Brixton BX125 Service Manual.

BRIXTON BX125
Service Manual
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Contents
前言 Preface ............................................................................................................................ 5
准备资料 Service Data ........................................................................................................... 6
检查/调整 Inspection/Adjustment ........................................................................................ 24
车体的检查和维护 Vehicle body Inspection and Maintenance .................................................. 47
一、刹车 I Braking System ......................................................................................................... 49
1.1 保养说明 Maintenance Instructions ............................................................................... 49
1.2 故障诊断 Fault Diagnosis ............................................................................................... 51
1.3 前液刹 Front Hydraulic Brake ........................................................................................ 53
1.4 后液刹 Rear Hydraulic Brake ......................................................................................... 55
二、车身覆盖 II Motorcycle Exteriors ....................................................................................... 58
三、前轮/前悬挂 III Front wheel/ front suspension ................................................................... 62
3.1 准备资料 Service Data ................................................................................................... 62
3.3 前轮 Front wheel ............................................................................................................. 66
3.4 方向把 Steering handlebar .............................................................................................. 69
3.5 前叉 Front fork................................................................................................................ 71
四、后轮/后悬挂 IV Rear Wheel/Rear Suspension .................................................................... 77
4.3 后轮 Rear Wheel ............................................................................................................. 81
4.4 后减震器 Rear Shock Absorber ...................................................................................... 82
4.5 后摇臂 Rear swing arm.................................................................................................... 83
4.6 驱动链条 Drive Chain .................................................................................................... 84
五、蓄电池/充电系统 V. Battery/Charging System ................................................................... 88
5.3 蓄电池 Battery ................................................................................................................ 92
5.4 充电系统 Charging System ............................................................................................ 94
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5.5 电压电流调整器 Voltage-current Regulator .................................................................. 95
5.6 发电机充电、照明线圈 Generator Charging and Lighting Coils ................................ 97
5.8 发电机的拆卸 Generator Removal .............................................................................. 97
六、点火系统 VI Ignition System .............................................................................................. 99
6.1 准备资料 Service Data ................................................................................................. 100
6.2 故障诊断 Fault Diagnosis ............................................................................................. 101
6.3 点火系统检查 Ignition System Inspection ................................................................... 103
6.4 点火线圈 Ignition Coil ................................................................................................. 106
6.5 触发器 Trigger .............................................................................................................. 107
七、启动系统 VII. Starting System .......................................................................................... 107
7.3 启动电机 Starter Motor ................................................................................................ 109
7.4 启动继电器 Starter Relay ............................................................................................. 112
八、灯泡类/开关/仪表 VIII. Bulbs/Switches/Instruments ....................................................... 114
8.3 前照灯灯泡更换 Headlamp bulb replacement ........................................................... 116
8.4 前转向灯更换 Replacement of the front turn signal light ............................................ 116
8.5 尾灯/牌照灯/后转向灯更换 Replacement of taillight/license plate light/rear turn signal
light....................................................................................................................................... 116
8.6 仪表 Instrument............................................................................................................. 117
8.7 主开关 Main Switch ..................................................................................................... 117
8.8 喇叭 Electric Horn ........................................................................................................ 119
8.9 把手开关 Handle Switch .............................................................................................. 119
发动机的检查和维护 Inspection and Maintenance of Engine ................................................. 120
九、润滑系统 IX Lubricating system .................................................................................. - 126 -
9.1 准备资料 Service Data ............................................................................................ - 126 -
9.2 故障诊断 Fault Diagnosis ........................................................................................ - 127 -
9.3 机油泵 Engine Oil Pump ......................................................................................... - 128 -
十、冷却系统（无水冷系统）(整条删除不用翻译) ......................................................... - 130 -
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10.1 准备资料 ................................................................................................................. - 130 -
10.2 故障诊断 ................................................................................................................. - 130 -
10.3 水泵 ......................................................................................................................... - 131 -
十、气缸头 Cylinder head .................................................................................................... - 135 -
10.1 准备资料 Service Data .......................................................................................... - 135 -
10.2 故障诊断 Fault Diagnosis ...................................................................................... - 136 -
10.3 气缸头 Cylinder Head ........................................................................................... - 137 -
十一、气缸体与活塞 XI Cylinder Block and Piston .......................................................... - 148 -
12.3 气缸体 Cylinder Block .......................................................................................... - 150 -
十二、曲轴箱 XII Crankcase ............................................................................................... - 157 -
12.3 曲轴箱 Crankcase .................................................................................................. - 161 -
12.4 离合器 Clutch ........................................................................................................ - 162 -
12.5 变档机构 Gearshift Mechanism ............................................................................ - 171 -
13.6 曲轴连杆组合 Crankshaft Connecting Rod Assembly ......................................... - 173 -
13.7 变速室 Transmission chamber ............................................................................... - 177 -
废气排放系统的检查与维护 Exhaust System Inspection and Maintenance ...................... - 181 -
十三、废气排放控制系统 XIII Exhaust control system ..................................................... - 182 -
13.1 废气排放控制系统保证书 Exhaust control system Guarantee ............................ - 182 -
13.2 定期保养须知 Periodical Maintenance Instructions ............................................. - 183 -
13.3 废气控制系统机械功能 Mechanical Functions of Exhaust Control System ....... - 185 -
13.4 触媒转化系统 Catalytic Conversion System ........................................................ - 185 -
电喷系统的检查和维护 Inspection and Maintenance of Electronic Fuel Injection System- 191 -
十四、电喷系统说明 XIV. Electronic Fuel Injection System ............................................. - 193 -
14.1 整车电喷系统介绍 Introduction to Electronic Fuel Injection System ................. - 193 -
14.2 电喷系统零件 Parts of Electronic Fuel Injection System ..................................... - 194 -
14.3 故障维修诊断方法 Fault diagnosis method.......................................................... - 205 -
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14.4 常见故障排除方法 Common Trouble Shooting Methods .................................... - 213 -
14.4.3 简明故障排除方法 Simple troubleshooting methods ........................................ - 215 -
BX125 电路图 BX125 Circuit Diagram ............................................................................... - 222 -
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Preface
BX125
The service manual contains descriptions of maintenance essentials on
BX125 motorcycle.
Service data include attentions that shall be paid on all the maintenance
operations in the service manual. Please read the manual carefully before
operation.
Check and adjustment contains statements on the main points of
inspection and adjustment, safety of the vehicle, maintenance means of
each component’s performance. This shall be implemented from the time
of periodical inspection.
The parts after Part 1 demonstrate disassembly, assembly and main points
of inspection of engine, finished motorcycle, engine and other
components. System diagrams, disassembly drawings, maintenance, fault
diagnosis and explanations are presented before each part when compiled.
Notes:
If patterns or structures of the motorcycles change, or differences exist
between pictures, drawings, instructions or others and physical products,
please take the later as the standard. The product is subject to change
without further notice.
5
Brixton Motorcycle
Service Data
General Safety Maintenance Regulation
Specification Sheet Fault Diagnosis
General Safety
Carbon monoxide (CO)

When it is necessary to start the engine, please make sure the workplace is well ventilated. You
shall never run the engine in an enclosed place.
Attentions
Gas exhausted from the motorcycle contains toxic carbon monoxide, which may lead to loss of consciousness
and even death. It is necessary to run the engine in an open area. If the engine is run in an enclosed site,
ventilation system shall be used.
Gasoline
Work in well-ventilated site. Fire and smoking are strictly forbidden in working sites or gasoline
storage places.
Battery
Battery electrolyte contains sulfuric acid, so do not let the eyes, skin, clothes infected with
electrolyte. Once the skin, clothes infected with electrolyte, thoroughly rinse with water; if
infected eyes, you should immediately go to hospital.
Special Tools
Correctly select the common tools and special tools when assembling or disassembling parts, and
the special tools shall not be alternated by common tools. In addition, the force should be
appropriate to avoid damaging parts.
High-temperature Burn
Pay attention to your safety during maintenance. Carefully, do not be burnt by the ghi-temperature
engine, exhaust pipe, muffler and other hot parts. You should take care of each other in case of
cooperation with others.
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Maintenance Regulations
While repairing and servicing, try to use tools of metric system as possible as you can. Incorrect
tools may damage the motorcycle.
Before take down or open protecting plate for maintenance work, please clean the dirt on external
surface of the component or the assembly to prevent the dirt from falling into the engine, chassis
or braking system.
After disassembly and before measuring friction, please clean

the components and purge with air compressor.
Do not bend or distort during operation to avoid difficult

operation or earlier damage.
Plastic parts may deteriorate due to aging, which are apt to be damaged by solvent or oil. Check
before re-installation and replace if necessary.
While removing a component with many assemblies, do from

outside to inside. Loosen firstly smaller assemblies.
For the complicated assemblies, such as gearbox, keep them in

a proper assembling order for the sake of easy assembly later.
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Pay special attention to the key fitting position before
disassembly. The components that are not used any more shall
be replaced on time before disassembly.
Length of bolts and screws are different for assemblies and protecting
plates. They shall be installed at correct positions. If confused, just put
the bolt inside the hole and see if it matches.
Fill lubricating grease into the groove during oil seal

installation. Check if the oil seal is smooth and if it is
possible to be damaged when installed.
Installation of rubber hose (fuel, vacuum, or coolant): insert its

end into bottom of connector so that there is enough room for the
hose clamp to grip the connector. Install the rubber or plastic
dustproof boot back to its originally designed position.
Disassembly of ball bearing: use a tool to push against one or

two (inner and external) bearing races. If the force works only
on one bearing race (whatever inner or external), the bearing
may be damaged when disassembled and it must be replaced.
8
BX125
Specifications (BX125)
Model BX125 Engine type 157FMI-C
Overall Length(mm) 2020 Fuel 93# unleaded gasoline
Number of
Overall Width(mm) 910 1
cylinders
Overall height(mm) 1105 Bore*stroke 57.3 mm *48.4 mm
Total
Wheelbase(mm) 1320 124.8
Displacement
Front
58kg Starting mode Electric
shaft
Engine
Weight (kg) Rear

76kg Cooling mode Air cooling
shaft
Total 134kg Lubricating
Combined force splash
mode
Cover tire of the front wheel
100/90-18
Tire
Spec. Cover tire of the rear wheel Air cleaner Paper - element
120/80-17
Wet multi-plate Fuel tank

Clutch type 14L
friction type capacity
Max. speed 101 km/h

Drive Train
Gearshift Maximum climbing

Manual
pattern Climbing
angle should not be less
capacity
than 20 degrees
Performance
Transmission Chain drive Idle speed-rpm 1500± 100rpm/min
Battery 12V-10AH/ Max. torque 11.4N.m/7000r/min

capacity/type lead-acid type
Max. power 8.3KW/ 8500 r/min
Electricals
permanent magnet
Generator type
AC motor
Compression
Spark plug D8RTC 9.3:1
ratio
Spark plug
0.6-0.8mm Diameter of
stroke
Brak
front brake φ276mm

e
Ignition type ECU disc
9
Diameter of
front brake
disc
φ220 mm
Diameter of
rear brake
disc
10
BX125
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故障诊断
启动困难或不能启动
故障诊断调整检查故障原因
检查汽油泵是否
工作正常汽油箱内无汽油
汽油箱喷油器的油管阻塞
汽油泵油管阻塞
供给喷油器的无汽油供给燃料箱蒸发控制系统管道阻塞
油量充足顺畅喷油器汽油滤清器阻塞
汽油泵泵油压力不够
拆下火花塞, 将火花火花塞不良
塞装入火花塞盖, 与火花塞污染
发动机搭铁检查火花 ECU 组不良
塞是否跳火触发器不良
点火线圈导线断路或短路
火花塞有火火花塞有弱火花点火线圈断路或短路
花跳火火花塞无火花主开关不良
充电线圈不良
压缩压力测定启动离合器不良
气缸活塞、活塞环不良
压缩压压缩压力太低
力正常无压缩压力气缸垫泄气
自动阻风作动不良
发动机无点发动机有爆发现
火爆发现象象但无发动的情进气歧管有空气吸入
形
点火时间不正确
节气门调整螺钉调整不良
再度拆下火花塞检查
喷油器喷油量过多
火花塞干燥火花塞潮湿自动阻风作动不良
油门开度过大
12
Fault Diagnosis
Hard to Start or Unable to Be Started
Fault Diagnosis Adjustment Fault Cause
Check whether
the gasoline No gasoline in the gasoline tank
pump works
normally Oil tube blockage of gasoline tank injector
Oil tube blockage of gasoline pump

Adequate and smooth No gasoline
gasoline supplied for supplied for Tube blockage of fuel tank evaporation
control system
the injector the injector Blockage of gas filter
Insufficient pressure of gasoline pump

Remove the spark plug, Failure of spark plug
put the spark plug into
spark plug cover, and Polluted spark plug
check whether there are
sparks of spark plug after
bonding with the engine Failure of ECU Assembly
Failure of trigger
Sparking of Weak sparks of Ignition coil wire is disconnected or under
spark plug spark plug, no short-circuits
sparks of spark plug Ignition coil is disconnected or under
short-circuit.
Failure of main switch
Determination of Failure of charge coil
compression pressure Failure of startup clutch
Failure of cylinder piston and piston ring

Compression Too low or no
pressure is compression
normal pressure Air leakage of cylinder gasket
Failure of automatic choke apparatus

No ignition Ignition outbreak
outbreak of of engine but Air in theinjection manifold
engine without starting
Improper ignition time
Remove the spark plug Improper adjustment of throttle

adjustment screw
for inspection again
Excessive gasoline injected by injector

Dry spark Wet spark Failure of automatic choke apparatus
plug plug
Large throttle opening
13
回转不顺（速度不起、无力）
空气滤清器阻塞
发动发动机轻轻
汽油不良
的加油看看
燃烧箱蒸发控制系统管道阻塞
发动机回转速发动机转速无排气管阻塞
上升法完全上升自动阻风不良
节气门不良
调整点火正时使用
点火正时灯 ECU 组不良
触发器不良
点火时间正确点火时间不正确
压缩压力测定
气缸活塞、活塞环不良
气缸垫泄气
压缩压力正常压缩压力太低
清除污物
节气门阻塞检查
无阻塞现象有阻塞
清除污物
拆下火花塞检查
火花塞热值不合
无污染无变色有污染变色
检查曲轴箱内机油量是机油量过多
否多或污染机油量过少
机油量正常机油量多机油无更换
活塞气缸磨损
检查气缸头机油润滑现象
混合气过稀薄
正常不正常汽油不良
发动机过热燃烧室积炭过多
点火时间过早
无过热有过热燃烧室积炭过多
汽油不良
加速行驶或运转离合器打滑
混合气稀薄
无爆震现象有爆震现象点火时间过早
14
Inflexible rotation (low revolutions or powerless)
Slowly start the

engine
Blockage of air filter
Failure of gasoline
Engine rpm Engine rpm
rises cannot rise Tube blockage of fuel tank
completely evaporation control system
Blockage of exhaust pipe
Failure of automatic choke
Adjust ignition apparatus
timing and adopt Failure of throttle
ignition timing light
Proper ignition Improper ignition
time Failure of ECU Assembly
time
Failure of trigger
Determination of
compression
pressure
Failure of cylinder piston and
Compression Compression piston ring
pressure is pressure is
normal too low Air leakage of cylinder gasket
Throttle blockage
inspection
No blockage Blocked Remove dirts
Remove the spark

plug for inspection Remove dirts
No pollution Polluted and Thermal value of spark plug is

and discoloring discolored sub-standard.
Check whether the machine
oil in crankshaft tank is
excessive or polluted Excessive machine oil
Machine oil is Excessive
normal machine oil Insufficient machine oil
Check the lubrication of No replacement of machine oil
machine oil in cylinder head
Normal Abnormal Piston cylinder is worn.
Gaseous mixture is too thin.
Engine overheat
Failure of gasoline
Too much carbon deposits in
No overheat Overheat
combustion chamber
Ignition time is too early
Too much carbon deposits in
Accelerate to travel
combustion chamber
or operate
Failure of gasoline
Clutch slippage
No knocking Knocking
Gaseous mixture is thin.
Ignition time is too early
15
回转不顺（特别是低速）
点火时间调整
ECU 组不良
正常不正常
触发器不良
节气门调整螺钉调
整
混合气太稀（放松螺钉）
调整良好调整不良
混合气太浓（锁紧螺钉）
垫片有空气吸入
隔热片垫片不良
节气门固定螺母放松
隔垫片破裂
无空气吸入有空气吸入
负压管破裂
拆下火花塞，装于火花
塞盖与发动机搭铁启动
火花塞不良或污染
发动机检查火花塞跳火
ECU 不良
火花塞跳火火花塞跳火不良点火线圈不良
良好时火花塞导线断路或短路
主开关不良
负压管损伤
良好不良
空气通孔阻塞
16
Inflexible rotation (especially low-speed)
Ignition time
adjustment
Failure of ECU Assembly
Normal Abnormal
Failure of trigger
Adjustment of
throttle adjustment
screw
Gasoline mixture is too thin

(release screw)
Proper Improper
adjustment adjustment
Gasoline mixture is too thick (lock
screw)
Air aspirated in
gasket
Failure of insulation pad
Fixed nut of throttle is loosen
No air Air aspirated
aspirated Insulation pad is broken.
Negative pressure tube is broken
Remove the spark plug, put the
spark plug into spark plug cover, and
start the engine to check whether
there are sparks of spark plug after Spark plug is failure of or polluted
bonding with the engine
Proper Improper Failure of ignition coil
sparking of sparking of spark
spark plug plug Ignition coil wire is disconnected
or under short-circuits.
Negative pressure tube is damaged

Proper Improper
Air hole is blocked
17
回转不顺（高速）
点火时间调整
ECU 组不良
正常不正常
触发器不良
汽油箱内汽油量少
汽油管汽油过滤器阻塞
正常不正常
燃油箱蒸发控制系统管道阻塞
自动油环不良
喷油器阻塞
无阻塞阻塞清除
良好弹簧折断弹力
疲乏弹簧不良
18
Inflexible rotation (high-speed)
Ignition time
adjustment
Normal Abnormal
Failure of trigger
Small quantities of gasoline in the

gasoline tank
Gasoline tube gasoline filter
Normal Abnormal
blockage
Tube blockage of fuel tank
evaporation control system
Injector clogged
Failure of automatic oil ring
No Blockage
blockage Remove
Good Fatigue elastic

force due to Failure of spring
breaking of spring
19
充电不良（蓄电池过放电或过充电）
测量蓄电池两端的
电压发动发动机
蓄电池寿命已到
蓄电池电压无蓄电池电压上升至
上升正常值，熄火后又蓄电池不良
恢复原电压
检查电压调整器插头是否松
插头接触不良
正常不正常配线的红色线断路
检查电压调整器插座红色线接万用
电表正负极线接车体其间的电压
电压调整器
有电压无电压配线的白色线断线
交流发电机线圈阻抗值测定
线圈不良
正常异常接头接触不良
交流发电机白色线断
蓄电池不良
充电不良过充电
发动发动机，电压调整器插座红色线
接三用电表正负极线接车体其间的电
电压高于正电压正常
常值
检查电压调整器配线是否接触不良
接头接触不良配线接地不良
正常松弛接触不良
电压调整器单体测试阻抗
电压调整器不良
20
Failure of charging (battery overdischarge or overcharge)
Measuring the voltage at

both ends of the battery
and starting the motor
Out of battery life
No voltage rise The battery voltage rises

of battery to normal, and then
restores to the original
Failure of battery
voltage after flameout
Check the voltage regulator

plug is loose
Poor contact of plug

Normal Abnormal
Red line breakage of wiring
Check the voltage between the pole lines

and the vehicle body when connecting the
red line of the voltage regulator socket to
multimeter positive and negative pole lines
and connecting it to the vehicle body
Voltage regulator
Voltage No voltage
found found White line breakage of wiring
Alternator coil impedance

measuring
Failure of ignition coil

Normal Abnormal
Poor contact of joint
Breakage of AC generator white line
Failure of battery
Failure of charging
Starting the engine, connecting the red
and overcharge
line of the voltage regulator socket to
avometer positive and negative pole lines
and connecting it to the vehicle body
The voltage is The voltage

higher than the is normal
normal
Check whether the wiring of the voltage
regulator is properly contacted
Normal Poor contact Poor contact of joint and poor

Test impedance of single
voltage regulator grounding of wiring
Failure of voltage regulator
21
火花塞无跳火
更换新火花塞再检查
原火花塞不良
火花塞跳火弱火花强
或无跳火
检查火花塞再检查
火花塞盖松弛
无松弛有松弛
检查 ECU 组插头是否松弛
插头接触不良
正常不正常
检查 ECU 组导线插头各端子间
主开关不良
的导通，抵抗值测定
充电线圈不良
触发器不良
正常不正常点火线圈不良
相关部位检查
主配线断
正常不正常接头插座接触不良
使用 ECU 测试器检查 ECU 组

CDI 组不良
正常不正常
使用 ECU 测试器检查点火线圈
点火线圈不良
不正常
22
No sparking of spark plug
Replace the spark plug

and reinspect
No or weak Strong Failure of original spark plug

sparking of sparking
spark plug
Inspect the spark

plug and reinspect
Not loose Loose Spark plug
Check whether the ECU

assembly plug is loose
Normal Abnormal Poor contact of plug
Check the conduction between

terminals of ECU assembly wire plug,
and measure the resistance value
Failure of charge coil
Normal Abnormal Failure of trigger
Failure of ignition coil
Related position
inspection
Normal Abnormal Breakage of main wiring

Poor contact of joint and socket
Use ECU tester to check the

ECU assembly
Normal Abnormal Failure of CDI Assembly
Use ECU tester to check the

ignition coil
Abnormal Failure of ignition coil
23
检查/调整 Inspection/Adjustment
准备资料前/后刹车自由行程
Service data Front/rear brake stroke
定期保养检查表前/后制动蹄块磨损
Periodic maintenance schedule chart Wearing of front/rear brake shoe
发动机机油/滤油网前大灯
Engine oil/ oil screen Headlamp
汽油滤清器离合器
Fuel filter clutch
油门拉线的检查/调整前/后悬挂系统
Inspection/adjustment of throttle cable Front/rear suspension
system
空气滤清器螺栓/螺母/固定件
Air cleaner Bolt/nut/fasteners
火花塞轮圈/轮胎
Spark plug Wheel rim/tire
蓄电池轮胎规格
Battery Tire specification
节气门方向柱轴承及把手固定件
Trottle Steering stem bearing and handlebar fixation
气缸压力 Cylinder pressure
驱动链条 Drive chain

24
准备基准 Basic Data
一般 General Precautions
警告！ Warning!
•发动机运转前，确认周围空气是否通风良好，绝不可在密闭场所发动发动机，废气含有一氧化碳会使
人失去知觉或丧命。
Before running the engine, please make sure if the workplace in is well ventilated. You shall never run the
engine in an enclosed site. Gas exhausted from the motorcycle contains carbon monoxide, which may lead to
loss of consciousness and even death.
•在某种情况下，汽油容易挥发并爆炸，工作地方要通风，并且熄火，在工作区内或储油处严禁烟火。
Under certain conditions, gasoline is highly volatile. Work in well-ventilated site. Fire and smoking are strictly
forbidden in working sites or gasoline storage places.
规格 Specifications
发动机
怠速回转速 1500±100rpm/min
火花塞间隙 0.6-0.8mm 机油容量 1.0L
火花塞规格 D8RTC
Engine
Idle speed 1500±100rpm/min
Spark plug stroke 0.6-0.8mm Engine oil 1.0L
capacity
Spark plug type D8RTC
车架（注意表格格式有变动）
前刹车手柄自由行程 10-20mm 后刹车踏板自由行程 10-20mm
轮胎气压单位：Kpa 前轮规格 100/90-18 前轮气压 225kpa
BX125
后轮规格 120/80-17 后轮气压 225kpa
扭力值前轮轴螺母 75-85 N·m 后轮轴螺母 75-85 N·m
Frame
Stroke of front brake 10-20mm Stroke of rear brake 10-20mm
handle pedal
Pneumatic pressure unit Front 100/90-18 Front wheel 225kpa
of tire: Kpa wheel pneumatic
spec. pressure
BX125
Rear 120/80-17 Rear wheel 225kpa
wheel pneumatic
spec. pressure
25
Front wheel 75-85 N·m Rear wheel shaft nut 75-85 N·m
Torque
shaft nut
定期保养检查表
300 1000 4000 8000 12000 16000

保养里程和时间 KM KM KM KM KM KM
使用工具
十二个十五个
新车一个月三个月六个月
月月
检查项目
* 空气滤清器 I C C R C 一般工具
* 汽油滤清器 I C C R C 一般工具
* 机油滤清器 C C C C C C 一般工具
发动机机油更换 R 每 5000KM 更换一次一般工具
胎压计
轮胎气压 I I I I I I
充气机
比重计
蓄电池检查 I I I I I I
万用电表
作动空隙检查 I I I I I I 一般工具
方向把松动情况检查 I I I I 一般工具
减震器作动检查 I I I I 一般工具
各部位螺栓松紧检查 I I I I I I 扭力扳手
检查齿轮箱是否漏油 I I I I I I 一般工具
* 火花塞检查或更换 I I R I I 一般工具
* 齿轮箱油的更换 I 每 5000KM：R 一般工具
车体各部位润滑 L L L 润滑油注油器
排气管 I I I I I I 一般工具
* 点火正时 I I I I I I 正时灯
* 节气门 A I 每 10000km：I 转速计
* 怠速废气检查 A I A A A A CO HC 分析仪
* 油门检查 I I I I I 一般工具
燃油管路检查 I I I I I 一般工具
灯光仪表电气设备 I I I I I I 目视万用电表
主脚架侧支架 I I I I 一般工具
减震器 I I I I 一般工具
* 发动机螺栓扭力 I I I I I 扭力扳手
Periodic maintenance schedule form
26
Mileage and 300 1000 4000 8000 12000 16000
interval
KM KM KM KM KM KM
Tools
New One three Six Twelve Fifteen
Vehicle month months months months months
Items
* Air cleaner I C C R C Common tool
* Gasoline filter I C C R C Common tool
* Engine oil filter C C C C C C Common tool
Engine oil replacement R Every 5000KM: R Common tool
Tire gauge, air
Tire pressure I I I I I I
inflator
Densimeter,
Battery inspection I I I I I I
multimeter
Actuating stroke
I I I I I I Common tool
inspection
Inspection of steering
I I I I Common tool
handle bar looseness
Shock absorber
I I I I Common tool
actuating inspection
Inspection of looseness
I I I I I I Torque wrench
of bolts at all positions
Check leakage of
I I I I I I Common tool
gearbox
Spark plug inspection

* I I R I I Common tool
and replacement
Replacement of
* I Every 5000KM: R Common tool
gearbox oil
Lubrication of all the Lubricant
L L L
places on the vehicle injector
Exhaust pipe I I I I I I Common tool
* Ignition timing I I I I I I Timing light
* Throttle A I Every 10000km: I Tachometer,
Idle exhaust gas CO HC
* A I A A A A analyzer
inspection
* Throttle inspection I I I I I Common tool
Fuel hose inspection I I I I I Common tool
Lamps, instrument and Visual
I I I I I I
electric apparatus multimeter
27
Main stand and side stand I I I I Common tool
Shock absorber I I I I Common tool
* Torque of engine bolt I I I I I Torque wrench
28
预期检查
1 点火系统—-有明显的连续性点火失常，发动机失火，后燃过热等现象进行保养检查。
2 积炭清除—-有明显的马力不足，将气缸头，活塞头，排气系统的积炭清除。
3 活塞、气缸—-气缸过度磨损，卡缸请更换新品。
Expected Inspection
1 Ignition system—-perform maintenance inspection on obvious and continuous ignition malfunctions,
engine on fire, overheated back burning and others.
2 Carbon deposit removal—-obvious underpower, get rid of carbon deposited at cylinder head, piston head
and air exhaust system.
3 Piston and cylinder—-When cylinder is over worn or stuck, please replace it.
请定期到 KSR 经销商作检查，调整以保最佳车况。

Please go to your local KSR periodically for inspection and adjustment to keep your vehicle in
best conditions.
上表以每月行使 1000 公里为参考。
In above table, monthly 1000km travel is employed as reference.
I—检查 A—调整 R—更换 C—清洗 L—润滑
I— Inspect A—Adjust R—Replace C—Clean L—Lubricate
注：1.“*”废气排放的项目，以当地国家环保局的规定，必须以公司使用说明书的规定实施
正常保养，严禁私自调整修理等，否则恕不负责。
Notes: 1. “*” for items involved in exhaust gas, which meets regulations of Local Environmental
Protection Agency. Normal maintenance shall be performed according to specifications on the
user’s manual; unauthorized repair and adjustment are forbidden. We will not be responsible for
the results.
2.在沙石路面或环境严重污染下行驶，应增加清洗空气滤清器的次数，以延长寿命。
2. You shall clean more frequently the air cleaner to extend its service life when your motorcycle
is used on sand-gravel roads or in severely polluted environment.
3.经常高速行驶，行驶里程较多者，保养频度要增加。
3. More frequent servicing may be required when the motorcycle is often driven at a high speed or
travels a long distance.
发动机机油/滤清器 Engine oil/Oil filter
机油量 Engine oil level

*注意 Attentions
•检查机油量时车辆必须停放在平坦地
面上作业。
Motorcycle shall stand on the flat ground
while checking engine oil level.
29
•发动机运转 2-3 分钟后，停止约 2-3
分钟后再检查机油量。
Inspect engine oil level when the engine
has run for 2~3 minutes and stopped for
2~3 minutes
检查机油量。
Check engine oil level.
机油量在下限以下位置时补充机油到上
限位置。
When the engine oil level is at the lower limit, refill engine oil to
its upper limit
机油更换 Engine oil replacement

