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Benelli TNT300 Service Manual FINAL (001-207)

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0% found this document useful (1 vote)
5K views207 pages

Benelli TNT300 Service Manual FINAL (001-207)

Uploaded by

alex gavrishev
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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TNT300 Service Manual

0
Preface
This maintenance manual which is prepared by the Benelli Company is intended
for the use by Benelli dealers and professional maintenance personnel. Not all the
service information related to motorcycles is included in this manual, so it is used only
for repairing and maintaining Benelli motorcycles, to learn the principles, maintenance
procedures and maintenance technologies of these motorcycles. We hope that the
person who uses this manual for repairing and maintaining a Benelli motorcycle has a
basic knowledge of motorcycle machinery and the necessary procedures for repair and
maintenance of motorcycles. The assembly may be conducted improperly when
repairing motorcycles and dangers may be caused after assembly without this
knowledge.
This manual is only for reference during repair and maintenance of the TNT300
motorcycle.
The Benelli Company will continue to redesign and improve this type of
motorcycle. Modifications or major changes in product specifications will be
announced to all Benelli authorized dealers, and compiled in the later version of this
maintenance manual.

Note:

Designs and specifications are subject to change without prior notice.

1
Important Information in This Maintenance
Manual

The following important items are included in this manual:

Warning: If this symbol is present, failure to follow the instructions may cause severe injuries and even death
to motorcyclists, people nearby or the one who is repairing the motorcycle.

Important: “Important” means specific preventive measures to avoid damaging the motorcycle.

Note: “Note” means important information which can make procedures much simpler and easier to complete.

2
User Guide
This manual is a practical reference guide which is easy to operate and use by

technicians. Instructions for: assembly, removal, disassembly, repair and check of all

of the components are in sequence, one step at a time.

1. Each chapter is divided into several sections, the headline included on the top

of each page explains what section of the vehicle is being repaired.

2. In order to better identify parts and make different processes clearer, breakdown

drawings are offered at the start of each section involving all parts in the

disassembly.

3. Operating sequences are listed on breakdown drawings, and the sequences are

numbered one by one. Each number refers to each step during the disassembly.

4. Parts that need to be lubricated when changed are symbolized. Please refer to

the “Symbol” section.

5. Breakdown drawings are equipped with a table with ID numbers, including

operating sequence, part name, precaution for work, etc.

6. Describe any other required information (such as special tools and technical

data) in sequence.

3
Exhaust Emission Control Information
In order to protect our environment, Benelli Company has introduced provisions that conform to environmental
protection regulations of China, Europe and the United States. This motorcycle is equipped with (1) crankcase blow-
by gas filtering system, (2) exhaust emission control system and (3) fuel evaporation recovery system.
1. Crankcase blow-by gas filtering system
This system can prevent gas in the crankcase from being discharged into the environment. The gas in the
crankcase is pumped into air inlets on both sides of the engine by an oil separator. When the engine is running, the
gas is pumped into the combustion chamber, and then combusts with air and fuel pumped out of the fuel injection
system.
2. Exhaust emission control system
This system can reduce the number of pollutants from exhaust gas from this type of motorcycle into the
environment. Fuel injection system, ignition system and exhaust system of this type of motorcycle have been
carefully designed and assembled to have fuel efficient engines and low quantity of pollutants discharged.
A catalytic converter system is included on this type of motorcycle.
3. Fuel evaporation recovery system
Fuel vapor in the fuel injection system will not be discharged into the environment, rather is pumped into the
running engine to be combusted. If the engine is not started, the vapor will be stored in a charcoal canister. If it is
liquid fuel, it will be pumped into separators, and then back into the fuel tank.

Warning
1. Before final buyers purchase or receive any motorcycle or motorcycle engine, no one shall disassemble or destroy
any parts mounted on the motorcycle or motorcycle engine based on the provisions of this manual; any manufacturer
or dealer shall not deliberately disassemble or destroy any parts after any motorcycle or motorcycle engine is sold
or delivered to the final buyer.
2. After any motorcycle or motorcycle engine is sold or delivered to the final buyer, anyone who is engaged in
repairing, maintaining, selling, leasing or trading motorcycles or motorcycle engines, or managing motorcycle
teams shall not disassemble or destroy any parts mounted on the motorcycles or motorcycle engines based on the
provisions of this manual…”

Remarks
“Disassembling or destroying any parts” is generally defined as follows:
1. Temporarily disassembling any parts or the situation in which the parts cannot temporarily run for the repairing
purpose does not belong to “refit”.
2. The following situations belong to “refit”:
a) Improperly adjust motorcycle parts to make its exhaust gas discharged exceed emission standards.
b) Use of replacement parts or accessories that impact the performance or durability of the motorcycle.
c) Add parts or accessories to make motorcycles exceed emission standards.
d) Permanently disassemble, separate or destroy any parts on exhaust emission control systems.

It is suggested that all dealers should abide by the above mentioned provisions for conformity with local laws.

4
Symbols
Specific Symbols

General Information

Specifications

Check and Regular

Adjustment

Chassis

Engine

Cooling System

Fuel System

Electrical System

Fault and

Troubleshooting

5
Symbol Interpretation

Wear Limit

Special Tool

Tightening Torque

Lubricating Point

Lubricating Grease

Sealant

Use a New Part

Thread Sealant

6
Content

General Information Chapter I

Specification Chapter II

Check and Regular


Chapter III
adjustment

Chassis Chapter IV

Engine Chapter V

Cooling System Chapter VI

Fuel System Chapter VII

Electrical System Chapter VIII

Fault and
Chapter IX
Troubleshooting

7
Contents
Preface .................................................................................................................................................................. 1
User Guide ............................................................................................................................................................ 3
Exhaust Emission Control Information ................................................................................................................ 4
Symbols ................................................................................................................................................................ 5
Specific Symbols .......................................................................................................................................... 5
Symbol Interpretation ................................................................................................................................... 6
Chapter I General Information ....................................................................................................................... 14
General Safety ............................................................................................................................................ 15
Identification............................................................................................................................................... 16
Motorcycle Identification ................................................................................................................... 16
Important Parts ................................................................................................................................... 17
Features....................................................................................................................................................... 18
Instruments and Lights ....................................................................................................................... 18
Important Information ................................................................................................................................ 20
Preparation for Disassembly and Disassembling Operation ............................................................... 20
Gaskets, O-rings, Seals and Bearings ................................................................................................. 21
Lock Washer/locking plate, Bolt and Thread Sealant ........................................................................ 22
Circlips ............................................................................................................................................... 22
Cable-To-Cable Connector Check ...................................................................................................... 23
Special Tools............................................................................................................................................... 25
Chapter II Specification ................................................................................................................................... 30
Basic Specifications .................................................................................................................................... 31
Technical Data of the Engine ...................................................................................................................... 32
Technical Details of the Engine .................................................................................................................. 35
Technical Data of the Motorcycle ............................................................................................................... 38
Electrical Data ............................................................................................................................................ 41
Technical Data of Nut Locking Torque ...................................................................................................... 45
Technical Data of Bolt and Screw Torque .................................................................................................. 46
Chapter III Check and Regular Adjustment.................................................................................................. 49
Regular Maintenance and Lubrication Interval .......................................................................................... 50
Regular Maintenance and Lubrication Interval Schedule ........................................................................... 51
Air Filter ..................................................................................................................................................... 54
Fuel Hose .................................................................................................................................................... 57
Control ........................................................................................................................................................ 58
Throttle Cable ............................................................................................................................................. 59
Clutch Cable ............................................................................................................................................... 60
Rearview Mirrors ........................................................................................................................................ 61
Engine Oil................................................................................................................................................... 62
Engine Oil Filter ......................................................................................................................................... 65
Coolant ....................................................................................................................................................... 66
Radiator Hoses............................................................................................................................................ 67
Spark Plugs ................................................................................................................................................. 68
Valve Clearance .......................................................................................................................................... 72

8
Brake Adjustment ....................................................................................................................................... 76
Check of Brake Fluid .................................................................................................................................. 78
Check of Brake Pads................................................................................................................................... 83
Check of Brake Hoses ................................................................................................................................ 84
Adjustment of the Drive Chain ................................................................................................................... 85
Check and Adjustment of the Steering Stem Bearings ............................................................................... 87
Check of Front Fork ................................................................................................................................... 90
Check of Rear Shock Absorber................................................................................................................... 91
Check of Front and Rear Tires .................................................................................................................... 92
Check and Battery Charging ....................................................................................................................... 93
Check of Fuses ......................................................................................................................................... 100
Replacement of the Headlight Bulb .......................................................................................................... 102
Adjustment of the Headlight..................................................................................................................... 104
Replacement of the Front Turn Signal Light Bulb ................................................................................... 105
Replacement of the Rear License Plate Light ........................................................................................... 106
Section IV Motorcycle .................................................................................................................................... 108
Front Wheel and Front Brake Rotor ......................................................................................................... 109
Rear Wheel and Rear Brake Rotor ........................................................................................................... 118
Front and Rear Brakes .............................................................................................................................. 127
Front and Rear Brakes / Front Brake Pads ....................................................................................... 129
Front and Rear Brakes / Rear Brake Pads......................................................................................... 130
Front and Rear Brakes / Front Brake ................................................................................................ 131
Front and Rear Brakes / Rear Brake ................................................................................................. 136
Front Suspension ...................................................................................................................................... 142
Front Suspension / Front Fork .................................................................................................................. 143
Front Suspension / Front Shock Absorber ................................................................................................ 144
Control ...................................................................................................................................................... 154
Control / Control............................................................................................................................... 155
Control / Handlebar .......................................................................................................................... 158
Rear Shock Absorber ................................................................................................................................ 162
Drive Chain and Rear Swing Arm ............................................................................................................ 166
Drive Chain and Rear Swing Arm .................................................................................................... 167
Drive Chain and Rear Swing Arm / Rear Swing Arm ...................................................................... 170
Frame ........................................................................................................................................................ 173
Frame / Engine Assembly................................................................................................................. 174
Frame / Rear License Plate Support ................................................................................................. 178
Frame / Side Stand ............................................................................................................................ 181
Frame / Left Foot Pedal .................................................................................................................... 184
Frame / Right Foot Pedal .................................................................................................................. 187
Muffler ...................................................................................................................................................... 190
Fairing / Cowling Parts ............................................................................................................................. 195
Fairing / Cowling Parts / Front Fender ............................................................................................. 197
Fairing / Cowling Parts / Rear Fender .............................................................................................. 200
Assembly of Fairing / Cowling Parts / Rear Lower Fender and Chain Cover.................................. 204
Fairing / Cowling Parts / Fuel Tank Cowling and Lower Fairing .................................................... 207
Fairing / Cowling Parts / Tailsection ................................................................................................ 211

9
Fairing / Cowling Parts / Headlight Fairing...................................................................................... 216
Lights ........................................................................................................................................................ 219
Lights / Rear Taillight....................................................................................................................... 220
Lights / Front Turn Signal Light ....................................................................................................... 221
Lights / Rear Turn Signal Light ........................................................................................................ 222
Chapter V Engine ........................................................................................................................................... 223
Cylinder Head and Cylinder Head Cover ................................................................................................. 224
Exploded View ................................................................................................................................. 224
Technical Parameters ........................................................................................................................ 226
Special Tools and Sealants ............................................................................................................... 227
Special Tools and Sealants ............................................................................................................... 228
Cylinder Head Cover ........................................................................................................................ 229
Camshaft Timing Chain Tensioner ................................................................................................... 231
Camshaft and Camshaft Timing Chain............................................................................................. 233
Cylinder Head ................................................................................................................................... 239
Valves ............................................................................................................................................... 244
Intake Manifolds ............................................................................................................................... 255
Clutch ....................................................................................................................................................... 256
Breakdown Drawing ......................................................................................................................... 256
Technical Parameters ........................................................................................................................ 257
Special Tools and Fastening Adhesives............................................................................................ 258
Right Engine Cover .......................................................................................................................... 259
Clutch ............................................................................................................................................... 261
Engine Lubrication System ...................................................................................................................... 267
Breakdown Drawing ......................................................................................................................... 267
Engine Oil Flow Diagram ................................................................................................................. 269
Technical Parameters ........................................................................................................................ 270
Special Tools and Fastening Adhesives............................................................................................ 271
Engine Oil and Engine Oil Filter ...................................................................................................... 272
Oil Pan .............................................................................................................................................. 273
Engine Oil Pump .............................................................................................................................. 275
Engine Oil Pressure Relief Valve ..................................................................................................... 277
Measurement of Engine Oil Pressure ............................................................................................... 278
Engine Oil Pressure Switch .............................................................................................................. 279
Crankshaft / Transmission ........................................................................................................................ 281
Breakdown Drawing ....................................................................................................................... 2812
Technical Parameters ........................................................................................................................ 284
Special Tools and Fastening Adhesives............................................................................................ 287
Crankcase.......................................................................................................................................... 288
Crankshaft and Connecting Rods ..................................................................................................... 295
Pistons............................................................................................................................................... 308
Electric Starter .................................................................................................................................. 314
Gear Change Mechanism.................................................................................................................. 318
Chapter VI Cooling system ............................................................................................................................ 329
Water Pump .............................................................................................................................................. 332
Thermostat ................................................................................................................................................ 336

10
Coolant Hose Connectors ......................................................................................................................... 338
Disassemble the Radiator ................................................................................................................. 340
Dismantle the Radiator ..................................................................................................................... 342
Radiator ............................................................................................................................................ 343
Fan .................................................................................................................................................... 344
Radiator Cap ..................................................................................................................................... 346
Water Temperature Sensor ............................................................................................................... 347
Radiator Assembly ........................................................................................................................... 348
Cooling Liquid Filling ...................................................................................................................... 349
Chapter VII Fuel System ............................................................................................................................... 350
Fuel System .............................................................................................................................................. 351
Fuel Tank .................................................................................................................................................. 352
Fuel Pump ................................................................................................................................................. 358
Operating Principles of the Fuel Pump ............................................................................................. 358
Fuel Pump Appearance ..................................................................................................................... 358
Fuel Pump Composition ................................................................................................................... 359
Tag and Identification Label of the Fuel Pump ................................................................................ 359
Working Environment of the Fuel Pump .......................................................................................... 360
Fuel Pump Maintenance Procedure .................................................................................................. 361
Operation Precautions....................................................................................................................... 364
Throttle Body............................................................................................................................................ 365
Operating Principles of the Throttle Body........................................................................................ 365
Appearance of the Throttle Body ..................................................................................................... 365
Technical Parameters ........................................................................................................................ 366
Working Environment of the Throttle Body..................................................................................... 366
Disassembly of the Throttle Body .................................................................................................... 366
Negative Pressure Balance of the Throttle Body .............................................................................. 367
Throttle Body Cleaning Method ....................................................................................................... 367
Assembly of the Throttle Body......................................................................................................... 367
Installation Cautions for the Throttle Body ...................................................................................... 367
Operation Cautions for the Throttle Body ........................................................................................ 367
Fuel Injectors ............................................................................................................................................ 368
Operating Principles of the Fuel Injectors ........................................................................................ 368
Appearance of the Fuel Injectors ...................................................................................................... 368
Sealing O-ring of the Fuel Injectors ................................................................................................. 369
Overvoltage Effects of the Fuel Injectors ......................................................................................... 370
Temperature Range of the Fuel Injectors ......................................................................................... 370
Fuel Pollutants of the Fuel Injectors ................................................................................................. 370
Wiring Harness Layout of the Fuel Injectors .................................................................................... 370
Operation Cautions for the Fuel Injectors......................................................................................... 371
Installation Requirements for the Fuel Injectors ............................................................................... 372
Fuel Injector Replacement Method................................................................................................... 372
Fuel Injector Selection ...................................................................................................................... 372
Blockage of Fuel Injectors ................................................................................................................ 373
Chapter VIII Electrical System ..................................................................................................................... 374
Charging System....................................................................................................................................... 375

11
Battery .............................................................................................................................................. 376
Stator / Generator.............................................................................................................................. 381
Regulator / Rectifier ......................................................................................................................... 386
Ignition System ......................................................................................................................................... 388
Ignition Coil...................................................................................................................................... 389
Crankshaft Position Sensor ............................................................................................................... 397
ECU .................................................................................................................................................. 398
Spark Plugs ....................................................................................................................................... 399
Ignition System Troubleshooting ..................................................................................................... 401
Starting System ......................................................................................................................................... 402
Starter Motor..................................................................................................................................... 403
Starter Relay ..................................................................................................................................... 408
Gauge Cluster ........................................................................................................................................... 411
Gauge Cluster Disassembly .............................................................................................................. 411
Gauge Cluster and Indicator Lights .................................................................................................. 411
Ignition Switch Disassembly ............................................................................................................ 414
Ignition Switch Inspection ................................................................................................................ 414
Horn .......................................................................................................................................................... 415
Disassembly ...................................................................................................................................... 415
Inspection ......................................................................................................................................... 415
Handlebar Switch (Chinese Market) ........................................................................................................ 416
Handlebar Switch (US-STANDARD) ...................................................................................................... 417
Speedometer Sensor ................................................................................................................................. 418
Disassembly of the Speedometer Sensor .......................................................................................... 418
Check of the Speedometer Sensor .................................................................................................... 418
Speedometer Sensor Assembly......................................................................................................... 418
Relay and Fuse-Block ............................................................................................................................... 419
Relays ............................................................................................................................................... 419
Fuse-Block ........................................................................................................................................ 421
Fuel Injection System ............................................................................................................................... 422
Fuel Injection System / ECU ............................................................................................................ 423
Fuel Injection System / Water Temperature Sensor ......................................................................... 429
Fuel Injection System / Intake Air Temperature Sensor................................................................... 430
Fuel Injection System/Intake Manifold Pressure Sensor .................................................................. 432
Fuel Injection System / Oxygen Sensor............................................................................................ 434
Fuel Injection System / Idle Speed Stepper Motor ........................................................................... 436
Fuel Injection System / ECP ............................................................................................................. 438
Chapter IX Faults and Troubleshooting ...................................................................................................... 440
Difficulty in Starting or Starting Failure................................................................................................... 441
Poor Running (Especial at low speed) ...................................................................................................... 442
Poor Running (High speed) ...................................................................................................................... 443
Charging Defect (Over Discharging or Over Charging of the Battery Voltage) ....................................... 444
No Spark Diagnosis .................................................................................................................................. 445
Diagnosis Breakdown Maintenance of the Fuel Injection System ........................................................... 446
Directly Use The Fault Indicating Light Flashing Diagnosis (FI) on the Instrument ....................... 447
Using Diagnostic Apparatus for Fault Diagnosis ............................................................................. 450

12
Check the Faults With Diagnostic Software PCHUD ...................................................................... 451
Common Trouble Shooting Methods of the Fuel Injection System.......................................................... 459
Repair Kit ......................................................................................................................................... 459
Engine Working Data Flow Indicated on the Diagnostic Apparatus ................................................ 460
Simple Troubleshooting Methods..................................................................................................... 460
Chapter X Appendices.................................................................................................................................... 464
Wire Wrapping Method of the Cables, Wires and Hoses.......................................................................... 465
TNT300 Circuit Diagram (Chinese Market) ............................................................................................ 486
TNT300 Circuit Diagram (EURO-STANDARD) .................................................................................... 487

13
Chapter I General Information

General Safety ............................................................................................................................................ 15


Identification............................................................................................................................................... 16
Motorcycle Identification ................................................................................................................... 16
Important Parts ................................................................................................................................... 17
Features....................................................................................................................................................... 18
Instruments and Lights ....................................................................................................................... 18
Important Information ................................................................................................................................ 20
Preparation for Disassembly and Disassembling Operation ............................................................... 20
Gaskets, O-rings, Seals and Bearings ................................................................................................. 21
Lock Washer / Locking Plate, Bolt and Thread Sealant ..................................................................... 22
Circlip ................................................................................................................................................. 22
Cable-to-Cable Connector Check ....................................................................................................... 23
Special Tools............................................................................................................................................... 25

14
General safety

Carbon monoxide
If an engine must be started, the workplace should be well-ventilated. Engines should not be allowed to run in
enclosed spaces.

Notes
A poisonous gas-carbon monoxide included in exhaust gas can make you lose consciousness and may cause
death.
Engines are required to run in open spaces. Scavenging systems should be used when running in enclosed spaces.

Gasoline
Gasoline must be used in well-ventilated places. Smoking is strictly prohibited in workplaces or places where
gasoline is stored.

Battery
Since the battery may emit explosive gas, it must be kept away from sparks, open flames and smoking areas. Keep
the area well-ventilated while it is charging.
The battery contains sulfuric acid (electrolyte). Since it may cause burns once exposed to skin or eyes, you must
wear a protective suit and a mask.
——Flush skin immediately with running water once electrolyte is splashed on it.
——Flush eyes immediately with running water for more than 15 min and seek a doctor for examination once
electrolyte is splashed on them.
Electrolyte is poisonous, if ingested: Drink a large amount of water, milk, milk of magnesium oxide (a kind of
laxative antacid) or vegetable oil immediately and ask a doctor for examination once electrolyte is accidentally
drank by mistake. Therefore, please keep electrolyte out of the reach of children.

Engine oil
Repeated skin exposure to engine oil and then to the air may cause cancer to form in the human body. Although you
may not be exposed to engine oil in daily life, you should clean yourself with water and soap immediately once it
happens. Therefore, please keep engine oil out of the reach of children.

Used oil contains carcinogenic, mutagenic and teratogenic substances along with waste acid and heavy metals which
are extremely harmful to human health. Aromatic compounds and other organic compounds among them are quite
harmful to the body. These substances not only stay in the lungs but also get into the blood and the whole body to
disturb our hematopoietic system, nervous system and other systems, which result in anemia, thrombocytopenia
and other blood diseases, dizziness, nausea, anorexia and weakness and even cancer for instances of long exposure.
Lead, cadmium and other heavy metals which are difficult to be discharged out of body and may accumulate in the
human body have severe impacts on the nervous system resulting in oral ulcer, gingival and other diseases and
symptoms. Since iron is an active metal, it will cause chronic inflammation in respiratory tracts and lungs further
resulting in pulmonary fibrosis, emphysema and other diseases.

