGE O GRAY Gr
N/B
GREEN/WHITE G/W YELLOW Y
GREEN/BLACK G/B RED R
YELLOW/GREEN Y/G ORANGE/WHITE O/W
N/B B Y G/W R/W W/BL N/G N/W R W W W B R/N W/B B

R/W BL G/B B/G R W/Y P G/Y Y/R R/W O/BL R LR B Gr G/Y B
R/W O/BL R Y R/P N/BL R/W
RIGHT TURN LIGHT

B B RIGHT TURN LIGHT
G/W G/W
B RIGHT TURN LIGHT

G/W
BL
HEAD LIGHT B
Y Y
B
P
TAIL/BRAKE LIGHT
Y
HEAD LIGHT B B
LBL G/B
LEFT TURN LIGHT
B B
LEFT TURN LIGHT
G/B G/B
LEFT TURN LIGHT
B
HORN
N
N R/W BL Y/R LBL G/B B G/W P G/R R/N W/B B/BL LR BL/B N/W B B/O W/Gr B/W R/W Dg R/W B G/W G/B R G/Y B/O B/BL Y/G B/BL B/BL B/BL B/R B/R B/W B/R
BL/W
O R/W R/P N/BL R/G Dg Y/G N/B W/O W/N Gr W/P B W/G W W W W/G BL/W R/G W/Gr B/R W/O B/G W/N G/R W/P
N/G B
W/G BL/W
R/W
N/G
B
N/G
N R/W
BL Y/R LBL G/B O G/W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 ALARM SYSTEM
>98
TURN SWITCH
LIGHT SWITCH
- 172 - OXYGEN SENSOR INTAKE AIR FUEL LIFT PUMP IGNITION COIL
SOLAR TERM POSITION TEMPERTURE SENSOR OIL RTOMIZER
FAN BRAKE SWITCH SENSOR ENGINE COOLANT SPARK PLUG
HORN SWITCH MAGNETO NEUTRAL SWITCH
TEMPERATURE SENSOR

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OUTLOOK(DIERRE) 125 EFI

KEEWAY Motorcycle Co., Ltd.

OUTLOOK (DIERRE) 125.

Preparing Documents include all necessary instructions and statements. Please

carefully read this manual before operation.

inspection of engine, entire motorcycle and electrical parts.

Breakdown drawing, systematic drawing, failure analysis and statements are

contained at the first part of each chapter.

KEEWAY Motorcycle Co., Ltd.

General safety Maintenance rules

Specification table Failure diagnosis

Engine must be started up in a well-ventilated place, not in a closed area.

Do not bend or twist it. Otherwise it will cause difficulty in

Solvent or oil can easily damage aging rubber articles. Check

When loosening assembly parts, please start from outside to

Complex assembly parts, such as gearbox, shall be stored in

Replace parts which will not be in use before disassembly.

groove clip connector

During dismantling ball bearings, one or two (inside & outside)

bearing rollers shall be supported by tools. Ball bearings may be

Bearings will be broken under either

Table 1-2 (continued)

Fig. 1-3 Fig. 1-4

Fig. 1-7 Fig. 1-8

Fig. 1-9 Fig. 1-10

Fig. 1-13 Fig. 1-14

Fig. 1-15 Fig. 1-16

(1) Ordinary tools for repairing the chassis

1. socket head 2. crank handle 3. ratchet spanner

Fig. 1-21 Fig. 1-22

Fig. 1-23 Fig. 1-24

Fig. 1-25 Fig. 1-26

Fig. 1-27 Fig. 1-28

Length mm 2070 Fuel type Unleaded petrol

Max. speed 90km/h

Preparing information Cylinder pressure

Periodic Maintenance & Inspection Table Gear oil

Engine oil/ Oil filter Replacement of gear oil

Fixing steering stem bearing & handlebar Driving belt

Inspection & adjustment of throttle cable Free stroke of front/rear brake

Air filter Inspection of brake fluid level

Spark plug Headlamp

Ignition timing Front/rear suspension system

Idle speed 1500100rpm/min

Free stroke of front brake 10-20mm

Add oil to the required level.

Throttle cable inspection/adjustment

Check whether the throttle cable works smoothly.

fixing nut adjusting nut

Air filter (picture to be

Check whether the cartridge is stained or damaged.

Remove the spark plug.

Check spark plug gap.

spark plug gap

Remove the fastening bolt.

fastening bolt magnetor end

Operate it when the engine warms up.

Compression pressure: 1.25Mpa/1500rpm

Remove the oil-check bolt after the engine is stopped.

Gear oil replacement

Remove the oil-check bolt.

Add gear oil. drain bolt right cover

Remove the cover of left crankcase.