*注意 Attentions
发动机暖机时更换可使机油更容易流
出。
When the engine is warm, replace engine
oil. The oil can flow out easily.
关掉发动机。
Shut down the engine.
拆下曲轴箱底部的机油放油螺栓，并将
机油放出。
Screw off the drain plug at the bottom of crankcase to drain engine oil.
在机油完全漏出后，将机油放油螺栓及密封垫圈清洗之后再安装回去。
When the engine oil is completely drained, put back cleaned drain plug and sealing ring.
补充机油至规定容量。
Refill engine oil to specified level.
机油容量：1.0-1.2L
Engine oil capacity: 1.0-1.2L
检查机油泄漏，发动发动机怠速运转速 3 分钟。
Check if there is engine oil leakage. Start the engine and run the engine on idle for 3 minutes.
再检查机油量。
Check engine oil level again.
汽油滤清器 Gasoline filter
燃油管劣化、损伤的检查。
Inspect the deterioration and damage for fuel pipe
如有劣化、损伤、燃料泄漏等现象则应更换新品。
Replace in case of deterioration, damage or fuel leakage.
30
警告！ Warning!
严禁烟火。
No smoke, no fire.
油门拉线的检查 / 调整 Throttle cable
inspection and adjustment
检查油门拉线是否顺畅。
Check if the throttle cable is unhindered.
检查油门拉线游隙。
Check stroke of throttle cable
自由行程：2-6mm
Stroke shall be: 2-6mm.
主要调整部位在节气门侧。
The main adjustment position is at the throttle.
把固定螺母放松，然后旋转调整螺母调整。
Release the locknut, and then adjust the adjusting nut.
空气滤清器 Air Cleaner
空气滤清器的更换。
Replace air cleaner.
拆下座垫
Remove seat cushion
拆下左侧盖
Remove the left side cover
拆下空滤器螺钉
Remove the screw of air cleaner
拆下空滤器螺栓
Remove the bolt of air cleaner
31
拆下空气滤清器盖固定螺钉。
Remove the fixed screw on the
air cleaner cover
拆下螺钉取下滤清器。
Unscrew the air cleaner.
将纸质滤芯从空气滤清器上拆下。
Remove the paper element from
the air cleaner.
检查纸质滤芯是否污染、损伤。
Check the contamination and damage of paper element.
如有损伤污染请更换新品。
If the filter is contaminated or
damaged, if necessary replace it with a new one.
如有污染请更换。
If it is contaminated, replace it with a new one.
更换时间 Replacing Time

车辆若经常在恶劣路面或雨天行走时应提早更换。
If driving under adverse conditions or in rainy days frequently, replace the air cleaner earlier.
*注意 Attentions
•安装空气滤清器盖要确认空气滤清器是否装好。
Check whether the air cleaner is installed in place
before installing the air cleaner cover.
火花塞 Spark plug
拔下火花塞帽
Remove the spark plug cap
32
用火花塞套筒拆下火花塞。
Remove the spark plug with a spark plug socket.
33
检查火花塞的烧损、污染、积炭
Check the burning, contamination and carbon deposits for
spark plug.
如有以上情况时请使用火花塞清除器或钢刷清除。
Eliminate with a spark plug eliminator or steel brush in case
of occurrence.
火花塞间隙检查。
Check the stroke of spark plug.
间隙：0.6-0.7mm
Stroke: 0.6-0.7mm
火花塞型号：D8RTC
Spark plug model: D8RTC
*注意 Attentions
火花塞安装时先用手装入后再使用火
花塞套筒上紧。
Install the spark plug manually, and then
tighten it with a spark plug sleeve.
蓄电池 Battery
蓄电池拆卸 Battery removal

拆下右侧盖。
Remove the right cover.
先拆下负极导线再拆下正极导线。
Disconnect the battery negative (-) lead wire first
and then the positive (+) lead wire.
取出蓄电池。
Take out the battery.
警告！ Warning!
正极拆卸时作业中工具不可与车架接
触，会引起短路火花会引燃汽油，蓄电
池会损坏非常危险。
During positive lead wire disconnection,
be sure to prevent the tools being used
from touching the frame; or it will result
in short circuit sparks, which may ignite
gasoline and damage battery. It is
34
dangerous!
安装时以拆卸反顺序作业。
Install the battery in reverse order of removal.
警告！ Warning!
防止短路，先接正极再接负极。
To avoid short circuit, please connect
positive (+) lead wire first and then the
negative (-) lead wire.
充电状态（闭路电压）的检查
Battery charging (circuit voltage) inspection

打开座垫。
Open the seat cushion.
打开空滤器上盖，把蓄电池接头导线拆下。
Open the top cover of air cleaner, and remove the connector
wire of battery.
测量蓄电池端子间电压。
Measure the battery voltage between terminals.
完全充电：13.1V
Fully charged: 13.1V
充电不足：12.3V
Undercharge: 12.3V
*注意 Attentions
充电状态检查必须使用伏特表作业。
Voltmeter shall be used for charging-state
inspection.
35
充电 Charging
连接方法：充电机正极与蓄电池正极连接。
充电机负极与蓄电池负极连接。
Connection method: Positive pole of battery charger is connected to battery positive lead
wire; Negative pole of battery charger is connected to battery negative lead wire.
警告！ Warning!
•蓄电池附近严禁火源。
Battery shall be away from fire source.
•充电开始或完毕时必须先将充电机开
关关掉。以防止连接部位发生火花产生
爆炸危险。
Shut off charger switch first before or
after charging in case sparks may be
generated at connection parts, which may
result in explosion.
•充电时必须依照蓄电池上所标示电流
时间为基准作业。
During charging, please take the current
time labeled on the battery as the basic
time.
*注意 Attentions
•蓄电池急速充电出紧急外不可使用。
Battery quick charging is not
recommended except in case of
emergency.
•充电后必须隔 30 分钟后再进行测量电
压。
After charging, wait at least 30minutes
and then measure the battery voltage.
充电电流：标准：0.4A
急速：4.0A
充电时间：标准：10-15 小时
急速：30 分钟
充电完成：闭路电压：12.8V 以上
Charging current: Standard: 0.4A
Quick charging: 4.0A
Charging time: Standard: 10-15hours
Quick charging: 30 minutes
After completion of charging: closed-circuit voltage: higher than 12.8V
36
节气门 Throttle
怠速调整 Idle speed adjustment

*注意 Attentions
怠速调整是在发动机暖机状态时实施。
Perform idle speed adjustment when the
engine is warm.
发动机暖机运转后实施。
Warm up the engine and then adjust idle speed.
运转发动机连接发动机回转计。
Run the engine and connect engine tachometer.
调整油门拉线制止螺钉止规定回转速。
Adjust the throttle cable lock-screw to specified RPM.
怠速转速：1400±100rpm/min
Idle speed RPM: 1400±100rpm/min
怠速回转不稳定，或轻轻加油不顺畅时再行调整
怠速调整螺钉。
If idle speed RPM is unsteady or idle speed is not smooth when the vehicle is gently accelerated,
adjust idle speed and adjust screws again.
37
驱动链松弛度 Drive chain slackness
驱动链的使用寿命依赖于适当的润滑、调整。维护
不当可能导致驱动链和链轮过早的磨耗。在严酷的
使用情况下，必须勤加维护。
The service lift of drive chain depends on the appropriate
lubrication, adjustment and maintenance. Improper
lubrication, adjustment and maintenance may cause the
earlier wearing of drive chain and sprocket. They shall
be maintained frequently under the adverse conditions.
将摩托车停放在平坦处，使之保持直立位置。
检查驱动链松弛度○,a。
Stand vertically the motorcycle on the flat ground and check drive chain slackness ○,a
驱动链松弛度：10-20mm。
Drive chain slackness: 10-20mm
驱动链的调整：
Adjustment of drive chain
每行车 1000 公里，调整驱动链以使链条
的垂度为 10—20mm。依据您的驾驶状况，
链条可能需要经常调整。
Adjust the drive chain after every traveling 1000km to make the chain sag to be 10-20mm. You
should frequently the drive chain as appropriate.
警告： Warning!
这些建议是最大调整时间间隔，实际上每次
驾驶前都应检查调整链条。链条过度松驰，可
能引起从链条脱链的事故或造成发动机的严重
损伤。
It is recommended to adjust the time interval to the
maximum extent. In fact, the chains should be
checked and adjusted before riding every time.
Excessive chain slack may cause the chain-off or
serious damage to the engine.
请按下述方法来调整链条：
Adjust the chains in accordance with the following methods:
(1)用支撑架支起摩托车。
(1) Prop up the motorcycle with a support.
(2)松开后轴螺母①。
(2)Unscrew the rear shaft nut ①.
(3)松开锁紧螺母②。
(3)Unscrew the locknut ②.
(4)向右或向左转动调整螺栓③，来调整链条的
松驰度，在调整链条的同时也必须保持前后
链轮对准中心成一直线。为有助于您进行这
38
个调整过程，在摆动臂及每一链条调整器上
均有基准标记，它们可以互相对准以及作为
从一端到另一端的参照。对准及调整好链条
的松驰度到 10—20 毫米之后，要重新固定
好后轴螺母，进行最后检查。
(4)Rotate the adjustment bolt ③ to the right and left to adjust the chain slackness; keep the
front/rear sprockets align the center in a straight line when adjusting the chains. To help you
make this adjustment process, there are reference marks on the swing arms and chain
regulators, and these reference marks can be aligned to each other and used as the reference
from one end to the other end. After aligning and adjusting the chain slackness to 10-20mm,
re-fix the rear shaft nut for final inspection.
注意： Attentions:
当换上新链条都必须检查两个链轮是否磨
损，如果必要的话，加以更换。
Check the wearing of both sprockets after

replacing the chains, and replace sprockets of
necessary.
定期检查时，链条检查下列的状况：
The followings should be checked during routine inspection:
(1)松动的销钉
Loosen pins
(2)损坏的滚轮
Damaged rollers
(3)干涸和生锈的链节
Dry or rusted chain links
(4)扭结或咬死的链节
Twisted or cut chain links
(5)过度的损伤
Excessive damage
(6)调整松驰的链条
Loosen chains
如果链条出现上述毛病时，那么链轮将有极大可
能也对之造成损伤。要对链轮检查下述内容：
In case of defects mentioned above occurred, the sprockets may be damaged. The followings
should be check for sprockets.
(1)过度磨损的轮齿
Excessively-worn wheel teeth
(2)折断或损坏的轮齿
fractured or broken wheel teeth
(3)松动的链轮固定螺母。
Loosen fixing nut of sprockets
驱动链的润滑
Lubrication of drive chain
应优先使用驱动链润滑脂润滑，可以购
39
买驱动链润滑脂，也可用机油或其它润
滑油代替。浸渍各链节接合，以使润滑
脂穿透到链板、销、衬套和滚子之间。
Select the drive chain lubricating grease in priority. The drive chain lubricating grease may be
purchased, or alternated with engine oil or other lubricating oil. Dip the joints of chain links to
make the lubricating grease penetrate into chain plate, pin, lining and roller.
*注意 Attentions
不要将新的驱动链条装在磨损的链轮上
或将磨损的链条装在新的链轮上。
Do not install new drive chains onto worn sprockets or install worn drive chains onto the new
sprockets.
链轮和链条都必须处于良好状态，
否则将会使更换的链条或链轮很快磨损。
Keep both sprocket and drive chain in good conditions, or newly replaced chain or sprocket will
be worn soon.
前/后刹车自由行程 Stroke of front/rear

brake
前刹车自由行程
Front brake stroke

在刹车拉杆的尖端处测量前刹车手柄的自由行程。
Measure stroke of front brake at the tip of front brake handle.
Stroke: 10-20mm
后刹车自由行程 Brake pedal stroke

在后刹车踏板的尖端处测量后刹车踏板的自由行程。
Measure stroke of brake pedal at the tip of front brake handle.
Stroke: 20-30mm.
请按下述方法来调整后刹车踏板自由行程：
Adjust the stroke of brake pedal as per the following methods:
(1)松开顶杆锁紧螺母①。
Release the locknut ① of lift rod.
40
(2)拧进或拧出顶杆②。来调整前刹车手柄的自由
行程，在自由行程调整到 20—30 毫米之后。
Screw or unscrew the lift rod ② to adjust the stoke of front brake handle to be 20-30mm.
(3)紧固顶杆锁紧螺母①。
Tighten the locknut of lift rod ①.
前 /后制动蹄块磨损 Wearing
of front/rear brake shoe
前制动蹄块磨损
Wearing of front brake shoe
当刹车刹到底时，从油镜处检查油位，如制动液的
液面低于图示箭头位置时，即应更换制动蹄块。
When stepping on the brakes in the end, check the oil level
at oil cup, if the brake fluid level is lower than the
arrow in the figure, intermediately replace the brake shoe.
后制动蹄块磨损
Wearing of rear brake shoe
当刹车刹到底时，查看油杯处检查制动液油位，
如制动液的液面低于图示箭头位置时，即应更
换制动蹄块。
When stepping on the brakes in the end, check the brake fluid level at oil cup, if the brake fluid
level is lower than the arrow in the figure, intermediately replace the brake shoe.
前大灯 Headlamp
调整 Adjustment
前大灯的光轴调整是旋松前大灯紧固
螺栓后，转动来调整。
Unscrew the mounting bolts of headlamp to adjust the headlight
optical axis.
41
离合器 Clutch
发动发动机，慢慢提高回转速检查离合器作动情况，
如车子不走或发动机熄火时检查离合器摩擦块。必要
时更换新品。
Start the engine, speed up the revolving speed slowly and check the clutch’s operating condition.
Check the friction block of the clutch if the motorcycle does not run or the engine is stalled.
Replace it with a new one if necessary.
离合器自由行程：10-20mm
Stroke of clutch: 10-20mm
请按下述方法来调整离合器自由行程：
Adjust the stroke of clutch as per the following
methods:
(1)松开顶杆锁紧螺母①。
Release the locknut ① of lift rod.
(2)拧进或拧出螺母②。来调整前刹车手柄的自
由行程，在自由行程调整到 10—20 毫米之后。
Screw or unscrew the lift rod ② to adjust the stoke of front brake handle to be 20-30mm.
(3)紧固锁紧螺母①。
Tighten the locknut of lift rod ①.
前 / 后悬挂系统
Front/Rear suspension
system
前悬挂 Front suspension

把前刹车拉紧将前减震器上下压缩检
查作动情形。
Grasp the front brake handle and
compress upward and downward the front shock absorber to check its actuation.
检查前减震器是否漏油，各部是否损伤松动。
42
Check if the front shock absorber leaks oil and if the components are loosened.
后悬挂 Rear Suspension

后减震器上下压缩检查作动情况。检查后减震器各部是否损伤松动。
Compress upward and downward the rear shock absorber to check its actuation. Check if
components on the rear shock absorber are loosened or injured.
把后轮悬架起来，将后轮摆动检查发动机悬挂衬套是否松动。
Lift and support the rear wheel and swing the wheel to check if engine suspension bushing is
loosened.
螺母/螺栓/固定件 Nuts/bolts/fasteners
检查车辆各部位螺栓，螺母，固定件是否松动。
Inspect whether bolts, nuts and fasteners at every part of the
motorcycle are loosened.
如有松动时，应上紧至规定扭力值。
If they are loosened, tighten them to specified torque.
轮圈/轮胎 Wheel rim/tire
检查、轮胎是否有裂痕及有铁钉类夹着或其他损伤。
Check whether there are cracks, nails and similar sharp objects, and other injuries on the tires.
检查轮胎气压。
Check tire pressure.
*注意 Attentions
轮胎气压测定在冷态时测定。
Measure cold inflation tire pressure.
规定气压单位：Kpa
轮胎规格轮胎气压
前轮 100/90-18 225±10kpa
BX125
后轮 120/80-17 225±10kpa
Specified air pressure Unit: Kpa

Tire specifications Tire pressure
43
Front 100/90-18 225±10kpa
tire
BX125
Rear 120/80-17 225±10kpa
tire
44
当轮胎中央胎面上的花纹深度达到表中程度时，
就应更换新的轮胎。
When the tread depth of the tire reaches the value in the table
below, the tire should be replaced.
最小胎面花纹深度
The minimum tread depth
Front tire 1.6mm
Rear tire 2.0mm
警告：Warning:
请勿试图修补损伤的轮胎。车轮平衡和轮胎
可靠性可能恶化。
Do not attempt to repair damaged tire. Wheel
balance and tire reliability may deteriorate.
轮胎充气不当将导致异常的胎面磨耗并威
胁安全。轮胎充气不足可能造成轮胎打滑，或
轮胎脱开，可能招致引起控制失灵的轮胎放气。
Improper tire inflation will cause abnormal tread
wear and threaten the safety. Underinflated tires
may cause tire slip, or tire disengagement, which
may lead to tire deflation caused by control
failure.
在轮胎过度磨耗情况下驾驶摩托车是一件危险
事情，不利于地面附着力和驾驶。
Driving a motorcycle at excessive tire wear

situation is a dangerous thing as the adhesive force
of the tire is lower than the normal.
检查前轮轴固定螺母是否松动。
Check whether the front axle fixing nut is loose.
检查后轮轴固定螺母是否松动。
Check whether the rear axle fixing nut is loose.
如有松动时上紧至规定扭力值。
If it is loose, it shall be tightened to the specified torque value.
扭力值：前轮轴 75-85N·m
45
Torque value: front axle 75-85N·m
后轮轴螺母 75-85N·m
Rear axle nut 75-85N·m
方向柱轴承及把手固定
Steering stem bearing and
handlebar fixation
把手左右摆动，检查确认导线类是否干涉。
Move left and right the handlebar and check if lead wires
disturb it.
前轮转动，把手自由摆动确认。
Rotate front wheel and confirm the handlebar can
move smoothly.
把手摆动不顺，松动时，检查方向柱轴承。
If the handlebar does not move smoothly and is loosened, check steering stem bearing.
46
车体的检查和维护
Vehicle body Inspection and Maintenance
前、后液刹（CBS）
Front and Rear Hydraulic Brakes (CBS)
序号名称序号名称
1 碟刹总成（CBS） 1-13 后碟刹推杆
1-1 前碟刹油管 2 1-14 后碟刹油管 2
1-2 碟刹 CBS 分配器 1-15 螺栓 M8×20
1-3 螺栓 M6×45 1-16 后碟刹连接板
1-4 前碟刹油管 1 1-17 后碟刹钳总成
1-5 前碟刹上泵 1-18 前碟刹下泵总成
1-6 螺栓 M6×25 1-19 前碟刹支架
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1-7 前碟刹手柄 1-20 螺栓 M10×35
1-8 碟刹半盖 1-21 前碟刹片
1-9 后碟刹油管 1 1-22 后碟刹片
1-10 后碟刹开关 1-23 螺栓 M6×16
1-11 后碟刹上泵总成 1-24 后碟刹支架
1-12 螺栓 M6×25
S/N Name S/N Name

1 Disc brake assembly (CBS) 1-13 Rear disc brake push rod
1-1 Front disc brake hose 2 1-14 Rear disc brake hose 2
1-2 Disc brake CBS dispenser 1-15 Bolt M8×20
Rear disc brake connecting
1-3 Bolt M6×45 1-16
plate
Rear disc brake caliper
1-4 Front disc brake hose 1 1-17
assembly
Front disc brake lower pump
1-5 Front disc brake upper pump 1-18
assembly
1-6 Bolt M6×25 1-19 Front disc brake support
1-7 Front disc brake handle 1-20 Bolt M10×35
1-8 Disc brake half-overlay 1-21 Front disc brake pad
1-9 Rear disc brake hose 1 1-22 Rear disc brake pad
1-10 Rear disc brake switch 1-23 Bolt M6×16
1-11 Rear disc brake upper pump assembly 1-24 Rear disc brake support
1-12 Bolt M6×25
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一、刹车 I Braking System
保养说明------------------------1.1
Maintenance Instruction-------------------1.1
故障诊断------------------------1.2
Fault Diagnosis-------------------------------1.2
前、后液刹（CBS） ------1.3
Front/rear Hydraulic brake-------------1.3
1.1 保养说明 Maintenance Instructions
作业注意事项 Precautions on operation

*注意 Attentions
•安装或拆卸时不能使刹车组件沾上油渍。
Please do not contaminate braking assembly with oil
while assembly or disassembly.
•清洗时应用规定清洗剂清洗以避免降低刹车性能。
Please use specified detergent to clean the braking
assembly, or it may reduce braking performance.
*在骑车前先检查刹车*
*Please check braking system before driving your motorcycle.*
1.1.1 规格
项目标准值可用限度项目标准值可用限度
专用刹车液 DOT4 - 液刹专用刹车液 DOT4 -
液刹盘厚度 4 3 液刹盘厚度 4.0 3.0
制动蹄块厚度 9mm 4.5mm 制动蹄块厚度 9mm 4.5mm
液刹盘直径 φ276mm - 液刹盘直径 φ220mm -
前后
液刹盘制动面跳动 0.1mm - 液刹盘制动面跳动 0.1mm -
泵油汽缸内径 Ф12.mm - 泵油汽缸内径 Ф16mm -
泵油活塞外径 Ф12 mm - 泵油活塞外径 Ф16mm -
卡钳汽缸内径 Ф25 mm - 卡钳汽缸内径 Ф25mm -
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卡钳活塞外径 Ф25 mm - 卡钳活塞外径 Ф25-mm -
分配阀活塞外径前端 Ф14 mm 分配阀活塞外径后端 Ф12.7 mm
Specifications
Items Standard Value Service Limit Items Standard Value Service Limit
Special brake fluid
Special brake fluid DOT4 - DOT4 -
for hydraulic brake
Hydraulic brake disc Hydraulic brake disc
4 3 4.0 3.0
thickness thickness
Brake shoe thickness 9mm 4.5mm Brake shoe thickness 9mm 4.5mm
φ276mm - φ220mm -
diameter diameter
0.1mm - 0.1mm -
Front brake surface runout Rear brake surface runout
Oil pumping cylinder Oil pumping cylinder
Ф12.mm - Ф16mm -
inner diameter inner diameter
Oil pumping piston Oil pumping piston
Ф12 mm - Ф16mm -
outer diameter outer diameter
Caliper cylinder Caliper cylinder
Ф25 mm - Ф25mm -
inner diameter inner diameter
Caliper piston outer Caliper piston outer
Ф25 mm - Ф25-mm -
diameter diameter
Distribution valve Front end Ф14 Distribution valve Rear end Ф12.7
piston outer diameter mm piston outer diameter mm
1.1.2 扭力值 Torque value

制动盘固定螺栓 15-25N·m
Brake disc mounting bolts 15-25N·m
前液刹下泵安装螺栓 25-35N·m
Front hydraulic brake lower pump mounting bolts 25-35N·m
前液刹油泵安装螺栓 7-9N·m
Front hydraulic brake oil pump mounting bolts 7-9N·m
前轮轴 75-85N·m
Front axle 75-85N·m
后制动盘固定螺栓 15-25N·m
Rear brake disc mounting bolts 15-25N·m
后液刹下泵安装螺栓 25-35N·m
Rear hydraulic brake lower pump mounting bolts 25-35N·m
后液刹油泵安装螺栓 7-9N·m
Rear hydraulic brake oil pump mounting bolts 7-9N·m
后轮轴 75-85N·m
Rear axle 75-85N·m
50
1.2 故障诊断 Fault Diagnosis
1.2.1 刹车性能不佳 Poor braking performance

 刹车调整不当
Improper brake adjustment
 制动蹄块组件、液刹盘磨损
Wearing of braking shoe assembly and hydraulic brake disc
 制动蹄块组件安装不当
Improper installation of braking shoe assembly
 制动蹄块组件液刹盘污染
Contamination of braking shoe assembly and hydraulic brake disc
1.2.2 刹车反应慢或手柄紧 Brake drags or tight handle

 刹车调整不当
Improper brake adjustment
 制动蹄块组件安装不当
Improper installation of braking shoe assembly
1.2.2 刹车异响 Noisy Braking

 制动蹄块组件液刹盘污染
Contamination of braking shoe assembly and hydraulic brake disc
1.2.4 制动手柄/踏板柔软或轻软 Spongy Brake Handle/Brake Pedal

 液压系统有空气
Air found in hydraulic system
 液压系统泄露
Leakage of hydraulic system
 制动踏板/盘脏
Dirty brake pedal/disc
 卡钳活塞密封磨损
Caliper piston seal wear
 制动踏板/盘磨损
Brake pedal/disc wear
 卡钳脏
Dirty caliper
 卡钳不能正常滑动
Improper sliding of caliper
 制动液少
Small quantity of brake fluid
51
 制动液通道堵塞
Brake fluid passage blockage
 卡钳活塞弯曲/残缺
Caliper piston bending / incompleteness
 主缸活塞弯曲/残缺
Master cylinder piston bending / incompleteness
 主缸活塞脏
Dirty master cylinder piston
 制动手柄/踏板弯曲
Brake handle / pedal bending
1.2.5 制动卡住或拉到一面 Brake Jammed Or Aside

 车轮偏差
Wheel bias
 制动软管接合处堵塞或受限
Brake hose junction clogged or restricted
 制动盘弯曲/残缺
Brake disc bending / incompleteness
 卡钳不正常的滑动
1.2.6 制动阻力 Brake Drag

 车轮偏差
Wheel bias
 制动踏板/盘磨损
Brake pedal/disc wear
 制动盘弯曲/残缺
Brake disc bending / incompleteness
 卡钳不正常滑动
5.2.7 制动手柄/踏板硬 Hard Brake Handle/Pedal

 制动系统堵塞/受限
Braking system clogged / restricted
 卡钳活塞粘着/磨损
Caliper piston adhesion/abrasion
 卡钳不正常滑动
 制动液管道堵塞/受限
Brake fluid pipe clogged / restricted
52
 卡钳活塞密封垫磨损
Caliper piston seal wear
 主缸活塞粘着/磨损
Master cylinder piston adhesion / abrasion
 制动手柄/踏板弯曲
Brake pedal/disc bending
1.3 前液刹 Front Hydraulic Brake
1.3.1 拆卸 Removal
*注意 Attentions
•制动蹄块总成组更换.
Replacement of brake shoe assembly
group.
•如有制动蹄块再次使用时，拆卸前应
在其侧部做上记号以使它能装回原来
位置。
If the brake shoe is reused, it shall be
marked on its side before demolition so
that it can be installed back to its original
position.
松开制动缸组件固定螺栓。
Release the brake cylinder assembly
mounting bolts.
从前减震器上拆下制动缸组件。
Remove the brake cylinder assembly
from the front shock absorber.
从前减震器处拆下下列组件
Remove the following components
from the front shock absorber
前液刹
Front hydraulic brake
1.制动蹄块
Brake shoe
2.前液刹油管
Front hydraulic brake tube
3.制动缸组件
Brake cylinder assembly
*注意 Attentions
•安装或拆卸时不能使刹车蹄块沾上油渍。
53
Please do not contaminate braking shoe
assembly with oil while assembly or
disassembly
•清洗时应用规定清洗剂清洗以避免降低刹
车性能。
Please use specified detergent to clean the
braking assembly, or it may reduce braking
performance.
拆下前轮轴。
Remove the front axle.
取下前轮。
Remove the front wheel.
从前轮上拆下前液刹盘
Remove the front hydraulic brake disc from the front wheel
1.3.2 检查 Inspection
检查制动蹄块、有无磨损，需要时应更换蹄块。
Check whether the braking shoe is worn out. Replace
the braking shoe if necessary.
测量制动蹄块、制动盘、记下最大值。
Measure the braking shoe and brake disc, and record the
maximum value.
测量制动蹄块的厚度
Measure the thickness of braking shoe.
可用限度：制动蹄块 4.5mm
Allowable limit: brake shoe 4.5mm
规格 Specifications
前液刹盘直径：φ276mm
Diameter of front hydraulic brake disc: φ276mm
*注意 Attentions
•如制动盘生锈,用#120 砂纸擦拭.
The brake disc shall be wrapped with #120
abrasive paper in case of rustiness.
•一定要用千分尺来测量.
A micrometer shall be used for the
measurement.
如制动盘和制动蹄块的厚度小于保养值或被
54
油脂污染,应更换.
If brake disc and braking shoe are contaminated by grease or their thickness is smaller than service
limit, replace them.
*注意 Attentions
•一定要用内游标卡尺、千分尺来测量.
Measure with vernier caliper and micrometer.
1.3.3 安装 Installation
安装前轮.
Install front wheel.
安装前液刹油管、制动缸组件。
Install the front hydraulic brake tubing and brake cylinder
assembly.
不要使制动蹄块粘上油脂
The braking shoe should not be contaminated by grease.
*注意 Attentions
如制动蹄块上有油脂,会降低刹车能力导致
刹车失效.
A contaminated braking shoe will reduce
braking performance and result in brake
failure.
将螺栓锁紧到规定扭力值。
Tighten the bolt to their specified torque value.
扭力值： Torque value:
前制动盘固定螺栓 15-25N·m
Front brake disc mounting bolts: 15-25N·m
前液刹下泵安装螺栓 25-35N·m
Front hydraulic brake lower pump mounting bolts 25-35N·m
前液刹油泵安装螺栓 7-9N·m
Front hydraulic brake oil pump mounting bolts 7-9N·m
前轮轴 75-85N·m
Front axle 75-85N·m
1.4 后液刹 Rear
Hydraulic Brake
55
拆下后刹车油泵体组件。
Remove the rear brake oil pump body assembly.
拆下后刹车制动缸组件。
Remove the brake cylinder assembly of rear brake.
拆下后轮
Remove the rear wheel.
从后轮轮毂上拆下制动盘
Remove the brake discs from the rear wheel hub.
注：Note:
本车刹车盘一般不能拆下，如需要请在加热
状态下进行。
The brake disc cannot be removed, if necessary, please
remove it after heating.
*注意 Attentions
•制动蹄块更换.
Replace braking shoes.
•如有制动蹄块再次使用时，拆卸前应在其
侧部做上记号以使它能装回原来位置。
If a braking shoe will be used again, please
mark it on the side before removal so as to
re-install it onto its original place.
从后轮处拆下下列组件
Remove the following assemblies from the rear wheel
后刹车：
Rear brake:
1.后液刹总成
Rear hydraulic brake assembly
2.制动蹄块组件
Braking shoe assembly
3.衬套
Lining
4,碟刹支架
Disc brake bracket
检查制动蹄块、有无磨损，需要时应更换蹄块。
Check whether the braking shoe is worn out. Replace
the braking shoe if necessary.
测量制动蹄块、制动盘、记下最大值。
Measure the braking shoe and brake disc, and record the maximum value.
56
测量制动蹄块的厚度
Measure the thickness of braking shoe.
可用限度：制动蹄块 4.5mm
Service limit: braking shoe: 4.5mm
规格
Specifications
后液刹盘直径 φ220mm
Diameter of rear hydraulic brake disc: φ220mm
*注意 Attentions
•如制动盘生锈,用#120 砂纸擦拭.
If the hydraulic brake disc is rusty, please
polish it with #120 abrasive paper
•一定要用千分尺来测量.
A micrometer shall be used for the
measurement.
如制动盘和制动蹄块的厚度小于保养值或被
油脂污染,应更换.
If the brake disc and braking shoe are contaminated by grease or their thickness is smaller than the
service limit, replace them.
*注意 Attentions
•一定要用内游标卡尺、千分尺来测量.
The vernier caliper and micrometer shall be
used for the measurement.
安装后轮。
Install the rear wheel.
安装后制动盘。
Install the rear brake disc.
装回后刹车制动缸。
Install the brake cylinder of rear brake.
*注意 Attentions
如制动蹄块上有油脂,会降低刹车能力
导致刹车失效.
A contaminated braking shoe will
decrease braking performance and result
in braking failure.
将螺钉和螺母锁紧到规定扭力值。
57
Tighten bolts and nuts to their specified torque value.
扭力值：
Torque force value:
后制动盘固定螺栓 15-25N·m
Rear brake disc mounting bolts 15-25N·m
后液刹下泵安装螺栓 25-35N·m
Rear hydraulic brake lower pump mounting bolts 25-35N·m
后液刹油泵安装螺栓 7-9N·m
Rear hydraulic brake oil pump mounting bolts 7-9N·m
后轮轴 75-85N·m
Rear axle 75-85N·m
不要让制动蹄块、制动盘沾上油渍。
Do not contaminate brake shoes and brake discs with grease.
如果制动蹄块和制动盘沾上油渍，需用刹车清洗液清洗。
If a braking shoe or a brake disc is polluted by grease, clean it with a brake cleaner.
*注意 Attentions
制动蹄块上油渍会降低刹车性能
A contaminated brake shoe will
decrease braking performance.
二、车身覆盖 II Motorcycle Exteriors