Thermal energy section


After start-up, the engine and the exhaust system sections will generate heat, they will begin to cool once the
engine is shut-down but will remain hot for some time. These sections should be handled with heat insulating
gloves or after the engine or exhaust system has cooled down.

15
Identification
Motorcycle identification
Identification data are as follows:
1. Serial number of frame (at the right side of steering tube on the frame)
2. Serial number of engine (at the lower right side of the engine)
3. Motorcycle nameplate (at the left side of steering tube on the frame)

Trademark
Registered
Motorcycle
Benelli model:
model

欧规款
Two-wheeled Unladen
Kerbmass:
mass
motorcycles
3 Engine model
Displacement:
Delivery
capacity
ZHEJIANG QIANJIANG Manufacturing
201__
date
date:
MOTORCYCLE CO., LTD, China

Model complying with European Regulations

1
2

16
Important parts
(1) Left rearview mirror
(2) Clutch lever
(3) Left handlebar switch
(4) Ignition switch
(5) Instrument cluster
(6) Right handlebar switch
(7) Right rearview mirror
(8) Front brake lever
(9) Throttle control grip
(10) Fuel tank
(11) Engine oil filler
(12) Rear brake lever
(13) Front footrest
(14) Rear footrest
(15) Rear brake caliper
(16) Front brake caliper
(17) Side stand
(18) Shifter lever
(19) Seat lock

17
Features
Instruments and Lights
When the ignition key is rotated to the “ON” position, the instruments and lights will turn on.
After preliminary inspection, information will correspond to the overall condition of the motorcycle at that
time.
The following indicator lights are included on the dashboard:
Status indicator lights
1A: Turn Signal indicator light (green)
This flickering indicator light means that the turn signal light is on.
1B: Neutral indicator light (green)
When this indicator light is on, it means that the motorcycle’s transmission is in neutral.
1C: High beam indicator light (blue)
When this indicator light is on, it means that the high beam light is on.
1D: Oil pressure warning light (red)
When the engine is not started after the power is turned on, the engine oil indicator light is always on; if the
oil pressure is normal after the engine is started, the engine oil indicator light will turn off; if the engine oil indicator
light is not off, the oil pressure may be abnormal, which means that the engine should be shut down and the unit
brought in for inspection;
If there is fuel or water in the engine oil, the indicator light will be on, which means that the engine should be
shut down and the unit brought in for inspection.
FI: “FI” means fault code diagnosis of EFI system (orange)
When the key is turned to the “ON” position the EFI indicator light will be on, the fuel pump will run for 3
seconds, and the motorcycle will start. If the indicator light turns off after the motorcycle is started, the motorcycle
is running normally without faults; if the indicator light is on, it means that there are some faults in the fuel injection
system, which means that you should shut down the engine. For inspection please contact an authorized Benelli
dealership which will use a special motorcycle fault diagnosis tester to check your motorcycle.
Function button (2)
Function button (3)

Button Function Table


Function Power supply Current interface display Left button Right button Display interface after
switching
Function switching ON <3sec
Function switching ON <3sec
Function switching ON >3sec
Function switching ON >3sec
Function switching ON
Function switching ON <3sec
Function switching ON <3sec
Clock setting ON >3sec Hour bit flickering
ON <3sec Hour bit+1 (0-23)
ON <3sec Switch to ten-of-minute
flickering
ON <3sec Tens of minutes+1 (0-5)
ON <3sec Switch to unit-of-minute
flickering
ON <3sec Units of minutes+1 (0-9)
ON <3sec Exit clock menu
Note In the adjusting state of clock, automatically exit the menu with no button being pressed in 5sec.

18
Tachometer (4):
It indicates the rotations per minute of the engine at that time.
Coolant temperature measurement (5):

It indicates the coolant temperature in F° (Fahrenheit) or C° (Centigrade).

Odometer / Trip Meter (6)


You can choose the functions of relative mileage (TRIP) or total mileage (TOTAL) on the odometer, and choose
the units of mph (miles) or km (kilometers) according to your needs.
Relative mileage (TRIP): It is an odometer that can be reset for recording the driving mileage in a certain
period. Pressing and holding function button (2) can reset the trip meter in the state of relative mileage (TRIP).
Total mileage (TOTAL): It is used for recording the total driving mileage.
An odometer is used for recording the miles of total driving distance.
Speedometer (7):
A speedometer indicates the driving speed. Short press the function buttons (2) and (3) simultaneously to
choose whether the unit is mph (miles/hour) or km/h (kilometers/hour) according to your needs.
Digital clock (8):
The time is shown in hours and minutes. Press and hold function button (3) if the clock requires adjustment.
Fuel Gauge (9):
It indicates how much fuel is stored in the fuel tank. It will indicate a total of 7 fuel levels when full; when the
fuel level is 1 or less than 1, the fuel level indicator will flash letting you know you need to refuel as soon as possible.

19
Important information
Preparation for disassembly and disassembling operations
Please get rid of dirt, mud, dust or foreign matter before
any disassembly or disassembling operation begins.
Only use appropriate cleaning tools and products. See the
section “Special Equipment”.
When the motorcycle is disassembled, we suggest putting
like parts together. These parts include gears, cylinder,
piston and other items. Their surfaces may “wear-in”
during normal operation. Matched pieces (i.e. brake pads)
must be used or changed in pairs. During disassembling
operations, clean all parts, and keep removed parts
organized according to the various sections to avoid lost
parts or mix-ups, which will make it easier to assemble
the parts and make sure all the parts are accurately
assembled.

All parts should be kept away from a heat source.

Replacement of parts
Use only original Benelli replacement of parts. Also only
use oil and grease recommended by Benelli to lubricate
parts.

Parts with multiple assemblies should be loosened from


outside to inside and small assembling units should be
loosened first.
Gearbox and other complicated assemblies should be
stored in the proper assembly sequence for future
assembly.

20
Pay special attention to important assembly
positions before disassembly. Prepare for the parts
which are no longer used before disassembly, and
change the parts after disassembly.

Different assemblies and components have different


bolts or screws which must be mounted in accurate
positions. If they are mixed-up, put the bolts into the
holes to check whether they will fit.

The end of rubber hoses (fuel hoses, vacuum hoses or


coolant hoses) should be inserted to the bottom of the Hose
joint so that the hose clamps have enough space to
clamp the joint. Rubber or plastic dirt-proof boots
should be assembled in their original design positions. Clamp

Joint

Gaskets, O-rings, Seals and


Bearings
Change all the gaskets, oil seals and O-rings when
engines are repaired.
Clean the surface of gaskets, oil seal lips and O-rings.

21
Assemble bearings and oil seals so that trademarks
or manufacturer numbers are outwards and visible.
When installing oil seals appropriately lubricate the
sealing lips of all new oil seals.
Appropriately lubricate bearings during assembly.
a. Oil seal
b. Bearing
Important Note
Never use compressed air to dry bearings, it may
damage their surfaces.

Lock washer/locking plate, bolt


and thread sealant
Replace all lock washers or locking plates “A” after
lock washers, locking plates, bolts or nuts are
disassembled.
After bolts or nuts are locked to specified torques,
lock washers or locking plates are opposite to the
planes of the bolts or nuts; use the locking marks and
lock washers in case of curved tail end of locking plates.

Degrease both sides of bolts or nuts with solvent


before the use of thread locking agents.

Circlip
Carefully check all the circlips, and change all the
damaged or deformed circlip rings before
reassembly. All used circlips for the piston pin
should be also changed.
The sharp edge “B” of the circlip should be on the
opposite of thrust “C” felt by this circlip when the
circlip “A” is assembled. And “D” is an axle.

22
Cable-to-cable connector check
Ensure that there is no dirt, rust, water, loose
terminals and/or other items on connectors.
1. Disconnect
Wire
Connector
Joint

2. Check
Wire
Connector
Joint
Use compressed air to dry water if any is present.
Connect and disconnect parts several times if there is
rust present.

3. Check
All the connecting terminals
Properly reconnect any terminal if it is loose.

Notes
Please bend foot “A” on terminals if it becomes flat.

4. Check
Wire
Connector
Joint

Notes
Ensure that all the joints are firmly assembled.

23
5. Check
Continuity (using a multimeter)

Notes
Clean terminals if there is no item that needs to be
checked.
Wire sleeves should be checked according to steps 1-
3.
Please use [contact rehabilitating agents] which are
sold at most parts stores for quick correction.

Loose cables are a hidden electrical safety hazard.


Check the cable after the connector is clipped to
ensure electrical safety;
Cable clips are not allowed to bend towards welding
spots;
Bind cables at specified positions;
Cables should be routed away from the end of the
frame or sharp corners;
Cables should be routed away from the end of bolts
or screws;
Cables should be kept away from heat sources or
from positions in which they may be cut during
movement;
Cables run along the frame or near the handlebars
should be prevented from being too tight or too
loose, and should not interfere with their adjacent
parts in any turning position;
Cables should be smooth without any twists or
knots;
Confirm whether connector jackets are damaged,
and/or connectors are excessively stretched before
the connectors are reconnected.
Please protect cables with tape or hoses if they are at
sharp corners or in turning positions;
Bind up exposed cables with tape after cables are
repaired;
Control cables should not be bent or twisted.
Damaged control cables will result in poor control.

24
Special tools
The following special tools are the ones necessary to conduct complete and correct adjustment and assembly.
The use of correct special tools can avoid damage caused by improper tools or non-professional techniques.
Required special tools may be different in different countries. Please refer to the following data when tools are
ordered in case of any error.
Special tools for engine
Quantity Name Image
The valve stem oil seal
KST02BS01004 tool is used for inserting
valve oil seals.

The clutch holder tool is


used for preventing
KST02BS01003 clutch drums from
turning and for
loosening nuts.

The sprocket locking


tool is used for holding
KST02BS01001 sprockets to mount or
disassemble output
sprocket nuts.

The piston pin remover


1 is used for taking out
piston pins.

The camshaft sprocket


adjustment tool is used
KST02BS01002
for adjusting the tension
of the cam chain.

The valve stem oil seal


remover is used for
1
taking oil seals out of
cylinder heads.

The breather pipe


installation tool is
used for mounting
1
breather pipes on
cylinder head covers
and cylinder heads.

25
The ring clamp tool is
used for assembling
KST03BL01024 piston rings on pistons
and inserting them into
the cylinders.

The gearshift lever


drum assembling tool is
1
used for assembling
gearshift lever drums.

The flywheel extractor


is used for removing
KST03BL01012
flywheels from
crankshafts.

The engine adjusting


1 tool is used for setting
TDC positions.

The oil filter tool is used


for tightening or
KST03BL01031
disassembling oil filters
n engines.

The cam chain tensioner


locking tool is used for
1 locking tensioners when
chain tensioners are
assembled.

The bearing shell


compression tool is used
for mounting bearing
shells. Lock either end
of the bearing shell into
1
the trough, put the tool
on it, and press the tool
by hand to make the
bearing shell stick into
the trough.

26
The tool for
disassembling /
fastening clutch
component clamp nuts
1
is used for
disassembling /
fastening clutch
component clamp nuts.

The valve spring


disassembling tool is
1
used for disassembling
springs from valves.

The valve removal


1 adapter is used for
removing valves.

This gauge is used for


1 measuring the internal
dimension of holes.

This gauge is used for


1 measuring the external
dimensions of parts.

Feeler gauges are used


1 for measuring
clearances.

Magnetic stands and V-


blocks are used for
1
aiding in measuring
dimensions.

27
Dial gauges are used for
1
measuring dimensions.

Vernier calipers are used


1 for measuring
dimensions.

The flywheel holder


tool is used for
KST03BL01030
disassembling the
flywheel on crankshafts.

The socket for the lock


nut at the steering head
KST02BS01006
is used for removal and
fastening steering heads.

Steering stem top nut


allen tool for removing
or adjusting the steering
1
stem bearings or
replacing the upper
triple clamp.

Oetiker clamp pliers


1 are used for locking
oetiker clamps.

28
Multimeters are used for
measuring the voltage,
1
current and resistance of
electrical parts.

29
Chapter II Specification
Basic Specifications .................................................................................................................................... 31
Technical Data of the Engine ...................................................................................................................... 32
Technical Details of the Engine .................................................................................................................. 35
Technical Data of the Motorcycle ............................................................................................................... 38
Electrical Data ............................................................................................................................................ 41
Technical Data of Nut Torque ..................................................................................................................... 45
Technical Data of Bolt and Screw Torque .................................................................................................. 46

30
Basic specifications
Dimension Standard
Total length (A) 83.66 inches
Total width (B) 31.5 inches
Total height (C) 44.5 inches
Wheelbase (D) 55.31 inches
Weight Standard
Curb weight (with oil and fuel) 432 lbs.
Empty motorcycle (with no oil and empty fuel tank) 404 lbs.
Maximum allowable load capacity (with cyclists and
353 lbs.
load)

31
Technical Data of the Engine

Engine Specifications

Engine Standard
Four-stroke, inline twin-cylinder, water cooled, four-
Engine valves per cylinder, and double overhead camshaft
(DOHC)
Total displacement 299.82CC
Quantity of cylinders 2
Inside diameter × stroke 65.0×45.2
Compression ratio 12: 1
Low free speed ……
High free speed ……
Double overhead camshaft, chain-controlled, and
Distribution
four-valves per cylinder
Maximum net power 37.6 HP @ 12000rpm
Maximum net torque 20.21 ft. lbs. @ 9000rpm
Fuel consumption limit ≤1.37gal./62 miles
Start-up mode Electrical starting

Fuel
Recommended fuel oil Lead-free 91 and above

Engine Oil
Lubricating mode Force and splash lubrication
Total quantity 3.0L
Total quantity without replaced engine oil filter 2.8L
Total quantity with replaced engine oil filter 3.0L

Type: API SH, SJ or SL, JASO MA

Viscosity: SAE 10W-40

Recommended engine oil

Air Filter
Type of air filter Sponge
Intake resistance 1.2±0.12 KP a

32
Technical Data of the Engine

Engine Specifications

Oil pump
Type of oil pump Rotor pump
Radial clearance of internal and external rotor 0.03-0.13mm

Ignition device
Ignition mode TLI

Spark plug
Type of spark plug NGK CR8EIA-9
Spark plug clearance 0.6-0.7mm

Cylinder head
Maximum curvature of cylinder gasket 0.03 mm

Camshaft
Control system Chain transmission
Diameter of camshaft support Ø23 (0,+0.021) mm
Clearance between support and camshaft follower 0.03-0.064 mm
Camshaft lobe dimension, intake side

Measurement A= 32.495 mm
Measurement B= 25 mm

Camshaft lobe dimension, exhaust side

Measurement A= 32.495 mm
Measurement B= 25 mm

Maximum bounce of camshaft

0.03 mm

33
Technical Data of the Engine

Engine Specifications

Valve, valve seat and valve guide


Intake valve clearance (cold) 0.13-0.19 mm
Exhaust valve clearance (cold) 0.19-0.25 mm
Valve dimension
Intake Ø 25 mm

Exhaust Ø 22 mm
Valve head diameter
Intake 1.9-2.1 mm

Exhaust 1.75 ~ 1.95 mm


Valve face width
Intake 1 ~ 1.1 mm

Exhaust 1 ~ 1.1 mm
Valve seat amplitude

1.9 ~ 2.1 mm
Intake

Exhaust 1.75 ~ 1.95 mm


Valve seat width
Intake 3.965 ~ 3.98 mm
Valve stem diameter
Exhaust 3.965 ~ 3.98 mm
Clearance between valve Intake 0.04 ~ 0.065 mm
stem and valve guide Exhaust 0.05 ~ 0.075 mm

0.05 mm

Bounce of valve stem


Intake 37.2 mm
Valve spring
Exhaust 40.5 mm
Effective pressure of Intake 895MPa~1024MPa
intake/exhaust Exhaust Lower end 751≥1000MPa, stem end 895-1042MPa

Intake 0.5mm

Exhaust 0.5mm

34
Technical Details of the Engine

Engine Specifications

Timing chain
Link number/type 92RH2015
Automatic tensioning Self-adjusting type

Cylinder
Cylinder layout Vertical inline
Stroke ratio 65.0: 45.2
Compression ratio 12: 1
Stroke 45.2 mm
/O/ 0.008 mm
Largest oval
/O/ 0.006 mm

Piston
Clearance between piston and cylinder 0.035~0045mm
Piston diameter “A” 65(-0.03,-0.025)/65(-0.025,-0.02)
Piston height “B” 11 mm
Piston pin boss diameter
16(0.002,0.008)mm
“C”
External diameter of piston pin 16(-0.008,0)mm
Clearance between top piston ring and ring trough 0.05-0.09 mm

Type of piston ring Drum type

Dimension A*B 2.3 × 0.8 mm

Clearance between the second piston ring and ring


0.04-0.08 mm
trough

Type of piston ring Ladder type

Dimension A*B 2.3 × 0.8 mm

Clearance between oil scraping ring and ring trough 0.04-0.14mm

2.25 × 1.5 mm
Dimension A*B

35
Technical Details of the Engine

Engine Specifications

Piston Stem
Color code of bearing A=red, B=blue, C=yellow
K1=black, K2=green, K3=white, K4=brown,
Stem weight code
K5=orange
Crankshaft

Width A 131mm
Maximum centrifugal force 22.6 ± 0.01 mm
Side clearance C at the large end C of connecting stem 0.1-0.25 mm
Color code of main bearing A=red, B=blue, C=yellow

Clutch
Clutch mode Oil-bath clutch with multiple plates
Clutch release mode Cable and spring
Clutch control action Cable action
Action Use left lever.
Position of clutch disengaging lever Align slotting positions with scribed lines on right
covers.
Free clearance of clutch disengaging lever Not Adjustable
Clutch cable clearance (at the end of clutch lever) 2 ~ 3 mm
Thickness of friction plate 3.0± 0.1mm
Quantity of friction plate 7
Thickness of steel plate 2.0± 0.1mm
Effective length of spring 36.7(0~0.2)mm
Quantity of spring 4

Throttle body
Diameter 34mm
Switch mode of throttle Rotating type

36
Technical details of engine

Engine Specifications

Transmission device
Type of transmission device 6-speed, constant mesh
Final ratio 2.645
The second decelerating system 3.071
Level 1 2.846
Level 2 1.947
Level 3 1.556
Transmission ratio
Level 4 1.333
Level 5 1.190
Level 6 1
Maximum speed 87 mph

Gear control mechanism


Type of gear control mechanism Sequence driven selector and pre-selector
Straightness 0.02mm
Maximum deformation of gear-shift guide rod
Roundness 0.005mm

Coolant
Recommended type Antifreezing agent
Color Green
Mixed ratio 50% distilled water, 50% coolant
Freezing point –35°C (–31°F)
Total quantity 2L

Fuel Pump
Type of fuel oil pump Electric type
Model (manufacturer) Delphi
Output pressure 37 psi

37
Technical Data of the Motorcycle

Motorcycle Specifications

Motorcycle
Frame type Steel Trellis
Rake 25°
Castor 86mm

Front wheel
Wheel type 6-spoke aluminum alloy
Wheel disc (dimension) 17×MT3.50
Wheel disc (material) Aluminum alloy
Wheel disc (diameter) 17 inches

Rear wheel
Wheel type 6-spoke aluminum alloy
Wheel disc (dimension) 17×MT4.50
Wheel disc (material) Aluminum alloy
Wheel disc (diameter) 17 inches

Front Tire
Tire type 110/70-17 M/C
Model (trademark) Cordial
Tire pressure 34 ± 2 psi

Rear Tire
Tire type 140/70-17 M/C
Model (trademark) Cordial
Tire pressure 36 ± 2 psi

38
Technical Data of the Motorcycle

Motorcycle Specifications

Front hydraulic brake Limit


Brake type Floating disc double-brake
Action Right hand lever
Recommended liquid DOT 4
Brake disc

Φ260×4

Diameter×thickness
Maximum thickness 4mm 3 mm
Maximum deformation 0.1mm
Thickness of worn brake pad 1mm
Diameter of pump cylinder 16mm (0.62 in)
Diameter of piston cylinder 34 (1.33in)

Rear hydraulic brake


Brake type Single disc brake
Action Right foot lever
Recommended liquid DOT 4
Brake disc

Φ260×5

Diameter×thickness
Maximum thickness 5mm 4 mm
Maximum deformation 0.1mm
Thickness of worn brake pad 1mm
Diameter of pump cylinder 12.9mm
Diameter of piston cylinder 32 mm

39
Technical Data of the Motorcycle

Motorcycle Specifications

Front suspension
Suspension type Extension sleeve type
Maximum stroke 135mm
Free length 310 mm
Gasket length 80 mm
Spring
Elasticity 8.9 N/mm
Spring stroke 0 ~ 135 mm
Damping oil
Recommended oil SAE 7.5 32#
Each amount of each damping oil 400ml
Horizon (pipes are fully compressed without fork 130 mm
spring from the top of lateral pipes)

Steering
Type of steering bearing Ball bearing
Left steering angle 30°
Right steering angle 30°

Rear suspension
Suspension type Rocker arm type with adjustable gas shock
Maximum stroke 42 mm
Free length 170±1,5 mm
Gasket length No gasket
Spring
Elasticity 180 N/mm
Spring stroke 42±1 mm
Standard pressure of preloading gas/air of spring 1.5Mpa
Minimum location 0
Adjustment location of
Standard 9 mm
spring preloading
Maximum location 20 mm
Minimum location 500N
Adjustment location of
Standard 1900N
rebound damping
Maximum location 5000N V=0.1m/s

Drive chain
Model (trademark) 525HO
Chain pitch quantity 108

40
Electrical Data

Electrical Specifications

System voltage
System voltage 12V
Ignition coil
Model (trademark) Delphi
Resistance of primary coil 0.6Ω
Resistance of secondary coil 10kΩ
Choke of primary coil 2.5 mH (1 kHz 0.3V)
Choke of secondary coil 23.5 mH (1kHz)
Maximum endurable current 7.6 A

Charging system
System type Magnetic AC (between white and white: 0.1~0.2Ω)
Model (trademark) 5-101211-502-1 (DENSO)
Rated output 13.5 V 48 A at 5000 rpm
Voltage regulator (in AC generator) Three-phase full wave
Voltage setting 14.5 + 0.3 V (5000 rpm 10 A 77°F)

Starting relay
Model (trademark) ……
Amperage 100 A
Coil resistance 4.4Ω at 68°F

Starting motor
Model (trademark) ……
Brush length of starting motor 12.5mm/5.5mm (limit of usage)
Bushing of starting idler shaft 8.3mm (limit of usage)
Outside diameter of starting idler shaft 7.94mm (limit of usage)

Battery
Model (trademark) YTX9-BS
Voltage of battery capacity 12V/8Ah
Relative density of electrolyte 1.280±0.01

41
Electrical Data

Electrical Specifications

Horn
Horn type Low pitch
Model (trademark) DL122 K.X.D
Maximum amperage 3A
Performance 105 ~ 118 db (A)

Headlight
Headlight type Halogen
Headlight H7(12V 55W)
Front position indicator light W5W
Rear position indicator LED
light/brake light
Steering light LED
Light bulb
License plate light W5W
(watt×quantity)
Neutral indicator light LED
High beam indicator light LED
Oil level warning light LED
Steering indicator light LED
Engine fault indicator light LED

Flasher
Model (trademark) Lihua 355 E10
Flasher type Digital controlled flasher
Flicker frequency of steering light Normal: 80±10 times/min; variable frequency:
160±10 times/min
Power 10W×4

Engine oil pressure sensor


Model (trademark) Delphi
Alarm 55KPa

Throttle body position sensor


Model (trademark) Delphi
Resistance 3k~12kΩ

Throttle body barometric sensor


Model (trademark) Smart

42
Electrical Data

Electrical Specifications

Fuse (amperage×quantity)
Fuse ECU (control unit) 15A (blue)
Headlight fuse 15A (blue)
Hot wire fuse 10A (red)
Radiator-fan fuse 15A (blue)
Backup fuse 15A (blue)+ 10A (red)
Oil pump fuse 15A (blue)
Charging fuse 40A (orange)

Fuel pump
Model Delphi
Working voltage 12V~14V

Maximum amperage 1.8A


Output oil pressure 250kPa

Fuel level sensor


E end (resistance value) 100Ω
F end (resistance value) 10Ω

Air temperature sensor


Model (trademark) HAIHUA
Structure Resistance type

Cylinder head temperature sensor


Model (trademark) HAIHUA
Structure Resistance type

Crankshaft position sensor


Model (trademark) CHONGQING LIJIAN

Outlet water temperature switch


Working temperature 208°F

Velocity sensor
Model (trademark) CHONGQING SANMU
Type Induction type

43
Electrical Data

Electrical specifications

Oxygen sensor
Model (trademark) Delphi
Resistance 9.6±1.5Ω (measured at 70°F)

Fuel injector
Model (trademark) Delphi

Relay unit
Model (trademark) Panasonic

Stepping motor
Model (trademark) Smart

44
Technical Data of Nut Torque

Basic Torque Specifications


Locking torques of parts or specific components are
offered in each chapter of this manual.
In order to avoid the risk of deforming the
components across several fasteners, cross torque
parts in proper order until required torques are
achieved.
Locking torques are specified, the threads of the
part must be clean and dry, unless otherwise
specified.
Parts must be fastened at room temperature.

