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1.Lubrication ............................9
This manual including the following model
2.Tire pressure ...........................9
③ ⑤ ④
3
Headlock
FUNCTION OF PARTS
headlock①is below the steering.
IGNITION SWITCH Please turn to the very left,take out
the key and turn at clockside, take
①
out the key
① ② ③ ④
5
③clutch controll handle
The EFI light is on when switched, it is off when when you want to shift the gear, please hold the
start the engine. If the light still on, it means that handle with grip hardly to seperate the clutch
the bike still have problem. If you wanna to start the engine, please pull the
Please use the Diagnostic to check the failure code handle as well, then the bike can start up.
and solve it. ④ Overtake
Fuel gage If you want to overtake the others. Please press
the high beam continuously for safety.
For EFI bike
⑤headlight changing switch
It shows the fuel in tank. If indicating below red
If you need dipped headlight, please switch to
line, please fuel the bike a.s.a.p.
“ D ”position;if you need high beam, please
Warning: switch to“ D ”。
⑥Choke handle
The EFI bike need enough fuel.otherwise few
carburator version only .
fuel will cause the fuel pump idling and distroy Please dial down the choke handle,open the choke
the fuel pump. when starting the bike,
Left switch
By starting the bike, please dial up the choke handle,
③ ④ ⑤
①horn close the choke.
① ②
Press horn if you need to use it.
②turning light switch Right handle switch(no AHO)
If you need to turn left, then ①cutoff preset switch
×
move “ ”position,If you ① ② “ ” position:all circuit
need to turn right, then move to“ ”position.Move shut off engine can not start or
the arrow to the middle, then it is 。 cutoff the running engine. ④ ③
6
① ②
“ ”:means the bikecircuit on, you can start
×
the engine.Please set the swith to“ ”position. “ ” position:all circuit
②throttle grip shut off engine can not start or
adjust the throttle full-size,controlling the bike cutoff the running engine.
speed grip turning to rider yourself,it's accelerating. ③
otherwise it's slowing speed. “ ”:means the bikecircuit on, you can start
③headlight switch the engine.Please set the swith to“ ”position.
It has three swtiches“ ”“ P ”and“ ". ②throttle grip
“ ”:headlight, taillight, odometer light are on adjust the throttle full-size,controlling the bike
“ P ”:front position light, tail light,odometer speed grip turning to rider yourself,it's accelerating.
light are on. otherwise it's slowing speed.
③power with electric press-button
“ ”:front light, tail light, front position light,
1、Engine is in Neutral or in gears, grasp the
odometer light are closed.
cluth handle to separate the clutch disc.
④power with electric press-button
2、key to the ignition switch,turn to“ ”position.
1、Engine is in Neutral or in gears, grasp the 3、cutoff switch to“ ”position, press power with
cluth handle to separate the clutch disc.
electric button“ ”turn throttle grip,the engine can start
2、key to the ignition switch,turn to“ ”position.
3、cutoff switch to“ ”position, press power with
NOTE: EURO 4 AHO.
electric button“ ”turn throttle grip,the engine can start
warning:
Right handle switch(EURO Ⅳ) Every ignition less than 5s and 10s between
①cutoff preset switch twice.If failure,please check oil-way &system
7
REAR SHOCK Fuel tank switch
Suit for carburator models
You can adjust the position Turn on
please loose the locknut ①, please turn to this position, the fuel enters into
loose or tighten the nut ②。 the carburator smoothly.
adjust the spring tention, to Spare
tighten or loosen the rear ①locknut ②Adjust When normal fuel is
suspension。 used up, please handle
please make sure the same this to use the spare.
tension Fuel tank cover Close Turn on Spare Close
The whole fuel is closed by this position。
Fuel tank & tank cover Please close this fuel switch by long time riding.
Open the cover, insert the ignition Warning:
key turn right at 90 degree.Yo can Please fuel the bike immediatley when you start
open the cover. Press it when you to use spares(only2.7L), please turn on the switch
want to close it and pull back&take after fueling it.
out the key.
Fuel pump
Fuel pump assy.
Suit for EFI models
Attention: EFI fuel the bike using fuel
It's not well locked to pull out the key.Please pump Open the ingition lock,
do not extract it strongly forced. fuel pump runs 5 s.Stop working
please do not over fuel exceeding the neck of after 2-3seconds.Pump always working afer engine
it.Please lock it when fully fuele。
d. starts, It's destroyed by the pump idling.please pay
attention to the fuel always.
8
Shifter Tyre pressure
This engine has 5 gears internationally,The Correct tyre pressure can hold the best stable ride
relationship chart please refer and comfort ride,make the tyre long time use.
to following:
① N ② ③ ④ ⑤ Load e Kp a )Pressur(
Pressur( e Kpa)
Lubrication fuction
Rider F.tyre:225 rear tyre:225
lubrication oil is very important for engine
rider and passengers front tyre:250 rear tyre:250
lifetime,please forbid to use bad quality oil.
