Benelli TNT300 Service Manual FINAL (001-207)
Benelli TNT300 Service Manual FINAL (001-207)
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:
1
Important Information in This Maintenance
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
1. Each chapter is divided into several sections, the headline included on the top
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
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
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
Thread Sealant
6
Content
Specification Chapter II
Chassis Chapter IV
Engine Chapter V
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
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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
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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
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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
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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
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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
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.
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
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)
18
Tachometer (4):
It indicates the rotations per minute of the engine at that time.
Coolant temperature measurement (5):
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.
Replacement of parts
Use only original Benelli replacement of parts. Also only
use oil and grease recommended by Benelli to lubricate
parts.
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.
Joint
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.
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.
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.
25
The ring clamp tool is
used for assembling
KST03BL01024 piston rings on pistons
and inserting them into
the cylinders.
26
The tool for
disassembling /
fastening clutch
component clamp nuts
1
is used for
disassembling /
fastening clutch
component clamp nuts.
27
Dial gauges are used for
1
measuring dimensions.
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
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
Measurement A= 32.495 mm
Measurement B= 25 mm
0.03 mm
33
Technical Data of the Engine
Engine Specifications
Exhaust Ø 22 mm
Valve head diameter
Intake 1.9-2.1 mm
Exhaust 1 ~ 1.1 mm
Valve seat amplitude
1.9 ~ 2.1 mm
Intake
0.05 mm
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
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
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
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)
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
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
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
45
Technical Data of Bolt and Screw Torque
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
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.
Symbol interpretation
Check, adjustment, cleaning, lubrication or replacement as required
Replacement
Tightening
Dealer ONLY
50
Regular Maintenance and Lubrication Interval Schedule
Frequency
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
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
Check operation I I I I I I I
36 Instruments
Check operation I I I I I I I
37 Battery
53
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
Remove the fuel tank fixing bolts (1), and take off the
fuel tank.
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
56
Fuel Hose
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”).
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
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.
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
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
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
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.
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
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).
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
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
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
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
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
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
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.
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
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.
69
Spark Plug
Overheated spark
Polluted spark plug
plug
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:
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
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
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
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
74
Valve Clearance
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
75
Brake Adjustment
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.
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:
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
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
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
79
Brake Fluid Inspection
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 22 ft·lb
81
Check of Brake Fluid
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:
82
Brake Pad Inspection
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.
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
Check:
Front / Rear brake hoses.
Check:
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
Torque 89 ft·lb
85
Drive Chain Adjustment
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.
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
Note:
Support the motorcycle using a rear stand; lift the front
wheel off of the ground using a jack under the header
pipe.
Disassembly:
Remove the fastening bolt (G) using special tool (F),
Fig. C
87
Steering Stem Bearing Adjustment
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
89
Front Fork Inspection
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
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
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.
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.
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)
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
Recharge
As shown in Fig. F, the voltage table after charging
the open-circuit voltage of battery for 30 minutes
Open-circuit voltage (V)
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
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.
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.
98
Battery Charging and Inspection
Battery
Installation:
Battery
Tighten the 4 bolts (C), after installing the battery hold
down bracket.
terminals.
99
Fuse Inspection
Fuses
The following procedures are applicable to all fuses.
Check: Fuse
Connect a multimeter to the fuse and check whether it
is in good condition.
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.
101
Replacement of the Headlight Bulb
Disassembly:
Remove the headlight support fastening bolts (1).
102
Replacement of the Headlight Bulb
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:
Use the adjusting screw (A) on the back of the
headlight to adjust the beam of the headlight, Fig. B
104
Front Signal Light Bulb
Assembly:
Install the light in inverse order of disassembly.
105
Rear License Plate Light
106
Rear License Plate Light
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
Note:
Support the motorcycle using a rear stand; lift the front
wheel off of the ground using a jack under the header
pipe.
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
11 Bearing 6204-2RS 2
110
Front Wheel and Front Brake Rotor
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
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.
112
Front Wheel and Front Brake Rotor
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
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
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
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
115
Front Wheel and Front Brake Rotors
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.
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
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:
Right wheel spacer (2) (Fig. C), Left wheel spacer
(11) (Fig. D).
119
Rear Wheel and the Rear Brake Rotor
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.
Check:
Sprocket Carrier
If there is any cracks / damage, please replace
120
Rear Wheel and the Rear Brake Rotor
Check:
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:
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
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
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.
Torque 33 ft·lb
Note
Fasten the self-locking nuts in a crisscrossed sequence.
124
Rear Wheel and 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.
Torque 7 ft·lb
Note
Fasten the bolts in a crisscrossed pattern.
125
Rear Wheel and the Rear Brake Rotor
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
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
127
Front and Rear Brakes
Rear Brake
128
Front and Rear Brakes / 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
Measurement:
Wear limit of the brake pads
If they are below the minimum specifications, please
replace the brake pads in pairs.
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
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
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 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
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)
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
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
136
Front and Rear Brakes / Rear Brake
Tighten the fastening bolts (X) to the brake master cylinder (6), Fig. B, to the following torque:
Torque 7 ft·lb
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
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)
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
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
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
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
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
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
Remove the front fork cap bolt (1), Fig. A
144
Front Suspension / Front Shock Absorber
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.
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
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
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
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.
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
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).
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:
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.
Inserting:
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
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:
Assembly:
Fasten the upper bolt (1) using a socket, and torque it,
Fig. M
Fasten it to the following torque:
152
Front Suspension / Front Shock Absorber
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.
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.
Torque 16 ft·lb
157
Control / Handlebar
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
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
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
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
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
162
Rear Shock Absorber
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
Check:
164
Rear Shock Absorber
Assembly:
Assemble the bolt (4), as shown in Fig C, and
tighten it to the following torque:
Torque 44 ft·lb
Torque 44 ft·lb
165
Drive Chain and Swing Arm
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
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.
167
Drive Chain
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
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
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:
171
Rear 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.
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
178
Frame / 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
Torque 7 ft·lb
Connect:
Rear turn signal lights and the license plate light wires.
179
Frame / Rear License Plate Support
Disassembly:
Conduct disassembly in reverse order of assembly.
180
Frame / Side Stand
181
Frame / 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.
Torque 33 ft·lb
182
Frame / Side Stand
Disassembly:
Conduct disassembly in reverse order of assembly.
183
Frame / 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
Assemble:
Front-left foot pedal support (1), as shown in Fig.
A.
Note
Use thread locker at the end of the threads.
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:
Conduct disassembly in reverse order of assembly.
186
Frame / 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
Assemble:
Front-right foot pedal support (1), as shown
in Fig. A.
Note
Use thread locker at the end of the threads.
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
Disassembly:
Conduct disassembly in reverse order of assembly.
189
Muffler
Muffler Assembly
190
Muffler
Muffler
Exhaust system
Manifold Muffler body
191
Muffler
Muffler Disassembly
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.
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.
Note
Apply lubricating grease to the exhaust pipe
gasket to keep it stuck to the engine exhaust outlet,
as shown in Fig. B.
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.
Torque 16 ft·lb
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
196
Front Fender / Mounting Brackets
197
Front Fender / Mounting Brackets
Assembly:
Assemble the front fender (1) and the rear front
fender (8) together, 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:
Conduct disassembly in reverse order of assembly.
199
Rear Fender / License Plate Mount
200
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.
201
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:
Conduct disassembly in reverse order of assembly.
203
Rear Lower Fender and Chain Cover
204
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
Disassembly:
Conduct disassembly in reverse order of assembly.
206