Basic fastening torque


Nut

45
Technical Data of Bolt and Screw Torque

Basic Locking Specifications


Fastening torque of bolt and screw and relevant parameters
Basic fastening torque
Bolt/screw Level 8.8 Level 10.9 Level 12.9
N.m ft·lb N.m ft·lb N.m ft·lb
M4×0.7 3 2.2 4.2 3.1 5.2 3.8
M5×0.8 6 4.43 7.5 5.5 9 6.6
M6×1 10 7.38 13 9.6 16 11.8
M8×1.25 22 16.23 30 22 40 29.5
M8×1(*) 25 18.44 36 26.5 45 33.2
M10×1.5 45 33.2 65 48 80 59
M10×1.25(*) 50 37 70 51.6 85 62.7
M12×1.75 80 59 110 81.1 135 99.6
M12×1.5(*) 85 62.7 120 88.5 145 107
M12×1.25(*) 90 66.38 130 96 150 110.6
M14×2 130 96 185 136 220 162.3
M14×1.5(*) 150 110.63 205 151 245 180.7
M16×2 200 147.5 280 207 335 247
M16×1.5(*) 225 166 310 228.6 360 265.5
M18×2.5 265 195.5 370 272.9 450 331.9
M18×1.5(*) 320 236 450 332 550 405.6
M20×2.5 390 287.6 550 405.7 650 479.5
M20×1.5(*) 440 325 630 465 750 553
M22×2.5 540 398 750 553 900 664
M22×1.5(*) 600 443 850 627 1000 737.5
M24×3 670 494 950 701 1130 833.5
M24×2(*) 750 553 1050 774.4 1250 922
*: refers to fine thread.

46
Technical Data of Bolt and Screw Torque

Locking Torque

Engine
Torque
Fastener Remarks
N·m kgf·m ft·lb
Cooling system
Coolant drain bole 10 1.0 89 in·lb
Cylinder fitting fixing bolt 9.8 1.0 87 in·lb
Radiator fixing bolt 9.8 1.0 87 in·lb
Radiator (water pipe) hose fastening screws 2.0 0.20 18 in·lb
Expansion kettle fixing bolt 6.9 0.70 61 in·lb
Bolt on the housing cover of thermostat 5.9 0.60 52 in·lb
Thermostat shell fixing bolt 9.8 1.0 87 in·lb
Water pump cover bolt 9.8 1.0 87 in·lb
Water pump impeller fastening bolt 9.8 1.0 87 in·lb
Cylinder head and cylinder head cover of engine
Camshaft sprocket fixing bolt 20 20 14.75 L
Camshaft cover bolt 12 1.2 106 in·lb S
Camshaft timing chain fairleader bolt 12 1.2 106 in·lb
Camshaft timing chain tensioner fixing bolt 12 1.2 106in·lb
Cylinder cover bolt (M10) 55 5.5 40.56 MO、S
Cylinder cover bolt (M6) 12 1.2 106 in·lb S
Cylinder head cover bolt 12 1.2 106 in·lb S
Spark plug 13 1.3 115 in·lb
Throttle body assembly fixing bolt 12 1.2 106 in·lb S
Clutch
Right cover bolt 12 1.2 106 in·lb Tighten
Hexagon head bolt 12 1.2 106 in·lb them
Engine oil filler plug screw — — manually
Clutch spring bolt 10 1.0 89 in·lb
Sprocket mounting bolt 8 0.8 71 in·lb
Balance shaft driving gear lock nut 60 6.1 44 L
Clutch lock nut 95 9.7 70
Clutch driving sprocket screw 8 0.8 71 in·lb
Engine lubrication system
Oil pan drain magnetic bolt 20 2.0 15
Oil pan bolt 10 1.0 89 in·lb
Engine oil pump mounting bolt 10 1.0 89 in·lb
Engine oil pump cover bolt 10 1.0 89 in·lb
Sprocket mounting bolt 8 0.8 71 in·lb
Engine oil pressure switch bolt 24.5 2.5 18 ft·lb L
Engine oil filter bolt 17 1.7 13 ft·lb

47
Technical Data of Bolt and Screw Torque

Locking Torque

Torque
Fastener N·m kgf·m ft·lb Remarks
Crankshaft/transmission mechanism
Balance shaft driven gear lock nut 100 10.2 73.7 L
Connecting rod big end nut See the text.
Crankshaft flywheel nut 105 10.7 77.4 L
Balance shaft driving gear lock nut 60 6 44 L
Follower bolt (M6, L = 14 mm) 10 1 89 in·lb L
Oil passage plug (M16, L = 15 mm) 24.5 2.5 18.1 L
Follower screw (M6, L = 16 mm) 7 0.71 62 in·lb L
Support bolt (M6, L = 20 mm) 10 1 89 in·lb L
Crankcase bolt (M8, L = 85 mm) 24.5 2.5 18.1 MO、S

Crankcase bolt (M6, L = 40 mm) 10 1 89 in·lb S


Crankcase bolt (M10, L = 60mm) 45 4.6 33.3 MO、S
Crankcase bolt (M8, L = 75 mm) 24.5 2.5 18.1 S
Crankcase bolt (M8, L = 115 mm) 24.5 2.5 18.1 S
Crankcase bolt (M10, L = 100mm) 45 4.6 33.3 MO、S
Crankcase bolt (M8, L = 45 mm) 24.5 2.5 18.1 S
Flywheel lock nut 100 10.2 73.7
Overrunning clutch bolt 20 2.04 15 L
Positioning roller rocker arm bolt 12 1.22 106.49 in·lb L
Shift positioning star wheel fixing bolt 12 1.22 106.49 in·lb
Left cover bolt 12 1.22 106.49 in·lb
Locking torques of main fasteners that need thread locking agent, silicone sealant and/or other adhesives are
listed in the above table. The letters in the “Remark” column are defined as follows:
AL: Alternatively tighten fastening bolts twice according to higher locking torques.
G: Coat lubricating grease.
L: Coat thread fastening adhesive.
M: Coat lubricating grease containing molybdenum disulfide.
MO: Coat oil solvent containing molybdenum disulfide.
(Mixture of engine oil and lubricating grease containing molybdenum disulfide prepared at the weight ratio of
10:1)
R: Replace parts.
S: Follow the specified tightening sequences.
Si: Coat silicone grease.
SS: Coat silicone sealants.

48
Chapter III Check and Regular adjustment
Regular Maintenance and Lubrication Intervals ......................................................................................... 50
Regular Maintenance and Lubrication Interval Schedule ........................................................................... 51
Air Filter ..................................................................................................................................................... 54
Fuel Hoses .................................................................................................................................................. 57
Control ........................................................................................................................................................ 58
Throttle Cables ........................................................................................................................................... 59
Clutch Cable ............................................................................................................................................... 60
Rearview Mirrors ........................................................................................................................................ 61
Engine Oil................................................................................................................................................... 62
Engine Oil Filter ......................................................................................................................................... 65
Coolant ....................................................................................................................................................... 66
Radiator Hoses............................................................................................................................................ 67
Spark Plugs ................................................................................................................................................. 68
Valve Clearance .......................................................................................................................................... 72
Brake Adjustment ....................................................................................................................................... 76
Brake Fluid Check ...................................................................................................................................... 78
Brake Pad Check ........................................................................................................................................ 83
Brake Hose Check ...................................................................................................................................... 84
Adjustment of the Drive Chain ................................................................................................................... 85
Check and Adjustment of the Steering Stem Bearings ............................................................................... 87
Front Fork Inspection ................................................................................................................................. 90
Rear Shock Absorber Inspection ................................................................................................................ 91
Front and Rear Tire Inspection ................................................................................................................... 92
Battery Charging and Inspection ................................................................................................................ 93
Fuse Check ............................................................................................................................................... 100
Headlight Bulb Replacement .................................................................................................................... 102
Adjustment of the Headlight..................................................................................................................... 104
Replacement of the Front Turn Signal Lights ........................................................................................... 105
Replacement of the Rear License Plate Light ........................................................................................... 106

49
Regular Maintenance and Lubrication Intervals
The specified mileage/time interval in the scheduled maintenance form is just a general guide for normal use.
It is necessary to reduce the time interval due to weather, topography, geographical position and personal usage
conditions. If users have the necessary skills, some operations can be completed by themselves; if it is explicitly
mentioned in this manual, they also can be completed by the end user.
In brief, these operations should be completed at an authorized Benelli dealership. The list of authorized
repair shops is available on our website at: www.usa.benelli.com.
Generally, motorcycles are kept upright by a rear support, engines are shut down, and switches are turned to
the “OFF” position when maintenance is conducted for the motorcycle:
Preferably, motorcycles should be on a level surface, and the front and rear tires should be on the ground.
When checking fluid levels the motorcycle must be vertical to the ground without the rear stand support.

Notes:
Annual checks should be conducted unless motorcycles have been maintained according to the set time
intervals.
At 24,000 mi, for example, start to repeat maintenance services at 8,000 mi.

For marked time intervals, we suggest contacting your authorized Benelli dealer because some special
equipment, professional information and/or experience/professional skills may be needed.
The following list shows all of the maintenance operations.

Notes:

Air Filter
Air filter elements should be replaced more often if the motorcycle is used in a particularly humid or dusty
environments.

Hydraulic Brake Maintenance


Regularly check brake fluid levels and complete brake fluid flushes as needed or per interval.
Replace brake master cylinders and the oil seals in brake calipers every two years; and replace the brake
fluids.
Replace brake hoses every four years; or replace them before if they are found broken or damaged.

Symbol interpretation
Check, adjustment, cleaning, lubrication or replacement as required
Replacement
Tightening
Dealer ONLY

50
Regular Maintenance and Lubrication Interval Schedule

Frequency

0 600 4,000 8,000 12,000 16,000 Annual


Item Content
mi mi mi mi mi mi inspection
I R R R R R R
1 Engine Oil Check / add / replace
Check engine oil level before using the motorcycle
Engine Oil Replace R R R R R R
2
Filter or when replacing oil engine
Check / replace I I R I
3 Fuel Filter

Check / replace I R I R
4 Air Filter Repair and maintenance must be conducted after 4000 mi; the interval
may be shortened appropriately under special conditions
Check / add / replace I I I I R I I
5 Coolant
Replace Every two years, or 12,000 miles
Check the cooling liquid I I I I I I I
Cooling
6 level, and ensure there is
System
no liquid leakage
Check / replace I R I R I
7 Spark Plug
Check the situation, wash and restore spark plug clearance
I I I I I I
Check chain tension,
After a new motorcycle has run for 600 mi, adjust the chain tension, use
Drive ensure that the rear wheel
8 the correct chain lube after every cleaning; later, adjust the chain tension
Chain has been correctly aligned,
once every 1,000 mi or under special use conditions, the adjustment cycle
clean and lubricate
can be shortened according to the actual tension
Rear Check / lubricate I I I I I I
9
Sprocket Replace it when replacing chain
Front Check / replace I I I I I I
10
Sprocket Replace it when replacing chain
Fault / leakage check I I I R
11 Fuel Hoses Replace every 16,000 miles; or under any circumstances, replace it every
three years
Check / add I I I I I I I
12 Brake Fluid Replace every 12,000 miles, or under any circumstances, replace it every
Replace
two years
Front / Check operation and I I I I R I I
13 Rear liquid level, and ensure
Brakes there is no liquid leakage
Check / replace I I I I I
14 Brake Pads
If the wear reaches the limit, please replace
Drive Check / replace I I I I I
15 Chain
If the wear reaches the limit, please replace
Protector
Check operation; if I I I I I I I
possible, adjust throttle
Throttle
16 cable clearance, lubricate
Grip
throttle grip enclosure and
throttle cable

51
Continued

Frequency

Annual
0 600 4,000 8,000 12,000 16,000
Item Contents inspectio
mi mi mi mi mi mi
n
Check/adjust I I I I I I I
17 Clutch

Check operation/ adjust the


Valve I
18 clearance
Clearance
Every 16,000 miles, check the clearance
Timing Check / replace R
19
Chain Every 16,000 miles
Timing Check / replace R
20 Chain
When replacing the timing chain
Guides
Cam Chain Check / replace R
21
Tensioner When replacing the timing chain
Steering Check / replace T T
22 Stem
Every 12,000 miles, lubricate with lithium base grease
Bearings
Front / Rear Check / replace I
23 Wheel
Every 15,000 miles
Bearings
Swing Arm Check / replace I I I R
24
Bearings Every 16,000 miles
Check operation and I I I I
Rocker
25 ensure that there is not too
Arms
much clearance
Check operation and
Front ensure that there is no I I I I I I
26
Suspension leakage

Front Replace R
27 Suspension
Every 16,000 miles
Oil
Check / adjust and ensure
Rear I I I I
28 that there is no leakage
Suspension
Before use of the motorcycle
Ensure that there is no I I I
29 Wheel
eccentricity or damage Before use of the motorcycle
Check the tire tread depth and I I I I I I
whether the tire has been
damaged, and replace it when
30 Tire
necessary; check the tire If the wear reaches the limit, please replace
pressure, and fill the tire with
air when necessary
Turn Signal Check operation I I I I I I I
31
Stay
Turn Signal Check operation I I I I I I I
32
Switch
Instrument Check operation I I I I I I I
33 Light Signal
and Switch

52
Continued

Frequency

0 600 4,000 8,000 12,000 16,000 Annual


Item Contents
mi mi mi mi mi mi inspection
Check operation I I I I I I
34 Headlight
Adjust
Check operation I I I I I I I
35 Horn

Check operation I I I I I I I
36 Instruments

Check operation I I I I I I I
37 Battery

Electrical Check operation I I I I I I I


38
System
Ignition Check operation I I I I I I I
39
System
Check operation I I I I I I I
40 Fan

Fuel Filter Check / replace I I I I I I I


41
Element Every 12,000 miles
Nuts, Bolts, T T T T T T
Ensure that all nuts, bolts
Fasteners
42 and screws have been
and Hose
accurately fastened
Clamps
Check / replace I I I I R
Catalytic
43 Without maintenance requirements, do not replace it unless there is a
Converter Fault
fault
Check / replace I I I I R
Charcoal
44 Without maintenance requirements, do not replace it unless there is a
Canister Fault
fault
Brake / Fault/leakage check I I I I I I I
45 Clutch Replace every four years
Hoses

53
Air Filter

Disassembly / Installation of Air Filter

No. Name and specifications Quantity No. Name and specifications Quantity
1 Clamp components 2 10 Charcoal canister solenoid valve 1
Solenoid valve and throttle valve
2 Intake air temperature sensor 1 11 1
connecting hose
3 Air Box Assembly 1 12 Screw M6×12-8.8-ZG 2
4 Charcoal canister mounting plate 1 13 Gas recovery hose 1
Fuel tank and check valve
5 1 14 Plate clamp 2
connecting hose
6 Check valve components 1 15 Plate clamp 4
Check valve and charcoal canister
7 1 16 Plate clamp 4
connecting hose
8 Charcoal canister combination 1 17 Rubber bushing II 2
Charcoal canister and solenoid valve
9 1
connecting hose

54
Air Filter

Disassembly / Installation of Air Filter

Replacement of Air Filter


Remove the fuel tank guard, see (the chapter of
motorcycle covering parts/fuel tank guards).
Open the seat cushion lock, and remove the seat
cushion.

Remove the fuel tank fixing bolts (1), and take off the
fuel tank.

Remove the air filter cover.


Remove the air filter element.

Check:
Whether the filter element is polluted or damaged.
Please replace the filter element if damaged.

Cleaning:
 Thoroughly and gently clean the filter element
with air filter cleaner.
 Do not use gasoline as to not cause fires.
 Do not distort or wring the filter element as
to avoid damaging the foam material.
 Then, coat the filter element in air filter oil, and
squeeze out the extra oil to make it moist without dripping oil.

55
Air Filter

Disassembly / Installation of Air Filter

Time Based Replacement


The air filter element should be cleaned/replaced often if the motorcycle is used in a particularly humid or
dusty environment.
*Notes
When disassembling the air filter
element, do not start the engine; otherwise,
unfiltered air will enter the engine resulting
in sharp wear on parts or possible damage to
the engine.
Additionally, operation without the air
filter element may impact the engine and the
engine may function improperly, and
overheat.

Assembly should be conducted in reverse order of disassembly.

56
Fuel Hose

Fuel Hose Inspection

Check:
Fuel hoses (fuel leakage, hose cracks and hose
routing)
Notes:
If the motorcycle is improperly handled,
high pressure from the fuel hose will cause
fuel leakage [A] or fuel hose cracks.

Disassembly:
Remove the fuel tank (see Section “Air filter” of
Chapter III “Check and Regular adjustment”).

Check: fuel hoses


If any wear, cracks [B] or expansion [C] is found, the fuel hose must be replaced.

57
Control

Control Cable

No. Name and specifications Quantity No. Name and specifications Quantity
1 Rearview Mirror Set 1 14 Right Rearview Mirror 1
2 Throttle Grip 1 15 Left Rearview Mirror 1
3 Throttle Housing Top 1 16 Socket Head Bolt M6×35 2
4 Throttle Housing Bottom 1 17 Lock Washer 6 2
5 Right Combination Switch 1 18 Gasket 6 2
6 Handlebar Vibration Damper Insert 2 19 Handlebar End Insert 2
7 Handlebar 1 20 Handlebar End 2
8 Left Combination Switch 1 21 Cable Clamp 1
9 Left Grip 1 22 Soft Cable Clamp 3
10 Clutch Perch Assy. 1 23 Handlebar Soft Cable Clamp 2
11 Clutch Cable 1 24 Cotter Pin 2×18 1
12 Throttle Cable I 1 25 Hinge Pin 6×14 1
13 Throttle Cable II 1 26 Clutch Lever 1

58
Throttle Cable

Throttle Cable Adjustment

Check:
Throttle Cable Free play (A)
Ensure that the throttle control grip works properly,
and can reach the maximum open position and
automatically closed position in all of the handlebar
positions. Make adjustments if needed, as shown in
Fig. A.

*Notes
The engine idle speed should be properly
adjusted before the throttle cables are
adjusted.

Check the free play of the throttle which is 3-5mm.


Make some adjustments if it does not conform to the specified values.

Adjustment:
The motorcycle is equipped with dual throttle cables
(push and pull). Throttle Cable A is the pull cable, and
throttle cable B is the push cable. Please adjust the free
play of the throttle grip according to the following
steps:
(1) Remove the dirt-proof boot of the throttle
cable.
(2) Loosen the lock nut ③.
(3) Completely screw in and adjust the nut ④.
(4) Loosen the lock nut ①.
(5) Rotate the adjusting nut ② to bring the free
play of the throttle grip to 5mm ~10mm.
(6) Tighten the lock nut ①.
(7) Adjusting nut ④; and check whether the
throttle grip turns easily.
(8) Tighten the lock nut ③.
After the free play is adjusted, the handlebar should be
turned to the left and right to make sure that there is no
change in the engines idle speed.