We suggest to use SAE15W / 40 API SJ oil.If you Please check the tyre pressure. Check its scratch ,
want to use others, the level need to reach above SG, nail or others sharps when bike is not started.Check
the viscosity shows a rather pronounced variation the tyre sunk or out of shape. If problem, please
with temperature. Please exhaust all lubrication in repare it or replace it immediately.
the crankcase and fuel the new lubrication oil。 Please change tyre of following limits pattern
Attention:: min.limit Deep pattern(mm)
Please send the used Front tyre:1.5 Rear tyre:2.0
lubrication to the recycle
bin.to avoid polluting the Dangerous
environment. It's dangerous to use over worn tyre,and effect
stability,steering and operation improper pressure
can cause the extra worn and cause accident, Less
pressure can cause the damage or get out of rim
and lead to accident.
9
Operation Guide Check throttle control…check free route of grip
Engine grinding-in to handle, cable connect, adjust it or change it if
New bike grinding in is 1000km necessary.
Please use only≤3/4 thorrtle to avoid over grinding in Check lighting and signal…check front light,tail
Change gears oftenly to avoid contineously light, turning light and function of horn.
running at one RPM.
Adjust it if necessary.
Control the engine RPM max.less than6000r/min
Check drive chain…check its tension or lubrication,
Max. speed shall less than 55km/h during 500km; If seriously worn or damaged, please change it.
during 500-1000km max speed shall less than 70km/h.
Check steering control mechanism…check its
Keep fit after first grind.tighten all screwsws,
flexibility and stablity,adjust it when necessaty.
adjust all parts,replace all polluted oil, examine the
Check engine…check its noise or not
first 1000km to ensure the best status of your
Check the coolant engough or not.
motorcycles,extend the life time of your engine.
Examination before ride
Take your few minutes to check your bike before
usage, it can save the failure rate and guarantee the Warning:
safety riding. Please don't start engine at narrow space to
check level of engine lubrication if need,add oil, escape the pollution. Please forbid to start
and check if it is oil leakage. engine when engine is in gear. It can damage
Check front,rear brake…Check &adjust the free the engine parts or cause accident.
route of brake, check braking function (locking or
no braking)
Check tyre…check both tyre pressure and wear
damage,please filling or fixing it
10
Ride Check and keep in good repair
Heating up the engine gradually Oil level check
1.To release clutch when engine idling,change Please check the oil lever before
gears to first gear position. running the bike.There is engine oil
2.throttling engine speed,releasing clucth handle, dipstick①backward the right crankcase
coordinate these two steps for better starting. to measure the lubrication level.
3.when you ride the bike steady, disconnecting Please measure it after 5 minutes ①Oil gauge
clutch, shifting to 2nd gear;please use the same way by stopping the engine.Please laythe
shifting to other speed. bike vertical with the ground.Clen the
Dangerous: dipstick,insert the dipstick into the oil,
Please do not shift gears without holding hard unlock screw, check the level.
14
Adjustment on brake
Rear brake disc suitable 20-30mm If
you happens often burnout fuse,
short circuit or overload. Please check
Holding motorcycle,test the with the local repair station.
pedal from update to free travel,
it is 20-30mm. Coolant
If adjustment,loose the nuts Suit for water cooling bike
⑦,adjust the doble bolts⑧,increase ⑥adjust nut
Coolant is made by coolant and distilled water.
or reduce pedal route and brake it
freeze-proofing function.
It can reduce
several times,release brake,turn
the engine temperature by circularly
rear wheel checking its running,
radiation of coolant.
lock it.
The new bike is with coolant.
Fuse replacement ⑦nut
Pleae pay attention to volume of
⑧bolts
please check fuse first when coolant when maintaining. You need
Radiator cover①
bike incoperation or cutoff. to add if needed open water bottle Water bottle cover②
cover②,add coolant into water
Loose the cross screw on right
bottle until 80%
cover when replacing.disassemble
If coolant become muddy or time
the right cover,open the fuse box
for maintain, please change coolant.
you can replace it. Fuse box Please follow the below steps.:
The rated fuse is 15A。 Stand the motorcycle at smooth ground.
15
Checklist on braking system: Brake liquid
A:check the level of brake liquidcup Check the liquid level of right
handle switch and brake liquid cup.
B:check leakage If it is few, please add the
C:check the cable leakage or crack 5-10mm appointed brake liquid inside.