按照下列顺序拆下车身
Disassemble the motorcycle body in the following sequence.
后视镜 → 前大灯 → 仪表支架 → 仪表 →前挡泥板 → 座垫→
左、右侧盖 →油箱→左、右脚蹬→ 尾灯→ 后泥板 → 后牌照支架
Rear-view mirror → Headlamp → Instrument bracket Instrument
Front mud fender → Seat cushion →Left and right cover → Fuel tank →
Left and right pedal →Tail lamp → Rear mud fender →License plate
bracket
58
*注意 Attentions
拆装时不得损坏各车身覆盖.
Do not damage the cover of the motorcycle while removing or installing.
拆装时车身覆盖上的钩爪部不得损坏.
Do not break the hooks of the cover while removing or installing.
将车身覆盖上的嵌板及盖板与各自的槽对正.
Place the panel and the cover board right to the respective slots.
在组合时各部位的钩爪部安装要正确.
Install correctly the hooks of each part while combining.
安装覆盖件时不得损坏配件.
Do not damage the accessories while installing covers.
59
前轮/前悬挂 Front wheel/ front suspension
前轮 Front wheel
1 轮轴橡胶套 5-5 滚动轴承 6302
2 前轮轴 5-6 轮毂油封
3 计速器 6 前制动盘
4 前轮胎总成 7 前轮轴套
5 前网轮总成 8 前碟刹盘锁紧片
5-1 前轮圈 9 螺栓 M6×16
5-2 气门嘴 10 前轮轴自锁螺母 M14×1.5
5-3 前轮毂 11 轮轴橡胶套
5-4 前轮辐条
S/N Name S/N Name

1 Axle rubber sleeve 5-5 Roller bearing 6302
2 Front axle 5-6 Hub oil seal
3 Speedometer 6 Front brake disc
60
4 Front wheel assembly 7 Front axle sleeve
5 Front wheel assembly 8 Front disc brake disc lock sheet
5-1 Front wheel rim 9 Bolt M6×16
5-2 Valve nozzle 10 Front axle self-lock nut M14×1.5
5-3 Front hub 11 Axle rubber sleeve
5-4 Front wheel spokes
61
三、前轮/前悬挂 III Front wheel/ front suspension
准备资料------------------------3.1
Service Data-----------------------------3.1
故障诊断------------------------3.2
Fault Diagnosis-------------------------3.2
前轮------------------------------3.3
Front Wheel-----------------------------3.3
方向把---------------------------3.4
Steering Handlebar---------------------7.4
前悬挂---------------------------3.5
Front suspension---------------------------3.5
3.1 准备资料 Service Data
作业注意事项 Precautions
拆卸前轮前,车体底部使用千斤顶等支撑住,前轮浮地面，注意不可倒转.
Prior to disassembly of the front wheel, use a jack to support against bottom of the motorcycle,
and it is important that the front wheels must not rotate reversely when they keep away from the
ground.
作业时注意,制动蹄块不可有油脂附着.
During operation, it is important that any grease must not be attached on the braking shoe.
整车基准 Reference for motorcycle

标准值可用限度
测量位置项目
(mm) (mm)
前轮轮轴弯曲度 0.2
纵方向 2.0
前轮轮圈摆振
横方向 1.0 以内 2.0
62
Reference for motorcycle
Standard value Allowable limit
Measuring position Item
(mm) (mm)
Front wheel shaft Bending 0.2
Longitudinal 2.0
Wheel
direction
Front wheel rim
Horizontal Not less than 1.0 2.0
shimmy
direction
扭力值工具
Torque force value Tool

方向把固定螺钉 22-29 N·m 轴承拆卸杆
Mounting bolt of steering handlebar 40-60 N·m Dismantling rod, bearing
前轮轴 75-85 N·m
Front wheel shaft 75-85 N·m
3.2.1 方向把转动难 Steering handlebar rotating without flexibility

 方向把有故障或者有损坏
Steering handlebar bearing is faculty.
 方向把轴承损坏。
Steering handlebar bearing is damaged
 龙头轴承调节螺母过紧
Adjusting nut of motorcycle faucet is too tight.
 轮胎压力不够。
Pressure within the tire is insufficient.
3.2.2 方向不稳 Direction not steady

 方向把轴承损坏。
The handlebar bearing is damaged.
 轮胎压力不够。
Tire pressure is insufficient.
 前叉弯曲、前轮轴弯曲。
Front fork and front wheel shaft are bent.
 前轮轮胎变形，轮胎偏歪。
Front wheel tire is subjected to deformation, and the tire is not aligned.
3.2.3 前轮摆动 Front wheel wobbling
63
 轮圈变形。
Wheel rim is deformed.
 前轮轴轴承磨损。
Front wheel bearing is worn.
 前轮胎有缺陷。
Front tire has defects.
 车胎或车轮不平衡。
Tires or wheels are unbalanced.
3.2.4 轮子转动难 Wheel failing to rotate

 前轮轴轴承故障。
Failure of bearing of front wheel shaft
 制动器制动故障。
Braking failure
 车轮轴有故障。
Failure of wheel shaft
 前轮弯曲。
Bending of front wheel
3.2.5 前减震异响 Abnormal noises from front shock absorber

 减震器中液体不足。
Inadequate fluid in the shock absorber
 减震器护板磨擦音。
Friction noise of shock absorber guard
 减震器各部分螺栓松动。
Looseness bolts of shock absorber
3.2.6 只能向一边操作或者不走直线 Only being operated to one
side or not traveling in a straight line

 左右叉调节的不平衡
Unbalanced adjustment of left and right fork
 减震器弯曲
Bending of shock absorber
 车轮弯曲
Bending of wheel
 车轮安装不准确
Improper installation of wheel
 车架弯曲
Bending of frame
 车轮轴承是坏的
Damaged wheel bearing
 摆臂中心轴组件是坏的
Damaged central axle of swing arm
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3.2.7 前减震柔软 Soft front shock absorber
 减震器中液体不足
Inadequate fluid in the shock absorber
 减震器弹簧不牢固
Infirm shock absorber spring
 轮胎压力太低
Low tire pressure
3.2.8 前减震太硬 Too hard front shock absorber

 液体重量不适当
Inappropriate fluid weight
 减震器液体通路被堵塞
Blocked shock absorber fluid channel
65
3.3 前轮 Front wheel
先将车体底部支撑着使前轮浮起。
Support the vehicle bottom to make the front wheel lifted
拆下前轮轴锁紧螺母。
Unscrew the locknut of front axle
拆下前轮轴。
Remove the front wheel shaft
取下前轮。
Remove the front wheel
用油封拆卸器和轴承拆卸器分别拆下油封、轴承。
Remove the oil seal and bearing of oil seal remover and
shaft bearing replacer.
3.3.2.1 轮轴弯曲检查 Inspection of
wheel shaft bending

将轮轴放置在 V 型座上使用千分表测量偏心率。
Place the wheel shaft onto a V-shaped base, and the measure eccentricity with a micrometer
gauge.
可用限度：0.2mm 以上更换
Service limit: replacing in case of exceeding 0. 2mm.
3.3.2.2 轮圈的摆动检查 Inspection of
wheel disk wobbling

可用限度：
Service limit:
纵方向：2.0mm 以上更换。
Longitudinal direction: replacing in case of
exceeding 2. 0mm
横方向：2.0mm 以上更换。
Horizontal direction: replacing in case of
exceeding 2. 0mm
66
3.3.2.3 前轮轴承检查 Inspection of front wheel bearing
拆下前轮中间衬套，取下油封。
Remove the middle lining of front wheel and the oil
seal.
检查轴承滚动情况。
Inspect rotation of bearing.
如不滚动，轴承磨损或松动，则更换新品。
If the bearing is found not to rotate, it indicates that
the bearing is worn or loosened, and it shall be
replaced with new bearing.
3.3.3 轴承更换 Bearing replacement

拆下前轮、前轮轴及前轮轴套后。
用油封拆卸器和轴承拆卸器分别拆下油封、轴承。
After remove front wheel, front wheel shaft and front
wheel lining, oil seal removing appliance and bearing
removing appliance must be used to remove the lower
oil seal and bearing respectively.
注：拆卸的轴承应用新的轴承来代替。
Note: the removed bearing must be replaced with new bearing.
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安装时使用润滑脂涂抹在轴承上。
During installation, apply the lubricating grease onto the bearing.
然后用轴承安装工具将轴承压入。
And then, use the bearing mounting tool to press the bearing.
*注意 Attentions
•轴承必须平行压入。
The bearing must be pressed in a parallel
manner.
•轴承油封面必须向外压入。
The bearing oil seal shall be pressed
towards outside.
前轮处的油封涂布润滑脂。
Apply lubricating grease for the oil seal at front wheel.
速度表齿轮啮合部及活动部涂布润滑脂。
Apply lubricating grease for the gear position and movable position of speedometer.
里程表齿轮座组件对合后安装制动盘。
Install the brake disc after the involution of the gear housing assembly of speedometer
注意 Attentions
•里程表齿轮座组件没有对合锁紧前
轮轴时里程表齿轮座组件会变形。
The odometer gear housing component
will deform if the component is not
aligned to the locked front wheel shaft.
•轮轴装入后，旋转轮子，确认速度
表驱动轴是否转动。
Rotate the wheel after mounting the
axle to check whether the drive axle of
speedometer to rotate.
装上前轮轴并紧锁。
Install the front axle and lock it
扭力 Torque value
前轮轴 75-85N·m
Front axle: 75-85N·m
68
3.4 方向把 Steering handlebar
1 后视镜组件 8-1 内六角螺栓 M6×22
1-1 右后视镜 8-2 固定半盖
1-2 左后视镜 8-3 左手柄座
2 右平衡器 8-4 左手柄
3 右手把胶 9 左闸把开关
4 右闸把开关 10 左手把胶
5 油门拉索 11 左平衡器
6 手把管 12 后制动臂
7 离合器拉索 13 后制动回位簧
7-1 离合拉索护套 14 螺栓 M8×16
8 离合手柄组件
S/N Name S/N Name

1 Rear-view assembly 8-1 Hexagon socket head bolts
69
M6×22
1-1 Right rear-view mirror 8-2 Fixed half cover
1-2 Left rear-view mirror 8-3 Left handle seat
2 Right balancer 8-4 Left handle
3 Right handle grip 9 Left brake handle switch
4 Right brake handle switch 10 Left handle grip
5 Throttle cable 11 Left balancer
6 Handlebar tube 12 Rear brake arm
7 Clutch cable 13 Rear brake return spring
7-1 Clutch cable sleeve 14 Bolt M8×16
8 Clutch handle assembly
拆下方向把护套、后视镜组件。
Remove the direction handlebar sleeve and rear-view mirror assembly
拆下前刹车手柄、左手柄组件。
Remove front brake handle and left handle assembly
取下油门座组件、右握把组件。
Remove the throttle seat and right handlebar assembly
取下油门线组件。
Remove the throttle cable assembly
取下左方向把套。
Remove the left direction handlebar sleeve
取下离合器线组件、风门线组件。
Remove the clutch cable assembly and valve cable assembly
取下把手固定螺栓，取下把手。
Remove the mounting bolts of handle and remove the handle
按拆卸反顺序安装。
It should be installed in reversing sequence of disassembly.
固定螺钉
Mounting bolt
扭力值：25-35N·m
Torque value: 25-35N·m
70
3.5 前叉 Front fork
1 装饰扣 2-10 方向柱上垫圈
2 方向柱总成 2-11 方向柱盖型螺母
2-1 方向把卡子 3 大灯支架组合
2-2 方向把卡座 3-1 螺钉 M6×16
2-3 方向把卡座减震胶 4 前左减震器
2-4 上联板 4-1 前减震防尘套
2-5 内六角螺栓 M8×30 4-2 前减震器油封
2-6 方向把卡座垫片 5 里程线钢丝线夹
2-7 螺母 M8 6 螺栓 M6×12
2-8 方向柱 7 侧反射器
2-9 方向轴承 8 前右减震器
S/N Name S/N Name

Steering stem upper
1 Decorative buckle 2-10
washer
2 Steering stem assembly 2-11 Steering stem cover nut
2-1 Steering handle clamp 3 Headlight bracket
2-2 Steering handle holder 3-1 Screw M6×16
71
Steering handle holder Front left shock
2-3 4
damped adhesive absorber
Front shock absorber
2-4 Upper steering 4-1
boot
Hexagon socket cap head Front shock absorber
2-5 4-2
screws M8×30 seal
2-6 Holder washer 5 Speedometer cable clip
2-7 Nut M8 6 Bolt M6×12
2-8 Steering stem 7 Side reflector
Front right shock
2-9 Steering bearing 8
absorber
拆下前挡泥板。
Remove the front fender.
拆下前轮。
Remove the front wheel.
拆下刹车制动软管，速度表导线。
Remove the brake hose and speedometer cable.
拆下前减震器。
Remove the front shock absorber.
拆下转向固定螺母。
Remove the steering fixing nut.
拆下方向把。
Remove the steering handle.
工具：Tools:
方向把固定螺钉扳手。
Steering handle fixing screw wrench.
固定螺母扳手。
Fixing nut wrench.
工具：Tools:
固定螺母扳手.
Fixing nut wrench.
前叉左右转动确认圆滑性，不可有松动。
Turn the front fork left and right to confirm its smoothness without any looseness.
步骤：Steps:
方向把安装。
Install the steering handle.
前减震安装。
Install the front shock absorber.
72
前轮安装。
Install the front wheel.
73
后轮
1 轮轴橡胶套 6-3 后轮毂
2 后轮轴 6-4 后轮辐条
3 台阶螺栓 M8×25 6-5 滚动轴承 6302
4 后制动盘 6-6 轮毂油封
5 后轮胎总成 7 链轮
6 后网轮总成 8 链轮自锁螺母 M10×1.25
6-1 后轮圈 9 后轮左轴套
6-2 气门嘴 10 后轮轴自锁螺母 M14×1.5
S/N Name S/N Name

1 Axle rubber sleeve 6-3 Rear hub
2 Rear axle 6-4 Rear wheel spoke
3 Step bolt M8×25 6-5 Rolling bearing 6302
4 Rear brake disc 6-6 Hub seal
5 Rear tire assembly 7 Sprocket
6 Rear wheel assembly 8 Sprocket self-lock nut M10×1.25
6-1 Rear rim 9 Real wheel left axle sleeve
74
6-2 Valve cock 10 Real axle self-lock nut M14×1.5
75
后平叉 Rear fork
1 单头平叉轴 7 螺栓 M6×16
2 平叉衬套 8 平垫 φ6
3 平叉组件 9 翻边垫圈
4 链条调节器 10 链条护卡
5 驱动链条 11 后叉防尘盖
6 半链盒 12 平叉自锁螺母 M14×1.5
S/N Name S/N Name

Single-head flat
1 7 Bolt M6×16
fork shaft
2 Flat fork sleeve 8 Plain washer φ6
Flat fork
3 9 Fanged washer
assembly
4 Chain adjuster 10 Chain protecting clamp
5 Drive chain 11 Rear fork dust cover
6 Half chain box 12 Flat fork self-lock nut M14×1.5
76
四、后轮 / 后悬挂 IV Rear Wheel/Rear
Suspension
准备资料---------------------4.1
Service Data------------------4. 1
故障诊断---------------------4.2
Fault Diagnosis---------------4.2
后轮---------------------------4.3
Rear Wheel------------------4.3
后减震器/后摇臂-----------4.4
Rear Shock Absorber/Rear Swing arm---------4. 4
驱动链条---------------------4.5
Drive chain ------------------4.5
作业上注意事项 Precautions
制动盘、制动蹄块面不能有油渍附着。
Any grease spot is not allowed on the brake disk and brake shoe.
准备基准
项目标准值（mm）可用限度（mm）
纵方向 2.0
后轮摆动度
横方向 2.0
Reference
Item Standard value (mm) Allowable limit (mm)
77
Rear wheel Longitudinal 2.0
wobbling Horizontal 2.0
锁紧扭力 Locking torque force

后轮轴螺母 75-85N·m
Nut, rear wheel shaft 75-85N·m
后减震器顶端螺母 35-45 N·m
Top nut, rear shock absorber 35-45 N·m
后减震器底端螺母 35-45 N·m
| Bottom nut, rear shock absorber 35-45 N·m
78
4.2.1 后轮摆动 Rear wheel wobbling

 轮圈变形
Wheel rim is deformed.
 后车轮轴承磨损
Rear wheel bearing is worn.
 轮胎故障
Tire is faulty.
 摆臂轴轴承磨损或损伤
Swing arm bearing is worn or damaged.
 传动链条调节器调节不正确
Driving chain regulator adjusts improperly.
 轮胎和车轮不平衡
Tires and wheels are unbalanced.
 轮胎压强太低
The tire pressure is too low.
 车架或后摆臂弯曲
Frame or rear swing arm is bent.
4.2.2 车轮转动不灵活 Wheel rotating without flexibility

 后液刹盘弯曲
Rear hydraulic brake disc bending
 后车轮轴承磨损
Rear wheel bearing wear
 传动链条过紧
Overtightness of drive chain
4.2.3 悬浮太软 Spongy suspension

 减震弹簧不牢固有震荡
Shock absorber spring is not firm with shake.
 前悬调节器不正确
Front suspension regulator is incorrect.
 减震器漏油
Oil leakage occurs to shock absorber.
 轮胎的压强太低
Tire pressure is too low.
4.2.4 悬浮太硬 Hard suspension

 减震器上的装配轴承被损坏
Assembly bearing on the shock absorber is damaged.
 减震器管筒弯曲
79
Shock absorber cylinder is bent.
 后摆臂枢轴承损坏
Rear swing arm pivot bearing is damaged.
 后摆臂枢轴弯曲
Rear swing arm pivot bearing is bent.
 悬浮调节器出错
Suspension regulator is incorrect.
 轮胎压强太高
Tire pressure is too high.
4.2.5 只能向一边操作或者不走直线 Only being operated to one side or not

traveling in a straight line
 后轮轴弯曲
Rear axle is bent.
 在两侧的轮轴排列/链条调节器不能胜任
Axle arrangement/chain adjusters on both sides are incompetent.
80
4.3 后轮 Rear Wheel
放松调节器
Release the adjuster.
放松后轮轴螺母。
Release rear axle nut.
拆下后轮轴螺母，从链轮座上取下链条。
Remove rear axle nut, and remove the chain from the sprocket seat.
取下后轮轴。
Remove the rear axle.
取下后轮。
Remove the rear wheel.
4.3.2.1 轮轴弯曲检查 Axle bending
inspection
将轮轴放置在 V 型座上使用千分表测量其偏心率。
Place the axle on a V-seat, and measure eccentricity with
a micrometer gauge.
可用限度：0.2mm 以上更换
Allowable limit: replacing in case of exceeding 0.2mm
4.3.2.2 轮圈的摆动检查 Wheel rim
wobbling inspection
用手旋转车轮，用千分表测量偏心率。
Rotate the rear wheel manually and measure eccentricity
with a micrometer gauge.
可用限度：
Allowable limit:
纵方向：2.0mm 以上更换。
Longitudinal direction: replacing in case of exceeding 2. 0mm
横方向：2.0mm 以上更换。
Horizontal direction: replacing in case of exceeding 2. 0mm
后轮摆动度超过可用限度时，后轮轴轴轴承
松动，导致后轮轴弯曲。检查后更换后轮轴。
If the rear wheel wobbling exceeds the allowable limit, the rear wheel bearing is loosened, and the
rear wheel is bent. Replace the rear wheel shaft after inspection.
81
按照拆装反顺序把后轮装上，锁紧轮轴螺母。
Install the rear wheel in reverse sequence of disassembly and lock the nut.
后轮轴锁紧螺母
Lock nut, rear wheel shaft
扭力值：75-85N·m
Torque value: 75-85N·m
4.4 后减震器 Rear Shock Absorber

4.4.1 拆卸后减震器 Removal
拆下后轮减震器固定螺钉。
Remove the fixing screws of rear shock absorber.
取下后减震器。
Remove the rear shock absorber.
4.4.2 检查后减震器 Inspection

目测减震器是否有损坏
Visually inspect whether the shock absorber is damaged.
检查以下项目：The inspection items include:

——减震器管筒是否有弯曲或损坏
——whether the shock absorber cylinder is bent or damaged
——减震器是有有变形或者漏油现象
——whether the shock absorber is subject to deformation or oil leakage
——橡胶块是否有磨损或者损坏
——whether the rubber block is worn or damaged
——弹簧是否有损坏
——whether the spring is damaged
检查其他的所有部分是否有损坏或磨损
Inspect whether the rest parts are damaged or worn
如果需要，替换减震器
If necessary, replace the shock absorber
4.4.3 安装后减震器 Installation

按与拆卸相反的步骤进行。
Installation must be initiated in the reverse sequence of removal.
安装后减震器上固定螺母及下固定螺栓。
Mount the upper fixing nut and lower mounting bolt on the rear shock absorber.
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锁紧到规定扭力值。
Lock to the specified torque value.
扭力值：
Torque value:
上固定螺母：35-45N·m
Upper fixing nut: 35-45N·m
下固定螺母：35-45N·m
Lowe fixing nut: 35-45N·m
4.5 后摇臂 Rear swing arm
4.5.1 拆卸后摇臂
Disassemble the rear swing
arm
拆卸链条护板。
Disassemble the chain guard plate
拆卸链条张紧轮、后轮轴。
Disassemble the chain tensioning wheel and the rear axle shaft
拆卸后轮、后减震器。
Disassemble the rear wheel and the rear shock absorber
拆卸后摇臂安装轴。
Disassemble the rear swing arm installation shaft
取下后摇臂焊接组件。
Take down the weld assembly of the rear swing arm
4.5.2 检查后摇臂 Inspection of rear swing arm

检查后摇臂安装轴，在一平坦表面转动此
轴或用千分表测量，若弯曲，则更换。
Check the mounting shaft of rear swing arm and
turn the shaft or measure it with a micrometer
gauge after it is placed onto a flat surface. If the
shaft is bent, replace it.
*注意 Attentions
切勿试图校直已弯曲的轴。
Do not attempt to straighten bent
83
shaft.
在溶剂中清洗后摇臂安装轴零件。
Clean parts of rear swing arm mounting shaft with a solvent.
检查后摇臂轴套组件、中间轴套，若损
坏，则更换。
Check rear swing arm shaft sleeve component and intermediate sleeve and if any damage is found,
replace it.
4.6 驱动链条 Drive Chain
4.6.1．拆卸 Removal
将摩托车放在平地上，牢固支好。
Stop the motorcycle on the flat ground, and support it
securely.
拆卸变档杆摇臂、左后盖、驱动链轮。
Remove the shifting lever arm, left rear cover, and
drive sprocket.
拆卸后轮、链条护罩、驱动链条。
Remove the rear wheel, chain guard, and chain drive.
4.5.2．检查 Inspection
清洗驱动链，将之放入煤油里，洗刷灰尘，然
后将链条从煤油中取出，并将其晾干。
Clean the drive chain, put it into kerosene, brush the dirt,
and then take out the chain from the kerosene and make it dry.
检查滚筒①及侧面板②，若损坏、磨损，更
换驱动链，
Check the roller ① and side panel ②,
if damaged or worn, replace the drive chain,
润滑驱动链，可从商店购买驱动链润滑剂。
Lubricate the drive chain with the lubricant
purchased from the store.
检查驱动链，若坚硬则清洗、润滑或更换。
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Check the drive chain, if it is hard, clean, lubricate or replace it.
检查驱动链轮、从动链轮，若有 1/4 的轮
齿○,a磨损，则更换链轮，轮齿弯曲也更换链轮。
Check the drive sprocket, driven sprocket, if 1/4
teeth ○,a is worn, replace the sprocket, and in case
of tooth bending, replace the sprocket.
检查车轮轴承，车轮轮毂内存在轴承间隙
或车轮转动不平衡，则更换；检查油封若
有磨损、损坏则更换.
Check wheel bearings, if bearing clearance is found in wheel hub or the wheel has an unbalanced
rotation, replace the bearings; check the oil seal, if worn or damaged, replace it.
4.5.3 驱动链松弛度调整 Drive
chain slack adjustment