59
Clutch Cable

Adjustment of Clutch Cable Clearance

Check:
Free play of the clutch lever (A)
Make an adjustment if needed:
Measure the free play of the clutch lever at the end of
the clutch handle.
Free play: 10 - 20mm

Adjustment:
1. Loosen the locking ring nut (C).
2. Rotate and adjust the clutch cable adjuster nut (B)
clockwise or anticlockwise to set the clutch cable
clearance as specified, as shown in Fig. B.
Increase clearance in clockwise direction.
Reduce clearance in anticlockwise direction.

Notes
Use the adjusting nut at (E) RH side of
engine if the clutch cable does not reach the
specified clearance at the lever, as shown in
Fig. C.

60
Rearview Mirror

Adjustment of Rearview Mirrors


The following steps are applicable to the adjustment of both rearview mirrors.

Adjustment
Fasten the rearview mirror on the handlebar, check
the nut (B) and tighten it to the perch, as shown in
Fig. A.
1. Unscrew the locking nut (C).
2. Rotate the rearview mirror rod to the proper
position, and adjust the mirror position.
3. Fasten the nut (C).

Notes
Adjust the right rearview mirror in the
same way.

61
Engine Oil

Engine Oil Level Inspection

Recommended Engine Oil


Model: API SE, SF or SG
API SH, SJ or SL, JASO MA, MA1 or MA2
Viscosity: SAE 10W-40
Capacity: 2.8 L (during oil change)
3.0 L (during disassembly)

Notes
○ DO NOT add any chemical additives into
the engine oil! The engine oil that meets the
above requirement is carefully prepared, and
can adequately lubricate the engine and
clutch.
○ Make corresponding changes according to
the atmospheric conditions of specific areas,
although it is recommended to use engine oil
with a viscosity of 10W-40 in most cases.

Parking: Park the motorcycle on flat ground.


Notes
When parking, the motorcycle should be
in a vertical position on flat ground.

Start:
View the oil window (B) after the motorcycle is in the
vertical position, the engine is running at idling speed for
2-3min, and then stopped for 2-3min, as shown in Fig.
A.
Warning
Please do not start the engine if the oil
level is less than the lowest value (L).

62
Engine Oil

Engine Oil Level Inspection

Check
Engine Oil Level
Add the recommended engine oil until the oil level is
between the lowest value (L) and the highest value
(H) if it is less than the lowest value (L).

Adding Engine Oil:


1. Shut down the engine, and unscrew the oil filler
cover (B).
2. Pour enough of the proper engine oil into the
engine and place it between “H” and “L”, as
shown in Fig. B.
3. Reinstall the Oil Filler Cap back into its original position.

Note:
When checking the engine oil level,
restart the engine to preheat it for several
minutes, and then shut it down. Wait for 2-3
minutes to have enough time for the engine
oil to flow down.

Important:
 Since engine oil also lubricates the clutch, engine oil of the wrong type or containing additives may cause
clutch slipping. Therefore, we recommend you only use engine oil without any chemical additives or other
types of engine oil not listed in the list of engine technical specifications.
 People or pets that swallow engine oil will be poisoned. In case of ingestion, send the poisoned people or
pets to the hospital; do not force them to vomit to prevent the oil from being inhaled. Short exposure to
engine oil may cause skin irritation.
 Store engine oil out of the reach of children and pets.
 Please wear long-sleeved clothing and waterproof gloves every time you handle engine oil.
 Please flush skin that is exposed to engine oil with soap or water.
 Please recycle all used engine oil.

63
Engine Oil

Replacement of Engine Oil

Start: engine, and preheat it for several


minutes before shutdown.

Place: an appropriate container under the


drain bolt (A) to collect the engine oil, as
shown in Fig. A.

Remove: the oil drain bolt (A) (with the


copper gasket).

Drain: engine oil from the crankcase.

Note:
Replace: sealing the gasket for the drain bolt.

Assemble
New sealing gasket
Magnetic drain bolt
Fasten the magnetic bolt according to the following torque:

Torque: 16 ft·lb

Fill: the specified amount of recommended engine


oil into the crankcase filling port.

Install: oil filler cover (B), as shown in Fig. B.

Start: Engine.
Preheat the engine for several minutes before
shutdown.

Note:
Ensure that the oil level is between the symbols “H”
and “L” on the oil window, as shown in Fig. B.
Add engine oil if needed.

64
Engine Oil Filter

Replacement of the Engine Oil Filter

Replacement of engine oil filter


● Drain the engine oil (see “Replacement of engine oil”).
● Remove the engine oil filter [A] with the oil filter
wrench.

Special tool- engine oil filter wrench


● Replace the engine oil filter with a new one.
● Tighten the engine oil filter with the engine oil filter
wrench.
Tightening torque:
Locking torque of engine oil filter:

Torque: 17 N·m (1.7 kgf·m, 13 ft·lb)

Note:
○ Please do not tighten the engine oil filter manually, because it cannot reach the specified locking torque.
● Pour in engine oil of the specified type according to the specified amount (see “Replacement of engine oil”).

65
Coolant

Coolant Level Check

Parking: Park the motorcycle on flat ground.

Note:
When parking, the motorcycle should be in a vertical
position on flat ground.
Remarks
○ Check the liquid level when the engine has cooled
(at room temperature or ambient temperature).
● Place the motorcycle vertically (do not use the side
stand), and check the coolant liquid level in the
coolant reservoir [A], as shown in Fig. A.
★ Unscrew the cover of the coolant reservoir, and
add coolant until the liquid level reaches the liquid
level “H” [C] if the coolant liquid level is less than the
liquid level “L” [B].
“L”: Lowest level
“H”: Highest level
Notes
When adding coolant, add the specified
mixture of coolant and distilled water. Adding
water separately will dilute the coolant and
reduce its anticorrosive property. The diluted
coolant may corrode aluminum engine parts. In
the case of an emergency you can add distilled
water separately, but it is recommended that you
change the fluid to the proper ratio again within
a few days.
If you notice that you must frequently add
coolant or the coolant reservoir is completely dry,
a leak may exist in the cooling system. Check for
cooling system leaks, since the coolant may
corrode painted surfaces.
Immediately rinse with water if the frame,
engine, wheels or other painted parts are
spattered with coolant.

66
Radiator Hoses

Radiator Hose Inspection

Check: radiator hoses (coolant leakage, radiator hose damage and installation of radiator hoses)

Warning:
If the radiator hoses are improperly repaired, high
pressure water from those hoses will cause coolant
leakage [A] or water hose cracking.

Check:
Check whether the radiator hoses are corroded.
Squeeze the radiator hoses, if they feel hard, fragile,
and/or overtly soft or swelling it is time to replace the
radiator hoses.

Note:
If any wear, cracks [B] or expansion [C] is found, the radiator hose must be replaced.

Check:
Check whether the radiator hoses are firmly seated, and the hose clamp is properly tightened.

Tightening torque of the radiator (water) hose clamps: 2.0 N·m (0.20 kgf·m, 18 in·lb).

67
Spark plug

Removal/Replacement of the Spark Plugs


The following steps are applicable to all the spark plugs.

Warning:
The engine must be cool during inspection and
replacement of the spark plugs.

Disassembly:
Follow the instructions in the earlier chapters of this
manual “Air filter” and “Disassembly / Assembly of Air
Box” prior to the below steps.

Important:
Before removal of the spark plugs, remove any dust
from the cylinder cover with a stream of compressed air
to prevent dust from falling into the cylinder.

Disassemble:
Bolt (6) and Washer (7)
Support (8)
Rubber grommet (2)
O-ring (3)

Disconnection:
Disconnect the connector (X) from the coil (29), as
shown in Fig. A.

Remove: the coils (29)

Remove: the spark plugs (30) below, as shown in Fig. B.

Note:
During removal of the spark plugs, make every attempt to keep impurities from entering the engine through the
spark plug holes.

68
Spark Plug

Spark Plug Inspection


The following steps are applicable to all spark plugs.
Check the model of the spark plug.

Check:
1. Replace the spark plugs if there is any damage /
wear on the electrode (A), as shown in Fig. C.
2. Insulated part (B), as shown in Fig. C.
If the color is abnormal, replace the spark plug.
The normal color is medium-light brown.

Spark plug gap


Check:
Check the spark plug gap.
Clearance: 0.6 - 0.7mm

69
Spark Plug

Spark Plug Inspection


The following table contains typical damages to the spark plugs due to different causes and their solutions.

Overheated spark
Polluted spark plug
plug

Cause Solution Cause Solution


Over-rich fuel mixture Adjust fuel / Ignition advance Adjust ignition
Vaporization setting error vaporization timing.
systems. Inadequate air / fuel mixing Adjust air / fuel
ratio.
Electrical failure Check coil
Poor coil connection connection and Lack of coolant / or lubricating Add coolant and /
relevant impedance oil or lubricating oil.

Special cycling The speed of Too low torque of spark plug Fasten it to the
Long-term low speed motorcycle needs proper torque.
to be 80km/h.
Use of a too hot spark plug Use colder spark
Too cold of a spark plug Use a hotter spark plug as specified.
plug as specified.

70
Spark Plug

Installation of the Spark Plugs


The following steps are applicable to all spark plugs.

Warning: Lubricate the spark plug threads with a


copper-based grease.

Note: Before installation of the spark plugs, clean


the parts and the side contacting with the gasket.

Installation:
Install the spark plugs into the cylinder head. At first,
put the spark plug in the spark plug socket by hand
and tighten it, and then fasten it with the spark plug
wrench to the proper torque.

Torque: 9 ft·lb

Note:
The spark plugs should not be over torqued, the threads are staggered to prevent the threads on the cylinder head
from being damaged.
During installation of the spark plugs, do not allow any impurities to enter the engine through the spark plug holes.

Assemble:
Coil (29)
Rubber grommet (2) and O-ring gasket, as shown in Fig. D.

Connect:
Coil connector

Assemble:
Bolt (6) and Washer (7)
Support (8)
Tighten Bolt (6) to the proper torque.

Torque: 6 ft·lb

71
Valve Clearance

Valve Clearance Inspection

Note:
● Valve clearance can only be checked and adjusted when the engine has cooled down (indoor temperature).

Disassembly:
Remove the cylinder head cover from the engine (see
“engine/cylinder head cover” section of Chapter V)

Check:
● Measure the valve clearance between the cam and
the valve tappet with a thickness gauge.
Valve clearance
Standard:
Exhaust valve: 0.19 ∼ 0.25 mm (0.0075 ∼ 0.0099 in.)
Intake valve: 0.13 ∼ 0.19 mm (0.0051∼ 0.0075 in.)

Note:
● Insert the thickness gauge on the valve tappet
horizontally.
Suitable: [A]
Unsuitable: [B]
Feeler gauge: [C]
Insert horizontally: [D]
Cam: [E]
Valve tappet: [F]
Clipping the front end of feeler gauge on the valve
tappet is incorrect: [G]
★ If the valve clearance is not within the specified range, record the valve clearance first, and then adjust the
clearance.

Assembly:
Assembly should be conducted in the reverse sequence of disassembly (see “engine/cylinder head cover” section of
Chapter V)

72
Valve Clearance

Valve Clearance Adjustment

Adjustment of Valve Clearance


● In order to change the valve clearance, remove the
camshaft chain tensioner, camshaft and valve tappet.
Replace the currently used valve shim with a valve
shim of different thickness.

Note:
● Be sure to install the valve tappet and valve shim
into their original positions, mark their locations
before removing them to help facilitate this.
● In addition to the standard valve shims in the valve clearance adjustment table, the following valve shims can also
be used.
Adjustment of valve shims:
Thickness Thickness
1.325mm 1.825mm
1.375mm 1.875mm
1.425mm 1.925mm
1.475mm 1.975mm
1.525mm 2.025mm
1.575mm 2.075mm
1.625mm 2.125mm
1.675mm 2.175mm
1.725mm 2.225mm
1.775mm 2.275mm

Check:
● Remove dust or grease from the valve shims.
● Measure the thickness of the removed valve shim
[A].

73
Valve Clearance

Adjustment of Valve Clearance

Valve Clearance Adjustment Table for Exhaust Valves


Examples of the current valve shims
Thickness (mm) 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3

0.00~0.02 — — — — — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05
0.03~0.06 — — — — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1
0.07~0.10 — — — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15
0.11~0.14 — — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2

Examples of measured values (mm) of valve clearance

0.15~0.18 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25
0.19~0.25 valve clearance/adjustment is unnecessary
0.26~0.30 1.35 1.4 1.45 1.5 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.31~0.35 1.4 1.45 1.5 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.36~0.40 1.45 1.5 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.41~0.45 1.5 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.46~0.50 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.51~0.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.56~0.60 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.61~0.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.66~0.70 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.71~0.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.76~0.80 1.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.81~0.85 1.9 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.86~0.90 1.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.91~0.95 2.0 2.05 2.1 2.15 2.2 2.25 2.3
0.96~1.00 2.05 2.1 2.15 2.2 2.25 2.3
1.01~1.05 2.1 2.15 2.2 2.25 2.3 Thickness (mm) of valve shims to be installed
1.06~1.10 2.15 2.2 2.25 2.3
1.11~1.15 2.2 2.25 2.3
1.16~1.20 2.25 2.3
1.21~1.25 2.3

1. Measure the valve clearance (engine has cooled down).


2. Check the size of the current valve shims.
3. The valve clearance in the vertical column corresponds to size of the current valve shim in the horizontal column.
4. The values in the crossing blank spaces of vertical and horizontal columns are the specified values of the shim
size. When the size of the valve shim is equal to the value in the blank space, the size of the valve clearance is
suitable.
Example: Thickness of the current valve shim is 1.60 mm.
The measured valve clearance is 0.33 mm.
Replace the 1.60 mm valve shim with 1.70 mm valve shim.
5. Re-measure the valve clearance, and re-adjust it if necessary.

74
Valve Clearance

Adjustment of Valve Clearance

Valve Clearance Adjustment Table for Intake Valves


Examples of the current valve shims
Thickness (mm) 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3

0.00~0.04 — — — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215
0.05~0.08 — — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2
0.09~0.12 — 1.3 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25
0.13~0.19 valve clearance/adjustment is unnecessary
Examples of measured values (mm) of valve clearance

0.20~0.24 1.35 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.25~0.29 1.4 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.301~0.34 1.45 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.35~0.39 15 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.40~0.44 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.45~0.49 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.50~0.54 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.55~0.59 1.7 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.60~0.64 1.75 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.65~0.69 1.8 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.70~0.74 1.85 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.75~0.79 1.9 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.80~0.84 1.95 2.0 2.05 2.1 215 2.2 2.25 2.3
0.85~0.89 2.0 2.05 2.1 215 2.2 2.25 2.3
0.90~0.94 2.05 2.1 215 2.2 2.25 2.3
Thickness (mm) of valve shims to be installed
0.95~0.99 2.1 215 2.2 2.25 2.3
1.00~1.04 215 2.2 2.25 2.3
1.05~1.09 2.2 2.25 2.3
1.10~1.14 2.25 2.3
1.15~1.19 2.3

1. Measure the valve clearance (engine has cooled down).


2. Check the size of the current valve shims.
3. The valve clearance in the vertical column corresponds to size of the current valve shim in the horizontal column.
4. The values in the crossing blank spaces of vertical and horizontal columns are the specified values of the shim
size. When the size of the valve shim is equal to the value in the blank space, the size of the valve clearance is
suitable
Example: Thickness of the current valve shim is 1.85 mm.
The measured valve clearance is 0.36 mm.
Replace the 1.85 mm valve shim with 2.05 mm valve shim.
5. Re-measure the valve clearance, and re-adjust it if necessary.

75
Brake Adjustment

Adjustment of Front Hydraulic Brake

Adjustment
Position of the brake handle is shown in Fig. A
(“X” is the distance between the throttle and the
brake handle)

Note:
Push the brake handle forward, to offset the spring
tension, at the same time, rotate the ring nut “Y”,
and adjust its position clockwise or
counterclockwise until the brake handle is in a
suitable position.

Position of the ring


Distance
nut
Away from the
Position 1
handle
Position 4 Close to the handle

Warning:
If the brake lever feels soft when you pull it in, there may be air in the brake system. Before using the motorcycle,
it is necessary that you discharge any air in the brake circuit. Air in the brake circuit will reduce braking
performance, and may even allow the vehicle to become unstable, and cause accidents. So, check the system and,
if necessary, remove any air in the brake circuit.

Important:
After adjusting the position of the brake lever, make sure that there is no braking drag.

76
Brake Adjustment

Adjustment of Rear Hydraulic Brake

Adjustment:
Adjust the position of the brake pedal with locknut and
the master cylinder pin, as shown in Fig. A
Loosen the locknut B
Unscrew the master cylinder pin A

Position of the Position of the brake


master cylinder pin pedal
Clockwise The pedal goes up
The pedal goes
Counter-clockwise down

Warning:
If the brake lever feels soft when you pull it in, there may be air in the brake system. Before using the motorcycle,
it is necessary that you discharge any air in the brake circuit. Air in the brake circuit will reduce braking
performance, and may even allow the vehicle to become unstable, and cause accidents. So, check the system and,
if necessary, remove any air in the brake circuit.

Important:
After adjusting the position of the brake pedal, make sure that there is no braking drag.

77
Brake Fluid Inspection

Inspection/Replacement of the Front Brake Fluid

Parking: Park the vehicle on flat ground.

NOTE: Stand the motorcycle up with a rear stand and


make sure it is vertical.

Check: the brake fluid level


If the brake fluid is below the minimum mark on the
observation window (A) in Figure A, add the
recommended brake fluid until it reaches the correct
fluid level.

Liquid adding procedure:


When the motorcycle is on flat ground, unscrew the master cylinder cover (B) from the brake master cylinder, as
shown in Fig. A

Check:
Check the brake fluid cylinder diaphragm on the cover.
If there is any damage/wear, replace the brake fluid
cylinder diaphragm

Important:
Brake fluid may damage painted surfaces or plastic
parts. Thus, wrap the pump with absorbent paper or a
rag, and clean up any spilled brake fluid immediately.
Add fluid, until the fluid level is above the observation
window of the pump, as shown in Fig. C

Warning
Use only the specified brake fluid. Other brake fluids may
cause deterioration of the rubber gaskets, leakage, and
improper operation of the braking system.
Use the same brake fluid in the system when adding brake
fluid. Different brake fluid mixtures may cause adverse
chemical reactions, which can lead to degradation of the
braking system.
Be careful not to let water flow into the fluid bottle when
adding brake fluid. Water will significantly reduce the
boiling point of the brake fluid and will produce vapor
bubbles when it is heated, which will cause degradation of the braking system.

78
Brake Fluid Inspection

Inspection/Replacement of the Front Brake Fluid


Replacement of brake fluid:
1. Place the master cylinder horizontally, and remove
the brake fluid cylinder cover.
2. Attach a tube to the end of the fluid drain screw,
and place a drip pan at the front end of the tube, as
shown in Fig. B
3. Pump and hold the lever then loosen the fluid
drain screw, once the fluid escapes tighten the screw.
4. Repeat step 3 several times until the discharge tube
no longer discharges dirty brake fluid.
5. Tighten the oil drain screw.
6. Fill with brake fluid until it is above the lower
limit.
7. Operate the brake handle slowly, until bubbles no
longer come out of holes in the brake cylinder and
the brake lever feels solid.
8. After adjustment is completed, conduct assembly
in the reverse sequence of disassembly.
Note:
Add brake fluid at the same time. The brake fluid
should not fall below the lower limit.
Tighten the drain screw to the following torque:

Torque 4.5 ft·lb


Sequence for Removing Air from the Brake System
1. Remove the brake fluid cylinder cover.
2. Remove the brake fluid cylinder diaphragm.
3. Attach a tube to the end of the fluid drain screw, and place a drip pan at the other end of the tube.
4. After pumping the brakes several times, hold the brake lever tight, loosen the fluid drain screw about a 1/2 a
turn, and then tighten it rapidly.
5. Repeat the above action until all the bubbles have been completely discharged out of the fluid drain screw.
6. Install the brake fluid cylinder diaphragm
7. Install the brake fluid cylinder cover
Note:
Do not let go of the brake lever before re-tightening the fluid drain screw.
Note:
Add brake fluid at the same time. The brake fluid should not fall below the lower limit.

79
Brake Fluid Inspection

Inspection/Replacement of the Rear Brake Fluid

Parking: Park the vehicle on flat ground

NOTE: Stand the motorcycle upright with a rear


stand and make sure it is vertical.

Check: the brake fluid level


If the brake fluid is below the minimum mark on the
reservoir (A) in Figure A, add the recommended
brake fluid until it reaches the upper fluid level mark.

Important:
Brake fluid may damage painted surfaces or plastic
parts. Thus, wrap the reservoir with absorbent paper
or a rag, and clean up any spilled brake fluid
immediately.

Adding fluid:
When parked on flat ground, unscrew the fluid
reservoir cap (B) from the fluid reservoir, as shown
in Fig. B

Check:
Check the reservoir diaphragm at (C). If there is any
damage/wear, replace the reservoir diaphragm, as
shown in Fig. C

80
Brake Fluid Inspection
Inspection/Replacement of the Rear Brake Fluid
Add liquid, until it is above lower limit.
Warning
Use only the specified brake fluid. Other brake fluids may cause deterioration of the rubber gaskets, leakage, and
improper operation of the braking system.
Use the same brake fluid in the system when adding
brake fluid. Different brake fluid mixtures may cause
adverse chemical reactions, which can lead to
degradation of the braking system.
Be careful not to let water flow into the fluid bottle
when adding brake fluid. Water will significantly
reduce the boiling point of the brake fluid and will
produce vapor bubbles when it is heated, which will
cause degradation of the braking system.
Sequence for Removing Air from the Brake System
1. Remove the fluid reservoir cap.
2. Remove the fluid reservoir diaphragm.
3. Attach a tube to the end of the oil drain screw (D),
and place a drip pan at the other end of the tube.
4. Remove bolt (E) from the rear brake caliper to lift
the brake cylinder
5. After braking several times, press and hold the
brake pedal down, loosen the fluid drain screw
about 1/2 a turn, and then tighten it rapidly.
6. Repeat the above action until all the bubbles have
been completely discharged out of the fluid drain
screw.
7. Install the brake reservoir diaphragm.
8. Install the brake reservoir cap.
Note:
Do not let go of the brake pedal before re-tightening the fluid drain screw.
Note:
Add brake fluid at the same time. The brake fluid should not fall below the lower limit.
Tighten the drain screw to the following torque:

Torque 4.5 ft·lb


Upon completion of the fluid flushing procedure, lower the caliper, and reinstall fastening bolt (D) to the
following torque:

Torque 22 ft·lb

81
Check of Brake Fluid

Check of Rear Brake Fluid Level/Add Brake Fluid

Replacement of brake fluid:


1. Place the oil cup horizontally, and remove the oil cup cap.
2. Mount a tube on the front end of the oil drain screw, and prepare a drip pan at the front end of the tube.
3. Loosen the oil drain screw.
4. Repeat braking several times until the oil discharge screw no longer discharges brake fluid.
5. Tighten the oil drain screw.
6. Add brake fluid until it is above the lower limit.
7. Press on the brake pedal, and fill the tube with brake fluid.
8. Operate the brake pedal slowly, until bubbles no longer come out of holes in the brake cylinder and the brake
pedal feels solid.
9. Release air.
10. After adjustment is completed, conduct assembly in the reverse sequence of disassembly.