D:check worn of disc &friction plate If the brake disc is worn, then
20-30mm lower limit
E:front brake lever free travel the liquid will be auto matically flow
hole of observation
5-10mm,rear brake foot bar free into oil-pressure pipe.Check and fill
in liquid is the most important item.
travel is 20-30mm
Attention:
Liquid disc brake pump is working under high
pressure to ensure its safe,please do not change Danger:
it
exceeding. Liquid has strong corrosive. Please
disgorge it if you drink it.please wash
Please maintain the braking system or disc
it if it is in eye or on skin. And see
brake to special appointed repair station. doctor immediately.
Brake friction plate
Check if the friction plate is max. worn.Please
change it if exceeding
Attention:
Please do not ride it just after changing. Please
run the front brake lever several time or rear
foot bar,let the disc brake and caliper well cotact,
function of braking sytem return to normal
16
up the radiator cap①,put fully coolant
Screw Fault repair
Screw tightenly after fitting on radiator cover. Suit for carburator model
Start the bike and idle it at 2-3seconds, open it cap Please
check out the reason if engine can not start:
again①, continuously add coolant. Add tripe coolant, 1.Check if the fuel tank switch at open position.
tighten it ①open water bottle cap②, put approx. 400 2.Check if fuel is enough
ml coolant,total volume is 1600ml 3.Pull out the oil tube below fuel tank,and check
Attention: if fuel is outflowing
When engine temperature reaches 125℃, 4.disassemble spark plug and connect ignition
odometer sense light on,means the engine need coil please put spark plug on unpainted hardware,
to have a rest,otherwise it will effect lifetime of press electric botton.If it has blue spark,ignition
engine. system is fine.If no spark,please go to the repair
station and fix it.
Warning: Fault repair Suit for EFI model
Please use 3500 anti-rusty antifreeze fluid
coolant is harmful and corrosive. please do Please check as following if engine can not start
EFI fault light no on):
not drink it or infect with skin. Please recycle
it to avoid pollution. 1.check the fuel indicator and ensure if you have
Please do not open the radiator cover,to enough fuel
avoid expulsion out and hurt people. 2.Check if the battery connect is correct.
Please exhaust coolant by disassembly cylinder 3.Check if the fuse is okay
body when repairing engine,this can avoid it into Warning:
crankcase. Start 3-5 minutes after replacing ECU,close
ignition switch and re start
Please check the leakage every 400km please shut down ignition switch when you
water pump or circulating tube is leakaged. want to pull out the EFI connector otherwise it will
Press the tube to find if it has flaw and replace it. leave the historic record,you need to get rid of it
Please contact maintainance people if leakage,Please by special diagnostic.please press the plug
do not open it by yourself. connector and pull out.
17
Clean switch when installation.
You should clean the motorcycle,and check its 5.air the tyre to regular air pressure, stand it
damagement,wear and oil leakage or not.
until front &rear wheel out of ground.
Please do not clean the bike by high-pressure water 6.Please cover the motorcycle by cloth or
to cause the damage.: breathability,save in the dry with ood ventilation place.
Ignition swtich,electric switch,odometer,exhaust ex. Use it
fuel tank。
please avoid wet the exhaust,spark plug and battery 1.Take off the cover, clean it.
please use clean water to wash 2.check the voltage of battery, if it is below
Dry motorcycle,start engine by running few minutes. 12.3V,charge the bike then install battery.
3.get rid of antirust agents, add new fuel
lubricate the drive chain.
please test your brakes for good function before you 4.test the bike carefully.
ride out. Daily maintain
Motorcycle
storage Please clean it by cloth oftenly, dry the wet.
You should do special check before your longtime storage. Put some antirust oil on chrome, put some wax on
1.clean and dry the motorcycle paint.
2.exhaust the fuel in fuel tank and carburator air the tyre accoring to pressue.
and have some antirust. check
. every bolt and nuts to avoid falling
3.Take out the spark plug,put some(15-20ml) down and cause accident.
lubrication in cylinder body. Close ignition switch, Check the tyre and brakes flexibility ,if it
press it several time again for more oil inside cyclinder, is over worn or damagement, please change it.
please install spark plug again.
4.disassemble the battery and store it into well Maintain chart
ventilate, dry shady place. Please maintain the bike according to following
Attention: please close ignition switch, please symbols:
disassemble negative wire first,then positive electrode; *you can fix it by your self if you can
please fix positive first then negative ,close ignition **you need to go the maintain shop to fix it
18
Remark:
①Often clean it driving in dusty area times maintance KM
②if data is over max speed of odometer,please times
project period 1000 4000 8000 12000
check details according to below details.