将摩托车停放在平坦处，使之保持直立位置。
Make the motorcycle parked on a flat place, so that
it remains upright.
检查驱动链松弛度○,a，驱动链松弛度 10-20 毫
米。
不符合规格则调整。
Check the drive chain slack ○,a, ranging 10-20 mm.
If out of this range, make adjustment.
拧松后轮轴螺母①。
Unscrew the rear axle nut ①.
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调整驱动链条松弛度。调整步骤为：
Adjust the drive chain slack. The adjustment steps include:
拧松锁定螺母②，拧进或拧回调整装置③，直至松
弛度符合规定值。
Unscrew the lock nut ②, screw or unscrew the adjustment device ③ until the slack meets the
specified value.
拧进，松弛度增大；
Screw, the slack may increase;
拧回，松弛度减小。
Unscrew, the slack may reduce.
注意：Attentions:
应使每一个调整装置转动圈数相同，以便
正确安装车轴。
The number of turns of each adjustment
device should be kept the same in order to
properly install the axle.
最后拧紧锁定螺母。
Finally, tighten the lock nut.
按与拆卸相反的步骤进行。
Installation must be initiated in the reverse sequence of removal.
调节驱动链松弛度及制动踏板自由行程；
Adjust the looseness of drive chain and free stroke of brake pedal.
如果链的松弛度太小，则会使发动机和其他重要零件超载；应使链松弛度保持在规定的极限
值范围内。
If the looseness is too small, the engine and other key parts will be consequently overloaded.
Maintain the chain looseness within the specified limits.
86
电器系统的检查和维护 Inspection and Maintenance of
Electrical System
充电系统 Charging system
87
五、蓄电池/充电系统 V. Battery/Charging System
准备资料---------------------5.1
Service Data ---------------------5.1
故障诊断---------------------5.2
Fault Diagnosis ---------------------5.1
蓄电池------------------------5.3
Battery ---------------------5.1
充电系统---------------------5.4
Charging System ---------------------5.1
电压电流调整器------------5.5
Voltage/Current Regulator ---------------------5.1
发电机充电线圈------5.6
Generator Charging Coil----------------------5.1
发电机照明线圈------5.7
Generator Lighting Coil--------------------5.1
发电机的拆卸---------5.8
Removal of Generator ---------------------5.1
作业上注意事项
Precautions
88
*注意 Attentions
1.蓄电池是可以充电和放电反复使用的，蓄电池在放电后放置，寿命缩短性能降低。通常使
用约 2-3 年的蓄电池的性能会降低。性能降低（容量下降）的蓄电池，在充电后电压虽会恢
复但加负载时电压会急下降。
The battery can be charged and discharged, and used repeatedly. If a battery is laid aside after
discharging, its service life will be shortened and its performance is degraded. Performance of a
battery is usually reduced after about 2-3 years’ use. Voltage of the performance-reduced (capacity
drops) battery can be resumed, but the voltage will run down quickly while loading.
2.蓄电池的过充电：一般过充电在蓄电池本体上可以看出来，如果蓄电池内部短路，在蓄电
池的端子就检测不到电压或电压很低。调整器失效：则蓄电池电压会过高，蓄电池的寿命会
缩短。
Overcharging of battery: Usually overcharging is demonstrated by the battery itself. If short circuit
occurs inside the battery, voltage or very low voltage on the terminals of the battery cannot be
inspected. If the regulator fails, it will have too high voltage on the battery and the life-span of
the battery will be shortened.
3.蓄电池如长时间放置，蓄电池会自行放电，电容量会降低，约 3 个月必须补充电。
When the battery is laid aside for a long period, it will self-discharge and its capacitance will drop.
The battery should be recharged every three months.
5.充电系统的检查，请依照故障诊断表上的顺序作检查。
Charging system inspection: please perform inspection in accordance with the sequence listed in
the fault diagnosis table.
6.电器件如有电流流通时，不可将接头拆下，否则会发生电压过高现象，电压调整器内的电
子零件会损坏。必须先将主开关“off”再作业。
If there is current going through the electric parts, the connector shall not be removed, or the
voltage will be very high and electronic components inside the voltage regulator will be damaged.
Set ignition switch at “Off” position and then begin your work.
7.免维护（干荷式）蓄电池不需要检查，不用加电解液及蒸馏水。
It is not necessary to inspect maintenance-free (dry-charged type) battery. Electrolyte and distilled
water are not required to be added.
8.检查全部用电负载。
Inspect the entire electric load.
9.除非在紧急情况下，不可使用紧急充电。
Quick charging is forbidden except in emergency.
10.蓄电池紧急充电时，蓄电池必须从车上取下后再进行充电。
During quick charging, the battery must be removed from the motorcycle first and then be
charged.
11.蓄电池互换换时请不要使用加液式蓄电池。
While battery is exchanged, please do not use liquid-feeding battery.
12.检查蓄电池充电状况时必须使用电压表。
A voltmeter shall be employed to check the state of charged battery.
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准备基准
项目规格
容量/型式 12V-10AH/铅酸式
电压完全充电时 13.5V
蓄电池（20℃）必须充电 12.3V(不工作 1 小时)
充电电流标准：0.9A，急速：9A
充电时间标准：10-15 小时，急速：30 分钟
容量 150W/1500rpm
磁电机
线圈阻抗值（20℃）白—白之间 0.5-10Ω
型式全波整流
电压调整器
畜电池充电电压 14.5V±0.4V/5.000rpm
Service Data
Item Specification
Capacity/type 12V-10AH/ lead-acid type
Voltage Fully charged 13.5V
Battery (20℃) Must be charged 12.3V(stop working for one hour)
Charging current Standard: 0.9A，Quick: 9A
Charging time Standard: 10-15hours; Quick: 30minutes
Capacity 150W/1500rpm
Magneto
Coiling impedance value (20℃) White-white 0.5-10Ω
Voltage Type Full-wave rectification

regulator Battery charging voltage 14.5V±0.4V/5.000rpm
紧锁扭力值工具
Tightening torque value Tools

整流器螺栓 5.0 N·m 万能固定扳手
Rectifier bolt 5.0 N·m Universal non-adjustable spanner
高压线圈固定螺栓 9.0 N·m 飞轮拆取器
High-voltage coil pinch bolt 9.0 N·m Flywheel remover
测试仪器 Testing device
万用电表 Multimeter
无电源 No power
 蓄电池过放电
Battery over discharged
90
 蓄电池配线未接
Wiring of battery is not connected.
 保险丝断
Fuse fails.
 电源开关不良
Failure of power switch
电压低 Low voltage

 蓄电池充电不良
Battery is poorly charged.
 接触不良
Poor contact.
 充电系统不良
Failure of charging system
 电压电流调整器不良
Failure of voltage and current regulator
电流断续 Unstable power

 蓄电池配线接触不良
Wiring of battery is poorly contacted.
 放电系统接触不良
Discharging system is of poor contact.
 照明系统接触不良或短路
Lighting system is of poor contact or short circuit.
充电系统不良 Failure of charging system

 电线接头接触不良，短线或短路
Wire connector is of poor contact, short circuit or short line
 电压电流调整器不良
Defective voltage and current regulator
 发电机不良
Failure of generator
91
5.3 蓄电池 Battery
5.3.1 蓄电池拆卸 Battery Removal

打开右侧盖。
Open the right side cover.
先拆下负极导线再拆下正极导线。
Disconnect the battery negative lead wire first and then
the positive lead wire.
取出蓄电池。
Take out the battery.
警告！Warning!
正极拆卸时作业工具不可与车架接触，短
路火花会引燃汽油损坏蓄电池，非常危
险。
During positive lead wire disconnection, be
sure to prevent the tools being used from
touching the frame; or it will result in short
circuit sparks, which may ignite gasoline
and damage battery. It is dangerous!
安装时以拆卸反顺序作业。
Install the battery in the reverse order of removal.
*注意 Attentions
防止短路，先接正极再接负极。
To avoid short circuit, please connect
positive lead wire first and then the
negative lead wire.
充电状态（开路电压）的检查。
Battery charging (open-circuit voltage) inspection
打开座垫。
Open the seat cushion.
打开空滤器上盖，把蓄电池接头导线拆下。
Open the top cover of air cleaner and disconnect lead wire
of the battery connector.
测量蓄电池端子间电压。
Measure voltage between terminals of the battery.
完全充电：13.5V
92
Fully charged: 13.5V
充电不足：12.3V （蓄电池不工作 1 小时）
Undercharged: 12.3V (battery stop working for 1 hour)
*注意 Attentions
充电状态检查必须使用伏特表作业。
| A voltmeter shall be employed to check
the state of charged battery.
5.3.2 充电 Charging
连接方法：充电机正极与蓄电池正极连接。
Connection method: Positive pole of battery charger is
connected to battery positive pole;
充电机负极与蓄电池负极连接。
Negative pole of battery charger is connected to battery
negative pole.
警告！ Warning!
•蓄电池应远离火源。
Battery shall be away from fire sources.
•充电开始或者完毕必须先将充电机关
掉。以防止连接部发生火花产生爆炸危
险。
Shut off charger first before or after
charging in case that sparks may be
generated at connection parts, which may
result in explosion.
•充电时必须依照蓄电池上所标示电流时
间为基准作业。
During charging, please take the current
time labeled on the battery as the basic
time.
*注意 Attentions
•蓄电池急速充电除紧急情况外不可使
用。
Battery quick charging is not recommended
except in case of emergency.
•充电后必须隔 30 分钟后再行测量电压。
After charging, measure the battery voltage
in 30minutes’ time.
充电电流：标准：0.4A
急速：4.0A
93
充电时间：标准：10-15 小时
急速：30 分钟
充电完成：开路电压：12.8V 以上
Charging current: Standard: 0.4A
Quick charging: 4.0A
Charging time: Standard: 10-15 hours
Quick charging: 30 minutes
Charging completed: open circuit voltage: higher than 12.8V
5.4 充电系统 Charging System
5.4.1 短路测试 Short circuit test

从蓄电池上把接地导线拆下来，电压表接于蓄电池负极与接地线之间开关扳在 OFF 位置，
检查是否短路。
Disconnect the grounding wire from the battery and use a voltmeter to connect battery negative
lead wire with grounding wire. Set the switch at OFF position and check if it is shorted.
*注意 Attentions
万用电表正极接蓄电池负极。
Positive lead wire of multimeter is
connected to negative lead wire of battery.
如有异常检查主开关及主配线是否有短路。
If abnormality is found, check if there is short circuit on ignition switch and main wiring.
5.4.2 充电状态的检查 Charging State Inspection

检查时蓄电池在完全充电状态下使用万用电表测试。
While in inspection, if the battery is fully charged, a multimeter shall be used for the test.
发动机暖机后把完全充电的蓄电池装上。
Warm up the engine and then install the fully charged battery onto the motorcycle.
蓄电池的端子间接上电压表。
Connect voltmeter between terminals of the battery.
主保险拆下俩端子间接电流表。
Remove the main fuse and connect an ammeter between the two terminals.
发动发动机，使转速慢慢上升测量限制电压及电流。
Start engine and slowly raise RPM. Measure limited voltage and current.
限制电压/转速：14-15V （5.000rpm）
Limited voltage/rpm: 14-15V (5.000rpm)
限制电压不在规定值范围内时，检查电压调整器。
If limited voltage is beyond the specified range, check the voltage regulator.
照明系统限制电压的检查。
94
Check the limited voltage of lighting system.
*注意 Attentions
万用电表设定在交流电压档位。
A multimeter shall be set at AC voltage.
限制电压：13.5（+/-）0.5V/5.000rpm
Limited voltage: 13.5(+/-)0.5V/5.000rpm
限制电压不在规定范围内时，检查电压电流调整器。
If limited voltage is beyond the specified range, check the voltage and current regulator.
5.5 电压电流调整器 Voltage-current Regulator
5.5.1 主配线端回路检查
Loop inspection on main wiring terminals
拆下电压电流调整器的 6P 插头。
Disconnect the 6P plug on the voltage-current
regulator.
以下列方法检查主配线端子间的导通行。
Check continuity between main wiring terminals
in the following way:
项目（配线色）判定
蓄电池（红）与车
有蓄电池电压
体搭铁之间
搭铁线（黑）与车
有导线
体搭铁之间
充电线圈（黄 1）
磁电机线圈有电阻
与黄 3 间
充电线圈（黄 1
与黄 2）间
充电线圈（黄 2
与黄 3）间
Item (wire color) Judgment

Between battery (red) and There is battery
ground of vehicle block voltage.
Between ground wire (black)
There is a lead wire.
and ground of vehicle block
95
Between charging coils There is resistance
(yellow 1 and yellow 3) between coils

5.5.2 电压电流调整器的检查 Voltage-current regulator inspection

主配线端检查完全正常时，检查电压电流
调整器的插头是否接触不良，电压电流调
压器各端子间阻抗值的测定。
If the main wiring end is checked as completely normal, check whether the voltage and current
regulator plug is in proper contact, and measure the impedance values between the terminals of the
voltage and current regulator.
*注意 Attentions
•检查中万用表测试棒金属部位手指不
可接触。
Do not touch the metal part of multimeter
probe with your finger.
•使用万用电表检查。不同的万用表检查
阻抗值不一样，检查会不正确。
Check with a multimeter. If impedance
values measured by different multimeters
are not the same, it indicates incorrect
inspection.
端子间的阻抗值异常时电压调整器应更换。
When impedance value between terminals is abnormal, voltage regulator shall be replaced.
万用表
黄1 黄2 黄3 黑红
万用正极
负极单位：MΩ
黄1 0.1~3 0.1~3 无无
黄2 0.1~3 0.1~3 无无
黄3 0.1~3 0.1~3 无无
黑无无无无
红无无无无
Multimeter Yellow Yellow Yellow

Black Red
Positive 1 2 3
Negative Unit: MΩ
Yellow 1 0.1~3 0.1~3 None None
96
Black None None None None
Red None None None None
5.6 发电机充电、照明线圈 Generator Charging and Lighting
Coils
*注意 Attentions
发电机照明线圈的检查可在发动机上作
业。
Inspection of generator charging coil can
be performed on the engine.
检查 Inspection
发电机 4P 接头拆下。
Disconnect the 4P connector on the generator.
使用万用表测量发电机白色线圈与车
体搭铁之间的阻抗值。
Use a multimeter to measure impedance value between white coils of the generator and vehicle
block.
标准值：0.6-1Ω（20℃）
Standard value: 0.6-1Ω(20℃)
测定值超过标准值时发电机线圈更换。
If measured value exceeds the standard value, the generator coiling shall be replaced.
5.8 发电机的拆卸
Generator Removal
拆下固定螺栓和螺钉。
Remove the fixed bolts and screws.
取下左盖。
Remove the left cover.
使用万能固定扳手将飞轮固定。
Fix the flywheel with an all-purpose non-adjustable wrench
97
拆下飞轮固定螺母。
Disassemble the flywheel hold-down nut
使用飞轮拔去器取下飞轮。
Take down the flywheel with a flywheel puller
拆下固定键。
Disassemble the fixed key
拆下发电机导线接头。
Disassemble the generator wire joint
拆下发电机定子。
Disassemble the generator stator
将发电机定子安装到发动机箱体上。
Install the generator stator onto the
engine crankcase
连接发电机线接头。
Connect the generator terminal
将曲轴，飞轮的锥形部清洗干净。
Clean the taper of the crankshaft and the
flywheel
将飞轮固定键确定装入曲轴上键的槽内并
确认。
Install the fixed key of the flywheel into
the groove on the crankshaft, and
confirm whether it is properly installed
将飞轮上的沟槽对准轴上的固定键上。
Align the groove on the flywheel with the fixed key on the shaft
*注意 Note
98
飞轮内面有磁性确认不可有螺栓。If the inner face of the flywheel is magnetic, make sure
no any bolt
使用万能固定扳手将飞轮固定然后锁紧固定
螺母。
Fix the flywheel using a universal
non-adjustable spanner and then tighten the
locknut.
扭力值：9.0 N·m
Torque value: 9.0 N·m
安装左后盖。
Install the left rear cover.
六、点火系统 VI Ignition System
准备资料--------------6.1 点火线圈--------------6.4
故障诊断--------------6.2 触发器----------------6.5
点火系统检查----------6.3
Service Data-----------------------6.1 Ignition Coil---------------------6.4
Fault Diagnosis--------------------6.2 Trigger----------------------------6.5
99
Ignition System Inspection-------6.3
作业上注意问题 Precautions on operation

1.点火系统的检查请依故障诊断表顺序逐步检查。
Ignition system inspection: please perform inspection in accordance with the sequence listed in the
fault diagnosis table.
2.点火系统已固化在 ECU 组内，所以点火时间不须调整。
The ignition system is solidified in the ECU assembly, so ignition time adjustment is unnecessary.
3.点火系统的检查，请依故障诊断表所列顺序检查。
Ignition system inspection: please perform inspection in accordance with the sequence listed in the
fault diagnosis table.
4.点火系统 ECU 不可脱落下垂或受强力敲击（这也是故障产生的主要原因），拆卸时特别注
意。
Ignition system ECU shall not be dropped and hung, or heavily knocked (this is also the main
reason for its failure). Pay special attention to this while removing it.
5.点火系统的故障，为插座接触不良原因最多，先检查接头各部是否接触不良。
Most of the ignition system problems are due to poor contact of sockets. Please check first if parts
of the connector are well contacted.
6.火花塞使用的热值是否适当，不适当的火花塞会使发动机运转不顺或烧坏火花塞的主要原
因。
Check if heat value of spark plug is proper. Improper spark plug may result in unsmooth engine
running or burnt of spark plug.
7.本章的检查是以最大电压为主要说明，点火线圈阻抗值的检查要领有一并的记载好与不好
时的判定。
The maximum voltage is taken to introduce inspection items in this Part. Inspection methods for
impedance value of ignition coil are also recorded and judged.
8.主开关的检查请依照导通表实施。
Check ignition switch according to the continuity test table.
9.发电机，定子的拆卸请依拆卸说明。
Remove generator and stator on operation instructions.
准备基准
项目标准值
推荐使用火花塞标准 D8RTC
火花塞间隙 0.5-0.7mm
点火线圈阻一次线圈 0.4Ω（+/-）10％
100
抗值（20℃）二次线圈 4.5-5.5KΩ
触发器的阻抗值（20℃） 100-200Ω
点火线圈一次测最大电压 95-400V
触发器电压 1.7V 以上
Service data
Item Standard Value
Recommended Spark Standard D8RTC
plug
Spark plug stroke 0.5-0.7mm
Ignition coil Primary coil 0.4Ω（+/-）10％
impedance 4.5-5.5KΩ
Secondary coil
value (20℃)
Impedance value of trigger (20℃) 100-200Ω
Ignition coil primary peak voltage 95-400V
Trigger voltage 1.7V 以上
工具 Tools
最大电压表附件 Accessories for maximum voltmeter
万用电表。
Multimeter
火花塞无跳火 No sparking of spark plug
异常情况不良原因（从一依照顺序确认）
①内部阻抗太小，使用指定测试器测试。
②曲轴回转速度太低。
③测试器受干扰（数回测定电压在基准以
点火线圈高压电太低时上为正常）。
④ 点火系统的配线接触不良。
⑤点火线圈不良。
⑥充电线圈不良。（最大电压测定）。
101
①测试器连接错误。
②主开关不良。
③接头接触不良。
④搭铁线短路或接触不良。
次侧电压无高压电时，高压电或时有时无 ⑤充电线圈不良（最大电压测试）。
⑥触发器不良（最大电压测试）。
⑦高压线接头不良。
⑧ECU 不良（①-⑦项测定异常时或火花塞
无火花时）。
①火花塞不良，或点火线圈二次漏电。
高压电正常火花塞无火花
②点火线圈不良。
②曲轴回转速度太慢。
无高压电 ③测试器受干扰（数回测定电压在基准以
充电、照明上为正常）
。
线圈 ④充电线圈不良。（①-③项无异常时）
①点火线圈不良。
无高压电，或时有时无
②充电线圈不良。
②曲轴回转速度太慢。
高压电太低 ③测试器受干扰（数回测定电压在基准以
触发器上为正常）
。
④触发器不良。
（①-③项无异常时）
①点火线圈不良。
无高压电，或时有时无
②触发器不良。
No sparking of spark plug

Symptom Possible causes(Determine the cause from 1
in sequence)
①When inner impedance is too small, use the
appointed tester to test.
Ignition ②Crankshaft rpm is too low.
coil When the high voltage power is too ③ Tester is disturbed (it is normal when
low. several times’ measured voltages are above
the basic) .
④ Wiring of ignition system is poorly
contacted. ⑤Ignition coil is no
good.
⑥ Charging coil is bad. (Peak voltage
measurement)
102
①Tester is wrongly connected.
②Poor ignition switch.
③Poor contact of joint
④Short-circuit or poor contact of bond strap
Secondary While no high-voltage power ⑤ Poor charging coil (Peak voltage
side supply, high voltage power is measurement) .
voltage sporadic. ⑥ Defective trigger (Peak voltage
measurement) .
⑦ Poor connector of high voltage wire.
⑧ Inferior ECU assembly.(after items ①-⑦
are tested and proved abnormal or spark plug
no sparking.)
①Inferior spark plug or secondary leakage of
High-voltage power is normal,
the ignition coil.
spark plug no sparking.
② Poor ignition coil.
①Inner impedance is too low. Use appointed
tester to test.
No high-voltage power supply ②Crankshaft rpm is too low.
Charging ③Tester is disturbed (it is normal when more
and than one time’s measured voltage is above the
lighting basic) .
coils ④Poor charging coils (when items (①-③
are proved normal)
No high-voltage power supply or ② Poor ignition coil.
high voltage power is sporadic. ②Poor charging coil.
①Inner impedance is too low. Use appointed
tester to test.
High-voltage power supply is too ②Crankshaft rpm is too low.
Trigger low. ③Tester is disturbed (it is normal when more
than one time’s measured voltage is above the
basic) .
④ Poor trigger (when items ( ① - ③ are
proved normal)
No high-voltage power supply or ①Poor ignition coil.
high voltage power is sporadic. ②Poor trigger.
6.3 点火系统检查 Ignition System Inspection
*注意 Attentions
•火花塞无火花时，应检查配线各部件是
否有松动，接触不良等，并确认各个电压
值是否正常。
When the spark plug is not sparking, check
103
if components of wiring are loosened or
badly contacted and make sure all the
voltage values are normal.
•万用电表品牌很多，内部阻抗不同，所
测试的值也不同。
There are many brands of multimeters with
different interior impedance. The values
they measured are not the same.
在万用表上连接高压分流器。
或输入阻抗 10MΩ10CV 以上的电表。
Connect a high-voltage shunt or an ammeter with input impedance higher than 10MΩ 10CV to the
multimeter.
6.3.1 点火线圈一次电压 Primary voltage of ignition coil

如果把火花塞拆下另装上良好的火花塞，
与发动机搭铁。
If an old spark plug is removed and replaced with
a good one, ground it with engine.
*注意 Attentions
各电路配线正确连接后方可测试。
Test when wirings of all the circuits are
correct.
气缸压缩压力正常情况是指火花塞安
装于气缸头上测试。
Normal cylinder compression pressure
means to test with spark plug installed on
the cylinder head.
拆下中间盖。
Remove the central cover.
把点火线圈的导线连接，一次线圈端子
（黑/白）于车体搭铁建连接分流器。
Connect lead wire of ignition coil and a shunt is connected between terminal (black/white) of
primary coil and grounding wire of vehicle block.
按启动电机，或踩启动杆测量点火线圈
一次的最大电压。
Press starter motor button or kick starter pedal to measure primary peak voltage of ignition coil.
最小电压：95V 以上。
Min. voltage: higher than 95V.
*注意 Attentions
测量电压时手指不可接触到测试棒金
104
属处，会被电击要特别注意。
Please do not touch the metal parts of
testing probe with your fingers while
measuring voltage, or you will be
shocked. Please take care.
6.3.2 充电、照明线圈
Charging and lighting coil

*注意 Attentions
把火花塞安装在气缸头，再压缩压力正常
的情况下检查。
Inspect when spark plug is installed on the
cylinder head and compression pressure is
normal.
拆下磁电机引出线接头，磁电机端的充电、
照明线圈电压，按下起动马达测量充电、照明线圈的最大电压。
Remove the magneto lead connector, magneto-end charging and lighting coil voltage, press the
starter motor to measure the the maximum voltage of the charging and lighting coil.
最小电压：95V 以上。
Minimum voltage: 95V or more.
6.3.3 触发器 Trigger

*注意 Attentions
火花塞安装在气缸头上，压缩压力正常情
况下检查。
Inspect when spark plug is installed on the
cylinder head and compression pressure is
normal.
拆下触发器引出线接头，用万用表电阻档一端接
蓝白线，另一端接绿白线，测量电阻。
Remove the trigger lead connectors, connect the resistance grade end of a multimeter with the
blue-white line, the other end with the green-white line, measure the resistance.
连接方法：见右图。
Connection mode: see the right figure.
电阻值：125±20Ω。
Resistance: 125±20Ω.
105
6.4 点火线圈 Ignition Coil
拆下车体盖。
Remove the motorcycle body cover.
拆下火花塞盖。
Remove spark plug cap.
拆下点火线圈一次导线。
Remove primary lead wire of ignition coil.
拆下点火线圈固定螺栓，取下点火线圈。
Unscrew locknut of ignition coil and take out the ignition
coil.
安装时以拆卸时相反顺序作业。
Install it in the reverse order of removal.
*注意 Attentions
一次线圈为黑/白色线接头安装。
The primary coil is installed with
black/white wire connector.
6.4.2 检查一次线圈 Primary coil inspection

一次线圈端子间阻抗测定。
Measure impedance between terminals of primary coil.
标准值：0.4Ω（+/-）10％（20℃）
Standard value:0.4Ω±10％(20℃)
阻抗值在标准值内为良好。
Impedance value within the range is good.
阻抗值“∞”表示线圈内断线，更换新品。
Impedance value “∞” indicates broken wire inside the coil. The coil shall be replaced.
6.4.3 二次线圈 Secondary coil

附火花塞，测量火花塞盖导线侧与端子间阻抗值。点火线图
Provided with a spark plug. Measure impedance between
lead-wire side of spark plug cap and terminal.
标准值：8-11KΩ（20℃）
Standard value:8-11KΩ(20℃) Ω
阻抗值在标准值内为良好。
Impedance value within the range is good.
阻抗值“∞”表示线圈为断线。
Impedance value “∞” indicates broken wire inside the coil.
拆下火花塞盖，测量点火线圈一次侧导线与负端子间的阻抗值。
106
Remove the spark plug cap and measure impedance value between primary side lead-wire of
ignition coil cap and negative terminal.
标准值：4.5-5.5KΩ（+/-）10％（20℃）
Standard value: 4.5-5.5KΩ(±)10%(20℃)
6.5 触发器 Trigger
*注意 Attentions
检查触发器可在发动机上作业。
Trigger inspection can be performed on the
engine.
检查 Inspection
拆下触发器引出线接头，用万用表电阻档一端接
蓝白线，另一端接绿白线，测量电阻。
Remove the trigger lead connectors, connect the resistance grade end of a multimeter with the
blue-white line, the other end with the green-white line, measure the resistance.
连接方法：见右图。
Connection mode: see the right figure.
电阻值：125±20Ω。
Resistance: 125±20Ω.
七、启动系统 VII. Starting System
准备资料---------------7.1
Service Data-----------7.1
故障诊断---------------7.2
Fault Diagnosis--------7.2
启动电机---------------7.3
Starter Motor-----------7.3
启动继电器-------------7.4
107
Starter Relay------------7.4
作业上注意问题
Precautions on operation
启动电机的拆卸，可在发动机上作业。
Starter motor removal can be performed on the engine.
拆卸请参照拆卸做法。
Removal refers to removal instructions.
准备基准
项目标准值使用限度
启动电机电刷长度 12.5mm 8.5mm
启动惰轮轴衬套 8.3mm
启动惰轮轴外径 7.94mm
Basic data
Item Standard Service Limit
Length of starter motor 12.5mm 8.5mm
electric carbon brush
Starter idler shaft bushing 8.3mm
Starter idler shaft OD 7.94mm
锁紧扭力值
Tightening torque value

启动电机离合器盖螺栓 12 N·m
Starter motor clutch cap bolt 12 N·m
启动电机离合器固定螺母 95 N·m
Starter motor clutch locknut 95 N·m
工具 Tools
固定螺母扳手
108
Locknut wrench
万能固定扳手
Universal un-adjustable wrench
不能启动启动电机转动力太弱启动电机回转发动机
不回转
Stator motor cannot run Stator motor runs weakly Starter motor rotates but the engine
does not
•保险丝断 •蓄电池电量不足 •启动离合器不良
•Broken Fuse •Low battery •Defective starter clutch
•蓄电池电量不足 •连接线接触不良 •启动电机逆回转
•Low battery •Poor connecting wire contact •Starter motor counter-rotate
•主开关不良 •启动电机齿轮被异物卡住 •蓄电池电力不足
•Defective ignition switch •Stator motor gear stuck by •Low battery
•启动离合器不良
•Defective starter clutch foreign substances
•刹车开关不良
•Defective braking switch
•启动继电器不良
•Defective starter relay
•连接线接触不良
•Defective connecting wire contact
•启动电机不良
•Defective starter motor
7.3 启动电机 Starter Motor
*注意 Attentions
启动电机拆卸之前，必须先将主开关
“OFF”，把蓄电池搭铁线拆下，然后再将
电源打开是看启动电机是否运转，以确
认安全。
Before removing starter motor, the ignition
switch must be set at “OFF” position.
Disconnect battery grounding wire and
109
then turn on the power supply to check if
the starter motor runs to confirm safety.
先将启动电机导线夹子拆下。
First remove the lead-wire clip of starter engine.
拆下启动电机固定螺栓，取下启动电机。
Remove starter motor pinch bolt and take down the starter motor.
将橡皮防水套卷起，拆下启动电机接头。
Roll up the rubber waterproof jacket and remove starter motor connector.
7.3.2 分解 Disassembly
电刷
拆下外壳螺钉、前盖、马达外壳及其他部分。
Disassemble housing screw, front cover, motor
housing and other parts.
其它零部件组合检查。
Inspect other component assemblies.
表面的偏磨损、损伤、烧损时更换新品。
Replace with a new one when there is surface partial friction, injuries or burning loss.
换向器表面间有附着金属粉末时必须清洗干净。
Commutator shall be cleaned when there is metal particles adhered to its surface.
其他组合部各接触面间的导通性检查。
Inspect continuity between contact surfaces of
电刷
other assemblies.
换向器各表面间电枢轴的不可导通要确认。
Confirm uncontinuity of armature shaft among
surfaces of commutator.
启动电机外壳导通检查。
Inspect continuity of starter motor housing.
导通端子与启动电机外壳之间不可导通确认。
Confirm uncontinuity between conducting terminal
and starter motor housing.
导通端子与电刷之间导通检查。
Inspect continuity between conducting terminal and brush.
如有异常时更换新品。
Replace it with a new one if abnormality exits.
电刷托架的导通检查，如有导通时更换新品。
Inspect carbon brush holder for continuity. If there is continuity, replace it.
110
电刷长度侧量。
Measure carbon brush length
可用限度：8.5mm 以下更换
Service limit: replace it when it is shorter than 8.5mm
前盖内的针状轴承旋转圆滑性及压入时是否松动的检查。
Check rotation smoothness of the needle bearing in the front cover and whether it is loosened
when it is pressed in.
如有异常更换新品。
If there is abnormality, replace it with a new one.
检查油封是否磨损、损伤。
Check whether the oil seal is worn or damaged.
7.3.4 组合 Assembly
前盖内的油封、涂布润滑脂。
Apply lubricating grease on the oil seal in the front cover.
把电刷安装在电刷托架上。
Install brush onto the carbon brush holder.
电刷轴两端活动部涂布润滑脂。
Apply lubricating grease on movable parts at both ends of brush shaft.
把各电刷压入托架内，然后装上电机前盖。
Press carbon brush into its holder and install front cover of motor.
*注意 Attentions
•电刷与电枢的接触面不可有损伤，要特
别注意。
There should be no hurt on the contact
surface of carbon brush and armature. Take
care.
•电枢安装轴不可伤及油封的唇部要注
意。
Installation shaft of armature cannot hurt
lip of oil seal. Take care.
把新的垫圈环装上前盖。
Install a new washer ring onto the front cover.
马达壳的螺孔与前盖的螺孔对合安装。
Align and install the thread-hole of motor housing to the thread-hole of front cover.
锁紧外壳螺钉。
Tighten housing screws.
*注意 Attentions
外壳与前盖组合时，电枢用以磁铁吸引
前盖较容易拔起，用手轻轻的押下就可
组合好。
When assembling housing and front cover,
armature can work as a magnet to easily
111
pull the front cover up; and then gently
press it down with hands to complete the
assembly.
装上启动电机导线，确定装好防尘套。
Install lead wire of starter motor and be sure to install the dust seal.
然后装上启动电机。
Install the starter motor.
安装后刹车导线夹子。
Install rear brake wire clip.
7.4 启动继电器 Starter Relay
7.4.1 作动检查 Actuation Inspection