Note:
Add brake fluid at the same time. The brake fluid should not fall below the lower limit.
Tighten the drain screw to the following torque:

Torque 4.5 ft·lb

82
Brake Pad Inspection

Front and Rear Brake Pad Inspection


The following procedures are applicable to all brake pads.

Check:
Front brake pads/rear brake pads
Wear limit of front and rear brake pads
If the wear limit has been reached, replace the brake
pads in pairs.

Brake Pad Standard Wear limit


Front Brake Pad 7.8mm 3.8mm
Rear Brake Pad 7.0mm 3.7mm

Note:
For replacement of brake pads, see “Front brake pad / rear brake pad” “Front and rear brake / rear brake pads” in
the “Motorcycle” chapter.

83
Brake Hose Inspection

Brake Hose Inspection


The following procedures are applicable to all brake
hoses and all brake hose clamps.

Check:
Front / Rear brake hoses.

If there are any signs of cracks / wear or damage,


please replace them.

Check:

Clamp (A) of the front brake hose, shown in Fig. A.


If the front brake hose is loosened, tighten the clamp
bolt.

Check
Clamp (A) of the rear brake hose, shown in Fig. B. If
the rear brake hose is loose, tighten it using the cable
clamp.

84
Drive Chain Adjustment

Drive Chain Adjustment

Note: When the engine is running, do not check or


adjust the drive chain.

Note: When checking the drive chain, conduct the


adjustment at the point which looks loosest.

Warning: If the drive chain is too tight, damage

may occur to the engine or other key parts; if the drive


chain is too loose, it may fall off and damage the
engine or cause an accident. We recommend keeping
the chain slack within the specified range.

Parking: Park the motorcycle on flat ground.

Warning: Support the motorcycle using a rear

stand, to avoid tipping and to lift the rear wheel.


Rotate the rear wheel several times to find the position
where the drive chain is loosest.

Check: If the drive chain slack is not within the

specified value, adjust it. Fig. A

Drive Chain Slack 10 - 20mm

Adjustment: Tension of Drive Chain. Fig. B


1. Loosen the rear wheel axle (C).
2. Loosen the lock nuts (A) on each side using an open-ended wrench.
3. Screw into or out the adjusting bolt (B), until the specified slack has been reached.
4. Tighten the lock nut (A).
5. Fasten the rear wheel axle (C).
Tighten the rear wheel axle according to the following torque.

Torque 89 ft·lb

Screw in (B) Slack increases


Screw out (B) Slack decreases

85
Drive Chain Adjustment

Drive Chain Adjustment


Important:
If the drive chain slack is too little, damage may be
caused to the engine and other main components and
the chain may break. To prevent this phenomena, the
chain slack must be kept within the specified range.

Note:
Make sure the scale of right chain adjusting block is at
Left Right
the eighth slot (E) of the swing arm (count backwards),
and the scale of left chain adjusting block is at the eighth
slot (D) of the swing arm (count backwards). Fig. C
Always ensure that the rear wheel is aligned using the scale on each side of the swing arm.

Lubrication of the Drive Chain

Important:
The drive chain consists of many interacting chain rollers. The chain needs proper maintenance to prevent rapid
deterioration.
Therefore, we suggest maintaining the drive chain weekly, especially when using it in the places with a lot of dust.
This motorcycle is equipped with a drive chain that has rubber O-rings which are installed between chain plate and
roller. The drive chain should not be cleaned using a steam nozzle or pressure washer, corrosive solvent, or a brush
with stiff bristles, to avoid damaging the rubber O-rings.
We suggest using only specifically designed chain cleaners and O-ring chain lubricants designed for on road
motorcycles.

Note:
Chain lubricants will stick to the chain better if it is lubed after the chain has become warm from use. The best time
to lube the chain is after the bike is shut down when parked for the day/night when the engine is still warm.

86
Steering Stem Bearing Adjustment

Steering Stem Bearing Adjustment


Parking: Park the motorcycle on flat ground

Note:
Support the motorcycle using a rear stand; lift the front
wheel off of the ground using a jack under the header
pipe.

Check: Steering Stem Bearing Adjustment


Hold the end of the handlebar, gently swing the front
forks left and right, adjust the bearings if there is any
sticking/binding point or if there is any excessive front
to rear play. Fig. A

Disassembly: Handlebars (see special section)

Disassembly: Upper handlebar holder (B), Fig. B

Loosening: Loosen the bolt (A) for the upper


triple clamp, Fig. B

Disassembly:
Remove the fastening bolt (G) using special tool (F),
Fig. C

87
Steering Stem Bearing Adjustment

Steering Stem Bearing Adjustment


Adjustment:
Faucet handle
1. Remove the lock nut (D) from the steering stem,
and loosen the retainer nut (E). Fig. D
Tighten the retainer nut (E) using the special tool.

Tighten the retainer nut (E) to the following value:

Torque 22~26 ft·lb


2. Rotate the handlebars to the left and the right 2-3 times, and ensure that there is no binding and the bearing
race is not loose;
3. Loosen the retainer nut by 1/4 turn and then tighten it, and tighten the retainer nut (E) using the special tool.

Tighten the retainer nut (E) to reach the following value,

Torque 15~18 ft·lb


4. Tighten lock nut (D) using the special tool,

Tighten lock nut (D) to reach the following torque

Torque 44 ft·lb

Warning:
Do not tighten locking nut (D) excessively

Check:
Ensure that the steering stem is not loose, rotate the front fork to the left and the right to ensure that there is no
binding point. If there is any binding point, disassemble the upper and lower triple clamps, and check the upper and
lower steering bearings.

88
Steering Stem Bearing Adjustment

Steering Stem Bearing Adjustment


Assembly:
Conduct assembly in inverse order of disassembly.

Recheck: Steering play/feel


Hold the end of the handlebar, rotate it to the left and the right, and repeat the operations to adjust the steering stem
bearings if there is any sticking / binding points.

89
Front Fork Inspection

Front Fork Inspection


Parking: Park the motorcycle at flat ground.

Note: Support the motorcycle correctly, to avoid it


tipping over.

Check
Outer cylinder of shock absorber (A), Fig. A
Inner cylinder of shock absorber (B), Fig. A
If there is any damage, please replace
If there is any leakage, please replace the oil seals

Keep: The motorcycle vertical

Apply: Front brake

Check:
Front fork operation
Push down firmly on the handlebars a few times to
ensure that the front fork travels without binding. Fig.
B

Note:
If it doesn’t move smoothly, please repair it

90
Rear Shock Absorber

Rear Shock Absorber Adjustment

Note: Support the motorcycle correctly, to avoid


tipping.

Adjustment: Adjust the spring preload, Fig. A


The rear shock absorber is equipped with an
adjustment ring nut (A) and a locking ring nut (D) for
spring preload adjustment.

1. Loosen the above-mentioned locking ring nut (D) using a spanner wrench.
2. Loosen the above-mentioned adjusting ring nut (A) using a spanner wrench, to adjust the rear shock absorber
to appropriate hardness.
 Rotate the adjusting ring nut (A) in the direction of (B) to increase the spring preload, to make the rear
shock absorber stiffer.
 Rotate the adjusting ring nut (A) in the direction of (C) to reduce the spring preload, to make the rear
shock absorber softer.
3. Upon completion of the adjustment, tighten the locking ring nut (D) using a spanner wrench

91
Front and Rear Tire Inspection
Inspection
The following procedures are applicable to the front and rear tires.
Check
Adjust the tire pressure if it is not within the specified
value, Fig. A.
Warning:
When checking and adjusting tire pressures, the tires must
be at room temperature.
Tire pressures and suspension should be adjusted
according to the total weight (including luggage, rider,
passenger and accessories), and assumed riding speed
should also be considered.
Tires may be damaged when overloaded during operation,
causing the risk of accidents and injuries.
Overload should be avoided.
Cold Tire pressure Front Rear
Load below 198 lbs. * 34 psi 36 psi
220 lbs. to the maximum 35 psi 38 psi
load*
Load includes luggage, rider, passenger and
accessories.

Specifications of front tire 110/70-17 M/C


Specifications of rear tire 140/70-17 M/C
Warning: Tires become very dangerous when their
tread is worn out.
If the tread reaches the tread wear indicator (TWI),
replace the tire immediately.

Check: Tire surface, Fig. B


Tire damage / wear → Replace

Minimum depth of tread pattern: 1mm

A. Depth of tread pattern


B. Sidewall
C. Tread Wear Indicator (TWI)
Warning:
When a tire is new, its grip level is not as good as that when slightly worn. Therefore, it is recommended that you
do not exceed 60 mph until the tires have been used for at least 60 miles to ensure the tires are properly scrubbed
in.

92
Battery Charging and Inspection
Battery
Warning:
The battery will produce an explosive gas composed of hydrogen. The battery contains electrolyte composed of
sulfuric acid which is poisonous and a highly corrosive substance. Therefore, the following precautions should be
followed:

 When handling batteries or working near them, please wear goggles and protective gloves.
 Batteries must be charged in an adequate place with good ventilation.
 The battery must be kept away from fire, sparks or open flames (e.g., welding equipment, lit cigarettes,
etc.).
 When charging or handling batteries, do not smoke.
 Batteries and electrolyte should be placed out of the reach of children.
 Do not get electrolyte on yourself or your clothing because it may cause severe burns or cause permanent
eye damage.
First Aid Treatment if Accidentally Exposed:
Detoxification methods (external
contact):
Skin: Wash with soap and water
Eyes: Flush with plenty of water for 15 minutes and
seek immediate medical attention.

Detoxification methods (internal):


Drink plenty of water or milk, and then milk
containing magnesium oxide, an egg or vegetable oil,
and seek immediate medical attention.
Important:
The battery is sealed. Do not remove the sealing cover
under any circumstances, because this will damage the
balance between the batteries cells and effect battery
performance.
The charging time, amperage and voltage of this
battery is different from that of traditional batteries. If
the battery is overcharged, the electrolyte level will be
relatively lowered. Therefore, please be very careful
when charging the battery.
Note: Check the battery condition by measuring the
voltage at the battery terminals.
Disassembly:
Remove the seat cushion using the key, Fig. A

93
Battery Charging and Inspection
Battery
Removal: Disconnect the terminal ends from the battery, Fig. B
Important: First disconnect the negative cable
from the battery (A), and then disconnect the positive
cable (B). Fig. B
Removal:
Battery
Remove the four bolts (C) which are used to attach the
battery hold down bracket, and then remove the
battery (D)
Check: Battery voltage
Connect a multimeter to the terminals of the battery,
Fig. C
As shown on the chart in Figure D, check battery charging
Note: Measure battery voltage by connecting a
multimeter to the positive and negative battery
terminals. If the open-circuit voltage is equal to or
exceeds 12.8V, charging is not required.
Example:
Open-circuit voltage = 12.0V
Charging time = 6.5 hours
Battery charge amount = 20 -30%
Charging
Battery (see the picture describing suitable charging
methods)
Important: DO NOT quick charge the battery.

Warning:
Do not remove the cover which is used to seal the
Open-circuit voltage (V)

Relationship between open-circuit


battery. voltage and charging time at 68F degrees
Do not use quick chargers, they will send high
amperage current to the battery at a high rate of speed;
this may cause overheating and damage to the battery.

If the charging current of the battery cannot be


adjusted, be careful not to overcharge it. Charging time (hour)
These values change with temperature variation, battery plate
Batteries should be removed from the motorcycle and electrolyte level
when charging. (If the battery has to be charged in the
motorcycle, disconnect the negative cable from the battery terminal)

To reduce the possibility of generating sparks, connect the battery charger to power only after connecting the charger
leads to the battery.

94
Battery Charging and Inspection

Battery

Make sure the charger is unplugged from the power


source before connecting it to the battery terminals.

Open-circuit voltage (V)


Ensure that the battery charger clamps are completely
connected to the battery terminals, and there are no
shorts. Corroded terminal ends will generate heat in
the contact area, and sparks can be generated. In this Room
Temperature
case clean the terminal ends before charging.

If battery is overheated during charging, immediately Battery Charging State


disconnect the charger and let the battery fully cool
before continuing to charge. Overheated batteries can explode!

Recharge
As shown in Fig. F, the voltage table after charging
the open-circuit voltage of battery for 30 minutes
Open-circuit voltage (V)

and completing charging, or before measuring open-


circuit voltage.

Test open-circuit voltage

95
Battery Charging and Inspection

Battery
Charging method: use a charger with variable current (voltage)
Battery charger
Note:
miltimeter
Measure the open-circuit voltage of the battery 30 minutes after completing
charging.
Set the charging voltage to 16-17V (low setting may cause insufficient
charging, while high setting may cause overload of the battery)
Connect one battery charger and one multimeter to battery, and then start
charging

96
Before charging, measure open-
circuit voltage

Connect one battery charger and one


multimeter to battery, and then start
charging

Check whether the voltage is higher


than the standard value marked on the
battery

Set the charging voltage to be 20-24V


by setting the voltage of charger

Set the voltage, and thus make the Monitor the ammeter for 3 to 5
current is equal to standard charging minutes, confirm whether the
amount standard charging current has been
reached

Set time based on the charging time If battery does not exceed the
suitable for open-circuit voltage. Refer standard charging current after 5
to the descriptions provided with minutes, replace the battery
battery

If the charging time is more than five hours, it is recommended to check the
charging current after five hours. If amperage changes, set again the voltage
to obtain the standard charging current.

Measure the open-circuit voltage of battery 30 minutes after stopping


charging
12.8V or higher> charging is completed
12.7V or lower> must be charged

97
Battery Charging and Inspection

Battery
Charging method: Use a charger with variable current (voltage)

Note:
Measure the voltage of the battery 30 minutes after completing charging
Set the maximum charging time to be 20 hours

Note:
To ensure the maximum performance and durability of the battery, we recommend using an electronic charger
which can provide stable charging voltage and current, and thus achieve the desired charging technology of the
battery.

Before charging, measure


open-circuit voltage

Connect one battery charger and one


ampmeter to battery, and then start charging

Check whether the voltage is higher than the


standard value marked on the battery

This kind of charger cannot be


Charge the battery, until the used to charge these batteries. It is
recommended to use chargers
charging voltage reaches 15V with variable voltage.

Measure the open-circuit voltage of battery 30 minutes after stopping


charging
12.8V or higher> charging is completed
12.7V or lower> must be charged
Lower than 12.0V > replace battery

98
Battery Charging and Inspection

Battery

Installation:
Battery
Tighten the 4 bolts (C), after installing the battery hold
down bracket.

Connection: Connect the cables to the battery

terminals.

Important: First connect the positive cable (B) of


the battery (D), and then the negative cable (A), Fig.
G

Check: Battery terminals


If there is any dirt, remove the dirt using a metal brush then check for loose terminal bolts.

99
Fuse Inspection

Fuses
The following procedures are applicable to all fuses.

Important: To prevent short circuits, the ignition is


always set to the OFF position before checking fuses.
Open the seat cushion using the key, Fig. A

Remove the fuse box cover (B), Fig. B

Check: Fuse
Connect a multimeter to the fuse and check whether it
is in good condition.

Note: Set the multimeter to the ohm function.


If the reading on the multimeter is “∞”, replace the
fuse.

Replacement: Burned-out fuse


Rotate the ignition switch to OFF

Install a new fuse, and ensure it is of the correct


amperage.
Turn ON the ignition switch, ensure the circuit is
functional. If the fuse immediately burns out, check
for shorts.

100
Fuse Location

Fuses

Warning:
Do not use fuses whose amperage is not specified. Makeshift fuses or ones with incorrect amperage may cause
irreversible damage to the electrical system, affect the normal operation of the lights and ignition, and can even
result in fire.

Fuse Position / Type


Reference drawing C
A. Fuel pump: 15A (blue)
B. Fan: 15A (blue)
C. ECU: 15A (blue)
D. Empty
E. Power lock: 10A (red)
F. Empty
G. Spare fuse 10A (red)
H. Spare fuse 15A (blue)
I. Spare fuse 15A (blue)

101
Replacement of the Headlight Bulb

Replacement of the Headlight Bulb


The following procedures are applicable to the
headlight.

Disassembly:
Remove the headlight support fastening bolts (1).

Tilt the combination headlight and fairing.


Remove the self-tapping screws (2).
Remove the rear decorative plate of the headlight
fairing.

Remove the self-tapping screws (3).


Remove the headlight dust cover.

102
Replacement of the Headlight Bulb

Replacement of the Headlight Bulb


Unplug the socket connector from the headlight bulb
(4), remove the socket seat, release the clamp spring
and remove the bulb.

In the following figure: (4) is the low-beam bulb and


(5) is the high-beam bulb. Removal for both the high
and low beam bulbs is the same as above.

Align the position of the bulb base to fit the socket,


and install the new light bulb.
Bulb type: H7 (12V / 55W) (High and Low Beam)
* Note
DO NOT change the headlight bulbs when the
headlight is still hot from use, wait until it has cooled down.

Assembly:
Install the headlight in reverse order to disassembly.

Note:
Avoid directly touching the glass part of bulb and do not make it oily; otherwise, the transparency, service life and
luminous flux of the bulb will be affected.
If it is stained with oil or you have touched the glass, completely wipe it with a cloth with alcohol or other solvents.

103
Adjustment of the Headlight

Adjustment of the Headlight


To adjust the headlight beam follow the steps below:
Park the motorcycle about 10m (30 feet) away from a
vertical wall, and park it on a perfectly flat surface. Fig.
A
Sit on the motorcycle in your normal riding position.
Check where the highest point of the headlight beam
falls on the wall, make it 1/10 lower than the horizontal
axis of headlight.
If the beam does not fall within this range, make
adjustments to keep it in the correct position.

Adjustment:
Use the adjusting screw (A) on the back of the
headlight to adjust the beam of the headlight, Fig. B

Adjustment screw in the upper left corner:


Rotate the screw counterclockwise to lower the
beam.
Rotate the screw clockwise to raise the beam.

Adjustment screw in the lower left corner:


Rotate the screw counterclockwise to move the
beam towards the left.
Rotate the screw clockwise to move the beam
towards the right.

104
Front Signal Light Bulb

Replacement of the Front Signal Light Bulb

Replacement of front signal lights


The front turn signal lights and headlight are attached
to the same body. As shown in the figure, there is one
front signal bulb ① on the left and right respectively.
(1) Conduct operations according to the prompts in
the section “Replacement of the headlight
bulb”.
(2) Remove the damaged signal, and replace it with a
new one as these lights are LED the entire unit
must be replaced.

Assembly:
Install the light in inverse order of disassembly.

105
Rear License Plate Light

Replacement of the Rear License Plate Light

Replacement of the Rear License Plate Light


1. Remove the mounting screws for the rear license
plate light (1), and then remove the rear license
plate light.

2. Remove the damaged bulb, and replace it with a


new bulb with the same specifications and
model.
Bulb specifications: W5W (12V/5W)

106
Rear License Plate Light

Replacement of the Rear License Plate Light

(1) After replacing bulb, install the light in inverse


order of disassembly.

107
Section IV Motorcycle
Front Wheel and Front Brake Rotors........................................................................................................ 109
Rear Wheel and Rear Brake Rotor ........................................................................................................... 118
Front and Rear Brakes .............................................................................................................................. 127
Front and Rear Brakes / Front Brake Pads ....................................................................................... 129
Front and Rear Brakes / Rear Brake Pads......................................................................................... 130
Front and Rear Brakes / Front Brake ................................................................................................ 131
Front and Rear Brakes / Rear Brake ................................................................................................. 136
Front Suspension ...................................................................................................................................... 142
Front Suspension / Front Fork .................................................................................................................. 143
Front Suspension / Front Shock Absorber ................................................................................................ 144
Control ...................................................................................................................................................... 154
Control / Control............................................................................................................................... 154
Control / Handlebar .......................................................................................................................... 155
Rear Shock Absorber ................................................................................................................................ 162
Drive Chain and Rear Swing Arm ............................................................................................................ 166
Drive Chain and Rear Swing Arm .................................................................................................... 166
Drive Chain and Rear Swing Arm / Rear Swing Arm ...................................................................... 170
Frame ........................................................................................................................................................ 173
Frame / Engine Assembly................................................................................................................. 174
Frame / Rear License Plate Support ................................................................................................. 178
Frame / Side Stand ............................................................................................................................ 181
Frame / Left Foot Pedal .................................................................................................................... 184
Frame / Right Foot Pedal .................................................................................................................. 187
Muffler ...................................................................................................................................................... 190
Fairing Assembly ...................................................................................................................................... 195
Covering Parts / Front Fender........................................................................................................... 197
Covering Parts / Rear Fender ............................................................................................................ 200
Assembly of the Covering Parts / Rear Lower Fender and Chain Cover ......................................... 204
Covering Parts / Fuel Tank Cowling and Lower Fairing .................................................................. 207
Covering Parts / Tail Cowling .......................................................................................................... 211
Covering Parts / Headlight Cowling ................................................................................................. 216
Lights ........................................................................................................................................................ 219
Lights / Rear Taillight....................................................................................................................... 220
Lights / Front Turn Signal Lights ..................................................................................................... 220
Lights / Rear Turn Signal Light ........................................................................................................ 222

108
Front Wheel and Front Brake Rotors

Removal of the Front Wheel

Parking: Park the motorcycle on flat ground

Note:
Support the motorcycle using a rear stand; lift the front
wheel off of the ground using a jack under the header
pipe.