③to adjust timing chain and valve clearanc, must brake wear check check check
** pipe every 4
be adjusted by authorized service shop for safety. years check check check check
** fluid cup check check check check
Times Milage(km)
period ** fluid once every 2 years
Period 1000 4000 8000 12000
** front brake check check check check
* Fuel route check check check check per
* rear brake month check check check check
* throttle system check check check check
check check check check
* carburator check check check change
clutch friction disc adjust adjust adjust adjust
core Replace check check check check
hanger check check check check
spark plug 4000km check check check check
bracket check check check check
lubricate first 500km, them 1000 km
one
* nut bolt month check check check
filter net clean it by placing the oil
** wheel/ tyre 3months check check check check
** tention adjust check check check check
** bearing 3months check check check check
adjust adjust adjust adjust adjust
** valve clearance
** coolant check check check check
drive chain c check check check check
** rear brake ** fuel injector clean every 30000km
check check check
Remark:valid for all EFI modles.
19
DD125E-5C specification
20
DD350E-6C specification
4th ratio
Electrical
21
DD400E-6C specification
22
Inlet pressure temperature sensor
Gn/Bk Br/Bk Gr/V Bk Gn/Bk Gr/V Bl/W Gr/Y Gr W Gr W Gr/R Bl/R Or/R Gn Br/R Bl/R W/R Br/R LG/R Gr/w Gn/Br Gn/Bl Gn/Y Y/W Gr/Y Bl/Br Bk/Bl R/Or Gn/W Bk/W Or/R
Br/Gn Gn/Bk R Or/Gr V/Y Bk/Or Bk/Or Bk V Bk V Gn/Y Br/W Gn/Bl Gn/Br Y/W Gr/W Br/V LG Br/V Gn Bk/Or P/W Gr/R Br/W Gn Bl/Y Bl/W Or/Gr Br/Bk Gr/V Br/Gn V/Y Gn/Bk
Bk/Or Bk/Or
Bk/Or Bk/Or
Br/Gn Br/Bk Gr/V Bk/Or Gn/Bk Gr/V R/Or Bk/Or P/W Bk/Or Gn/Y Br/W Gr/R Bl/R Or/R Gn Br/R LG Br/V Gn Bk/Or P/W Gr/R Br/W Gn Bl/Y Bl/W Or/Gr Br/Bk Gr/V Br/Gn V/Y Gn/Bk
Bk/Bl Bk/Or Bk/Or Gn/Bk W/R Gn/Bl Gn/Br Y/W Gr/W Br/V Bl/R W/R Br/R LG/R Gr/w Gn/Br Gn/Bl Gn/Y Y/W Gr/Y Bl/Br Bk/Bl R/Or Gn/W Bk/W Or/R
Gn/Bk Gn/Bk Or/Gr V/Y Gn/Bk Bl/Br
Bl/W Gr/Y
Bk
BK Y/Gn Bl/W Br/R Y/R Gn Bk/W Bk Gn Gr Gn Gn/Y Gn/Y
R LG/R Or/R Bk/W Gn Bk Gn R Y Y Y
Br Bk Br Bk Y/Bk Bk/Or Or/R Gn
Gn/W Bl/Y LG
Bk/Or
Gn Gn
Right front turn light12V10W
LB LB LB LB
Right rear turn light12V10W
Gn Gn
Br
Odometer light12V3
Gn .4W Br
Gn
Gn/Y Gn/Y
LB LB Gn Gn License plate light.
Right indicator12V2W
Gn
Br Br
Tail light12V21W/5W
Or Or
Left indicator12V2W
Gn
Gn
High beam12V2W
Bl Bl
Bk Bk
Neutral indicator 12V2W
LG/R LG/R
Bk
EFI indicator12V2W
Gn/Bk LG
Gn Gn
Left rear turn light 12V10W
Or Or
Bl Bl
Head light12V35W/35W
W W
Gn Gn
Charge
Fuse
Gn
Front Br/R
Br position light12V5W
LG Gn
Single-Wizard Electric
Gn Gn LG/R P
Left front turn light12V10W
Or Or
Single-Wizard Electric
Bl/Y Gr P Bl/Y
Bk Gn R/Bk P
W Bl LG Or LB Gn Bk Bk R/Bk Bk Gn/W Y Y Y LG/R Y/R
Fuse
W Bl Bl P Bk Bk Bl/W
Bl/Y LG Or LB Gn R/Bk Bk R/Bk Gn/WBl/Y Y Y Y LG/R R Gn Gn/RY/R
Bk Gr Bk
M Start relay
Horn switch
Dimmer switch
ClutchHorn
Turn signal switch switch
Fan Water temperature
Magneto sensor Battery
Neutral switch
R
Overtake switch
Start motor
Black
SYMBOL White Blue Brown Green Red Yellow Grey Orange Light Blue Light Green Pink
Violet
COLOR Bk W Bl Br Gn R Y Gr Or LB LG P V
燃油类型:
93号汽油
有关细节,可参照第6页
机油类型:
SAE15W/40 APE SJ
有关细节,可参照第7页
燃油箱:
容积为18.5L,备用燃油容量为2.7L。
修订时间:20
10年7
月