拆下右车盖。
Remove the right cover.
主开关打在“ON”按下启动电机时有“卡答”声音的检查。
When the ignition switch is set at “ON” position, press starter
motor and a “Click” sound can be heard.
有声音时为正常。
“Click” sound indicates normal.
无声音时：•检查启动继电器电压。
•检查启动继电器搭铁回路。
•启动继电器的作动检查。
No sound: • Check starter relay voltage.
• Check starter relay ground wire loop.
• Inspect starter relay actuation.
7.4.2 启动继电器电压检查 Starter relay voltage inspection

把主脚架起来，测量启动继电器接头的绿/黄
线负极与车体搭铁间的电压。
Lift and support the main stand. Measure the voltage
between negative pole (green/yellow) of starter relay
connector and vehicle ground wire. Ω
主开关打在“ON”把刹车拉杆接住，蓄电池电压灰
112
须符合规定。
Set ignition switch at “ON” position and catch the brake
lever. Battery voltage shall meet the requirements.
启动继电器线端无电压时，刹车开关导通及导
线检查。
When there is no voltage at wire terminal of starter relay, inspect braking switch continuity and
lead wire.
7.4.3 启动继电器搭铁回路的检查 Starter relay ground loop

Ω
inspection
拆下启动继电器接头。
Remove starter relay connector.
导线接头端子的灰线与车体搭铁间的导通检
查。
Inspect continuity between grey wire of connector
terminal and vehicle ground wire.
启动按钮按下时接头的灰线与车体搭铁导通
要良好。
When the starter button is pressed, continuity between grey wire of connector and vehicle ground
wire shall be fine.
无导通时启动按钮的导通性及导线检查。
If there is no continuity, inspect starter button
continuity and lead wire.
7.4.4 作动检查 Actuation inspection

把启动继电器接下蓄电池，接启动电机的端子连接万用电表。
Connect starter relay with battery and connect terminal of starter motor with multimeter.
把完全充满电的蓄电池接在继电器的黑线与绿/
黄线之间。此时继电器应有‘哒’吸合声且万用表电
阻指示为‘零’。
Connect fully charged battery between black wire and green/yellow wire of relay. A “tap” sound
of operation can be heard on the relay and resistance displayed by multimeter is “zero”.
113
八、灯泡类 / 开关 / 仪表 VIII.
Bulbs/Switches/Instruments
准备资料--------------------------------------------8.1
Service Data-------------------------------------------8.1
故障诊断--------------------------------------------8.2
Fault Diagnosis----------------------------------------8.2
前照灯灯泡更换-----------------------------------8.3
Headlamp Bulb Replacement-----------------------8.3
前转向灯灯泡更换--------------------------------8.4
Front Turn Signal Lamp Bulb Replacement--------8.4
尾灯/牌照灯/后转向灯灯泡更换---------------8.5
Tail Lamp/number-plate lamp/Rear Turning Signal Lamp Bulb
Replacement--------------------------------8.5
仪表--------------------------------------------------8.6
Instrument--------------------------------------------8.6
主开关-----------------------------------------------8.7
Main switch----------------------------------------8.7
喇叭--------------------------------------------------8.8
Electric Horn-----------------------------------------8.8
把手开关--------------------------------------------8.9
Handle Switch---------------------------------------8.9
114
作业上注意问题
Precautions on operation
开关的导通测量，可从车上拆下测定。
Remove switches from the motorcycle and perform continuity test.
主开关“ON”灯不亮。
“ON” lamp of main switch is not lit.
•灯泡不良。
Defective bulb.
•开关不良。
Defective switch.
•接头接触不良或断线。
Poor contact of connector or broken wire.
115
8.3 前照灯灯泡更换
Headlamp bulb replacement
拆下螺钉以便将前照灯能够拆下。
Remove the screws to facilitate the removal of the headlight.
拆下接插头。
Remove the connectors.
拆下大灯锁紧夹将灯泡拆下。
Remove the headlight locking clip to take off the bulb.
按照拆卸的相反顺序，依照此序将灯
泡安装回去。
Install the light back in the reverse order of removal.
8.4 前转向灯更换
Replacement of the front turn signal light
松开转向灯固定螺钉。
Loosen the light fixing screw.
将转向灯取下。
Take off the light.
按照拆卸的相反顺序，以此序将
转向灯安装回去。
Install the light back in the reverse order of removal.
8.5 尾灯/牌照灯/后转向灯更换
Replacement of taillight/license plate light/rear turn signal
light
116
拆下螺钉，将尾灯灯罩拆下。
Remove the screws and take off the lampshade.
将灯泡从插座上拆下。
Remove the bulb from the socket.
按照拆卸的相反顺序，以此序将灯泡安装回去。
Install the bulb in the reverse order of removal.
8.5.3 后转向灯更换 Replacement of rear turn signal light
8.5.3.1 拆卸 Removal
松开转向灯固定螺钉。
Loosen the fixing screws.
将转向灯取下。
Take off the light.
8.5.3.2 安装 Installation
按照拆卸的相反顺序，依次将灯泡安装。
Install the bulb in the reverse order of removal.
8.6 仪表 Instrument
拆下前大灯。
Remove the front headlight.
拆下仪表接插件。
Remove the meter connectors.
拆下螺钉。
Remove the screws
拆下仪表。
Remove the meters.
按照拆卸的相反顺序，依次将速度表安装。
Install the instrument orderly in the reverse order of removal.
8.7 主开关 Main Switch
拆下前大灯。
Remove the headlamp.
拆下主开关导线接头。
117
Disconnect connector of main switch lead wire.
接头端子的导通检查。
Check the connector terminal for continuity.
4.7.2 主开关更换
拆下车体前护板。
拆下固定螺栓，取下主开关固定座。
拆下固定螺栓，主开关更换。
118
8.8 喇叭 Electric Horn
检查 Inspection
拆下喇叭电线。
Disconnect wire to the electric horn.
将喇叭电线接上蓄电池后响则良好。
Connect lead wire of horn with the battery.
When the electric horn sounds, it indicates the
horn is in good condition.
8.9 把手开关 Handle Switch
拆下刹车拉杆固定螺栓，取下托架。
Screw off mounting bolt on the brake lever and
take down the bracket.
拆下油门把手、螺钉。
Remove throttle handle and bolts.
从把手上取下油门把手，
取下油门线。
Take down the throttle handle from the handle and remove the throttle cable.
取下把手固定螺栓，取下把手。
Remove mounting bolt on the handle and
take down the handle.
119
发动机的检查和维护 Inspection and
Maintenance of Engine
发动机紧固件扭力值表
List of Engine Fastener Torque Value
序号检查项目螺纹直径力矩要求(N.m)
1 定位片螺栓扭矩(五星板) M6 10～15
2 定位器安装螺栓扭矩(定位轮) M6 10～15
3 机油过滤器锁紧螺母扭矩 M16 45～55
4 离合器锁紧螺母扭矩 M16 45～55
5 紧固机油滤网扭矩 M36 20～28
6 缸头螺母扭矩 M8 25～35
7 起动离合器螺栓 M8 25～32
8 气门调整螺母扭矩 M6 13～17
9 火花塞扭矩 M12 15～20
10 导线压板螺栓扭矩 M6 8～12
11 合箱螺钉 M6 10～15
12 机油泵安装螺钉 M6 6～10
13 转子盖螺钉 M5 4～6
14 离合器盖螺栓 M6 10～15
15 轴承推栓扭矩 M6 8～12
16 链轮螺栓扭矩 M6 10～15
120
17 档位开关螺钉 M4 1～3
18 磁电机定子螺栓 M6 5～8
19 触发线圈螺栓 M5 4～6
20 磁电机转子固定螺栓扭矩 M10 40～50
21 磁电机盖螺栓 M6 10～15
22 起动电机螺栓 M6 8～12
23 气缸体侧螺栓 M6 8～12
24 进气管螺栓扭矩 M6 8～12
25 齿轮室盖螺栓 6 8～12
26 气缸头盖螺栓 M6 8～12
27 左商标盖螺钉 M6 8～12
28 左商标盖螺钉 M6 8～12
29 离合器钢索支架螺栓扭矩 M6 8～12
30 正时从动链轮螺钉 M6 10～15
31 张紧条螺栓 M8 10～15
32 张紧器螺栓 M6 8～12
33 气门盖复紧力矩 M45 15～20
34 起动轴限位螺栓 M12 25～30
35 轴承定位板压板紧固力矩 M6 8～12
36 平衡轴轴承压板紧固力矩 M6 8～12
37 平衡轴螺母紧固力矩 M16 25～35
121
Diameter of Required Moment of
S/N Inspection Items
Thread Force (N.m)
Positioning piece bolt torque (five-star
1 M6 10～15
plate)
Positioner mounting bolt torque
2 M6 10～15
(Positioning wheel)
3 Oil filter lock nut torque M16 45～55
4 Clutch lock nut torque M16 45～55
5 Oil strainer tightening torque M36 20～28
6 Cylinder head nut torque M8 25～35

7 Starting clutch bolt M8 25～32
8 Valve adjustment nut torque M6 13～17
9 Spark plug torque M12 15～20
10 Conductor press plate bolt torque M6 8～12
11 Box closing screw M6 10～15
12 Oil pump mounting screw M6 6～10

13 Rotor cover screw M5 4～6
14 Clutch cover bolt M6 10～15
15 Bearing thrust bolt torque M6 8～12
16 Sprocket bolt torque M6 10～15
17 Gear switch screw M4 1～3
18 Magneto stator bolt M6 5～8

19 Trigger coil bolt M5 4～6
20 Magneto rotator fixing bolt torque M10 40～50
21 Magneto cover bolt M6 10～15
22 Starter motor bolt M6 8～12
23 Cylinder block side bolt M6 8～12
24 Intake manifold bolt torque M6 8～12
25 Gear chamber cover bolt 6 8～12
26 Cylinder head cover bolt M6 8～12
122
27 Left trademark cover screw M6 8～12
28 Left trademark cover screw M6 8～12
29 Clutch cable bracket bolt torque M6 8～12
30 Timing driven sprocket screw M6 10～15

31 Tensioning strip bolt M8 10～15
32 Tensioner bolt M6 8～12
33 Re-tightening torque of the valve cover M45 15～20

34 Starting shaft limit bolt M12 25～30
Bearing retainer plate and press plate
35 M6 8～12
tightening torque
Balance shaft bearing press plate fastening
36 M6 8～12
torque
37 Balance shaft nut tightening torque M16 25～35
123
润滑系统图 Lubricating System Diagram
凸轮轴油孔2
凸轮轴油孔1
曲柄销右曲柄缸
头
主副轴
离合器盖
缸
活塞喷孔体
机油滤清器
机油泵
粗滤网
油底壳
- 124 -
Camshaft hole 2
Camshaft hole1
Cylinder
Crank pin Right crank
head
Main and auxiliary
shaft
Clutch cover
Cylinder
Piston orifice body
Engine oil filter
Engine oil pump
Primary strainer
Oil pan
- 125 -
九、润滑系统 IX Lubricating system
准备资料-----------------------------9.1
Service Data-------------------------9.1
故障诊断-----------------------------9.2
Fault Diagnosis-----------------------9.2
机油泵--------------------------------9.3
Engine Oil Pump----------------------9.3
润滑系统作用：
Function of lubricating system:
发动机润滑系统的功能就是将润滑油供给机件磨擦表面，使表面的干磨擦变为润滑油质粒间的液体磨
擦，减少零件的磨损；冷却热负荷较高的零件；吸收轴承及其它机件的冲击，减少噪音；增加活塞环与
气缸壁之间的密封性；清洗并带走零件表面的杂质等。
Engine lubricating system is to supply lubrication oil to friction surface of engine elements,
turning the dry friction on the surface into liquid friction between lubrication oil particles, thus
mitigating part wearing, cooling down parts with high thermal load, absorbing impact from
bearing and the elements and consequently reducing noises, increasing tightness between
cylinder ring and wall, and cleaning and taking away foreign matters from surface of parts.
作业注意事项：
Precautions:
机油泵拆卸后，要对各零件认真清洗并用高压气体将零件表面吹净。
After engine oil pump is disassembled, carefully clean its parts and purge the surface with high-pressure gas.
机油泵拆卸时，注意不可将异物落入曲轴箱内。
To disassemble engine oil pump, it is important to prevent any foreign matter from falling into crankcase.
基准项目标准值及许用极限表
项目标准使用极限
换油时 1L -
机油容量
拆卸时 1.2L -
压油泵 0.025-0.175 0.23
内外转子间径向间隙
油泵转子吸油泵 0.025-0.175 0.23
外转子与泵体间隙压油泵 0.11-0.163 0.22
- 126 -
吸油泵 0.11-0.163 0.22
压油泵 0.05-0.11 0.15
转子端面间隙
吸油泵 0.05-0.11 0.15
Standard Value and Allowable Limit of Reference Items

Item Standard Allowable limit
Engine oil For changing oil 1L -
capacity For disassembly 1.2L -
Oil pressure
0.025-0.175 0.23
Radial stroke between inner and pump
outer rotors Oil suction
0.025-0.175 0.23
pump
Oil pressure
0.11-0.163 0.22
Stroke between outer rotor and pump
Pump rotor
pump Oil suction
0.11-0.163 0.22
pump
Oil pressure
0.05-0.11 0.15
pump
Rotor face-to-face stroke
Oil suction
0.05-0.11 0.15
pump
机油量减少
Engine oil decreases
机油自然消耗
Engine oil is consumed naturally.
机油泄露
Engine oil leakage
引擎烧损
Engine damaged
无油压或油压太低
No or too low oil pressure
油路阻塞
Oil circuit clogged.
- 127 -
9.3 机油泵 Engine Oil Pump
拆卸 Disassembly
拆下右盖，拆下离合器, 拆下挡圈,取下机油泵齿轮，机
油泵过渡齿轮；
Remove the right cover, remove the clutch, remove retainer
ring, remove the oil pump gears and oil pump gear
transition gears;
取下固定销，拆下螺钉，取下油泵盖，分解机油泵；
Remove the fixing pin, remove screws, remove the oil pump cover, and break down oil pump;
装配 Assembly
依拆卸的相反顺序进行。
Assemble in the reverse order of disassembly.
测试
检查 Inspection
检查内外转子间的径向间隙
Check radial stroke between inner and outer rotors
许用极限：0.15 mm
Allowable limit: 0.15 mm
测试规
检查外转子与泵体之间的间隙。
Check stroke between outer rotor and pump body.
许用极限： 0.15 mm
测试规
平
检查转子端面间隙。
- 128 -
Check rotor end surface stroke
- 129 -
十、冷却系统（无水冷系统）(整条删除不用翻译)
准备资料---------------------------10.1
故障诊断---------------------------10.2
水泵---------------------------------10.3
10.1 准备资料
冷却系统作用：
在气缸及缸盖的内壁铸造出一些可以流通液体的通道，并在发动机机体之外设有专门的散热器，通
过水泵和管道使冷却水强制循环，然后通过空气高速吹过散热器的散热片表面，带走发动机散出的热量，
使发动机冷却。
10.2 故障诊断
漏水
密封圈损坏
泵体破裂
水管断裂
气缸体温度过高
水泵叶轮损坏
散热器风扇坏
冷却液缺少
温度传感器坏
- 130 -
10.3 水泵
拆卸
松开紧固螺栓,拆下曲轴箱右盖取下垫片
螺栓
右盖
取下水泵齿轮
松开固定螺钉,取下水泵盖,垫片
螺钉
水泵盖
水泵齿轮
拆下叶轮
取下水泵轴,水封组件等
叶轮
- 131 -
检查
检查零件磨损情况。
磨损严重，则应更换。
注意：
操作中不得损伤垫片及箱体接合面
安装
安装依拆卸的相反顺序进行。
水泵分解
1 内六角圆柱螺钉 2 垫圈 6 3 水泵盖 4 水泵盖密封垫片 5 销 6 叶轮 7 水封组件 8 水泵轴

9 销 3×22 10 水泵齿轮 11 垫圈
- 132 -
气缸头 Cylinder head
1 O 形圈 10 气缸头组成
2 气缸头左盖垫片 11 O 形圈
3 气缸头左盖 12 观察孔盖
4 六角法兰面螺栓 13 火花塞
5 曲轴箱右盖螺钉垫圈 14 盖形螺母
6 平垫圈（铜） 15 平垫圈
7 十字槽六角小螺钉 16 发动机温度传感器
8 气缸头密封垫 17 金属平垫圈
- 133 -
9 定位销
S/N Name S/N Name

1 O-ring 10 Cylinder head composition
2 Cylinder head left cover gasket 11 O-ring
3 Cylinder head left cover 12 Observation hole cover
4 Hexagon flange bolt 13 Spark plug
Crankcase right cover screw
5 14 Cap nut
washer
6 Plain washer (copper) 15 Plain washer
7 Cross recessed hexagon screw 16 Engine temperature sensor
8 Cylinder head seal gasket 17 Metal plain washer
9 Locating pin
- 134 -
十、气缸头
准备资料 10.1
Service data 10.1
故障诊断 10.2
Fault Diagnosis 10.2
气缸头/气门 10.3
Cylinder head/Valve 10.3
气缸头作用：
Function of cylinder head:

气缸头是用来密封气缸，并与活塞构成燃烧室，承受高温高压燃气。并通过配气机构完成进排气。
It is used to seal cylinder and form the combustion chamber along with the piston in order to
withstand high-temperature and high-pressure combustible gas. Through the valve system, the
cylinder head intakes and discharges gas.
Precautions:
为了保证气缸头与气缸体的密封，气缸头承受很大的螺栓锁紧力。预紧力值 12 N·m，锁紧力值：30 N·m。
To ensure seal between the cylinder head and cylinder body, the head withstand large locking tension force
from bolt. Locking-tension value: 30Nm.
所有零件在检查测定前应清洗，并用高压空气吹干净。
All parts must be cleaned before being checked, and purged with high-pressure air.
基准项目标准值及许用极限表单位：mm
项目标准使用极限
气缸盖平面度 0.03 0.05
进 0.04-0.06 -
气门间隙
气门排 0.09-0.11 -
气门导管进 4.975-4.990 4.955
气门杆外径
排 4.955-4.970 4.958
- 135 -
进 5-5.012 5.03
气门导管内径
排 5-5.012 5.03
进 0.01-0.037 0.065
气门杆与气门导管间隙
排 0.03-0.057 0.082
进 1.1-1.3 1.6
气门座宽
排 1.0-1.2 1.6
进 41.8 39.5
气门弹簧自由长度
排 41.8 39.5
凸轮轴凸轮轴与缸头的配合间隙 0.02-0.054 0.08
Standard Value and Allowable Limit of Reference Items Unit: mm

Item Standard Allowable limit
气缸盖平面度 0.03 0.05
Intake 0.04-0.06 -
Valve stroke
Discharge 0.09-0.11 -
Intake 4.975-4.990 4.955
OD, valve rod
Discharge 4.955-4.970 4.958
Valve Intake 5-5.012 5.03
OD, valve rod
Valve guide Discharge 5-5.012 5.03
Clearance of valve rod and Intake 0.01-0.037 0.065
valve guide Discharge 0.03-0.057 0.082
Intake 1.1-1.3 1.6
Width, valve base
Discharge 1.0-1.2 1.6
Intake 41.8 39.5
Valve spring Free length
Discharge 41.8 39.5
Camshaft Stroke of camshaft and cylinder head 0.02-0.054 0.08
压缩压力低
Low compression pressure
气门间隙调整不好
Bad valve stroke adjustment
气门烧损或弯曲
Valve burned or bent
气门座气密性不好
Bad valve base air tightness
气缸头垫片漏气
Air leakage from cylinder head gasket
火花塞安装不良
Poor installation of spark plug
气缸头异音
Abnormal noise in cylinder head
气门间隙调整不好
- 136 -
Bad valve stroke adjustment
气门弹簧损伤
Valve spring damaged
压缩压力过高
Too high compression pressure
燃烧室积碳过多
Too much carbon deposits in combustion chamber
10.3 气缸头 Cylinder Head
拆卸 Disassembly
松开固定螺栓,
拆下气缸盖罩(摇臂，摇臂轴）。
Loosen the mounting bolts and remove the cylinder
head cover (swing arm and its shaft).
拆下张紧器，放松链条，
取下凸轮轴。
Remove the tightener, loosen chain and take down the
camshaft.
- 137 -
凸轮轴测量 Camshaft measuring
测量凸轮配合轴颈尺寸
进气凸轮轴：进气凸轮轴
许用极限：Φ24.957 mm 排气凸轮轴
排气凸轮轴：
许用极限：Φ24.957 mm
测量凸轮高度
Measure the height of the cam.
许用极限：进气 31.336 mm
排气 31.241 mm
Allowable limit: intake: 31.336 mm
Discharge: 31.241 mm
配合轴颈
拆下螺钉、螺母，取下气缸盖。
Remove the screws, nuts and remove the cylinder head.
拆下挺柱，用气门弹簧压缩工具压缩气门弹簧，拆掉气门锁夹。
Remove the tappet, compress the valve spring with a valve spring compression tool, and remove valve cock
clamp..
取下气门调整垫片、气门弹簧、气门弹簧上下座、气门。
Remove the valve adjustment shims, valve springs, valve spring upper and lower seats, and valves.
- 138 -
气门分解 Decomposition of valve
E07-1 单罩滚珠轴承 E07-10 气阀内弹簧
E07-2 凸轮轴组成 E07-11 气阀外弹簧
E07-3 气门摇臂组成 E07-12 油封
E07-3-1 挺杆调节螺钉 E07-13 调整垫片
E07-3-2 气门间隙锁紧螺母 E07-14 调整垫片
E07-4 扭转弹簧 E07-15 进气阀
E07-5 排气阀摇臂轴 E07-16 排气阀
- 139 -
E07-6 凸轮轴链轮 E07-17 进气阀摇臂轴
E07-7 六角头螺栓 E07-18 摇臂轴挡板
E07-8 气阀弹簧盘 E07-19 十字槽小螺钉
E07-9 气阀锁夹
S/N Name S/N Name

E07-1 Single-shield ball bearing E07-10 Valve inner spring
E07-2 Camshaft composition E07-11 Valve outer spring
E07-3 Valve rocker composition E07-12 Oil seal
E07-3-1 Tappet adjustment screw E07-13 Adjusting washer
E07-3-2 Valve lash lock nut E07-14 Adjusting washer
E07-4 Torsion spring E07-15 Intake valve
E07-5 Exhaust valve rocker arm shaft E07-16 Exhaust valve
E07-6 Camshaft sprocket E07-17 Intake valve rocker shaft
E07-7 Hexagon bolt E07-18 Rocker shaft baffle
E07-8 Valve spring plate E07-19 Cross recessed screw
E07-9 Valve locking clip
检查 Inspection
清除气缸盖的积碳。
Clear carbon deposits on the cylinder cover.
测量气缸盖结合面平面度。
气缸盖结合面平面度超过使用极限时，应把细沙纸
放在平板上，气缸盖结合面与沙纸贴合，按 8 字形
推磨。
If the flatness exceeds the allowable limit, place fine
sands on a flat board, engage the interfacing surface
with the board, and then grind in a “8” shape.
测试规
- 140 -
测量气门弹簧自由长度。
Measure free length of valve spring.
气门内弹簧自由长度：39mm
Free length of the inner valve spring: 39mm
气门外弹簧自由长度：41.8mm
Free length of the outer valve spring: 41.8mm
游标卡尺
测量气门杆外径。千分尺
Measure the outer diameter of valve rod.
许用极限：进气 Ф4.955 mm
Allowable limit: air inlet: Ф4.955 mm
排气 Ф4.948 mm
Air exhaust: Ф4.948 mm
检查气门导管，检查前请用铰刀除去气门导管内的积碳。
Check the valve guide. Prior to check, use a reamer to eliminate
carbon accumulated within the guide.
注意：铰刀要顺时针旋转，切不可逆时针旋转铰刀。
Attention: the reamer shall be turned clockwise and do not turn it
counterclockwise.
- 141 -
测量各气门导管内径。测试计
Measure the inner diameter of valve guide.
许用极限：
Allowable limit:
进/排：Ф5.03 mm
Intake/discharge: Ф5.03 mm
气门杆与气门导管间隙许用极限：
Allowable limit for stroke between valve rod and its
guide:
进气门： 0.04mm
Intake: 0.04mm
排气门： 0.09mm
Discharge: 0.09mm
置换气门导管
Valve Guide Replacement
起子
注意：气门与气门导管之间的间隙超过极限值时，
需更换气门导管。气门导管更换后，必须修整气门
门座圈表面。
Attention: If stroke between the valve and its guide,
replace the guide. After the guide is replaced, trim
surface of the valve washer.
将气门导管放进电冰箱的冷冻室内进行冷却一个
小时。
Place the guide into the freezing chamber of electrical
refrigerator for one-hour cooling.
用电炉或热烤箱将气缸头加热到 100-150℃。
Heat the cylinder head to 100-150℃ with an electric oven or thermal oven.
固定气缸头，利用气门导管拆卸工具将气门导管从缸头上侧拆卸出来。
Fix cylinder head, and use the guide disassembly tool to remove the guide out of the head.
在新的气门导管上放一个新的 O 形环。
Place a new O ring onto the new guide. 起子
- 142 -
从气缸头顶端安装气门导管。
Fit the guide from the head top.
注意：安装气门导管时，不可伤及气缸头。
Attention: Do not damage the head when fit the valve.
- 143 -
将气门导管嵌入后，用气门导管铰刀进行修整。
After the guide is inserted, trim it with a reamer. 气门铰刀
注意：用铰刀切削时，要加适量的切削油。铰刀
的旋转方向为顺时针旋转。
Attention: Inject right amount of cutting oil when cut
with the reamer. The reamer rotates clockwise.
清除燃烧室及气门积碳，并彻底清洗进、排气门。
Clear carbon accumulated within the combustion
chamber and valve, and thoroughly clean the intake
and discharge valves.
检查气门座接触面宽度（气门座圈宽度）。
Check width of valve contact surface (valve race
width).
许用极限：进/排：1.6 mm
Allowable limit: Intake/discharge: 1.6mm.
气门座接触面
气门座圈的修整 Valve Race Fixing and