Disassembly: Disassemble the fastening bolts


(A) from the two brake calipers, Fig. A

Separation: Right front caliper

Note
Repeat the above operations for the left front caliper.

Note
After removing the calipers, do not pull the front
brake lever.
Loosen: pinch bolts (B), Fig. B

Disassembly:
Front wheel axle, Fig. C
Front wheel

109
Front Wheel and Front Brake Rotor

Disassembly and Assembly of the Front Wheel

No. Name Quantity


1 Bolt M8×16 12
2 Front brake rotor ф260×4 2
3 Left wheel spacer 1
4 Tire 120/70-17 1
5 Front wheel rim 1
6 Front wheel axle 1
7 Valve Stem (not pictured) 1
8 Right front wheel spacer 1
9 Bearing spacer sleeve 1
10 Dust seal 2

11 Bearing 6204-2RS 2

110
Front Wheel and Front Brake Rotor

Disassembly and Assembly of the Front Wheel

Disassembly:
After removing the front wheel from the front forks,
remove the 6 bolts (1) used for attaching the two brake
rotors (2), Fig. A
If both rotors need to be replaced, please conduct the
operations as follows:

Note
Heat may be necessary to more easily remove the
rotor bolts as they are installed with locktite. Use
a torch to heat each bolt taking care not to use too
much heat that could cause damage to the painted
wheel.

Assembly:
Insert the front brake rotor (2) into the edge of wheel rim (5).
After adding one drop of thread locker to the end of the threads, insert the 6 fastening bolts (1)

Note
Repeat the above steps for the right front brake rotor.
The following procedure is applicable to both of the brake rotors.
Tighten the bolts for the rotor in a crisscross pattern as shown in Fig. A
Fasten the 6 bolts to the following torque:

Torque 16 ft·lb

111
Front Wheel and Front Brake Rotor
Front Brake Rotor Wear Inspection
The following procedures are applicable to both brake
rotors.
Check: Brake Rotor
If there is any damage / wear, please replace

Brake Rotors Deformation limit


Front brake rotor 0.1mm
Rear brake rotor 0.15mm
Park the motorcycle on flat ground, lift the wheel using a
front stand or use a rear stand and a jack under the header.
Before measuring the runout of the front brake rotors,
ensure that the front wheel will spin freely.
Remove the front brake calipers.
Place the gauge at the surface of brake rotor at a right
angle.
Measure the runout 1.5mm (0.05in) below the edge of the
brake rotor. Fig. A

Note
Tighten the bolts for the brake rotor one by one in a
crisscross pattern, Fig. C

Tightening torque
Brake Rotors Tightening torque
Front brake rotor 16 ft·lb
Rear brake rotor 7 ft·lb
Measurement:
Brake rotor thickness
Measure the brake rotor thickness at several different
points, Fig. D
If it exceeds the specifications, please replace.

Brake Rotors Standard Lower wear


limit
Front brake rotor 4.0mm 3.0mm
Rear brake rotor 5.0mm 4.0mm

112
Front Wheel and Front Brake Rotor

Check / Replacement of the Front Wheel Bearings

Check:
Front wheel bearings
If the front wheel rotates irregularly or is binding,
please replace wheel bearings.

Replacement:
Front wheel bearings
Remove the front wheel bearings (A) using a
conventional bearing remover. Fig. B
Install the new wheel bearings in inverse order of
disassembly.

Important

When installing the bearings, do not touch the inner


seat (B) or the ball bearing (C) of the wheel. Only
contact the outer seat (D) of the bearing, Fig. C

Note
The tool used should be suitable for the diameter of
the outside (D) of the wheel bearing, Fig. C

113
Front Wheel and Front Brake Rotor

Inspection / Replacement of the Front Wheel Axle

Check:
Front wheel axle
Roll the front wheel axle (A) on a flat surface, Fig. A
If there is any run out, please replace.

Warning
If the front wheel axle is bent, do not try to straighten
it using force or a press.

Check:
Front wheel
Please refer to “Chapter III front and rear tires
inspection”
Front wheel rim
If there is any run-out, please replace

Measurement:
Radial run-out of the wheel (B). Fig. B
Axial run-out of the wheel (C). Fig. B
If it exceeds the specified limit, please replace

Run-out Limit
Longitudinal 0.05mm
Lateral 0.05mm

114
Front Wheel and Front Brake Rotors

Static Balance Adjustment of the Front Wheel

Note:
 After replacing the tire, wheel rim or both, perform a static balance of the front wheel.
 When adjusting the static balance of the front wheel, the brake rotors should be installed.

Remove:
Any old balancing weights

Inspect:
 Gravity point of the front wheel

Note:
Place the front wheel in a proper balancing stand
1. Rotate front wheel; Fig. A

2. When the front wheel stops rotating, make an


“X1” mark at the bottom of front wheel; Fig. B

3. Rotate the front wheel by 90° to make “X1”


mark stop at the position shown in the figure;
Fig. C
4. Release the front wheel;

115
Front Wheel and Front Brake Rotors

Static Balance Adjustment of the Front Wheel


5. When the front wheel stops rotating, make an
“X2” mark at the bottom of the front wheel; Fig. D
6. Repeat the above steps 3 to 5 times, until all marks
stop at the same position;
7. The position where all the marks stop is the
gravity point of the front wheel “X”.

Adjustment:
 Static balance of the front wheel
1. Install a “balance weight” (1) at the lower
opposite side of the balance point “X” on the
wheel rim, Fig. E

Note:
Start with the lightest balancing weight.

2. Rotate the front wheel by 90° to move the gravity


point to the position shown in the figure. Fig. F
3. If the gravity point does not stop at this position,
please use a heavier balancing weight;
4. Repeat steps 2 and 3, until the front wheel is
balanced.

Check
 Static balance of front wheel
Rotate the front wheel, and ensure that it will stop at
each position shown in the figure. Fig. G
If the front wheel remains still at each position,
please re-balance it.

116
Front Wheel and Front Brake Rotors

Front Wheel Assembly

Assembly:
Insert the entire front wheel between the two front
shock absorbers.
First apply grease to the front wheel axle (C) and then
insert it.
Fasten the front wheel axle using the special tools.

The tools used for tightening the front wheel axle are
shown in the list of special tools.

Torque 74 ft·lb

Assembly:
Insert the two bolts (B) and tighten them by hand.
Press the handlebars downward two to three times to
align the front wheel axle in the forks, Fig. B
Fasten the two bolts (B) using the following torque:

Torque 6 ft·lb

Assembly:
Right brake caliper, insert fastening bolts (A). Fig. C
Use the following torque to fasten the two bolts (A):

Torque 33 ft·lb

Note
For the left brake caliper, please repeat the above
steps. Put the calipers between the brake rotors, and
ensure that there is enough of a gap between the
brake pads.
Check whether the routing of the brake hose is correct.

117
Rear Wheel and Rear Brake Rotor
Disassembly of the Rear Wheel

No. Name and specifications Quantity No. Name and specifications Quantity
1 Rear wheel axle 1 13 Bearing 6204-2RS 2
2 Right rear wheel spacer 1 14 Dust seal 1
3 Bolt M6×20-10.9-ZG 6 15 Bolt M10×1.25×41 5
4 Rear brake rotor 1 16 Sprocket carrier hub 1
5 Valve Stem 1 17 Rear sprocket 1
6 Rear wheel rim 1 18 Locking nut M10×1.25 5
7 Bearing spacer sleeve 1 19 Sprocket carrier spacer 1
8 Tire 160/60-17 1 20 Bearing 30×62×23.8 1
9 Locking nut M20×1.5 1 21 C-Clamp Φ62 1
10 Rear wheel dampers 5 22 Chain 108 Link 1
11 Left rear wheel spacer 1 23 Dust seal 1
12 O-ring φ53×φ3.55 1

118
Rear Wheel and Rear Brake Rotor

Disassembly of the Rear Wheel

Parking: Park the motorcycle on flat ground.

Support the motorcycle using a rear stand, to lift the


rear wheel easily.
Disassembly: Remove the mounting bolts (A) from
the brake caliper, Fig. A

Separation: Brake caliper.

Disassembly: Rear axle nut (9) and rear wheel


axle (1)
Note
During this process, note that the following parts
may be separated:
Mounting bracket for the brake caliper, Fig. A.
Chain adjusting blocks (B), Fig. B.
Right wheel spacer, Fig. C
Left wheel spacer, Fig. D

Disassembly:
Right wheel spacer (2) (Fig. C), Left wheel spacer
(11) (Fig. D).

119
Rear Wheel and the Rear Brake Rotor

Disassembly of the Rear Brake Rotor and Rear Sprocket

Disassembly of the brake rotor


After removing the rear wheel, remove the brake
rotor.
Loosen the 6 fastening bolts (3), and remove the
brake disc (4), Fig. A

Note
Heat may be necessary to more easily remove the
rotor bolts as they are installed with locktite. Use a
torch to heat each bolt taking care not to use too
much heat that could cause damage to the painted
wheel.

Disassembly of the sprocket carrier:


After removing the rear wheel, disassemble the
sprocket carrier (17), Fig. B. Remove the 5 fastening
nuts, and separate the sprocket from the sprocket
carrier (16).
Separate the sprocket carrier (16) from the bolts (15)
and rear wheel cushion dampers (10).

Check:
Sprocket Carrier
If there is any cracks / damage, please replace

120
Rear Wheel and the Rear Brake Rotor

Rear Wheel and Rear Axle Inspection

Check:

Rear wheel axle


Roll the rear wheel axle (A) on a flat surface, Fig. A
If there is any run-out, please replace.

Warning
If the rear wheel axle is bent, do not try to straighten
it using force or a press.

Check:
Rear wheel
Please refer to “Chapter III Front and Rear Tire
Inspection”
Rear wheel
If there is any run-out, please replace

Measurement:
Radial run-out of wheel (B). Fig. B
Axial run-out of wheel (C). Fig. B
If it exceeds the specified limit, please replace

Run-out Limit
Longitudinal 0.05mm
Lateral 0.05mm

121
Rear Wheel and the Rear Brake Rotor

Check / Replacement of the Rear Wheel Bearings

Check:
Wheel bearings
If the rear wheel rotates irregularly or is binding, please
replace the wheel bearings.

Replacement:
Wheel bearings
Remove the bearing from the wheel (A) using a generic
bearing remover. Fig. B
Install new wheel bearings in inverse order of
disassembly.

Important
When pressing bearings, do not touch the inner ring (B)
or the ball bearing (C) of bearing. Only contact the outer
seat (D) of the bearing, Fig. C

Note
The tool used should be suitable for the diameter of the
outside (D) of the wheel bearing, Fig. C

122
Rear Wheel and the Rear Brake Rotor

Static Balance Adjustment of the Rear Wheel

Note:
 After replacing tire, wheel rim or both, check the static balance of the rear wheel.
 When adjusting the static balance of the rear wheel, the brake rotor should be installed properly.

Adjustment
Please refer to “Static balance adjustment of the front wheel”

123
Rear Wheel and the Rear Brake Rotor

Inspection and Replacement of the Rear Sprocket

Check: Rear Sprocket


If more than 1/4 of each tooth has been worn, replace
the rear sprocket.
If the tooth is bent, replace the rear sprocket.

Replacement of Rear Sprocket:


After disassembling the rear wheel, remove the rear
sprocket, as described in the section above.

Replacement:
Wipe off any dust or dirt from the surface of the
sprocket carrier (16) with a clean cloth, especially the
surface in contact with the sprocket.

Insert the 5 fastening bolts (15), and tighten the self-


locking nuts to the following torque.

Torque 33 ft·lb

Note
Fasten the self-locking nuts in a crisscrossed sequence.

124
Rear Wheel and the Rear Brake Rotor

Installation of the Rear Brake Rotor

Brake rotor:
After removing the rear wheel, remove the brake rotor
as described in the above section.
Wipe any dust off of the surface of the wheel hub with
a clean cloth, especially the surface in contact with the
brake rotor.

Assembly:
Brake rotor (17) and 6 bolts (6), Fig. A
Use thread locker at the end of the threads.

Tighten the fastening bolts to the following torque:

Torque 7 ft·lb

Note
Fasten the bolts in a crisscrossed pattern.

125
Rear Wheel and the Rear Brake Rotor

Rear Wheel Assembly


Assembly:
Preassemble the support, connecting plate (3), and
install the speed sensor (4) and bolts (5).

Insert the left wheel spacer (11) into the left side of
the wheel, and insert the right wheel spacer (2) into
the right side of the wheel, Fig. B

Insert the chain adjuster block onto the axle, and


insert the axle on the brake rotor side first, Fig. C
Assembly: Rear wheel
Lubricate and assemble:

Rear wheel axle (14)


Fasten nut (1) to the following torque, Fig. D

Torque 103 ft·lb


Assembly: Brake caliper, and respectively fasten Left Right
the bolts to the following torque:

Torque 18 ft·lb
Note
Install the caliper on the brake rotor, ensure that there
is enough space between two brake pads.
Important
Ensure that the routing of the brake hose is correct.

126
Front and Rear Brakes

Front Brake

No. Name Quantity No. Name Quantity


1 Complete Front Brake Assy. 1 12 Nut M6 1
2 Front brake hose 1 13 Screw M4×12 1
3 Front right brake caliper 1 14 Washer 4 1
4 Front left brake caliper 1 15 Front brake lever 1
5 Gasket, Banjo Bolt 6 16 Brake light switch, front 1
6 Valve, Bleeder 2 17 Clamp, master cylinder 1
7 Dust cover, bleeder valve 2 18 Pads, Front brake (set) 4
8 Bolt M6×23 2 19 Banjo bolt 2
9 Banjo bolt 1 20 Seal, brake piston A 4
10 Bolt, clutch lever pivot 1 21 Seal, brake piston B 4
Front Brake Master Cylinder Socket head bolt
11 1 22 4
Assy. M10×1.25×40

127
Front and Rear Brakes

Rear Brake

No. Name Quantity


1 Rear brake assy. 1
2 Bolt M8×1.25×25 2
3 Spring gasket φ8 2
4 Bolt M6×20 1
5 Bolt M6×30 2
6 Rear brake master cylinder 1
7 Rear brake line 1
8 Rear brake caliper complete 1
9 Sealing washer 4
10 Banjo bolt 1
11 Reservoir, master cylinder 1
12 Clamp, hose 1
13 Reservoir hose 1
14 Rear brake light switch 1

128
Front and Rear Brakes / Front Brake Pads

Disassembly and Assembly of the Front Brake Pads

Disassembly
Remove the circlips (C) with circlip pliers and then
remove the locating pins (A) used to retain the brake
pads, Fig. A

Note
When removing the brake pins (A), press down the
retainer spring (B), Fig. A

Remove the worn brake pads, Fig. B

Measurement:
Wear limit of the brake pads
If they are below the minimum specifications, please
replace the brake pads in pairs.

Brake Pads Standard Lower wear limit


Front brake Pads 7.8mm 3.8mm

Assembly: Continue to assemble in reverse order of disassembly.

Check: Brake fluid level (B), Fig. C


If it is lower than the minimum notch, add a sufficient
amount of the recommended brake fluid, until it
reaches the correct fluid level.

Check:
Operation of brake handle
If the brake lever is soft or feels light, bleed any air
from the brake circuit.

129
Front and Rear Brakes / Rear Brake Pads

Disassembly and Assembly of the Rear Brake Pads

Disassembly

Disassemble the two fastening bolts (A) from the


brake caliper, Fig. A.
Disassemble bolt (B) from the brake caliper, and
rotate the brake caliper (E) towards the front of the
motorcycle.

Remove: brake pads (D), Fig. B

Measurement: Wear limit of the brake pads.


If they are below the minimum specifications, please
replace the brake pads in pairs.

Brake Pads Standard Lower wear


limit
Rear brake
7.0mm 3.7mm
Pads

Assembly:
Continue to assemble in reverse order of disassembly.
Fasten bolt (B) to the following torque:

Torque 18 ft·lb

Check:
Brake fluid level (B), Fig. C
If it is lower than the minimum notch, add a
sufficient amount of the recommended brake fluid, until it reaches the correct fluid level.

Check:
Operation of the brake pedal
If the brake pedal is soft or feels light, bleed any air from the brake circuit.

130
Front and Rear Brakes / Front Brake

Front Brake

No. Name Quantity No. Name Quantity


1 Complete Front Brake Assy. 1 12 Nut M6 1
2 Front brake hose 1 13 Screw M4×12 1
3 Front right brake caliper 1 14 Washer 4 1
4 Front left brake caliper 1 15 Front brake lever 1
5 Gasket, Banjo Bolt 6 16 Brake light switch, front 1
6 Valve, Bleeder 2 17 Clamp, master cylinder 1
7 Dust cover, bleeder valve 2 18 Pads, Front brake (set) 4
8 Bolt M6×23 2 19 Banjo bolt 2
9 Banjo bolt 1 20 Seal, brake piston A 4
10 Bolt, clutch lever pivot 1 21 Seal, brake piston B 4
Front Brake Master Cylinder Socket head bolt
11 1 22 4
Assy. M10×1.25×40

131
Front and Rear Brakes / Front Brake
Assembly of the Front Brake Master Cylinder
Assembly:
Follow the steps below:
Warning
Before assembly, wash all of the internal parts of the
brake, and lubricate using clean or new brake fluid.
Do not apply any solvent on the internal parts of brake
cylinder.
Assemble the brake light switch by tightening the
screw (13) and washer (14) to the pump. The torque is
as follows:

Torque 13 in. lbs.


Insert the connector (X) for the front brake switch (16), Fig. A
Install the banjo bolt (9) and related gaskets (5) to the front brake hose and connect it to the pump.
Fasten the banjo bolt to the following torque:

Torque 19 ft·lb
Warning
Make sure the routing of the brake hose is correct.
Tighten nut (12) and fastening bolt (10) to the following torque, and install the front brake lever (15):

Torque 5 ft·lb

Install the master cylinder clamp (17) to the cylinder, and tighten the two fastening bolts (8) to the following torque,
first torque the upper one and then lower one;

Note
Upon completion of these operations, add a little brake fluid. See Chapter 3, "checks and pre-maintenance", "front
brake fluid check / add a little

Torque 6 ft·lb

Note
Assemble the master cylinder clamp, make sure it’s
“UP” logo is facing up (A), Fig. B
Note
Upon completion of these operations, add a sufficient
amount of brake fluid. See Chapter III “Checks and
early maintenance”, “Check / adding of front brake
fluid”.

132
Front and Rear Brakes / Front Brake

Assembly of the Front Brake Calipers

Disassembly: The following procedures are


applicable to both of the brake calipers.

Note
Before disassembling the brake calipers, drain the
brake fluid in the brake circuit. Before
disassembling brake cylinder, drain the brake fluid
in the brake circuit.

Separation:
Banjo bolt (19) and sealing washer (5), Fig. A
Remove the front brake hose.

Note
Place the end of the brake hose into a container, and
then slowly pull it out to drain all the brake fluid.
Disassemble the two calipers, and remove the
fastening bolts (A) at the front forks, Fig. B

Separation:
Brake caliper piston (B), Fig. C
Piston gasket (E) on brake caliper (first the smallest
oil seal - washer, followed by the sealing ring –
large gasket)

Place the pistons of the brake caliper against a large


piece of wood, Fig. D
Blow compressed air into brake caliper banjo fitting
to remove the pistons from the brake caliper, Fig. D

Warning
Remove the sealing rings from the pistons and the
brake caliper.
Repeat the same steps to remove the pistons from the
right side of the brake caliper, Fig. D

133
Front and Rear Brakes / Front Brake
Assembly of the Front Brake Calipers
Disassembly: The following steps are applicable to
both brake calipers.
Warning
Before assembly, wash all of the internal parts of the
brake, and lubricate using new brake fluid.
Do not apply any solvent to the internal parts of the
brake, because solvent may cause the piston gaskets
to swell or deform.
Replace the piston gaskets when disassembling the
brake caliper every time.
Assembly:
Install the piston gasket (E) into the brake caliper,
Fig. A (first the smallest oil seal - washer, followed
by the sealing ring – large gasket)
Brake caliper piston (B), Fig. A
Assembly: Tighten the fastening bolts (A) to front
fork to attach the two calipers, Fig. B, according to
the following torque:

Torque 33 ft·lb
Front brake hose, Fig. C
Sealing washer (5)
Banjo bolt (19)
Note
Tighten the banjo bolts, fasten them with a torque
wrench twice, and tighten it to the following torque

Torque 19 ft·lb
Warning
To ensure the safety of the motorcycle, make sure the
path of the brake hose is correct.
Fill: the brake fluid container
Warning
Use only the specified brake fluid. Rubber sealing rings may be damaged when using other types of brake fluid,
resulting in leakage and reducing brake performance.
Only use brake fluid with the same brand when filling brake fluid. Mixing brake fluids of different brands should
not be done, because this may cause a dangerous chemical reaction, and reduce braking performance.
When adding brake fluid, be careful not to let any water into the container. Water will significantly reduce the
boiling point of the fluid and lead to the formation of steam bubbles.

134
Front and Rear Brakes / Front Brake

Assembly of the Front Brake Cylinder

Important
Brake fluid may damage painted surfaces and
plastic parts. Clean up any spilled brake fluid.

Emptying:
Brake circuit

Check:
Check the brake fluid level, A, Fig. A
If it is lower than the minimum notch, add a
sufficient amount of recommended brake fluid.

Check:
Operation of the brake lever
If the brake pedal is soft or feels light, bleed any air from the brake circuit.