Adjustment
利用 45°角的铣刀除去气门座圈表面粗糙不平或
参差不齐的部分。粗糙不平部位
Use a 45° cutter to clear coarse or uneven parts on
the surface of valve race.
注：给气门座圈涂一层透明的或普鲁士篮的覆层。
以便可以看得更清晰。
Notes: apply a layer of transparent or Prussian blue
coating across the race for more visibility.
- 144 -
用 30°角的铣刀除去气门座圈外端的 1/4。
Use a 30° cutter to clear 1/4 of external end of race.
30°
用 70°的铣刀去除去气门座圈底端的 1/4。取下铣
刀，检查处理过的地方。
Use a 70° cutter to clear 1/4 of bottom of race.
Remove the cutter and check the processed
locations.
70°
用 45°角的精修铣刀磨削气门座圈使其达到适
当的宽度。
Use a 45° trimming cutter to grind the race so that 0.9mm
it meets the suitable width.
一定要除去所有的凹痕和参差不齐的部分。
Make sure all caves and unevenness are
eliminated.
标准气门座圈宽：进：1.1-1.3 mm 45°
排：1.0-1.2mm
Standard valve base width: Intake: 1.1-1.3 mm
Discharge: 1.0-1.2mm
- 145 -
如果相接触的地方是气门太高的部分，请用 32°角的平铣刀将气门座圈降低。
If the contact is higher part in the valve, use a 32°
cutter to lower the race to its minimum height.
如果相接触的地方是气门太低的部分，必须将
60°角的内铣刀将气门座圈抬高。接触面高
If the contact is lower part in the valve, use a 60° 32°
cutter to raise the valve base to its minimum height. 接触面低
使用 45°角的精修铣刀，再次精修气门座圈使其
符合要求的规格。
60°
Use a 45°trimming cutter to trim the valve base so
that it meets the required specifications.
完成气门座圈磨削后，请在气门表面涂上抛光剂，
轻轻地给气门抛光。
After the valve base is ground, apply polishing agent across the valve surface to polish the valve gently.
安装 Installation
安装依拆卸时的相反顺序进行。
Installation is executed in the reverse sequence of disassembly.
在安装气门弹簧时，将弹簧节距较小的一端朝向燃烧室安装。
To install the valve spring, it shall be such installed that the end with smaller spring pitch faces the combustion
chamber.
安装气门锁夹时，用气门弹簧压缩工具压缩气门弹簧进行安装。
To install valve locking clamp, compress the spring with its compression tool.
安装气门时，应将气门杆表面涂适量机油再装入气门导管中。
To install the valve, apply a right amount of engine oil across the valve rod, and then place the rod into the
guide.
气门间隙的调整 Valve lash
adjustment
装上气门间隙调整专用气缸盖罩，用测试规测量凸
轮基圆与挺柱的间隙
Install the cylinder cover hood special for valve lash
adjustment, measure the clearance between the cam
base circle and the tappet with a test gauge.
进气门：0.04-0.06mm
Intake valve: 0.04-0.06mm
排气门：0.09-0.11mm
Exhaust valve: 0.09-0.11mm
- 146 -
气缸体与活塞 Cylinder Block and Piston
1 气缸体组成 6 活塞环组合
2 气缸体密封垫 7 活塞
3 气缸双头螺栓 B 8 孔用挡圈
4 定位销 9 活塞销
5 气缸双头螺栓
- 147 -
S/N Name S/N Name
1 Cylinder block composition 6 Piston ring combination
2 Cylinder block gasket 7 Piston
3 Cylinder stud B 8 Retainer ring for holes
4 Locating pin 9 Piston pin
5 Cylinder stud
十一、气缸体与活塞 XI Cylinder Block and

Piston
准备资料 11.1
Service Data 11.1
故障诊断 11.2
气缸体 11.3
Cylinder Block 11.3
活塞 11.4
Piston 11.4
气缸体作用：
Function of cylinder block:
气缸体给气体压缩、燃烧和膨胀提供了一个空间，并对活塞运动起导向作用。
It offers a space for gas compression, combustion and expansion, and guides in piston motion.
它还将气缸中一部分热量传递给周围冷却介质。
It also transfers some of heat to surrounding cooling media.
活塞作用：
Function of piston:
1．承受气缸中混合可燃气燃烧所产生的压力，并将此压力传递给连杆，以带动曲轴转动。
- 148 -
Withstand pressure as a result of combustion of combustible mixed gas, and transfer such pressure to the
connecting rod to drive the crankshaft.
2．与气缸盖等共同形成燃烧室。
Form the combustion chamber along with the cylinder cover.
作业注意事项：Precautions
基准项目标准值及许用极限表
项目标准值使用极限
内径 57.3-57.301 57.351
圆柱度 0.007 0.027
圆度 0.005-0.007 0.025
平面度 0.05 0.055
活塞外径(测量点) 57.270-57.275 57.26
活塞销孔内径 14.002-14.008 14.04
活塞销外径 13.996-14 13.966
气缸活塞与活塞销之间的间隙 0.002-0.012 0.062
第一环 0.03-0.07 0.12
活塞环与环槽的间隙
第二环 0.03-0.07 0.12
第一环 0.15-0.3 0.4
活塞环合口间隙第二环 0.25-0.4 0.5
油环 0.15-0.6 -
连杆小头内径 13.990-14.017 14.067
连杆与活塞销之间的间隙 0.010-0.021 0.089
Standard Value and Allowable Limit of Reference Items
Item Standard value Allowable limit
ID 57.3-57.301 57.351
Cylindricality 0.007 0.027
Roundness 0.005-0.007 0.025
Flatness 0.05 0.055
Piston OD (measuring point) 57.270-57.275 57.26
Piston pin hole ID 14.002-14.008 14.04
Piston pin OD: 13.996-14 13.966
Stroke between piston and piston
Cylinder 0.002-0.012 0.062
pin
Stroke between piston Ring 1 0.03-0.07 0.12
ring and ring slot Ring 2 0.03-0.07 0.12
Ring 1 0.15-0.3 0.4
Piston ring closure
Ring 2 0.25-0.4 0.5
stroke
Oil ring 0.15-0.6 -
Piston pin end ID 13.990-14.017 14.067
Stroke between connecting rod and
0.010-0.021 0.089
piston pin
- 149 -
压缩压力低
活塞磨损、烧损或折断
Piston worn, burnt or broken
气缸、活塞磨损或损坏
Cylinder and piston worn or damaged
垫片损坏，曲轴箱与气体之间漏气
Gasket damaged and air leakage between crankcase and gas
压缩压力过高
Too high compression pressure
燃烧室积碳过多
Too much carbon deposits in combustion chamber
排气管白烟
White smoke from discharge duct
活塞环磨损、损坏
Piston ring worn or damaged
活塞、气缸磨损或损坏
Cylinder and piston worn or damaged
活塞异响
Abnormal noise from piston
气缸、活塞、活塞环损坏
Cylinder, piston and piston ring damaged
活塞销孔与活塞销磨损
Piston pin hole and piston pin worn
12.3 气缸体 Cylinder Block
拆卸 Disassembly
取下气缸体。
Remove the cylinder block.
检查 Inspection
检查气缸内壁磨损情况。
如磨损严重，则应更换。
取下垫片、定位销。
Check wearing of inner wall of cylinder.
If serious wearing is found, replace it.
Remove the gasket and locating pin.
- 150 -
活塞 Piston
拆卸 Disassembly
拆下活塞销挡圈。
Remove the piston retaining ring.
注意：拆卸时，不要将挡圈落入曲轴箱内。
Attention: During removal, do not fall the retaining
ring into crankcase.
取出活塞销，取下活塞。
Take out the piston pin and remove the piston.
取下活塞环。
Remove the piston ring.
检查活塞、活塞销、活塞环。
Check piston, piston pin and piston ring.
注意：Attentions
不要将活塞环折断或损伤。
Do not break or damage the piston ring.
清除活塞环槽内的积碳。
Clear the carbon deposits within the piston ring.
装上活塞环。活塞
Install the piston ring. 测试规
测量活塞环与活塞环槽之间的间隙。
Measure stroke between the piston ring and its slot. 推入
许用极限：第一环：0.12 mm
Allowable limit: Ring 1: 0.09mm
Ring 2:: 0.12 mm
活塞环
取下活塞环，将各活塞环装在气缸底部。
Remove the piston ring and install the piston rings
at the bottom of cylinder.
活塞环
用活塞头将活塞环压入气缸内。
Use the piston head to press the piston ring into the cylinder.
测试规
- 151 -
测量活塞环合口间隙。
Measure piston ring closure stroke
许用极限：第一环 0.4 mm
Allowable limit: Ring 1: 0.4 mm
第二环 0.5 mm
Ring 2: 0.5 mm
活塞销孔内径测量。
Measure piston pin hole ID.
许用极限： Φ14.04 mm
Allowable limit: 14.04mm.
测试计
活塞销外径测量。
Measure piston pin hole OD.
许用极限：Ф13.966mm 1
Allowable limit: Ф13.966mm. 2
活塞销孔与活塞销间隙。 3
Stroke between piston pin hole and piston pin
许用极限：0.062mm
Allowable limit: 0.062mm
活塞外径测量。
Measure piston OD. 90°
注意：Attention:
- 152 -
11mm
测量位置为与活塞销成 90 度角，活塞裙部下约 11mm 处。
Measurement is made at such position as to
form 90° with piston pin and around 11mm
from the piston skirt bottom.
许用极限：Φ57.26mm
Allowable limit: Φ57.26mm
气缸内壁划伤、磨损检查。
Inspection of cylinder inner wall scratch and
wearing.
与活塞销成 90 度直角方向，分上、中、下三个位测试计
置测量气缸内径。
Measure cylinder inner diameter at upper,
middle and lower positions at 90° with the piston
pin.
测量气缸与活塞之间的间隙，以最大值为准。
Measure the stroke between the cylinder and piston,
and the maximum value prevails.
测量气缸内壁的圆度（X 方向与 Y 方向内径差）。

Measure the roundness of cylinder inner wall
(difference between X ID and Y ID).
许用极限：0.01mm Upper
Allowable limit: 0. 01mm
测量气缸内壁的圆柱度（X 方向或 Y 方向在上、 Middle
中下三个位置内径差）。
Measure the cylindricality of cylinder inner wall (ID Lower
difference at the upper, middle and lower positions
between X and Y).
- 153 -
检查气缸面平面度。
Check the flatness of cylinder surface. 直尺
测试规
气缸
测量连杆小端内径。
Measure connecting rod small end ID.
连杆小端内径
活塞的安装 Installation
顶环
安装定位销。
Install locating pin. 第二环
- 154 - 油环
将各活塞环及活塞涂均机油，将活塞环记号面向上安装到位。
Apply engine oil on the piston rings and pistons, and install the piston rings at their positions with the marking
face upward.
活塞不可划伤，活塞环不可折断；
Do not scratch the piston and do not break the piston ring.
活塞环安装后，在活塞环槽内能自由转动。
After the piston ring is installed, the piston ring is capable to rotate within the piston slot freely.
将曲轴箱上面附着的垫片刮除干净。
Clear all of gaskets attached on the crankcase.
曲轴箱内不可有异物落入。
Any foreign matter shall not fall into the
crankcase.
安装活塞、活塞销、活塞销挡圈。
Install piston, piston pin and its retaining ring.
活塞顶部凹槽较大端向进气门安装。
Install the larger end of the groove at the top of the piston toward the intake valve.
气缸的安装 Installation of Cylinder

将垫片、定位销装在曲轴箱上。
Install the gasket and locating pin on the crankcase.
将气缸内壁、活塞及活塞环涂均机油。
Apply engine oil across the cylinder inner wall, piston and piston ring.
活塞环注意小心装入气缸内。
Care shall be excised to locate the piston ring into the cylinder.
- 155 -
不可损伤活塞环。
Do not damage piston ring.
- 156 -
十二、曲轴箱 XII Crankcase
准备资料 12.1
Service Data 12.1
故障诊断 12.2
曲轴箱 12.3
Crankcase 12.3
离合器 12.4
Clutch 12.4
变档机构 12.5
曲轴连杆组合 12.6
变速室 12.7
曲轴箱作用：
Function of crankcase:
曲轴箱是发动机的承力部件。它的主要作用是支承曲轴、离合器、变速箱、气缸体和气缸盖，承受燃烧
爆发冲击和曲轴连杆机构运动的惯性力，并构成一部分密闭（封油、封气）空间。
It is a bearing component in the engine. It is provided to support the crankshaft, clutch, gearbox, cylinder block
and cover, withstand impact from combustion and inertia force due to crankshaft connecting rod mechanism,
and it also forms some enclosed spaces (oil-seal and gas-seal).
曲轴箱上还设有悬挂孔，通过与车身上的悬挂孔相连使发动机与车架和其它部分相连接。
Suspension hole is provided on the crankshaft, and it is connected with the suspension hole on the motorcycle
so that the engine is connected with frame and other parts.
Precautions
曲轴箱为薄壁铸件，作业中要避免冲击，以免产生变形或断裂。
Crankcase is thin-wall casting, so it is required to avoid impact during operation for fear of deformation or
breaking.
- 157 -
作业前，应将曲轴箱内的润滑油放出。
Prior to any operation, release lubricating oil from the crankcase.
基准项目标准值及许用极限表单位：mm
项目标准值许用极限
连杆大端左右间隙 0.1-0.30 0.5
连杆大端径向间隙 0.002-0.010 -
跳动 0.03 0.03
曲轴连杆组件、
摩擦片厚度 2.8-2.9 2.8-2.9
离合器
从动摩擦片平面度 0.04 0.04
压力弹簧长度 30.4-31.6 30.4-31.6
面滚针轴承厚度 1.88-2 1.88-2
拔叉轴外径 11.976-11.994 11.95
拨叉内孔直径 12-12.018 12.05
变档机构拨叉厚度 4.993-5 4.7
变档毂外径 35.8-36 35.75
变档毂锁槽宽度 7.1-7.2 7.35
Standard Value and Allowable Limit of Reference Items Unit: mm
Item Standard value Allowable limit
Right-left stroke of
0.1-0.30 0.5
connecting rod large end
Radial stroke of connecting
0.002-0.010 -
rod large end
Crank linkage
Run-out 0.03 0.03
assembly, clutch
Friction plate thickness 2.8-2.9 2.8-2.9
Driven friction plate flatness 0.04 0.04
Pressure spring length 30.4-31.6 30.4-31.6
Needle bearing thickness 1.88-2 1.88-2
Fork shaft outer diameter 11.976-11.994 11.95
Fork bore diameter 12-12.018 12.05
Shifting
Fork thickness 4.993-5 4.7
mechanism
Shifting hub outer diameter 35.8-36 35.75
Shifting hub lock slot width 7.1-7.2 7.35
压缩压力低
曲轴箱漏气
Air leakage of crankcase
- 158 -
发动机过热
Engine overheating
离合器打滑
Clutch slip
润滑不良
Poor lubrication
挂不上档
Shifting failure
变速拨叉折断或变形
Shift fork breakage or deformation
拨叉导销折断
Fork pin breakage
齿轮凸爪磨损
Gear detent wear
自动脱档
Auto out-of-gear
接合爪磨损，边缘变成了圆角
Engaging claw wear, and edges become rounded
变速机构回位弹簧弹力减弱
Transmission mechanism return spring deflation
花键轴的花键齿与滑动齿轮的花键槽磨损，致使齿轮工作时产生较大的轴向力
Wear of the spline shaft spline teeth and sliding gear spline groove results in the occurrence of a greater axial
force during the working of the gear.
变档鼓及拨叉磨损
Wear of shifting drum and fork
曲轴箱内有异音
Abnormal sound from crankcase
曲轴箱内有零件散落或折断
Scattered or broken parts in crankcase
发动机自动停车
- 159 -
Automatic shutdown of engine
离合器卡死
Clutch stuck
换档困难
Shifting difficulties
离合器分离不彻底
Incomplete release of clutch
变速器回拉弹簧动作不良
Malfunction of transmission pull-back spring
变档鼓锁槽磨损
Shifting drum lock groove wear
- 160 -
12.3 曲轴箱 Crankcase
曲轴箱左盖的拆卸 Removal of
crankcase left cover

松开起动电机固定螺栓，取下起动电机。
Loosen the starter motor fixing bolts and remove the
starter motor.
松开左盖固定螺栓，取下左盖。
Loosen the left cover fixing bolts and remove the left
cover.
利用电动或气动工具松开飞轮锁紧螺母。
Use electric or pneumatic tools to loosen the flywheel
lock nut.
拨出飞轮组件(含星轮)，取下起动电机惰齿轮。
Pull out the flywheel assembly (including star wheel),
remove the starter motor idler gear.
取下垫片。
Remove the gasket.
曲轴箱右盖的拆卸 Removal of
crankcase right cover

- 161 -
松开紧固螺栓，取下曲轴箱右盖、垫片、定位销。
Loosen the fixing bolts and remove the crankcase right cover, gaskets, and locating pin.
12.4 离合器 Clutch
拆卸 Disassembly
套筒扳手
按对角交叉方式拧松压盘五个螺栓。
Loosen five pressure plate bolts by diagonal cross.
拆下离合器弹簧、弹簧垫圈、压力盘、轴承垫圈、平
面滚针轴承及轴承座、离合器分离轴套等。
Disassemble the clutch spring, spring gasket, pressure
plate, bearing washer, plane needle roller bearing,
bearing seat and clutch sleeve.
利用专用工具拧松离合器锁紧螺母,拆下锁紧螺母及万能固定器
垫圈。
Loosen the clutch lock nut with special tools, then remove the lock nut and washer.
拆下离合器中心支架。
Disassemble the clutch center support.
拆下离合器主动、从动磨擦片。
Disassemble the driving and driven friction plates of clutch.
拆下零件见分解图。
Remove the parts as per the disassembly diagram.
拆下止推垫圈。
Remove the thrust washer. Housing
拆下外壳组件。外壳组件
component
Remove the housing component.
离合器装配按拆卸的相反顺序进行。
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The clutch is assembled in the reverse order of removal.
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离合器分解 Clutch Disassembly
1 初级从动齿轮总成 3-6 离合器主动片
2 离合器花键垫片 3-7 离合器从动片
3 离合器从动毂组成 3-8 离合器压盘
3-1 六角法兰面螺栓 4 防松垫圈
3-2 离合器推杆盘 5 锁紧螺母
3-3 离合器弹簧 6 轴承 16003
3-4 离合器从动毂 7 离合器推动块
3-5 离合器主动片 8 离合器推杆
S/N Name S/N Name

1 Primary driven gear assembly 3-6 Clutch driving plate
2 Clutch spline washer 3-7 Clutch driven plate
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3 Clutch hub composition 3-8 Clutch compression disk
3-1 Hexagon flange bolt 4 Lock washer
3-2 Clutch putt disc 5 Lock nut
3-3 Clutch spring 6 Bearing 16003
3-4 Clutch hub 7 Clutch push block
3-5 Clutch driving plate 8 Clutch putt
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检查 Inspection
检查离合器的外壳槽有无毛刺或破损的痕迹，若有
用锉刀修整，修整量过大时，则应更换。
Check if there are burrs or damage in the shell
components of the clutch, and get rid of them with a
file. Replace the clutch if too much such work needs
doing.
检查压力盘与中心支架的齿形有无损伤，如有损
伤，则应更换。
Check whether it is damaged in the dents of the
pressure plate and the center bearing support. Replace
it if it is damaged.
测量压力弹簧的自由长度。
Measure the free length of the pressure spring.
许用极限：29.7mm 以下更换。
Allowable limit: replace in case of below 29.7mm
自由长度
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用游标卡尺测量磨擦片的厚度。
Measure the thickness of the friction disc with a
vernier caliper.
许用极限：2.5mm 以下更换。厚度
用塞规检查从动摩擦片的平面度
Measure the flatness of the driven friction disc with a
plug gauge.
许用极限：0.2mm 以上更换
测量平面滚针轴承的厚度
Measure the thickness of the plane needle roller
bearing.
许用极限：1.8mm 以下更换
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曲轴连杆组合
1 活塞环组合 11-2-4 过油管
2 活塞 12 十字槽沉头小螺钉
3 孔用挡圈 13 防松垫圈
4 活塞销 14 锁紧螺母
5 曲轴总成 15 转子盖垫片
5-1 半圆键 16 六角法兰面螺栓
5-2 轴承 17 垫圈
5-3 平键 18 波形垫圈
5-4 平键 19 平衡轴从动齿轮组合
5-5 曲轴调整垫片 19-1 平衡轴从动齿轮内圈
6 平衡轴驱动轮 19-2 平衡轴齿轮减震垫
7 初级主动齿轮 19-3 调整垫片
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8 初级主动齿轮弹簧 19-4 压缩弹簧
9 初级主动齿轮 2 19-5 圆柱销
10 锁紧垫圈 19-6 轴用挡圈
11 机油滤清器组合 20 衬套
11-1 机油过滤器转子 21 球形轴承
11-2 机油滤清器盖总成 22 平衡轴轴承压板
11-2-1 过油管弹簧 23 六角法兰面螺栓
11-2-2 转子盖 24 平衡轴
11-2-3 保险销 25 球形轴承
S/N Name S/N Name

1 Piston ring combination 11-2-4 Oil tube
2 Piston 12 Cross recessed countersunk head screw
3 Retainer ring for holes 13 Lock washer
4 Piston pin 14 Lock nut
5 Crankshaft assembly 15 Rotor cover gasket
5-1 Woodruff key 16 Hexagon flange bolt
5-2 Bearing 17 Washer
5-3 Flat key 18 Wave washer
5-4 Flat key 19 Balance shaft driven gear combination
5-5 Crankshaft adjustment shims 19-1 Balance shaft driven gear inner ring
6 Balance shaft driving wheel 19-2 Balance shaft gear cushion
7 Primary driving gear 19-3 Adjusting washer
8 Primary driving gear spring 19-4 Compression spring
9 Primary driving gear 2 19-5 Straight pin
10 Lock washer 19-6 Circlips for shaft
11 Oil filter combination 20 Bushing
11-1 Oil filter rotor 21 Spherical bearing
11-2 Oil filter cover assembly 22 Balance shaft bearing plate
11-2-1 Oil tube spring 23 Hexagon flange bolt
11-2-2 Rotor cover 24 Balance shaft
11-2-3 Safety pin 25 Spherical bearing
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曲轴箱盖组 Crankcase cover group
1 离合器盖组成 16 六角法兰面螺栓
2 定位销 17 六角法兰面螺栓
3 离合器盖密封垫 18 齿轮室盖
4 六角法兰面螺栓 19 六角法兰面螺栓
5 六角法兰面螺栓 20 六角法兰面螺栓
6 六角法兰面螺栓 21 O 形圈
7 机油标尺 22 O 形圈
8 O 形圈 23 磁电机外盖
9 离合器分离轴组成 24 磁电机盖
10 分离杆油封 25 上死点塞密封垫
11 弹性销 26 六角法兰螺塞
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12 扭转弹簧 27 六角法兰面螺栓
13 离合器拉索支架 28 磁电机盖密封垫
14 链轮盖 29 定位销
15 定位销
S/N Name S/N Name

1 Clutch cover composition 16 Hexagon flange bolt
2 Locating pin 17 Hexagon flange bolt
3 Clutch cover gasket 18 Gear chamber cover
4 Hexagon flange bolt 19 Hexagon flange bolt
5 Hexagon flange bolt 20 Hexagon flange bolt
6 Hexagon flange bolt 21 O-ring
7 Oil dipstick 22 O-ring
8 O-ring 23 Magneto outer cover
9 Clutch release shaft composition 24 Magneto cover
10 Release rod seal 25 Top dead center stopper gasket
11 Spring pin 26 Hexagon flange plug screw
12 Torsion spring 27 Hexagon flange bolt
13 Clutch cable bracket 28 Magneto cover gasket
14 Sprocket cover 29 Locating pin
15 Locating pin
12.5 变档机构 Gearshift Mechanism
拆卸 Disassembly
拆下止动臂。
Remove the brake arm. 止动臂
拆下变档定位板。
Remove the shifting positioning plate.
拆下变档轴组合。变档定位板
Remove the gearshift combination.
变档轴组合
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拆下零件见变速换挡组件
The removed parts refer to the gear shift assembly.
分解图
Disassembly drawing
检查 Inspection
未分解前，变档板应回位灵活，无卡滞现象。
Before dismounting, the gearshift baffle should be flexible, without clamping.
检查变档板及变档轴组合的磨损情况。磨损严重，则应更换组件。
Check the wearing of the baffle and the gearshift mechanism. Replace it if it is seriously worn.
检查变档定位板板磨损情况。磨损严重，则应更换组件。
Check the wearing of the locating plate of the gearshift. Replace it if it is seriously worn.
检查变档轴有无弯曲现象，如有过度弯曲，则应更换。
Check whether the gearshift shaft is bent. Replace it if it is excessively bent.
检查回位弹簧是否弹力减弱，必要时更换。
Check the elasticity of the restoring spring. Replace it if necessary.
利用电动或气动工具松开右曲轴的螺母、垫圈，
拆下离合器传动齿轮。
Unscrew the bolt and washer on the right crank
shaft with electric or compression tools. Remove
driving gear of clutch.
拆下副轴螺母，取下链轮，轴套
Remove the auxiliary shaft nut, sprocket and sleeve.
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松开合箱螺栓。
Unscrew the bolt in the veneer case.
分开曲轴箱。
Separate the crankcase.
注意：不可损伤结合箱面。
Note: do not damage the surface of the case.
取下左箱体。
Remove the left part of the case.
13.6 曲轴连杆组合 Crankshaft Connecting Rod Assembly
拆卸 Removal
从右曲轴箱上取下平衡轴组合，曲轴连杆组合。
Remove the balance shaft assembly and
crankshaft connecting rod assembly from the
right crank case.
注意：不可损伤合箱面。
Note: do not damage the surface of the case.
检查 Inspection
连杆大端左右间隙测量。
Measure the stroke on the left and right side of the
big end of the collecting rod.
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- 174 -
连杆大端部 X-Y 方向间隙的测量。
Measure the stroke along X-Y direction of the big end of the connecting rod.
许用极限：0.002-0.010mm
Allowable limit: 0.002-0.010mm
连杆大端测量位置
曲轴跳动的测量。
Measure the dislocation of the crank shaft.
检查曲轴轴承回转是否有异音或松动。
如有异音、松动时，更换曲轴组件。
Check if the crank shaft is noisy or loose while restoring.
Replace it if so.
曲轴轴承
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拨出拔叉轴。
Draw out the shifting fork.
取下变档鼓。
Remove the gearshift drum.
取下变档拔叉。
Remove the gearshift fork.
检查 Inspection
测量拔叉轴外径。
Measure the shifting fork hole OD.
许用极限：11.95mm。千分尺
测量拔叉孔内径。
Measure the shifting fork hole ID.
许用极限：12.05mm。
测试计
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测量拔叉厚度。
Measure the the shifting fork thickness.
许用极限：4.7mm 游标卡尺
测量变档鼓外径。
Measure the gearshift drum OD.
锁槽宽度
测量变档鼓锁槽宽度。
Measure gearshift drum lock groove width
13.7 变速室 Transmission chamber

副轴组件
取下主轴组件。
Remove the primary shaft assembly.
取下副轴组件。
Remove the secondary shaft assembly.
主轴组件
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变速换档组件分解图 Transmission Component Disassembly
1 六角头螺栓 14 变档轴油封
2 变挡凸轮定位机枪组成 15 变挡轴总成
3 变挡凸轮定位弹簧 15-1 弹性挡圈
4 十字槽六角小螺钉 15-2 硬钢垫片
5 变挡凸轮定位片 15-3 变挡轴回位弹簧
6 定位销 15-4 变挡轴组成
7 滚针轴承 15-5 压缩弹簧
8 变挡凸轮 15-6 弹性挡圈
9 压缩弹簧 16 变挡拨叉轴
10 凸轮挡位定位销 17 右变挡拨叉
11 O 形圈 18 中间变挡拨叉
12 十字槽盘头小螺钉 19 左变挡拨叉
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13 挡位开关座总成
S/N Name S/N Name

1 Hexagon bolt 14 Gearshift shaft seal
2 Gear shifting cam positioner composition 15 Gearshift shaft assembly
3 Gear shifting cam positioning spring 15-1 Circlip
4 Cross recessed hexagon screw 15-2 Hard steel shim
5 Gear shifting cam positioning plate 15-3 Gearshift shaft return spring
6 Locating pin 15-4 Gearshift shaft composition
7 Needle bearing 15-5 Compression spring
8 Gear shifting cam 15-6 Circlip
9 Compression spring 16 Gearshift fork shaft
10 Cam gear positioning pin 17 Right gearshift fork
11 O-ring 18 Intermediate gearshift fork
12 Cross recessed pan head screw 19 Left gearshift fork
13 Gear switch seat assembly
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检查 Inspection
分别检查齿轮的齿面及传动爪处的磨损情况。
Inspect the abrasion at the surface and transmission
claw of the gear. 齿面
如磨损严重或损坏，则应更换。
Replace it in case of severe abrasion or damage.
传动爪
取下左、右曲轴箱的轴承和油封。
Remove the bearing and oil seals of left and right crankcase.
检查轴承和油封是否有损伤，如有则更换
Inspect the damage to bearings and oil seals, replace them if any.
打出的轴承不能再用，应更换新品。
Abandon the outgoing bearings and replace with new products.
轴承及油封的拆卸要用专用工具。
Disassemble the bearings and oil seals with special tools.
主副轴组合 Primary/ Secondary Shaft Assembly
注意：Attentions
组合时，将各齿轮及轴涂均润滑油。保证组合后，各齿轮无卡阻现象。
Coat the gears and shafts with lubricating oil when assembling. Protect the gears against jamming upon
assembly.
注：Notes:
曲轴箱的装配依拆卸的相反顺序进行。
The crankcase is assembled in reverse procedures of removal.
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废气排放系统的检查与维护 Exhaust System Inspection and
Maintenance
消声器 Muffler
F05-1 消声器组件 F05-2 螺栓 M8×25
F05-1-1 防烫带 F05-3 氧传感器
F05-1-2 消声器抱箍 F05-4 螺栓 M10×1.5×25
F05-1-3 排气管密封垫
S/N Name S/N Name

F05-1 Muffler assembly F05-2 Bolt M8×25
F05-1-1 Anti-scald strip F05-3 Oxygen sensor
F05-1-2 Muffler hoop F05-4 Bolt M10×1.5×25
F05-1-3 Exhaust pipe gasket
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十三、废气排放控制系统 XIII Exhaust control
system
废气排放控制系统保证书----------------13.1
Exhaust control system Guarantee---------13.1
定期保养须知/确保排放标准------------13.2
Periodical Maintenance Instructions/Ensuring Emissions Standards---------13.2
废气控制系统机械功能-------------------13.3
Mechanical Functions of Exhaust control system----------------13.3
触煤转化系统-------------------------------13.4
Catalytic Conversion System------------------13.4
怠速排放值超过规定值时的对策-------13.5
Solutions to the problem of idle exhaust exceeding specified value----13.5
13.1 废气排放控制系统保证书 Exhaust control system Guarantee
1.本车废气排放控制系统符合欧盟 134/2014/EU 法规要求，在其废气排放控制系统有效使用期使用者完