135
Front and Rear Brakes / Rear Brake

Assembly of the Rear Brake Master Cylinder

No. Name Quantity


1 Rear brake assembly complete 1
2 Bolt M8×1.25×25 2
3 Spring gasket φ8 2
4 Bolt M6×20 1
5 Bolt M6×30 2
6 Rear brake master cylinder 1
7 Rear brake line 1
8 Rear brake caliper complete 1
9 Sealing washer 4
10 Banjo bolt 1
11 Reservoir, master cylinder 1
12 Clamp, hose 1
13 Reservoir hose 1
14 Rear brake light switch 1

136
Front and Rear Brakes / Rear Brake

Assembly of the Rear Brake Master Cylinder

Assembly: Assemble in the following order:


Install the heim joint (Y) on the brake control rod
(T), fasten connector (Y) to the brake pedal (Z), Fig.
A

Tighten the fastening bolts (X) to the brake master cylinder (6), Fig. B, to the following torque:

Torque 7 ft·lb

Connect the rear brake caliper and related gaskets to


the rear brake line and master cylinder. Tighten the
rear brake caliper to the following torque:

Torque 19 ft·lb

Warning
To ensure the safety of the motorcycle, make sure the path of the brake hose is correct.

137
Front and Rear Brakes / Rear Brake

Rear Brake Caliper

Disassembly:

Note:
Before disassembling the brake caliper, drain the
brake fluid from the brake circuit.

Separation:
Banjo bolt (A) and gasket (B), Fig. A
Remove the rear brake hose.

Note:
Disassemble the brake caliper, and remove the
fastening bolt at the supporting plate of the brake
caliper.

Separation:
Brake cylinder piston (B), Fig. B
Spacer (C)
Piston seal on the brake caliper (first the smallest oil
seal - washer, followed by the sealing ring – large
gasket)

Support the piston and brake caliper using a piece


of wood, Fig. D
Blow compressed air into brake hose connector to
extrude the piston at the right of the brake caliper,
Fig. C

Warning
Do not try to open the piston of brake cylinder
Disassemble the seal ring of piston from brake
cylinder. D

138
Front and Rear Brakes / Rear Brake

Rear Brake Caliper Inspection

Check:
Brake caliper piston
If there is any rust / patterns / signs of wear, replace the brake caliper piston.
Brake caliper
If there are any patterns / sign of wear, replace the entire brake caliper.
Main brake caliper body
If there are any cracks / damage, replace the entire brake caliper body.
Brake fluid conveying pipe (main brake cylinder body)
If there is a blockage, clean with a blast of compressed air.
Dust seals
If there are any cracks / signs of wear, replace the dust seals.

Important:
Replace piston gaskets when disassembling the brake caliper.

Check:
Connectors at the rear brake caliper support and rear swing arm.
If there is any rust / signs of wear, please replace.

139
Front and Rear Brakes / Rear Brake
Assembly of the Rear Brake Caliper
Assembly:
Warning
Before assembly, wash all internal parts of the brake, and lubricate them using new brake fluid.
Do not apply any solvents to the internal parts of brake, because solvent may cause the piston gaskets to swell or
deform.
Replace piston gaskets when disassembling the brake caliper each time.
Assembly:
Install the piston gasket (D) into the brake caliper, Fig.
A (first the smallest oil seal - washer, followed by the
sealing ring – large gasket)
Insulator (C), Fig. A
Brake caliper piston B, Fig. A
Assembly: Tighten the fastening bolts to the caliper
mounting plate according to the following torque:

Torque 16 ft·lb

Rear brake hose, Fig. B


Sealing washer (B), Fig. B
Banjo bolt (A), Fig. B
Note
Tighten the banjo bolt, and set the torque twice after a
few minutes according to the following torque:

Torque 19 ft·lb
Warning
To ensure the safety of motorcycle, the path brake
hose must be correct.
Filling: Fluid reservoir of the brake pump
Warning
Use only the specified brake fluid. Rubber seal ring may be damaged when using other types of brake fluid, resulting
in leakage and reducing brake performance.
Use the brake fluid with the same brand when filling brake fluid. The mixture of brake fluid with different brands
should not be used, because this may cause a dangerous chemical reaction, and reduce brake performance.
When adding brake fluid, be careful not to let any water into the container. Water will significantly reduce the
boiling point of the fluid and lead to the formation of steam bubbles.

140
Front and Rear Brakes / Rear Brake

Assembly of the Rear Brake Cylinder

Important
Brake fluid may damage painted surfaces and plastic parts. Clean up spilled brake fluid.

Filling:
Brake circuit

Check:
Check the brake fluid level, A, Fig. A
If it is lower than the minimum notch, add a
sufficient amount of the recommended brake fluid.

Check:
Operation of the brake pedal
If the brake pedal is soft or light, remove air from the brake circuit.

141
Front Suspension

Disassembly of the Front Shock Absorbers

No. Name and specifications Quantity No. Name and specifications Quantity No. Name and specifications Quantity
Right shock absorber Left hydraulic brake
1 1 11 Upper triple clamp 1 21 1
complete Hose clamp
Left shock absorber Right hydraulic brake
2 1 12 Nut, steering stem 1 22 1
complete hoses clamp
3 Bolt M8×1.25×25 10 13 Nut, special 1 23 Bolt M10×1.25×40 4
Upper Triple Clamp
4 1 14 Dust seal 2 24 Bolt M6×30 2
Mounting Bolt
Upper handlebar holder Lower triple clamp
5 1 15 Steering stem bearing 2 25 1
clamp complete
6 Lower handlebar clamps 2 16 Steering stem 1
7 Damper, Rubber 4 17 C-Clamp 1
8 Washer 2 18 Bolt M6×14 2
Hydraulic brake hose
9 double-end stud 2 19 1
clamp
10 Self-locking nut M10×1.25 2 20 Lower triple clamp 1

142
Front Suspension / Front Fork

Disassembly of the Front Forks


The following procedures are applicable to both front fork assemblies.

Parking: Park the motorcycle on flat ground.

Note
Support the motorcycle using a rear stand, lift the front wheel of the motorcycle using a jack placed under the header
pipes.

Disassembly
Front brake calipers (see the steps in the section “front and rear brake”)
Front wheel (see the steps in the section “front wheel and front brake rotor”)
Front fender (see the steps in the section “covering parts/front fender”)

Disassembly
Remove the fastening bolts (3) from the
upper triple clamp (11), Fig. A
Remove the fastening bolts (3) from the
lower triple clamp (20), Fig. B

Important
Before releasing the fastening bolts on the
lower triple clamp, first remove the support
from the upper front shock absorber.

143
Front Suspension / Front Shock Absorber

Disassembly of the Front Forks

Note: The following steps are applicable to both of


the front shock absorbers.

Disassembly
Remove the front fork cap bolt (1), Fig. A

Important: Front shock absorbing spring is


compressed.

144
Front Suspension / Front Shock Absorber

Disassembly of the Front Forks

Pushdown:
After compressing the spring using the special tool,
remove the front fork cap bolt (1) and nut (B) using a
wrench, Fig. B

Note:
This is right shock absorber, the left shock absorber
bolt is not equipped with an adjustment lever (X),
otherwise the disassembly method is the same.

Slide the spring off of the sleeve, Fig. C:


Buffer block and adjusting sleeve seat (L)
Adjusting sleeve (M)
Spring seat (N)
Shock absorbing spring (8)

Releasing:
Release the rod from the clamp
Pour the fork oil into a container for disposal, Fig. D

Note
To help to drain the fork oil in the shock absorber, push
the dampening rod (15) in and out at a slow speed, Fig.
D

Important
This operation can only be conducted after draining
the oil from the shock absorber.

145
Front Suspension / Front Shock Absorber

Disassembly of the Front Forks


Lock the lower portion of the fork in a vice (A), Fig.
E.

Disassembly
Bolt (18), gasket (17), and damping cylinder (15)

Important
This operation can only be conducted after draining
the oil from the shock absorber.

Disassembly
Disassemble the dust seal (14) from the outer fork leg
using a small flathead screwdriver. Fig. F

Disassembly
Remove the locking ring using the same
screwdriver, Fig. G

Slide out:
Slide the inner pipe (B) out from inside the shock
absorber outer cylinder (10) of the front fork Fig. H.

Note
To separate these two parts, pull them with a small
amount of force.
Oil seal (12)
Positioning ring (11)
Lower fork bushing (8)

146
Front Suspension / Front Shock Absorber

Disassembly of the Front Forks

Manual disassembly
Upper fork bushing (6), Fig. I

Note
If it is difficult to remove, use a flathead screwdriver
in the open slot of the shock absorber bushing to
spread it apart to make it easier to remove.
Lower guide sleeve (8)
Positioning ring (11)
Oil seal (12)
Locking ring (13)
Dust seal (14)

Note
If the oil seal and dust seal have been removed, they cannot be reused.

147
Front Suspension / Front Shock Absorber

Front Fork Inspection


The following steps are applicable to both of the front
shock absorbers.

Check:
Shock absorber (A), Fig. A
Outer tube of the shock absorber (10)
If there is any deformation / damage / wear, please
replace.

Warning
If the internal pipe of the shock absorber is bent, do not try to straighten it, because this may cause the internal pipe
of the shock absorber become brittle and result in
failure of the part.

Measurement: Full length (B) of the spring (5)


(uncompressed state).
If it exceeds the specifications, please replace

Item Standard Lower


deformation limit
Front shock 310mm 300mm
absorbing spring

Check:
Damping cylinder (15), Fig. C
If there is any damage or wear, please replace.
If there is any blockages, blow out the entire oil passage with compressed air.

Important
When disassembling or reinstalling front shock absorber, do not let foreign bodies enter the shock absorber.

148
Front Suspension / Front Shock Absorber

Assembly of the Front Shock Absorber


The following steps are applicable to both of the front
shock absorbers.

Important
After disassembly, the oil seal and the dust seal
cannot be reused.
Before reinstallation, check the inner fork tube and
the bushings; if there is any dents, chips, or scratches
replace it.
Cover the end of the inner fork tube with tape, Fig. A
This will cover the sharp edge to keep it from cutting
the seal or dust seal.
Slightly lubricate lower oil seal and dust seal with
grease or fork oil.
Insert the dust seal, Fig. B
Dust seal (14)
Locking ring (13)
Oil seal (12)
Positioning ring washer (11)
Lower fork bushing (8)

Important
Pay attention to the orientation of the oil seal (12).

Remove the tape from the end of internal fork tube,


and remove any remaining tape residue.
Insert the following parts by hand: upper guide
bushing (6), Fig. C
Insert the internal fork tube into the outer fork tube
slowly, as to not damage the bushings.

Inserting simultaneously
Lower the guide bushing, until the sleeve contacts the
front fork, Fig. D
Positioning ring
Oil seal
And then install them in the base of the outer fork tube.

149
Front Suspension / Front Shock Absorber

Assembly of the Front Shock Absorber

Assembly:
Install the locking ring (13) on the top of the oil seal
with a small flathead screwdriver, ensure that it is
properly inserted to the internal groove, and pay
attention to not damage the internal fork tube, Fig. E.

And then put the following parts into the base:


Install the dust seal (14) by hand, Fig. F

Inserting:

Insert the assembled damping rod (15) into the outer


fork tube (10), Fig. G.

Assembly:
Clamp the bottom on the inner fork tube in a bench
vise to install the bolt. Fig. H
Fasten the inner and outer fork tubes with a gasket
(17) and socket head bolt (18), and fasten it to the
following torque using an Allen wrench.

Torque 16 ft·lb

150
Front Suspension / Front Shock Absorber

Assembly of the Front Shock Absorber


Add 400mL of 7.5 weight fork oil with a
graduated cylinder, Fig. I.

Lift the entire outer fork tube then use the graduated
cylinder container, prepare the correct amount of fork oil
and pour it into the outer fork tube, pour about 2/3 of oil
into the fork cylinder (A), and then move the rod up and
down to remove any air. Fig. I. Continue to pour, until the
required volume is reached.

Assembly:
Install the following components on the dampening rod,
Fig. J
Shock absorbing spring (8)
Spring seat (N)
Adjusting sleeve (M)
Buffer block and adjusting sleeve seat (L)

151
Front Suspension / Front Shock Absorber

Assembly of the Front Shock Absorber

Assembly:

Compress the spring with the special tool, apply a proper


amount of thread sealant (1261# glue), and lock it with a
wrench, Fig. K
Fasten it to the following torque:

Torque 12–14 ft·lb

Assembly:
Fasten the upper bolt (1) using a socket, and torque it,
Fig. M
Fasten it to the following torque:

Torque 13-15 ft·lb

152
Front Suspension / Front Shock Absorber

Assembly of the Front Shock Absorber

Assembly: Outer cylinder of


the shock absorber (A), Fig. A
Fastening loosely.
Fasten the mounting bolts (3) to the lower triple
clamp, Fig. A.

Note
Check assembly position (X), as shown in Fig. B
Assembly position (X)
204.5mm
Fastening: Fasten the mounting bolts (3) to the
lower triple clamp (7); the torque is as follows:

Torque 16 ft·lb

Note
The assembly is divided into three steps
Assemble the upper triple clamp, insert a straight
blade screwdriver at the opening (Y), to simplify
insertion of the front forks, Fig. C
Fasten: Install mounting bolts (3) to the upper triple
clamp (9), and torque them as follows:

Torque 16 ft·lb

Important
Ensure that the routing of the brake hose is correct.

153
Control

Handlebar Disassembly

No. Name and specifications Quantity No. Name and specifications Quantity
1 Throttle cable housing 1 13 Throttle cable II 1
2 Throttle grip 1 14 Right rearview mirror 1
3 2×18 cotter pin 1 15 Left rearview mirror 1
4 6×14 hinge pin 1 16 M6×35 bolt 2
5 Right combination switch 1 17 Lock washer 6 2
6 Handlebar end insert 2 18 Washer 6 2
7 Handlebar 1 19 Insert, handlebar end mounting 2
8 Left combination switch 1 20 Handlebar end weight 2
9 Left grip 1 21 Clutch lever 1
10 Clutch perch assembly 1 22 Soft wire clamp 3
11 Clutch cable 1 23 Soft wire clamp 2
12 Throttle cable I 1 24 Clutch actuator 1

154
Control

Handlebar Disassembly
Park the motorcycle on flat ground.
Important
Support the motorcycle with a rear stand, so that it will not topple.
Remove the bolt (16), washer (18) and spring washer (17)
Remove the handlebar end weight (20)
Remove the handlebar end mounting insert (19) and the handlebar end insert (6)

Removal: Remove the left grip (9) from the handlebar by blowing compressed air between the handlebar and
the handlebar grip. Fig. A
Note
Blow compressed air directly between the left side of
the handlebar and the grip, so the grip can be slipped off
gently.

Remove the left combination switch.

Remove the clutch cable component.

Remove the rearview mirror and the adjusting nut

Remove the clutch perch by unscrewing the two


fastening bolts from the clutch perch bracket, and then
disassemble the clutch handle assembly.

Repeat the same procedures for the right-hand grip, until


the throttle grip is removed. In this case, the bolts on the
throttle cable housing must be removed, so that the
throttle grip can be removed.

Remove throttle cable I and throttle cable II.

Remove the right combination switch.

Unscrew the two fastening bolts (8), remove the


mounting bracket from the master cylinder (17), and
then remove the front brake master cylinder. Fig. B.

Loosen the four mounting bolts (A) from the handlebar


holder bracket on the handlebars (B), and remove the
handlebars. Fig. C.

155
Control

Handlebar Inspection

Check:
Handlebar (7). Fig. D.
If there are bends / breakage / damage, please
replace it.

Warning
If the handlebar is bent, do not try to bend it
straight, because the handlebar will become weak
and this increases the risk or breakage.

156
Control
Control Assembly
Prepare for assembly, conduct it in reverse order of
disassembly, but pay attention to the following
information:
Assembly:
Install the right combination switch (5) and the left
combination switch (8) onto the handlebar. Align
the hole in the handlebar (B) with the projected part
(A) of the switch. Both sides have a hole and tab.
Fig. E.
Tighten the two bolts for the mounting bracket of
the master cylinder (17), as shown in Fig. B,
according to the following torque.

Torque 6 ft·lb
Note
Place the “UP” upwards when assembling the
mounting bracket to the master cylinder Fig. F.

There should be a clearance of 2mm between the


right handlebar switch and the master cylinder.
Assembly:
While holding the left grip, apply a thin layer of
rubber adhesive to the end of the handlebar.
Slide the left grip onto the handlebar. The end of the left grip and the handlebar should line up.
Remove all traces of the rubber adhesive with a clean cloth.
Important
Do not touch the left grip until the rubber adhesive
is completely dry.
Assemble:
Handle
When installing the handlebars, put the handlebar in
the correct position, as shown in Fig. G, on the
fourth reference mark (X).
Tighten the two bolts (C) near the fuel tank at the
back first, and then tighten two bolts (A) near the
instrument in the front
Tighten the bolts to the following torque:

Torque 16 ft·lb

157
Control / Handlebar

Disassembly of Triple and Handlebar Clamps

No. Name and specifications Quantity No. Name and specifications Quantity
3 M8×1.25×25 bolt 4 10 M10×1.25 self-locking nut 2
Upper Triple Clamp Mounting
4 1 11 Upper triple clamp 1
Bolt
5 Upper handlebar clamp 1 12 Nut, steering stem 1
6 Lower handlebar clamps 2 13 Nut, special 1
7 Damper, rubber 4 14 Dust seal 2
8 Washer 2 15 Steering stem bearing 2
9 double-end stud 2 25 Lower triple clamp complete 1

158
Control / Handlebar

Disassembly of the Upper + Lower Triple Clamps


Park the motorcycle on flat ground.

Important
Support the motorcycle with a rear stand and a jack
under the header pipe, so that it will not topple over
without the front fork.

Disassemble:
Bolts on the upper triple clamp (3). Fig. A

Disassembly:
Disassemble the retaining nut on the upper triple
clamp with the special tool. Fig. B.

Loosen:
The special nut on the upper triple clamp.
Gland nut
Special tool used for the locknuts of the steering
stem Fig. C.

159
Control / Handlebar

Disassembly of the Upper + Lower Triple Clamps

Check:
Steering stem bearings (13). Fig. A.
Dust seal (12). 图 A
If there is any damage, replace them.

Replace
Bearing
Bearing Race
Remove the bearing outer ring (A) from the headstock
tube of the motorcycle frame with a punch and a
hammer (B). Fig. B
Remove the bearing inner ring (C) from the lower
triple clamp with a chisel (D) and a hammer. Fig. B
Install a new rubber seal and a new bearing.

Important
If the bearing outer ring is not installed properly, the
headstock tube will be damaged.

Note
The ball bearing and the bearing race should be replaced together.
Each time the steering bearing is disassembled, a new rubber dust seal should be installed.

Check:
Upper steering bearing
Lower steering bearing (and the bushing)
If there is any bend/crack/damage, replace them.

160
Control / Handlebar
Disassembly of the Upper + Lower Triple Clamps
Lubricate:
Ball bearing, Fig. A
Bearing outer race, Fig. A
Bearing inner race, Fig. A
Note: Use lithium based grease on the steering
bearings to prevent rust.
Assembly: assemble the nuts on the upper triple
clamp with the special tools according to the
following torque:

Torque 12 ft·lb

Tighten the locknuts for the steering stem.


Important
Do not over-tighten the steering stem nut.
Tighten the steering stem nut with the special tool to
the following torque:

Torque 44 ft·lb
Assembly: assemble the front forks according to the above description.
Assembly: tighten the fastening nut on the upper triple clamp (4) with the special tool to the following torque:

Torque 44 ft·lb

Steering head wench


Fasten the bolts on the upper triple clamp (3), as shown
in Fig. B, according to the following torque:

Torque 16 ft·lb
Check: Steering play, Fig. C
Grab the end of the fork and move it front to rear, and
rotate the front fork gently from left to right. If it is
binding / loose, readjust the steering stem bearing torque.

161
Rear Shock Absorber

Disassembly of the Rear Shock Absorber

No. Name and specifications Quantity


1 Rear shock absorber 1
2 Bolt, lower shock mounting 1
Decorative Washer, lower
3 1
bolt
4 Bolts, upper shock mounting 1

162
Rear Shock Absorber

Disassembly of the Rear Shock Absorber

Park the motorcycle on flat ground.

Important
Support the motorcycle with a front stand and
a jack under the header pipe, so that it will not
topple over without the rear shock absorber
installed.

Disassemble:
Bolt (16)
Bolt (18), Fig. A

163
Rear Shock Absorber

Rear Shock Absorber Inspection

Check:

Rear shock absorber rod 9, Fig. B


If there is any damage/bends, replace the rear
shock absorber component.

Rear shock absorber cylinder 8, Fig.


B
If there is any gas/oil leakage, replace the rear
shock absorber component.

Rear shock absorber spring 7, Fig. B


If there is any damage/wear, replace the rear
shock absorber component.

Rear shock absorber scraper seal


If there is any damage or wear, replace it.

Bolt (4) and Bolt (2), Fig. B


If there is any bend/damage/wear, replace
them.

164
Rear Shock Absorber

Assembly of the Rear Shock Absorber

Assembly:
Assemble the bolt (4), as shown in Fig C, and
tighten it to the following torque:

Torque 44 ft·lb

Assemble the bolt (2) and the decorative


washer (3) according to the following torque:

Torque 44 ft·lb

165
Drive Chain and Swing Arm

Disassembly of the Drive Chain


Park the motorcycle on flat ground.

Important
Support the motorcycle with a rear stand, so that it
will not topple and the rear wheel is lifted.

Remove:
Drive chain
(Use a suitable tool for the drive chain (A), as
shown in Fig. A, or use a special tool for the
drive chain specified by the manufacturer)

166
Drive Chain and Rear Swing Arm

Drive Chain Inspection

Check: drive chain, Fig. C


O-ring (B)
Drive chain roller (D)
Side plate of the drive chain (C)
Replace a damaged/worn drive chain
If there are any cracks, replace the drive
chain. If the chain is stretched, replace it.

Clean: drive chain, Fig. B


Use a clean cloth to clean the drive chain.
Soak the drive chain in engine oil or chain
cleaner to remove all the dirt.
Remove the drive chain from the oil/chain
cleaner and dry it thoroughly.