全依正常使用及规定的保养下，本公司予以保证。
This exhaust control system is in accordance with the requirements of 134/2014/EU. Our guarantee is set for
products in effective service life that are maintained absolutely following our instruction.
2.保证范围
Scope of guarantee
1〉废气排放控制系统功能保证
Guarantee on the function of the exhaust control system
保证在使用（一万五千公里）内，均符合政府机关执行的定期或不定期废气检验。
During the service life (15,000 km), it can pass all the periodic and non-periodic emissions control inspection
of the government authorities.
3.有下列情况者，不适用本保证条款，唯有保养维护的需要，本公司各省市经销商或服务部仍愿以合理
的价格为顾客服务。
The following cases are out of the scope of the guarantee. If maintenance services are needed, services from
the franchisers or service centers of our company in different places will be available for the customers at a
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reasonable price.
1〉未依照本公司所指定的时间或行驶里程实施定期保养。
Maintenance is not conducted according to the intervals or distance of drive specified in our instructions.
2〉未在本公司经销商或服务中心定期检查，调整或维修者，或无法提出保养记录证明者。
Periodic maintenance, adjustments or repair work is not done in our franchisers or service centers, or no
evidence of maintenance is available.
3〉超载或使用不当。
Overload or improper use.
4〉随意改造车辆、拆卸原装零件或填装其他设备。
The vehicle is modified, the original components are removed or replaced with other components privately.
5〉用于赛车或经常行使与非机动车适行的道路。
The vehicle is used in racing or frequently operated in roads that are used for non-motor vehicles.
6〉受台风、水灾等天气灾害造成的损坏，或因使用疏忽，车祸，外物撞击造成的损伤及故障。
The vehicle is damaged by such climate disasters as typhoons and floods, or in improper use, car accidents and
clashes;
7〉长期停止使用未作定期保养者。
Not in use for a long time and lack of periodic maintenance.
8〉里程表损坏未立即维护或以人为的变造、停用、更换者。
The odometer is damaged but not repaired immediately, or it is modified, stopped or replaced.
9〉每三个月请至检验站，定期废气检验。
Please send the vehicle to the inspection place every three months to check emission control.
·本公司出厂的新车，经噪音检验结果，符合欧盟 134/2014/EU 法规要求。
Through noise test, the new vehicles produced in our company comply with the requirements of 134/2014/EU.
13.2 定期保养须知 Periodical Maintenance Instructions
为确保环境污染程度不日益严重，国家要求各生产厂商所生产的机动车都要符合空气污染排放标准规
定，本公司除了生产符合空气污染排放标准规定外，并极力净化空气，为减少空气污染而努力。
To prevent deterioration of environmental pollution, the government requires all the manufacturers to ensure
their products meet the emissions control standards. Our products meet those standards. We are also making
our due contribution to air purification and reducing air pollution.
·本机车出厂前皆经过严格检验，一切符合空气污染排放标准规定，但由于顾客使用本产品情况不同，
因而，我们制定以下有关废气排放的定期检查表，为确保排放的正常，使用者请以规定时间作检查、调
整或维修。
This vehicle has passed strict inspection. It completely meets the emissions control standards. Due to the
varying concrete conditions of use of the vehicles, we made the following inspection table for periodic
emissions inspection. To ensure normal levels of emissions, the user should follow the specified intervals of
maintenance, adjustment or repair.
若有其他使用上的各别问题，请讯问 KSR 经销商，或 KSR 服务中心。
Please consult the dealers or the customer service centers of KSR if you have other problems.
有关排放规定如下：
Relevant emission standards are as follows:
排放规定 CO HC NOX
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排放标准 ≤1140mg/km ≤ 380mg/km ≤ 70mg/km
Emission regulation CO HC NOX

Emission standard ≤1140mg/km ≤ 380mg/km ≤ 70mg/km
※排放标准若有变更，应国家最新规定为准。
※effective emission standards are subject to the newest updated changes made by the government.
未依本公司经销商或服务中心作定期检验的，遭取缔时本公司概不负责，请随时作必要的检查，以保
持最佳车况。
If periodic maintenance is not done in our franchisers or service centers, we will not be responsible for
possible case of being canceled. Please do necessary checks at all times to ensure optimal functions of the
vehicle.
注：①在沙石路面或环境严重污染应增加经常清洗空气滤清器的次数，以延长发动机的寿命。
Note: ① the air filters on vehicles running on gravel pavements or severely polluted environment need to be
cleaned more frequently, so as to lengthen their service life.
②常高速行驶或行驶频繁，里程较多者，保养程度应增加。
② better maintenance should be given to vehicles that are constantly used or frequently running at high
speeds.
确保排放标、请注意下列各项 Please notice the following items to ensure
consistence with emission standards:

1〉燃料的使用，请务必限用 E5 及以上无铅汽油。
Fuel: only E5 or above unleaded gas can be used.
2〉机油的使用，请勿必使用指定规格的机油。
Engine oil: only specified engine oil can be used.
3〉请以定期保养表的规定保养。
Maintain it according to the instruction in the periodic maintenance table.
4> 关于废气控制系统，严禁任意调整或更换等（包括火花塞使用、怠速调整、点火正时、节气门调整
等）。
No private adjustment or replacement can be done to the exhaust control system, including: use of spark plug,
idling adjustment, ignition timing and adjustment to the throttle.
5〉注意事项：
Notes:
·因为点火系、充电系、燃料系不顺将对触媒装置产生很大影响，所以感觉发动机不顺时，请马上到
本公司指定经销商或服务中心检查、调整或维修。
Problems in ignition system, charging system and fuel system have great impacts on the catalytic device, so if
there are problems in the engine, please send it to the franchisers or service centers for check, adjustment or
repair without delay.
6〉本车废气控制系统符合走国家规定，因此需要更换系统的任意零件时，务必使用本公司的正厂零件，
并由指定经销商或服务中心实施。
The exhaust control system of this vehicle complies with the national regulation, so only the components
produced in our company can be used while replacing any components in the system, and it should be done in
our franchisers or service centers.
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13.3 废气控制系统机械功能 Mechanical Functions of Exhaust
Control System
概要 Overview
废气对策是以四行程单缸发动机，节气门方式为基本，采用空气导入装置，维持良好的废气水准，另外
燃油蒸发废气采用活性碳罐方式。
The exhaust solution is based on the use of the four-stroke single cylinder engine and the throtle, air inhaling
device, high standards of emission control and use of charcoal canister for emission evaporation.
※ 发动机改良 Improvements in the engine

中置火花塞加上压缩比，燃烧室，点火时间，及排气系统等的发动机元素的良化，共同遇到高的进
排气效率，谋求燃烧效率的提高。
Central spark plug are improved by improving the compression ratio, ignition time and exhaust system in
the engine to improve the efficiency of fuel.
※ 空气导入装置 Air inhaling device

将空气导入排气管，是不完全燃烧的 CO、HC 再次反应成无害气体。
Air is led into the exhaust pipe to compose the CO and HC that are not completely burned into harmless
emission.
区分装置构成部品目的功能
燃烧系燃烧室半球形燃烧室中置火花塞半球形的燃烧室，谋求燃烧的安全性。
排气系触媒装置触媒转换器装于排气管中央的罐装氧化触媒，使 CO、HC NOX 氧化。
Division Device Component Purposes and functions

Hemispherical The hemispherical combustion chamber with a
Combustion
Combustion chamber combustion centrally-placed spark plug ensures the
system
chamber combustion safety.
Exhaust Canned oxidation catalyst contained in the center
Catalytic device Catalytic converter
system of the exhaust pipe oxidizes CO, HC and NOX.
—可调整参数及建议的设定值
—Adjustable parameters and recommended setpoint
·怠速调整—发动机转速 1500±100rpm/min
Idle speed adjustment - engine speed 1500 ± 100rpm / min
CO 浓度 0.5-1.2％
CO concentration of 0.5-1.2%
13.4 触媒转化系统 Catalytic Conversion System
13.4.1 构造：Structure:
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13.4.2 说明： Instructions:
1.转化触媒的作用是将燃烧为完全的废气 HC、CO、NOX 转化成 H2O、CO2、、、N2 等无害气体后放出。
The function of the converting catalytic is to convert the complete waste gas like HC, CO and NOX after
combustion to harmless gas like H2O, CO2 and N2, etc. and then discharge them.
2.转化触媒含铂、及铑等稀有金属，限用无铅汽油。
The converting catalytic contains rare metals like platinum and rhodium, unleaded gasoline is permitted only.
※注意含铅汽油会使触媒失效。
Please be noticed that leaded gasoline will disable the catalytic.
•检修装有触媒转化器的车辆（排气管）时，一般性的注意事项：
General considerations of maintaining vehicles (exhaust pipes) equipped with catalytic converters:
1〉装有转化触媒器的车辆，发动机发动中或熄火后，短时间内温度高不可触摸。
Keep off the engine of the vehicles equipped with catalytic converters during the startup or after flameout due
to the high temperature in short time.
2〉装有转化触媒器的车辆不可靠近易燃物。
Vehicles equipped with catalytic converters shall be kept away from the combustibles.
3〉排气管中含有一氧化碳，对健康有害，因此不要在密闭的空间内运转发动机。
Do not start the engine in the airtight space as CO (which is insalubrious) remains in the exhaust pipe.
4〉装有转化触媒器的车辆，不可使用有铅汽油。（预防触媒中毒）
Vehicles equipped with catalytic converters shall not use leaded gasoline. (in case of catalytic poisoning)
5〉不可利用推车来发动发动机。如果必须靠推车来发动发动机，也需等发动机与触媒转化器的温度
降低。
Do not start the engine by pulling the vehicle. If necessary, please wait till the engine and catalytic converter
cool down.
6〉下坡时不可利用上档，熄火的方式驾驶车辆。
Shutting down or gearing up while driving downhill is prohibited.
7〉不可驾驶点火不良的车辆。
Do not drive vehicles with poor ignition condition.
8〉维修发动机点火系统时，不可利用将火花塞拆下，发动发动机检视火花塞有无火花的方法。如必
须时，时间也不可太长。
Do not remove the ignition plug or start the engine to inspect the spark while repairing the ignition system.
If necessary, do not take too long.
13.5 怠速排放值超过规定值时的对策 Solutions to the Problem of
Idle Exhaust Exceeding Specified Value

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- 187 -
合格
实行定期检验（维修保养计划）
合格
测定怠速排放（注 1）
合格
调整节气门（注 2）
合格可出厂
拆洗喷油器
合格
合格
换喷油器
拆修发动机
•阀（泄漏）合格
•活塞（磨损）
•燃烧室（清洗）
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Qualified
Implement periodic check (maintenance
Qualified
Idling emissions
Qualified
Adjust throttle (Note 1)
Qualified Qualified &

Remove and wash injector
finished product
Qualified
Replace injector
Dismount and repair the

engine Qualified
•Valve (leakage)
•Piston (abrasion)
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注：Notes:
1.以怠速测定程序测定。
1: Test it according to the idling testing procedure.
2.调整发动机怠速转速至规定内，并测定怠速 CO/HC。
Adjust the engine idle speed to the specific value, and test CO/HC in idling.
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电喷系统的检查和维护 Inspection and
Maintenance of Electronic Fuel Injection System
电气线路图
Electrical Schematic Diagram
- 191 -
- 192 -
十四、电喷系统说明
XIV. Electronic Fuel Injection System
电喷系统---------------------------------------------------------------------14.1
Electronic Fuel Injection System------------------------------------------14.1
电喷系统零件---------------------------------------------------------------14.2
Parts of Electronic Fuel Injection System--------------------------------14.1
故障诊断----------------------------------------------------------------------14.3
Fault Diagnosis---------------------------------------------------------------14.3
常见故障排除方法----------------------------------------------------------14.4
Common Trouble Shooting Methods--------------------------------------14.4
14.1 整车电喷系统介绍
Introduction to Electronic Fuel Injection System
BX125 采用的是德尔福公司的小型发动机电喷系统，本系统是通过氧传感器进行闭环控制。独立喷油
和点火控制。采用三元催化器对发动机燃烧后的气体进行后处理，使之转化为无害气体排到大气中。该
系统采用了闭环控制自学习系统，它能有效地消除系统及相关机械零部件的制造差异，提高整车的综合
一致性，它可消除车辆在实际使用后由于磨损等原因造成的误差。
BX125 adopts small engine EFI system pr26Voduced by Delphi Company, and the system can realize
closed-loop control through oxygen sensor. The system is featured by independent fuel injection and ignition
control. Three-way catalytic converter is used to deal with the gas after combustion in the cylinder to make it
converted into harmless gas into the atmosphere. The system is a closed-loop control and self-learning system,
effectively eliminating the manufacturing differences of the system and relevant mechanical parts and
components, enhancing the overall consistency of the whole vehicle, and eliminating the error caused by wear
and other reasons after the vehicle is operated.
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14.2 电喷系统零件
Parts of Electronic Fuel Injection System
14.2.1 发动机控制器(MT05 ECU)

Engine controller (ECU MT05)
14.2.1.1 ECU 工作原理：
ECU working principles
发动机控制器通过各类传感器实时地检测发动机的运行状态，通过合理的计算、以及自学习控制输
出装置，在优化了各个工况下车辆的驾驶性的同时，又保证了原车排放以及燃油经济性。当系统有故障
时发动机控制器也可以惊醒自诊断。
Engine controller inspects engine running conditions at real time with the assistance of various sensors,
optimizes the driving performance under different working conditions through rational calculation and
self-learning control output device, and ensure the emission and fuel economical efficiency of the original
vehicle. When the system is in trouble, the engine controller can also wake up the self diagnosis.
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14.2.1.2 ECU 外观：
ECU appearance
14.2.1.3 ECU 针脚定义：
Definition of ECU pin
J1-功能对应表：(GREY)
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J1- Function correspondence table: (GREY)
序号代号功能描述序号代号功能描述
S/N Code Description S/N Code Description
怠速步进电机A 高
1 J1-1 10 J1-10
Idle speed stepper motor A (high)
怠速步进电机A 低
2 J1-2 11 J1 -11
Idle speed stepper motor A (low)
故障灯(传给仪表报警）怠速步进电机B 高
3 J1-3 12 J1 -12
Fault indicator (send alarm to the meter) Idle speed stepper motor B (high)
怠速步进电机B 低
4 J1-4 13 J1 -13
Idle speed stepper motor B (low)
5 J1-5 14 J1 -14
转速表(传给仪表转速）
6 J1-6 15 J1 -15
Tachometer (send speed to the meter)
CAN 线信号低熄火（诊断开关）
7 J1-7 16 J1 -16
CAN wire cable (low) Shutdown (diagnostic switch)
CAN 线信号高
8 J1-8 17 J1 -17
CAN wire cable (high)
电源（系统）接地空档/离合信号输入
9 J1-9 18 J1 -18
Power supply (system) ground Neutral position / clutch signal input
J1-功能对应表：(BLACK)
序号代号功能描述备注序号代号功能描述
S/N Code Description Remarks S/N Code Description
点火线圈驱动A (I缸) 5V 参考电压接地（信号地）
1 J2-1 10 J2-10
5V voltage reference ground (signal ground)
电源（系统）接地进气压力信号
2 12-2 11 J2-11
Power supply (system) ground Intake air pressure signal
节气门位置信号
3 J2-3 KW2000 12 J2-12
Throttle valve position signal
23 齿信号高 23 齿信号低
4 J2-4 13 J2-13
23-teeth signal (high) 23-teeth signal (low)
喷嘴A 缸盖温度信号
5 J2-5 14 J2-14
Nozzle A Cylinder head temperature signal
点火电源
6 J2-6 15 J2-15
Power supply for ignition
1 缸氧传感器加热 5V 参考电压
7 J2-7 16 J2-16
Heating of 1# cylinder oxygen 5V reference voltage
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sensor
进气温度信号 1 缸氧传感器信号
8 J2-8 17 J2-17
Intake air temperature signal Signal of 1# cylinder sensor
油泵控制信号电瓶电源
9 J2-9 18 J2-18
Fuel pump control signal Power supply of accumulator
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14.2.1.4 电喷线路图：
Circuit diagram of electronic fuel injection
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14.2.1.5 ECU 使用注意事项：
Precautions for ECU operation
1. 不要将 ECU 放置在高温部位，如消音器或发动机；

Do not put the ECU in a high-temperature part, e.g, muffler or engine;
2. 不要将 ECU 放置在靠近水滴，机油或者任何液体处；
Do not put the ECU near water droplets, oil or any liquid;
3. 不要让泥或其他污染物覆盖 ECU 而影响 ECU 散热；
Do not cover ECU with mud or other contaminants, thereby not affecting its heat dissipation
performance;
4. 使用 M8 螺栓连接并保证扭紧力矩为 3.9Nm 左右，安装表面必须保证平整以防止对 ECU 产生外力
造成电路板弯曲。
Use M8 bolt for connection and keep the tightening torque at about 3.9Nm, ensure smooth installation
surface to prevent against circuit board bending caused by external force on the ECU.
5. ECU 正常工作的直流电源电压范围是 9 到 16V,在不超过 26V 的直流电压下工作一分钟，ECU 不会
产生永久性损坏，在反向电压不超过 13V 的直流电压下工作 1 分钟内，也不会造成 ECU 永久性损
坏。
The voltage of DC power supply is 9 to 16V when the ECU is under normal operation. If DC voltage is
not more than 26V and the ECU operates only 1 min, no permanent damage will be caused. If the reverse
voltage is not more than 13V DC voltage and the ECU works less than 1 min, no permanent damage will
be caused.
14.2.2 喷油器
Fuel injector
14.2.2.1 喷油器工作原理：
Working principles of fuel injector
喷油器内部设计有环绕铁芯的电磁线圈，电磁线圈所引出的两个电极即为喷油器的输入控制接口，
当电磁线圈通电时，所产生的电磁力克服球阀的弹簧力和燃油压力，使球阀升起，燃油管内的高压燃油
（250Kpa）就可以通过喷油器的阀座孔，流经喷孔板并形成锥形雾状喷到进气门上，当喷油器断电后，
电磁线圈的电磁力消失，喷油器的球阀在回位弹簧的作用下自行关闭，使喷油器喷油动作停止。
Fuel injector is designed as having electromagnetic coil inside to surrounding the iron core. Two electrodes of
the coil are taken s the input control ports of thee injector. When the coil is powered, the electromagnetic force
can overcome the spring force of the ball valve and the pressure of fuel to make the ball valve raise, and then
the high-pressure fuel (250Kpa) in fuel pipe can flow through the valve seat hole to orifice plate, further
forming conical mist to inject to the intake valve. When the injector is powered off, the electromagnetic force
disappears, the ball valve is self-closed under the action of return spring to stop the injection.
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14.2.2.2 喷油器外观：
Fuel injector appearance
14.2.2.3 喷油器使用注意事项：
Precautions for fuel injector operation
1. 喷油器内部设计有过滤器，但它不是一个可维修的
部件，因为它的设计功能仅仅是可以过滤掉油路中
燃油滤清器到喷油器之间的累积杂质，杂质可以引
Fuel injector
起喷油器粘结、流量偏移和泄露等故障，故燃油过
滤器非常重要。
Fuel injector interior is provided with a filter that is an
non-repairable part. The filter is designed to filter out
the accumulated impurities between fuel filter and fuel
injector. The impurities may result in bonding, flow
excursion, leakage and other faults to the injector.
Therefore the fuel filter is very important.
2. 只能使用相同零件号的喷油器才能进行更换，
It can be replaced only when the fuel injector has the same parts.
14.2.3 节气门体
Throttle valve
14.2.3.1 节气门体工作原理： Throttle Valve

Working principles of throttle valve
主要由主铸造阀体、回位弹簧、油门拉线、节气门
体位置传感器及怠速调节螺钉等组成，节气门体位置传
感器给 ECU 提供油门开度；
怠速调节螺钉能够控制怠速
转速及其稳定性，顺时针减小旁通气量，降低怠速转速，
逆时针增加旁通气量，提高怠速转速，一般要求其位置
在 2 圈左右。
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Throttle valve is mainly composed of main cast body, return spring, accelerator cable, throttle valve position
sensor and idle speed control screw. Throttle valve position sensor sends the accelerator opening to the ECU,
idle speed control screw can control idle rotational speed and its stability, specifically reducing the speed by
decreasing the air volume of bypass channel in clockwise direction and increasing the speed by increasing the
air volume of bypass channel in counterclockwise direction. The screw is generally screwed in about 2 turns.
14.2.3.2 节气门体外观：
Throttle valve appearance
14.2.3.3 节气门体清洁方法
Throttle valve cleaning method
使用节气门清洁剂清洁节气门体，将清洁剂喷在节气门体内壁上，并用刷子轻轻刷掉灰尘积碳等，
注意不要让脏东西堵塞了旁通道。
Throttle valve is cleaned by throttle valve cleaning agent. Specifically, spray the agent to inner valve wall,
gently brush off the dust, and prevent against dirty matters blocking the bypass channel.
14.2.4 缸头温度传感器
Temperature sensor at cylinder end

Temperature sensor at cylinder end
14.2.4.1 缸头温度传感器工作原理：
Working principle of temperature sensor
at cylinder end
发动机缸头温度传感器用于风冷发动机，用于测量发动机缸头温度，在该传感器温度范围内，其电
阻会随发动机的温度不同而改变，其温度特性为负温度系数电阻特性。它是不可维修零件。
Temperature sensor at cylinder end serves at air cooled engine, and it used to measure the temperature of
engine cylinder end. Within the range of sensor temperature, the resistance will change along with engine
temperature, and its character is the negative temperature coefficient resistance. It is an non-repairable part.
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14.2.4.1 缸头温度传感器外观：
Appearance of temperature sensor at cylinder end
14.2.5 进气温度压力传感器
Intake air temperature and pressure sensors
14.2.5.1 进气温度压力传感器工作原理：
Working principles of intake air temperature
and pressure sensors
用于测量进入的空气温度，其电阻会随着进气的温度不同
而改变，其特性也为负温度系数电阻特性，它也是不可维修零
件。
Temperature sensor is used to measure the temperature of intake air, and its resistance will change with the air
temperature, and its character is the negative temperature coefficient resistance. The sensor is an
non-repairable part.
该传感器用于测量进气弯管绝对压力，根据电阻值的不同反映进气压力的大小，从而间接换算成计
算进入发动机燃烧室的进气量大小，它也是不可维修零件
Temperature sensor is used to measure the temperature of intake air, and its resistance will change with the air
temperature, and its character is the negative temperature coefficient resistance. The sensor is an
non-repairable part.
14.2.5.2 进气温度压力传感器外观：
Appearance of intake air temperature and pressure sensor
14.2.7 氧传感器
Oxygen sensor
14.2.7.1 氧传感器工作原理：
Working principle of oxygen sensor

该传感器可以检测发动机排气管中废气中的氧含量，用于 ECU 内部燃油闭环控制，使发动机燃烧
始终维持在最合理的空气和汽油比（14.7）状态。
The sensor can detect the oxygen content in the exhaust gas from engine exhaust pipe, and is used for closed
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loop control of inner fuel of the ECU to make the combustion in engine at the most reasonable air-gasoline
ratio (Article 14.7).
14.2.7.2 氧传感器外观：
Appearance of oxygen sensor
14.2.8 点火线圈
Ignition coil
14.2.8.1 点火线圈工作原理：
Working principles of ignition coil
点火线圈能够提供能量给火花塞，连接点火线圈和火花塞的是高压线。
The ignition coil can provide energy to the spark plug, and is connected to the spark plug through a high
voltage wire.
14.2.8.2 点火线圈外观：Appearance of ignition coil：
14.2.9 怠速步进电机 Idle speed stepper motor
14.2.9.1 怠速步进电机工作原理：
Working principles of idle speed stepper motor
怠速控制阀的功能是控制节流阀体旁通气道的流通面积，以调节进入发动机的空气量，实现发动机
怠速的控制。
Idle speed control valve is to control the flow area of the bypass airway of throttle valve to adjust the amount
of air into the engine, thereby realizing idle speed control.
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14.2.9.1 怠速步进电机外观：Appearance of idle speed stepper motor
14.2.10 燃油泵 Fuel pump
14.2.10.1 燃油泵工作原理：
Working principles of fuel pump

由电动式油泵及压力调节器共同工作为发动机提供 250Kp
汽油压力，安装在汽油箱的底部。
Electric fuel pump provides 250Kp gasoline pressure along with
pressure regulator to the engine, and is mounted at the bottom of
gasoline tank.
14.2.10.2 燃油泵外观：Appearance of fuel pump
14.2.10.3 燃油泵故障诊断：Fault diagnosis of fuel pump
1. 钥匙开启后，油泵会运转大约 3 秒钟左右，如果能听到油泵转动，请直接到第 4 条：
After the key is turned on, fuel pump will run for about 3 seconds; if you can hear the sound of oil
pump rotation, please directly read Step 4;
2. 断开油泵接插件，检测油泵供电电压是否在 12V 左右；
Disconnect the pump connector and inspect whether the power supply voltage of fuel pump is about
12V;
3. 如果步骤 2 没有问题，外接电瓶给油泵供 12V 直流电，检测油泵是否运转。
If there is problem is Step 2, connect the accumulator to provide 12V DC to the fuel pump, and
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inspect whether the pump operates;
4. 如果油泵运转正常，在发动机怠速时使用汽油压力表检测喷油器前端油管压力是否在 250Kpa
左右；
If the pump can normally operate, use gasoline pressure gauge to check whether the fuel pipe
pressure in the front of fuel injector is around 250Kpa at idle speed of the engine;
5. 如果管路压力低于 220Kpa,检查油管路是否有漏油，油泵是否反转，滤清器是否有堵塞等。
If fuel pipe pressure is less than 220KPa, inspect whether fuel pipe has leakage, fuel pump is in
contra-rotation, and fuel filter is block.
14.2.10.4 燃油泵常见出现的问题：
Common faults of fuel pump
1. 燃油泵总成插件接反了，导致燃油泵反转，无法给发动机提供足够的燃油压力，导致发动机无
法正常工作。
The plug of fuel pump assembly is reversely connected, leading to contra-rotation of fuel pump,
failing to provide enough fuel pressure to the engine, and making the engine not work properly.
2. 油泵损坏无法转动。
Fuel pump is damaged and cannot rotate.
14.2.10.5 燃油泵使用注意事项：
Precautions for fuel pump operation
1. 新车由于刚开始油箱内没有汽油，在加完汽油后，燃油管路上有很多空气，需要打动马达很多
下，才能排干净油路中的空气，发动机才可以正常工作，这是正常现象，以后的启动就不会
出现长时间无法启动的问题。
The fuel tank of new car has not gasoline, and fuel pipe has a a lot of air after gasoline feeding, so it
is necessary to start up the engine for many times to discharge the air in fuel pipe, and then the
engine can work normally. This is a normal phenomenon, and after then car startup will not take a
long time.
2. 由于汽油可以冷却燃油泵，所以不要让油泵处在少油或没有汽油的状况下工作，这样会烧坏燃
油泵。
Since the gasoline can cool down the fuel pump, the pump cannot be operated with little or no
gasoline, otherwise, the pump will be burn out.
14.3 故障维修诊断方法 Fault diagnosis method
故障灯位于仪表盘上，下面有个 FI 标记。正常情况下，打开钥匙，故障灯会长亮，表示电喷系统
处于有电源状态，可以工作，故障灯不亮，表示电喷电路无电源，不会工作，需要检查保险丝及电瓶正
负极连接情况。在启动发动机后，故障灯熄灭，表示无故障；相反，如果启动发动机后故障灯依然长亮，
表示电喷系统工作不正常，有故障，需要排除故障。
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Fault indicator is on the dashboard and marked with FI. Under normal circumstances, after turning the key on,
if the fault indicator blinks, the EFI system is powered on and can work; if the light is not lit, the EFI system is
not powered on and will not work, and it is necessary to inspect the connection between the fuse and
accumulator negative electrode. After the engine is started, the fault indicator goes out, indicating there is no
fault; on the contrary, if the engine is started and the fault indicator is still on, the EFI system doesn't work
properly and has faults which to be excluded.
目前检测故障的方法有 3 种：
There are 3 methods to detect faults.
14.3.1 直接使用仪表上的故障灯（FI）闪烁诊断。
The flicker of fault indicator (FI) is directly used for diagnosis.
在确认有故障的情况下，通过开关 3 次钥匙，既打开---关闭---打开---关闭--打开钥匙的操作，故障
灯会闪出相对应故障的闪码。然后通过故障码表查出相对应的故障。
After it is confirmed that there is fault, turn on and off the key for three times (i.e., turn on - turn off - turn on -
turn off - turn on - turn off), and then the fault indicator will flash out a corresponding fault code. Find out
the fault as per the List of Fault Codes.
其中用故障灯读取故障的方法时，闪码的规则举例如下，例如故障是进气压力传感器断路或信号端
针脚短路到电瓶负极，则故障灯会在钥匙开关三次后，先闪 10 次代表 0，间隔 1.2 秒后闪 1 次代表 1，
再间隔 1.2 秒闪 10 次代表 0，再间隔 1.2 秒闪 7 次代表 7，即 P0107。可见，除了数字 0 用闪 10 次代表
外，其他数字 1 到 9，是数字几就闪几次。如果还有其他的故障码，如还有故障 P0201，即前缸喷油器
有故障时，会再闪完 P0107 后等待 3.2 秒继续闪 P0201 故障码，如果没有其他的故障，会循环闪 P0107、
P0201.然后可根据故障码表查相关的故障了。
The fault indicator is used to find out the fault, for example, if the fault is that intake air pressure sensor is in
open circuit or signal port pin is short connected to the negative electrode of the accumulator, after three time
of turning on and off the key, the first 10 times of fault indicator flashing represents for 0, 1 time of flashing
after 1.2s represents for 1, 10 times of flashing after another 1.2s represents for 0, and 7 times of flashing after
more 1.2s, and then the fault code is P0107. In this way, except 0 is represented by 10 times of flashing, the
numbers 1 to 9 are represented by corresponding times. If there are other fault codes, such as P0201 (i.e., fuel
injector in front cylinder has faults), the indicator will continually flash out the fault code P0201 3.2 seconds
after flashing out P0107. If no other fault codes, the indicator will circularly flash out P0107 and P0201, and
find out the fault as per the List of Fault Codes.
使用 PCHUD 软件时，软件会用十进制数报故障码，在故障码表中十进制与前面的十六进制是一一
对应的，可以根据对应关系找到相应的故障。如在软件中 MULFCURR（当前故障）=263，则在故障码
表中与 P0107 相对应，即为进气压力传感器故障。
If PCHUD software is adopted, it will report the fault code with decimal numbers, the decimal system in the
List of Fault Codes is one-to-one correspondent to the hexadecimal system and the fault can be found out
according to the corresponding relationship. If MULFCURR (current fault) = 263, it is correspond to P0107 in
the List of Fault Codes, i.e., it is the fault of intake air pressure sensor.
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14.3.2 使用诊断仪诊断故障
Diagnosis tester is used to diagnose the faults.
操作方法：
Operation method:
1. 找到摩托车上 6 孔的诊断接口；
Find the 6-hole diagnosis interface of the motorcycle;
2. 将连接线和诊断仪接口相连，
Connect the connection wire to the diagnosis tester interface,
3. 打开钥匙即可诊断；
Turn on the key to diagnose;
14.3.3 在笔记本上的使用诊断软件 PCHUD 来检查故障。