Important
This motorcycle is equipped with an O-ring
drive chain. There are rubber O-rings (B)
between every two chain plates.
Do not use high pressure water or air to clean
the chain. Do not use steam, gasoline,
corrosive solvents (such as petroleum ether)
or an excessively hard brush.
Using a pressure washer will force dirt into
the crevices of the drive chain, and corrosive
solvents can cause deterioration of the O-
rings.
O-rings will be damaged by an excessively hard brush.

Lubricate: drive chain


It is recommended that only motorcycle drive chain lubricants are used to lubricate the drive chain.

167
Drive Chain

Drive Chain Inspection

Check: drive sprocket / drive chain


sprocket. Fig. A
If the wear of each tooth is greater than 1/4
(4), replace the drive chain and the sprockets
together.
If any teeth are bent, replace the drive chain
and sprockets together.

Note
When installing a new chain, new sprockets
should also be installed. Installing a new drive chain on used sprockets will rapidly wear out the chain.

168
Drive Chain
Replacement of the Drive Chain
Loosen: the drive chain
Use the special tool according to the manufacturer’s
specification as well as the type required for use of that
chain. There are three tools to disassemble the rivet
chain link (A), assemble the side plate (B), and flare
the pins on the side plate (C) in Fig. A
Warning
Never use old chains, main chain plates, main chain
side plates, or rubber O-rings.
Insert:
Rivet chain link (A), Fig. B
Rubber O-ring (B), Figure B
Chain side plate (C), Fig. B
Important
Insert the rivet chain link thru the drive chain, then
assemble the side plate, and place the ID logo
outwards.

Fastening:
Press the rivet chain link against the chain side plate
with a tool for assembling the chain side plate (B).

Clutch:
Press the pin on the chain side plate (C) with the
special tool. Fig. D
Check:
Make sure the chain side plate is properly seated
before riveting the rivet chain link.
If there are any gaps, replace the rivet chain link, O-
rings and side plate.
Important
Never use a used drive chain.

169
Drive Chain and Swing Arm

Assembly of the Swing Arm

Qua
No. Name and specifications No. Name and specifications
ntity No.
1 Rear swing arm complete 1 11 Screw M6×19.2 2
2 Rear swing arm bushing 2 12 Swing arm Spool 2
3 Oil seal, swing arm pivot25×37×7 2 13 Bolt M6×30 2
4 Circlip φ37 2 14 Rear Brake Caliper Carrier 1
5 Needle Bearing NA4904 2 15 Screw M6×14 1
6 Roller Bearing 61904-2RS 2 16 Speedometer Sensor 1
7 Swing arm bearing spacer sleeve 1 17 Chain adjusting block 2
8 Rear swing arm Axle 1 18 M8 Chain Adjusting Bolt 2
9 Self-Locking Nut M20×1.5 1 19 Nut M8 2
10 Chain Slider 1

170
Swing Arm

Installation of the Swing Arm

Assemble:
Swing arm component (A)
Swing arm shaft (8)
Arrange the swing arm components (A) in a row
on both sides of the swing arm shaft (8). Insert
the swing arm shaft (5) from the left side of the
motorcycle frame (C) to the right side. Fig. A

Note
Use lithium base grease during assembly. Apply
it on the inner bores at both ends of the rear swing
arm component (A). Fig. B

Screw the nut (9) onto the swing arm shaft (8)
which is fastened to the motorcycle frame, as
shown in Fig. C, to the following torque:

Torque 148 ft·lb

171
Rear Swing Arm

Assembly of the Swing Arm

Assembly:
Install the right decorating plate (N) on the
motorcycle frame, and fix it with screws (L);
Install the left decorating plate (M) on the
motorcycle frame, and fix it with screws (L); as
shown in Fig. D, according to the following
torque:

Torque 7 ft·lb

Assemble:
Rear shock absorber (see “rear shock absorber section”)
Rear wheel (see “rear wheel section”)

172
Frame

Frame Assembly

No. Name and specifications Quantity No. Name and specifications Quantity
1 Main Frame 1 16 Screw M6×12-8.8-ZG 4
2 Frame Plate 1 17 Cable, Seat Lock 1
3 Rivet, Frame Plate 3×6 2 18 Bolt M6×30 2
4 Bolt, Socket Head M10×22 4 19 Bracket, Plate Carrier 1
5 Damper, Fuel Tank 2 20 Bolt M6×1×16 4
Frame, Engine Mounting
6 1 21 Bolt M6×1×20 4
Left
Frame, Engine Mounting
7 1 22 Bracket, License Plate 1
Right
Bolt, Socket Head Left decorative cover
8 2 23 1
M10×1.25×45 (electroplated silver C9)
Right decorative cover
9 4 24 1
Bolt, Socket Head M10×30 (electroplated silver C9)
10 Elastic washer 10 4 25 Cushion, Battery Box 1
11 Nut, Self-locking M10×1.25 1 26 Cable Clip II 1
12 Rubber Washer B 1 27 Screw M6×12 2
13 Battery Tray, Lower 1 28 Washer, Nylon 1
14 Battery Tray, Upper 1 29 Bolt M6×15.2 1
15 Rubber Damper 12 30 Cushion, Battery Box 65×25×4 1

173
Frame / Engine Assembly

Engine Assembly

Important
Place the engine (B) on a liftable support (C) so that the
engine or frame will not fall over by accident and injure
the operators when assembling the motorcycle, as
shown in Fig. A.

Assembly:
Install the welded engine mounting brackets on the left
side (6) and right side (7) of the frame (1), and slightly
screw in the socket head cap bolts (4) onto both sides of
the frame (1), as shown in Fig. B.

Assembly:
Lift the engine (B), and screw in the four socket head
cap bolts (9) fastened into the back of the engine and
frame (1).
Screw in the rear upper left socket head cap bolts (9)
into the engine (B), as shown in Fig. C.

174
Frame / Engine Assembly

Engine Assembly

Assembly:
Screw in the rear upper right socket head cap bolts (9)
into the engine (B), as shown in Fig. D.

Screw in the rear lower left socket head cap bolts (9) into
the engine (B), as shown in Fig. E.

Screw in the rear lower right socket head cap bolts (9)
into the engine (B), as shown in Fig. F.

175
Frame / Engine Assembly

Engine Assembly

Assembly:
Screw in the socket head cap bolts (8) to loosely attach
the welded assembly of the left engine mounting support
(6) and the engine (B), as shown in Fig. B.
Screw in the socket head cap bolts (8) to loosely attach
the welded assembly of right engine mounting support
(7) and the engine (B), as shown in Fig. B.

Tightening:
Fasten the engine mounting bolts in order, and mark them after fastening.
1. Four rear socket head bolts (9) of the frame / engine, as shown in Fig. C, D, E and F.
2. The welded assembly for the front-left frame / left engine mounting support (6) and socket head cap bolts (4),
as shown in Fig. B.
3. The welded assembly for the front-right frame / right engine mounting support (6) and socket head cap bolts
(4), as shown in Fig. B.
4. One socket head cap bolt for the front-left engine (8), as shown in Fig. B.
5. One socket head cap bolt for the front-right engine (8), as shown in Fig. B.
Use thread locker at the end of each threaded bolt.

Tighten the fastening bolts to the following torque:

Torque 33 ft·lb

176
Frame / Engine Assembly

Engine Disassembly

Disassembly:
Conduct disassembly in reverse order of assembly.

Note:
Disassemble fastening screws from the front to back.

177
Frame / Rear License Plate Support

Assembly of the Rear License Plate Support

No. Name and specifications Quantity


1 Bolt M6×1×16 4
2 Bracket, Plate Carrier 1
3 Screw M6×12 2
4 Bracket, License Plate 1
5 Bolt M6×1×20 4
6 Nut M6 2
7 Bolt M6×1×16 2
8 Bolt M6×16 2
9 License plate holder 1

178
Frame / Rear License Plate Support

Assembly of the Rear License Plate Support

Assembly:
Assemble the rear fender, and screw the four
socket head cap bolts (5) to the frame, as
shown in Fig. A.
Tighten the fastening bolts to the following
torque:

Torque 7 ft·lb

Screw the two socket head cap bolts (7) into


the license plate support (9), and assemble it to
the welded assembly of the rear fender support
(4), as shown in Fig. B.
Tighten the fastening bolts to the following
torque:

Torque 7 ft·lb

Connect:
Rear turn signal lights and the license plate light wires.

179
Frame / Rear License Plate Support

Disassembly of the Rear License Plate Support

Disassembly:
Conduct disassembly in reverse order of assembly.

180
Frame / Side Stand

Assembly of the Side Stand

No. Name and specifications Quantity


1 Side Stand 1
2 Bolt, Side Stand Pivot 1
3 Washer, Side Stand Bolt 1
4 Spring, Side Stand 1
5 Bolt M6×8 1
6 Bolt, Socket Head M10×30 1
7 Bushing 1
8 Bolt M5×0.8×14 2
9 Switch, Side Stand Lockout 1
10 Bracket, Side Stand Mounting 1
11 Thin nut M12×1.25 1
12 Socket Head Cap Bolt M10×50 1

181
Frame / Side Stand

Assembly of the Side Stand

Assemble:
Install the side stand mounting bracket (5) on the frame
using the two fastening bolts (X), as shown in Fig. A.

Note:
Use thread locker at the end of the threads.

Fasten the two bolts to the following torque:

Torque 33 ft·lb

Assemble: inner screw (5) and outer screw (8).


Connect the side stand lockout switch connector for the side stand to the wire harness.

182
Frame / Side Stand

Disassembly of the Side Stand

Disassembly:
Conduct disassembly in reverse order of assembly.

183
Frame / Left Foot Pedal

Assembly of the Left Foot Pedal

No. Name and specifications Quantity No. Name and specifications Quantity
1 Front-left foot pedal support 1 17 Nut M6 2
2 Bushing, Foot Pedal Support 1 18 Bolt M5×0.8×18 1
Socket Head Cap Bolt
3 1 19 1
M10×22 Lever, Shifter
4 Pin, Foot Pedal Pivot 2 20 Lever End, Adjustable Tip 1
5 Left, Rear Foot Pedal 1 21 Damper, Shifter End 1
6 Spring, Pedal Ball Stopper 1 22 Nut M6-8-ZG 1
7 Foot Pedal Ball Stopper 1 23 Shaft, Gear Change Lever 1
8 Stopper Plate, Foot Pedal 1 24 Nut, LH Thread M6 1
9 E-Clip φ5 2 25 Heim Joint M6 LH Thread 1
10 Left Foot Pedal, Driver 1 26 Screw M6×25-8.8-ZG 1
11 Mount, LH Driver Footpeg 1 27 Sleeve 1
Return Spring, Driver Foot
12 1 28 1
Pedal Knuckle, Shifter
13 Bolt M10×25 2 29 Bolt M6×1×20 1
14 Bushing, Brass 1 30 Damper, Rubber Left Foot Pedal 2
Damper, Rubber Lower L Foot
15 Bolt M6×30 1 31 2
Pedal
16 Heim Joint M6 1 32 Bolt M4×10 2

184
Frame / Left Foot Pedal

Assembly of the Left Foot Pedal

Assemble:
Front-left foot pedal support (1), as shown in Fig.
A.

Note
Use thread locker at the end of the threads.

Fasten two bolts (3) and bolts (13) to the following


torque:

Torque 33 ft·lb

Note
Please replace the left foot pedal rubber damper if damaged.

Assembly:
Install the shifter knuckle for the shift lever (28) on the shift shaft spline, and lubricate it using a lithium-based
grease. Tighten the fastening bolt (29) on the shifter knuckle for the shift lever.

Adjustment:
The distance between the connecting rod shaft (23) and connectors (16) and (25) is 185mm, as shown in Fig. A.

Note
If necessary, adjust this item according to the needs of the rider.

185
Frame / Left Foot Pedal

Disassembly of the Front-Left Foot Pedal

Disassembly:
Conduct disassembly in reverse order of assembly.

186
Frame / Right Foot Pedal

Assembly of the Front-Right Foot Pedal

No. Name and specifications Quantity No. Name and specifications Quantity
Front-Right Foot Pedal
1 14 Bushing, Brass 1
Support 1
2 Bushing, Foot Pedal Support 1 15 Spring, Brake Lever Return 1
3 Socket head Bolt M10×22 1 16 Lever, Rear Brake 1
Lever End, Brake Pedal
4 2 17 1
Pin, Foot Pedal Pivot Adjustable
5 Right, Rear Foot Pedal 1 18 Rubber Damper, Brake Lever 1
6 Spring, Pedal Ball Stopper 1 19 Bolt M5×0.8×18 1
7 Foot Pedal Ball Stopper 1 20 Spring Pin, Upper 1
8 Stopper Plate, Foot Pedal 1 21 Bolt M6×1×16 1
9 E-Clip φ5 2 22 Heim Joint M6 1
10 Right Foot Pedal, Driver 1 23 Nut M6-8-ZG 2
11 Mount, RH Driver Foot Lever 1 24 Damper, Right Foot Peg 2
Damper, Lower Right
12 1 25 2
Return Spring, Driver Foot Pedal Footpeg
13 Bolt M10×25 2 26 Bolt M4×10 2

187
Frame / Right Foot Pedal

Assembly of the Front-Right Foot Pedal

Assemble:
Front-right foot pedal support (1), as shown
in Fig. A.

Note
Use thread locker at the end of the threads.

Fasten the two bolts (3) and bolts (13) to the


following torque:

Torque 33 ft·lb

Note
If worn, replace the right pedal foot rubber
damper (24).

Assembly:
Assemble the brake pedal lever (22) to the
foot pedal stay, insert the bushing first (14)
and then the screw (13) after greasing it, as
shown in Fig. B, and fasten it to the
following torque:

Torque 33 ft·lb

Assembly:
Fix the brake pedal lever (16) to the heim joint (21) using the fastening bolt (22), as shown in Fig. B, and fasten it
to the following torque:

Torque 7 ft·lb

Assembly:
Assemble the upper spring pin (20) to the front-right foot pedal support (1), as shown in Fig. B.
Attach the return spring for the brake pedal (15) to the upper spring pin (20) of brake pedal lever (16).

188
Frame / Right Foot Pedal

Assembly of the Front-Right Foot Pedal

Disassembly:
Conduct disassembly in reverse order of assembly.

189
Muffler

Muffler Assembly

No. Name and specifications Quantity


1 Gasket, Header Pipe 2
2 Nut M8 4
3 Header, Exhaust 1
4 Gasket, Packing 1
5 Bolt 1
6 Cover, Thermal Protective 1
7 Screw M6×12 2
8 Oxygen Sensor 2
9 Damper, Rubber 3
10 Collar 3
11 Bolt M8×1.25×25 3
12 Muffler Assembly 1

190
Muffler

Muffler
Exhaust system
Manifold Muffler body

Catalytic Converter Catalytic Converter


Sign: N12-1
Sign: N12-1 CCC noise emission and
control information

Catalytic Converter Catalytic Converter


Sign: C5390
European III noise
Sign: C5390
emission and control
information

Manifold Placement [C] of Oxygen


Manifold mark position [A] Mark position on Muffler Body
Sensor [D]

The position of the Catalytic Converter [A]

191
Muffler

Muffler Disassembly

Parking: Park the motorcycle on flat ground.

Note:
Support the motorcycle with a rear stand to prevent
it from tipping over.

Disassembly:
Remove the nuts fastening the flange of exhaust
pipe to the engine, as shown in Fig. A.

Unscrew the socket head cap screw (5) on the


muffler clamp (20), as shown in Fig. B.

Remove the socket head cap bolts (11) fastening


the muffler body, as shown in Fig. C.

Note:
Remove the right foot pedal stay followed by
disassembling the socket head cap bolt (11) on the
right (see Chapter IV “Frame / right foot pedal” of
“Motorcycle”).

Left Right

192
Muffler

Muffler Assembly

Assembly:
Install the oxygen sensors (8) on the exhaust pipe
(3), as shown in Fig. A, and fasten it to the
following torque.

Torque 30-44 ft·lb

Apply lubricating grease to the two exhaust outlets


(B) of the engine, and install the exhaust pipe
gasket (1), as shown in Fig. B.

Note
Apply lubricating grease to the exhaust pipe
gasket to keep it stuck to the engine exhaust outlet,
as shown in Fig. B.

Slightly tighten the nuts (2) onto the exhaust studs,


as shown in Fig. C.

Note
Conduct this operation for all of the stud nuts.

193
Muffler

Muffler Assembly

Assembly:
Install the packing gasket (4) on the exhaust pipe, as
shown in Fig. D.

Note
Slightly screw the bolt (5) into the muffler clamp (20), as
shown in Fig. D.

Assembly:
Insert the exhaust manifold into the muffler barrel and
align the manifold with the bottom surface of packing
gasket (4) and wiggle the inlet pipe surface into the
muffler barrel, as shown in Fig. E.

Attach the muffler. Install the rubber dampers (9), and


collars (10) and then bolt (11) it to the frame, and fasten it
to the following torque:

Torque 16 ft·lb

Fastening: Left Right


Fasten the nuts (2) on the muffler studs, as shown in Fig. C, to the following torque:

Torque 18 ft·lb
Fasten the socket head cap bolt (5) for the muffler clamp (20), as shown in Fig. D, to the following torque.

Torque 16 ft·lb

194
Fairing

Fairing Assembly

No. Name and specifications Quantity No. Name and specifications Quantity
1 Front Fender 1 15 Rear Headlight Fairing 1
2 Rear, Front Fender 1 16 Rear Left Headlight Fairing 1
3 Right Lower Cowling 1 17 Right Decorative Plate, Fuel Tank 1
4 Center Lower Cowling 1 18 Left Decorative Plate, Fuel Tank 1
5 Left Lower Cowling 1 19 Left Frame Deco Cap 1
6 Side Reflector 2 20 Battery box cover 1
7 Left Fuel Tank Cowling 1 21 Right Frame Decorative Cover 1
8 Inner Left Fuel Tank Cowling 1 22 Sun Visor, Speedometer 1
Decorative Inner Left Fuel Tank 1
9 1 23 Lower Instrument Cover
Cowling
Decorative Inner Right Fuel Tank 1
10 1 24 Rear-Right Tail Cowling
Cowling
11 Inner Right Fuel Tank Cowling 1 25 Rear-Right Lower Tail Cowling 1
12 Right Fuel Tank Cowling 1 26 Seat Assembly 1
13 Rear Right Headlight Fairing 1 27 Passenger Grab Rail 1
14 Headlight Fairing 1 28 Rear-Left Lower Tail Cowling 1

195
Fairing

Fairing Assembly

No. Name and specifications Quantity


29 Rear-Left Tail Cowling 1
30 Rear Fender Liner 1
31 Left upper frame cover 1
32 Left Frame Decorative Cover 1
33 Rear Reflector 1
34 Right Rear Fender Half 1
35 Left Rear Fender Half 1

196
Front Fender / Mounting Brackets

Assembly of the Front Fender

No. Name and specifications Quantity


1 Front fender 1
2 Screw M6×15.2 6
3 Screw M6×14 4
4 Mounting Bracket, Front Fender 2
5 Washer, Nylon 6
6 T-type Bushing 5×7×6×10×0.8 2
7 Nut M5 2
8 Rear, Front Fender 1
9 Bolt M5×0.8×14 2
10 Clamping Nut 1
11 Screw 5×12 1
12 Washer φ5 1
13 Spring Washer φ5 1

197
Front Fender / Mounting Brackets

Assembly of the Front Fender

Assembly:
Assemble the front fender (1) and the rear front
fender (8) together, as shown in Fig. A.

Install the mounting brackets for the front fender (4)


and their bolts (3) at the bottom of both front forks, as
shown in Fig. A.

Assembly:
Assemble the front fender (1), rear front fender (8)
and their fastening bolts (2) on both sides, as shown
in Fig. C.

198
Front Fender / Mounting Brackets

Disassembly of the Front Fender

Disassembly:
Conduct disassembly in reverse order of assembly.

199
Rear Fender / License Plate Mount

Assembly of the Rear Fender

No. Name and specifications Quantity


1 Right Rear Fender Half 1
2 Left Rear Fender Half 1
3 Rear Fender Liner 1
4 License Plate Bracket 1
6 Nut M6 2
7 Bolt M6×1×16 2
8 Bolt M6×16 2
9 Rubber Damper 1
10 Decorative Bolt M6×25 1
11 Nut M6 1
12 Ring Nut M6 1
13 Rear Reflector 1
14 Gasket φ5 2
15 Lock Washerφ5 2
16 Nut M5 2
17 Mounting Plate, Rear Reflector 1
18 Tool Kit Strap 1

200
Rear Fender

Assembly of the Rear Fender

Assembly:
Assemble the right piece of the rear fender (1), left piece
of the rear fender (2) and the welded assembly of the rear
fender support (D) together, as shown in Fig. A.
Install the license plate holder (4), rear reflector (3), rear
left and right turn signals (R) and license plate light (T)
on the rear fender assembly, as shown in Fig. A.

Install the front of the rear fender (3) on the motorcycle,


as shown in Fig. B.

201
Rear Fender

Assembly of the Rear Fender

Assembly:
Install the four screws (5) into the assembled
rear fender, and attach it to the frame, as
shown in Fig. A.
Fasten four bolts to the following torque:

Torque 7 ft·lb

202
Rear Fender

Disassembly of the Rear Fender

Disassembly:
Conduct disassembly in reverse order of assembly.

203
Rear Lower Fender and Chain Cover

Assembly of the Rear Lower Fender and Chain Cover

No. Name and specifications Quantity


1 Rear Lower Fender 1
2 Screw M6×15.2 5
3 Chain Cover 1

204
Rear Lower Fender and Chain Cover

Assembly of the Rear Lower Fender and Chain Cover

Assembly:
Attach the rear lower fender (1) onto the swing arm, and
install the fastening screws (2), as shown in Fig. A and
B.

Note:
Fasten the three screws to the following torque:

Torque 7 ft·lb

Assemble:
Attach the chain cover (3) to the swing arm, and install
the fastening screws (2), as shown in Fig. C.

Note:
Fasten the two screws to the following torque:

Torque 7 ft·lb

205
Lower Rear Fender and Chain Cover

Assembly of the Rear Lower Fender and Chain Cover

Disassembly:
Conduct disassembly in reverse order of assembly.

206

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