PCHUD software is used to inspect the faults on the computer.
PCHUD 软件用于检测和记录发动机运行数据，使用前应通过 K 线将笔记本电脑与摩托车 6 孔诊断

口相连。使用前，需要在笔记本上安装 K 线驱动软件。
PCHUD is used to detect and record engine operating data. Before using the software, connect the computer
and 6-hole diagnosis interface of the motorcycle through K line. Before use, it is necessary to install the driver
software of K line on the computer.
PCHUD 软件使用说明：
Instructions to PCHUD software:

（1）使用 K 线连接笔记本电脑与摩托车 6 孔诊断口并打开钥匙
Connect the computer and 6-hole diagnosis interface of the motorcycle through K line, and open the key.
（2）点击“HUD.EXE”图标，启动 PCHUD 软件
Click "HUD.EXE" to start PCHUD.
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（3）在软件界面上选择“File”,点击“Open”选择“PCHUD.HAD”，选择 OK 确认即可。
On the software interface, click "File", "Open", "PCHUD.HAD" and "Ok" step by step.
（4）选择“Setup”下的“Parameter File”,点击 MT05common.par 文件,并在“Setup”下选择“Comm

protocol”,选择“Keyword2000”然后点击 OK，同时 Device Code 选择 17.
Select "Parameter File" under "Setup", then click "MT05common.par", and then select "Comm protocol"
under "Setup", select "Keyword2000" and click "Ok", and select 17 under Device Code at the same time.
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（5）如果软件界面在通电的情况下不能显示实时的通信数据，需要继续以下工作，在“Setup”下检
查 COM 口连接设置是否有问题，通常设置 COM Port：4、Baud Rate：10400、不选择 DTR High at startup
If the software interface cannot display communication data after the computer is powered, it is necessary to
conduct the following work: inspect whether COM port is correctly arranged in the state of "Setup" (generally
set as COM Port: 4. Baud Rate: 10400; don't select "DTR high at startup"),
然后就可以正常通信了，在 MALFCURR 处显示目前故障码，在 MALFHIST 显示历史故障码

再根据故障码表查询相应的故障。
Then the software interface will recover communication, display current fault code at "MALFCURR" and past
fault code at "MALFHIST", and inquire the corresponding faults as per the List of Fault Codes.
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附表 1：PCHUD 软件参数解释：
Schedule 1: Interpretation of PCHUD Software Parameters

VRPM 发动机转速 engine speed
VTHROT 节气门开度 throtle position
VBARO 大气压力 BARO
VMAP 进气歧管压力 manifold air pressure
VMAPEXP 进气歧管压力估计值 expect manifold air pressure
VIGN 电瓶电压 ignition key voltage
VCLTS 发动机缸温或者冷却水温 cylinder temperature or coolant temperature
VIAT 进气温度 intake air temperature
STATUSBYTE5 状态标志 5 STATUSBYTE5
VAFCMET 空气流量学习条件满足 airflow correction met
VBAROCMET 大气压力更新条件满足 Baro update met
VCSINSYNSPRK 顺序点火标志 sequential spark enable
SATITRIG tip-in 点火角修正条件满足 tip-in Spark Advance retard trigger
CATLOENB 触媒起燃逻辑使能 catlyst light-off logic enable
IF ENGSTATE=3 发动机正常工作标志位 engine work in run state
NISTBLIDLE 暖机怠速条件满足 stable warm idle
FO2REDY2 2 缸氧传感器加热完成标志位 O2 ready
FCNO 进气效率长效学习单元 block learn memory cell
FBLMCOR1 1 缸长效学习值 cylinder 1 block learn memory
FCLCINT1 闭环学习 I 项 intergral of close loop correction
FCLCMUL1 闭环学习修正量 close loop correction
IARDRPM 目标怠速转速 desired idle rpm
IARPMERR 怠速偏差 idle rpm error
FPWVC1 1 缸喷油脉宽 base pulse width of cylinder 1
VO2 氧传感器信号 Oxygen sensor signal
FO2STAT1 1 缸氧传感器浓稀标志位 cylinder 1 oxygen sensor signal rich lean state
FCLREST1 1 缸闭环修正重置标志位 cylinder 1 close loop correction reset
FOSHTREN 氧传感器加热使能 Oxygen sensor heater enable
FO2REDY1 1 缸氧传感器加热完成标志位 cylinder 1 Oxygen sensor ready
IF IACV MODE=0 怠速步进电机闭环学习使能 idle airflow control valve close loop correction enable
IAMTRLOST 怠速步进电机丢步标志位 IACV lost
IACMVIHB 怠速步进电机禁止移动标志位 IACV move disable
VIGNS 点火状态标志位 ignition state
FVE1 1 缸充气效率 cylinder 1 Volumetric efficiency
VMAPRANG 进气压力读取角度 MAP read angle
AFFNLAFR 目标空燃比 target air fuel ratio
SAESTA 1 缸点火提前角 cylinder 1 Spark Advance
SAIDLDYN 怠速动态点火角 idle dynamic Spark Advance
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SPDWELL 充磁时间 dwell time
IAINTEGOFST 怠速步进电机气量学习值 airflow integral of idle air control valve
IACVDSMP 怠速步进电机目标步数 desired position of idld air control valve
FCLCEN1 1 缸闭环修正使能 cylinder 1 close loop correction enable
PPDSEBL 预喷禁止标志位 prime pulse disable
FPENABL 油泵使能标志位 fuel pump enable
FTRNSAES 加速加浓使能 acceleration enrich enter
FTRNSDES 减速减稀使能 deceleration enlean enter
FTRNSAEDCLOAD 加速加浓退出 acceleration enrich exit
FTRNSDEINLOAD 减速减稀退出 deceleration enlean exit
FCLCEN2 2 缸闭环修正使能 cylinder 2 close loop correction enable
附表 2：故障码对应表。
Schedule 2: List of Fault Codes

MT05 故障码表
List of MT05 Fault Codes
对应的十进制数
故障代码描述
Corresponding
Fault code Description
decimal number
进气压力传感器断路或信号端针脚短路到电瓶负极
P0107 Intake air pressure sensor is in open circuit or signal port pin is 263
short connected to the negative electrode of the accumulator.
进气压力传感器信号端针脚短路到电瓶正极
P0108 The signal port pin of intake air pressure sensor is short connected 264
to the passive electrode of the accumulator.
进气温度传感器信号端针脚短路到电瓶负极
P0112 The signal port pin of intake air temperature sensor is short 274
connected to the negative electrode of the accumulator.
进气温度传感器断路或信号端针脚短路到电瓶正极
P0113 Intake air temperature sensor is in open circuit or signal port pin is 275
short connected to the passive electrode of the accumulator.
缸头温度传感器信号端针脚短路到电瓶负极
P0117 The signal port pin of intake air temperature sensor at cylinder end 279
is short connected to the negative electrode of the accumulator.
缸头温度传感器断路或信号端针脚短路到电瓶正极
P0118 Intake air temperature sensor at cylinder end is in open circuit or 280
signal port pin is short connected to the passive electrode of the
accumulator.
节气门位置传感器断路或信号端针脚短路到电瓶负极
P0122 Throttle valve position sensor is in open circuit or signal port pin is 290
short connected to the negative electrode of the accumulator.
节气门位置传感器信号端针脚短路到电瓶正极
P0123 The signal port pin of throttle valve position sensor is short 291
connected to the passive electrode of the accumulator.
前缸氧传感器信号端针脚短路到电瓶负极
P0131 The oxygen sensor in front cylinder is short connected to the 305
negative electrode of the accumulator.
P0132 前缸氧传感器信号端针脚短路到电瓶正极 306
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The signal port pin of oxygen sensor in front cylinder is short
前缸氧传感器加热端针脚短路到电瓶负极
P0031 The heating port pin of oxygen sensor in front cylinder is short 50
前缸氧传感器加热端针脚短路到电瓶正极
P0032 The heating port pin of oxygen sensor in front cylinder is short 49
前缸喷油器故障
P0201 513
Fuel injector in front cylinder has faults.
后缸喷油器故障（如喷油器插件没插好）
P0202 Fuel injector in rear cylinder has faults (e.g., the injector plug is not 514
plugged in).
油泵断路或短路到电瓶负极
P0230 Fuel pump is in open circuit or short connected to the negative 560
electrode of the accumulator.
油泵短路到电瓶正极
P0232 Fuel pump is short connected to the negative electrode of the 562
accumulator.
曲轴位置传感器有干扰
P0336 822
Crankshaft position sensor is interfered.
曲轴位置传感器无信号
P0337 823
Crankshaft position sensor has no signal.
前缸点火线圈故障
P0351 849
Ignition coil of front cylinder has faults.
后缸点火线圈故障
P0352 850
Ignition coil of rear cylinder has faults.
电喷系统电压过低
P0562 1378
Electronic fuel injection system is at lower voltage.
电喷系统电压过高
P0563 1379
Electronic fuel injection system is at higher voltage.
故障灯故障（灯丝坏或插件没插）
P0560 Fault indicator is in failure (the filament is broken or the plug is not 1616
inserted).
转速表线短路到电瓶负极
P1693 The tachometer is short connected to the negative electrode of the 5779
accumulator.
转速表线短路到电瓶正极
P1694 The tachometer is short connected to the passive electrode of the 5780
accumulator.
后缸氧传感器信号端针脚短接到电瓶负极
P0137 The oxygen sensor in rear cylinder is short connected to the 311
negative electrode of the accumulator.
后缸氧传感器信号端针脚短接到电瓶正极
P0138 The signal port pin of oxygen sensor in rear cylinder is short 312
后缸氧传感器加热端针脚短接到电瓶正极
P0038 The heating port pin of oxygen sensor in rear cylinder is short 56
后缸氧传感器加热端针脚短接到电瓶负极
P0037 The heating port pin of oxygen sensor in rear cylinder is short 55
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14.4 常见故障排除方法
Diagnosis tester
Common Trouble Shooting
Methods
14.4.1 维修工具
Maintenance tools
a) 电控系统零部件的拆装 - 常用汽车机械零部件拆
卸工具
Assembly and disassembly of parts and components of electronic control system - common disassembly
tools of automotive parts and components;
b) 电控系统电路及系统电信号 - 数字式万用表(带蜂鸣)
Circuit and electric signal of electronic control system - digital versatile meter (with buzzer);
c) 电控系统故障诊断及发动机工作状况检测
Fault diagnosis of electronic control system and detection of engine working condition;
 电控系统故障诊断仪 (推荐)
Fault diagnosis tester of electronic control system (recommended);
 故障诊断软件 (PCHUD)和接口连线 (有条件可使用)
Fault diagnosis software (PCHUD) and interface connection (used if possible);
d) 电控系统故障故障码表(应急使用)
List of Fault Codes of Electronic Control System (used in case of emergency);
e) 燃油压力表，量程 0 ~ 300kPa
Fuel pressure gauge, range: 0 ~ 300kPa.
14.4.2 诊断仪所显示发动机工作数据流
Diagnosis tester used to display the working data flow of engine
使用诊断仪所显示发动机工作数据流来分析和判断发动机故障.
Diagnosis tester is used to display thee working data flow of engine, further to analyze and judge the faults of
the engine.
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14.4.2.1 第一步 Step 1
a) 发动机线束及真空管路 – 可能影响系统控制空气流量和供油量
Engine cable harness and vacuum line may affect the system to control air flow and fuel supply;
b) 氧传感器安装是否到位 – 可能会影响系统对空燃比的判断。
Whether oxygen sensor is installed in place may affect the system to judge the air fuel ratio;
c) 发动机故障指示灯 – 影响系统对故障的报警
Engine fault indicator may affect the system to alarm the faults;
d) 电瓶电压 – 判断电瓶电量是否足够
Accumulator voltage can be used to determine whether the accumulator has sufficient electric power;
e) 根据经验判断冷却液温度传感器，进气温度传感器，进气歧管绝对压力传感器及氧传感器显示值
是否正常
he experience can be used to judge whether coolant liquid temperature sensor, intake air temperature
sensor, intake manifold absolute pressure sensor and oxygen sensor can normally display the value;
f) 节气门位置传感器工作范围 – 不能全开或不能全关可能影响发动机动力性能和部分系统功能
Work scope of throttle valve position sensor - Whether it can fully opened or closed may affect engine
dynamic performance and some system functions.
14.4.2.2 第二步 Step 2
ECU 电源是否关断 – 关断钥匙开关后诊断仪与系统通讯中止

Whether ECU power supply if off - The communication between the diagnosis tester and the system is
interrupted after lock switch is turned off.
14.4.2.3 第三步 Step 3
a) 冷却液温度及冷却液温度循环—预示节温器是否工作正常
The temperature and temperature cycle of coolant liquid can indicate whether the thermostat is working
properly；
b) 电瓶电压—显示发电机是否正常工作。
Accumulator voltage can indicate whether the generator is in normal operation；
过高：可能发电机调节器故障；
If higher, the generator regulator may break down；
过低：可能是发电机连线不当或发电机故障
If lower, the generator may improperly connected or break down;
c) 进气歧管压力—可预示进气有无漏气和气门间隙问题。
Intake manifold pressure can indicate whether there is air leakage or valve clearance;
气门间隙过小：此值偏高，可能影响发动机的动力性，并因排气门过早开启，排温升高而大大缩短
氧传感器及三元催化器使用寿命；
If valve clearance is too small, the pressure is high and may affect the dynamic performance of the
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engine, and due to earlier opening of exhaust valve, exhaust temperature increases, greatly shortening the
service of oxygen sensor and three-way catalytic converter;
气门间隙过大：会引起进气歧管压力偏低，而影响系统对发动机工作状态的判断，造成热车时怠速
异常.
If valve clearance is too large, the pressure is low and may affect the system to judge the working status
of the engine, thereby causing idle speed exception f hot car;
此外，若排气系统堵塞，如：有异物存在于排气道内，机油消耗过高而堵塞三元催化器，以及因
三元催化器内部破碎而堵塞；都会造成此值偏高.
In addition, the pressure will be increased if the exhaust system is blocked, e.g., exhaust port has foreign
matter and three-way catalytic converter is blocked due to high fuel consumption, and further the exhaust
port is blocked due to broken catalytic converter;
d) 氧传感器值循环次数—循环次数太少，预示氧传感器失效。
As for the number of oxygen sensor cycles, less cycle indicates the failure of oxygen sensor.
14.4.3 简明故障排除方法
Simple troubleshooting methods
修理电喷系统时，请按以下步骤顺序进行，若在某一步骤中修复故障，可中止后续步骤。然后使用
诊断仪，对照 14.3 条进行检查验收并清除故障码。
EFI system shall be repaired in the following sequence. If it is necessary to repair fault in some step, the
subsequent steps may be suspended, and the diagnosis tester is used for inspection, acceptance and the removal
of fault codes as per article 14.3.
使用诊断仪时，电瓶电压不得低于 8.5 伏。
In the operation of diagnosis tester, the accumulator voltage shall not be less than 8.5 volts.
16.4.3.1 日常使用及保养
Daily use and maintenance
 汽油应使用 92 号或 95 号优质无铅汽油。
92# or 95# high-quality unleaded gasoline can be adopted.
 ECU 具有防潮功能，但不得使用高压水枪冲涮其外壳。
ECU is moisture-proof, but its shell may not be washed by water cannon.
 汽油滤清器每 7000～10000km 更换一次。
Gasoline filter is replaced every 7,000 ~ 10,000km.
 正常使用条件下，每 1 万公里或 1 年清洗节流阀体一次。
Under normal service conditions, throttle valve is cleaned every 10,000kg or 1 year.
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16.4.3.2 故障现象—无法起动
Symptom - Startup failure
a) 点火开关开至”ON”档，发动机故障灯是否点亮
Switch the ignition switch to "ON" gear, and check whether engine fault indicator blinks.
 检查保险丝及接地线
Inspect the fuse and ground wire,
 检查 ECU 接插头是否接牢
Check whether ECU patch plug is firmly connected,
若不亮：
 也可用诊断仪执行机构检查功能检查此灯及线路是否正常
If not
Use the actuator of the diagnosis tester to check whether the light and the line are normal,
flash:
 检查并修复灯泡及其线路
Check and repair the light bulb and the line,
 使用另外一只 ECU 判断
Use another ECU to judge.
若能亮：  连接诊断仪到系统诊断插口
If flash: Connect the diagnosis tester to the diagnosis port of the system.
b) 诊断仪能否与系统连接通讯
Check whether the diagnosis tester can communicate with the system.
 检查保险丝及接地线
Inspect the fuse and ground wire,
 检查 ECU 接插头是否接牢
若不能： Check whether ECU patch plug is firmly connected,
If not:  在另外一台正常的车辆上测试诊断仪是否工作正常
Test whether the diagnosis tester can work properly on another normal car;
若能：  则按诊断仪所指示的故障进行排除
If yes: Eliminate faults as indicated by the diagnosis tester,
c) 检查点火系统故障 - 火花塞是否正常点火
Check the fault of ignition system - whether spark plug is normal.
 检查高压线及火花塞是否接插牢固或是否损坏
Inspect whether high voltage wire and spark plug are firmly plugged or damaged,
若不能：  使用另外一只点火线圈总成判断
If not: Use the other ignition coil assembly to judge,
若能：  检查高压线是否正确连接点火线圈和火花塞
If yes: Check whether high voltage wire is properly connected to the ignition coil and spark plug.
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d) 检查供油系统故障
Inspect the fault of fuel supply system,
燃油泵是否工作—起动发动机时可在油箱附近听到油泵工作的声音
Check whether the fuel pump works (you can hear the sound of fuel pump operation around the fuel tank when
starting the engine);
 检查燃油泵继电器是否工作正常
Check whether the fuel pump relay works properly,
 检查曲轴位置传感器连接及工作是否正常
不工作： Check whether crankshaft position sensor is connected and works normally,
If not:  使用另外一只 ECU 判断
Use another ECU to judge,
 检查燃油泵线路
Check the circuit of fuel pump.
1) 供油压力是否大于 220Kpa
Inspect whether fuel supply pressure is greater than 220Kpa,
 检查油箱是否有足够油量
Check whether fuel tank has enough fuel,
 检查汽油滤清器是否应该更换(注：电喷专用汽油滤清器每 7000 ~
2) 压力不足：
10000 km 更换一次)
Insufficient
能工作： Check whether it is necessary to replace the gasoline filter (Note:
pressure:
If yes: Gasoline filter of EFI is replaced every 7,000 ~ 10,000km),
 供油管及回油管是否损坏
Check whether fuel supply pipe and return pipe are damaged;
 检查喷嘴控制线路有无异常
3) 压力正常：
Check whether the nozzle control circuit is abnormal,
Normal
 油嘴是否应该清洗
pressure:
Whether the nozzle is necessary to be cleaned,
e) 确定是否淹缸
Confirm whether the cylinder has excessive fuel.
若是：  将油门全开，接通起动机，数秒钟后发动机应有工作的迹象
If yes: Fully open the accelerator, turn on the engine, and the engine may work after a few seconds
f) 曲轴位置传感器间隙是否过大
Check whether the clearance of crankshaft position sensor is too large.
16.4.3.3 故障现象—无法起动并伴随回火
Symptom - Startup failure with exhaust failure
a) 检查点火线圈的高压线是否松脱
Check whether the high voltage wire of ignition coil is loose,
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b) 正时齿圈是否松动.
Verify whether the ring gear is loose.
16.4.3.4 故障现象—怠速不稳
Symptom - Unstable idle speed
怠速控制系统：检查怠速旁痛螺栓是否旋得过大或过小，一般是 2 圈
Idle speed control Inspect whether the idle speed bypass bolt is screwed properly, generally screwed into 2
system: turns.
供油系统：油管管路是否有漏油发生。
Fuel supply Whether fuel pipe has leakage.
system:
16.4.3.5 故障现象—怠速过高或过低(怠速明显与目标怠速不吻合)
Symptom - Higher/lower idle speed (idle speed obviously inconsistent with the
target idle speed)
 当水温低于 68 度，系统将提高怠速以加速暖机过程，这属正常现象。除此之外，按
下列步骤检查
When water temperature is lower than 68℃, the system will increase the idle speed to
怠速过高： accelerate the heating process, which is normal. Besides, inspect the system as the
Higher idle following steps,
speed:  检查怠速旁通孔是否旋得过大
Inspect whether the idle bypass hole is too big,
 气门间隙，特别是排气门间隙是否过大
Whether valve clearance, especially exhaust valve clearance, is too large.
 检查油箱油量，燃油滤清器，油路压力及油嘴
Check fuel level in fuel tank, fuel filter, fuel path pressure and nozzle,
怠速过低：
 检查怠速旁通孔是否旋得过小
Lower idle
Inspect whether the idle bypass hole is too small,
speed:
 检查气门间隙，是否间隙过小
Inspect whether valve clearance is too small.
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16.4.3.6 故障现象—怠速不稳并伴随减速熄火
Symptom - Unstable idle speed with deceleration & shutdown
a) 检查气门间隙
Check valve clearance
b) 检查怠速旁通孔及节气门体是否过脏
Check whether the idle speed bypass hole and throttle valve are dirty
16.4.3.7 故障现象—加速无力
Symptom - Incapability to speed up
a) 怠速及高怠速时参数是否正常；
Whether the parameters are normal at idle speed and high idle speed;
b) 检查油箱油量，燃油滤清器；
Check fuel level in fuel tank and fuel filter;
c) 检查排气系统是否堵塞，如：三元催化器是否因烧机油或破碎而堵塞；
Check whether the exhaust system is blocked, e.g., three-way catalytic converter is blocked due to burn
fuel or break-up;
d) 检查油路压力及油嘴.
Inspect fuel path pressure and nozzle;
e) 检查故障灯是否亮，是否是由于只有一个气缸能正常点火
Check whether the fault indicator blinks and whether the reason is that only one cylinder can normally
ignite.
16.4.3.8 故障现象—轻微失火现象
Symptom - Slight sparking
检查火花塞间隙是否符合规范 0.6 ~ 0.8 mm

Check whether the spark plug clearance is in line with the specification ( 0.6 ~ 0.8 mm)
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16.4.3.9 故障现象—故障灯亮，而故障码与故障不符
Symptom - Fault indicator blinks but fault code is inconsistent with actual
fault
可能是系统地线连接不实，重新连接地线，断开电瓶电源线 3 分钟后在接上并起动发动机
The fault may be caused by loose connection of ground wire of the system; re-connect the ground wire, then
disconnect the power cord of the accumulator for 3 minutes and re-connect the cord, and start the engine.
16.4.3.10 故障现象—油耗异常高
Symptom - Abnormally high fuel consumption
a) 检查两个缸的氧传感器是否安装到位，若是松散的状态，则氧传感器错误判断气缸里燃烧偏稀，而
增加燃油，导致油耗异常高。
Inspect the oxygen sensors of two cylinders are installed in place; if loose, the oxygen sensor erroneously
judges there is little burning in the cylinder and the fuel is added, resulting in abnormally high fuel
consumption.
b) 在确定发动机机械部件及氧传感器状态正常后，运转发动机观察氧传感器读数，在正常水温下，若
读数始终大于 500 mV，检查喷油嘴是否漏油
After confirming the engine mechanical components and oxygen sensors are in normal state, operate the
engine to observe the reading of oxygen sensor, if always greater than 500 mV at normal water
temperature, inspect whether the fuel injector has leakage.
注意事项
Precautions
 决大多数的电喷零件是不可修复的，在确认零件损坏后，一般是替换处理。
Most parts of EFI are non-repairable and generally replaced if confirmed as being damaged.
 起动发动机时，不得操作发动机上任何机构(包括油门，不拉油门启动)。
No mechanism is allowed to operate at engine startup (including the accelerator, i.e., start the engine
without pulling the accelerator).
 发动机故障灯在发动机运行过程中点亮，务必尽快查明原因并排除。
If engine fault indicator blinks in engine running, it is required to find out the causes and eliminate the
fault as soon as possible.
 不得使用含铅汽油，铅会损害氧传感器及三元催化器。
Leaded gasoline shall not be used, because lead will damage the oxygen sensor and three-way catalytic
converter.
 机油消耗异常时，应尽快解决，机油中的一些物质也会损坏氧传感器及三元催化器。
For abnormally rapid fuel consumption, it is necessary to resolve the fault immediately, because some
matter in the fuel will damage the oxygen sensor and three-way catalytic converter.
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 气门间隙不宜太小，若排气关闭不严会使排气温度过高而缩短三元催化器的寿命。
Valve clearance shall not be too small; if the exhaust port is not tightly closed, the service life of
three-way catalytic converter will be shortened by higher exhaust temperature.
 在气温低于 10C 时，而整车及发动机长时间低速运行，排气管可能有积炭并发黑，这属正常现
象。在高速运行一段时间后即会消除，或采取适当手段使发动机冷却液温保持在规定的温度范围内。
When the temperature is lower than 10℃ and the whole vehicle and engine operate at low speed for a
long time, the exhaust pipe may have carbon deposit and become black, which is normal, and will be
eliminated after a period of high-speed operation. Optionally, appropriate measures can be taken to make
the temperature of coolant liquid of the engine within the range of specified temperature.
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BX125 电路图 BX125 Circuit Diagram
- 222 -

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BRIXTON BX125

The service manual contains descriptions of maintenance essentials on

Check and adjustment contains statements on the main points of

inspection and adjustment, safety of the vehicle, maintenance means of

each component’s performance. This shall be implemented from the time

of inspection of engine, finished motorcycle, engine and other

components. System diagrams, disassembly drawings, maintenance, fault

If patterns or structures of the motorcycles change, or differences exist

between pictures, drawings, instructions or others and physical products,

without further notice.

General Safety Maintenance Regulation

Specification Sheet Fault Diagnosis

Carbon monoxide (CO)

After disassembly and before measuring friction, please clean

Do not bend or distort during operation to avoid difficult

While removing a component with many assemblies, do from

For the complicated assemblies, such as gearbox, keep them in

Fill lubricating grease into the groove during oil seal

Installation of rubber hose (fuel, vacuum, or coolant): insert its

Disassembly of ball bearing: use a tool to push against one or

Model BX125 Engine type 157FMI-C

Overall Length(mm) 2020 Fuel 93# unleaded gasoline

Weight (kg) Rear

Wet multi-plate Fuel tank

Max. speed 101 km/h

Gearshift Maximum climbing

Transmission Chain drive Idle speed-rpm 1500± 100rpm/min

Battery 12V-10AH/ Max. torque 11.4N.m/7000r/min

front brake φ276mm

Ignition type ECU disc

火花塞干燥 火花塞潮湿 自动阻风作动不良

Oil tube blockage of gasoline pump

Insufficient pressure of gasoline pump

Failure of cylinder piston and piston ring

Failure of automatic choke apparatus

Improper ignition time

Remove the spark plug Improper adjustment of throttle

Excessive gasoline injected by injector

Large throttle opening

Slowly start the

No blockage Blocked Remove dirts

Remove the spark

No pollution Polluted and Thermal value of spark plug is

Ignition time is too early

Failure of ECU Assembly

Gasoline mixture is too thin

Negative pressure tube is damaged

Air hole is blocked

Failure of ECU Assembly

Small quantities of gasoline in the

Good Fatigue elastic

Measuring the voltage at

No voltage rise The battery voltage rises

Check the voltage regulator

Poor contact of plug

Check the voltage between the pole lines

Alternator coil impedance

火花塞干燥火花塞潮湿自动阻风作动不良